Genie Z-45J Operator's Manual

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Operator's Manual

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Z®-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

Operator's Manual Fifth Edition • First Printing

Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Front Matter

Contents

Introduction ............................................................1

Symbol and Hazard Pictorials Definitions ..............7

General Safety .................................................... 10

Personal Safety ................................................... 18

Work Area Safety ................................................ 19

Legend ................................................................ 28

Controls ............................................................... 29

Inspections .......................................................... 36

Operating Instructions ......................................... 54

Transport and Lifting Instructions ....................... 63

Maintenance ....................................................... 66

Specifications ...................................................... 69

Dakota, Inc. in the U.S.A. and many other countries. These machines comply with

ANSI/SAIA A92.20 CAN/CSA B354.6

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Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 1

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.

Serial number stamped on 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 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.

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Introduction

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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

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Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 3

Ground 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

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.

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 level ground.

Stability enhancing means:

 Foam filled tires

Restricted operating envelope:

 500 lbs/227 kg platform capacity.

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Introduction

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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.

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Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 5

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 worksite 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.

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Introduction

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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.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a property damage message.

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Symbol and Hazard Pictorials Definitions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 7

Symbol and Hazard Pictorials Definitions

Fire 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

Tire specifications

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Symbol and Hazard Pictorials Definitions

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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

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Symbol and Hazard Pictorials Definitions

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Electrocution hazard

Avoid contact

Disconnect battery

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. 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

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General Safety

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General Safety

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General Safety

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General Safety

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General Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 13

* These decals are model, option or configuration specific.

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General Safety

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General Safety

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General Safety

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* These decals are model, option or configuration specific.

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Personal Safety

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Personal 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.

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

manufacturer’s instructions.

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Work Area Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 19

Work Area Safety

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.

Obey all local and governmental regulations regarding required clearance from electrical power lines. At a minimum, the required clearance contained in the chart below must be followed.

Line Voltage

Required Clearance

0 to 50KV

10 ft

3.05 m

50 to 200KV

15 ft

4.60 m

200 to 350KV

20 ft

6.10 m

350 to 500KV

25 ft

7.62 m

500 to 750KV

35 ft

10.67 m

750 to 1000KV

45 ft

13.72 m

Allow for platform movement, electrical line sway or sag, and beware of strong 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 capacity.

Maximum platform capacity

500 lbs

227 kg

Maximum platform capacity

Machine equipped with Aircraft Protection Package

440 lbs

200 kg

Maximum occupants

The weight of options and accessories, such as pipe cradles, panel cradles and welders, will reduce the rated platform capacity and must be subtracted from the platform capacity. See the decals with the options and accessories.

If using accessories, read, understand and obey the decals, instructions and manuals with the accessory.

Do not alter or disable the limit switches.

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Work Area Safety

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Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight and proper counterweight configuration are critical to stability.

Do not raise or extend the boom unless the machine is on a firm, level surface.

Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds in the platform only when the machine is on a severe slope.

If the tilt alarm sounds while the boom is lowered: Do not extend, rotate or raise the boom above horizontal. Move the machine to a firm, level surface before 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 alarm sounds with the platform uphill:

1 Lower the primary

boom.

2 Lower the

secondary boom.

3 Retract the primary

boom.

If the tilt alarm sounds with the platform downhill:

1 Retract the primary

boom.

2 Lower the

secondary boom.

3 Lower the primary

boom.

Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.

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Work Area Safety

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Do not raise the boom when wind speeds may exceed 28 mph/12.5 m/s. If wind speeds exceed 28 mph/12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.

Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.

Do not push off or pull toward any object outside of the platform.

Maximum allowable side force – 90 lbs/400 N

Do not alter or disable machine components that in any way affect safety and stability.

Do not replace items critical to machine stability 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 overhanging loads to any part of this machine.

Do not place ladders or scaffolds in the platform or against any part of this machine.

Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.

Do not use the machine on a moving or mobile surface or vehicle.

Be sure the tires are in good condition and the lug nuts tightened.

Do not use the platform controls to free a platform that is caught, snagged, or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.

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Work Area Safety

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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.

Do not use the machine as a crane. Do not push the machine or other objects with the

boom. Do not contact adjacent structures with the boom. Do not tie the boom or platform to adjacent

structures. Do not place loads outside the platform perimeter.

Operation on Slopes Hazards

Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine. Slope rating applies only to machines in the stowed position.

Maximum slope rating, 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. Attach the lanyard to the anchor provided in the platform.

Do not sit, stand, or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

Do not climb down from the platform when raised.

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Work Area Safety

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Keep the platform floor clear of debris. Lower the platform entry mid-rail or close the entry

gate before operating. Do not enter or exit the platform unless the

machine is in the stowed position and the platform is at ground level.

Hazards related with the specific product application of exiting at height have been considered in the design of the machine, for further information contact Genie (see section Contacting the Manufacturer).

Collision Hazards

Be aware of limited sight distance and blind spots when driving or operating.

Be aware of the boom position and tailswing when rotating the turntable.

Check the work area for overhead obstructions or other possible hazards.

Be aware of crushing hazards when grasping the platform guard rail.

Operators must comply with employer, job site, 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 factors which may cause collision.

Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

No stunt driving or horseplay while operating a machine.

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Work Area Safety

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Explosion and Fire Hazards

All models:

Charge the battery only in an open, well-ventilated area away from sparks, flames and lighted tobacco.

Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

Bi-Energy models:

Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.

Do not refuel the machine 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 serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection. All compartments must remain closed and secured during operation.

