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

Dc power bi-energy power
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Operator's Manual
Z
-45J
®
DC Power
Bi-Energy Power
Serial Number Range
from Z4525F-62000
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Fifth Edition
First Printing
Part No. 1297032GT

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Summary of Contents for Genie Z-45J

  • Page 1 Operator's Manual Serial Number Range -45J ® from Z4525F-62000 ANSI/CSA North America South America Asia DC Power Bi-Energy Power with Maintenance Information Original Instructions Fifth Edition First Printing Part No. 1297032GT...

  • Page 2: Table Of Contents

    Maintenance ............66 Specifications ............69 Copyright © 1999 Terex Corporation Fifth Edition: First Printing, April 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 A92.20 CAN/CSA B354.6...

  • Page 3: Introduction

    This book is an operation and daily maintenance aerial work site. Before operating the machine, it’s manual for the user or operator of a Genie the operator’s responsibility to read and machine. understand this familiarization guide.
  • Page 4 Fifth Edition • First Printing Operator's Manual Introduction Platform controls symbology and related Secondary boom up/down machine movement: Platform level Drive forward/reverse Platform rotate Jib boom up/down Steer right/left Primary boom up/down Turntable rotate Primary boom extend/retract -45J DC • Z ®...
  • Page 5 Fifth Edition • First Printing Operator's Manual Introduction Ground controls symbology and related Sequential functions and movement: machine movement:  Drive and steer. Platform level Interlocked functions:  Elevated drive speed.  Elevated drive in an off-level condition. Platform rotate ...
  • Page 6 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 7 Fifth 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.
  • Page 8 Fifth Edition • First Printing Operator's Manual Introduction 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.

  • Page 9: Symbol And Hazard Pictorials Definitions

    Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine.
  • Page 10 Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Support the platform or boom during maintenance Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 11 Fifth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated. Read the operator’s Platform uphill: Platform downhill: Access by trained...

  • Page 12: General Safety

    Fifth Edition • First Printing Operator's Manual General Safety Gener al Safety -45J DC • Z ® ® -45J Bi-Energy Part No. 1297032GT...
  • Page 13 Fifth Edition • First Printing Operator's Manual General Safety -45J DC • Z ® ® Part No. 1297032GT -45J Bi-Energy...
  • Page 14 Fifth Edition • First Printing Operator's Manual General Safety -45J DC • Z ® ® -45J Bi-Energy Part No. 1297032GT...
  • Page 15 Fifth Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. -45J DC • Z ® ® Part No. 1297032GT -45J Bi-Energy...
  • Page 16 Fifth Edition • First Printing Operator's Manual General Safety -45J DC • Z ® ® -45J Bi-Energy Part No. 1297032GT...
  • Page 17 Fifth Edition • First Printing Operator's Manual General Safety -45J DC • Z ® ® Part No. 1297032GT -45J Bi-Energy...
  • Page 18 Fifth Edition • First Printing Operator's Manual General Safety -45J DC • Z ® ® -45J Bi-Energy Part No. 1297032GT...
  • Page 19 Fifth Edition • First Printing Operator's Manual General Safety These decals are model, option or configuration specific. -45J DC • Z ® ® Part No. 1297032GT -45J Bi-Energy...

  • Page 20: Personal Safety

    Fifth Edition • First Printing Operator's Manual Personal Safety Pers onal 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.

  • Page 21: Work Area Safety

    Fifth Edition • First Printing Operator's Manual Work Area Safety Wor k Ar ea 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 proximity to electrical current.
  • Page 22 Fifth Edition • First Printing Operator's Manual Work Area Safety Do not use air-filled tires. These machines are If the tilt alarm sounds when the platform is raised, equipped with foam-filled tires. Wheel weight and use extreme caution. The Machine Not Level proper counterweight configuration are critical to indicator light will come on and the drive function stability.
  • Page 23 Fifth Edition • First Printing Operator's Manual Work Area Safety Do not raise the boom Do not modify or alter a mobile elevating work when wind speeds may platform without prior written permission from the exceed 28 mph/12.5 m/s. manufacturer. Mounting attachments for holding If wind speeds exceed tools or other materials onto the platform, 28 mph/12.5 m/s when...
  • Page 24 Fifth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Do not use batteries that weigh less than the original equipment. Batteries are used as Occupants must wear a counterweight and are critical to machine stability. safety belt or harness in Each battery must weigh a minimum of 105 lbs / accordance with 47.6 kg.
  • Page 25 Genie (see section Contacting the Manufacturer). Collision Hazards Be aware of limited sight Limit travel speed...
  • Page 26 Fifth Edition • First Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Bodily Injury Hazard All models: All models: Charge the battery only in an open, well-ventilated Do not operate the machine with a hydraulic oil or area away from sparks, flames and lighted air leak.
  • Page 27 Be sure all maintenance has been performed as specified in this manual and the appropriate Genie service manual. 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 Avoid spilling or contacting battery acid.
  • Page 28 Fifth Edition • First Printing Operator's Manual Work Area Safety Explosion Hazards Electrocution/Burn Hazards Keep sparks, flames, and Connect the battery charger to a lighted tobacco away from grounded, AC 3-wire electrical batteries. Batteries emit outlet only. explosive gas. Inspect daily for damaged cords, The battery pack covers cables and wires.
  • Page 29 Fifth Edition • First Printing Operator's Manual Work Area Safety Lockout 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 30: Legend

