Z-45
Operator’s Manual
Z-45 25
Fourth Edition
First Printing
Part No. 114339
with
Maintenance
Information
IC Power
Z-45 25J
ANSI/CSA
North America
South America
Asia
AUS
Australia
Operator's Manual
Z-45/25 • Z-45/25J Part No . 114339
Fourth Edition • First Printing
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this 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, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symbol and Hazard Pictorial Definitions..................... 3
General Safety........................................................... 5
Personal Safety ........................................................ 11
Work Area Safety...................................................... 12
Legend ...................................................................... 19
Controls .................................................................... 20
Inspections ............................................................... 27
Operating Instructions............................................... 40
Transport and Lifting Instructions .............................. 46
Maintenance ............................................................. 49
Specifications ........................................................... 53
Contact us:
Internet: www.genielift.com
E-mail: techpub@genieind.com
Copyright © 1998 by Genie Industries
First Edition: Seventh Printing, May 2002
Second Edition: Second Printing, August 2004
Third Edition: Second Printing, October 2005
Fourth Edition: First Printing, March 2007
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
These machines comply with
ANSI/SIA 92.5
CAN B.354.4
Printed on recycled paper
Printed in U.S.A.
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 1
Introduction
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.
Owners, Users and Operators:
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.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators, directed
by informed and knowledgeable supervision,
running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.genielift.com
E-mail: techpub@genieind.com
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Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Introduction
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
Genie uses 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 hazardous situation
which, if not avoided, could result
in property damage.
Red
Orange
Yellow
Blue
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 3
Crush Hazard
Burn Hazard Fire Hazard Explosion Hazard Electrocution
Hazard
Fall Hazard Crush Hazard Tip-over Hazard
Symbol and Hazard Pictorials Definitions
Tip-over Hazard
Electrocution
Hazard
Maintain required
clearance.
Read the
operator’s
manual.
Keep off this
surface.
Keep away from
moving parts.
Keep away from
path of moving
platform.
Only trained
maintenance
personnel should
access
compartments.
No smoking.
No flame.
Stop engine.
Do not use ether
or other high
energy starting
aids on machines
equipped with
glow plugs.
Platform uphill:
1 Lower primary
2 Lower secondary
3 Retract primary
Platform downhill:
1 Retract primary
2 Lower secondary
3 Lower primary
3
3
Recovery procedure if tilt alarm sounds
while elevated.
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Lanyard
attachment point
Symbol and Hazard Pictorials Definitions
Wheel load Voltage rating for
power to platform
Pressure rating for
air line to platform
Replace tires with
tires of same
specification.
Tie-down
instructions
Tie-down
instructions
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 5
Safety signs and
locations
General Safety
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General Safety
Safety signs and locations
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 7
Safety signs and locations
General Safety
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General Safety
Safety signs and locations
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 9
General Safety
Safety signs and locations
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10 Z-45/25 • Z-45/25J Part No . 114339
General Safety
Safety signs and locations
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 11
Personal Safety
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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12 Z-45/25 • Z-45/25J Part No . 114339
Work Area Safety
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
and apparatus in accordance with applicable
governmental regulations and the following chart.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 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 use the machine as a ground for welding.
Do not operate the machine during lightning or
storms.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
Maximum capacity
Machine equipped with
Aircraft Protection Package 440 lbs 200 kg
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will reduce
the rated platform capacity and must be factored
into the total platform load. See the decals with the
options.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 13
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. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the
platform uphill:
1 Lower the primary boom.
2 Lower the secondary boom.
3 Retract the primary boom.
If the tilt alarm sounds
with the platform downhill:
1 Retract the primary
boom.
2 Lower the secondary
boom.
3 Lower the primary
boom.
Do not 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.
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 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.
Work Area Safety
3
3
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Work Area Safety
Z-45/25 and Z-45/25J Narrow Base Models:
Do not use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight and
proper counterweight configuration are critical to
stability.
Z-45/25 and Z-45/25J models equipped with
Aircraft Protection Package:
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 modify or alter an aerial 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 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 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
side force - ANSI & CSA
150 lbs / 667 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.
Operator's ManualFourth Edition · First Printing
Part No . 114339 Z-45/25 • Z-45/25J 15
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, 2WD
Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
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
and adequate traction. See Driving on a Slope in
the Operating Instructions Section.
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.
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.
Work Area Safety
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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.
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 the 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.
Work Area Safety
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