Genie Z-45 XC Operator's Manual

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Operator's Manual

Z-45 XC

with Maintenance Information

Original Instructions First Edition First Printing Part No. 1268193GT

Operator's Manual First Edition • First Printing

Z-45 XC Part No. 1268193GT

Front Matter

Contents

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

Symbol and Hazard Pictorials Definitions ............. 5

General Safety ...................................................... 7

Personal Safety ................................................... 10

Work Area Safety ................................................ 11

Legend ................................................................ 20

Controls ............................................................... 21

Inspections .......................................................... 29

Operating Instructions ......................................... 42

Transport and Lifting Instructions ....................... 50

Maintenance ....................................................... 53

Specifications ...................................................... 57

Terex South Dakota, Inc. in the U.S.A. and many other countries.

Complies with EC Directive 2006/42/EC See EC Declaration of Conformity

First Edition • First Printing Operator's Manual

Introduction

Part No. 1268193GT Z-45 XC 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

This machine is intended to be used only to lift personnel, along with their tools, and materials to an aerial work site.

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.

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Introduction

2 Z-45 XC Part No. 1268193GT

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. 1268193GT Z-45 XC 3

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.

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Introduction

4 Z-45 XC Part No. 1268193GT

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

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.

First Edition • First Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1268193GT Z-45 XC 5

Symbol and Hazard Pictorials Definitions

Crush hazard

Keep away from moving parts

Read the operator’s

manual

Overhead obstruction

Collision hazard

Electrocution hazard

Maintain required clearance

Tip-over hazard

Tip-over hazard Electrocution hazard

Avoid contact

Disconnect battery

Wind speed

Machine not level

Manual force

No smoking. No flame. Stop engine.

Explosion hazard

Burn hazard

Explosion hazard

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Symbol and Hazard Pictorials Definitions

6 Z-45 XC Part No. 1268193GT

Wheel load

Tire specifications

No smoking

Explosion hazard

Fire hazard

Platform tie-down instructions

Lifting & tie down instructions

Lanyard anchorage points

Tie-down point

Lifting point

Maximum capacity

Runaway hazard

Color coded direction arrows

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.

Access by trained and authorized personnel onlyl

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General Safety

Part No. 1268193GT Z-45 XC 7

General Safety

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General Safety

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General Safety

Part No. 1268193GT Z-45 XC 9

Operator's Manual First Edition • First Printing

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. 1268193GT Z-45 XC 11

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

3.05 m

50 to 200KV

4.60 m

200 to 350KV

6.10 m

350 to 500KV

7.62 m

500 to 750KV

10.67 m

750 to 1000KV

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 Unrestricted range of motion

300 kg

Maximum occupants

Maximum platform capacity Restricted range of motion

454 kg

Maximum occupants

Maximum platform capacity Unrestricted range of motion Machine equipped with Aircraft Protection Package

273 kg

Maximum occupants

Maximum platform capacity Restricted range of motion Machine equipped with Aircraft Protection Package

427 kg

Maximum occupants

If the platform load is greater than 301 kg, or 274 kg with Aircraft Protection Package do not move the platform into the unrestricted range of motion zone.

Do not exceed the maximum platform capacity. Do not attach a platform rated at 300 kg

(unrestricted range of motion) or 454 kg (restricted range of motion) to machines with any other rated load. See the serial label for the maximum rated load.

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.

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Work Area Safety

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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 when the platform is raised, use extreme caution. Identify the condition of the boom on the slope as shown in the tilt alarm procedure. 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 raise the boom when wind speeds may exceed 12.5 m/s. If wind speeds exceed 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.

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

Part No. 1268193GT Z-45 XC 13

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 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.

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

Maximum allowable manual force – CE

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 replace factory-installed tires with tires of different specification or ply rating.

Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight is critical to stability.

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.

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.

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Work Area Safety

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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 all tires are in good condition, air-filled tires are properly inflated and lug nuts are properly tightened.

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, 4WD

Platform downhill

45%

(24°)

Platform uphill

25%

(14°)

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.

