Terex Genie Lift Tools Expo Installer Z-45/25 User manual

Operator's Manual Supplement
Lift Tools™ Expo Installer
First Edition
Third Printing
Part No. 1286259GT

Operator's Manual Supplement First Edition • Third Printing
Introduction
2 Lift Tools
™
Expo Installer Part No. 1286259GT
Introducti on
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine. Only trained and authorized personnel
shall be permitted to operate this 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 us.
Contact Us:
Internet: www.genielift.com
E-mail: [email protected]
Approved Models
Z-45/25 S-60HC
Z-45/25J Z-60/34
Z-45/25 RT Z-60/37DC
Z-45/25J RT Z-60/37FE
Z-51/30 Z-62/40
Z-45 XC S-40 XC
S-40 S-45 XC
S-45 S-60 XC
S-60 S-65 XC
S-60X
S-65
Do not install the LTEI system on
any Genie boom product other
than the designated models.
Copyright © 2018 by Terex Corporation
First Edition: Third Printing, July 2019
Genie is registered trademarks of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
These machines comply with
ANSI/SAIA A92.20
CAN/CSA B.354.6
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
WARNING

First Edition • Third Printing Operator's Manual Supplement
Introduction
Part No. 1286259GT Lift Tools™Expo Installer 3
Genie Self-propelled Boom
Products and Lift Tools Expo
Installer (LTEI) Guidance
Background
Mobile Elevated Work Platforms (MEWPs) are
designed to carry personnel to elevated work
locations. As part of this function, materials are
sometimes raised to specific heights for installation
and display. A Lift Tools™ Expo Installer (LTEI) is
designed to lift signs in controlled workplace
environments. Depending on the work being
performed a LTEI may be used while in the
platform to raise a sign to a desired location and
make the work easier or more efficient. This
document provides guidance for the use of LTEIs
on Genie products.
This document provides guidance for the
use of Genie Booms to serve as an indoor
lifting tool for expo sign installations.
Definitions
Qualified person
A "qualified person" one who, by possession of a
recognized degree, certificate, or professional
standing, or by extensive knowledge, training and
experience, has demonstrated his/her ability to
solve or resolve problems related to the subject
matter, the work, or the project.
Genie Self-propelled Booms may be used
to lift under the following guidelines:
1The owner/employer/user/operator of the
boom is responsible for providing fall protection
for boom operator.
2A "qualified person" with knowledge of fall
protection regulations and systems must
design the work space and the LTEI system to
insure worker safety.
3Genie Booms have been stability tested on
level ground for a 240 lb/108.9 kg sign with the
remaining rated load in the platform. Therefore
the weight of the sign must not exceed
240 lbs/108.9 kg.
4Fabrication, attachment and use of an LTEI
must be approved and authorized by the
equipment owner.
5It is the responsibility of the equipment owner
and/or the contractor to perform a hazard
analysis on the design and use of the LTEI,
and ensure that the equipment complies with
the essential health and safety requirements
applicable to the jobsite, as well as local, state,
provincial, and federal rules and regulations,
and standards related to the use of the
equipment.
6Employers and operators must be aware of
and plan for potential vertical and horizontal
platform movement while using LTEI.

Operator's Manual Supplement First Edition • Third Printing
Introduction
4 Lift Tools™Expo Installer Part No. 1286259GT
7The boom must be on firm level ground to use
the LTEI.
8A person trained in the operation of the Genie
boom shall remain on the ground near the
machine base controls to prevent unauthorized
use and to prevent the machine from being
operated while using the LTEI.
9Wind speed indoors does not exceed
0 mph/0 m/sec.
Owner/Employer/User/Operator
Requirements:
Owner/Employer/User/Operator
Requirements:
1Operators must be trained and qualified on
safe operation of the equipment, and be
familiar with the specific model of Genie
equipment as follows:
Be familiar and comply with the equipment
operating and safety manuals, decals and
warnings.
Understand all control functions.
Be aware of and understand all safety
devices specific to the equipment being used.
Be instructed how to avoid the hazards.
1Comply with all applicable jobsite, local, state,
provincial, and federal rules and regulations,
and standards related to the use of the
equipment.
2The equipment must be in proper working
condition and configuration.
In consideration for Genie's guidance herein, the
equipment owner, employer, user and operator
hereby agree to indemnify and hold harmless
Terex USA and its parent and affiliated companies
against any and all liabilities, claims, suits, losses,
costs and legal fees caused by, arising out of, or
resulting from any negligent act or omission in the
operation of the equipment; the failure to comply
with the criteria set forth in this manual related to
the use of a boom with a LTEI; the safety rules and
operating instructions in the Operator's Manual. By
proceeding with the use of a boom with a LTEI,
you agree to adhere to the requirements set
forth herein, including said indemnification. If
you do not agree, do not proceed with the
proposed use.

