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Operator's Manual

Seventh Edition • First Printing

Maintenance

56 Z

®

-45J DC • Z

®

-45J Bi-Energy

Part No. 1307436GT

Maintenance

Observe and Obey:



Only routine maintenance items specified in
this manual shall be performed by the operator.



Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer’s specifications
and the requirements specified in the
responsibilities manual.



Dispose of material in accordance with
governmental regulations.



Use only Genie approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

Indicates that tools will be required to
perform this procedure.

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.

Check the Batteries

Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.

Electrocution hazard. Contact with hot or live
circuits may result in death or serious injury.
Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.
Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda
and water.

1

Put on protective clothing and eye wear.

2

Be sure that the battery cable connections are
tight and free of corrosion.

3

Be sure that the battery hold-down brackets
are in place and secure.

Standard Batteries

4

Remove the battery vent caps.

5

Check the battery acid level of each battery. If
needed, replenish with distilled water to the
bottom of the battery fill tube. Do not overfill.

6

Install the vent caps.

Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.

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Summary of Contents for Genie Z-45 BE

Page 1: ...Operator s Manual Serial Number Range Z 45J from Z4525F 62000 CE DC Power Bi Energy Power with Maintenance Information Original Instructions Seventh Edition First Printing Part No 1307436GT ...

Page 2: ...uction 1 Symbol and Hazard Pictorials Definitions 6 General Safety 9 Personal Safety 13 Work Area Safety 14 Legend 22 Controls 23 Inspections 30 Operating Instructions 44 Transport and Lifting Instructions 53 Maintenance 56 Specifications 59 Copyright 2006 Terex Corporation Seventh Edition First Printing November 2020 Genie and Z are registered trademarks of Terex South Dakota Inc in the U S A and...

Page 3: ...n chassis Serial label located under cover 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 Elevating Work Platform MEWP Familiarization with...

Page 4: ... DC Z 45J Bi Energy Part No 1307436GT Platform controls symbology and related machine movement Platform level Platform rotate Jib boom up down Primary boom up down Turntable rotate Primary boom extend retract Secondary boom up down Drive forward reverse Steer right left ...

Page 5: ...ons 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 Limitations 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 firm le...

Page 6: ...ith 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 Ques...

Page 7: ... regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine 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 De...

Page 8: ...als Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or other high energy starting aids on machines equipped with glow plugs No smoking No flame Stop engine Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Tip over hazard Tire specifications ...

Page 9: ... Bi Energy 7 Wheel load Wind speed Maximum capacity Manual force Support the platform or boom during maintenance Tie down point Lifting point Platform tie down instructions Lifting tie down instructions Lanyard anchorage points Corrosive acid Color coded direction arrows Runaway hazard Collision hazard Overhead obstruction ...

Page 10: ...ge 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 3 Retract primary Platform downhill 1 Retract primary 2 Lower secondary 3 Lower primary Read the operator s manual Access by trained and authorized personnel only Read the service manual Emergency lowering Crush hazard ...

Page 11: ...Seventh Edition First Printing Operator s Manual General Safety Part No 1307436GT Z 45J DC Z 45J Bi Energy 9 General Safety ...

Page 12: ...Operator s Manual Seventh Edition First Printing General Safety 10 Z 45J DC Z 45J Bi Energy Part No 1307436GT ...

Page 13: ...Seventh Edition First Printing Operator s Manual General Safety Part No 1307436GT Z 45J DC Z 45J Bi Energy 11 ...

Page 14: ...Operator s Manual Seventh Edition First Printing General Safety 12 Z 45J DC Z 45J Bi Energy Part No 1307436GT These decals are model option or configuration specific ...

Page 15: ...s 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE man...

Page 16: ...rong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capa...

Page 17: ...ore raising the platform If the tilt alarm sounds when the platform is raised use extreme caution The Machine Not Level indicator light will come on and the drive function in one or both directions will not operate Identify the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering If the tilt...

Page 18: ...tability with items of different weight or specification Do not modify or alter a mobile elevating work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Do not place or attach fixed or over...

Page 19: ... stowed position Platform downhill 30 17 Platform uphill 20 11 Side slope 25 14 Note Slope rating is subject to ground conditions with one person in the platform and adequate traction Additional platform weight may reduce slope rating See Driving on a Slope in the Operating Instructions section Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations At...

Page 20: ...ite and governmental rules regarding use of personal protective equipment Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other ...

Page 21: ...achine with the engine running Refuel the machine only in an open well ventilated area away from sparks flames and lighted tobacco Do not spray ether into engines equipped with glow plugs Bodily Injury Hazard All models Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause...

Page 22: ...ner located on the machine Component Damage Hazards All models Do not use the machine as a ground for welding Bi Energy models Do not use any battery or charger greater than 12V to jump start the engine Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills ...

Page 23: ...t with battery terminals Remove all rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh a minimum of 105 lbs 47 6 kg Each battery box including batteries must weigh a minimum of 530 lbs 240 4 kg Lifting Hazard Use a forklift to remove or ins...

