Terex Genie Z-45J DC User manual

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

Operator's Manual Seventh Edition • First Printing
Z
®
-45J DC • Z
®
-45J Bi-Energy Part No. 1307436GT
Front Matter
Manufacturer:
Terex South Dakota, Inc.
500 Oakwood Road
Watertown, SD 57201, USA
Authorized representative:
Genie Industries B. V.
Boekerman 5
4751 XK OUD GASTEL
The Netherlands
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 6
General Safety ...................................................... 9
Personal Safety................................................... 13
Work Area Safety................................................ 14
Legend ................................................................ 22
Controls............................................................... 23
Inspections.......................................................... 30
Operating Instructions......................................... 44
Transport and Lifting Instructions ....................... 53
Maintenance ....................................................... 56
Specifications...................................................... 59
Copyright © 2006 Terex Corporation
Seventh Edition: First Printing, November 2020
Genie and "Z" are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number stamped on
chassis
Serial label
(located under cover)
Intended Use and Familiarization
Guide
The intended use of this machine is to lift personnel,
including tools, and materials to an aerial work site.
Before operating the machine, it’s the operator’s
responsibility to read and understand this
familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual Seventh Edition • First Printing
Introduction
2 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Platform controls symbology and related
machine movement:
Platform level
Platform rotate
Jib boom up/down
Primary boom up/down
Turntable rotate
Primary boom extend/retract
Secondary boom up/down
Drive forward/reverse
Steer right/left

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 3
Ground controls symbology and related
machine movement:
Platform level
Platform rotate
Jib boom up/down
Primary boom up/down
Turntable rotate
Primary boom extend/retract
Secondary boom up/down
Sequential functions and movement:
•Drive and steer.
Interlocked functions:
•Elevated drive speed.
•Elevated drive in an off-level condition.
•Drive enable when the boom is rotated past the
non-steer wheels.
•All platform and ground controls.
Limitations of use:
•The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
•Do not elevate the platform unless the machine
is on firm level ground.
Stability enhancing means:
•Foam filled tires
Restricted operating envelope:
•500 lbs/227 kg platform capacity.

Operator's Manual Seventh Edition • First Printing
Introduction
4 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Genie. Various bulletins are used by Genie to
communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their associated
dealer, so it is important to register your machine
and keep your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 5
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules–safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
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.
DANGER
WARNING
CAUTION
NOTICE

Operator's Manual Seventh Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Symbol and Hazard P ictorials Definiti ons
Fire hazard Explosion hazard Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking.
No flame.
Stop engine.
Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Tire specifications

Seventh Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 7
Wheel load Wind speed Maximum capacity Manual force Support the platform
or boom during
maintenance
Tie-down point Lifting point Platform tie-down
instructions
Lifting & tie down
instructions
Lanyard anchorage
points
Corrosive acid. Color coded direction
arrows
Runaway hazard Collision hazard Overhead obstruction

Operator's Manual Seventh Edition • First Printing
Symbol and Hazard Pictorials Definitions
8 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Electrocution hazard Avoid contact Disconnect battery Voltage rating for
power to platform
Pressure rating for air
line to platform
Recovery procedure if tilt alarm sounds while
elevated.
Platform uphill:
1Lower primary.
2Lower secondary.
3Retract primary.
Platform downhill:
1Retract primary.
2Lower secondary.
3Lower primary.
Read the operator’s
manual
Access by trained
and authorized
personnel only
Read the service
manual
Emergency lowering Crush hazard

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 9
General Safety

Operator's Manual Seventh Edition • First Printing
General Safety
10 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 11

Operator's Manual Seventh Edition • First Printing
General Safety
12 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
* These decals are model, option or configuration specific.

Seventh Edition • First Printing Operator's Manual
Personal Safety
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 13
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.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
14 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
WorkArea Safety Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 13.72 m
Allow for platform movement, electrical line sway or
sag, and beware of strong or gusty winds.
Keep away from the
machine if it contacts
energized power lines.
Personnel on the ground
or in the platform must not
touch or operate the
machine until energized
power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum platform capacity
Machine equipped with Aircraft
Protection Package 440 lbs 200 kg
Maximum occupants 2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not alter or disable the limit switches.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 15
Do not use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight and
proper counterweight configuration are critical to
stability.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.
If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. The Machine Not Level
indicator light will come on and the drive function in
one or both directions will not operate. Identify the
condition of the boom on the slope as shown below.
Follow the steps to lower the boom before moving
to a firm, level surface. Do not rotate the boom
while lowering.
If the tilt alarm sounds
with the platform uphill:
1Lower the primary
boom.
2Lower the secondary
boom.
3Retract the primary
boom.
If the tilt alarm sounds
with the platform
downhill:
1Retract the primary
boom.
2Lower the secondary
boom.
3Lower the primary
boom.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
16 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Do not raise the boom
when wind speeds may
exceed 28 mph/12.5 m/s.
If wind speeds exceed
28 mph/12.5 m/s when
the boom is raised, lower
the boom and do not
continue to operate the
machine.
Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable side
force — 90 lbs/400 N
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not modify or alter a mobile elevating work
platform without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not place or attach
fixed or overhanging loads
to any part of this machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled by
person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure the tires are in good condition and the lug
nuts tightened.
Do not use the platform controls to free a platform
that is caught, snagged, or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1307436GT Z®-45J DC • Z®-45J Bi-Energy 17
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh a minimum of 105 lbs /
47.6 kg. Each battery box including batteries must
weigh a minimum of 530 lbs / 240.4 kg.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position
Platform downhill 30% (17°)
Platform uphill 20% (11°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
with one person in the platform and adequate
traction. Additional platform weight may reduce
slope rating. See Driving on a Slope in the
Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand, or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
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).

Operator's Manual Seventh Edition • First Printing
Work Area Safety
18 Z®-45J DC • Z®-45J Bi-Energy Part No. 1307436GT
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or
operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site, and
governmental rules regarding use of personal
protective equipment.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the condition
of the ground surface,
congestion, slope,
location of personnel,
and any other factors
which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.