Operator’s Manual |
Second Edition |
First Printing |
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with Maintenance Information |
Part No. 82595 |
DC Power
Operator's Manual |
Second Edition · First Printing |
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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 |
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Page |
Safety ........................................................................ |
1 |
Controls ..................................................................... |
8 |
Pre-operation Inspection ........................................... |
11 |
Maintenance ............................................................. |
13 |
Function Tests .......................................................... |
15 |
Workplace Inspection ................................................ |
20 |
Operating Instructions ............................................... |
21 |
Transport and Lifting Instructions .............................. |
25 |
Decals ...................................................................... |
28 |
Specifications ........................................................... |
32 |
Contact us:
Internet: http://www.genielift.com
E-mail: techpub@genieind.com
Copyright © 1999 by Genie Industries
First Edition: |
Fifth Printing, April 2002 |
Second Edition: First Printing, June 2003
"Genie" and "Z" are registered trademarks of Genie Industries in the U.S.A. and many other countries.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
Genie Z-45/25 DC & Genie Z-45/25J DC |
Part No. 82595 |
Second Edition · First Printing |
Operator's Manual |
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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 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.
Part No. 82595 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
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Operator's Manual |
Second Edition · First Printing |
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SAFETY RULES
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.
Voltage |
Minimum Safe |
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Phase to Phase |
Approach Distance |
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Feet |
Meters |
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0 to 300V |
Avoid Contact |
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300V to 50KV |
10 |
3.1 |
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50KV to 200KV |
15 |
4.6 |
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200KV to 350KV |
20 |
6.1 |
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350KV to 500KV |
25 |
7.6 |
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500KV to 750KV |
35 |
10.7 |
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750KV to 1000KV |
45 |
13.7 |
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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 |
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Maximum occupants |
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2 |
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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:
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 to retract the boom and lower the platform. Do not rotate the boom while lowering. Move the machine to a firm, level surface before raising the platform.
Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.
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Genie Z-45/25 DC & Genie Z-45/25J DC |
Part No. 82595 |
Second Edition · First Printing |
Operator's Manual |
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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 push off or pull toward any object outside of the platform.
Maximum allowable side force - ANSI & CSA
150 lbs / 667 N
Maximum allowable side force - CE
90 lbs / 400 N
Do not alter or disable machine components that in any way affect safety and stability.
Do not alter or disable the limit switches.
Do not replace items critical to machine stability with items of different weight or specification.
SAFETY RULES
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 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.
Part No. 82595 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
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Operator's Manual |
Second Edition · First Printing |
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SAFETY RULES
Fall Hazards |
Collision 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.
Be aware of limited sight distance and blind spots when driving or operating.
Be aware of the boom position 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.
Do not lower the boom unless the area below is clear of personnel and obstructions.
Component Damage Hazard
Do not use the machine as a ground for welding.
Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision.
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Genie Z-45/25 DC & Genie Z-45/25J DC |
Part No. 82595 |
Second Edition · First Printing |
Operator's Manual |
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Observe and use color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.
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
Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin.
Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.
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.
SAFETY RULES
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 batteries only in an open, well-ventilated area away from sparks, flames and lighted tobacco.
Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.
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 Genie Z-45/25 DC & Z-45/25J DC 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 platform.
Part No. 82595 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
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Operator's Manual |
Second Edition · First Printing |
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SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding and signal words to identify the following:
Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Red—used to indicate the 
presence of an imminently 
hazardous situation which, if not avoided, will result in death or serious injury.
Orange—used to indicate the presence of a potentially 
hazardous situation which, if not avoided, could result in death or serious injury.
Yellow with safety alert symbol— 
used to indicate the presence of a 
potentially hazardous situation which, if not avoided, may cause minor or moderate injury.
Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.
Green—used to indicate operation or maintenance information.
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Genie Z-45/25 DC & Genie Z-45/25J DC |
Part No. 82595 |
Second Edition · First Printing |
Operator's Manual |
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Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
The battery pack must remain in the upright position.
Do not expose the batteries or the charger to water or rain.
Explosion Hazards
Keep sparks, flames and lighted tobacco away from batteries. Batteries emit an explosive gas.
The battery pack cover must remain off during the entire charging cycle.
Do not contact the battery terminals or the cable clamps with tools that may cause sparks.
SAFETY RULES
Component Damage Hazards
Do not use any battery charger greater than 48V to charge the batteries.
Both battery packs must be charged together.
Disconnect the battery pack plug before removing the battery pack.
Electrocution Hazards
Connect the battery charger to a grounded, AC 3-wire electrical outlet only.
Inspect daily for damaged cord, cables and wires. Replace damaged items before operating.
Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability. Each battery must weigh 88 lbs / 40 kg. Each battery box including batteries must weigh a minimum of 452 lbs / 205 kg.
Lifting Hazard
Use a forklift to remove or install the battery packs.
Part No. 82595 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
7 |
Operator's Manual |
Second Edition · First Printing |
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Controls
1 |
2 |
3 |
4 |
5 |
6 |
7 |
18 8 17 16 15
Platform Control Panel |
7 |
Platform level switch |
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1 |
Horn button |
8 |
Not used |
2 |
Auxiliary power switch |
9 |
Platform overload indicator light (if equipped) |
3 |
Drive enable indicator light |
10 |
Machine not level indicator light (if equipped) |
4 |
Drive enable switch |
11 |
Red Emergency Stop button |
5 |
Z-45/25J DC models: Jib boom |
12 |
Proportional control handle for drive function and |
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up/down switch |
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thumb rocker for steer function |
6 |
Platform rotate switch |
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8 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
Part No. 82595 |
Second Edition · First Printing |
Operator's Manual |
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CONTROLS
8 |
8 |
8 |
8 |
9 |
10 |
11 |
14 |
13 |
12 |
13Boom function speed controller
14Primary boom extend/retract switch
15Primary boom up/down switch
16Secondary boom up/down switch
17Turntable rotate switch
18Battery charge indicator
Part No. 82595 |
Genie Z-45/25 DC & Genie Z-45/25J DC |
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