Page 24: ...t No 1307436GT Legend 1 Foot switch 2 Manual storage container 3 Sliding mid rail 4 Lanyard anchorage points 5 Jib boom 6 Platform 7 Platform controls 8 Primary boom 9 Secondary boom 10 Ground controls 11 Power to charger between steer tires 12 Steer tire 13 Battery box 14 Non steer tire ...

Page 25: ...und Control Panel 1 Platform rotate switch 2 Turntable rotate switch 3 Primary boom up down switch 4 Primary boom extend retract switch 5 Used for optional equipment 6 Bi Energy models Engine idle rpm select switch Turtle low idle Rabbit high idle and quickest battery charging 7 Auxiliary power switch 8 Key switch for platform off ground selection 9 Red Emergency Stop button 10 Platform overload i...

Page 26: ...itch to the left turtle for low idle Move the switch to the right rabbit for high idle and quickest battery charging 7 Auxiliary power switch Use auxiliary power if the primary power source fails Simultaneously hold the auxiliary power switch on and activate the desired function 8 Key switch for platform off ground selection Turn the key switch to the platform position and the platform controls wi...

Page 27: ...side to start the engine 15 Secondary boom up down switch Move the switch up and the secondary boom will raise Move the switch down and the secondary boom will lower 16 10A breaker for control electrical circuits 17 Z 45 25J Jib boom up down switch Move the switch up and the jib boom will raise Move the switch down and the jib boom will lower 18 Platform level switch Move the platform level switch...

Page 28: ...cator light 4 Drive enable switch 5 Z 45 25J Jib boom up down switch 6 Platform rotate switch 7 Platform level switch 8 Used for optional equipment 9 Bi Energy models Glow plug switch 10 Bi Energy models Engine start switch 11 Bi Energy models Engine idle rpm select switch Rabbit foot switch foot switch activated high idle Turtle low idle Rabbit high idle and quickest battery charging ...

Page 29: ...13 Machine not level indicator light 14 Red Emergency Stop button 15 Proportional control handle for drive function and thumb rocker for steer function 16 Boom function speed controller 17 Primary boom extend retract switch 18 Primary boom up down switch 19 Secondary boom up down switch 20 Turntable rotate switch 21 Battery charge indicator ...

Page 30: ... platform rotate switch to the right and the platform will rotate to the right Move the platform rotate switch to the left and the platform will rotate to the left 7 Platform level switch 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 8 Used for optional equipment 9 Bi Energy models Glow plug s...

Page 31: ... right side of the thumb rocker and the machine will steer to the right 16 Boom function speed controller Turn the dial to increase or decrease the speed of the machine functions 17 Primary boom extend retract switch Move the switch to the left and the boom will extend Move the switch to the right and the boom will retract 18 Primary boom up down switch Move the switch up and the primary boom will...

Page 32: ...inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any ...

Page 33: ...e section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Hydraulic tank Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Engine and related components if equipped Fuel tank if equipped Limit switches an...

Page 34: ...5 Only use the machine as it was intended 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 tagged and removed from service Repairs to the mach...

Page 35: ...form function toggle switch Result No boom and platform functions should operate 9 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test the Tilt Sensor 10 Turn the key switch to platform control Pull out the p...

Page 36: ... not press down the foot switch Result No functions should operate Test Machine Functions and Descent Alarm 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test the Steering 26 Press down the foot switch 27 Press the th...

Page 37: ...e drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Drive Enable System 32 Press down the foot switch and lower the boom to the stowed position 33 Rotate the turntable until the primary boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is ...

Page 38: ...ot exceed 1 ft 30 cm per second 45 Retract the boom If the drive speed with the primary or secondary boom raised or the primary boom extended exceeds 1 ft 30 cm per second immediately tag and remove the machine from service Test Drive Tilt Cutout 46 Press down the foot switch 47 With the boom fully stowed drive the machine onto a slope where the chassis pitch angle is greater than 2 5 Result The m...

Page 39: ...Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 60 Lower the primary boom to the stowed position or drive in the opposite direction Result The machine should drive 61 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 62 Drive the machine onto a slope where the chassis roll angle is greater t...

Page 40: ... alarm cable to release the actuator from the switch socket Result The contact alarm lights will flash and the machine horn will sound 73 Operate each machine function Result All machine functions should not operate 74 Insert the actuator into the switch socket Result The lights and horn will turn off 75 Operate each machine function Result All machine functions should operate a actuator b contact...

Page 41: ... the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace 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 Workplace Inspection Checklist Be aware of and avoid the following hazardous ...

Page 42: ...Label Tip over Hazard Tilt Alarm 1 Part No Decal Description Qty 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 1 114252 Label Tip over Hazard Limit Switches 3 114334 Label Electrocution Hazard Plug 1 114343 Label Emergency Lowering 1 114345 Label Tip over Hazard Batteries 2 114391 Label Bodily Injury Hazard 1 133067 Label Electrocution Hazard 3 133286 Label Power to Charger 1 ...

