Genie Z-45, Z-25, Z-25J User Manual

Operator’s Manual

Z-45 25
Z-45 25J

ANSI/CSA
North America
South America
Asia

IC Power

AUS
Australia

with

Maintenance

Information

Fourth Edition

First Printing

Part No. 114339

Operator's Manual

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

Fourth Edition • First Printing

Contact us:

Internet: www.genielift.com
E-mail: [e-mail]

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.

Z-45/25 • Z-45/25J Part No . 114339

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:

Operator's ManualFourth Edition · First Printing

Introduction

Danger

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: [e-mail]

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 . 114339 Z-45/25 • Z-45/25J 1

Operator's Manual Fourth Edition · First Printing

Introduction

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

Red

Orange

Yellow

Blue

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.

Intended Use

This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.

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.

2 Z-45/25 • Z-45/25J P art No. 114339

Operator's ManualFourth Edition · First Printing

Symbol and Hazard Pictorials Definitions

Crush Hazard

Burn Hazard Fire Hazard Explosion Hazard Electrocution

Fall Hazard Crush Hazard Tip-over Hazard

Keep off this
surface.

Keep away from
moving parts.

Maintain required
clearance.

Hazard

Tip-over Hazard

Electrocution
Hazard

Keep away from
path of moving
platform.

Only trained
maintenance
personnel should
access
compartments.

Recovery procedure if tilt alarm sounds
while elevated.

Read the
operator’s
manual.

No smoking.
No flame.
Stop engine.

Do not use ether
or other high
energy starting
aids on machines
equipped with
glow plugs.

3

Platform uphill:
1 Lower primary
2 Lower secondary
3 Retract primary

Platform downhill:
1 Retract primary
2 Lower secondary
3 Lower primary

3

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Operator's Manual Fourth Edition · First Printing

Symbol and Hazard Pictorials Definitions

Lanyard
attachment point

Tie-down
instructions

Wheel load Voltage rating for

power to platform

Tie-down
instructions

Pressure rating for
air line to platform

Replace tires with
tires of same
specification.

4 Z-45/25 • Z-45/25J P art No. 114339

Safety signs and
locations

Operator's ManualFourth Edition · First Printing

General Safety

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Operator's Manual Fourth Edition · First Printing

General Safety

Safety signs and locations

6 Z-45/25 • Z-45/25J P art No. 114339

Safety signs and locations

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General Safety

Part No . 114339 Z-45/25 • Z-45/25J 7

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General Safety

Safety signs and locations

8 Z-45/25 • Z-45/25J P art No. 114339

Safety signs and locations

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General Safety

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Operator's Manual Fourth Edition · First Printing

General Safety

Safety signs and locations

10 Z-45/25 • Z-45/25J Part No . 114339

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 ManualFourth Edition · First Printing

Personal Safety

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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

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.

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.

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Operator's ManualFourth Edition · First Printing

Work Area Safety

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

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.

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.

Part No . 114339 Z-45/25 • Z-45/25J 13

3

Operator's Manual Fourth Edition · First Printing

Work Area Safety

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.

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.

14 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Work Area Safety

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.

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.

Part No . 114339 Z-45/25 • Z-45/25J 15

Operator's Manual Fourth Edition · First Printing

Work Area Safety

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.

16 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Work Area Safety

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.

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.

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.

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 appropriate Genie
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.

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.

Part No . 114339 Z-45/25 • Z-45/25J 17

Operator's Manual Fourth Edition · First Printing

Work Area Safety

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.

Explosion Hazard

Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.

Electrocution Hazard

Avoid contact with electrical terminals.

Lockout After Each Use

1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowed

position.

3 Rotate the turntable so that the boom is between

the non-steer wheels.

4 Turn the key switch to the off position and

remove the key to secure from unauthorized
use.

5 Chock the wheels.

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Operator's ManualFourth Edition · First Printing

Legend

1 Foot switch
2 Manual storage container
3 Sliding mid-rail
4 Lanyard anchorage point
5 Jib boom (Z-45/25J and Z-51/30)
6 Platform
7 Platform controls

Part No . 114339 Z-45/25 • Z-45/25J 19

8 Primary boom
9 Secondary boom
10 Ground controls
1 1 Steer tire
1 2 LPG tank (if equipped)
13 Non-steer tire

Operator's Manual Fourth Edition · First Printing

Controls

1 3

2 4 5 6

Platform Control Panel

1 Horn button
2 Platform level switch
3 Platform rotate switch
4 Z-45/25J: Jib boom up/down switch

19

6 Drive speed select switch
7 Diesel models: Glow plug switch
8 Engine start switch
9 Engine idle (rpm) select switch
10 Gasoline/LPG models: Gasoline/LPG

171820

select switch

5 Auxiliary power switch

20 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Controls

117 8 9 10

14

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 Not used
1 4 Machine not level indicator light (if equipped)
1 5 Drive enable indicator light

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

1216 15 13

Part No . 114339 Z-45/25 • Z-45/25J 21

Operator's Manual Fourth Edition · First Printing

Controls

Platform Control Panel

1 Horn button

Push the horn button and the horn will sound.

Release the horn button and the horn will stop.

2 Platform level switch

Move the platform level

switch up and the level of
the platform will raise. Move
the platform level switch
down and the level of the
platform will lower.

3 Platform rotate switch

Move the platform rotate

switch to the right and the
platform will rotate to the
right. Move the platform
rotate switch to the left and
the platform will rotate to the left.

4 Jib boom up/down switch

Move the jib boom switch up

and the jib boom will raise.
Move the jib boom switch down
and the jib boom will lower.

5 Auxiliary power switch

Use auxiliary power if the primary power source

(engine) fails.
Simultaneously hold the auxiliary power switch
to either side and activate the desired function.

6 Drive speed select switch

Machine on incline symbol: Low range operation

for inclines.

Machine on level surface symbol: High range

operation for maximum drive speed.
7 Glow plug switch

Move the glow plug switch to either side and

hold for 3 to 5 seconds.
8 Engine start switch

Move the engine start switch to either side to

start the engine.
9 Engine idle (rpm) select switch

Move the engine idle select switch to the turtle

position for foot switch activated low idle.

Move the engine idle select switch to the rabbit

position for foot switch activated high idle.
1 0 Gasoline/LPG models: Fuel select switch

Move the fuel select switch to the gasoline

position to select gasoline. Move the fuel select

switch to the LPG position to select LPG.
1 1 Red Emergency Stop button

Push in red Emergency Stop button to the off

position to stop all functions and turn the engine

off. Pull out the red Emergency Stop button to

the on position to operate the machine.