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Work Area Safety

Part No. 1268193GT Z-45 XC 15

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.

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.

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Work Area Safety

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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.

Bodily Injury Hazard

Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.

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.

Explosion and Fire Hazards

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 and charge the battery only in

an open, well-ventilated area away from sparks, flames and lighted tobacco.

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

Do not spray ether into engines equipped with glow plugs.

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Work Area Safety

Part No. 1268193GT Z-45 XC 17

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

Do not use any battery or charger greater than 12V to jump-start the engine.

Do not use the machine as a ground for welding. Do not operate the machine in locations where

extremely high magnetic fields may be present.

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.

Explosion Hazards

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

Electrocution Hazard

Avoid contact with electrical terminals.

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Work Area Safety

18 Z-45 XC Part No. 1268193GT

Panel Cradle Safety

Read, understand and obey all warnings and instructions provided with the panel cradles.

Do not exceed the rated platform capacity. The combined weight of the cradles, panels, occupants, tools and any other equipment must not exceed rated capacity.

The panel cradle assembly weighs 13.6 kg. The maximum capacity of the panel cradles is

113 kg. The weight of the panel cradles and the load in the

panel cradles may limit the maximum number of occupants in platform to one person.

Secure the cradles to the platform. Secure the panel (s) to the platform railing using the straps provided.

Do not operate unless you are adequately instructed and are aware of all hazards associated with lifting panels.

Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load.

Maximum vertical height of panels: 1.2 m. Maximum wind speed: 6.7 m/sec. Maximum panel area: 3 m2.

Pipe Cradle Safety

Read, understand, and obey all warnings and instructions provided with the pipe cradles.

Do not exceed the rated platform capacity. The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform load.

The pipe cradle assembly weighs 9.5 kg. The maximum capacity of the pipe cradle

assembly is 91 kg. The weight of the pipe cradle assembly and the

load in the pipe cradles may limit the maximum number of occupants in platform.

Center the load within the perimeter of the platform.

Secure the load to the platform. Do not obstruct the entrance or the exit of the

platform. Do not obstruct the ability to operate the platform

controls or the red Emergency Stop button. Do not operate unless you are adequately

instructed and are aware of all of the hazards associated with movement of the platform with an overhanging load.

Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load.

Electrocution Hazard: Keep pipes away from all energized electrical conductors.

First Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1268193GT Z-45 XC 19

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

20 Z-45 XC Part No. 1268193GT

Legend

1 Foot switch 2 Manual storage container 3 Sliding mid-rail 4 Lanyard anchorage points 5 Swing gate 6 Jib boom 7 Platform

8 Platform controls 9 Primary boom 10 Secondary boom 11 Ground controls 12 Steer tire 13 Non-steer tire

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Controls

Part No. 1268193GT Z-45 XC 21

Controls

Ground Control Panel

Operator's Manual First Edition • First Printing

Controls

22 Z-45 XC Part No. 1268193GT

Ground Control Panel

1 Diesel models: Oil pressure light

Light on and engine stopped: Tag the machine and remove from service.

Light on and engine still running: Contact

service personnel within 24 hours. 2 15A breaker for engine electrical circuits 3 LCD display

At machine start up the LCD screen displays

total hours the machine has operated, the

battery charge level and the alarm beeps

4 seconds. The screen also displays fault

codes and other service information. 4 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. 5 Red Emergency Stop button

Push in the red Emergency Stop button to the

off position to stop all functions and turn the

engine off. Pull out the red Emergency Stop

button to the on position to operate the

machine. 6 Not used 7 Primary boom up/down switch

Move the primary boom up/down switch up

and the boom will raise. Move the primary

boom up/down switch down and the boom will

lower.

8 Engine idle (rpm) select switch

Move the engine idle select switch to the turtle position for foot switch activated low idle. Move the engine idle select switch to the rabbit position for foot switch activated high idle.

9 Diesel models: Glow plug switch (if equipped)

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

10 Engine start switch

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

11 Secondary boom up/down switch

Move the secondary boom up/down switch up and the secondary boom will raise. Move secondary boom up/down switch down and the secondary boom will lower.

