Genie Z-45 XC Operator's Manual

Operator's Manual

Z-45 XC

with Maintenance Information

Original Instructions First Edition First Printing Part No. 1268193GT

Operator's Manual First Edition • First Printing

Z-45 XC Part No. 1268193GT

Front Matter

Contents

Introduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 5

General Safety ...................................................... 7

Personal Safety ................................................... 10

Work Area Safety ................................................ 11

Legend ................................................................ 20

Controls ............................................................... 21

Inspections .......................................................... 29

Operating Instructions ......................................... 42

Transport and Lifting Instructions ....................... 50

Maintenance ....................................................... 53

Specifications ...................................................... 57

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

First Edition • First Printing Operator's Manual

Introduction

Part No. 1268193GT Z-45 XC 1

Introduction

About this manual

Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. This book is an operation and daily maintenance manual for the user or operator of a Genie machine.

This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, contact Genie.

Product Identification

The machine serial number is located on the serial label.

Serial number stamped on chassis

Serial label (located under cover)

Intended Use

This machine is intended to be used only to lift personnel, along with their tools, and materials to an aerial work site.

Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Genie. Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners.

The information contained in the bulletins is tied to specific machines using the machine model and serial number.

Distribution of bulletins is based on the most current owner on record along with their associated dealer, so it is important to register your machine and keep your contact information up to date.

To ensure safety of personnel and the reliable continued operation of your machine, be sure to comply with the action indicated in a respective bulletin.

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Introduction

2 Z-45 XC Part No. 1268193GT

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 Standards and regulatory compliance information Current owner updates, such as changes in

machine ownership or changes in your contact information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information will ensure that you receive important safety, maintenance and operating information that applies to your machine.

Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800.

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Introduction

Part No. 1268193GT Z-45 XC 3

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.

1 Avoid hazardous situations. Know and understand the safety rules

before going on to the next section.

2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended.

 You read, understand and obey the

manufacturer’s instructions and safety rules— safety and operator’s manuals and machine

decals.

 You read, understand and obey employer’s

safety rules and worksite regulations.

 You read, understand and obey all applicable

governmental regulations.

 You are properly trained to safely operate the

machine.

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Introduction

4 Z-45 XC Part No. 1268193GT

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 this machine use symbols, color coding, and signal words to identify the following:

Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a property damage message.

First Edition • First Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1268193GT Z-45 XC 5

Symbol and Hazard Pictorials Definitions

Crush hazard

Keep away from moving parts

Read the operator’s

manual

Overhead obstruction

Collision hazard

Electrocution hazard

Maintain required clearance

Tip-over hazard

Tip-over hazard Electrocution hazard

Avoid contact

Disconnect battery

Wind speed

Machine not level

Manual force

No smoking. No flame. Stop engine.

Explosion hazard

Burn hazard

Explosion hazard

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Symbol and Hazard Pictorials Definitions

6 Z-45 XC Part No. 1268193GT

Wheel load

Tire specifications

No smoking

Explosion hazard

Fire hazard

Platform tie-down instructions

Lifting & tie down instructions

Lanyard anchorage points

Tie-down point

Lifting point

Maximum capacity

Runaway 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: 1 Lower primary. 2 Lower secondary. 3 Retract primary.

Platform downhill: 1 Retract primary. 2 Lower secondary. 3 Lower primary.

Access by trained and authorized personnel onlyl

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General Safety

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General Safety

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General Safety

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General Safety

Part No. 1268193GT Z-45 XC 9

Operator's Manual First Edition • First Printing

Personal Safety

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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.

All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE

manufacturer’s instructions.

First Edition • First Printing Operator's Manual

Work Area Safety

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Work Area Safety

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.

Obey all local and governmental regulations regarding required clearance from electrical power lines. At a minimum, the required clearance contained in the chart below must be followed.

Line Voltage

Required Clearance

0 to 50KV

3.05 m

50 to 200KV

4.60 m

200 to 350KV

6.10 m

350 to 500KV

7.62 m

500 to 750KV

10.67 m

750 to 1000KV

13.72 m

Allow for platform movement, electrical line sway or 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 maximum platform capacity.