22 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Controls

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

Move the control handle in the direction

indicated by the blue arrow on the control panel
and the machine will drive forward. Move the
control handle in the direction indicated by the
yellow arrow and the machine will drive
backwards. Move the control handle in the
direction indicated by the blue triangle and the
machine will steer to the left. Move the control
handle in the direction indicated by the yellow
triange and the machine will steer to the right.
OR
Move the control handle in the direction
indicated by the blue arrow on the control panel
and the machine will drive forward. Move the
control handle in the direction indicated by the
yellow arrow and the machine will drive
backwards. Press the left side of the thumb
rocker and the machine will steer to the left.
Press the right side of the thumb rocker and the

machine will steer to the right.
1 3 Not used
1 4 Machine not level indicator light (if equipped)

The machine not level indicator light will come

on when the tilt alarm sounds.
1 5 Drive enable indicator light

Light on indicates that the boom has moved just

past either non-steer wheel and drive function

has been interrupted.

1 6 Drive enable switch

To drive when the drive enable light is on, hold

the drive enable switch to either side and slowly
move the drive control handle off center. Be
aware that the machine may move in the
opposite direction that the drive and steer
controls are moved.

1 7 Proportional control handle for secondary boom

up/down function

Move the control handle up

and the secondary boom
will raise. Move the control
handle down and the
secondary boom will lower.

1 8 Primary boom extend/retract switch

Move the primary boom

switch up and the primary
boom will retract. Move the
primary boom switch down
and the primary boom will

extend.
1 9 Used for optional equipment
2 0 Dual axis proportional control handle for primary

boom up/down and turntable rotate left/right

functions

Move the control handle up and

the primary boom will raise.

Move the control handle down

and the primary boom will

lower. Move the control handle

to the right and the turntable

will rotate to the right. Move the

control handle to the left and the

turntable will rotate to the left.

Part No . 114339 Z-45/25 • Z-45/25J 23

Operator's Manual Fourth Edition · First Printing

Controls

Ground Control Panel

1 Platform level switch
2 Platform rotate switch
3 Z-45/25J: 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 Not used
9 Auxiliary power switch
1 0 Gasoline/LPG models: Check engine light

Diesel models: Oil pressure light

24 Z-45/25 • Z-45/25J Part No . 114339

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

Operator's ManualFourth Edition · First Printing

Controls

Ground Control Panel

1 Platform level switch

Move the platform level

switch up and the level of
the platform will raise.
Move the platform level
switch down and the level
of the platform will lower.

2 Platform rotate switch

Move the platform rotate

switch to the right and the
platform will rotate to the
right. Move the platform
rotate switch to the left and
the platform will rotate to the
left.

3 Jib boom up/down switch

Move the jib boom switch up

and the jib boom will raise.
Move the jib boom switch down
and the jib boom will lower.

4 Turntable rotate switch

Move the turntable rotate switch to

the right and the turntable will
rotate to the right. Move the
turntable rotate switch to the left
and the turntable will rotate to the
left.

6 Primary boom extend/retract switch

Move the primary boom

extend/retract switch to the

right and the boom will

retract. Move the boom

extend/retract switch to the

left and the boom will

extend.
7 Gasoline/LPG models: Fuel select switch

Move the fuel select switch to the gasoline

position to select gasoline. Move the fuel select

switch to the LPG position to select LPG.
8 Not used
9 Auxiliary power switch

Use auxiliary power if the primary power source

(engine) fails.

Simultaneously hold the auxiliary power switch

to either side and activate the desired function.
1 0 Gasoline/LPG models: Check engine light

Diesel models: Oil pressure light

Light on and engine stopped: Tag the machine

and remove from service.

Light on and engine still running: Contact

service personnel within 24 hours.

5 Primary boom up/down switch

Move the primary boom up/

down switch up and the boom
will raise. Move the primary
boom up/down switch down
and the boom will lower.

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Operator's Manual Fourth Edition · First Printing

Controls

1 1 Key switch for platform/off/ground selection

Turn the key switch to the platform position and

the platform controls will operate. Turn the key
switch to the off position and the machine will
be off. Turn the key switch to the ground
position and the the ground controls will operate.

1 2 Red Emergency Stop button

Push in red Emergency Stop button to the off

position to stop all functions and turn the engine
off. Pull out the red Emergency Stop button to
the on position to operate the machine.

13 Hour meter

The hour meter displays the number of hours the

machine has operated.

1 4 Diesel models: Water temperature light

Light on and engine stopped: Tag the machine

and remove from service.
Light on and engine still running: Contact
service personnel within 24 hours.

1 5 Diesel models: Glow plug switch (if equipped)

1 7 Engine start switch

Move the engine start switch to either side to

start the engine.
1 8 15A breaker for engine electrical circuits
1 9 Secondary boom up/down switch

Move the secondary boom

up/down switch up and the

secondary boom will raise.

Move secondary boom up/

down switch down and the

secondary boom will lower.
2 0 15A breaker for control electrical circuits

Move the glow plug switch to either side and

hold for 3 to 5 seconds.

1 6 Function enable switch

Move the function enable switch to either side to

enable the functions on the ground control panel
to operate.

26 Z-45/25 • Z-45/25J Part No . 114339

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.

Operator's ManualFourth Edition · First Printing

Inspections

Pre-operation Inspection
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 . 114339 Z-45/25 • Z-45/25J 27

Operator's Manual Fourth Edition · First Printing

Inspections

Pre-operation Inspection

!

!

Be sure that the operator’s, safety and

responsibilities manuals are complete, legible
and in the storage container located in the
platform.

!

Be sure that all decals are legible and in place.

See Decals section.

!

Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

!

Check for hydraulic oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

!

Check for engine coolant leaks and proper level

of coolant. Add coolant if needed. See
Maintenance section.

!

Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See
Maintenance section.

!

Z-45/25 RT and Z-45/25J RT models with air-

filled tires: Check for proper tire pressure. Add
air if needed. See Maintenance section.

Engine and related components

!

Limit switches and horn

!

Alarms and beacons (if equipped)

!

Nuts, bolts and other fasteners

!

Platform entry mid-rail or gate

Check entire machine for:

!

Cracks in welds or structural components

!

Dents or damage to machine

!

Excessive rust, corrosion or oxidation

!

Be sure that all structural and other critical

components are present and all associated

fasteners and pins are in place and properly

tightened.

!

After you complete your inspection, be sure that

all compartment covers are in place and

latched.

Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:

!

Electrical components, wiring and
electrical cables

!