12 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.

13 Emergency power switch

Use emergency power if the primary power source (engine) fails. Simultaneously hold the emergency power switch to either side and activate the desired function.

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Controls

Part No. 1268193GT Z-45 XC 23

14 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.

15 Jib boom up/down switch

Move the jib boom switch up and the jib boom

will raise. Move the jib boom switch down and

the jib boom will lower.

16 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.

17 Primary boom extend/retract switch

Move the primary boom extend/retract switch

to the right and the primary boom will retract.

Move the boom extend/retract switch to the left

and the primary boom will extend.

18 Function enable button

Press and hold the function enable button to

enable the functions on the ground control

panel to operate.

19 Platform overload indicator light

Light flashing indicates the platform is

overloaded. The engine will stop and no

functions will operate. Remove weight until the

light goes off and then restart the engine.

20 15A breaker for control electrical circuits

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Controls

24 Z-45 XC Part No. 1268193GT

Platform Control Panel

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Controls

Part No. 1268193GT Z-45 XC 25

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Controls

26 Z-45 XC Part No. 1268193GT

Platform Control Panel

1 Horn button

Press this button and the horn will sound.

Release the button and the horn will stop. 2 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.

3 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.

4 Jib boom up/down switch

Move the jib boom switch up and the jib boom will raise. Move the jib boom switch down and the jib boom will lower.

5 Platform overload indicator light

Light flashing indicates the platform is overloaded. The engine will stop and no functions will operate. Remove weight until the light goes off and then restart the engine.

6 Restricted range of motion indicator light

Light on indicates that the range of motion is restricted.

7 Unrestricted range of motion indicator light

Light on indicates that the range of motion is unrestricted.

8 Emergency lowering switch

Use emergency power if the primary power source (engine) fails. Simultaneously hold the emergency power switch to either side and activate the desired function.

9 Machine not level indicator light

The machine not level indicator light will come on when the tilt alarm sounds.

10 Generator switch (if equipped)

Move the generator switch up to activate the generator. Move the switch down to turn off the generator.

11 Aircraft protection override switch (if equipped)

Move and hold the aircraft protection override switch to operate the machine when the platform bumper is against an object.

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Controls

Part No. 1268193GT Z-45 XC 27

12 Work light switch (if equipped)

Move the work light switch up to activate the

lights. Move the work light switch down to turn

off the lights.

13 Red Emergency Stop button

Push in the red Emergency Stop button to the

off position to stop all functions and turn the

engine off. Pull out the red Emergency Stop

button to the on position to operate the

machine.

14 Dual axis proportional control handle for drive

and steer functions.

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. Move the control handle

in the direction indicated by the blue triangle

and the machine will steer to the left. Move the

control handle in the direction indicated by the

yellow triangle and the machine will steer to

the right.

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.

15 Drive speed select switch

Machine on incline symbol: Low range operation for inclines. Machine on level surface symbol: High range operation for maximum drive speed.

16 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.

17 Drive enable indicator light

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

18 Glow plug switch

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

19 Engine idle (rpm) select switch

Move the engine idle select switch to the turtle position for foot switch activated low idle. Move the engine idle select switch to the rabbit position for foot switch activated high idle.

20 Engine start switch

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

21 Models with LCD screen: Engine shut-down

indicator light Light on indicates that the engine has shut

down. Contact service personnel.

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Controls

28 Z-45 XC Part No. 1268193GT

22 Proportional control handle for secondary

boom up/down function

Move the control handle up and the secondary boom will raise. Move the control handle down and the secondary boom will lower.

23 Primary boom extend/retract switch

Move the primary boom extend/retract switch up and the primary boom will retract. Move the boom extend/retract switch down and the primary boom will extend.

24 Dual axis proportional control handle for

primary boom up/down and turntable rotate

left/right functions

Move the control handle up and the primary boom will raise. Move the control handle down and the primary boom will lower.

Move the control handle to the right and the turntable will rotate to the right. Move the control handle to the left and the turntable will rotate to the left.

