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

Terex Genie Z-45 FE Operator's Manual

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Operator's Manual
Z
-45 FE
®
Z
-45 DC
®
Front Matter
Serial Number Range
CE
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1326146GT

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Summary of Contents for Terex Genie Z-45 FE

  • Page 1 Operator's Manual Serial Number Range -45 FE ® -45 DC ® with Maintenance Information Original Instructions Third Edition First Printing Part No. 1326146GT Front Matter...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2019 Terex Corporation Third Edition: First Printing, January 2024 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

    Third Edition • First 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 Third Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level Platform overload indicator light platform level, jib boom up/down, primary boom extend/retract, primary Secondary boom up/down boom up/down, secondary boom up/down...
  • Page 5 Third Edition • First 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 Third Edition • First 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

    Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Explosion hazard Read the operator’s Collision hazard Collision hazard manual Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact Disconnect battery...
  • Page 8 Operator's Manual Third Edition • First Printing Symbol and Hazard Pictorials Definitions Wheel load Tire specifications No smoking Explosion hazard Fire hazard Platform tie-down Lifting and tie down Lanyard anchorage Tie-down point Lifting point instructions instructions points Maximum capacity Runaway hazard Color coded Voltage rating for Pressure rating for air...
  • Page 9 Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Access by trained Do not use ether or Grounded AC and authorized other high energy 3-wire only 1 Lower primary.

  • Page 10: General Safety

    Operator's Manual Third Edition • First Printing General Safety General Safety ® ® -45 FE • Z -45 DC Part No. 1326146GT...
  • Page 11 Third Edition • First Printing Operator's Manual General Safety ® ® Part No. 1326146GT -45 FE • Z -45 DC...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety ® ® -45 FE • Z -45 DC Part No. 1326146GT...
  • Page 13 Third Edition • First Printing Operator's Manual General Safety ® ® Part No. 1326146GT -45 FE • Z -45 DC...
  • Page 14 Operator's Manual Third Edition • First Printing General Safety ® ® -45 FE • Z -45 DC Part No. 1326146GT...
  • Page 15 Third Edition • First Printing Operator's Manual General Safety ® ® Part No. 1326146GT -45 FE • Z -45 DC...

  • Page 16: Personal Safety

    Operator's Manual Third Edition • First 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 17: Work Area Safety

    Third Edition • First 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 18 Operator's Manual Third Edition • First Printing Work Area Safety If the tilt alarm sounds If using accessories, read, understand and obey with the platform uphill: the decals, instructions and manuals with the accessory. Lower the primary boom. Do not alter or disable the limit switches. Lower the Do not raise or extend the secondary boom.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Do not operate the machine in strong or gusty Do not push off or pull winds. Do not increase the surface area of the toward any object outside platform or the load. Increasing the area exposed of the platform.
  • Page 20 Operator's Manual Third Edition • First Printing Work Area Safety Operation on Slopes Hazards Do not modify or alter a mobile elevating work platform without prior written permission from the Do not drive the machine on a slope that exceeds manufacturer.
  • Page 21 Third Edition • First 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 22 Operator's Manual Third Edition • First Printing Work Area Safety Explosion and Fire Hazards Limit travel speed according to the condition Do not start the engine if you smell or detect diesel of the ground surface, fuel or other explosive substances. congestion, slope, location of personnel, and any Do not refuel the machine with the engine running.
  • Page 23 Third Edition • First 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. Disconnect the battery pack plug before removing Always wear protective the battery pack.
  • Page 24 Operator's Manual Third Edition • First Printing Work Area Safety Contact Alarm Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand, and obey all warnings and instructions provided with the contact alarm. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.
  • Page 25 Third Edition • First Printing Operator's Manual Work Area Safety Panel Cradle Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the panel cradles. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 26: Legend

    Operator's Manual Third Edition • First 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 27: Controls

    Third Edition • First 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 28 Operator's Manual Third Edition • First Printing Controls Function enable button DC mode light: FE models Press and hold the function enable button to Light on indicates the machine is in DC mode enable the functions on the ground control Red Emergency Stop button panel to operate.
  • Page 29 Third Edition • First Printing Operator's Manual Controls 13 Platform overload indicator light Light flashing indicates the platform is overloaded and no functions will operate. Remove weight until the light goes off. 14 Turntable rotate switch Move the turntable rotate switch up and the turntable will rotate to the right.
  • Page 30 Operator's Manual Third Edition • First Printing Controls Platform Control Panel ® ® -45 FE • Z -45 DC Part No. 1326146GT...
  • Page 31 Third Edition • First Printing Operator's Manual Controls ® ® Part No. 1326146GT -45 FE • Z -45 DC...
  • Page 32 Operator's Manual Third Edition • First Printing Controls Platform Control Panel Function speed control switch Move the switch to the left and the function Horn button speeds for jib up/down, platform rotate and Press this button and the horn will sound. primary boom extend/retract will decrease.
  • Page 33 Third Edition • First Printing Operator's Manual Controls 12 Drive speed select switch 11 Dual axis proportional control handle for drive and steer functions. Machine on incline symbol: Low range operation with reduced drive speed Proportional control handle for drive function for improved control.
  • Page 34 Operator's Manual Third Edition • First Printing Controls 15 Machine mode select switch: FE Models Move the switch to the left to select DC mode Move the switch to the right to select Hybrid mode 16 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary...

