Operator`s Manual - Genie Industries
Contents
1. DECALS 31060 28174 230V 27564 32700 28158 Unleaded 52230 28235 115V 4347 28159 Diesel 31060 T 33503 28161 28157 or 82283 52607 52511 acres or 72442 44769 mm 43663 jy 98160 6292 or 526 2 62926 or 43595 52447 pel or 65301 28181 28161 EX 52672 or 43595 52969 DI 52447 or 65301 33952 27204 43647 or 82283 Li mi 27206 KP Platform 32700 97907 l 28174 230V da 28985 115V Drive BE 40434 27207 Chassis 28236 31060 eds A la 27206 Es M 28165 27205 33550 Fan 44981 6294701 33550 62948 28163 Serial Plate or 44986 A Engine Side 28171 261 9 id Hl i 28164 pO hS Io 27564 onl T J 25994 u T 28161 ME ON Shading indicates decal is hidden 02447 526 2 026 72 OF 52447 or 49741 or from view i e or 65301 or 43595 28160 43595 65301 44981 52784 28177 under covers Part No 52421 Genie Z 45 25 amp Genie Z 45 25J 31 Operators Manual First Edition Seventh Printing Specifications Standard Base Models Height working maximum Height platform maximum Height stowed maximum Horizontal reach maximum Width Length stowed Maximum load capacity 6 foot platform Wheelbase Turning radius outside Turning radius inside Turntable rotation degrees Turntable tailswing Power source Choice Drive speed stowed Z 45 25 no jib 51 ft 8 in 15 74 m 45 ft 8 in 13 9 m2. af E i r r First Editi Operator S Manual a with Maintenance Information Part No 52421 Z 45 25 Z 45 25J Operators Manual First Edition Seventh Printing EE 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 SS EE OR N EN EE EN 1 Be ige ER EE EE N 7 Pre operation InspectiON ese ee Ee Ee ee 10 Maintenance iese ee ee Ee EER ER ee EE RE ee ee eek ee ee 12 elle ile sd Es EE OE OR EN OE N 16 Workplace Inspection ee ee ee ek ER RE RE ee 23 Operating Instructions ees ee ee EE Ee ee Ee 24 TransportinstructiOns iese ee ER EER Ee EE Ee ee 29 Dora RD GE Ee 30 SDEGCINCATIONS ee a 32 Contact us Copyright 1998 by Genie Industries First Edition Seventh Printing May 2002 Internet http www genielift com E mail techpub genieind com 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 ay t Printed on recycled paper Printed in U S A Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual Safet
3. Part No 52421 First Edition Seventh Printing Operators Manual 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 Ibs side force ANSI amp CSA 667 N Maximum allowable 90 Ibs side force CE 400 N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine Stability with items of different weight or specification Part No 52421 Genie Z 45 25 amp Genie Z 45 25J 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 o Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machin
4. 5 Simultaneously hold auxiliary power switch on and activate the desired function The drive and steer functions will not operate with auxiliary power Operation from Ground J 2 Turn the key switch to ground control Pull out the red Emergency Stop button to the on position Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position Start the engine Genie Z 45 25 amp Genie Z 45 25J 25 Operators Manual First Edition Seventh Printing OPERATINGINSTRUCTIONS 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 Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch 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 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 To Position Platform 1 Move the lift drive select switch to the lift position if equipped 2 Press down the foot switch 3 Slowly move the appropriate function control handle or t
5. AO ft 5 7 sec 12 2 m 5 7 sec 12 2 m 5 7 sec Drive speed booms raised 0 3 mph 0 5 km h Z 45 25J jib 51 ft 3 in 15 6 m 45 ft 3 in 13 8 m 6 ft 7 in 2 05 m 25 ft 3 in 7 7 m 5 ft 9 in 1 8 m 22 ft 3 in 6 8 m 500 Ib 227 kg 6 ft 8 in 2 0m 11 ft 3 35 m 5 ft 1 5 m 359 O in O cm Ford Gasoline LPG LRG 425 EFI OR Deutz Diesel F3L 1011 4 8 mph 7 7 km h 4 8 mph 7 7 km h AO ft 5 7 sec 0 3 mph 0 5 km h Operator s Manual SPECIFICATIONS Narrow Base Models Z 45 25 no jib Controls Weight Z 45 25J jib 12V DC proportional See Serial Plate Machine weights vary with option configurations Platform dimensions 6 foot 72 in x 30 in length x width 1 8m x 76 cm Platform leveling self leveling Platform rotation 180 degrees AC outlet in platform standard Hydraulic pressure maximum 3200 psi boom functions 221 bar Tire size 2WD Industrial Foam filled only Gradeability stowed 2WD 30 Fuel tank capacity 17 gallons 64 3 liters 72 in x 30 in 1 8m x 76 cm self leveling 160 degrees standard 3200 psi 221 bar 9 14 5 LT 30 17 gallons 64 3 liters 1 Outreach specification with platform rotated 90 degrees 50 ft 15 2m 40 ft 12 2 m 30 ft 9 1 m 20 ft 6 1 m 40 ft 91 sec 40 ft 91 sec 12 2 m 91 sec 12 2 m 91 sec Airborne no