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Inspections

Part No. 1268193GT Z-45 XC 29

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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Inspections

30 Z-45 XC Part No. 1268193GT

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.  Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.  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

 Fuel and hydraulic tanks

 Drive and turntable motors and drive hubs

 Wear pads

 Tires and wheels

 Engine and related components

 Limit switches and horn

 Alarms and beacons (if equipped)  Nuts, bolts and other fasteners  Platform entry mid-rail or gate  Platform load cell  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.

 After you complete your inspection, be sure

that all compartment covers are in place and latched.

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Inspections

Part No. 1268193GT Z-45 XC 31

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.

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32 Z-45 XC Part No. 1268193GT

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 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 will shut off after 2 to

3 seconds. 6 Pull out the red Emergency Stop button to the

on position and restart the engine.

Test Machine Functions

7 Do not push and hold the

function enable button. Attempt to activate each boom and platform function toggle switch.

Result: No boom and platform functions

should operate.

8 Press and hold the function enable button 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.

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Part No. 1268193GT Z-45 XC 33

Test the Tilt Sensor

9 Turn the key switch to

platform control. Pull out the platform red Emergency Stop button to the on position.

10 Open the engine side

turntable cover and locate the tilt sensor to the right of the hydraulic pump.

11 Press down one side of the tilt sensor.

Result: The alarm, located in the platform,

should sound.

Test Emergency Controls

12 Turn the key switch to ground control and shut

the engine off.

13 Pull out the red Emergency Stop button to the

on position.

14 Simultaneously hold the

emergency 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.

At the Platform Controls

Test Emergency Stop

15 Turn the key switch to platform control and

restart the engine.

16 Push in the platform red Emergency Stop

button to the off position.

Result: The engine will shut off after 2 to

3 seconds.

17 Pull out the red Emergency Stop button and

restart the engine.

Test the Horn

18 Press the horn button.

Result: The horn should sound.

Test the Foot Switch

19 Push in the platform red Emergency Stop

button to the off position.

20 Pull out the red Emergency Stop button to the

on position and do not start the engine.

21 Press down the foot switch and attempt to

start the engine by moving the start toggle switch to either side.

Result: The engine should not start.

22 Do not press down the foot switch and restart

the engine.

Result: The engine should start.

23 Do not press down the foot switch and test

each machine function.

Result: No functions should operate.

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34 Z-45 XC Part No. 1268193GT

Test Machine Functions

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.

Test the Steering

26 Press down the foot switch. 27 Press the thumb rocker switch on top of the

drive control handle in the direction indicated

by the blue triangle on the control panel OR

slowly move the control handle in the direction

indicated by the blue triangle.

Result: The steer wheels should turn in the

direction that the blue triangles point on the

drive chassis. 28 Press the thumb rocker switch in the direction

indicated by the yellow triangle on the control

panel OR slowly move the control handle in

the direction indicated by the yellow triangle.

Result: The steer wheels should turn in the

direction that the yellow triangles point on the

drive chassis.

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.

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Inspections

Part No. 1268193GT Z-45 XC 35

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.

Test Limited Drive Speed

36 Press down the foot switch. 37 Raise the primary boom approximately 61 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 30 cm/s.

39 Lower the primary boom to the stowed

position.

40 Raise the secondary boom approximately

61 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 30 cm/s.

42 Lower the secondary boom to the stowed

position.

43 Extend the primary boom approximately

30 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 30 cm/s. 45 Retract the boom to the stowed position. If the drive speed with the primary boom raised,

the secondary boom raised or the primary boom extended exceeds 30 cm/s, immediately tag and remove the machine from service.

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36 Z-45 XC Part No. 1268193GT

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).

49 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.

50 Lower the primary boom to the stowed position

or drive in the opposite direction.

Result: The machine should drive.

51 Return to level ground and extend the primary

boom approximately 0.5 m.

52 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.

53 Retract the primary boom to the stowed

position or drive in the opposite direction.

Result: The machine should drive.

54 Return to level ground and stow the boom. 55 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.

56 Return to level ground and raise the

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

57 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.

58 Lower the secondary boom to the stowed

position or drive in the opposite direction.

