operator’s manual second edition second printing with...

Second Edition

Second Printing

Part No. 82600

Operator’s Manualwith Maintenance Information

Bi-Energy PowerIC Power

Genie Z-45/25 & Genie Z-45/25J Part No. 82600

Operator's Manual Second Edition · Second Printing

Copyright © 1998 by Genie Industries

First Edition: Seventh Printing, May 2002

Second Edition: Second Printing, August 2004

"Genie" and "Z" are registered trademarks ofGenie Industries in the U.S.A. and many othercountries.

These machines comply withANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Important

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

Contents

PageSafety ........................................................................ 1Controls ..................................................................... 7Pre-operation Inspection ........................................... 10Maintenance ............................................................. 12Function Tests .......................................................... 16Workplace Inspection ................................................ 23Operating Instructions ............................................... 24Transport and Lifting Instructions .............................. 29Decals ...................................................................... 32Specifications ........................................................... 36

Contact us:

Internet: http://www.genielift.comE-mail: [email protected]

Part No. 82600 Genie Z-45/25 & Genie Z-45/25J 1

Operator's ManualSecond Edition · Second Printing

Safety Rules

Danger

Failure to obey the instructions andsafety rules in this manual will resultin death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safemachine operation contained in this operator'smanual.

1 Avoid hazardous situations.

Know and understand the safety rules beforegoing 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 themanufacturer's instructions and safety rules—safety and operator's manuals and machinedecals.

You read, understand and obey employer'ssafety rules and worksite regulations.

You read, understand and obey all applicablegovernmental regulations.

You are properly trained to safely operate themachine.

2 Genie Z-45/25 & Genie Z-45/25J Part No. 82600


SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and willnot provide protection from contact with orproximity to electrical current.

Maintain safe distances from electrical power linesand apparatus in accordance with applicablegovernmental regulations and the following chart.

Voltage Minimum SafePhase to Phase Approach Distance

Feet Meters

0 to 300V Avoid Contact

300V to 50KV 10 3.1

50KV to 200KV 15 4.6

200KV to 350KV 20 6.1

350KV to 500KV 25 7.6

500KV to 750KV 35 10.7

750KV to 1000KV 45 13.7

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

Keep away from the machine if it contactsenergized power lines. Personnel on the ground orin the platform must not touch or operate themachine until energized power lines are shut off.

Do not use the machine as a ground for welding.

Do not operate the machine during lightning orstorms.

Tip-over Hazards

Occupants, equipment and materials shall notexceed the maximum platform capacity.

Maximum platform capacity 500 lbs 227 kg

Maximum occupants 2

Do not raise or extend the boom unless themachine 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 themachine is on a severe slope.

If the tilt alarm sounds:Do not extend, rotate or raise the boom abovehorizontal. Move the machine to a firm, levelsurface before raising the platform. If the tilt alarmsounds when the platform is raised, use extremecaution to retract the boom and lower the platform.Do not rotate the boom while lowering. Move themachine to a firm, level surface before raising theplatform.

Do not use the platform controls to free a platformthat is caught, snagged or otherwise preventedfrom normal motion by an adjacent structure. Allpersonnel must be removed from the platformbefore attempting to free the platform using theground controls.

Do not alter or disable the limit switches.



SAFETY RULES

Do not operate the machine in strong or gustywinds. Do not increase the surface area of theplatform or the load. Increasing the area exposed tothe wind will decrease machine stability.

Use extreme care and slow speeds while drivingthe machine in stowed position across uneventerrain, debris, unstable or slippery surfaces andnear holes and drop-offs.

Do not drive the machine on or near uneven terrain,unstable surfaces or other hazardous conditionswith the boom raised or extended.

Do not push off or pull toward any object outsideof the platform.

Maximum allowableside force - ANSI & CSA150 lbs / 667 N

Maximum allowableside force - CE90 lbs / 400 N

Do not alter or disable machine components that inany way affect safety and stability.

Do not replace items critical to machine stabilitywith items of different weight or specification.

Do not modify or alter an aerial work platformwithout prior written permission from themanufacturer. Mounting attachments for holdingtools or other materials onto the platform, toeboardsor guard rail system can increase the weight in theplatform and the surface area of the platform or theload.

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

Do not transport tools and materials unless they areevenly distributed and can be safely handled byperson(s) in the platform.

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

Do not use the machine on a moving or mobilesurface or vehicle.

Be sure all tires are in good condition, air-filled tiresare properly inflated and lug nuts are properlytightened.

Do not replace factory-installed tires with tires ofdifferent specification or ply rating.

Z-45/25 and Z-45/25J Narrow Base Models: Donot use air-filled tires. These machines areequipped with foam-filled tires. Wheel weight andproper counterweight configuration are critical tostability.



SAFETY RULES

Do not use the machine as a crane.

Do not push the machine or other objects with theboom.

Do not contact adjacent structures with the boom.