First Edition • Third Printing Operator's Manual Supplement
Introduction
Part No. 1286259GT Lift Tools™Expo Installer 5
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Note
The Lifting Tools™ Expo Installer (LTEI) is only
authorized for use in the ANSI, CSA and CE
markets. All other markets are prohibited from use.
The LTEI can only be used on Genie Booms
equipped with the following 6 ft/1.83 m or 8 ft/
2.44 m platforms:
Standard entry platforms manufactured from
January, 2003
Side entry swing gate platforms manufactured
from August, 2015
Use on all other machines is prohibited.

Operator's Manual Supplement First Edition • Third Printing
Introduction
6 Lift Tools™Expo Installer Part No. 1286259GT
The LTEI shall not be used with machines
equipped with the following:
Panel cradle option
Traveling Fall Arrest Anchor System
Center mounted swing gate option
Tri-entry platform with three sliding mid-rails
Tri-entry platform with two sliding mid-rails and
center mounted swing gate
Using the LTEI with the above
options could result in death or
serious injury.
LTEI Safety
Read, understand and obey all warnings and
instructions provided with the LTEI.
Do not exceed the rated platform capacity. The
weight of the LTEI assembly will reduce the rated
platform capacity and must be subtracted from the
total platform load.
The LTEI assembly weighs 84 lbs/38.1 kg.
Be sure the LTEI is securely installed.
When the LTEI structure is attached, this manual
should be considered a permanent part of your
machine and should remain with the machine at all
times.
DANGER

First Edition • Third Printing Operator's Manual Supplement
Introduction
Part No. 1286259GT Lift Tools™Expo Installer 7
Symbol and Hazard Pictorials
Definitions
LTEI system weighs
84 lbs/38.1 kg
Read the
supplement, part
number 1286259
Tip over hazard.
Maximum capacity
240 lbs/108.9 kg.
= 240 lbs/108.9 kg
Maximum wind
speed 0 m/sec
(indoor only)
Pre-operation Inspection
Be sure that the operator’s, safety manual,
responsibilities manual and any necessary
supplements are complete, legible and in the
storage container located in the platform.
Be sure that all decals are legible and in place.
Check the LTEI for damage or wear, improperly
installed, loose or missing parts and unauthorized
modifications.
Nuts, bolts and other fasteners
Cracks in welds or structural components.
Dents or damage to LTEI
Verify that the trolley can move freely
along the entire length of the track.
Inspect brake material for excessive wear.
Brake surface to be clean and free of
contamination.
Decal Inspection
Use the inspection to verify that all decals are
legible and in place. Decals may vary depending
on machine configuration.
Part No. Decal Description Qty
1286260 Decal – Lift Tool Expo Installer, Word 1
1286260FR Decal – Lift Tool Expo Installer, Word FR 1
1286262 Decal – Lift Tool Expo Installer, Symbol 1
1286393 Decal – Cosmetic, Lift Tool Expo Installer 1
84 lbs /
38.1 kg
+

Operator's Manual Supplement First Edition • Third Printing
Introduction
8 Lift Tools™Expo Installer Part No. 1286259GT
Annual Inspection
Inspect for missing or loose components.
Check all fasteners for proper torque. Refer to the
installation instructions section of this document for
the torque specifications.
Inspect all components for damage or wear. Check
for cracks, bends and corrosion.
Inspect all welds for cracks.
Inspect the lower track flanges. If the flanges are
bent, damaged or worn, replace the track.
Verify the trolley can freely move the entire length
of the track.
Test the operation of the trolley and verify the
wheels rotate freely.
Verify the track end stops and hardware are
present and secure.
Verify the brake material does not show signs of
wear.

First Edition • Third Printing Operator's Manual Supplement
Operating Instructions
Part No. 1286259GT Lift Tools™Expo Installer 9
Operating Ins tructions
Observe and Obey:
This procedure shall be completed by a person
authorized to install the Lift Tools™ Expo
Installer.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Do not exceed the rated platform capacity.
Combined weight of LTEI, occupants, tools
and any other equipment.
Subtract the weight of attached accessory from
rated load.
The weight of LTEI and sign may limit
maximum number of occupants in platform to
one person.
Do not operate unless you are adequately
instructed and are aware of all hazards
associated with lifting signs.
Do not cause a horizontal force due to a sign
that is caught, snagged or otherwise prevents
normal motion.Maximum wind speed:
0 mph/0 m/sec.
Before elevating a sign, the area shall be
marked to warn of work being performed by
personnel.
Do not transport signs unless they are evenly
distributed and can be safely handled by a
person in the platform.
Be certain that the path of sign travel is clear of
hazards, such as storage racks, scaffolds,
overhead obstructions, and electrical wires.
All movements of the load must be
accomplished gradually and at the slowest
practical speed to prevent the load from
swinging.
Only use proper rigging, capable of
withstanding the expected loads, to tether the
load. Do not use tethers that are damaged.
Always remove any tethers before placing a
suspended load.
Only lift a load vertically; do not pull a load
horizontally as it could cause excessive
swinging of the load.
Identify the proper lifting points of the load,
taking into consideration the center of gravity
and load stability.