Result: The machine should drive.

59 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.

60 Return to level ground and raise the primary

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

61 Drive the machine onto a slope where the

chassis roll 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.

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Part No. 1268193GT Z-45 XC 37

62 Lower the primary boom to the stowed position

or drive in the opposite direction.

Result: The machine should drive.

63 Return to level ground and extend the primary

boom approximately 0.5 m.

64 Drive the machine onto a slope where the

chassis roll 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.

65 Retract the primary boom to the stowed

position or drive in the opposite direction.

Result: The machine should drive. 66 Return to level ground and stow the boom. 67 With the boom fully stowed, drive the machine

onto a slope where the chassis roll angle is greater than 2.5°.

Result: The machine should continue to drive. 68 Return to level ground and raise the

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

69 Drive the machine onto a slope where the

chassis roll 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.

70 Lower the secondary boom to the stowed

position or drive in the opposite direction.

Result: The machine should drive.

Test the Oscillating Axle (if equipped)

71 Start the engine from the platform controls. 72 Drive the right steer tire up onto a 15 cm block

or curb.

Result: The three remaining tires should stay

in firm contact with the ground.

73 Drive the left steer tire up onto a 15 cm block

or curb.

Result: The three remaining tires should stay

in firm contact with the ground.

74 Drive both steer tires up onto a 15 cm block or

curb.

Result: The non-steer tires should stay in firm

contact with the ground.

Test the Lift/Drive Select Function

75 Press down the foot switch. 76 Move the drive control handle off center and

activate a boom function toggle switch.

Result: No boom functions should operate.

The machine will move in the direction indicated on the control panel.

Repair any malfunctions before operating the machine.

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38 Z-45 XC Part No. 1268193GT

Test Aircraft Protection Package (if equipped)

Note: Two people may be required to perform this test.

77 Extend the primary boom approximately

30 cm.

78 Move the yellow bumper at the bottom of the

platform 10 cm in any direction.

79 Activate each function control handle or toggle

switch.

Result: No boom and steer functions should

operate.

80 Move and hold the aircraft

protection override switch.

81 Activate each function control handle or toggle

switch.

Result: All boom and steer functions should

operate.

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Inspections

Part No. 1268193GT Z-45 XC 39

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

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Inspections

40 Z-45 XC Part No. 1268193GT

Decal Inspection

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

40434 Label – Lanyard Anchorage Point

44981 Label – Air Line to Platform (option)

52475 Label – Transport Tie-down

52969 Cosmetic – Genie Boom

62948 Cosmetic – IC Power 4 x 4

72086 Label – Lifting Point

82240 Label – 105 dB

82481 Label – Battery/Charger Safety

82487 Label – Read the Manual

97815 Label – Lower Mid-rail

114248 Label – Tip-over Hazard, Tilt Alarm

Part No. Decal Description

Qty

114249 Label – Tip-over Hazard, Tires

114251 Label – Explosion Hazard

114252 Label – Tip-over Hazard, Limit Switches

133067 Label – Electrocution Hazard

214932 Ground Control Panel

219952 Label – Emergency Lowering

219956 Label – Platform Overload

219958 Label – Tip-over, Crush Hazard

1255581 Cosmetic – Genie

1255582 Cosmetic – Genie

1263542 Label – Compartment Access

1268192 Label – Wheel Load

1268195 Cosmetic – Z-45 XC

1268199 Label – Tip-over Hazard

1268200 Label – Transport and Lifting

Instructions

1272242 Label – Machine Registration/Owner

Transfer

1272738 Label – Slope Rating

1274536 Platform Control Panel, Z-45 XC

1278357 Label – Load Sense Calibration

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

under covers

* These decals are model, option or configuration

specific.

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Inspections

Part No. 1268193GT Z-45 XC 41

Operator's Manual First Edition • First Printing

Operating Instructions

42 Z-45 XC Part No. 1268193GT

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.

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Operating Instructions

Part No. 1268193GT Z-45 XC 43

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.

Diesel models

1 Move the glow plug switch to either side and

hold for 3 to 5 seconds.