Do not tie the boom or platform to adjacentstructures.

Do not place loads outside the platform perimeter.

Fall Hazards

Occupants must wear asafety belt or harness inaccordance withgovernmental regulations.Attach the lanyard to theanchor provided in theplatform.

Do not sit, stand or climb on the platform guardrails. Maintain a firm footing on the platform floor atall 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 entrygate before operating.

Collision Hazards

Be aware of limited sightdistance and blind spotswhen driving or operating.

Be aware of the boom position when rotating theturntable.

Check the work area for overhead obstructions orother possible hazards.

Be aware of crushing hazards when grasping theplatform guard rail.

Operators must comply with employer, job site andgovernmental rules regarding the use of personalprotective equipment.

Observe and use the color-coded direction arrowson the platform controls and drive chassis for driveand steer functions.



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

Limit travel speed according to the condition of theground surface, congestion, slope, location ofpersonnel, and any other factors which may causecollision.

Do not operate a boom in the path of any craneunless the controls of the crane have been lockedout and/or precautions have been taken to preventany potential collision.

No stunt driving or horseplay while operating amachine.

Explosion and Fire HazardsDo not start the engine if you smell or detect liquidpetroleum gas (LPG), gasoline, diesel fuel or otherexplosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge the battery only inan open, well-ventilated area away from sparks,flames and lighted tobacco.

Do not operate the machine in hazardous locationsor locations where potentially flammable orexplosive gases or particles may be present.

Do not spray ether into engines equipped with glowplugs.

Damaged Machine HazardsDo not use a damaged or malfunctioning machine.

Conduct a thorough pre-operation inspection of themachine and test all functions before each workshift. Immediately tag and remove from service adamaged or malfunctioning machine.

Be sure all maintenance has been performed asspecified in this manual and the Genie Z-45/25 &Genie Z-45/25J Service Manual.

Be sure all decals are in place and legible.

Be sure the operator’s, safety and responsibilitiesmanuals are complete, legible and in the storagecontainer located on the platform.

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil orair leak. An air leak or hydraulic leak can penetrateand/or burn skin.

Always operate the machine in a well-ventilatedarea to avoid carbon monoxide poisoning.

Improper contact with components under any coverwill cause serious injury. Only trained maintenancepersonnel should access compartments. Accessby the operator is only advised when performing apre-operation inspection. All compartments mustremain closed and secured during operation.

SAFETY RULES



SAFETY RULES

Battery Safety

Burn HazardsBatteries contain acid. Always wear protectiveclothing and eyewear when working with batteries.

Avoid spilling or contacting battery acid. Neutralizebattery acid spills with baking soda and water.

Explosion HazardKeep sparks, flames and lighted tobacco awayfrom batteries. Batteries emit explosive gas.

Electrocution HazardAvoid contact with electrical terminals.

Component Damage Hazards

Do not use any battery or charger greater than 12Vto jump-start the engine.

Do not use the machine as a ground for welding.

Decal Legend

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

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.



Controls

Ground Control Panel

1 Platform level switch

2 Platform rotate switch

3 Z-45/25J models only: Jib boom up/down switch

4 Turntable rotate switch

5 Primary boom up/down switch

6 Primary boom extend/retract switch

7 Gasoline/LPG models: Fuel select switch

8 Platform overload indicator light (if equipped)

9 Auxiliary power switch

10 Gasoline/LPG models: Check engine lightDiesel models: Oil pressure light

11 Key switch for platform/off/ground selection

12 Red Emergency Stop button

13 Hour meter

14 Diesel models: Water temperature light

15 Diesel models: Glow plug switch (if equipped)

16 Function enable switch

17 Engine start switch

18 15A breaker for engine electrical circuits

19 Secondary boom up/down switch

20 15A breaker for control electrical circuits



1 3

6 Drive speed select switch

7 Diesel models: Glow plug switch (if equipped)

8 Engine start switch

9 Engine idle (rpm) select switch

10 Gasoline/LPG models: Gasoline/LPGselect switch

Platform Control Panel

1 Horn button

2 Platform level switch

3 Platform rotate switch

4 Z-45/25J models only: Jib boom up/down switch

5 Auxiliary power switch

2

CONTROLS

4 5 6

171820 19



CONTROLS

11 Red Emergency Stop button

12 Dual axis proportional control handle for driveand steer functionsOR Proportional control handle for drive functionand thumb rocker for steer function

13 Platform overload indicator light (if equipped)

14 Machine not level indicator light (if equipped)

15 Drive enable indicator light

117 8 9 10

1216 15

16 Drive enable switch

17 Proportional control handle for secondary boomup/down function

18 Primary boom extend/retract switch

19 used for optional equipment

20 Dual axis proportional control handle for primaryboom up/down and turntable rotateleft/right functions

1314



Pre-operation Inspection




2 Always perform a pre-operationinspection.

Know and understand the pre-operationinspection before going on to the nextsection.