Bi-Energy models:

When the engine is running, operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.

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Work Area Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 25

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of

the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.

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 container 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 with baking soda and water.

The battery pack must remain in the upright position.

Do not expose the batteries or the charger to water or rain during charging.

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Work Area Safety

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Explosion Hazards

Keep sparks, flames, and lighted tobacco away from batteries. Batteries emit explosive gas.

The battery pack covers should remain open during the entire charging cycle.

Do not contact the battery terminals or the cable clamps with tools that may cause sparks.

Component Damage Hazard

Do not use any battery charger greater than 48V to charge the batteries.

Both battery packs must be charged together. Disconnect the battery pack plug before removing

the battery pack.

Electrocution/Burn Hazards

Connect the battery charger to a grounded, AC 3-wire electrical outlet only.

Inspect daily for damaged cords, cables and wires. Replace damaged items before operating.

Avoid electrical shock from contact 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 install a battery pack.

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Work Area Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 27

Lockout After Each Use

1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowed

position.

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.

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Legend

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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

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Controls

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 29

Controls

Ground 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 indicator light 11 Hour meter 12 Bi-Energy models: Glow plug switch 13 Function enable button 14 Bi-Energy models: Engine start switch 15 Secondary boom up/down switch 16 10A breaker for control electrical circuits 17 Jib boom up/down switch 18 Platform level switch

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Controls

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Ground Control Panel

1 Platform rotate switch

Move the 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.

2 Turntable rotate switch

Move the turntable rotate switch to the right and the turntable will rotate to the right. Move the turntable rotate switch to the left and the turntable will rotate to the left.

3 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.

4 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.

5 Used for optional equipment

6 Bi-Energy models: Engine idle (rpm) select

switch Move the switch 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 will operate. Turn the key switch to the off position and the machine will be off. Turn the key switch to the ground position and the ground controls will operate.

9 Red Emergency Stop button

Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine.

10 Platform overload indicator light

Light flashing indicates the platform is overloaded and no functions will operate. Remove weight until the light goes off.

11 Hour meter

The hour meter displays the number of hours the machine has operated.

12 Bi-Energy models: Glow plug switch

Move the glow plug switch to either side and hold for 3 to 5 seconds.

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Controls

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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.

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 up and the level of the platform will raise. Move the platform level switch down and the level of the platform will lower.

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Controls

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Platform Control Panel

1 Horn button 2 Auxiliary power switch 3 Drive enable indicator 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

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Controls

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12 Platform overload indicator light 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

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Controls

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Platform Control Panel

1 Horn button

Press this button and the horn will sound. Release the button and the horn will stop.

2 Auxiliary power switch with cover

Use auxiliary power if the primary power source fails.

Simultaneously hold the auxiliary power switch on and activate the desired function.

3 Drive enable indicator light

Light on indicates that the boom has moved just past either non-steer wheel and drive function has been interrupted.

4 Drive enable switch

To drive when the drive enable light is on, hold the drive enable switch to either 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.

5 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.

6 Platform rotate switch

Move the 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 switch

Move the glow plug switch to either side and hold for 3 to 5 seconds.

10 Bi-Energy models: Engine start switch

Move the engine start switch to either side to start the engine.

11 Bi-Energy models: Engine idle (rpm) select

switch Move the switch to the left (rabbit & foot

switch) for foot switch activated high idle. Move the switch to the center (turtle) for low

idle. Move the switch to the right (rabbit) for high

idle and quickest battery charging.

12 Platform overload indicator light

Light flashing indicates the platform is overloaded and no functions will operate. Remove weight until the light goes off.

13 Machine not level indicator light

Light flashes when the platform is raised and the machine is on a severe slope. The drive function in one or both directions will not operate.

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Controls

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14 Red Emergency Stop button

Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine.

15 Proportional control handle for drive function

and thumb rocker for steer function Move the control handle in the direction

indicated by the blue arrow on the control panel and the machine will drive forward. Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards.

Press the left side of the thumb rocker and the machine will steer to the left. Press the 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 raise. Move the switch down and the primary boom will lower.

19 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.

20 Turntable rotate switch

Move the turntable rotate switch to the right and the turntable will rotate to the right. Move the turntable rotate switch to the left and the turntable will rotate to the left.

21 Battery charge indicator

The battery charge indicator displays the charge level of the batteries.

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Inspections

36 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Inspections

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation

inspection.

Know and understand the pre-operation inspection before going on to the next section.

3 Always perform function tests prior to use. 4 Inspect the workplace. 5 Only use the machine as it was intended.

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. The 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 unauthorized variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the

manufacturer’s specifications. After repairs are

completed, the operator must perform a preoperation inspection again before going on to the function tests.

Scheduled maintenance inspections shall be performed by qualified service technicians,

according to the manufacturer’s specifications and

the requirements listed in the responsibilities manual.

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Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 37

Pre-operation Inspection

 Be sure that the operator’s, safety, and

responsibilities manuals are complete, legible and in the storage container located in the platform.

 Be sure that all decals are legible and in place.

See Inspections section.

 Check for hydraulic oil leaks and proper oil

level. Add oil if needed. See Maintenance section.

 Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See Maintenance section.

 Bi-Energy models: Check for engine oil leaks

and proper oil level. Add oil if needed. See Maintenance section.