2 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.

All models

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, -6°C and below, warm the engine for 5 minutes before operating to prevent hydraulic system damage.

In extreme cold conditions, -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when temperatures are below -18°C may require the use of a booster battery.

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.

Emergency Power

Use emergency power if the primary power source (engine) 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 using the

controls from the platform.

4 Break the security tie and lift the emergency

power switch cover.

Note: If the security tie is broken or missing, consult the appropriate Genie Service Manual.

5 Simultaneously hold the

emergency power switch on and activate the desired function.

The drive function will not operate with emergency power.

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Operating Instructions

44 Z-45 XC Part No. 1268193GT

Operation from Ground

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

on position.

3 Gasoline/LPG models: Choose fuel by moving

the fuel select switch to the desired position.

4 Start the engine.

To Position Platform

1 Push and hold the function

enable button.

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.

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.

3 Gasoline/LPG models: Choose fuel by moving

the fuel select switch to the desired position.

4 Start the engine. Do not press down the foot

switch when starting the engine.

To Position Platform

1 Press down the foot switch. 2 Slowly move the appropriate function control

handle or toggle switch or press the appropriate button according to the markings on the control panel.

To Steer

1 Press down the foot switch. 2 Slowly move the drive control handle in the

direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle.

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

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 function enable 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 boom is raised.

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Operating Instructions

Part No. 1268193GT Z-45 XC 45

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):

4WD: 45% (24°)

Maximum slope rating, platform uphill:

25% (14°)

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 counterweight uphill configuration only.

Be sure the boom is below horizontal and the platform is between the circle-end wheels.

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

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 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 = 3.6 m Run = 3.6 m Rise = 0.3 m

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.

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Operating Instructions

46 Z-45 XC Part No. 1268193GT

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.

Drive Speed Select

 Machine on incline symbol: Low range

operation for inclines

 Machine on level surface symbol: High range

operation for maximum drive speed

Engine Idle Select (rpm)

To select engine idle (rpm), move the switch to the turtle symbol or the rabbit symbol.

When the foot switch is not pressed, the engine will idle at the lowest rpm.

 Turtle symbol: Foot

switch activated low idle

 Rabbit symbol: Foot

switch activated high idle

Generator (if equipped)

To start the generator, move the generator toggle switch to the on position.

Plug a power tool into the power to platform GFCI outlet.

To turn off the generator, move the generator toggle switch to the off position.

Note: Machine functions will not operate while the generator is running and the foot switch is not pressed down. When the foot switch is pressed down, the generator will turn off and the machine functions will operate.

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Operating Instructions

Part No. 1268193GT Z-45 XC 47

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.

Platform Capacity Selection

Range of motion is controlled automatically based on platform load.

Unrestricted Range of Motion: When the platform load is less than 300 kg, the unrestricted range of motion light is on.

Restricted Range of Motion: When the platform load is 301-454 kg, the restricted range of motion light is on and the jib function is limited.

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Operating Instructions

48 Z-45 XC Part No. 1268193GT

Platform Capacity Selection with Aircraft Protection

Range of motion is controlled automatically based on platform load.

Unrestricted Range of Motion: When the platform load is less than 273 kg, the unrestricted range of motion light is on.

Restricted Range of Motion: When the platform load is 274-427 kg, the restricted range of motion light is on and the jib function is limited.

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Operating Instructions

Part No. 1268193GT Z-45 XC 49

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.

Aircraft Protection Package (if equipped)

If the platform bumper comes into contact with an object, 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 override switch.

4 Move the appropriate

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

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.

Operator's Manual First Edition • First Printing

Transport and Lifting Instructions

50 Z-45 XC Part No. 1268193GT

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.

4WD models: Release the wheel brakes by turning over all four 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.

Note: Towing the Genie Z-45 XC is not recommended. If the machine must be towed, do not exceed 3.2 km/h.

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Transport and Lifting Instructions

Part No. 1268193GT Z-45 XC 51

Securing to Truck or Trailer for Transit

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

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. For diagram, refer to the Lifting Instructions.