Operator's Manual Supplement First Edition • Third Printing
Operating Instructions
10 Lift Tools™Expo Installer Part No. 1286259GT
Be sure that the operator keeps the load
vertical under the lifting point.Do not adjust the
length of the suspension element during
movement or lifting operations.
The Expo Installer is not a personal fall
protection system. This device does not have a
lanyard anchorage point.
Check that the brake is applied when the
handle is released.
Tip-over hazard. Swinging loads
will significantly increase
suspended weight.
Note: Perform this procedure on a firm, level
surface with the machine in the stowed position.
Suspended Load Hazards
Work Area Safety
General Safety
Do not lift a suspended load without first
understanding the local, state, federal, or provincial
rules, standards and regulations related to the
activity. Additional training may be required.
Read, understand and obey all warnings and
instructions provided with the attachment that is
approved for suspending loads.
Tip-over Hazards
Do not permit the
load to swing
freely.
Do not use this tool to lift people. It is intended to lift
material only.
Keep the boom retracted as much as practical.
Do not lift suspended loads when wind speeds can
cause an unsafe situation.
All movements of the load must be accomplished
gradually and at the slowest practical speed to
prevent the load from swinging.
Never drag or pull a load sideways.
WARNING

First Edition • Third Printing Operator's Manual Supplement
Operating Instructions
Part No. 1286259GT Lift Tools™Expo Installer 11
Only lift a load vertically; do not pull a load
horizontally as it could cause excessive swinging of
the load.The weight of all rigging (slings, shackles
etc.) must be included as part of the load.
Tip-over hazard. The weight of
the LTEI assembly and the load
on the LTEI will reduce the rated
platform capacity of the machine
and must be factored into the
total platform load.
Tip-over hazard. The weight
of the LTEI assembly and
the load on the LTEI may
limit the maximum number
of occupants in the platform.
Identify the proper lifting points of the load, taking
into consideration the center of gravity and load
stability.
Do not try to move fixed or obstructed loads.
Do not leave the Genie Boom unattended with a
suspended load.
Keep the boom and load as low as practical while
maintaining visibility in the direction of
travel.Maximum capacity of the LTEI is
240 lbs/108.9 kg.
The LTEI assembly weighs 84 lbs/38.1 kg.
Do not exceed walking speed (0.7 mph/1.1 km/h)
with a suspended load.
Start, travel, turn and stop slowly to prevent the
load from becoming unstable or swinging.
Do not use any controls to re-position the load
when traveling. Come to a gradual and complete
stop before attempting to re-position the load.
Do not attempt to cross inclines as the load center
will move towards the tipping line, thereby reducing
stability.
Only climb or descend inclines with extreme care
as the load center will move towards the tipping
line, thereby reducing stability.
WARNING
WARNING

Operator's Manual Supplement First Edition • Third Printing
Installation Instructions
12 Lift Tools™Expo Installer Part No. 1286259GT
InstallationInstructions
Before Starting Installation
Read, understand and obey the safety rules
and operating instructions in the appropriate
Genie Operator’s Manual and Supplements.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
Notes:
New mounting hardware is recommended to be
used with each new installation of the LTEI,
including re-installation on the same machine. A
replacement hardware kit (Genie part number
1260849) is available through the Genie Parts
Department.
Refer to the illustration page for installation
instructions.
Contents of Kit 1285719
For use with 6 ft / 1.83 m platforms with
word decals.
Part Description Genie Part
Number
Qty.
(1) Spacer 1256481 8
(2) Screw, 3/8-16 x 2.5 ** 1256856 8
(3) Flange nut, 3/8-16** 1274322 8
(4) Manual, Supplement 1286259 1
(5) Inner hanger 1286621 2
Components of *1285720
Part Description Genie Part
Number
Qty.
(6) Decal, LTEI Max Capacity, Word 1286260 1
(7) Decal, LTEI Max Wind Speed, Word 1286261 1
(8) End stop 1260892 2
(9) Rubber bumper 36388 2
(10) Screw, 1/2-13 x 3.5 *** 1256851 2
(11) Flange nut, 1/2-13 *** 1251997 2
(12) Decal, Cosmetic, Lift Tools™ Expo
Installer
1286393 1
(13) Weldment 1286620 1
(14) Trolley* 1285721 1
* Lower level components of p/n 1285721
(a) 1289692 Grip Handle 1
(b) 1289693 Brake Pad 1
(c) 1285730 Spring 2
** Torque to 44 ft-lbs/60 Nm
*** Tighten until snug. Do not over tighten or the
track may be damaged.