Hydraulic hoses, fittings, cylinders and
manifolds

!

Fuel and hydraulic tanks

!

Drive and turntable motors and drive hubs

!

Boom wear pads

!

Tires and wheels

28 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Inspections

Function Test 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.

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 workplace.
5 Only use the machine as it was intended.

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.

Part No . 114339 Z-45/25 • Z-45/25J 29

Operator's Manual Fourth Edition · First Printing

Inspections

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: The beacon (if equipped) should flash.

4 Start the engine. See Operating Instructions

section.

Test Emergency Stop

5 Push in the red Emergency Stop button to the

off position.
Result: The engine will shut off after 2 to 3

seconds.

6 Pull out the red Emergency Stop button to

the on position and restart the engine.

Test the Machine Functions

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

not operate.

Test the Tilt Sensor

9 Turn the key switch to

platform control. Pull out the
platform red Emergency Stop
button to the on position.

1 0 Open the engine side turntable

cover and locate the tilt
sensor to the right of the
hydraulic pump.

1 1 Press down one side of the tilt sensor.

Result: The alarm, located in the platform,

should sound.

Test Auxiliary Controls

1 2 Turn the key switch to ground control and shut

the engine off.

1 3 Pull out the red Emergency Stop button to the

on position.

1 4 Simultaneously hold the

auxiliary power 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.

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. The descent alarm

should sound while the boom is lowering.

30 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Inspections

At the Platform Controls

Test Emergency Stop

1 5 Turn the key switch to platform control and

restart the engine.

1 6 Push in the platform red Emergency Stop button

to the off position.
Result: The engine will shut off after 2 or 3

seconds.

1 7 Pull out the red Emergency Stop button and

restart the engine.

Test the Horn

1 8 Push the horn button.

Result: The horn should sound.

Test the Foot Switch

1 9 Push in the platform red Emergency Stop button

to the off position.

2 0 Pull out the red Emergency Stop button to

the on position but do not start the engine.

2 1 Press down the foot switch and attempt to start

the engine by moving the start toggle switch to

either side.
Result: The engine should not start.

Test Machine Functions

2 4 Press down the foot switch.
2 5 Activate each machine function control handle

or toggle switch.

Result: All boom/platform functions should

operate through a full cycle.

Test the Steering

2 6 Press down the foot switch.
2 7 Press the thumb rocker switch on top of the

drive control handle in the direction indicated by
the blue triangle on the control panel OR slowly
move the control handle in the direction
indicated by the blue triangle.

Result: The steer wheels should turn in the

direction that the blue triangles point on the
drive chassis.

2 8 Press the thumb rocker switch on top of the

drive control handle in the direction indicated by
the yellow triangle on the control panel OR
slowly move the control handle in the direction
indicated by the yellow triangle.

Result: The steer wheels should turn in the

direction that the yellow triangles point on the
drive chassis.

2 2 Do not press down the foot switch and restart

the engine.
Result: The engine should start.

2 3 Do not press down the foot switch and test each

machine function.
Result: The machine functions should not

operate.

Part No . 114339 Z-45/25 • Z-45/25J 31

Operator's Manual Fourth Edition · First Printing

Inspections

Test Drive and Braking

2 9 Press down the foot switch.
3 0 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 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.

3 1 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 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 brakes must be able to hold the machine
on any slope it is able to climb.

Test the Drive Enable System

3 2 Press down the foot switch and lower the boom

to the stowed position.

3 4 Move the drive control handle off center.

Result: The drive function should not operate.

3 5 Move and hold the drive enable toggle switch to

either side and slowly move the drive control
handle off center.

Result: The drive function should operate.

Note: When the drive enable system is in use, the
machine may drive in the opposite direction that the
drive and steer control handle is moved.

Use the color-coded direction
arrows on the platform

Blue

controls and the drive
chassis to identify the
direction of travel.

Yellow

3 3 Rotate the turntable until the primary boom

moves past one of the non-steer wheels.
Result: The drive enable

indicator light should

come on and remain on

while the boom is

anywhere in the range

shown.

32 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Inspections

Test Limited Drive Speed - Standard Base
Models

3 6 Press down the foot switch.
3 7 Raise the primary boom approximately

2 feet / 61 cm.

3 8 Slowly move the drive control handle to the full

drive position.
Result: The maximum achievable drive speed

with the primary boom raised should not exceed

1 foot / 30 cm per second.

3 9 Lower the primary boom to the stowed position.
4 0 Raise the secondary boom approximately

2 feet / 61 cm.

4 1 Slowly move the drive control handle to the full

drive position.
Result: The maximum achievable drive speed

with the secondary boom raised should not

exceed 1 foot / 30 cm per second.

4 2 Lower the secondary boom to the stowed

position.

4 3 Extend the primary boom approximately

1 foot / 30 cm.

4 4 Slowly move the drive control handle to the full

drive position.
Result: The maximum achievable drive speed

with the primary boom extended should not

exceed 1 foot / 30 cm per second.

4 5 Retract the boom to the stowed position.
If the drive speed with the primary boom raised, the

secondary boom raised or the primary boom
extended exceeds 1 foot / 30 cm per second,
immediately tag and remove the machine from
service.

Test Limited Drive Speed - Narrow Base Models

3 6 Press down the foot switch.
3 7 Raise the primary boom approximately

2 feet / 61 cm.

3 8 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the primary boom raised should not exceed

6 in / 15 cm per second.
3 9 Lower the primary boom to the stowed position.
4 0 Raise the secondary boom approximately

2 feet / 61 cm.
4 1 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the secondary boom raised should not

exceed 6 in / 15 cm per second.
4 2 Lower the secondary boom to the stowed

position.
4 3 Extend the primary boom approximately

1 foot / 30 cm.
4 4 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the primary boom extended should not

exceed 6 in / 15 cm per second.
4 5 Retract the boom to the stowed position.
If the drive speed with the primary boom raised, the

secondary boom raised or the primary boom
extended exceeds 6 in / 15 cm per second,
immediately tag and remove the machine from
service.

Part No . 114339 Z-45/25 • Z-45/25J 33

Operator's Manual Fourth Edition · First Printing

Inspections

Test the Oscillate Axle
(oscillating axle-equipped models)

4 6 Start the engine from the platform controls.
4 7 Drive the right steer tire up onto a 6 inch /

15 cm block or curb.

Result: The three remaining tires should stay in

firm contact with the ground.

4 8 Drive the left steer tire up onto a 6 inch /

15 cm block or curb.

Result: The three remaining tires should stay in

firm contact with the ground.

4 9 Drive both steer tires up onto a 6 inch /

15 cm block or curb.

Result: The non-steer tires should stay in firm

contact with the ground.

Test Auxiliary Controls

5 0 Shut the engine off.
5 1 Pull out the red Emergency Stop button to

the on position.
5 2 Press down the foot switch.
5 3 Simultaneously hold the auxiliary power switch

on and activate each function control handle or

toggle switch.

Test the Lift/Drive Select Function
(if equipped)

5 4 Press down the foot switch.
5 5 Move the drive control handle off center and

activate a boom function toggle switch.

Result: No boom functions should operate. The

machine will move in the direction indicated on
the control panel.

5 6 Repair any malfunctions before operating the

machine.

Test Aircraft Protection Package (if equipped)

5 7 Move the gray bumper at the bottom of the

platform 4 inches / 10 cm in any direction.

5 8 Activate each function control handle or toggle

switch.

Result: All boom and steer functions should not

operate.
5 9 Move the function override switch to either side.
6 0 Activate each function control handle or toggle

switch.

Result: All boom and steer functions should

operate.

Note: To conserve battery power, test each
function through a partial cycle.

Result: All boom and steer functions should

operate. Drive functions should not operate with
auxiliary power.

34 Z-45/25 • Z-45/25J Part No . 114339

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.

4 Inspect the workplace.
Know and understand the workplace

inspection before going on to the next

section.

Operator's ManualFourth Edition · First Printing

Inspections

Workplace Inspection

Be aware of and avoid the following hazardous
situations:

· drop-offs or holes

· bumps, floor obstructions or debris

· sloped surfaces

· unstable or slippery surfaces

· overhead obstructions and high voltage
conductors

· hazardous locations

· inadequate surface support to withstand all load
forces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions

5 Only use the machine as it was intended.

Fundamentals

The workplace inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the
workplace.

It is the operator's responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up and
operating the machine.

Part No . 114339 Z-45/25 • Z-45/25J 35

Operator's Manual Fourth Edition · First Printing

Inspections

Inspection for Decals with Words

Determine whether the decals on your machine
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.

Part No. Decal Description Quantity

25994 Notice - Component Damage Hazard 1
27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle - Blue 2
27207 Triangle - Yellow 2
28158 Label - Unleaded 1
28159 Label - Diesel 1
28160 Label - Liquid Petroleum Gas 2
28161 Warning - Crushing Hazard 1
28165 Instructions - Foot Switch 1
28174 Label - Power to Platform, 230V 2
28175 Caution - Compartment Access 1
28176 Instructions - Missing Manuals 1
28177 Warning - Platform Rotate 2
28181 Warning - No Step or Ride 1
28235 Label - Power to Platform, 115V 2
28236 Warning - Improper Use 1
30080 Instructions - Maximum Load,

500 lbs / 227 kg 1
31060 Danger - Tip-over Hazard, Interlock 3
32728 Label - Generator (option) 1
40434 Label - Lanyard Anchorage Point 3
43595 Danger - Tip-over Hazard, Tires 4
44248 Instructions - Maximum Load,

440 lbs / 200kg 1

Part No. Decal Description Quantity

52607 Label - Test Switch 1
52672 Danger - Tip-over Hazard, Tires 4
52968 Cosmetic - Genie Boom 1
62926 Cosmetic - Genie Z-45/25J 1
62927 Cosmetic - Genie Z-45/25 1
62947 Cosmetic - IC Power 4 x 2 1
62948 Cosmetic - IC Power 4 x 4 1
65301 Instructions - Foam-Filled Tire Specs 4
72442 Ground Control Panel 1
72847 Instructions - Hi-Flotation Tire Specs 4
82238 Platform Control Panel 1
82366 Label - Chevron Rykon 1
82644 Instructions - Perkins Engine

Specifications 1
82918 Instructions - Tire Specifications 4
97548 Instructions - Deutz Engine Specifications 1
97602 Warning - Explosion Hazard 1
97887 Instructions - Max Side Force,

150 lbs / 667N 1
114023 Label - Wheel Load, Z-45/25 4
114024 Label - Wheel Load, Z-45/25J 4
114114 Label - Transport Diagram 2
114169 Instructions - Ford Engine Specifications 1
114258 Label - Explosion Hazard 1
114277 Label - Belt Routing 1

44981 Label - Air Line to Platform (option) 2
44986 Instructions - Max Manual Force,

90 lbs / 400N 1

46468 Label - Function Override (Aircraft

Protection Package) 1

114389 Danger - Safety Rules 2
114390 Danger - Electrocution Hazard 2
114397 Danger - Tilt-Alarm 1
1000000 Instructions - Operating Instructions 2

36 Z-45/25 • Z-45/25J Part No . 114339

Ground
Controls
Side

Operator's ManualFourth Edition · First Printing

Inspections

Drive

Chassis

Platform

Engine Side

Shading indicates
decal is hidden
from view, i.e.
under covers

Part No . 114339 Z-45/25 • Z-45/25J 37

Operator's Manual Fourth Edition · First Printing

Inspections

Inspection for Decals with
Symbols

Determine whether the decals on your machine
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.

Part No. Decal Description Quantity

27204 Arrow - Blue 1
27205 Arrow - Yellow 1
27206 Triangle - Blue 2
27207 Triangle - Yellow 2
28158 Label - Unleaded 1
28159 Label - Diesel 1
28160 Label - Liquid Petroleum Gas 1
28174 Label - Power to Platform, 230V 2
28235 Label - Power to Platform, 115V 2
32728 Label - Generator (option) 1
40434 Label - Lanyard Anchorage 3
44981 Label - Air Line to Platform 2
52969 Cosmetic - Genie Boom 1
62926 Cosmetic - Genie Z-45/25J 1
62927 Cosmetic - Genie Z-45/25 1
62947 Cosmetic - IC Power 4 x 2 1
62948 Cosmetic - IC Power 4 x 4 1
72442 Ground Control Panel 1
82238 Platform Control Panel 1

Part No. Decal Description Quantity

82487 Label - Read the Manual 2
82544 Label - Electrocution Hazard 2
82548 Label - Platform Rotate 2
82587 Label - Tire Pressure,

High Flotation Tires 4
82601 Label - Maximum Load, 227 kg 1
82602 Label - Max Manual Force, 667 N 1
82612 Label - Maximum Load, 200 kg 1
82633 Label - Tire Pressure, RT Tires 4
82646 Label - Drive Enable Patch 1
97815 Label - Lower Mid-rail 1
114023 Label - Wheel Load, Z-45/25 4
114024 Label - Wheel Load, Z-45/25J 4
114114 Label - Transport Diagram 2
114247 Label - Fall Hazard 1
114248 Label - Tip-over Hazard, Tilt Alarm 1
114249 Label - Tip-over Hazard, Tires 4
114251 Label - Explosion Hazard 1
114252 Label - Tip-over Hazard, Limit Switches 3

82472 Label - Crushing Hazard 1
82473 Label - Compartment Access 1

38 Z-45/25 • Z-45/25J Part No . 114339

Ground
Controls
Side

Operator's ManualFourth Edition · First Printing

Inspections

Drive

Chassis

Platform

Engine Side

Shading indicates
decal is hidden
from view, i.e.
under covers

Part No . 114339 Z-45/25 • Z-45/25J 39

Operator's Manual Fourth Edition · First Printing

Operating Instructions

Fundamentals

The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's,
safety and 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.
3 Always perform function tests prior to use.
4 Inspect the workplace.

5 Only use the machine as it was intended.

Using the machine for anything other than lifting
personnel, along with their tools and materials, to
an aerial work site is unsafe and dangerous.

Only trained and authorized personnel should be
permitted to operate a machine. If more than one
operator is expected to use a machine at different
times in the same work shift, they must all be
qualified operators and are all expected to follow all
safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
inspection, function tests, and a workplace
inspection before using the machine.

40 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Operating Instructions

Starting the Engine

1 At the ground controls, turn the key switch to

the desired position.

2 Be sure both ground and platform control red

Emergency Stop buttons are pulled out to the
on position.

Gasoline/LPG models

3 Choose fuel by moving the fuel select switch to

the desired position.

4 Move the engine start toggle switch

to either side. If the engine fails to
start or dies, the restart delay will
disable the start switch for 3
seconds.

Diesel models

3 Move the glow plug switch to either side and

hold for 3 to 5 seconds.

4 Move the engine start toggle switch to either

side. If the engine fails to start or dies, the
restart delay will disable the start switch for 3
seconds.

All models

If engine fails to start after 15 seconds of cranking,
determine the cause and repair any malfunction.
Wait 60 seconds before trying to start again.

In cold conditions, 20°F / -6°C and below, warm the
engine for 5 minutes before operating to prevent
hydraulic system damage.

In extreme cold conditions, 0°F / -18°C and below,
machines should be equipped with optional cold
start kits. Attempting to start the engine when
temperatures are below 0°F / -18°C may require the
use of a booster battery.

Gasoline/LPG models: In cold conditions, 20°F /

-6°C and below, the machine should be started on
gasoline and warmed for 2 minutes, then switched
to LPG. Warm engines can be started on LPG.

Emergency Stop

Push in either ground or platform red Emergency
Stop button to the off position to stop all functions
and turn the engine off.

Repair any function that operates when the red
Emergency Stop button is pushed in.

Selecting and operating the ground controls will
override the platform red Emergency Stop button.

Auxiliary Controls

Use auxiliary power if the primary power source
(engine) fails.

1 Turn the key switch to ground or platform

control.

2 Pull out the red Emergency Stop button to the

on position.

3 Press down the foot switch when operating the

auxiliary controls from the platform.

4 Simultaneously hold auxiliary

power switch on and activate the
desired function.

The drive and steer functions will not operate with
auxiliary power.

Part No . 114339 Z-45/25 • Z-45/25J 41

Operator's Manual Fourth Edition · First Printing

Operating Instructions

Operation from Ground

1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to

the on position.

3 Gasoline/LPG models: Choose fuel by moving

the fuel select switch to the desired position.

4 Start the engine.

To Position Platform

1 Hold the function enable switch to

either side.

2 Move the appropriate toggle switch according to

the markings on the control panel.

Drive and steer functions are not available from the
ground controls.

Operation from Platform

1 Turn the key switch to platform control.
2 Pull out both ground and platform red

Emergency Stop buttons to the on position.

To Position Platform

1 Press down the foot switch.
2 Slowly move the appropriate function control

handle or toggle switch according to the
markings on the control panel.

To Steer

1 Press down the foot switch.
2 Slowly move the control handle in the direction

indicated by blue or yellow triangles
OR press the thumb rocker switch located on
top of the drive control handle.

Use the color-coded direction triangles on the
platform controls and the drive chassis to identify
the direction the wheels will turn.

To Drive

1 Press down the foot switch.
2 Increase speed: Slowly move the drive control

handle off center.

Decrease speed: Slowly move the drive control

handle toward center.

3 Gasoline/LPG models: Choose fuel by moving

the fuel select switch to the desired position.

4 Start the engine. Do not press down the foot

switch when starting the engine.

42 Z-45/25 • Z-45/25J Part No . 114339

Stop: Return the drive control handle to center or

release the foot switch.

Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.

Machine travel speed is restricted when the booms
are raised.

Operator's ManualFourth Edition · First Printing

Operating Instructions

Driving on a slope

Determine the uphill, downhill and side slope ratings
for the machine and determine the slope grade.

Maximum slope rating,
platform downhill (gradeability):
2WD: 30% (17°)
4WD: 45% (24°)

Maximum slope rating, platform
uphill:
25% (14°)

Maximum side slope rating:
25% (14°)

Note: Slope rating is subject to ground conditions
and adequate traction. The term gradeability applies
to the platform downhill configuration only.

Be sure the boom is below horizontal and the
platform is between the non-steer wheels.

Move the drive speed select switch to machine on
incline symbol.

Lay the piece of wood on the slope.
At the downhill end, lay the level on the top edge of

the piece of wood and lift the end until the piece of
wood is level.

While holding the piece of wood level, measure the
vertical distance from the bottom of the piece of
wood to the ground.

Divide the tape measure distance (rise) by the
length of the piece of wood (run) and multiply by

100.
Example:

run

rise

Piece of wood = 144 inches (3.6 m)
Run = 144 inches (3.6 m)
Rise = 12 inches (0.3 m)
12 in ÷ 144 in = 0.083 x 100 = 8.3% grade

To determine the slope grade:

Measure the slope with a digital inclinometer OR
use the following procedure.

You will need:

carpenter’s level
straight piece of wood, at least 3 feet / 1 m long
tape measure

Part No . 114339 Z-45/25 • Z-45/25J 43

0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade
If the slope exceeds the maximum uphill, downhill

or side slope rating, then the machine must be
winched or transported up or down the slope. See
Transport and Lifting section.

Operator's Manual Fourth Edition · First Printing

Operating Instructions

Drive Enable

Light on indicates that the
boom has moved just past
either non-steer wheel and the
drive function has been
interrupted.

To drive, hold the drive enable switch to either side
and slowly move the drive control handle off center.

Be aware that the machine may move in the
opposite direction that the drive and steer controls
are moved.

Always use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.

Drive Speed Select

· Machine on incline symbol: Low range operation
for inclines

· Machine on level surface symbol: High range
operation for maximum drive speed

Generator (if equipped)

To start the generator,
move the generator toggle
switch to the on position.

Plug a power tool into the
power to platform GFCI
outlet.

To turn off the generator, move the generator toggle
switch to the off position.

Note: Machine functions will not operate while the
generator is running and the foot switch is not
pressed down. When the foot switch is pressed
down, the generator will turn off and the machine
functions will operate.

Machine Not Level Indicator
Light (if equipped)

Light on indicates the machine is not
level. The tilt alarm will be sounding
when this light is on. Move the
machine to a firm level surface.

Engine Idle Select (rpm)

When the foot switch is not pressed, the engine will
idle at the lowest rpm.

· Turtle symbol: Foot
switch activated low
idle

· Rabbit symbol: Foot
switch activated high
idle

44 Z-45/25 • Z-45/25J Part No . 114339

Check Engine Light
(if equipped)

Light on and engine stopped: Tag
the machine and remove from
service.

Light on and engine still running:
Contact service personnel within 24
hours.

Aircraft Protection Package
(if equipped)

If the platform bumpers come in contact with
aircraft components, the machine will shut down
and no functions will operate.

Operator's ManualFourth Edition · First Printing

Operating Instructions

Move the function override toggle switch to either
side to operate the machine.

After Each Use

1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowed

position.

3 Rotate the turntable so that the boom is between

the non-steer wheels.

4 Turn the key switch to the off position and

remove the key to secure from unauthorized
use.

5 Chock the wheels.

Part No . 114339 Z-45/25 • Z-45/25J 45

Operator's Manual Fourth Edition · First Printing

Transport and Lifting Instructions

Do not drive the machine on a slope that

exceeds the uphill, downhill or side slope rating.
See Driving on a Slope in the Operating
Instructions section.

If the slope of the transport vehicle bed exceeds

the uphill or downhill maximum slope rating, the

Observe and Obey:

Genie Industries provides this securement

information as a recommendation. Drivers are
solely responsible for making sure machines
are properly secured and the correct trailer is
selected pursuant to US Department of
Transportation regulations, other localized
regulations, and their company policy.

machine must be loaded and unloaded using a
winch as described. See the Specifications
section for the slope ratings.

Genie customers needing to containerize any lift

or Genie product should source a qualified
freight forwarder with expertise in preparing,
loading and securing construction and lifting
equipment for international shipment.

Only qualified aerial lift operators should move

the machine on or off the truck.

The transport vehicle must be parked on a level

surface.

The transport vehicle must be secured to

prevent rolling while the machine is being
loaded.

Be sure the vehicle capacity, loading surfaces

and chains or straps are sufficient to withstand
the machine weight. Genie lifts are very heavy
relative to their size. See the serial label for the
machine weight. See the Inspections section for
the serial label location.

Be sure the turntable is secured with the

turntable rotation lock before transporting. Be
sure to unlock the turntable for operation.

Free-wheel Configuration for
Winching

Chock the wheels to prevent the machine from
rolling.

Release the non-steer
wheel brakes by
turning over the drive
hub disconnect caps
(see below).

Be sure the winch line
is properly secured to
the drive chassis tie
points and the path is
clear of all obstructions.

Reverse the procedures described to re-engage the
brakes.

Note: Towing the Genie Z-45/25 or the Z-45/25J is
not recommended. If the machine must be towed,
do not exceed 2 mph / 3.2 km/h.

Disengage

Engage

46 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Transport and Lifting Instructions

Securing to Truck or Trailer

for Transit

Always use the turntable rotation lock pin each time
the machine is transported.

Turntable rotation

lock pin

Turn the key switch to the off position and remove
the key before transporting.

Inspect the entire machine for loose or unsecured
items.

Securing the Chassis

Use chains of ample load capacity.
Use a minimum of 4 chains.
Adjust the rigging to prevent damage to the chains.

Truck bed

Securing the Platform - Z-45/25

Make sure the platform is in the stowed position.
Secure the platform with a nylon strap placed over

the platform mount near the platform rotator (see
below). Do not use excessive downward force when
securing the boom section.

Securing the Platform - Z-45/25J

Make sure the jib and platform are in the stowed
position.

Secure the platform with a nylon strap placed over
the platform mount near the platform rotator (see
below). Do not use excessive downward force
when securing the boom section.

Part No . 114339 Z-45/25 • Z-45/25J 47

Operator's Manual Fourth Edition · First Printing

Transport and Lifting Instructions

Lifting Instructions

Fully lower and retract the boom. Fully lower the jib
(if equipped). Remove all loose items on the
machine.

Determine the center of gravity of your machine

Observe and Obey:

Only qualified riggers should rig and lift the

machine.

Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to withstand
the machine weight. See the serial label for the
machine weight.

using the table and the picture on this page.
Attach the rigging only to the designated lifting

points on the machine. There are four lifting points
on the chassis.

Adjust the rigging to prevent damage to the
machine and to keep the machine level.

X Axis Y Axis

Z-45/25 47 in 42 in

1.19 m 1.06 m

Y Axis

Z-45/25J 49 in 44.5 in

1.24 m 1.13 m

X Axis

48 Z-45/25 • Z-45/25J Part No . 114339

Observe and Obey:

Operator's ManualFourth Edition · First Printing

Maintenance

Check the Engine Oil Level

Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.

Only routine maintenance items specified in this

manual shall be performed by the operator.

Scheduled maintenance inspections shall be

completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.

Use only Genie approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

Indicates that tools will be required to
perform this procedure.

Note: Check the oil level with the engine off.
1 Remove the safety pin from the engine pivot

plate latch.

The engine pivot plate latch is located under the
engine turntable pivot plate at the counterweight
end of the machine.

2 Open the engine pivot plate latch and swing the

engine pivot plate out and away from the

machine.
3 Check the oil dipstick. Add oil as needed.
4 Swing the engine back to its original position

and close the engine pivot plate latch.
5 Install the engine pivot plate safety pin.

Perkins 404C-22 Engine

Oil type 15W-40
Oil type - cold conditions 5W-40

Ford DSG-423 EFI Engine (EPA Compliant)

Oil type 5W-20

Deutz F3L 2011 Engine

Indicates that new parts will be required to
perform this procedure.