Maximum platform capacity Unrestricted range of motion

300 kg

Maximum occupants

Maximum platform capacity Restricted range of motion

454 kg

Maximum occupants

Maximum platform capacity Unrestricted range of motion Machine equipped with Aircraft Protection Package

273 kg

Maximum occupants

Maximum platform capacity Restricted range of motion Machine equipped with Aircraft Protection Package

427 kg

Maximum occupants

If the platform load is greater than 301 kg, or 274 kg with Aircraft Protection Package do not move the platform into the unrestricted range of motion zone.

Do not exceed the maximum platform capacity. Do not attach a platform rated at 300 kg

(unrestricted range of motion) or 454 kg (restricted range of motion) to machines with any other rated load. See the serial label for the maximum rated load.

The weight of options and accessories, such as pipe cradles, panel cradles and welders, will reduce the rated platform capacity and must be subtracted from the platform capacity. See the decals with the options and accessories.

If using accessories, read, understand and obey the decals, instructions and manuals with the accessory.

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Work Area Safety

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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 platform is raised, use extreme caution. Identify the condition of the boom on the slope as shown in the tilt alarm procedure. Follow the steps to lower the boom before moving to a firm, level surface. Do not rotate the boom while lowering.

If the tilt alarm sounds with the platform uphill:

1 Lower the primary

boom.

2 Lower the

secondary boom.

3 Retract the primary

boom.

If the tilt alarm sounds with the platform downhill:

1 Retract the primary

boom.

2 Lower the

secondary boom.

3 Lower the primary

boom.

Do not raise the boom when wind speeds may exceed 12.5 m/s. If wind speeds exceed 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.

Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.

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Work Area Safety

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Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.

Do not use the machine 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 – CE

400 N

Do not alter or disable machine components that in any way affect safety and stability.

Do not replace items critical to machine stability with items of different weight or specification.

Do not replace factory-installed tires with tires of different specification or ply rating.

Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight is critical to stability.

Do not use the platform controls to free a platform that is caught, snagged, or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.

Do not modify or alter a mobile elevating work platform without prior written permission from the manufacturer. Mounting attachments for holding tools or other materials onto the platform, toeboards, or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

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Work Area Safety

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Do not place or attach fixed or overhanging loads to any part of this machine.

Do not place ladders or scaffolds in the platform or against any part of this machine.

Do not transport 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 all tires are in good condition, air-filled tires are properly inflated and lug nuts are properly 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 applies only to machines in the stowed position.

Maximum slope rating, stowed position, 4WD

Platform downhill

45%

(24°)

Platform uphill

25%

(14°)

Side slope

25%

(14°)

Note: Slope rating is subject to ground conditions with one person in the platform and adequate traction. Additional platform weight may reduce slope rating. See Driving on a Slope in the Operating Instructions section.

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Work Area Safety

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Fall Hazards

Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform.

Do not sit, stand, or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

Do not climb down from the platform when raised.

Keep the platform floor clear of debris. Lower the platform entry mid-rail or close the entry

gate before operating. Do not 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 operating.

Be aware of the boom position and tailswing when rotating the turntable.

Check the work area for overhead obstructions or other possible hazards.

Be aware of crushing hazards when grasping the platform guard rail.

Operators must comply with employer, job site, and governmental rules regarding use of personal protective equipment.

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Work Area Safety

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Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.

Do not lower the boom unless the area below is clear of personnel and obstructions.

Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision.

Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

No stunt driving or horseplay while operating a machine.

Bodily Injury Hazard

Always operate the machine in a well-ventilated area to avoid carbon 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 and secured during operation.

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.

Do not refuel the machine with the engine running. Refuel the machine and charge the battery only in

an open, well-ventilated area away from sparks, flames and lighted tobacco.

Do not operate the machine or charge the battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

Do not spray ether into engines equipped with glow plugs.

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Work Area Safety

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Damaged Machine Hazards

Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of

the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.

Be sure all maintenance has been performed as specified in this manual and the appropriate Genie service manual.

Be sure all decals are in place and legible. Be sure the operator's, safety, 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 wear protective clothing and eye wear when working with batteries.

Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.

Explosion Hazards

Keep sparks, flames, and lighted tobacco away from batteries. Batteries emit explosive gas.

Electrocution Hazard

Avoid contact with electrical terminals.

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