6. Label Tire Pressure Ground Control Panel Label Test Switch Danger Tip over Hazard Tires Notice Deutz Diesel Specifications Cosmetic Genie Boom Cosmetic Genie Z 45 25J Cosmetic Genie Z 45 25 Cosmetic IC Power 4 x 2 Cosmetic IC Power 4 x 4 Notice Foam Filled Tire Specs Platform Control Panel Ground Control Panel Platform Control Panel Notice Operating Instructions Quantity o_o Part No 52421 First Edition Seventh Printing Operators Manual
7. 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 A DANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION 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 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual Controls AUXILIARY POWER amp O BOE OROS Ox Orr OO Ea CONTROLS ENGINE oS Oe ea Wa a 15 AMP 15 AMP is Gis 7 Ge a Ground Control Panel Platform rotate switch 11 Diesel models Water temperature light Turntable rotate switch 12 Gasoline LPG models Choke switch Primary boom
8. Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING 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 Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 14 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual Check the Tire Pressure Bodily injury hazard An over AWARNING inflated tire can explode which can result in death or serious injury Tip over hazard Do not use AWARNING temporary flat tire repair products This procedure does not need to be performed on machines equipped with foam filled tires To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as
9. FUNCTIONTESTS 54 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 0 5 foot 15 cm per second 55 Move the lift drive select switch to the lift position if equipped 56 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 0 5 foot 15 cm cm per second immediately tag and remove the machine from service Test the Oscillate Axle oscillating axle equipped models 57 Move the lift drive select switch to the drive position if equipped 58 Start the engine from the platform controls 59 Drive the right steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground 60 Drive the left steer tire up onto a 6 inch 15 2 cm block or curb Result The three remaining tires should stay in firm contact with the ground 61 Drive both steer tires up onto a 6 inch 15 2 cm block or curb Result The non steer tires should stay in firm contact with the ground Genie Z 45 25 amp Genie Z 45 25J 21 Operators Manual First Edition Seventh Printing FUNCTIONTESTS Test Auxiliary Controls 62 Shut the engine off 63 Pull out the red Emergency Stop button to the on position 64 Move the lift drive select switch to the lift p
10. 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 Symbol Legend Indicates that a specific result is expected after performing a series of steps Part No 52421 First Edition Seventh Printing Operators Manual 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 Beacon if equipped should flash 4 Start the engine See Operating Instruction 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 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 th
11. needed Tire specifications 2WD Models 4WD Models Narrow base models Industrial tire Foam Filled Only Standard base models Rough terrain tire 14 17 5 NHS 14 17 5 NHS 45 psi 3 1 bar 45 psi 3 1 bar Part No 52421 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 Genie Z 45 25 amp Genie Z 45 25J 15 Operators Manual First Edition Seventh Printing Function Tests Do Not Operate Unless Mi 16 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 Genie Z 45 25 amp Genie Z 45 25J 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 A malfunctioning machine must never be used If
12. 002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 60 4 228 1235 Fax 60 4 226 6872 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie Africa Phone 27 11 455 0373 Fax 27 11 455 0355 Genie Latin America Phone 55 11 4055 2499 Fax 55 11 4043 1661
13. 6 ft 10 in 2 1m 124 ft 6 in 17 5 m 7 ft 4 in 2 2 M 18 ft 5 5 m 500 Ib 227 kg 6 ft 8 in 2 0m 11 ft 6 in 3 5 m 4 ft 6 in 1 4 m 359 O in O cm AO ft 5 7 sec 12 2 m 5 7 sec 12 2 m 5 7 sec Drive speed booms raised 0 6 mph 1 km h 40 ft 45 sec Z 45 25J jib 51 ft 6 in 15 69 m 45 ft 6 in 13 8 m 6 ft 10 in 2 1 m 25 ft 3 in 7 7 m 7 TA in 2 2 M 22 ft 3 in 6 8 m 500 Ib 227 kg 6 ft 8 in 2 0m 11 ft 6 in 3 5 m 4 ft 6 in 1 4 m 359 O in O cm Ford Gasoline LPG LRG 425 EFI OR Deutz Diesel F3L 1011 4 8 mph 7 7 km h 4 8 mph 7 7 km h AO ft 5 7 sec 0 6 mph 1 km h 4O ft 45 sec 12 2 m 45 sec 12 2 m 45 sec Airborne noise emissions 73 dB 73 dB Maximum sound level at normal operating workstations A weighted Ground clearance center Ground clearance minimum 32 13 25 in 33 6 cm 10 in 25 4 cm Genie Z 45 25 amp Genie Z 45 25J 13 25 in 33 6 cm 10 in 25 4 cm Standard Base Models Z 45 25 Z 45 25J no jib jib Controls 12V DC proportional Weight See Serial Plate Machine weights vary with option configurations 72 in x 30 in 1 8 m x 76 cm 1 8 m x 76cm Platform dimensions 6 foot 72 in x 30 in length x width Platform leveling self leveling self leveling Platform rotation 180 degrees 160 degrees AC outlet in platform standard standard Hydraulic pressure maximum 3200 psi 3200 psi boom functions 221 bar 221 b