    Fifth Edition • First Printing Operator's Manual Legend Leg end Foot switch Primary boom Manual storage container Secondary boom Sliding mid-rail 10 Ground controls Lanyard anchorage points 11 Power to charger (between steer tires) Jib boom 12 Steer tire Platform 13 Battery box Platform controls 14 Non-steer tire...

  • Page 31: Controls

    Fifth Edition • First Printing Operator's Manual Controls Controls Ground Control Panel Platform rotate switch Red Emergency Stop button Turntable rotate switch 10 Platform overload indicator light Primary boom up/down switch 11 Hour meter Primary boom extend/retract switch 12 Bi-Energy models: Glow plug switch Used for optional equipment 13 Function enable button Bi-Energy models:...
  • Page 32 Fifth Edition • First Printing Operator's Manual Controls Ground Control Panel Bi-Energy models: Engine idle (rpm) select switch Platform rotate switch Move the switch to the left (turtle) for low idle. Move the platform rotate Move the switch to the right (rabbit) for high switch to the right and the idle and quickest battery charging.
  • Page 33 Fifth Edition • First Printing Operator's Manual Controls 13 Function enable switch Move the function enable switch to either side to enable the functions on the ground control panel to operate. 14 Bi-Energy models: Engine start switch Move the engine start switch to either side to start the engine.
  • Page 34 Fifth Edition • First Printing Operator's Manual Controls Platform Control Panel Horn button Bi-Energy models: Glow plug switch Auxiliary power switch 10 Bi-Energy models: Engine start switch Drive enable indicator light 11 Bi-Energy models: Engine idle (rpm) select switch Drive enable switch Rabbit &...
  • Page 35 Fifth Edition • First Printing Operator's Manual Controls 12 Platform overload indicator light 17 Primary boom extend/retract switch 13 Machine not level indicator light 18 Primary boom up/down switch 14 Red Emergency Stop button 19 Secondary boom up/down switch 15 Proportional control handle for drive function and 20 Turntable rotate switch thumb rocker for steer function 21 Battery charge indicator...
  • Page 36 Fifth Edition • First Printing Operator's Manual Controls Platform level switch Platform Control Panel Move the platform level Horn button switch up and the level of Press this button and the horn will sound. the platform will raise. Release the button and the horn will stop. Move the platform level switch down and the Auxiliary power switch with cover...
  • Page 37 Fifth Edition • First Printing Operator's Manual Controls 18 Primary boom up/down switch 14 Red Emergency Stop button Move the switch up and the Push in the red Emergency Stop button to the primary boom will raise. off position to stop all functions. Pull out the Move the switch down and red Emergency Stop button to the on position the primary boom will lower.

  • Page 38: Inspections

    Fifth Edition • First Printing Operator's Manual Inspections Ins pections 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 39 Fifth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Alarms and beacons (if equipped)  Nuts, bolts and other fasteners  Be sure that the operator’s, safety, and  Platform entry mid-rail or gate responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 40 Fifth 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 41 Fifth Edition • First Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of 10 Turn the key switch to hazards. platform control. Pull out the platform red Emergency Turn the key switch to ground control.
  • Page 42 Fifth Edition • First Printing Operator's Manual Inspections Test Machine Functions and Descent At the Platform Controls Alarm 17 Pull out the red Emergency Stop button to the 24 Press down the foot switch. on position. 25 Activate each machine function control handle 18 Bi-Energy models: Start the engine.
  • Page 43 Fifth Edition • First Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 33 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 44 Fifth Edition • First Printing Operator's Manual Inspections Test Limited Drive Speed Test Drive Tilt Cutout 36 Press down the foot switch. 46 Press down the foot switch. 37 Raise the primary boom approximately 3 feet / 47 With the boom fully stowed, drive the machine 91 cm.
  • Page 45 Fifth Edition • First Printing Operator's Manual Inspections 53 Return to level ground and stow the boom. 61 Return to level ground and extend the primary boom approximately 1.6 ft / 0.5 m. 54 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 62 Drive the machine onto a slope where the greater than 2.5°.
  • Page 46 Fifth Edition • First Printing Operator's Manual Inspections Test the Contact Alarm (if equipped) Test Auxiliary Lowering 69 Do not activate the foot switch and press on 76 Pull out the red Emergency Stop button to the the contact alarm cable to release the actuator on position.
  • Page 47 Fifth 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  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 48 Fifth Edition • First Printing Operator's Manual Inspections Decal Inspection - Bi-Energy Part No. Decal Description Label – Wheel Load Models with Words 114025 Notice – Battery Connection Diagram 114117 Use the pictures on the next page to verify that all Danger –...
  • Page 49 Fifth Edition • First Printing Operator's Manual Inspections Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT...
  • Page 50 Fifth Edition • First Printing Operator's Manual Inspections Decal Inspection - DC Models Part No. Decal Description with Words 110282 Instructions - Kubota Engine Specs Label – Wheel Load 114025 Use the pictures on the next page to verify that all Notice –...
  • Page 51 Fifth Edition • First Printing Operator's Manual Inspections Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT...
  • Page 52 Fifth Edition • First Printing Operator's Manual Inspections Decal Inspection - Bi-Energy Part No. Decal Description Models with Symbols Label – Tip-over Hazard, Limit 114252 Switches Use the pictures on the next page to verify that all Label – Electrocution Hazard, Plug 114334 decals are legible and in place.
  • Page 53 Fifth Edition • First Printing Operator's Manual Inspections Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT...
  • Page 54 Fifth Edition • First Printing Operator's Manual Inspections Decal Inspection - DC Models Part No. Decal Description with Symbols Label – Tip-over Hazard, Limit 114252 Switches Use the pictures on the next page to verify that all Label – Electrocution Hazard, Plug 114334 decals are legible and in place.
  • Page 55 Fifth Edition • First Printing Operator's Manual Inspections Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT...