Indicates that a cold engine is required
before performing this procedure.

Part No . 114339 Z-45/25 • Z-45/25J 49

Oil type 15W-40
Oil type - cold conditions 5W-30

Operator's Manual Fourth Edition · First Printing

Maintenance

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.

1 Be sure that the boom is in the stowed position,

then visually inspect the sight gauge located on
the side of the hydraulic oil tank. The hydraulic
oil level should be within the top 2 inches / 5 cm
of the sight gauge.

2 Add oil as needed.

Hydraulic oil specifications

Hydraulic oil type Chevron Rykon

Premium MV equivalent

Check the Engine Coolant Level

- Ford and Perkins Models

Maintaining the engine coolant at the proper level is
essential to engine service life. Improper coolant
level will affect the engine's cooling capability and
damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.

Burn hazard. Beware of hot engine parts and
coolant. Contact with hot engine parts and/or
coolant may cause severe burns.

1 Check the fluid level in the coolant recovery

tank. The fluid level should be at the

FULL mark.

2 Add fluid as needed.
Note: Do not remove the radiator cap.

50 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Maintenance

Check the Batteries

Proper battery condition is essential to good engine
performance and operational safety. Improper fluid
levels or damaged cables and connections can
result in engine component damage and hazardous
conditions.

Electrocution hazard. Contact with hot or live
circuits may result in death or serious injury.
Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.
Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda

and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are

tight and free of corrosion.

3 Be sure that the battery hold-down bracket is

secure.
4 Remove the battery vent caps.
5 Check the battery acid level. If needed,

replenish with distilled water to the bottom of the

battery fill tube. Do not overfill.
6 Install the vent caps.
Note: Adding terminal protectors and a corrosion

preventative sealant will help eliminate corrosion on
the battery terminals and cables.

Check the Tire Pressure

Tip-over hazard. An over-inflated tire can
explode which may compromise machine
stability and cause the machine to tip over.

Tip-over hazard. The use of temporary flat tire
repair products may lead to tire failure which
could compromise machine stability and
cause the machine to tip over.

Bodily injury hazard. An over-inflated tire can
explode and may cause death or serious
injury.

Note: This procedure does not need to be
performed on machines equipped with foam-filled
tires.

1 Check each tire with an air pressure gauge and

add air as needed.

Tire specifications 2WD Models 4WD Models

Narrow base models Foam-filled
Industrial tire Only

Models with Aircraft Foam-filled Foam-filled
Protection Package Only Only

Standard base models
Industrial tire 100 psi /
Tire size: 9-14.5 LT 6.9 bar

Standard base models 50 psi / 50 psi /
Rough terrain tire 3.5 bar 3.5 bar
Tire size: 355/55D625 14 ply

High flotation tires 38 psi / 38 psi /
Tire size: 33/16LL500 2.6 bar 2.6 bar

Part No . 114339 Z-45/25 • Z-45/25J 51

Operator's Manual Fourth Edition · First Printing

Maintenance

Scheduled Maintenance

Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on this
machine according to the procedures found in the
service manual for this machine.

Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

52 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Specifications

Standard Base Models Z-45/25 (no jib)

Height, working maximum 51 ft 11 in 16 m
Height, platform maximum 45 ft 11 in 14 m
Height, stowed maximum 6 ft 11 in 2.11 m
Horizontal reach maximum

1

25 ft

1

7.62 m
Width 7 ft 6 in 2.29 m
Length, stowed 18 ft 3 in 5.56 m
Maximum load capacity 500 lbs 227 kg
Maximum load capacity

Models with Aircraft Protection
Package 440 lbs 200 kg

Maximum wind speed 28 mph 12.5 m/s
Wheelbase 6 ft 8 in 2.0 m
Turning radius (outside) 14 ft 9 in 4.5 m
Turning radius (inside) 5 ft 6 in 1.7 m
Turntable rotation 355°
Turntable tailswing 0 in 0 cm
Drive speed, stowed 5 mph 8.0 km/h

40 ft/5.5 sec12.2 m/5.5 sec

Drive speed, 0.6 mph 1 km/h
booms raised 40 ft/45 sec 12.2 m/45 sec

Airborne noise emissions 73 dB
Maximum sound level at normal operating workstations
(A-weighted)

Ground clearance, center 15.5 in 39.4 cm

AC outlet in platform standard
Hydraulic pressure, maximum 3200 psi 221 bar

(boom functions)
System voltage 12V
Tire size, 4WD & 2WD RT 355/55 D625
Tire size, High Flotation 33/16LL 500, 10 ply

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.
Fuel tank capacity 17 gallons 64.4 liters

Floor loading information

Tire load, maximum 8000 lbs 3629 kg
Tire contact pressure 50 psi 3.51 kg/cm

345 kPa

Occupied floor pressure (2WD) 187 psf 913 kg/m

8.95 kPa

Occupied floor pressure (4WD) 190 psf 928 kg/m

9.10 kPa

2

2

2

Ground clearance, minimum 11.5 in 29.2 cm
Controls 12V DC proportional

Note: Floor loading information is approximate and
does not incorporate different option configurations. It
should be used only with adequate safety factors.

Weight See Serial Label
(Machine weights vary with option configurations)

Platform dimensions, 6 foot 72 in x 30 in

1

Outreach specification with platform rotated

90 degrees
(length x width) 1.8 m x 76 cm
Platform leveling self-leveling
Platform rotation 180 degrees
Vibration value does not exceed 2.5 m/s

2

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

Part No . 114339 Z-45/25 • Z-45/25J 53

Operator's Manual Fourth Edition · First Printing

Specifications

Standard Base Models Z-45/25J (jib)

Height, working maximum 52 ft 2 in 16.07 m
Height, platform maximum 46 ft 2 in 14.07 m
Height, stowed maximum 6 ft 11 in 2.1 m
Horizontal reach maximum 25 ft 1 in 7.6 m
Width 7 ft 6 in 2.29 m
Length, stowed 22 ft 5 in 6.83 m
Maximum load capacity 500 lbs 227 kg
Maximum load capacity

Models with Aircraft Protection
Package 440 lbs 200 kg

Maximum wind speed 28 mph 12.5 m/s
Wheelbase 6 ft 8 in 2.0 m
Turning radius (outside) 14 ft 9 in 4.5 m
Turning radius (inside) 5 ft 6 in 1.7 m
Turntable rotation 355°
Turntable tailswing 0 in 0 cm
Drive speed, stowed 5 mph 8.0 km/h