  • Page 35: Inspections

    Third Edition • First 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 36 Operator's Manual Third Edition • First Printing Inspections Pre-operation Inspection ❑ Nuts, bolts and other fasteners ❑ Platform entry mid-rail or gate ❑ Be sure that the operator’s manual is ❑ Platform load cell complete, legible and in the storage container located in the platform.
  • Page 37 Third Edition • First 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 38 Operator's Manual Third Edition • First Printing Inspections At the Ground Controls Test Auxiliary Controls FE Models: Select a test area that is firm, level and free of hazards. 10 Turn the key switch to ground control. Turn the key switch to ground control. 11 Pull out the red Emergency Stop button to the on position.
  • Page 39 Third Edition • First Printing Operator's Manual Inspections Test the Tilt Sensor At the Platform Controls FE Models: 25 Turn the key switch to platform control. 17 Select a test area that is firm, level and free of 26 Pull out the red Emergency Stop button to the hazards.
  • Page 40 Operator's Manual Third Edition • First Printing Inspections Test the Horn Test Machine Functions 31 Press the horn button. 39 Press down the foot switch. Result: The horn should sound. 40 Activate each machine function control handle or toggle switch. Test the Foot Switch Result: All boom and platform functions should operate through a full cycle.
  • Page 41 Third Edition • First Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 44 Press down the foot switch. 47 Press down the foot switch and lower the boom to the stowed position. 45 Slowly move the drive control handle in the direction indicated by the blue arrow on the 48 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 42 Operator's Manual Third Edition • First Printing Inspections Test Limited Drive Speed 59 Slowly move the drive control handle to the full drive position. 51 Press down the foot switch. Result: The maximum achievable drive speed 52 Raise the primary boom approximately 61 cm. with the secondary boom raised should not exceed 30 cm/s.
  • Page 43 Third Edition • First Printing Operator's Manual Inspections 65 Lower the primary boom to the stowed 72 Drive the machine onto a slope where the position. chassis pitch angle is greater than 4.5°. Result: The machine should drive. Result: The machine should stop once the machine reaches 4.5°...
  • Page 44 Operator's Manual Third Edition • First Printing Inspections Test the Oscillating Axle (if equipped) 78 Return to level ground and extend the primary boom approximately 0.5 m. 86 Drive the right steer tire up onto a 15 cm block 79 Drive the machine onto a slope where the or curb.
  • Page 45 Third Edition • First Printing Operator's Manual Inspections Test the Lift/Drive Select Function (if 99 Operate each machine function. equipped) Result: All machine functions should not operate. 93 Press down the foot switch. 100 Insert the actuator into the switch socket. 94 Move the drive control handle off center and activate a boom function toggle switch.
  • Page 46 Operator's Manual Third Edition • First Printing Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 102 Extend the primary boom approximately 30 cm. 103 Move the yellow bumper at the bottom of the platform 10 cm in any direction.
  • Page 47 Third Edition • First 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 48 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols Z-45 DC 219958 Label – Tip-over, Crush Hazard 1256425 Label – Danger, Electrocution Hazard, Use the pictures on the next page to verify that all Symbol decals are legible and in place.
  • Page 49 Third Edition • First Printing Operator's Manual Inspections 1315548 114252 114236 1263542 133205 1256425 133067 1294855 1299209 1286362 114249 1294851 72086 *1271943 52475 *1271944 *28174 *28235 *44981 72086 114248 219956 52475 219958 1294851 1272738 114249 44981 27205 27207 114252 27206 1281174 27206 133067...
  • Page 50 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols Z-45 FE 219956 Label – Platform Overload 219958 Label – Tip-over, Crush Hazard Use the pictures on the next page to verify that all 1256425 Label –...
  • Page 51 Third Edition • First Printing Operator's Manual Inspections 1315548 114252 114251 114236 1263542 133205 1256425 133067 1294855 1299209 1286362 114249 1294851 133411 72086 *1271943 52475 *1271944 *28174 *28235 *44981 72086 114248 219956 52475 219958 1294851 1272738 114249 44981 27205 27207 114252 27206 1281174...

  • Page 52: Operating Instructions

    Operator's Manual Third Edition • First 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 53 Third Edition • First Printing Operator's Manual Operating Instructions Machine Operation Auxiliary Power FE models can be operated with or without the Use auxiliary power if the primary power source engine running. fails. Turn the key switch to ground or platform Turn the key switch to ground or platform control.
  • Page 54 Operator's Manual Third Edition • First Printing Operating Instructions FE Models: Starting the Engine In cold conditions, -6°C and below, warm the engine for 5 minutes before operating to prevent From the ground control panel: hydraulic system damage. Turn the key switch to ground control. In extreme cold conditions, -18°C and below, machines should be equipped with optional cold Be sure both ground and platform control red...
  • Page 55 Third Edition • First Printing Operator's Manual Operating Instructions Operation from Platform To Steer Press down the foot switch. Note: When operating the machine from the platform, the following foot switch messages may Slowly move the drive control handle in the appear on the platform control LCD screen.
  • Page 56 Operator's Manual Third Edition • First Printing Operating Instructions To determine the slope grade: Driving on a slope Measure the slope with a digital inclinometer OR Determine the uphill, downhill and side slope use the following procedure. ratings for the machine and determine the slope grade.
  • Page 57 Third Edition • First Printing Operator's Manual Operating Instructions Drive Enable Function Speed Control LCD symbol on indicates that Move the switch to the the boom has moved just past left to decrease the either non-steer wheel and the function speeds for jib drive function has been up/down, platform rotate interrupted.
  • Page 58 Operator's Manual Third Edition • First Printing Operating Instructions Machine Not Level LCD Symbol Tilt Sensor Activation Settings If the tilt alarm sounds when the Model Parallel to boom Perpendicular to structure boom structure platform is raised, the Machine Not Level LCD symbol will come on Z-45 DC 4.5°...
  • Page 59 Third Edition • First Printing Operator's Manual Operating Instructions Platform Overload LCD Symbol The contact alarm cable is tripped, releasing the actuator from the switch socket. LCD symbol flashing indicates the Insert the actuator into the switch socket to platform is overloaded and no turn off flashing lights and audio alarm.
  • Page 60 Operator's Manual Third Edition • First Printing Operating Instructions FE Models: Charging Batteries with Engine Running the engine will automatically charge the batteries. The engine will automatically shut off when the battery charge cycle reaches 85%. After the charge cycle reaches 85% the platform Battery and Charger Instructions control panel LCD screen will display the following message, HYBRID CHARGE COMPLETE.
  • Page 61 Third Edition • First Printing Operator's Manual Operating Instructions Dry Battery Filling and Charging Pipe Cradle Instructions Instructions The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform This procedure applies to flooded lead acid and mounted to the guardrails with U-bolts.
  • Page 62 Operator's Manual Third Edition • First Printing Operating Instructions Observe and Obey: Pipe Cradle Operation  Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
  • Page 63 Third Edition • First Printing Operator's Manual Operating Instructions Panel Cradle Assembly Installation of Padding Apply the warning decal to the front of each Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 64 Operator's Manual Third Edition • First Printing Operating Instructions Panel Cradle Operation Secure both panel cradles to the platform. Place the load so that it rests in both panel cradles. Center the load on the platform. Secure the load to the platform using the strap.
  • Page 65 Third Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 66: Transport And Lifting Instructions

    Operator's Manual Third Edition • First Printing 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 67 Third Edition • First Printing Operator's Manual 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 68 Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Rotate 90° the swing chassis, from the transport position. Observe and Obey: Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 69: Maintenance

    Third Edition • First Printing Operator's Manual 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 70 Operator's Manual Third Edition • First Printing Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 71 Third Edition • First 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 72: Specifications

    Operator's Manual Third Edition • First Printing Specifications Specifications Model Highest root mean square value of weighted Z-45 DC acceleration to which the whole body is subjected does Height, working maximum 15.92 m not exceed 0.5 m/s Height, platform maximum 13.92 m Ambient operating temperature -20°...
  • Page 73 Third Edition • First Printing Operator's Manual Specifications Highest root mean square value of weighted Model Z-45 FE acceleration to which the whole body is subjected Height, working maximum 15.92 m does not exceed 0.5 m/s Height, platform maximum 13.92 m Ambient operating -20°...
  • Page 74 Operator's Manual Third Edition • First Printing Specifications Z-45 FE Range of Motion Chart Z-45 FE Range of Motion Chart with Aircraft Protection ® ® -45 FE • Z -45 DC Part No. 1326146GT...
  • Page 75 Third Edition • First Printing Operator's Manual 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, relevant harmonized standards, technical standards or specifications used: <standard(s)' name>...
  • Page 76 Operator's Manual Third Edition • First Printing 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 <standard(s)' name>.
  • Page 77 Third Edition • First Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 1 <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) relevant designated standards, technical standards or specifications used: <standard(s)' name>...
  • Page 78 Operator's Manual Third Edition • First Printing Specifications Contents of UK Declaration of Conformity - 2 <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) conformity assessment procedure according to Part 3, 11.

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