Fundamentals

It is the responsibility of the operator to perform apre-operation inspection and routine maintenance.

The pre-operation inspection is a visual inspectionperformed by the operator prior to each work shift.The inspection is designed to discover if anythingis apparently wrong with a machine before theoperator performs the function tests.

The pre-operation inspection also serves todetermine if routine maintenance procedures arerequired. Only routine maintenance items specifiedin this manual may be performed by the operator.

Refer to the list on the next page and check eachof the items.

If damage or any unauthorized variation fromfactory delivered condition is discovered, themachine must be tagged and removed fromservice.

Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications. After repairs arecompleted, the operator must perform apre-operation inspection again before going on tothe function tests.

Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer's specifications andthe requirements listed in the responsibilitiesmanual.



PRE-OPERATION INSPECTION

Pre-operation Inspection

� Be sure that the operator’s, safety andresponsibilities manuals are complete, legibleand in the storage container located in theplatform.

� 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 levelof coolant. Add coolant if needed. SeeMaintenance section.

� Check for battery fluid leaks and proper fluidlevel. Add distilled water if needed. SeeMaintenance section.

� Z-45/25 RT and Z-45/25J RT models: Check forproper tire pressure. Add air if needed. SeeMaintenance section.

Check the following components or areas fordamage, improperly installed or missing parts andunauthorized modifications:

� Electrical components, wiring andelectrical cables

� Hydraulic hoses, fittings, cylinders andmanifolds

� Fuel and hydraulic tanks

� Drive and turntable motors and drive hubs

� Boom wear pads

� Tires and wheels

� 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

� Be sure that all structural and other criticalcomponents are present and all associatedfasteners and pins are in place and properlytightened.

� After you complete your inspection, be sure thatall compartment covers are in place andlatched.



Maintenance

Observe and Obey:

Only routine maintenance items specified in thismanual shall be performed by the operator.

Scheduled maintenance inspections shall becompleted by qualified service technicians,according to the manufacturer's specificationsand the requirements specified in theresponsibilities manual.

Maintenance Symbols Legend

The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.

Indicates that tools will be required toperform this procedure.

Indicates that new parts will berequired to perform this procedure.

Indicates that a cold engine is requiredbefore performing this procedure.

Check the Engine Oil Level

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

Check the oil level with theengine off.

1 Check the oil dipstick. Add oil as needed.

Ford LRG-425 EFI Engine

Oil type 10W-40

Oil type - cold conditions 10W-30

Use oils meeting API classification SH or SG.Units ship with 10-40 CC/SG.

Deutz Engine F3L 1011F

Oil type 15W-40


Engine oil should have properties of API classificationCC/SE, CD/SE, SF/CC or SF/CD grades.Units ship with 10-40 CC/SG.

Perkins Engine 104-22 Engine

Oil type 15W-40


Engine oil should have properties of API classificationCC/SE, CD/SE, SF/CC or SF/CD grades.Units ship with 10-40 CC/SG.



Perkins 404-22 Engine

Oil type 15W-40


Engine oil should have properties of API classificationCH-4 grade.Units ship with 10-40 CC/SG.

Ford LRG-425 EFI Engine (EPA Compliant)

Oil type 10W-40


Deutz F3L 2011F Engine (Tier II)

Oil type 15W-40


Engine oil should have properties of API classificationCC/SE or CC/SF grades.Units ship with 10-40 CC/SG.

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level isessential to machine operation. Improper hydraulicoil levels can damage hydraulic components. Dailychecks allow the inspector to identify changes in oillevel that might indicate the presence of hydraulicsystem problems.

1 Be sure that the boom is in the stowed position,then visually inspect the sight gauge located onthe side of the hydraulic oil tank.

Result: The hydraulic oil level should be withinthe top 2 inches / 5 cm of the sight gauge.

2 Add oil as needed.

Hydraulic oil specifications

Hydraulic oil type Chevron RykonPremium MV equivalent

MAINTENANCE



Check the Engine Coolant Level -Ford and Perkins Models

Maintaining the engine coolant at the proper levelis essential to engine service life. Improper coolantlevel will affect the engine's cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

Burn hazard. Beware of hotengine parts and coolant. Contactwith hot engine parts and/orcoolant may cause severe burns.

1 Check the fluid level in the coolant recoverytank. Add fluid as needed.

Result: The fluid level should be at theFULL mark.

Do not remove the radiator cap.

Check the Batteries

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

Electrocution hazard. Contact withhot or live circuits may result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections aretight and free of corrosion.

3 Be sure that the battery hold-down bracket issecure.

4 Remove the battery vent caps.

5 Check the battery acid level. If needed,replenish with distilled water to the bottom ofthe battery fill tube. Do not overfill.

6 Install the vent caps.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.

MAINTENANCE



Check the Tire Pressure

Bodily injury hazard. An over-inflated tire can explode, which canresult in death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

This procedure does not needto be performed on machinesequipped with foam-filledtires.

To safeguard maximum stability, achieveoptimum machine handling and minimize tirewear, it is essential to maintain proper pressurein all air-filled tires.

1 Check each tire with an air pressure gauge andadd air as needed.

Tire specifications 2WD Models 4WD Models

Narrow base modelsIndustrial tire Foam Filled Only

Standard base modelsRough terrain tire 45 psi / 3.1 bar 45 psi / 3.1 barTire size: 14-17.5 NHS

Standard base modelsIndustrial tire 100 psi / 6.9 barTire size: 9-14.5 LT

Standard base modelsRough terrain tire 50 psi / 3.5 bar 50 psi / 3.5 barTire size: 355/55D625 14 ply

MAINTENANCE

Scheduled MaintenanceMaintenance performed quarterly, annually andevery two years must be completed by a persontrained and qualified to perform maintenance on thismachine according to the procedures found in theservice manual for this machine.

Machines that have been out of service for morethan three months must receive the quarterlyinspection before they are put back into service.



Function Tests

Fundamentals

The function tests are designed to discover anymalfunctions before the machine is put intoservice. The operator must follow the step-by-stepinstructions to test all machine functions.

A malfunctioning machine must never be used. Ifmalfunctions are discovered, the machine must betagged and removed from service. Repairs to themachine may only be made by a qualified servicetechnician, according to the manufacturer'sspecifications.

After repairs are completed, the operator mustperform a pre-operation inspection and functiontests again before putting the machine into service.





3 Always perform function tests prior touse.

Know and understand the function testsbefore going on to the next section.





FUNCTION TESTS

Test the Tilt Sensor

9 Turn the key switch toplatform control. Pull outthe platform red EmergencyStop button to the onposition.

10 Open the engine sideturntable cover and locatethe tilt sensor to the right ofthe hydraulic pump.

11 Press down one side of the tilt sensor.

Result: The alarm, located in the platform,should sound.

Test Auxiliary Controls

12 Turn the key switch to ground control and shutthe engine off.

13 Pull out the red Emergency Stop button to theon position.

14 Simultaneously hold theauxiliary power switch on andactivate each boom functiontoggle switch.

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

Result: All boom functions should operate.

1 Select a test area that is firm, level and free ofobstruction.

At the Ground Controls2 Turn the key switch to ground control.

3 Pull out the red Emergency Stop button tothe on position.

Result: The beacon (if equipped) should flash.

4 Start the engine. See Operating Instructionsection.

Test Emergency Stop

5 Push in the red Emergency Stop button to theoff position.

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

6 Pull out the red Emergency Stop button tothe on position and restart the engine.

Test the Machine Functions

7 Do not hold the function enableswitch to either side. Attempt toactivate each boom and platformfunction toggle switch.

Result: All boom and platform functions shouldnot operate.

8 Hold the function enable switch to either sideand activate each boom and platform functiontoggle switch.

Result: All boom and platform functions shouldoperate through a full cycle. The descent alarm(if equipped) should sound while the boom islowering.

Machines equipped with Platform Level ControlDisable Function: The platform level toggle switchwill not operate when the primary boom is raisedpast the drive speed limit switch.



FUNCTION TESTS

Test Machine Functions

24 Press down the foot switch.

25 Activate each machine function control handleor toggle switch.

Result: All boom/platform functions shouldoperate through a full cycle.


Test the Steering


27 Press the thumb rocker switch on top of thedrive control handle in the direction indicated bythe blue triangle on the control panel OR slowlymove the control handle in the directionindicated by the blue triangle.

Result: The steer wheels should turn in thedirection that the blue triangles point on thedrive chassis.

28 Press the thumb rocker switch on top of thedrive control handle in the direction indicated bythe yellow triangle on the control panel ORslowly move the control handle in the directionindicated by the yellow triangle.

Result: The steer wheels should turn in thedirection that the yellow triangles point on thedrive chassis.

At the Platform ControlsTest Emergency Stop

15 Turn the key switch to platform control andrestart the engine.

16 Push in the platform red Emergency Stopbutton to the off position.

Result: The engine will shut off after 2 or 3seconds.

17 Pull out the red Emergency Stop button andrestart the engine.

Test the Horn

18 Push the horn button.

Result: The horn should sound.

Test the Foot Switch

19 Push in the platform red Emergency Stop buttonto the off position.

20 Pull out the red Emergency Stop button tothe on position but do not start the engine.

21 Press down the foot switch and attempt to startthe engine by moving the start toggle switch toeither side.

Result: The engine should not start.

22 Do not press down the foot switch and restartthe engine.

Result: The engine should start.

23 Do not press down the foot switch and test eachmachine function.

Result: The machine functions should notoperate.



Test Drive and Braking


30 Slowly move the drive control handle in thedirection indicated by the blue arrow on thecontrol panel until the machine begins to move,then return the handle to the center position.

Result: The machine should move in thedirection that the blue arrow points on the drivechassis, then come to an abrupt stop.

31 Slowly move the drive control handle in thedirection indicated by the yellow arrow on thecontrol panel until the machine begins to move,then return the handle to the center position.

Result: The machine should move in thedirection that the yellow arrow points on thedrive chassis, then come to an abrupt stop.

Note: The brakes must be able to hold the machineon any slope it is able to climb.

Test the Drive Enable System

32 Press down the foot switch and lower the boomto the stowed position.

33 Rotate the turntable until the primary boommoves past one of the non-steer wheels.

Result: The drive enableindicator light should comeon and remain on while theboom is anywhere in therange shown.

34 Move the drive control handle off center.

Result: The drive function should not operate.

35 Move and hold the drive enable toggle switch toeither side and slowly move the drive controlhandle off center.

Result: The drive function should operate.

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

Use the color-coded directionarrows on the platformcontrols and the drivechassis to identify thedirection of travel.

FUNCTION TESTS

Blue

Yellow



FUNCTION TESTS

Test Limited Drive Speed - Standard BaseModels


37 Raise the primary boom approximately2 feet / 61 cm.

38 Slowly move the drive control handle to the fulldrive position.

Result: The maximum achievable drive speedwith the primary boom raised should not exceed1 foot / 30 cm per second.

39 Lower the primary boom to the stowed position.

40 Raise the secondary boom approximately2 feet / 61 cm.


Result: The maximum achievable drive speedwith the secondary boom raised should notexceed 1 foot / 30 cm per second.

42 Lower the secondary boom to the stowedposition.

43 Extend the primary boom approximately1 foot / 30 cm.


Result: The maximum achievable drive speedwith the primary boom extended should notexceed 1 foot / 30 cm per second.

45 Retract the boom to the stowed position.

If the drive speed with the primary boom raised, thesecondary boom raised or the primary boomextended exceeds 1 foot / 30 cm per second,immediately tag and remove the machine fromservice.

Test Limited Drive Speed - Narrow Base Models


37 Raise the primary boom approximately2 feet / 61 cm.


Result: The maximum achievable drive speedwith the primary boom raised should not exceed6 in / 15 cm per second.

39 Lower the primary boom to the stowed position.

40 Raise the secondary boom approximately2 feet / 61 cm.


Result: The maximum achievable drive speedwith the secondary boom raised should notexceed 6 in / 15 cm per second.



42 Lower the secondary boom to the stowedposition.

43 Extend the primary boom approximately1 foot / 30 cm.


Result: The maximum achievable drive speedwith the primary boom extended should notexceed 6 in / 15 cm per second.

45 Retract the boom to the stowed position.

If the drive speed with the primary boom raised, thesecondary boom raised or the primary boomextended exceeds 6 int / 15 cm cm per second,immediately tag and remove the machine fromservice.

Test the Oscillate Axle(oscillating axle-equipped models)

46 Start the engine from the platform controls.

47 Drive the right steer tire up onto a 6 inch /15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground.

48 Drive the left steer tire up onto a 6 inch /15 cm block or curb.

Result: The three remaining tires should stay infirm contact with the ground.

49 Drive both steer tires up onto a 6 inch /15 cm block or curb.

Result: The non-steer tires should stay in firmcontact with the ground.

FUNCTION TESTS



FUNCTION TESTS

Test Auxiliary Controls

50 Shut the engine off.



53 Simultaneously hold the auxiliary power switchon and activate each function control handle ortoggle switch.

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

Result: All boom and steer functions shouldoperate. Drive functions should not operate withauxiliary power.

Test the Lift/Drive Select Function(if equipped)


55 Move the drive control handle off center andactivate a boom function toggle switch.

Result: No boom functions should operate. Themachine will move in the direction indicated onthe control panel.

56 Repair any malfunctions before operating themachine.



Workplace Inspection

Workplace Inspection

Be aware of and avoid the following hazardoussituations:

· drop-offs or holes

· bumps, floor obstructions or debris

· sloped surfaces

· unstable or slippery surfaces

· overhead obstructions and high voltageconductors

· hazardous locations

· inadequate surface support to withstand all loadforces imposed by the machine

· wind and weather conditions

· the presence of unauthorized personnel

· other possible unsafe conditions







Know and understand the workplaceinspection before going on to the nextsection.


Fundamentals

The workplace inspection helps the operatordetermine if the workplace is suitable for safemachine operation. It should be performed by theoperator prior to moving the machine to theworkplace.

It is the operator's responsibility to read andremember the workplace hazards, then watch forand avoid them while moving, setting up andoperating the machine.



Operating Instructions








Fundamentals

The Operating Instructions section providesinstructions for each aspect of machine operation.It is the operator's responsibility to follow all thesafety rules and instructions in the operator's,safety and responsibilities manuals.

Using the machine for anything other than liftingpersonnel, along with their tools and materials, toan aerial work site is unsafe and dangerous.

