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Terex Genie Z-45 FE User Manual

Terex Genie Z-45 FE
80 pages
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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

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Terex Genie Z-45 FE Specifications

General IconGeneral
Gradeability - 4WD45%
Fuel TypeDiesel
Gradeability45%
Working Height15.92 m
Platform Height13.92 m
Up and Over Clearance7.50 m
Lift Capacity660 lb (300 kg)
Power SourceHybrid (Diesel and Electric)
Stowed Height2.00 m
Engine Power24.8 hp

Summary

Introduction

About This Manual

Provides information about the operator's manual and its purpose.

Product Identification

Explains where to find the machine's serial number.

Intended Use and Familiarization Guide

Outlines the intended use and familiarization requirements for operating the machine.

Introduction - Controls and Limitations

Platform Controls Symbology

Illustrates platform control symbols and their corresponding machine movements.

Ground Controls Symbology

Illustrates ground control symbols and their corresponding machine movements.

Limitation of Use

Defines the limitations on using the machine, including intended use and operating conditions.

Introduction - Bulletins and Contact

Bulletin Distribution and Compliance

Explains Genie's bulletin system for safety and product information updates.

Contacting the Manufacturer

Provides guidance on when and how to contact Genie for support.

Transfer of Machine Ownership

Details the process for updating machine ownership information with Genie.

Introduction - Safety Fundamentals

Danger Warning

Warns that failure to obey instructions can lead to death or serious injury.

Safety Sign Maintenance

Provides instructions for maintaining safety signs on the machine.

Hazard Classification System

Explains the system of symbols, color coding, and signal words for hazard identification.

Symbol and Hazard Pictorials Definitions

Crush Hazard

Depicts the hazard of being crushed by moving parts or equipment.

Keep Away From Moving Parts

Advises to maintain a safe distance from moving mechanical components.

Read Operator's Manual

Emphasizes the importance of reading and understanding the operator's manual.

Overhead Obstruction Hazard

Warns of potential hazards from overhead obstructions.

Collision Hazard

Alerts to the risk of colliding with objects or other equipment.

Electrocution Hazard

Warns of the danger of electric shock from contact with power sources.

Maintain Required Clearance

Advises to maintain a safe distance from hazards like power lines.

Tip-over Hazard

Highlights the risk of the machine tipping over.

Avoid Contact

Advises against touching potentially hazardous parts or substances.

Disconnect Battery

Instructs to disconnect the battery before certain operations or maintenance.

Wind Speed Hazard

Indicates hazards related to wind speed affecting machine stability.

Machine Not Level Indicator

Warns when the machine is on an unstable or unlevel surface.

No Smoking/Flame Safety

Safety instructions regarding fire and explosion hazards.

Explosion Hazard

Warns of the risk of explosions due to flammable materials or conditions.

Burn Hazard

Alerts to the risk of burns from hot surfaces or fluids.

Symbol and Hazard Pictorials Definitions (Continued)

Wheel Load and Tire Specifications

Indicates hazards related to wheel load and tire specifications.

Fire and Explosion Hazards

Warns of explosion and fire risks from flammable materials.

Tie-Down and Lifting Instructions

Instructions for securing and lifting the machine.

Lanyard Anchorage and Tie-down Points

Identifies points for attaching safety lanyards and securing the machine.

Capacity and Runaway Hazard

Specifies maximum capacity and warns of runaway hazards.

Direction Arrows and Power Ratings

Explains color-coded arrows and indicates power/pressure ratings.

Tilt Alarm Recovery Procedures

Details steps to take if the tilt alarm activates during operation.

Slope Operation Safety

Describes procedures for platform movement when uphill or downhill.

Authorized Personnel and Starting Aids

Restricts access and warns against using starting aids with glow plugs.

Grounded Electrical Connection

Specifies requirements for electrical grounding.

General Safety

Tip-over Hazard Information

Factors, consequences, and warnings related to machine tip-over.

Electrocution Hazard and Clearances

Danger of electrocution and required clearances from power lines.

Battery Service and Inspection Safety

Risks during service without battery disconnect and annual inspection requirements.

Crush Hazard Warnings

Danger from contact with moving parts or boom/platform.

General Safety (Continued)

Sensor, Switch, and Overload Safety

Tip-over risks from altering sensors; platform overload warnings.

Slope Operation and Runaway Hazards

Tilt alarm warnings and safe operation on slopes, plus runaway hazards.

Wind Speed and Panel Cradle Safety

Max wind speed, capacity limits, and panel cradle injury risks.

General Safety - Electrical and Battery

Electrical Safety and Clearances

Required clearances from line voltages and electrical connection safety.

Battery Box and Weight Hazards

Battery box hazards, tip-over from battery weight, and servicing safety.

General Safety - Specific Hazards

Sensor Alteration and Burn Hazards

Tip-over risks from sensor alteration; burn risks from fuel/fumes.

General Safety - Operational Limits

Electrical, Slope, and Capacity Safety

Electrical clearances, tilt alarm warnings, and capacity limits.

General Safety - Mixed Hazards

Electrical, Flammable, and Battery Safety

Electrocution/fire risks, explosion/burns from fuel, battery box hazards.

General Safety - Hazard Summary

Electrical, Slope, and Cradle Safety

Electrical clearances, tilt alarm, and panel cradle injury risks.

Work Area Safety

Electrocution Hazards and Clearances

Warns about electrocution hazards and required clearances from power lines.