 Bi-Energy models: Check for engine coolant

leaks and proper level of coolant. Add coolant if needed. See Maintenance 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 and horn

 Alarms and beacons (if equipped)  Nuts, bolts and other fasteners  Platform entry mid-rail or gate  Lanyard anchorage points

Check entire machine for:

 Cracks in welds or structural components  Dents or damage to machine  Excessive rust, corrosion or oxidation

 Verify that all structural and other critical

components are present and all associated fasteners and pins are in place and properly tightened.

 Be sure that both battery packs are in place

and properly connected.

 After you complete your inspection, be sure

that all compartment covers are in place and latched.

Operator's Manual Fifth Edition • First Printing

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38 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection.

3 Always perform function tests prior to

use.

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.

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 machine may only be made by a qualified service

technician, according to the manufacturer’s

specifications. After repairs are completed, the operator must

perform a pre-operation inspection and function tests again before putting the machine into service.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 39

At the Ground Controls

1 Select a test area that is firm, level and free of

hazards. 2 Turn the key switch to ground control. 3 Pull out the red Emergency Stop button to the

on position.

Result: The beacon (if equipped) should flash.

4 Bi-Energy models: Start the engine. See

Operating Instructions section.

Test Emergency Stop

5 Push in the red Emergency Stop button to the

off position.

Result: The engine (if equipped) should turn

off. 6 Activate each machine function control handle

or toggle switch.

Result: No functions should operate.

7 Pull out the red Emergency Stop button to the

on position.

Test Machine Functions and Descent Alarm

8 Do not hold the function enable

switch to either side. Attempt to activate each boom and platform 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 platform red Emergency Stop button to the on position.

11 Open the turntable cover on

the side opposite the ground controls and locate the tilt sensor.

12 Press down one side of the tilt sensor.

Result: The alarm, located in the platform,

should sound.

Test Auxiliary Lowering

13 Turn the key switch to ground control. 14 Pull out the red Emergency Stop button to the

on position.

15 Simultaneously hold the auxiliary

power switch on and activate each boom function toggle switch.

Note: To conserve battery power, test each function through a partial cycle.

Result: All boom functions should operate.

16 Turn the key switch to platform control.

Operator's Manual Fifth Edition • First Printing

Inspections

40 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

At the Platform Controls

17 Pull out the red Emergency Stop button to the

on position.

18 Bi-Energy models: Start the engine. See

Operating Instructions section.

Test Emergency Stop

19 Push in the platform red Emergency Stop

button to the off position.

Result: The engine (if equipped) should turn

off.

20 Activate each machine function control handle

or toggle switch.

Result: No functions should operate.

21 Pull out the red Emergency Stop button to the

on position.

Test the Horn

22 Press the horn button.

Result: The horn should sound.

Test the Foot Switch

23 Do 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 thumb rocker switch on top of the

control handle in the direction indicated by the blue triangle on the control panel.

Result: The steer wheels should turn in the

direction that the blue triangles point on the drive chassis.

28 Press the thumb rocker switch on top of the

control handle in the direction indicated by the yellow triangle, on the control panel.

Result: The steer wheels should turn in the

direction that the yellow triangles point on the drive chassis.

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Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 41

Test Drive and Braking

29 Press down the foot switch. 30 Slowly move the drive control handle in the

direction indicated by the blue arrow on the

control panel until the machine begins to

move, then return the handle to the center

position.

Result: The machine should move in the

direction that the blue arrow points on the

drive chassis, then come to an abrupt stop. 31 Slowly move the control handle in the direction

indicated by the yellow arrow on the control

panel until the machine begins to move, then

return the handle to the center position.

Result: The machine should move in the

direction that the yellow arrow points on the

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 anywhere in the range shown.

34 Move the drive control handle off center.

Result: The drive function should not operate.

35 Move and hold the drive enable toggle switch

to either side and slowly move the drive control handle off center.

Result: The drive function should operate.

Note: When the drive enable system is in use, the machine may drive in the opposite direction that the drive and steer control handle is moved.

Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction of travel.

Operator's Manual Fifth Edition • First Printing

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42 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Test Limited Drive Speed

36 Press down the foot switch. 37 Raise the primary boom approximately 3 feet /

91 cm.

38 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the primary boom raised should not exceed 1 ft / 30 cm per second.

39 Lower the primary boom to the stowed

position.

40 Raise the secondary boom approximately

3 feet / 91 cm.

41 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the secondary boom raised should not exceed 1 ft / 30 cm per second.

42 Lower the secondary boom to the stowed

position.

43 Extend the primary boom approximately

2 feet/61 cm.

44 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the primary boom extended should not 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 machine should continue to drive.

48 Return to level ground and raise the primary

boom to an out of stowed position (approximately 10° above horizontal).

Result: The machine should stop once the

machine reaches 2.5° of chassis tilt and the alarm should sound at the platform controls.

49 Lower the primary boom to the stowed

position.

Result: The machine should drive.

50 Return to level ground and extend the primary

boom approximately 1.6 ft / 0.5 m.

51 Drive the machine onto a slope where the

chassis pitch angle is greater than 2.5°.

Result: The machine should stop once the

machine reaches 2.5° of chassis tilt and the alarm should sound at the platform controls.

52 Retract the primary boom to the stowed

position.

Result: The machine should drive.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 43

53 Return to level ground and stow the boom. 54 With the boom fully stowed, drive the machine

onto a slope where the chassis pitch angle is

greater than 2.5°.

Result: The machine should continue to drive.

55 Return to level ground and raise the

secondary boom to an out of stowed position

(approximately 15° above horizontal).