First Edition • Third Printing Operator's Manual Supplement
Installation Instructions
Part No. 1286259GT Lift Tools™Expo Installer 13
Contents of Kit 1286618
For use with 6 ft / 1.83 m platforms with
symbol decals.
Part Description Genie Part
Number
Qty.
(1) Spacer 1256481 8
(2) Screw, 3/8-16 x 2.5 ** 1256856 8
(3) Flange nut, 3/8-16** 1274322 8
(4) Manual, Supplement 1286259 1
(5) Inner hanger 1286621 2
Components of *1286619
Part Description Genie Part
Number
Qty.
(6) Decal, LTEI Max Capacity, Symbol 1286262 1
(7) Decal, LTEI Max Wind Speed,
Symbol
1286263 1
(8) End stop 1260892 2
(9) Rubber bumper 36388 2
(10) Screw, 1/2-13 x 3.5 *** 1256851 2
(11) Flange nut, 1/2-13 *** 1251997 2
(12) Decal, Cosmetic, Lift Tools™ Expo
Installer
1286393 1
(13) Weldment 1286620 1
(14) Trolley* 1285721 1
* Lower level components of p/n 1285721
(a) 1289692 Grip Handle 1
(b) 1289693 Brake Pad 1
(c) 1285730 Spring 2
** Torque to 44 ft-lbs/60 Nm
*** Tighten until snug. Do not over tighten or the
track may be damaged.
Contents of Kit 1288801
For use with 8 ft / 2.44 m platforms with
word decals.
Part Description Genie Part
Number
Qty.
(1) Spacer 1256481 8
(2) Screw, 3/8-16 x 2.5 ** 1256856 8
(3) Flange nut, 3/8-16** 1274322 8
(4) Manual, Supplement 1286259 1
(5) Inner hanger 1286621 2
Components of *1288802
Part Description Genie Part
Number
Qty.
(6) Decal, LTEI Max Capacity, Word 1286260 1
(7) Decal, LTEI Max Wind Speed, Word 1286261 1
(8) End stop 1260892 2
(9) Rubber bumper 36388 2
(10) Screw, 1/2-13 x 3.5 *** 1256851 2
(11) Flange nut, 1/2-13 *** 1251997 2
(12) Decal, Cosmetic, Lift Tools™ Expo
Installer
1286393 1
(13) Weldment 1286620 1
(14) Trolley* 1285721 1
* Lower level components of p/n 1285721
(a) 1289692 Grip Handle 1
(b) 1289693 Brake Pad 1
(c) 1285730 Spring 2
** Torque to 44 ft-lbs/60 Nm
*** Tighten until snug. Do not over tighten or the
track may be damaged.

Operator's Manual Supplement First Edition • Third Printing
Installation Instructions
14 Lift Tools™Expo Installer Part No. 1286259GT
Contents of Kit 1288803
For use with 8 ft / 2.44 m platforms with
symbol decals.
Part Description Genie Part
Number
Qty.
(1) Spacer 1256481 8
(2) Screw, 3/8-16 x 2.5 ** 1256856 8
(3) Flange nut, 3/8-16** 1274322 8
(4) Manual, Supplement 1286259 1
(5) Inner hanger 1286621 2
Components of *1288804
Part Description Genie Part
Number
Qty.
(6) Decal, LTEI Max Capacity, Symbol 1286262 1
(7) Decal, LTEI Max Wind Speed,
Symbol
1286263 1
(8) End stop 1260892 2
(9) Rubber bumper 36388 2
(10) Screw, 1/2-13 x 3.5 *** 1256851 2
(11) Flange nut, 1/2-13 *** 1251997 2
(12) Decal, Cosmetic, Lift Tools™ Expo
Installer
1286393 1
(13) Weldment 1286620 1
(14) Trolley* 1285721 1
* Lower level components of p/n 1285721
(a) 1289692 Grip Handle 1
(b) 1289693 Brake Pad 1
(c) 1285730 Spring 2
** Torque to 44 ft-lbs/60 Nm
*** Tighten until snug. Do not over tighten or the
track may be damaged.

First Edition • Third Printing Operator's Manual Supplement
Installation Instructions
Part No. 1286259GT Lift Tools™Expo Installer 15
Lift Tools™ Expo Inst aller Part No. 1286259GT O
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erator's Manual Su
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lement First Edition• Third Printing