Page 43: ...Seventh Edition First Printing Operator s Manual Inspections Part No 1307436GT Z 45J DC Z 45J Bi Energy 41 ...

Page 44: ...over Hazard Tilt Alarm 1 114249 Label Tip over Hazard Tires 4 Part No Decal Description Qty 114252 Label Tip over Hazard Limit Switches 3 114334 Label Electrocution Hazard Plug 1 114343 Label Emergency Lowering 1 114345 Label Tip over Hazard Batteries 2 114350 Label AC Inverter Power option 2 133067 Label Electrocution Hazard 3 133286 Label Power to Charger 1 219954 Label Tip over Hazard CE 1 2199...

Page 45: ...Seventh Edition First Printing Operator s Manual Inspections Part No 1307436GT Z 45J DC Z 45J Bi Energy 43 ...

Page 46: ...n It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected...

Page 47: ...t the engine In extreme cold conditions 20 F 6 C and below hold the glow plug switch to either side for 10 seconds and then start the engine Warm the engine use low idle for 5 minutes to prevent hydraulic system damage Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions and turn the engine off Repair...

Page 48: ...d then restart the engine Note An alarm will sound at the platform when an overload condition occurs and will stop sounding when weight is removed from the platform Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position To Position Platform 1 Set the boom function speed controller to the desired speed Note...

Page 49: ...side and slowly move the drive control handle off center Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Driving on a slope Determine the uphill downhill and side slope ratings for the machine and deter...

Page 50: ...the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example Piece of wood 144 inches 3 6 m Run 144 inches 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 3 grade ...

Page 51: ...e platform when external AC power is removed Plug the power to platform cable on the machine into the the inverter power cable Move the inverter switch up to activate the inverter Move the switch down to turn off the inverter All boom functions will operate while the inverter is in use Machine Not Level Indicator Light If the tilt alarm sounds when the platform is raised the Machine Not Level indi...

Page 52: ...may be needed These notifications will continue until the system is reset 1 The contact alarm cable is tripped releasing the actuator from the switch socket 2 Insert the actuator into the switch socket to turn off flashing lights and audio alarm 1 actuator 2 contact alarm cable 3 flashing alarm 4 switch socket Aircraft Protection Package if equipped If the platform bumpers come into contact with a...

Page 53: ...omatically charge the batteries At high idle the engine supplies enough power for charging and for machine functions At low idle machine functions will use battery power All lift and drive functions can be operated while the engine is running The battery charge indicator will reset when the engine has been turned off for 2 3 minutes Charging the batteries with the engine does not fully charge the ...

Page 54: ...ete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete O...

Page 55: ...e sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight See the inspections section for the serial label location Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Do ...

Page 56: ...ation lock pin Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 4 chains or straps Adjust the rigging to prevent damage to the chains Securing the Platform Z 45 25J Make sure the jib and platform are in the stowed position Secure the platform...

Page 57: ...withstand the machine weight See the serial label for the machine weight 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 Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting poin...

Page 58: ...that a cold motor or pump will be required to perform this procedure Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings ...

Page 59: ...e located on the side of the hydraulic oil tank Result The fluid level should be at the FULL mark 3 Add oil as needed Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Check the Engine Oil Level Bi Energy models Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level ...

Page 60: ... hazard Beware of hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns Note Do not remove the radiator cap 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and q...

Page 61: ...ht Ambient operating temperature 20 F to 120 F 29 C to 49 C Platform dimensions 6 foot length x width 72 in x 30 in 1 8 m x 76 cm Platform dimensions 5 foot length x width 60 in x 30 in 1 5 m x 76 cm Platform dimensions 4 foot length x width 48 in x 30 in 1 2 m x 76 cm Platform leveling self leveling Platform rotation 160 Controls 24V DC proportional AC outlet in platform Standard Hydraulic pressu...

Page 62: ...hine weight Ambient operating temperature 20 F to 120 F 29 C to 49 C Platform dimensions 6 foot length x width 72 in x 30 in 1 8 m x 76 cm Platform dimensions 5 foot length x width 60 in x 30 in 1 5 m x 76 cm Platform dimensions 4 foot length x width 48 in x 30 in 1 2 m x 76 cm Platform leveling self leveling Platform rotation 160 Controls 24V DC proportional AC outlet in platform Standard Hydraul...

Page 63: ...rator s Manual Specifications Part No 1307436GT Z 45J DC Z 45J Bi Energy 61 Z 45J Range of motion chart Max Height Max Reach 1 50 ft 15 2 m 7 0 ft 0 m 2 40 ft 12 2 m 8 5 ft 1 5 m 3 30 ft 9 1 m 9 15 ft 4 6 m 4 20 ft 6 1 m 10 25 ft 7 6 m ...

Page 64: ... engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specif...

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