Result: The machine should stop once the

machine reaches 2.5° of chassis tilt and the

alarm should sound at the platform controls. 56 Lower the secondary boom to the stowed

position or drive in the opposite direction.

Result: The machine should drive.

57 With the boom fully stowed, drive the machine

onto a slope where the chassis pitch angle is

greater than 2.5°.

Result: The machine should continue to drive.

58 Return to level ground and raise the primary

boom to an out of stowed position

(approximately 10° above horizontal). 59 Drive the machine onto a slope where the

chassis roll angle is greater than 4.5°.

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 than 4.5°.

Result: The machine should stop once the

machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.

63 Retract the primary boom to the stowed

position.

Result: The machine should drive. 64 Return to level ground and stow the boom. 65 With the boom fully stowed, drive the machine

onto a slope where the chassis roll angle is greater than 4.5°.

Result: The machine should continue to drive. 66 Return to level ground and raise the

secondary boom to an out of stowed position (approximately 15° above horizontal).

67 Drive the machine onto a slope where the

chassis roll angle is greater than 4.5°.

Result: The machine should stop once the

machine reaches 4.5° of chassis tilt and the alarm should sound at the platform controls.

68 Lower the primary boom to the stowed

position.

Result: The machine should drive.

Operator's Manual Fifth Edition • First Printing

Inspections

44 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Test the Contact Alarm (if equipped)

69 Do not activate the foot switch and press on

the contact alarm cable to release the actuator from the switch socket.

Result: The contact alarm lights will not flash

and the machine horn will not sound.

70 Activate the foot switch by pressing the foot

switch down.

Result: The contact alarm lights will flash and

the machine horn will sound.

71 Insert the actuator into the switch socket.

Result: The lights and horn will turn off.

72 Activate the foot switch by pressing the foot

switch down and press on the contact 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 alarm cable c flashing alarm d switch socket

Test Auxiliary Lowering

76 Pull out the red Emergency Stop button to the

on position. 77 Press down the foot switch. 78 Simultaneously hold the auxiliary power switch

on and activate each function control handle or

toggle switch. 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.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 45

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s manual.

1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use.

4 Inspect the workplace. Know and understand the workplace

inspection before going on to the next section.

5 Only use the machine as it was intended.

Workplace Inspection Fundamentals

The workplace inspection helps 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 situations:

 drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces  unstable or slippery surfaces  overhead obstructions and high voltage

conductors

 hazardous locations  inadequate surface support to withstand all

load forces imposed by the machine

 wind and weather conditions  the presence of unauthorized personnel  other possible unsafe conditions

Operator's Manual Fifth Edition • First Printing

Inspections

46 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Decal Inspection - Bi-Energy Models with Words

Use the pictures on the next page to verify that all decals are legible and in place.

Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow – Blue

27205 Arrow – Yellow

27206 Triangle – Blue

27207 Triangle – Yellow

28159 Label – Diesel

28162 Warning – Bodily Injury Hazard

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

28236 Warning – Improper Operation

28372 Label – Disconnect Battery Pack Plug

29104 Warning – Tow Package (option)*

31060 Danger – Tip-over Hazard, Limit Switch

31508 Danger – Electrocution Hazard

31785 Notice – Battery Charger Operating Instr.

31787 Danger – Tip-over, Batteries

31788 Danger – Explosion/Burn Hazard

32728 Label – Generator (option)*

35526 Notice – Tow Package (option)*

38149 Label – Patent

44981 Label – Air Line to Platform (option)*

44986 Instructions – Max Manual Force,

90 lbs/400 N

46468 Function Override*

52475 Label – Transport Tie Down**

52664 Label – Controller Status Indicator Light

52865 Warning – Annual Inspection Record*

72086 Label – Lifting Point**

72444 Ground Control Panel

72833 Label – Open

72867 Label – Work Lights (option)*

82279 Platform Control Panel

82366 Label – Chevron Rando*

97602 Warning – Explosion Hazard

97815 Label – Lower Mid-rail

110282 Instructions - Kubota Engine Specs*

Part No. Decal Description

Qty

114025 Label – Wheel Load

114117 Notice – Battery Connection Diagram

114258 Danger – No Smoking

114343 Label – Emergency Lowering

114390 Danger – Electrocution Hazard

114397 Danger – Tilt-Alarm

133278 Label – Low Sulfur Fuel

133286 Label – Power to Charger

139306 Notice – Kubota Diesel Engine

Specifications*

218550 Danger – Tip-over Hazard, 500 lbs /

227 kg

218559 Danger, Warning – Tip-over, Crush

Hazard

219487 Label – Platform Overload

227214 Instructions - Operating Instructions*

1000027 Instructions – Operating Instructions*

1262342 Warning – Slope Rating

1263543 Warning – Compartment Access

1267121 Warning – Crush Hazard, Service

1272242 Label – Machine Registration/Owner

Transfer

1278542 Label – Contact Alarm Weight

1278982 Label – Actuator Switch Socket

1280819 Label – Warning, Prop 65*

1280820 Label – Fuel, Diesel Exhaust, Prop 65*

1281174 Label – Lanyard Anchorage Point, Fall

Arrest/Fall Restrained

1293324 Label – ICES-2/CAN-2 Compliance

1294398 Label – ANSI/CSA Compliant

1298825 Label – Relays, Z-45, Z-45BE, Z-45DC

1299743 Danger – Tip-over Hazard, Tires, Z-45

1299744 Label – Transport Diagram, Z-45

1299791 Label – Maximum Capacity, 440 lbs, Side

Force 90 lbs (Aircraft Protection Package)*

Shading indicates decal is hidden from view, i.e.

under covers

* These decals are model, option or configuration

specific.