14. KV to 1000KV 45 13 7 Allow for platform movement electrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not use the machine as a ground for welding 2 Genie Z 45 25 amp Genie Z 45 25J Tip over Hazards Occupants and equipment shall not exceed the maximum platform capacity 500 Ibs Maximum platform capacity 227 kg Maximum occupants 2 Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a firm level surface before raising the platform Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Do not alter or disable the limit switch es
15. Result The oil level should be between the ADD and SAFE marks Add oil as needed Deutz models Result The oil level should be within the two marks on the dipstick Add oil as needed Perkins Models Result The oil level should be within the two notches on the dipstick Ford LRG 425 EFI Engine Oil viscosity requirements below 60 F 15 5 C SW 30 10 to 90 F 23 to 32 C SW 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG Units ship with 10 40 CC SG Part No 52421 First Edition Seventh Printing Operators Manual Deutz Engine F3L 1011F Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE CD SE SF CC or SF CD grades Units ship with 10 40 CC SG Perkins Engine 104 22 Oil viscosity requirements below 60 F 15 5 C 5W 20 10 to 90 F 23 to 32 C 10W 30 above 10 F 23 C 15W 40 above 25 F 4 C 20W 50 Engine oil should have properties of API classification CC SE CD SE SF CC or SF CD grades Units ship with 10 40 CC SG Part No 52421 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 ide
16. ar Tire size 4WD amp 2WD RT 14 17 5 14 ply Gradeability stowed 2WD 30 30 Gradeability stowed 4WD 45 45 Fuel tank capacity 17 gallons 17 gallons 64 3 liters 64 3 liters 1 Outreach specification with platform rotated 90 degrees a 50 ft E 15 2 m z s AO ft E 12 2 m B 30 ft s 9 1 m BE 20 ft 6 1m a 10 ft 3m ion ot OHO a Om oft 5ft 15 ft 25ft oft 5ft 15 ft 25 ft Om 1 5m 46m 7 6m Om 1 5m 4 6m 7 6 m Continuous improvementofour products isa Genie policy Product specifications are subjectto change withoutnoticeorobligation Part No 52421 First Edition Seventh Printing EE EE EE EE Narrow Base Models Height working maximum Height platform maximum Height stowed maximum Horizontal reach maximum Width Length stowed Maximum load capacity 6 foot platform Wheelbase Turning radius outside Turning radius inside Turntable rotation degrees Turntable tailswing Power source Choice Drive speed stowed Z 45 25 no jib 51 ft 5 in 15 7 m 45 ft 5 in 13 9 m 6 ft 7 in 2 05 m 124 ft 6 in 17 5 m 5 ft 9 in 1 8 m 18 ft 5 5 m 500 Ib 227 kg 6 ft 8 in 2 0m 11 ft 3 35 m 5 ft 1 5 m 359 O in O cm
17. asoline LPG models 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 If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to 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 Part No 52421 OPERATING INSTRUCTIONS Auxiliary Controls Use auxiliary power if the primary power source engine fails r Turn the key switch to ground or platform control Pull out the red Emergency Stop button to the on position Move the lift drive select switch to the lift position when operating the auxiliary controls from the platform Press down the foot switch when operating the auxiliary controls from the platform
18. ate 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 rl Sai y N a 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 Part No 52421 First Edition Seventh Printing Operators Manual 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 locat
19. ctrical cables _I Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads L LL L Tires and wheels Part No 52421 Genie Z 45 25 amp Genie Z 45 25J 11 Operators Manual First Edition Seventh Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required CK A f i AN before performing this procedure 12 Genie Z 45 25 amp Genie Z 45 25J 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 Check the oil level with the engine off 1 Check the oil dipstick Ford models
20. e 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 amp 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 Operators 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 ha 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 amp Genie Z 45 25J 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 oper