  • Page 56: Operating Instructions

    Fifth Edition • First Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons 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, safety, and responsibilities manuals.
  • Page 57 Fifth Edition • First Printing Operator's Manual Operating Instructions Introduction Emergency Stop Bi-Energy models can be operated with or without Push in the red Emergency Stop button to the off the engine running. position at the ground controls or the platform controls to stop all machine functions and turn the Starting the Engine engine off.
  • Page 58 Fifth Edition • First Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 59 Fifth Edition • First Printing Operator's Manual Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
  • Page 60 Fifth Edition • First Printing Operator's Manual Operating Instructions To determine the slope grade: Example: Measure the slope with a digital inclinometer OR use the following procedure. You will need: carpenter’s level   straight piece of wood, at least 3 feet/1 m long ...
  • Page 61 Chassis Angle If the tilt alarm sounds when the (side to side) (front to back) platform is raised, the Machine Not Level indicator light will come on Z-45J DC 4.5° 2.5° and the drive function in one or Z-45J BE 4.5°...
  • Page 62 Fifth Edition • First Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Aircraft Protection Package (if equipped) The contact alarm is designed to alert ground If the platform bumpers come into contact with personnel when an operator makes contact with aircraft components, the machine will shut down the platform control panel, interrupting boom and no functions will operate.
  • Page 63 Use proper AC input voltage for charging as Charging the Batteries with the AC indicated on the charger. Charger  Use only a Genie authorized battery and Be sure the batteries are connected before charger. charging the batteries.  Do not operate the machine with the battery Open the battery compartment.
  • Page 64 Fifth Edition • First Printing Operator's Manual Operating Instructions Standard Batteries Dry Battery Filling and Charging Instructions Remove the battery vent caps and check the battery acid level. If necessary, add only Remove the battery vent caps and enough distilled water to cover the plates. Do permanently remove the plastic seal from the not overfill prior to the charge cycle.

  • Page 65: Transport And Lifting Instructions

    Free-wheel Configuration for  Genie customers needing to containerize any Winching lift or Genie product should source a qualified freight forwarder with expertise in preparing, Chock the wheels to prevent the machine from loading and securing construction and lifting rolling.
  • Page 66 Fifth Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform – Z-45/25J Securing to Truck or Trailer for 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 67 Fifth Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable.

  • Page 68: Maintenance

    Put on protective clothing and eye wear. governmental regulations. Be sure that the battery cable connections are  Use only Genie approved replacement parts. tight and free of corrosion. Maintenance Symbols Legend Be sure that the battery hold-down brackets are in place and secure.
  • Page 69 Fifth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Oil Level (Bi- Energy models) Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the proper engine oil level is essential oil levels can damage hydraulic components.
  • Page 70 Fifth Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level Scheduled Maintenance (Bi-Energy models) Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in Maintaining the engine coolant at the proper level the service manual for this machine.

  • Page 71: Specifications

    It should -29° C to 49° C be used only with adequate safety factors. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. -45J DC • Z ®...
  • Page 72 -20° F to 120° F be used only with adequate safety factors. -29° C to 49° C Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. -45J DC • Z ®...
  • Page 73 Fifth Edition • First Printing Operator's Manual Specifications Z-45 Range of motion chart Max Height Max Reach 50 ft 15.2 m 0 ft 40 ft 12.2 m 5 ft 1.5 m 30 ft 9.1 m 15 ft 4.6 m 20 ft 6.1 m 25 ft 7.6 m...

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