** These decals are installed on both sides of chassis.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 47

Operator's Manual Fifth Edition • First Printing

Inspections

48 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Decal Inspection - DC Models with Words

Use the pictures on the next page to verify that all decals are legible and in place. Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow – Blue

27205 Arrow – Yellow

27206 Triangle – Blue

27207 Triangle – Yellow

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

28236 Warning – Improper Operation

28372 Label – Disconnect Battery Pack Plug

29104 Warning – Tow Package (option)*

31060 Danger – Tip-over Hazard, Limit Switch

31508 Danger – Electrocution Hazard

31785 Notice – Battery Charger Operating Instr.

31787 Danger – Tip-over, Batteries

31788 Danger – Explosion/Burn Hazard

32728 Label – Generator (option)*

35526 Notice – Tow Package (option)*

38149 Label – Patent*

44980 Label – Power to Charger, 115V*

44981 Label – Air Line to Platform (option)*

44986 Instructions – Max Manual Force,

90 lbs/400 N

46468 Function Override*

48731 Label – FM Approval (option)***

48732 Label – EE Rating (option)***

52475 Label – Transport Tie Down**

52664 Label – Controller Status Indicator Light

52865 Warning – Annual Inspection Record*

52947 Notice – Operating Instructions, Ground*

72086 Label – Lifting Point**

72444 Ground Control Panel

72833 Label – Open

72867 Label – Work Lights (option)*

82279 Platform Control Panel

82366 Label – Chevron Rando*

97815 Label – Lower Mid-rail

Part No. Decal Description

Qty

110282 Instructions - Kubota Engine Specs

114025 Label – Wheel Load

114117 Notice – Battery Connection Diagram

114343 Label – Emergency Lowering

114350 Label - AC Inverter Power (option)*

114390 Danger – Electrocution Hazard

114397 Danger – Tilt-Alarm

133286 Label – Power to Charger

139306 Notice – Kubota Diesel Engine

Specifications

218550 Danger – Tip-over Hazard, 500 lbs /

227 kg

218559 Danger, Warning – Tip-over, Crush

Hazard

219487 Label – Platform Overload

227213 Instructions Label – Wheel Load

Operating Instructions, Ground Controls*

1262342 Warning – Slope Rating

1263543 Warning – Compartment Access

1267121 Warning – Crush Hazard, Service

1272242 Label – Machine Registration/Owner

Transfer

1278542 Label – Contact Alarm Weight

1278982 Label – Actuator Switch Socket

1280819 Label – Warning, Prop 65*

1280820 Label – Fuel, Diesel Exhaust, Prop 65*

1281174 Label – Lanyard Anchorage Point, Fall

Arrest/Fall Restrained

1293324 Label – ICES-2/CAN-2 Compliance

1294398 Label – ANSI/CSA Compliant

1298825 Label – Relays, Z-45, Z-45BE, Z-45DC

1299743 Danger – Tip-over Hazard, Tires, Z-45

1299744 Label – Transport Diagram, Z-45

1299791 Label – Maximum Capacity, 440 lbs, Side

Force 90 lbs (Aircraft Protection Package)*

Shading indicates decal is hidden from view, i.e.

under covers

* These decals are model, option or configuration

specific. ** These decals are installed on both sides of chassis. *** These decals are installed on both sides of chassis

and are model, option, or configuration specific.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 49

Operator's Manual Fifth Edition • First Printing

Inspections

50 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Decal Inspection - Bi-Energy Models with Symbols

Use the pictures on the next page to verify that all decals are legible and in place.

Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow – Blue

27205 Arrow – Yellow

27206 Triangle – Blue

27207 Triangle – Yellow

28159 Label – Diesel

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

44981 Label – Air Line to Platform (option)*

46468 Function Override*

52475 Label – Transport Tie-down**

72086 Label – Lifting Point**

72444 Ground Control Panel

72867 Label – Work Lights (option)*

82240 Label – 105 dB*

82279 Platform Control Panel

82481 Label – Battery/Charger Safety

82487 Label – Read the Manual

82647 Label – Drive Enable Patch

97815 Label – Lower Mid-rail

114025 Label – Wheel Load

114248 Label – Tip-over Hazard, Tilt Alarm

114249 Label – Tip-over Hazard, Tires

114251 Label – Explosion Hazard

Part No. Decal Description

Qty

114252 Label – Tip-over Hazard, Limit

Switches

114334 Label – Electrocution Hazard, Plug

114343 Label – Emergency Lowering

114345 Label – Tip-over Hazard, Batteries

114391 Label – Bodily Injury Hazard

133067 Label – Electrocution Hazard

133286 Label – Power to Charger

219954 Label – Tip-over Hazard, CE

219956 Label – Platform Overload

219958 Label – Tip-over, Crush Hazard

1262343 Label – Runaway Machine Hazard

1263542 Label – Compartment Access

1272242 Label – Machine Registration/Owner

Transfer

1281174 Label – Lanyard Anchorage Point, Fall

Arrest/Fall Restrained*

1281175 Label – Lanyard Anchorage Point, Fall

Restrained*

1286362 Label – Crush Hazard, Service

1294398 Label – ANSI/CSA Compliant

1299744 Label – Transport Diagram, Z-45

1299792 Label – Tip-over Hazard Aircraft

Protection, Z-30N (Aircraft Protection Package)*

Shading indicates decal is hidden from view, i.e.

under covers * These decals are model, option or configuration

specific. ** These decals are installed on both sides of chassis. *** These decals are installed on both sides of chassis

and are model, option, or configuration specific.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 51

Operator's Manual Fifth Edition • First Printing

Inspections

52 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Decal Inspection - DC Models with Symbols

Use the pictures on the next page to verify that all decals are legible and in place.

