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

Genie Z-45 Operator's Manual

Dc power bi-energy power boom lifts
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See also: Service & Repair Manual
Operator's Manual
Z-45/25
Z-45/25J
DC Power
Bi-Energy Power
CE
with
Maintenance
Information
Fourth Edition
First Printing
Part No. 114358

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Summary of Contents for Genie Z-45

  • Page 1 Operator’s Manual Z-45/25 Z-45/25J DC Power Bi-Energy Power with Maintenance Information Fourth Edition First Printing Part No. 114358...

  • Page 2: Table Of Contents

    Genie Industries in the U.S.A. and many other countries. "Z" is a trademark of Genie Industries. Printed on recycled paper Printed in U.S.A. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi Energy Part No. 114358...

  • Page 3: Introduction

    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. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 4 Yellow in minor or moderate injury. Indicates a hazardous situation which, if not avoided, could result in property damage. Blue Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...

  • Page 5: Symbol And Hazard Pictorials Definitions

    1 Lower primary 1 Retract primary instructions, no jib instructions, jib 2 Lower secondary 2 Lower secondary 3 Retract primary 3 Lower primary Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 6 Stay clear of belts and fan when Bodily Injury Replace tires with engine is running Maximum Hazard same tire platform capacity Burn hazard Maximum Wind Maximum Manual Speed Force Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...

  • Page 7: General Safety

    82544 114249 82472 82487 82481 114345 114252 82548 114249 114345 82548 82487 114248 82601 114249 82604 82604 114249 A 114252 82601 114248 82487 82472 82481 82544 Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 8 82548 114334 114391 A 114345 114251 114252 82544 (Bi-Energy) 114252 (Bi-Energy) 82473 (Bi-Energy) 114251 (Bi-Energy) 114391 (Bi-Energy) 82473 82544 114249 82481 82548 114249 114334 114345 114247 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...

  • Page 9: Personal Safety

    All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 10: Work Area Safety

    The tilt alarm sounds in the platform only when the Do not use the machine as a ground for welding. machine is on a severe slope. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 11 400 N 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. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 12 25% (14°) are properly tightened. Note: Slope rating is subject to ground conditions and adequate traction. See Driving on a Slope in the Operating Instructions section. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 13 Do not enter or exit the platform unless the and steer functions. machine is in the stowed position and the platform is at ground level. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 14 Do not spray ether into engines equipped with glow any potential collision. plugs. No stunt driving or horseplay while operating a machine. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 15 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 platform. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 16 Use a forklift to remove or install the battery packs. the entire charging cycle. Do not contact the battery terminals or the cable clamps with tools that may cause sparks. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 17 3 Rotate the turntable so that the boom is between the non-steer wheels. 4 Turn the key switch to the off position and remove the key to secure from unauthorized use. 5 Chock the wheels. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 18: Legend

    4 Lanyard anchorage point 11 Power to charger (between tires) 5 Jib boom (Z-45/25J) 12 Steer tire 6 Platform 13 Battery box 7 Platform controls 14 Non-steer tire Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...

  • Page 19: Controls

    15 Secondary boom up/down switch • charging 16 10A breaker for control electrical circuits 7 Auxiliary power switch 17 Z-45/25J: Jib boom up/down switch 18 Platform level switch Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 20 7 Auxiliary power switch Use auxiliary power if the primary power source fails. Simultaneously hold the auxiliary power switch to either side and activate the desired function. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 21 Move the platform level switch up and the level of the platform will raise. Move the platform level switch down and the level of the platform will lower. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 22 Rabbit & Foot Switch: foot switch activated • 6 Platform rotate switch high idle Turtle: low idle • 7 Platform level switch Rabbit: high idle and quickest battery • charging Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 23 15 Proportional control handle for drive function and 21 Battery charge indicator thumb rocker for steer function 16 Boom function speed controller 17 Primary boom extend/retract switch Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 24 Move the platform rotate switch to the left and the platform will rotate to the left. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 25 18 Primary boom up/down switch Move the switch up and the primary boom will raise. Move the switch down and the primary boom will lower. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 26: Inspections

    Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 27 Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Limit switches and horn Alarms and beacons (if equipped) Engine and related components (if equipped) Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 28 Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 29 Result: All boom and platform functions should operate through a full cycle. The descent alarm should sound while the boom is lowering. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 30 Result: All boom and platform functions should operate through a full cycle. The descent alarm should sound while the boom is lowering. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 31 If the drive speed with the primary boom raised, the secondary boom raised or the primary boom extended exceeds 30 cm per second, immediately tag and remove the machine from service. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 32 Note: To conserve battery power, test each function through a partial cycle. Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 33 It is the operator's responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 34 Label - Crushing Hazard 114345 Label - Tip-over Hazard, Batteries 82473 Warning - Compartment Access 82481 Label - Battery Safety 82487 Label - Read the Manual Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 35 62070 view, i.e. under covers 28174 or 28235 114252 40434 82473 82548 82544 114249 114249 44981 28174 114025 114114 114025 or 28235 Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 36 82472 Label - Crushing Hazard 114391 Label - Crushing Hazard 82473 Warning - Compartment Access 82481 Label - Battery Safety 82487 Label - Read the Manual Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 37 62068 view, i.e. under covers 82544 28174 114252 or 28235 82473 40434 28159 114251 114391 82548 114249 114249 44981 28174 114025 114114 114025 or 28235 Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 38: Operating Instructions

    5 Only use the machine as it was intended. inspection before using the machine. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 39 Repair any function that operates when the red Emergency Stop button is pushed in. Selecting and operating the ground controls will override the platform red Emergency Stop button. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 40 Always use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 41 If the slope exceeds the maximum uphill, downhill or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 42 Platform Overload Indicator Light Light flashing indicates the platform is overloaded and no functions will operate. Remove weight from the platform until the light goes off. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 43 Charging the batteries with the engine does not fully to the bottom of the fill tube. Do not overfill. charge the batteries. Periodically, use the AC battery charger to fully charge the batteries. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 44: Transport And Lifting Instructions

    Reverse the procedures described to re-engage the machine weight. brakes. Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 45 Secure the platform with a nylon strap placed over the platform mount near the platform rotator (see below). Do not use excessive downward force when securing the boom section. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 46 Adjust the rigging to prevent damage to the machine weight. machine and to keep the machine level. X Axis 44 in 1.1 m Y Axis 41 in 1.0 m Y Axis X Axis Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...

  • Page 47: Maintenance

    Indicates that new parts will be required to perform this procedure. Indicates that a cold motor or pump will be required to perform this procedure. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 48 1 Check the fluid level in the coolant recovery Hydraulic oil type Chevron Rykon tank. The fluid level should be at the Premium MV equivalent mark. FULL 2 Add fluid as needed. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 49 Kubota Engine Z482-E Oil viscosity requirements 10W-30 Engine oil should have properties of API classification CC/SE, CD/SE, CC/SF or CD/SF grades. Units ship with 10W-40 SG/CC Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...

  • Page 50: Specifications

    Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 51 Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 52 Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 53 (Machine weights vary with option configurations. See serial label for specific machine weight.) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 114358 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy...
  • Page 54 Operator's Manual Fourth Edition • First Printing Specifications Range of motion - models without jib Range of motion - models with jib Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No. 114358...
  • Page 55 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570 Phone +46 31 575100...

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