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

Operator’s Manual

with Maintenance Information

First Edition

Seventh Printing

Part No. 52421

Operator's Manual First Edition · Seventh Printing

Important

Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries.

Contents

Page

Safety ........................................................................ 1

Controls ..................................................................... 7

Pre-operation Inspection........................................... 10

Maintenance ............................................................. 12

Function Tests .......................................................... 16

Workplace Inspection ................................................ 23

Operating Instructions ............................................... 24

Transport Instructions ............................................... 29

Decals ...................................................................... 30

Specifications ........................................................... 32

Internet: http://www.genielift.com E-mail: techpub@genieind.com

First Edition: Seventh Printing, May 2002

"Genie" and "Z" are registered trademarks of Genie Industries in the U.S.A. and many other countries.

These machines comply with ANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Genie Z-45/25 & Genie Z-45/25J Part No. 52421

Operator's ManualFirst Edition · Seventh 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: Manufacturer's instructions and safety

rules—safety and operator's manuals and machine decals

employer's safety rules and worksite

regulations

applicable governmental regulations You are properly trained to safely operate the

machine.

Part No. 52421 Genie Z-45/25 & Genie Z-45/25J 1

Operator's Manual First Edition · Seventh 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

Tip-over Hazards

Occupants and equipment 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.

Allow for platform movement, electrical line sway or sag and beware of strong or gusty winds.

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

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

personnel must be removed from the platform before attempting to free the platform using the ground controls.

machine until energized power lines are shut off.

Do not alter or disable the limit switch(es).

Do not use the machine as a ground for welding.

2 Genie Z-45/25 & Genie Z-45/25J Part No. 52421

Operator's ManualFirst Edition · Seventh 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 150 lbs side force - ANSI & CSA 667 N

Do not modify or alter an aerial work platform. Mounting attachments for holding tools or other materials onto the platform, toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

Do not place or attach overhanging loads to any part of this machine.

Do not place ladders or scaffolds in the platform or against any part of this machine.

Do not 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.

Maximum allowable 90 lbs side force - CE 400 N

Z-45/25 & 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. 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.

Part No. 52421 Genie Z-45/25 & Genie Z-45/25J 3

Operator's Manual First Edition · Seventh 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.

It is recommended that operators wear an approved hard hat when operating the machine.

Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

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.

Collision Hazards

Be aware of limited sight distance and blind spots when driving or operating.

Be aware of boom position when rotating the

turntable.

Check the work area for overhead obstructions or

other possible hazards.

Be aware of crushing hazard when grasping the

platform guard rail.

Observe and use color-coded direction arrows on

the platform controls and drive chassis for drive

and steer functions.

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.

4 Genie Z-45/25 & Genie Z-45/25J Part No. 52421

Operator's ManualFirst Edition · Seventh Printing

SAFETY RULES

Do not lower the boom unless the area below is clear of personnel and obstructions.

Limit travel speed according to condition of 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.

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-45/25J Service Manual.

Be sure all decals are in place and legible.

Be sure operator’s, safety and responsibilities

manuals are complete, legible and in the storage

container located on the platform.

Genie Z-45/25 &

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.

Be sure the hydraulic shutoff valves (located by

hydraulic tank) are open before starting the engine.

Part No. 52421 Genie Z-45/25 & Genie Z-45/25J 5

Operator's Manual First Edition · Seventh Printing

SAFETY RULES

Decal Legend

Genie product decals use symbols, color coding and signal words to identify the following:

Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Green—used to indicate operation or maintenance information.

6 Genie Z-45/25 & Genie Z-45/25J Part No. 52421

Operator's ManualFirst Edition · Seventh Printing

Controls

141516171819

Ground Control Panel

1 Platform rotate switch 2 Turntable rotate switch 3 Primary boom up/down switch 4 Primary boom extend/retract switch 5 Gasoline/LPG models: Fuel select switch 6 Auxiliary power switch 7 Key switch for platform/off/ground selection 8 Red Emergency Stop button 9 Gasoline/LPG models: Check engine light

Diesel models: Oil pressure light

11 Diesel models: Water temperature light

12 Gasoline/LPG models: Choke switch

Diesel models: Glow plug switch (option) 13 Function enable switch 14 Engine start switch 15 15A breaker for engine electrical circuits 16 Secondary boom up/down switch 17 15A breaker for control electrical circuits 18 Z-45/25J models only: Jib boom up/down switch 19 Platform level switch

10 Hour meter

Part No. 52421 Genie Z-45/25 & Genie Z-45/25J 7

Operator's Manual First Edition · Seventh Printing

CONTROLS

1 3

4 5 6

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

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

select switch

161718

8 Genie Z-45/25 & Genie Z-45/25J Part No. 52421

Operator's ManualFirst Edition · Seventh Printing

117 8 9 10

CONTROLS

11 Red Emergency Stop button 12 Dual axis proportional control handle for drive

and steer functions OR Proportional control handle for drive function

and thumb rocker for steer function 13 used for optional equipment 14 Drive enable indicator light

15 Drive enable switch 16 Proportional control handle for secondary boom

up/down function 17 Primary boom extend/retract switch 18 Dual axis proportional control handle for primary

boom up/down and turntable rotate

left/right functions

1215 14

Part No. 52421 Genie Z-45/25 & Genie Z-45/25J 9

+ 25 hidden pages