Below is a numerical list with quantities and descriptions.

Part No. Decal Description

Qty

27204 Arrow – Blue

27205 Arrow – Yellow

27206 Triangle – Blue

27207 Triangle – Yellow

28174 Label – Power to Platform, 230V*

28235 Label – Power to Platform, 115V*

44981 Label – Air Line to Platform (option)*

46468 Function Override*

52475 Label – Transport Tie-down**

72086 Label – Lifting Point**

72444 Ground Control Panel

72867 Label – Work Lights (option)*

82279 Platform Control Panel

82481 Label – Battery/Charger Safety

82487 Label – Read the Manual

82647 Label – Drive Enable Patch

97815 Label – Lower Mid-rail

114025 Label – Wheel Load

114248 Label – Tip-over Hazard, Tilt Alarm

114249 Label – Tip-over Hazard, Tires

Part No. Decal Description

Qty

114252 Label – Tip-over Hazard, Limit

Switches

114334 Label – Electrocution Hazard, Plug

114343 Label – Emergency Lowering

114345 Label – Tip-over Hazard, Batteries

114350 Label - AC Inverter Power (option)*

133067 Label – Electrocution Hazard

133286 Label – Power to Charger

219954 Label – Tip-over Hazard, CE

219956 Label – Platform Overload

219958 Label – Tip-over, Crush Hazard

1262343 Label – Runaway Machine Hazard

1263542 Label – Compartment Access

1272242 Label – Machine Registration/Owner

Transfer

1281174 Label – Lanyard Anchorage Point, Fall

Arrest/Fall Restrained*

1281175 Label – Lanyard Anchorage Point, Fall

Restrained*

1286362 Label – Crush Hazard, Service

1299744 Label – Transport Diagram, Z-45

1299792 Label – Tip-over Hazard Aircraft

Protection, Z-30N (Aircraft Protection Package)

Shading indicates decal is hidden from view, i.e.

under covers * These decals are model, option or configuration

specific. ** These decals are installed on both sides of chassis. *** These decals are installed on both sides of chassis

and are model, option, or configuration specific.

Fifth Edition • First Printing Operator's Manual

Inspections

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 53

Operator's Manual Fifth Edition • First Printing

Operating Instructions

54 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Operating Instructions

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s

manual. 1 Avoid hazardous situations. 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.

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. 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 to use a machine at different times in the same work shift, they must all be qualified operators and are all expected to follow

all safety rules and instructions in the operator’s,

safety, and responsibilities manuals. That means every new operator should perform a preoperation inspection, function tests, and a workplace inspection before using the machine.

Fifth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 55

Introduction

Bi-Energy models can be operated with or without the engine running.

Starting the Engine

1 At the ground controls, turn the key switch to

the desired position.

2 Be sure both ground and platform control red

Emergency Stop buttons are pulled out to the on position.

3 Move the engine start toggle

switch to either side. If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds.

If the engine fails to start after 15 seconds of cranking, determine the cause and repair any malfunction. Wait 60 seconds before trying to start again.

In cold conditions, hold the glow plug switch to either side for 3 to 5 seconds and then start 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 any function that operates when either red Emergency Stop button is pushed in.

Selecting and operating the ground controls will override the platform red Emergency Stop button.

Auxiliary Controls

Use auxiliary power if the primary power source fails.

1 Turn the key switch to ground or platform

control.

2 Pull out the red Emergency Stop button to the

on position.

3 Press down the foot switch when operating the

auxiliary controls from the platform.

4 Simultaneously hold the auxiliary

power switch on and activate the desired function.

The drive function will not operate with auxiliary power.

Operator's Manual Fifth Edition • First Printing

Operating Instructions

56 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Operation from Ground

1 Turn the key switch to ground control. 2 Pull out the red Emergency Stop button to the

on position.

To Position Platform

1 Hold the function enable switch

to either side.

2 Move the appropriate toggle switch according

to the markings on the control panel.

Drive and steer functions are not available from the ground controls.

Platform Overload Indicator Light

Light flashing indicates the platform is overloaded. The engine will stop and no functions will operate.

Remove weight from the platform until the light goes off and 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: Drive and steer functions are not affected by the boom function speed controller.

2 Press down the foot switch. 3 Move the appropriate toggle switch according

to the markings on the control panel.

To Steer

1 Press down the foot switch. 2 Turn the steer wheels with the thumb rocker

switch located on the top of the control handle.

Use the color-coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn.

Fifth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 57

To Drive

1 Press down the foot switch. 2 Increase speed: Slowly move the control

handle off center. Decrease speed: Slowly move the control

handle toward center. Stop: Return the control handle to center or

release the foot switch.

Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel.

Machine travel speed is restricted when the booms are raised or extended.

Drive Enable

Light on indicates that the boom has moved just past either nonsteer wheel and the drive function has been interrupted.

To drive, hold the drive enable switch to either 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 determine the slope grade.

Maximum slope rating, platform downhill (gradeability):

30% (17°)

Maximum slope rating, platform uphill:

20% (11°)

Maximum side slope rating: 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. The term gradeability applies to the platform downhill configuration only.