Securing the Platform - Z-45 XC, Z-45 HF

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.

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Transport and Lifting Instructions

52 Z-45 XC Part No. 1268193GT

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. Remove all loose items on the machine.

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.

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

Center of gravity

X Axis

Y Axis

Z-45 XC

118 cm

113 cm

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Maintenance

Part No. 1268193GT Z-45 XC 53

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 engine is required before performing this procedure.

Check the Engine Oil Level

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. Check the oil level dipstick. Add oil as needed.

Deutz D2011 L03i Engine

Oil type

15W-40

Oil type - cold conditions

5W-40

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Maintenance

54 Z-45 XC Part No. 1268193GT

Diesel Fuel Requirements

Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following result: long engine life and acceptable exhaust emissions levels.

Minimum diesel fuel requirements for each engine are listed below.

Deutz D2011 L03i Engine

Fuel Type

Low Sulfur Diesel (LSD)

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 hydraulic oil level should be within

the top 5 cm of the sight gauge.

3 Add oil as needed. Do not overfill.

Hydraulic oil specifications

Hydraulic oil type

Chevron Rando HD equivalent

First Edition • First Printing Operator's Manual

Maintenance

Part No. 1268193GT Z-45 XC 55

Check the Engine Coolant Level – Liquid Cooled 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.

Burn hazard. Do not remove the radiator cap if

the engine has been running. Contact with pressurized coolant may cause severe burns. Allow engine to cool before removing 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 on the tank or visible in the sight gauge.

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.

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

Operator's Manual First Edition • First Printing

Maintenance

56 Z-45 XC Part No. 1268193GT

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.

First Edition • First Printing Operator's Manual

Specifications

Part No. 1268193GT Z-45 XC 57

Specifications

Z-45 XC

Height, working maximum

15.86 m

Height, platform maximum

13.86 m

Height, stowed maximum

2.25 m

Horizontal reach, maximum

7.55 m

Width, standard tires

2.29 m

Length, stowed

6.66 m

Maximum platform capacity, unrestricted range of motion

300 kg

Maximum platform capacity, restricted range of motion

454 kg

Maximum platform capacity, unrestricted range of motion, models with Aircraft Protection Package

273 kg

Maximum platform capacity, restricted range of motion, models with Aircraft Protection Package

427 kg

Jib articulation

78°

Down

-57°

Maximum wind speed

12.5 m/s

Wheelbase

2.03 m

Turning radius (outside)

4.5 m

Turning radius (inside)

1.68 m

Turntable rotation

355°

Turntable tailswing

0 cm

Ground clearance, center

37.5 cm

Ground clearance, axle

26.7 cm

Controls

12V DC proportional

Weight

6870 kg

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

Platform dimensions, 6 foot

183 cm x 76 cm

Platform leveling

self-leveling

Platform rotation

160°

AC outlet in platform

standard

Fuel tank capacity

64.4 liters

Hydraulic pressure, maximum (boom functions)

221 bar

System voltage

12V

Tire size

315/55 D20 foam filled

Airborne noise emissions

Sound pressure level at ground workstation

87 dBA

Sound pressure level at platform workstation

82 dBA

Guaranteed sound power level

105 dBA

Total vibration value to which the hand/arm system is subjected does not exceed 2.5 m/s2.

Highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0.5 m/s2.

Maximum slope rating, stowed position, 4WD

Platform downhill

45% (24°)

Platform uphill

25% (14°)

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.

Drive speeds

Drive speed, stowed

7.2 km/h

Drive speed, booms raised

0.14 m/s

Floor loading information

Tire load maximum

4226 kg

Tire contact pressure

5.63 kg/cm2 552 kPa

Occupied floor pressure

1037 kg/m2

10.17 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 First Edition • First Printing

Specifications

58 Z-45 XC Part No. 1268193GT

Z-45 XC Range of Motion Chart

Z-45 XC Range of Motion Chart with Aircraft Protection

Z-45 XC

Part No. 1268193GT

Operator's Manual

First Edition • First Printing

Genie Z-45 XC Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual