Genie Industries Z-45/22 Series User manual

Technical
Publications
First Edition, Fifth Printing
Part No. 41960
®
Operator's
Manual
-45
Z22
Incorrect operation can result from use of this manual on machines that have not been updated
according to Genie Campaign Bulletin 070001. Death or Serious Injury can result.
This manual only applies to machines that have been updated according to Genie Campaign
Bulletin 070001. Contact Genie Industries for information on this bulletin.
Series
®-45
Z22
DC2WD

Genie Z-45/22 Series Part No. 41960
Operator's Manual First Edition
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidered apermanentpart of yourmachineand
should remain with the machine at all times. If you have
any questions, call Genie Industries.
Contents
Page
Safety Rules .............................................................. 1
Controls ..................................................................... 8
Pre-operationInspection ........................................... 11
Function Tests.......................................................... 13
Work Place Inspection .............................................. 19
OperatingInstructions............................................... 20
TransportInstructions ............................................... 26
Decals ...................................................................... 28
Specifications ........................................................... 31
Genie North America
Telephone [phone]
Toll Free 800 536-1800 in U.S.A.
Toll Free 800 426-8089 in Canada
Fax [phone]
E-mail: [email protected]
http://www.genielift.com
Genie Europe
Telephone [phone]
Fax [phone]
Copyright © 1996 by Genie Industries
First Edition: Fifth Printing, June 2007
Genie® is a registered trademark
of Genie Industries. Registered 2009987
Printed on recycled paper
Printed in U.S.A.
®

PartNo.41960 GenieZ-45/22Series 1
Operator's ManualFirst Edition
Safety Rules
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 work place.
5 Only use the machine as it was intended.
You read, understand and obey:
Manufacturer's instructions and safety
rules—safety and operator's manuals
and machine decals
employer's safety rules and worksite
regulations
applicable governmental regulations
You are properly trained to safely operate the
machine.

2 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
SAFETY RULES
Tip-over Hazards
Occupants and equipment shall not exceed the
maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
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.
Tilt alarm sounds in platform only when machine is
on a severe slope.
If tilt alarm sounds:
Do not extend, rotate or raise boom above
horizontal. Move machine to a firm, level surface
before raising platform. If tilt alarm sounds when
platform is raised, use extreme caution to retract
boomand lower platform.Donot rotate boomwhile
lowering. Move machine to a firm, level surface
beforeraisingplatform.
Do not alter or disable the limit switches.
Do not drive over 0.6 mph (1 km/h) with the primary
orsecondaryboomsraised.
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintain safe distances from electrical power lines
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Approach Distance
Phase to Phase Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines. Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not use the machine as a ground for welding.

PartNo.41960 GenieZ-45/22Series 3
Operator's ManualFirst Edition
SAFETY RULES
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.
Use extreme care and slow speeds while driving
the machine in stowed position across uneven
terrain,debris,unstableor slippery surfaces and
nearholesanddrop-offs.
Donotdrivethe machine on or near uneven terrain,
unstable surfacesorother hazardous conditions
withtheboomraisedor extended.
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies to machines in
thestowed position.
Maximum slope rating, stowed position
Counterweight uphill 20% (11°)
Counterweight downhill 20% (11°)
Side slope 20% (11°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not push off or pull
towardany object outside
theplatform.
Maximum allowable
side force -
ANSI & CSA
150 lbs / 667 N
Maximum allowable
manual force - CE
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.
Batteries are used as counterweight and are critical
to machine stability. Each battery must weigh 110
pounds (49.9 kg). Each battery box including
batteries must weigh a minimum of 538 pounds
(244kg).
Do not place or attach overhanging loads to any
part of this machine.
Do not place ladders or scaffolds in platform or
against any part of this machine.

4 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
SAFETY RULES
Do not use machine on a moving or mobile surface
or vehicle.
Be sure all tires are in good condition, air-filled tires
areproperlyinflatedandlugnutsareproperly
tightened.
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.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmental
regulations.Attach
lanyardtoanchor
providedinplatform.
Itisrecommendedthatoperators wearanapproved
hardhatwhenoperatingthemachine.
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
gatebeforeoperating.

PartNo.41960 GenieZ-45/22Series 5
Operator's ManualFirst Edition
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware ofprimaryand secondary boomand
platformpositionwhenrotatingturntable.
Checkworkareafor overheadobstructions orother
possiblehazards.
Beawareof crushinghazardwhengraspingthe
platformguardrail.
Observeandusecolor-codeddirectionarrowson
the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom unless the area below is
clearof personnel andobstructions.
Limittravel speed according to ground surface
condition,congestion, slope, location of personnel,
and any other factors which may cause collision.
Use extreme care and slow speeds while driving
the machine in the stowed position on any slope.
Do not drive on a slope with boom raised.
Do not allow the machine speed on any slope to
exceed 3 mph / 4.8 km/h (walking pace).
Stop the machine by returning the drive control
handle to the center position or releasing the foot
switch.
When stopped on a slope, the machine may initially
moveslightlydownhillwhenthe drive control handle
is moved to drive up the slope. Be sure the area
behind the machine is clear.
Do not drive on a slope with the wheels turned. Be
surethewheelsarealignedupanddown the slope.
Always use a winch to
loadandunloada
machinefrom atransport
vehicle.
SAFETY RULES

6 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
SAFETY RULES
Do not operate a boom in the path of an overhead
bridgecrane unless the controls of the overhead
bridgecranehavebeenlocked outand/or
precautionshave been taken to prevent any
potentialcollision.
Machine must be on level surface or secured
beforereleasingbrakes.
Do not drive the machine with the remote brake
system released. If the travel alarm sounds when
not driving, the remote brake system is released.
Component Damage Hazard
Do not use the machine as a ground for welding.
Be sure the hydraulic shut-off valves (located by
hydraulictank)areopenbeforeoperatingthe
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Damaged Machine Hazards
Donotusea damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenance has been performed as
specified in this manual and the Genie Z-45/22
SeriesServiceManual.
Be sure all decals are in place and legible.
Besuresafetyand operator's manuals are
complete,legibleand in the storage container
located on the platform.
Decal Legend
Genie product decals use color coding and signal
words to identify the following:
Red—usedtoindicatethe
presence of a hazard that will
cause death or serious injury.
Orange—usedtoindicatethe
presence of a hazard that may
cause death or serious injury.
Yellow—usedto indicate the
presence of a hazard that will or
may cause serious personal injury
ordamage to the machine.
Green—usedtoindicateoperation
ormaintenanceinformation.

PartNo.41960 GenieZ-45/22Series 7
Operator's ManualFirst Edition
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworkingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Battery pack must remain in upright position.
Donotexposebatteryorchargertowater and/or
rain.
Explosion Hazards
Keep sparks, flames and
lightedtobaccoaway
from batteries. Batteries
emit explosive gas.
The battery pack cover
mustremain off during
charging.
Do not contact battery
terminals or cable clamps
with tools that may cause
sparks.
Component Damage Hazards
Do not use any battery charger greater than 36V to
chargebatteries.
Both battery packs must be charged together.
Disconnectbattery pack plugbeforeremoving
battery pack.
Electrocution Hazards
Connectbattery charger to a
groundedAC3-wireelectrical
outlet only.
Inspect daily for damaged cord,
cablesandwires.Replace
damageditemsbeforeoperating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Batteries are used as counterweight and are critical
to machine stability. Each battery must weigh 110
pounds (49.9 kg). Each battery box including
batteries must weigh a minimum of 538 pounds
(244kg).
Lifting Hazard
Use a forklift to install or remove battery pack(s).

8 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
81 34 567
16
Platform Controls
1 Service horn button
2 Auxiliary power switch with cover
3 Drive enable switch
4 Drive enable indicator light
5 Optional equipment
6 Platform rotate switch
7 Platform level switch
8 not used
9 Emergency Stop button
10 Proportional control handle for drive function
and thumb rocker for steer function
12
2
13
14155
Controls

PartNo.41960 GenieZ-45/22Series 9
Operator's ManualFirst Edition
CONTROLS
11 Boom function speed controller
12 Primary boom extend/retract switch
13 Primary boom up/down switch
14 Secondary boom up/down switch
15 Turntable rotate left/right switch
16 Battery charge indicator/low voltage interrupt
(option)
8 8 88 9
10
11
5

10 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
8 Platform level switch
9 Platform rotate switch
10 Turntablerotateswitch
11 Primaryboomup/downswitch
12 Primaryboom extend/retract switch
13 Auxiliary power switch with cover
Ground Controls
1 Key switch for platform/off/ground selection
2 EmergencyStopbutton
3 notused
4 Hourmeter(option)
5 Functionenableswitch
6 Secondaryboomup/downswitch
7 10A breaker for control electrical circuits
837633
5
4
3
2
1
3
3
12
11
10
9
13
3
3
CONTROLS

PartNo.41960 GenieZ-45/22Series 11
Operator's ManualFirst Edition
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
Pre-operationInspection.
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
isapparentlywrong with a machine before the
operator performs the function tests.
Refer to the list on page 12 and check each of the
items and locations for modifications, damage or
loose or missing parts.
A damaged or modified machine must never be
used. If damage or any variation from factory
deliveredcondition 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'sspecifications.Afterrepairsare
completed,the operatormustperform a
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedbyqualifiedservicetechnicians,
accordingtothe manufacturer's specifications and
the requirements listed in the responsibilities
manuals.
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 work place.
5 Only use the machine as it was intended.

12 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
Pre-operation Inspection
· Be sure that the operator's, the safety and the
responsibilitiesmanualsarecomplete,legible
and in the storage container located on the
platform.
· Be sure the decals are legible and in place (see
Decals,page28).
· Check the hydraulic oil level. Check for leaks.
Checkthefollowingcomponentsor areas for
damageand improperly installed ormissingparts:
· Electricalcomponents,wiringandelectrical
cables
· Hydraulic power units, hoses, fittings,
cylindersand manifolds
· Hydraulictank
· Driveandturntablemotorsandtorque hubs
· Boomwearpads
· Tiresandwheels
· Limit switches
· Alarm,hornandbeacon
· Nuts, bolts and other fasteners
· Platformentrymid-railor gate
PRE-OPERATIONINSPECTION
Check the entire machine for:
· Cracks in welds or structural components
· Dentsor damage tomachine
· Be sure that all structural and other critical
componentsare present and allassociated
fastenersand pins are in place and properly
tightened.
· Be sure both battery packs are in place and
properlyconnected.
· After you complete your inspection, be sure that
compartment covers are in place and secured.

PartNo.41960 GenieZ-45/22Series 13
Operator's ManualFirst Edition
Function Tests
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.
Symbol Legend
Indicates that a specific result is expected after
performing a series of steps.
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 work place.
5 Only use the machine as it was intended.

14 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
8 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. Descent alarm (if
equipped)shouldsoundwhileboomislowering.
MachinesequippedwithPlatformLevelControl
Disable Function: The platform level toggle switch
will not operate when the primary boom is raised
past the drive speed limit switch.
Test the Tilt Sensor
9 Pull out the platform red Emergency Stop button
to the on position. Turn the key switch to
platformcontrol.
10 Opentheturntablecoveron the
groundcontrolsside.Locatethe
tilt sensor next to the ground
controlbox.
11 Press down one side of the tilt
sensor.
Result: The alarm, located in the platform,
shouldsound.
FUNCTIONTESTS
Function Tests
1 Select a test area that is firm, level and free of
obstruction.
At the Ground Controls
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to
the on position.
Result:Beacon(ifequipped)should flash.
TestEmergencyStop
4 Push in the red Emergency Stop button to
the off position.
Result: All ground and platform control functions
shouldnotoperate.
5 Pull out the red Emergency Stop button to
the on position.
TesttheMachineFunctions
6 Turn boom function speed controller to "9".
7 Do not hold the function enable switch to either
side. Attempt to activate each boom and
platform function toggle switch.
Result: All boom and platform functions should
notoperate.

PartNo.41960 GenieZ-45/22Series 15
Operator's ManualFirst Edition
Testthe FootSwitch
19 Do not press down the foot switch. Activate
eachmachine function.
Result: The machine functions should not
operate.
TesttheMachineFunctions
20 Move the lift/drive select switch to the lift
position(ifequipped).
21 Press down the foot switch.
22 Activate each boom function toggle switch.
Result: All boom/platform functions should
operate through a full cycle.
Note: Control the speed of boom functions by
adjustingthe boom functionspeedcontroller.
Platform, drive and steer functions are not affected
by the boom function speed controller.
MachinesequippedwithPlatformLevelControl
Disable Function: The platform level toggle switch
will not operate when the primary boom is raised
past the drive speed limit switch.
TesttheAuxiliaryControls
12 Turn the key switch to ground control.
13 Lift the red auxiliary power switch cover.
14 Simultaneouslyhold the auxiliarypower 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.
15 Turn the keyswitch to platform control.
At the Platform Controls
TestEmergencyStop
16 Push in the platform red Emergency Stop button
to the off position.
Result: All ground and platform control functions
shouldnotoperate.
TesttheServiceHorn
17 Pull out the red Emergency Stop button to
the on position.
18 Push the service horn button.
Result: The service horn should sound.
FUNCTIONTESTS

16 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
TesttheSteering
23 Move the lift/drive select switch to the drive
position(ifequipped).
24 Press down the foot switch.
25 Depress the thumb rocker switch on top of the
drive control handle in the direction identified by
theblue triangle on the control panel.
Result: The steer wheels should turn in the
direction that the blue triangles point on the
drive chassis.
26 Depress the thumb rocker switch in the direction
identified 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.
TestDriveandBraking
27 Move the lift/drive select switch to the drive
position(ifequipped).
28 Press down the foot switch.
29 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 control 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.
FUNCTION TESTS
30 Slowly move the drive control handle in the
direction indicated by the yellow arrow on the
control panel until the machine begins to move,
then return the control 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 drive brakes must be able to hold the
machine on any slope it is able to climb.
Testthe Drive EnableSystem
31 Move the lift/drive select switch to the lift
position(ifequipped).
32 Press down the foot switch. Then lower the
boom to the stowed position.
33 Rotatetheturntable until the
primary boom moves past
one of the steering wheels.
Result:Thedriveenable
indicatorlight should come
onandremain on while the
primaryboomisanywhere
intherangeshown.
34 Move the lift/drive select
switch to the drive position
(ifequipped).
35 Move the drive control handle off center.
Result: The drive function should not operate.

PartNo.41960 GenieZ-45/22Series 17
Operator's ManualFirst Edition
Blue
Yellow
36 Move and hold the drive enable toggle switch to
either side and slowly move the drive control
handleoff center.
Result:Thedrivefunctionshouldoperate.
Note: When the drive enable system is in use, the
machine will drive in the opposite direction that the
drive and steer control handle is moved.
Usethecolor-codeddirection
arrowsontheplatform
controls and the drive
chassis to identify the
direction of travel.
TestLimited Drive Speed
37 Move the lift/drive select switch to the lift
position(ifequipped).
38 Press down the foot switch.
39 Raisetheprimaryboomapproximately
2 feet (61 cm).
40 Move the lift/drive select switch to the drive
position(ifequipped).
41 Move the drive select switch to high range and
then slowly move the drive control handle to the
full drive position.
Result:Themaximum achievable drive speed
with the primary boom raised should not exceed
40 feet per 45.5 seconds (12.2 meters per 45.5
seconds).
42 Move the lift/drive select switch to the lift
position(ifequipped).
43 Lowertheprimary boom to the stowed position.
44 Raisethesecondaryboomapproximately
2 feet (61 cm).
45 Move the lift/drive select switch to the drive
position(ifequipped).
46 Slowly move the drive control handle to the full
driveposition.
Result:Themaximum achievable drive speed
withthe secondary boom raised should not
exceed 40 feet per 45.5 seconds (12.2 meters
per45.5seconds).
If the drive speed with the primary boom raised
or the secondary boom raised exceeds 40 feet
per45.5seconds(12.2 meters per 45.5
seconds), immediately tag and remove the
machine from service.
FUNCTIONTESTS

18 GenieZ-45/22Series PartNo.41960
Operator's Manual First Edition
FUNCTIONTESTS
TestAuxiliaryControls
47 Move the lift/drive select switch to the lift
position(ifequipped).
48 Press down the foot switch.
49 Lift the red auxiliary power switch cover.
50 Simultaneouslyhold auxiliary power switch on
and activate each function toggle switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom and steer functions should
operate.
TesttheLift/Drive SelectSwitch (if equipped)
51 Move the lift/drive select switch to the lift
position.
52 Press down the foot switch.
53 Move the drive control handle off center.
Result:No drive functions should operate.
54 Activate each boom function toggle switch.
Result: All boom functions should operate.
55 Move the lift/drive select switch to the drive
position.
56 Press down the foot switch.
57 Activate each boom function toggle switch.
Result:Noboom functions should operate.
58 Move the drive control handle off center.
Result:The drive functions should operate.
59 Repairanymalfunctionsbeforeoperatingthe
machine.