Be sure the boom is below horizontal and the platform is between the non-steer wheels.

Move the drive speed select switch to machine on incline symbol.

Operator's Manual Fifth Edition • First Printing

Operating Instructions

58 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

To determine the slope grade:

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  tape measure

Lay the piece of wood on the slope. At the downhill end, lay the level on the top edge

of 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

0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade 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.

Fifth Edition • First Printing Operator's Manual

Operating Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 59

Tilt Sensor Activation Settings

Model

Chassis Angle (side to side)

Chassis Angle (front to back)

Z-45J DC

4.5°

2.5°

Z-45J BE

4.5°

2.5°

When the Machine On Incline indicator light is on and the tilt alarm sounds, the following functions are affected; drive functions are disabled.

Follow the Boom lowering procedure (see Operating Instructions) to restore drive function.

When the machine is stowed, on a slope, and the tilt alarm sounds, the following functions are affected; lift functions are disabled.

Return the machine to level ground to restore lift functions.

AC Inverter (if equipped)

The inverter supplies power to the 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 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 alarm sounds with the platform uphill:

1 Lower the primary

boom.

2 Lower the

secondary boom.

3 Retract the primary

boom.

If the tilt alarm sounds with the platform downhill:

1 Retract the primary

boom.

2 Lower the

secondary boom.

3 Lower the primary

boom.

Operator's Manual Fifth Edition • First Printing

Operating Instructions

60 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Contact Alarm (if equipped)

The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel, interrupting boom movement, sounding an alarm and flashing warning lights.

When the contact alarm cable is tripped, the lift and drive functions are disabled at the platform. The audio and visual warnings will activate alerting others that assistance 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.

a actuator b contact alarm cable c flashing alarm d switch socket

Aircraft Protection Package (if equipped)

If the platform bumpers come into contact with aircraft components, the machine will shut down and no functions will operate.

1 Start the engine. 2 Press down the foot switch. 3 Move and hold the aircraft protection function

override switch.

4 Move the appropriate function control handle

or toggle switch to move the machine away from aircraft components.

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Operating Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 61

Battery and Charger Instructions Observe and Obey:

 Do not use an external charger or booster

battery.

 Charge the battery in a well-ventilated area.  Use proper AC input voltage for charging as

indicated on the charger.

 Use only a Genie authorized battery and

charger.

 Do not operate the machine with the battery

charger plugged in.

Charging the Batteries

Use the engine (if equipped) or the AC battery charger to recharge the batteries.

Bi-Energy models: Charging the Batteries with the Engine

Running the engine will automatically 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 batteries. Periodically, use the AC battery charger to fully charge the batteries.

Charging the Batteries with the AC Charger

1 Be sure the batteries are connected before

charging the batteries.

2 Open the battery compartment. The

compartment should remain open for the entire charging cycle.

Maintenance-free batteries

1 Connect the battery charger to a grounded AC

circuit.

2 The charger will indicate when the battery is

fully charged.

Operator's Manual Fifth Edition • First Printing

Operating Instructions

62 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Standard Batteries

1 Remove the battery vent caps and check the

battery acid level. If necessary, add only enough distilled water to cover the plates. Do

not overfill prior to the charge cycle. 2 Replace the battery vent caps. 3 Connect the battery charger to a grounded AC

circuit. 4 The charger will indicate when the battery is

fully charged. 5 Check the battery acid level when the charging

cycle is complete. 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. Overfilling can cause the battery acid to overflow during charging. Neutralize battery acid spills with baking soda and water.

3 Install the battery vent caps. 4 Charge the battery. 5 Check the battery acid level when the charging

cycle is complete. Replenish with distilled water to the bottom of the fill tube. Do not overfill.

Fifth Edition • First Printing Operator's Manual

Transport and Lifting Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 63

Transport and Lifting Instructions

Observe and Obey:

 Genie provides this securement information as

a recommendation. Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations, other localized regulations, and their company policy.

 Genie customers needing to containerize any

lift or Genie product should source a qualified freight forwarder with expertise in preparing, loading and securing construction and lifting equipment for international shipment.

 Only qualified mobile elevating work platform

operators should move the machine on or off the truck.

 The transport vehicle must be parked on a

level surface.

 The transport vehicle must be secured to

prevent rolling while the machine is being loaded.

 Be 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 not drive the machine on a slope that

exceeds the uphill, downhill or side slope rating. See Driving on a Slope in the Operating Instructions section.

 If the slope of the transport vehicle bed

exceeds the uphill or downhill maximum slope rating, the machine must be loaded and unloaded using a winch as described in the brake release operation. See the Specifications section for the slope ratings.

Free-wheel Configuration for Winching

Chock the wheels to prevent the machine from rolling.

Release the non-steer wheel brakes by turning over the drive hub disconnect caps.

Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions.

Reverse the procedures described to re-engage the brakes.

Operator's Manual Fifth Edition • First Printing

Transport and Lifting Instructions

64 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Securing to Truck or Trailer for Transit

Always use the turntable rotation lock pin each time the machine is transported.

The lock pin is located under the turntable on the hydraulic tank side of the machine.

1 Turntable rotation 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 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.

Fifth Edition • First Printing Operator's Manual

Transport and Lifting Instructions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 65

Observe and Obey:

 Only qualified riggers should rig the machine.  Only certified crane operators should lift the

machine and only in accordance with the applicable crane regulations.

 Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to 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 points on the machine. There are four lifting points on the chassis.

Adjust the rigging to prevent damage to the machine and to keep the machine level.

Y Axis (1)

41.9 in

106.5 cm

X Axis (2)

34.6 in

88 cm

Operator's Manual Fifth Edition • First Printing

Maintenance

66 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

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.

Fifth Edition • First Printing Operator's Manual

Maintenance

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 67

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems.

1 Be sure that the boom is in the stowed

position.

2 Visually inspect the sight gauge 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 (BiEnergy models)

Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level can damage engine components.

Note: Check the oil level with the engine off. 1 Check the oil level dipstick. Add oil as needed.

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

Operator's Manual Fifth Edition • First Printing

Maintenance

68 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Check the Engine Coolant Level (Bi-Energy models)

Maintaining the engine coolant at the proper level is essential to engine service life. Improper coolant

level will affect the engine’s cooling capability and

damage engine components. Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems.

Burn 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 qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine.

Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

Fifth Edition • First Printing Operator's Manual

Specifications

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 69

Specifications

Z-45J DC (jib)

Height, working maximum

51 ft 9 in

15.9 m

Height, platform maximum

45 ft 9 in

13.9 m

Height, stowed maximum

6 ft 7 in

2.0 m

Horizontal reach, platform 90°, maximum

25 ft 1 in

7.7 m

Width

5 ft 10.3 in

1.79 m

Length, stowed

22 ft 5 in

6.83 m

Maximum load capacity

500 lbs

227 kg

Maximum wind speed

28 mph

12.5 m/s

Wheelbase

6 ft 8 in

2.0 m

Turning radius (outside)

14 ft

4.3 m

Turning radius (inside)

6 ft

1.8 m

Turntable rotation

355°

Turntable tailswing

0 in

0 cm

Power source

8 Group 903, L-16,

6V 390AH Batteries

Drive speed, stowed

3.0 mph

40 ft/9 sec

4.8 km/h

12.2 m/9 sec

Drive speed, booms raised

0.6 mph

40 ft/45 sec

1 km/h

12.2 m/45 sec

Airborne noise emissions

73 dB

Maximum sound level at normal operating workstations (A-weighted)

Ground clearance, center

9.5 in

24.1 cm

Ground clearance, minimum

7.5 in

19.1 cm

Weight

16,300 lbs

7394 kg

(Machine weights vary with option configurations. See serial label for specific machine 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

Hydraulic pressure, maximum (boom functions)

3200 psi

221 bar

System voltage

48V

Tire size, 2WD Industrial Foam filled only

9-14.5 LT

Fuel tank capacity

9 gallons

34.1 liters

Maximum slope rating, 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.

Floor loading information

Tire load maximum

8100 lbs

3674 kg

Tire contact pressure

100 psi

7.03 kg/cm2 689 kPa

Occupied floor pressure

315 psf

1538 kg/m2

15.08 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should 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.

Operator's Manual Fifth Edition • First Printing

Specifications

70 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Z-45J Bi-Energy (jib)

Height, working maximum

51 ft 9 in

15.9 m

Height, platform maximum

45 ft 9 in

13.9 m

Height, stowed maximum

6 ft 7 in

2.0 m

Horizontal reach, platform 90°, maximum

25 ft 1 in

7.7 m

Width

5 ft 10.3 in

1.79 m

Length, stowed

22 ft 5 in

6.83 m

Maximum load capacity

500 lbs

227 kg

Maximum wind speed

28 mph

12.5 m/s

Wheelbase

6 ft 8 in

2.0 m

Turning radius (outside)

14 ft

4.3 m

Turning radius (inside)

6 ft

1.8 m

Turntable rotation

355°

Turntable tailswing

0 in

0 cm

Power source

8 Group 903, L-16,

6V 390AH Batteries

with Kubota Z482-E engine

Drive speed, stowed

3.0 mph

40 ft/9 sec

4.8 km/h

12.2 m/9 sec

Drive speed, booms raised

0.6 mph

40 ft/45 sec

1 km/h

12.2 m/45 sec

Airborne noise emissions

73 dB

Maximum sound level at normal operating workstations (A-weighted)

Ground clearance, center

9.5 in

24.1 cm

Ground clearance, minimum

7.5 in

19.1 cm

Weight

16,800 lbs

7620 kg

(Machine weights vary with option configurations. See serial label for specific machine 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

Hydraulic pressure, maximum (boom functions)

3200 psi

221 bar

System voltage

48V

Tire size, 2WD Industrial Foam filled only

9-14.5 LT

Fuel tank capacity

9 gallons

34.1 liters

Maximum slope rating, 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.

Floor loading information

Tire load maximum

8100 lbs

3674 kg

Tire contact pressure

100 psi

7.03 kg/cm2 689 kPa

Occupied floor pressure

325 psf

1587 kg/m2

15.56 kPa

Note: Floor loading information is approximate and does not incorporate different option configurations. It should 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.

Fifth Edition • First Printing Operator's Manual

Specifications

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 71

Z-45 Range of motion chart

Max Height

Max Reach

50 ft

15.2 m

7 0 ft

0 m

40 ft

12.2 m

8 5 ft

1.5 m

30 ft

9.1 m

9 15 ft

4.6 m

20 ft

6.1 m

25 ft

7.6 m

Z®-45J DC • Z®-45J Bi-Energy

Part No. 1297032GT

Operator's

Manual

Fifth Edition • First Printing

Genie Z-45J Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual