Terex Genie Z-45 FE User manual

1.
Operator's Manual
Z®-45 FE
Z®-45 DC
First Edition
First Printing
Part No. 1299207GT
with
Maintenance
Information
Serial number range
From serial n.: Z45EM-101 ANSI/CSA
North America
South America
Asia

II Z®-45 FE • Z®-45 DC Part No. 1299207GT
First Edition • First Printing
Operator's Manual
Contents
Introduction.......................................................... 1
Symbol and Hazard Pictorials Definitions............ 5
General Safety..................................................... 8
Personal Safety ................................................. 20
Work Area Safety .............................................. 21
Legend............................................................... 29
Controls ............................................................. 30
Inspections ........................................................ 38
Operating Instructions ....................................... 57
Transport and Lifting Instructions ...................... 69
Maintenance...................................................... 72
Specifications .................................................... 75
Copyright © 2019 by Terex Corporation
First Edition: First Printing, January 2020
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
These machines comply with
ANSI/SAIA A 92.20
CAN/CSA B354.6

Part No. 1299207GT Z®-45 FE • Z®-45 DC 1
First Edition • First Printing Operator's Manual
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.
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevated Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the manual
storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.
Serial label
(located under cover)
Serial number stamped
on chassis

2 Z®-45 FE • Z®-45 DC Part No. 1299207GT
First Edition • First Printing
Operator's Manual
Introduction
Platform controls symbology and
related machine movement:
Platform level
Secondary boom up/
down
Primary boom up/
down
Jib boom up/down
Turntable rotate
Platform rotate
Primary boom
extend/retract
Drive forward/
reverse
Steer right/left
Ground controls symbology and
related machine movement:
Platform overload
indicator light
platform level, jib
boom up/down,
primary boom
extend/retract,
primary boom up/
down, secondary
boom up/down
Turntable rotate,
platform rotate
Sequential functions and movement:
• Drive and steer.
Interlocked functions:
• Elevated drive speed.
• Elevated drive in an off-level condition.
• Drive enable when the boom is rotated past the
non-steer wheels.
• All platform and ground controls
Limitation of use:
• The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
• Do not elevate the platform unless the machine
is on a firm level ground.

Part No. 1299207GT Z®-45 FE • Z®-45 DC 3
First Edition • First Printing Operator's Manual
Introduction
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.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
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.

4 Z®-45 FE • Z®-45 DC Part No. 1299207GT
First Edition • First 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.
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.
DANGER
Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a hazardous situation
which, if not avoided, could
result in minor or moderate
injury.
NOTICE
Indicates a property damage
message.
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 work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Part No. 1299207GT Z®-45 FE • Z®-45 DC 5
First Edition • First Printing Operator's Manual
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 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

6 Z®-45 FE • Z®-45 DC Part No. 1299207GT
First Edition • First Printing
Operator's Manual
Symbol and Hazard Pictorials Definitions
Wheel load Tire specifications No smoking Explosion hazard Fire hazard
Lifting point
Platform tie-down
instructions
Lifting & tie down
instructions
Lanyard anchorage
points
Tie-down 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
2 Retract primary
Platform downhill:
1 Retract primary
2 lower secondary
3 Lower primary
Access by trained
and authorized
personnel only
Do not use ether
or other high
energy starting
aids on machines
equipped with glow
plugs
Grounded AC
3-wire only

Part No. 1299207GT Z®-45 FE • Z®-45 DC 7
First Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Replace damaged
wires and cords
Batteries used as
counterweights
Read the service
manual
Battery box torque Crush Hazard
Keep hands clear
of moving parts
during equipment
operation
Crush hazard Support the
platform or
boom during
maintenance
Emergency
lowering

8 Z®-45 FE • Z®-45 DC Part No. 1299207GT
First Edition • First Printing
Operator's Manual
General Safety
97865 114390
1263543
1301780
31060
1267121
1298002
219484
219484
31060
52865
219484 1301780 114390
31060
52865 1267121
1298002
97865 1263543
1301780 A
Electrocution Hazard
This machine is not electrically insulated. Death or
injury can result from contacting electric power lines.
Always contact the electric power line owner. The
electric power shall be disconnected or the power
lines moved or insulated before machine operations
begin.114390 B
DANGER
Maintain required clearance.
Line Voltage Required Clearance
m0.3tf01VK05ot0
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
219484 A
RT Tires
Tire size: 315/55D20
minimum 12 ply
Foam-Filled Tire,
Minimum New Weight:
290 lbs / 131 kg
Wheel Lug To rque
Dry: 125 ft-lbs / 169 Nm
Lubricated: 94 ft-lbs /
127 Nm
Tip-over Hazard
Do not use air-filled tires.
This machine is equipped
with foam-filled tires.
Wheel weight and
proper counterweight
configuration are critical
to stability.
Improper operation or maintenance of
this equipment can result in death or
serious injury.
Access by trained and
authorized personnel only.
1263543 A
DANGER
Tip-over Hazard
Altering or disabling sensors
or limit switches can result in
machine tip-over. Machine tip-over
will result in death or serious injury.
Do not alter or disable sensors
and/or limit switches.
31060 D
Crush Hazard
Contact with moving work platform or
boom can result in death or serious injury.
Securely brace work platform or boom
during maintenance. 1267121 A
1298002 A
Z-45 DC