Tip-over Hazards and Capacity Limits

Highlights hazards related to platform capacity and limit switches causing tip-over.

Collision Hazards and Blind Spots

Advises awareness of blind spots and obstructions to prevent collisions.

Work Area Safety (Continued)

Operation on Slopes Hazards

Details safe operation procedures and limits when working on slopes.

Fall Hazards and Protection

Emphasizes wearing fall protection and maintaining stable footing.

Collision Hazards Awareness

Advises awareness of blind spots and obstructions to prevent collisions.

Work Area Safety - Specific Hazards

Bodily Injury and Explosion Hazards

Warns about injury from hydraulic leaks and explosion/fire risks.

Work Area Safety - Hazard Mitigation

Damaged Machine and Battery Safety

Advises against using damaged machines and covers battery safety.

Component Damage Hazards

Warns against using incorrect voltage for jump-starting and welding.

Work Area Safety - Alarm and Cradle

Electrocution and Contact Alarm Safety

Safe battery charging, contact alarm function, and tip-over hazards.

Work Area Safety - Cradle and Lockout

Pipe and Panel Cradle Safety

Instructions and warnings for installing and using pipe and panel cradles.

Lockout After Each Use

Steps for securing the machine after operation.

Legend

Controls - Ground Panel

Ground Control Panel Functions

Details the components and functions of the ground control panel.

Controls - Platform Panel

Platform Control Panel Functions

Details the components and functions of the platform control panel.

Inspections

Pre-operation Inspection Fundamentals

Explains the importance and process of performing a pre-operation inspection.

Function Test Fundamentals

Explains the purpose of function tests and procedures for malfunctioning machines.

Ground Controls Inspection Procedures

Step-by-step inspection procedures for ground controls, emergency stop, and functions.

Steering and Drive System Inspections

Procedures to test steering, drive, braking, and drive enable systems.

Drive Speed and Tilt Cutout Inspections

Tests for limited drive speed and drive tilt cutout functionality.

Contact Alarm and Aircraft Protection Tests

Procedures for testing the contact alarm and aircraft protection systems.

Workplace Inspection Checklist

A checklist of potential hazards to identify and avoid in the work area.

Decal Inspection for Z-45 DC

A list of decals with part numbers, descriptions, and quantities for the Z-45 DC.

Decal Inspection for Z-45 FE

A list of decals with part numbers, descriptions, and quantities for the Z-45 FE.

Decal Inspection for Symbols Z-45 FE

A list of decals with part numbers, descriptions, and quantities for the Z-45 FE.

Operating Instructions

Operating Instructions Fundamentals

Outlines the importance of following safety rules and using the machine correctly.

Machine Operation and Emergency Stop

Steps for operating the machine, including power and emergency stop controls.

Auxiliary Power Usage

Instructions for using auxiliary power when the primary source is unavailable.

Starting the Engine and Controls Operation

Procedures for starting the engine and operating from ground/platform.

Platform Operation: Steering and Driving

Procedures for operating steering and driving functions from the platform.

Driving on a Slope Procedures

Instructions for determining slope grades and operating the machine safely on slopes.

Drive Enable and Speed Controls

Explains drive enable system, speed selection, and function speed controls.

Machine Not Level and Overload Indicators

Explains machine not level and overload indicators and recovery.

Contact Alarm and Aircraft Protection

Explains contact alarm function and aircraft protection package operation.

Battery and Charger Instructions

Safety guidelines and procedures for charging batteries.

Pipe and Panel Cradle Installation

Instructions for installing pipe and panel cradles on the platform.

Pipe and Panel Cradle Operation

Procedures for using pipe and panel cradles to carry loads.

Transport and Lifting Instructions

Observe and Obey Transport Guidelines

General safety recommendations for transport and lifting operations.

Free-wheel Configuration for Winching

Instructions for putting the machine in free-wheel mode for winching.

Securing to Truck or Trailer

Procedures for securing the machine chassis and platform to a transport vehicle.

Lifting Instructions

Detailed steps for lifting the machine using a spreader bar and rigging.

Maintenance

Engine Oil Level Check

Instructions for checking and maintaining the engine oil level.

Diesel Fuel Requirements

Specifies the minimum diesel fuel requirements for the engine.

Hydraulic Oil Level Check

Instructions for checking and maintaining the hydraulic oil level.

Engine Coolant Level Check

Procedures for checking and maintaining the engine coolant level.

Battery Condition Check

Safety precautions and procedures for checking the condition of the batteries.

Scheduled Maintenance Overview

Outlines requirements for quarterly, annual, and biennial maintenance inspections.

Specifications - Z-45 DC

Airborne Noise Emissions

Specifies noise levels at ground and platform workstations.

Maximum Slope Ratings

Lists maximum slope ratings for the machine in stowed position.

Drive Speeds

Provides information on drive speeds in stowed and raised boom conditions.

Floor Loading Information

Details tire load and contact pressure for floor loading.

Specifications - Z-45 FE

Airborne Noise Emissions

Specifies noise levels at ground and platform workstations.

Maximum Slope Ratings

Lists maximum slope ratings for the machine in stowed position.

Drive Speeds

Provides information on drive speeds in stowed and raised boom conditions.

Floor Loading Information

Details tire load and contact pressure for floor loading.

Specifications - Z-45 FE Range of Motion

Z-45 FE Range of Motion Chart

Illustrates the operational range of motion for the Z-45 FE model.

Z-45 FE Range of Motion with Aircraft Protection

Illustrates the operational range of motion with the aircraft protection package.

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