Z-45
Second Edition
Second Printing
Part No. 82600
Operator’s Manual
with Maintenance Information
Bi-Energy PowerIC Power
Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
Copyright © 1998 by Genie Industries
First Edition: Seventh Printing, May 2002
Second Edition: Second Printing, August 2004
"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.
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
Safety ........................................................................ 1
Controls ..................................................................... 7
Pre-operation Inspection........................................... 10
Maintenance............................................................. 12
Function Tests.......................................................... 16
Workplace Inspection................................................ 23
Operating Instructions............................................... 24
Transport and Lifting Instructions .............................. 29
Decals ...................................................................... 32
Specifications ........................................................... 36
Contact us:
Internet: http://www.genielift.com
E-mail: techpub@genieind.com
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 1
Operator's ManualSecond Edition · Second Printing
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.
2 Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
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
Phase to Phase Approach Distance
Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.1
50KV to 200KV 15 4.6
200KV to 350KV 20 6.1
350KV to 500KV 25 7.6
500KV to 750KV 35 10.7
750KV to 1000KV 45 13.7
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
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.
Do not alter or disable the limit switches.
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 3
Operator's ManualSecond Edition · Second Printing
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, 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 replace items critical to machine stability
with items of different weight or specification.
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 transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s) in the platform.
Do not place ladders or scaffolds in the platform or
against any part of this machine.
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 replace factory-installed tires with tires of
different specification or ply rating.
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.
4 Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
SAFETY RULES
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
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.
Collision Hazards
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.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 5
Operator's ManualSecond Edition · Second Printing
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.
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 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.
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 &
Genie Z-45/25J 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.
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
6 Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
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.
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.
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 7
Operator's ManualSecond Edition · Second Printing
Controls
Ground Control Panel
1 Platform level switch
2 Platform rotate switch
3 Z-45/25J models only: Jib boom up/down switch
4 Turntable rotate switch
5 Primary boom up/down switch
6 Primary boom extend/retract switch
7 Gasoline/LPG models: Fuel select switch
8 Platform overload indicator light (if equipped)
9 Auxiliary power switch
1 0 Gasoline/LPG models: Check engine light
Diesel models: Oil pressure light
1 1 Key switch for platform/off/ground selection
1 2 Red Emergency Stop button
13 Hour meter
1 4 Diesel models: Water temperature light
1 5 Diesel models: Glow plug switch (if equipped)
1 6 Function enable switch
1 7 Engine start switch
1 8 15A breaker for engine electrical circuits
1 9 Secondary boom up/down switch
2 0 15A breaker for control electrical circuits
8 Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
1 3
6 Drive speed select switch
7 Diesel models: Glow plug switch (if equipped)
8 Engine start switch
9 Engine idle (rpm) select switch
10 Gasoline/LPG models: Gasoline/LPG
select switch
Platform Control Panel
1 Horn button
2 Platform level switch
3 Platform rotate switch
4 Z-45/25J models only: Jib boom up/down switch
5 Auxiliary power switch
2
CONTROLS
4 5 6
171820
19
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 9
Operator's ManualSecond Edition · Second Printing
CONTROLS
1 1 Red Emergency Stop button
1 2 Dual axis proportional control handle for drive
and steer functions
OR Proportional control handle for drive function
and thumb rocker for steer function
1 3 Platform overload indicator light (if equipped)
1 4 Machine not level indicator light (if equipped)
1 5 Drive enable indicator light
117 8 9 10
1216 15
1 6 Drive enable switch
1 7 Proportional control handle for secondary boom
up/down function
1 8 Primary boom extend/retract switch
1 9 used for optional equipment
2 0 Dual axis proportional control handle for primary
boom up/down and turntable rotate
left/right functions
13
14
10 Genie Z-45/25 & Genie Z-45/25J Part No. 82600
Operator's Manual Second Edition · Second Printing
Pre-operation Inspection
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.
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
pre-operation 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.
Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 11
Operator's ManualSecond Edition · Second Printing
PRE-OPERATION INSPECTION
Pre-operation Inspection
o
Be sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
o
Be sure that all decals are legible and in place.
See Decals section.
o
Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
o
Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
o
Check for engine coolant leaks and proper level
of coolant. Add coolant if needed. See
Maintenance section.
o
Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
o
Z-45/25 RT and Z-45/25J RT models: Check for
proper tire pressure. Add air if needed. See
Maintenance section.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
o
Electrical components, wiring and
electrical cables
o
Hydraulic hoses, fittings, cylinders and
manifolds
o
Fuel and hydraulic tanks
o
Drive and turntable motors and drive hubs
o
Boom wear pads
o
Tires and wheels
o
Engine and related components
o
Limit switches and horn
o
Alarms and beacons (if equipped)
o
Nuts, bolts and other fasteners
o
Platform entry mid-rail or gate
Check entire machine for:
o
Cracks in welds or structural components
o
Dents or damage to machine
o
Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
o
After you complete your inspection, be sure that
all compartment covers are in place and
latched.
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