Only trained and authorized personnel should bepermitted to operate a machine. If more than oneoperator is expected to use a machine at differenttimes in the same work shift, they must all bequalified operators and are all expected to follow allsafety rules and instructions in the operator's,safety and responsibilities manuals. That meansevery new operator should perform a pre-operationinspection, function tests, and a workplaceinspection before using the machine.



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

Gasoline/LPG models: In cold conditions, 20°F /-6°C and below, the machine should be started ongasoline and warmed for 2 minutes, then switchedto LPG. Warm engines can be started on LPG.

Emergency Stop

Push in either ground or platform red EmergencyStop button to the off position to stop all functionsand turn the engine off.

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

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

Starting the Engine

1 At the ground controls, turn thekey switch to the desired position.

2 Be sure both ground and platform control redEmergency Stop buttons are pulled out to theon position.

Gasoline/LPG models

3 Choose fuel by moving the fuel select switch tothe desired position.

4 Move the engine start toggle switch to eitherside. If the engine fails to start or dies, therestart delay will disable the start switch for 3seconds.

Diesel models

3 Move the glow plug switch (if equipped) to eitherside and hold for 3 to 5 seconds.

4 Move the engine start toggle switch to eitherside. If the engine fails to start or dies, therestart delay will disable the start switch for 3seconds.

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 theengine for 5 minutes before operating to preventhydraulic system damage.

OPERATING INSTRUCTIONS




Auxiliary Controls

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

1 Turn the key switch to ground or platformcontrol.

2 Pull out the red Emergency Stop button to theon position.

3 Press down the foot switch when operating theauxiliary controls from the platform.

4 Simultaneously hold auxiliarypower switch on and activate thedesired function.

The drive and steer functions will not operate withauxiliary power.

Operation from Ground

1 Turn the key switch to ground control.


3 Gasoline/LPG models: Choose fuel by movingthe fuel select switch to the desired position.

4 Start the engine.

To Position Platform

1 Hold the function enable switch toeither side.

2 Move the appropriate toggle switch according tothe markings on the control panel.

Drive and steer functions are not available from theground controls.


Operation from Platform

1 Turn the key switch to platform control.

2 Pull out both ground and platform redEmergency Stop buttons to the on position.

3 Gasoline/LPG models: Choose fuel by movingthe fuel select switch to the desired position.

4 Start the engine. Do not press down the footswitch when starting the engine.

To Position Platform


2 Slowly move the appropriate function controlhandle or toggle switch according to themarkings on the control panel.


To Steer


2 Slowly move the control handle in the directionindicated by blue or yellow trianglesOR press the thumb rocker switch located ontop of the drive control handle.

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




To Drive


2 Increase speed: Slowly move the drive controlhandle off center.

Decrease speed: Slowly move the drive controlhandle toward center.

Stop: Return the drive control handle to center orrelease the foot switch.

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

Machine travel speed is restricted when the boomsare raised.

Drive Enable

Light on indicates that the boomhas moved just past either non-steer wheel and the drivefunction has been interrupted.

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

Be aware that the machine may move in theopposite direction that the drive and steer controlsare moved.

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

Drive Speed Select

· Machine on incline symbol: Low range operationfor inclines

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

Engine Idle Select (rpm)

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

· Turtle symbol: Footswitch activated lowidle

· Rabbit symbol: Footswitch activated highidle

Generator

To operate the generator, move the generatortoggle switch to the on position. The engine willcontinue to run but no drive or platform functionswill operate.

Plug a power tool into the power to platform GFCIoutlet.

To resume machine functions, move the generatortoggle switch to the off position. All functions willoperate.



Platform Overload IndicatorLight (if equipped)

Light flashing indicates theplatform is overloaded and nofunctions will operate.

Remove weight from the platformuntil the light goes off.

Machine Not Level IndicatorLight (if equipped)

Light on indicates themachine is not level. The tiltalarm will be sounding whenthis light is on. Move themachine to a firm levelsurface.

Check Engine Light(if equipped)

Light on and engine stopped: Tagthe machine and remove fromservice.

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


Fall Protection

Personal fall protection equipment (PFPE) isrequired when operating this machine.

All PFPE must comply with applicablegovernmental regulations, and must be inspectedand used in accordance with the PFPEmanufacturer’s instructions.

After Each Use1 Select a safe parking location—firm level

surface, clear of obstruction and traffic.

2 Retract and lower the boom to the stowedposition.

3 Rotate the turntable so that the boom is betweenthe non-steer wheels.

4 Turn the key switch to the off position andremove the key to secure from unauthorizeduse.

5 Chock the wheels.



Free-wheel Configuration forWinchingChock the wheels to prevent the machine fromrolling.

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

Be sure the winch line is properly secured to thedrive chassis tie points and the path is clear of allobstructions.

Reverse the procedures described to re-engage thebrakes.

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

Transport and Lifting Instructions

Transport InstructionsObserve and Obey:

The transport vehicle must be parked on a levelsurface.

The transport vehicle must be secured toprevent rolling while the machine is beingloaded.

Be sure the vehicle capacity, loading surfacesand chains or straps are sufficient to withstandthe machine weight. See the serial plate for themachine weight.

Be sure the turntable is secured with theturntable rotation lock before transporting. Besure to unlock the turntable for operation.

DisengagePosition

EngagePosition



Securing to Truck or Trailer forTransitAlways use the turntable rotation lock pin each timethe machine is transported.

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

Inspect the entire machine for loose or unsecureditems.

Securing the Chassis

Use chains of ample load capacity.

Use a minimum of 4 chains.

Adjust the rigging to prevent damage to the chains.

Securing the Platform - Z-45/25

Make sure the platform is in the stowed position.

Secure the platform with a nylon strap placed overthe platform mount near the platform rotator (seebelow). Do not use excessive downward force whensecuring the boom section.

Securing the Platform - Z-45/25J

Make sure the jib and platform are in the stowedposition.

Secure the platform with a nylon strap placed overthe platform mount near the platform rotator (seebelow). Do not use excessive downward forcewhen securing the boom section.

TRANSPORT AND LIFTING INSTRUCTIONS



Observe and Obey:

Only qualified riggers should rig and lift themachine.

Be sure the crane capacity, loading surfacesand straps or lines are sufficient to withstandthe machine weight. See serial plate.

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

Determine the center of gravity of your machineusing the table and the picture on this page.

Attach the rigging only to the designated liftingpoints on the machine. There are four lifting pointson the chassis.

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

X Axis Y Axis

Z-45/25 47 in 42 in1.19 m 1.06 m

Z-45/25J 49 in 44.5 in1.24 m 1.13 m

TRANSPORT AND LIFTING INSTRUCTIONS

X Axis

Y Axis



Decals

Part No. Decal Description Quantity

27204 Arrow - Blue 1

27205 Arrow - Yellow 1

27206 Triangle- Blue 2

27207 Triangle - Yellow 2

27564 Danger - Electrocution Hazard 2

28158 Label - Unleaded 1

28159 Label - Diesel 1

28160 Label - Liquid Petroleum Gas 2

28161 Warning - Crushing Hazard 3

28163 Notice - Max Side Force, 150 lbs / 667N 1

28164 Notice - Hazardous Materials 1

28165 Notice - Foot Switch 1

28171 Label - No Smoking 1

28174 Label - Power to Platform, 230V 2

28175 Caution - Compartment Access 1

28176 Notice - Missing Manuals 1

28177 Warning - Platform Rotate 2

28181 Warning - No Step or Ride 1


28236 Warning - Failure To Read . . . 1

30080 Notice - Maximum Load, 500 lbs / 227 kg 1

31060 Danger - Tip-over Hazard, Interlock 3

32700 Danger - Safety Rules 2

32728 Label - Generator (option) 1

33952 Danger - Tilt-Alarm 1

40434 Label - Lanyard Anchorage Point 3

43595 Danger - Tip-over Hazard, Tires 4

44981 Label - Air Line to Platform 2


44986 Notice - Max Manual Force, 90 lbs / 400N 1

49741 Notice - Ford Engine Spec LRG-425 EFI 1

52447 Notice - Tire Pressure 4

52607 Label - Test Switch 1

52672 Danger - Tip-over Hazard, Tires 4

52784 Notice - Deutz Diesel Specifications 1

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


65301 Notice - Foam-Filled Tire Specs 4

72085 Notice - Perkins Engine Specifications 1

72442 Ground Control Panel 1

82238 Platform Control Panel 1

82283 Notice - Operating Instructions 2

82366 Label - Chevron Rykon 1

82631 Label - Wheel Load, Z-45/25 4

82632 Label - Wheel Load, Z-45/25J 4

82644 Notice - Perkins Engine Specifications 1

82918 Notice - Tire Specifications 4

97548 Notice - Deutz Engine Specifications 1

97571 Notice - Ford Engine Specifications 1

97602 Warning - Explosion Hazard 1

Inspection for Decals with WordsDetermine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.



DECALS

DriveChassis Platform

Shading indicatesdecal is hiddenfrom view, i.e.under covers

Ground Controls Side

Engine Side



Decals

Inspection for Decals withSymbolsDetermine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.


27204 Arrow - Blue 1

27205 Arrow - Yellow 1

27206 Triangle- Blue 2

27207 Triangle - Yellow 2

28158 Label - Unleaded 2

28159 Label - Diesel 2

28160 Label - Liquid Petroleum Gas 1

28171 Label - No Smoking 2



32728 Label - Generator (option) 1

40434 Label - Lanyard Anchorage 3

44981 Label - Air Line to Platform 2

52968 Cosmetic - Genie Boom 1

62926 Cosmetic - Genie Z-45/25J 1

62927 Cosmetic - Genie Z-45/25 1




72442 Ground Control Panel 1

82238 Platform Control Panel 1

82472 Warning - Crushing Hazard 3

82473 Caution - Compartment Access 1

82487 Label - Operating Instructions 2

82544 Danger - Electrocution Hazard 3

82545 Danger - Maximum Load 227 kg 1

82548 Warning - Platform Rotate 2

82602 Danger - Max Manual Force, 667 N 1

82604 Danger - Max Manual Force, 400 N 1

82631 Label - Wheel Load, Z-45/25 4

82632 Label - Wheel Load, Z-45/25J 4

82633 Label - Tire Pressure, RT Tires 4

82643 Label - Tire Pressure, Industrial Tires 4

82646 Label - Drive Enable Patch 1



DECALS

Platform

Shading indicatesdecal is hiddenfrom view, i.e.under covers

Ground Controls Side

Engine Side

DriveChassis



Specifications

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

Height, working maximum 51 ft 8 in 15.74 m

Height, platform maximum 45 ft 8 in 13.9 m

Height, stowed maximum 6 ft 10 in 2.1 m

Horizontal reach maximum 124 ft 6 in 17.5 m

Width 7 ft 4 in 2.2 m

Length, stowed 18 ft 5.5 m

Maximum load capacity 500 lbs 227 kg

Wheelbase 6 ft 8 in 2.0 m

Turning radius (outside) 15 ft 4.5 m

Turning radius (inside) 4 ft 6 in 1.4 m

Turntable rotation (degrees) 359°

Turntable tailswing 0 in 0 cm

Drive speed, stowed 4.8 mph 7.7 km/h 40 ft/6 sec 12.2 m/6 sec

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

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

Ground clearance, center 13.25 in 33.6 cm

Ground clearance, minimum 10 in 25.4 cm

Controls 12V DC proportional

Weight See Serial Plate(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

AC outlet in platform standard

Hydraulic pressure, maximum 3200 psi 221 bar(boom functions)

System voltage 12V

Tire size, 4WD & 2WD RT 14-17.5 14 ply

Gradeability, stowed, 2WD 30%


Fuel tank capacity 17 gallons 64.3 liters

Floor Loading Information

GVW+Rated Load 14,300 lbs 6486 kg

Axle load, maximum 11,200 lbs 5079 kg

Wheel load, maximum 7100 lbs 3219 kg

Localized pressure per tire 50 psi 3.51 kg/cm2

345 kPa

Occupied floor pressure 196 psf 9.55 kPa

Note: Floor loading information is approximate anddoes not incorporate different option configurations. Itshould be used only with adequate safety factors.

1 Outreach specification with platform rotated90 degrees

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



SPECIFICATIONS

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






Length, stowed 22 ft 3 in 6.8 m




Turning radius (inside) 4 ft 6 in 1.4 m



Drive speed, stowed 4.8 mph 7.7 km/h40 ft/6 sec 12.2 m/6 sec












System voltage 12V

Tire size, 4WD & 2WD RT 14-17.5 14 ply

Gradeability, stowed, 2WD 30 %








345 kPa






SPECIFICATIONS

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






Length, stowed 18 ft 5.5 m




Turning radius (inside) 5 ft 1.5 m



Power source Ford Gasoline/LPG LRG 425 EFI(choice) OR Deutz Diesel F3L 1011

OR Perkins Diesel 104-22

Drive speed, stowed 4.8 mph 7.7 km/h 40 ft/6 sec 12.2 m/6 sec












System voltage 12V

Tire size, 2WD IndustrialFoam-filled only 9-14.5 LT








690 kPa



1 Outreach specification with platform rotated90 degrees





SPECIFICATIONS

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






Length, stowed 22 ft 3 in 6.8 m




Turning radius (inside) 5 ft 1.5 m



Power source Ford Gasoline/LPG LRG 425 EFI(choice) OR Deutz Diesel F3L 1011

OR Perkins Diesel 104-22

Drive speed, stowed 4.8 mph 7.7 km/h40 ft/6 sec 12.2 m/6 sec












System voltage 12V

Tire size, 2WD IndustrialFoam-filled only 9-14.5 LT








690 kPa



Dis

trib

ute

d B

y:

California Proposition 65

WARNINGWARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie ChinaPhone +86 21 53852570

Fax +86 21 53852569

Genie MalaysiaPhone +65 98 480 775

Fax +65 67 533 544

Genie JapanPhone +81 3 3453 6082

Fax +81 3 3453 6083

Genie KoreaPhone +82 25 587 267

Fax +82 25 583 910

Genie BrasilPhone +55 11 41 665 755

Fax +55 11 41 665 754

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 575100

Fax +46 31 579020

Genie FrancePhone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Genie IbericaPhone +34 93 579 5042

Fax +34 93 579 5059

Genie GermanyPhone +49 (0)4202 88520

Fax +49 (0)4202 8852-20

Genie U.K.Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

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