40 ft/5.5 sec12.2 m/5.5 sec

Drive speed, 0.6 mph 1 km/h
booms raised 40 ft/45 sec 12.2 m/45 sec

Airborne noise emissions 73 dB
Maximum sound level at normal operating workstations
(A-weighted)

Ground clearance, center 15.5 in 39.4 cm

AC outlet in platform standard
Hydraulic pressure, maximum 3200 psi 221 bar

(boom functions)
System voltage 12V
Tire size, 4WD & 2WD RT 355/55 D625
Tire size, High Flotation 33/16LL 500, 10 ply

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.
Fuel tank capacity 17 gallons 64.4 liters

Floor loading information

Tire load, maximum 8800 lbs 3992 kg
Tire contact pressure 50 psi 3.51 kg/cm

345 kPa

Occupied floor pressure (2WD) 196 psf 957 kg/m

9.38 kPa

Occupied floor pressure (4WD) 198 psf 967 kg/m

9.48 kPa

2

2

2

Ground clearance, minimum 11.5 in 29.2 cm
Controls 12V DC proportional

Note: Floor loading information is approximate and
does not incorporate different option configurations. It
should be used only with adequate safety factors.

Weight See Serial Label
(Machine weights vary with option configurations)

Platform dimensions, 6 foot 72 in x 30 in
(length x width) 1.8 m x 76 cm

Platform leveling self-leveling
Platform rotation 160 degrees
Vibration value does not exceed 2.5 m/s

2

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

54 Z-45/25 • Z-45/25J Part No . 114339

Operator's ManualFourth Edition · First Printing

Specifications

Narrow Base Models Z-45/25 (no jib)

Height, working maximum 51 ft 6 in 15.9 m
Height, platform maximum 45 ft 6 in 13.9 m
Height, stowed maximum 6 ft 7 in 2.05 m
Horizontal reach maximum

1

25 ft

1

7.62 m
Width 5 ft 10.3 in 1.79 m
Length, stowed 18 ft 3 in 5.56 m
Maximum load capacity 500 lbs 227 kg
Maximum load capacity

Models with Aircraft Protection
Package 440 lbs 200 kg

Maximum wind speed 28 mph 12.5 m/s
Wheelbase 6 ft 8 in 2.0 m
Turning radius (outside) 14 ft 4.3 m
Turning radius (inside) 6 ft 1.8 m
Turntable rotation 355°
Turntable tailswing 0 in 0 cm
Drive speed, stowed 5 mph 8.0 km/h

40 ft/5.5 sec12.2 m/5.5 sec

Drive speed, 0.4 mph 0.64 km/h
booms raised 40 ft/68 sec 12.2 m/68 sec

AC outlet in platform standard
Hydraulic pressure, maximum 3200 psi 221 bar

(boom functions)
System voltage 12V
Tire size, 2WD Industrial

Foam-filled only 9-14.5 LT

Maximum slope rating, stowed position

Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and

adequate traction.
Fuel tank capacity 17 gallons 64.4 liters

Floor loading information

Tire load, maximum 8000 lbs 3629 kg
Tire contact pressure 100 psi 7.03 kg/cm

689 kPa

Occupied floor pressure 324 psf 1582 kg/m

15.51 kPa

Note: Floor loading information is approximate and
does not incorporate different option configurations. It
should be used only with adequate safety factors.

2

2

Airborne noise emissions 73 dB
Maximum sound level at normal operating workstations
(A-weighted)

1

Outreach specification with platform rotated

90 degrees

Ground clearance, center 9.5 in 24.1 cm
Ground clearance, minimum 7.5 in 19.1 cm
Controls 12V DC proportional
Weight See Serial Label

(Machine weights vary with option configurations)
Platform dimensions, 6 foot 72 in x 30 in

(length x width) 1.8 m x 76 cm
Platform leveling self-leveling
Platform rotation 180 degrees
Vibration value does not exceed 2.5 m/s

2

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

Part No . 114339 Z-45/25 • Z-45/25J 55

Operator's Manual Fourth Edition · First Printing

Specifications

Narrow Base Models Z-45/25J (jib)

Height, working maximum 51 ft 9 in 15.9 m
Height, platform maximum 45 ft 9 in 13.9 m
Height, stowed maximum 6 ft 7 in 2.0 m
Horizontal reach maximum 25 ft 1 in 7.7 m
Width 5 ft 10.3 in 1.79 m
Length, stowed 22 ft 5 in 6.8 m
Maximum load capacity 500 lbs 227 kg
Maximum load capacity

Models with Aircraft Protection
Package 440 lbs 200 kg

Maximum wind speed 28 mph 12.5 m/s
Wheelbase 6 ft 8 in 2.0 m
Turning radius (outside) 14 ft 4.3 m
Turning radius (inside) 6 ft 1.8 m
Turntable rotation 355°
Turntable tailswing 0 in 0 cm
Drive speed, stowed 5 mph 8.0 km/h

40 ft/5.5 sec12.2 m/5.5 sec

Drive speed, 0.4 mph 0.64 km/h
booms raised 40 ft/68 sec 12.2 m/68 sec

AC outlet in platform standard
Hydraulic pressure, maximum 3200 psi 221 bar

(boom functions)
System voltage 12V
Tire size, 2WD Industrial

Foam-filled only 9-14.5 LT

Maximum slope rating, stowed position

Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions and

adequate traction.
Fuel tank capacity 17 gallons 64.4 liters

Floor loading information

Tire load, maximum 8800 lbs 3992 kg
Tire contact pressure 100 psi 7.03 kg/cm

689 kPa

Occupied floor pressure 328 psf 1601 kg/m

15.70 kPa

Note: Floor loading information is approximate and
does not incorporate different option configurations. It
should be used only with adequate safety factors.

2

2

Airborne noise emissions 73 dB
Maximum sound level at normal operating workstations
(A-weighted)

Ground clearance, center 9.5 in 24.1 cm
Ground clearance, minimum 7.5 in 19.1 cm
Controls 12V DC proportional
Weight See Serial Label

(Machine weights vary with option configurations)
Platform dimensions, 6 foot 72 in x 30 in

(length x width) 1.8 m x 76 cm
Platform leveling self-leveling
Platform rotation 160 degrees
Vibration value does not exceed 2.5 m/s

2

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

56 Z-45/25 • Z-45/25J Part No . 114339

Z-45/25J Range of Motion Z-45/25 Range of Motion

Operator's ManualFourth Edition · First Printing

Specifications

Part No . 114339 Z-45/25 • Z-45/25J 57