Operator’s Manual |
First Edition |
Seventh Printing |
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with Maintenance Information |
Part No. 52421 |
Operator's Manual |
First Edition · Seventh Printing |
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Important
Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries.
Contents |
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Page |
Safety ........................................................................ |
1 |
Controls ..................................................................... |
7 |
Pre-operation Inspection ........................................... |
10 |
Maintenance ............................................................. |
12 |
Function Tests .......................................................... |
16 |
Workplace Inspection ................................................ |
23 |
Operating Instructions ............................................... |
24 |
Transport Instructions ............................................... |
29 |
Decals ...................................................................... |
30 |
Specifications ........................................................... |
32 |
Contact us:
Internet: http://www.genielift.com
E-mail: techpub@genieind.com
Copyright © 1998 by Genie Industries
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 |
First Edition · Seventh Printing |
Operator's Manual |
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Safety Rules
Danger
Failure to obey the instructions and safety rules in this manual will result in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe machine operation contained in this operator's manual.
1 Avoid hazardous situations.
Know and understand the safety rules before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
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 |
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Operator's Manual |
First Edition · Seventh Printing |
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SAFETY RULES
Electrocution Hazards
This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.
Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.
Voltage |
Minimum Safe |
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Phase to Phase |
Approach Distance |
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Feet |
Meters |
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0 to 300V |
Avoid Contact |
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300V to 50KV |
10 |
3.1 |
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50KV to 200KV |
15 |
4.6 |
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200KV to 350KV |
20 |
6.1 |
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350KV to 500KV |
25 |
7.6 |
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500KV to 750KV |
35 |
10.7 |
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750KV to 1000KV |
45 |
13.7 |
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Allow for platform movement, electrical line sway or sag and beware of strong or gusty winds.
Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants and equipment shall not exceed the maximum platform capacity.
Maximum platform capacity |
500 lbs |
227 kg |
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Maximum occupants |
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2 |
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Do not raise or extend the boom unless the machine is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds in the platform only when the machine is on a severe slope.
If the tilt alarm sounds:
Do not extend, rotate or raise the boom above horizontal. Move the machine to a firm, level surface before raising the platform. If the tilt alarm sounds when the platform is raised, use extreme caution to retract the boom and lower the platform. Do not rotate the boom while lowering. Move the machine to a firm, level surface before raising the platform.
Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.
Do not alter or disable the limit switch(es).
2 |
Genie Z-45/25 & Genie Z-45/25J |
Part No.52421 |
First Edition · Seventh Printing |
Operator's Manual |
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Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.
Use extreme care and slow speeds while driving the machine in 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 |
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Maximum allowable |
90 lbs |
side force - CE |
400 N |
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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.
SAFETY RULES
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.
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.
Part No.52421 |
Genie Z-45/25 & Genie Z-45/25J |
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Operator's Manual |
First Edition · Seventh Printing |
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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.
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.
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.
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Genie Z-45/25 & Genie Z-45/25J |
Part No.52421 |
First Edition · Seventh Printing |
Operator's Manual |
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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.
SAFETY RULES
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 operator’s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform.
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 |
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Operator's Manual |
First Edition · Seventh Printing |
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SAFETY RULES
Decal Legend
Genie product decals use symbols, color coding and signal words to identify the following:
Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Red—used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Orange—used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.
Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.
Green—used to indicate operation or maintenance information.
6 |
Genie Z-45/25 & Genie Z-45/25J |
Part No.52421 |
First Edition · Seventh Printing |
Operator's Manual |
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Controls
6 |
7 |
5
4
3 
2
1
19 |
18 |
17 |
16 |
15 |
14 |
8
9
10
11
12
13
Ground Control Panel
1Platform rotate switch
2Turntable rotate switch
3Primary boom up/down switch
4Primary boom extend/retract switch
5Gasoline/LPG models: Fuel select switch
6Auxiliary power switch
7Key switch for platform/off/ground selection
8Red Emergency Stop button
9Gasoline/LPG models: Check engine light Diesel models: Oil pressure light
10Hour meter
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
Part No.52421 |
Genie Z-45/25 & Genie Z-45/25J |
7 |
Operator's Manual |
First Edition · Seventh Printing |
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CONTROLS
1 |
2 |
3 |
4 |
5 |
6 |
18 13 17 16
Platform Control Panel |
6 |
Drive speed select switch |
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1 |
Horn button |
7 |
Glow plug switch |
2 |
Platform level switch |
8 |
Engine start switch |
3 |
Platform rotate switch |
9 |
Engine idle (rpm) select switch |
4 |
Z-45/25J models only: Jib boom up/down switch |
10 |
Gasoline/LPG models: Gasoline/LPG |
5 |
Auxiliary power switch |
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select switch |
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8 |
Genie Z-45/25 & Genie Z-45/25J |
Part No.52421 |
First Edition · Seventh Printing |
Operator's Manual |
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CONTROLS
7 |
8 |
9 |
10 |
11 |
15 14 13 13 12
11 |
Red Emergency Stop button |
15 Drive enable switch |
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12 |
Dual axis proportional control handle for drive |
16 Proportional control handle for secondary boom |
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and steer functions |
up/down function |
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OR Proportional control handle for drive function |
17 Primary boom extend/retract switch |
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and thumb rocker for steer function |
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13 used for optional equipment |
18 Dual axis proportional control handle for primary |
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boom up/down and turntable rotate |
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14 |
Drive enable indicator light |
left/right functions |
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Part No.52421 |
Genie Z-45/25 & Genie Z-45/25J |
9 |
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