21. e 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 Check for proper tire pressure Add air if needed See Maintenance section Operator s Manual PRE OPERATION INSPECTION H Engine and related components _I Limit switches and horn Alarms and beacons if equipped Nuts bolts and other fasteners H Platform entry mid rail or gate Check entire machine for L Crack in welds or structural components L Dents or damage to machine Hd Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened H After you complete your inspection be sure that all compartment covers are in place and latched Check the following components or areas for damage and improperly installed loose or missing parts H Electrical components wiring and ele
22. e the lift drive select switch to the lift position if equipped 35 Press down the foot switch and lower the boom to the stowed position 36 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 37 Move the lift drive select switch to the drive position if equipped 38 Move the drive control handle off center Result The drive function should not operate 39 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 controls and the drive chassis Blue d t to identify the direction of travel Yellow Genie Z 45 25 amp Genie Z 45 25J 19 Operators Manual First Edition Seventh Printing FUNCTION TESTS Test Limited Drive Speed Z 45 25 amp Z 45 25J Standard Base Models ANSI and CSA Z 45 25 amp Z 45 25J Narrow Base Models before serial number 19081 40 Move the lift drive select switch to the lift position if equipped 41 Press down the foot switch 42 Raise the primary boom approximately 2 feet 61 cm 43 Move the lift drive select
23. function is turned off To drive hold drive enable switch to side and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved Use color coded direction arrows on this panel and drive chassis to identify the direction machine will travel 05 11 Red Emergency Stop button 04 UP 4 TO START DOWN TO STOP SFEER ms mm UI 13 Q3 15 Drive enable switch 12 Dual axis proportional control handle for drive 16 Proportional control handle for secondary boom and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 13 used for optional eduipment 14 Drive enable indicator light Part No 52421 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 Genie Z 45 25 amp Genie Z 45 25J 9 Operators Manual First Edition Seventh Printing Pre operation Inspection Do Not Operate Unless M 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 a
24. g and remove the machine from service Test Limited Drive Speed CE Z 45 25 amp Z 45 25J Narrow Base Models before serial number 19081 All Z 45 25 amp Z 45 25J Narrow Base Models after serial number 19080 40 Move the lift drive select switch to the lift position if equipped 41 Press down the foot switch Part No 52421 First Edition Seventh Printing Operators Manual 42 Raise the primary boom approximately 2 feet 61 cm 43 Move the lif drive select switch to the drive position if equipped 44 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 0 5 foot 15 cm per second 45 Move the lift drive select switch to the lift position if equipped 46 Lower the primary boom to the stowed position 47 Raise the secondary boom approximately 2 feet 61 cm 48 Move the lift drive select switch to the drive position if equipped 49 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 0 5 foot 15 cm per second 50 Move the lift drive select switch to the lift position if equipped 51 Lower the secondary boom to the stowed position 52 Extend the primary boom approximately 1 foot 30 cm 53 Move the lift drive select switch to the drive position if equipped Part No 52421
25. ine Part No 52421 First Edition Seventh Printing Operators Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris Do Not Operate Unless overhead obstructions and high voltage M You learn and practice the principles of safe conductors machine operation contained in this operator s hazardous locations manual inadequate surface support to withstand all load 1 Avoid hazardous situations forces imposed by the machine 2 Always perform a pre operation wind and weather conditions inspection the presence of unauthorized personnel 3 Always perform function tests prior to use N other possible unsafe conditions 4 Inspectthe workplace Know and understand the workplace inspection before going on to the next section 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 52421 Genie Z 45 25 amp Genie Z 45 25J 23 Operators Manual First Edition Seventh Printing Operating Instructions Do Not Operate Unless M Yo
26. ions or locations where potentially flammable or explosive gases or particles may be present Part No 52421 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 amp 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 Genie Z 45 25 amp Genie Z 45 25J 5 Operators Manual First Edition Seventh Printing EE
27. ise emissions 73 dB 73 dB Maximum sound level at normal operating workstations A weighted Ground clearance 8 5 in 8 5 in center 21 6cm 21 6 cm Ground clearance 7 in 7 in minimum 17 7 cm 17 7 cm Part No 52421 10 ft 3m f TT De oft OHHO 0 oft 5ft 15 ft 25 ft Om 1 5m 4 6m 7 6m oft 5ft 15 ft 25 ft Om 1 5m 4 6m 7 6 m Continuous improvementofour products isa Genie policy Product specifications are subjectto change without notice or obligation Genie Z 45 25 amp Genie Z 45 25J 33 Genie Holland Phone 31 70 51 78836 Fax 31 7051 13993 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Ib rica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 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 City Phone 52 5 653 03 84 Fax 52 5 664 40 16 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 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 1
28. ive 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 Generator To operate the generator move the generator toggle switch to the generator position The engine will continue to run but no drive or platform functions will operate Plug a power tool into the power to platform GFCI outlet To resume machine functions move the generator toggle switch to machine functions position All functions will operate Drive Speed Select Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Part No 52421 Genie Z 45 25 amp Genie Z 45 25J OPERATINGINSTRUCTIONS Engine Idle Select rpm Select the engine idle speed rpm using the symbols on the control panel Ie Turtle symbol low idle Rabbit symbol high idle If your control panel looks like When the foot switch is not pressed the engine will idle at the lowest rpm If your control panel looks like this Rabbit and foot switch symbol foot switch activated high idle Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle 27 Operators Man
29. ntify 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 Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge 2 Addoil as needed Hydraulic oil specifications Hydraulic oil type Dexron equivalent Genie Z 45 25 amp Genie Z 45 25J 13 Operators Manual First Edition Seventh Printing MAINTENANCE 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 ACAUTION 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 Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap 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
30. oggle switch according to the markings on the control panel Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch To Steer 1 Move the lift drive select switch to the drive position if equipped Press down the foot switch 3 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 arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Move the lift drive select switch to the drive position if equipped Press down the foot switch Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward center 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 26 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual 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 dr
31. osition if equipped 65 Press down the foot switch 66 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch 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 22 Genie Z 45 25 amp Genie Z 45 25J Test the Lift Drive Select Function CE models Machines with lift drive select switch 67 Move the lift drive select switch to the lift position 68 Press down the foot switch 69 Move the drive control handle off center Result No drive functions should operate 70 Activate each boom function toggle switch Result All boom functions should operate 71 Move the lift drive select switch to the drive position 72 Press down the foot switch 73 Activate each boom function toggle switch Result No boom functions should operate 74 Move the drive control handle off center Result The drive functions should operate 75 Repair any malfunctions before operating the machine Machines without lift drive select switch 76 Press down the foot switch 77 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 78 Repair any malfunctions before operating the mach
32. rgency Stop button and restart 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 button to the off position 20 Pull out the red Emergency Stop button to the on position but do not start the engine 21 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 22 Do not press down the foot switch and restart the engine Result The engine should start 23 Move the lift drive select switch to the lift position if equipped 24 Do not press down the foot switch and test each machine function Result The machine functions should not operate 18 Genie Z 45 25 amp Genie Z 45 25J Test Machine Functions 25 Press down the foot switch 26 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch Test the Steering 27 Move the lift drive select switch to the drive position if equipped 28 Press down the foot switch 29 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
33. rough a full cycle The descent alarm if equipped should sound while the boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch Part No 52421 FUNCTION TESTS Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform control 10 Open the engine side turntable cover and locate the tilt sensor to the right of the 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 shut the engine off 13 Pull out the red Emergency Stop button to the on position 14 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 Genie Z 45 25 amp Genie Z 45 25J 17 Operators Manual First Edition Seventh Printing FUNCTION TESTS At the Platform Controls Test Emergency Stop 15 Turn the key switch to platform control and restart the engine 16 Push in the platform red Emergency Stop button to the off position Result The engine will shut off after 2 or 3 seconds 17 Pull out the red Eme
34. s it was intended Fundamentals It is the responsibility of the operator to perform a Pre operation Inspection and routine maintenance The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any 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 10 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing 5 Pre operation Inspection Hd B
35. s on the drive chassis for anchoring down to the transport surface Use the rotator guard under the platform to secure the boom from side to side movement Do not use excessive downward force when securing the boom section Use chains or straps of ample load capacity Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Part No 52421 Transport 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 Position Engage Position Genie Z 45 25 amp Genie Z 45 25J 29 Operators Manual First Edition Seventh Printing Decals Decal Inspection Use the pictures on this and the next page to verify that all decals are legible and in place Below is a numerical list with guanti
36. 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 30 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 Part No 52421 First Edition Seventh Printing Operators Manual Test Drive and Braking 31 Press down the foot switch 32 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 33 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 Part No 52421 FUNCTION TESTS Test the Drive Enable System 34 Mov
37. switch to the drive position if equipped 44 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 45 Move the lift drive select switch to the lift position if equipped 46 Lower the primary boom to the stowed position 47 Raise the secondary boom approximately 2 feet 61 cm 48 Move the lift drive select switch to the drive position if equipped 49 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 20 Genie Z 45 25 amp Genie Z 45 25J 50 Move the lift drive select switch to the lift position if equipped 51 Lower the secondary boom to the stowed position 52 Extend the primary boom approximately 1 foot 30 cm 53 Move the lift drive select switch to the drive position if equipped 54 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 55 Move the lift drive select switch to the lift position if equipped 56 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 ta
38. ties and descriptions Part No Decal Description 25994 Caution Component Damage Hazard 27204 Arrow Blue 27205 Arrow Yellow 27206 Triangle Blue 27207 Triangle Yellow 27564 Danger Electrocution Hazard 28157 Label Dexron 28158 Label Unleaded 28159 Label Diesel 28160 Label Liquid Petroleum Gas 28161 Warning Crushing Hazard 28163 Notice Max Side Force 150 lbs 667N 28164 Notice Hazardous Materials 28165 Notice Foot Switch 28171 Label No Smoking 28174 Label Power to Platform 230V 28175 Caution Compartment Access 28176 Notice Missing Manuals 28177 Warning Platform Rotate 28181 Warning No Step or Ride 28235 Label Power to Platform 115V 28236 Warning Failure To Read 30080 Notice Maximum Load 31060 Danger Tip over Hazard Interlock 32700 Danger Safety Rules 32728 Generator option 30 Genie Z 45 25 amp Genie Z 45 25J Quantity 1 1 DIN N Part No 33550 33952 40434 43595 43663 43647 44769 44981 44986 49741 52230 52447 52511 52607 52672 52784 52968 62926 62927 62947 62948 65301 72441 72442 82238 82283 Decal Description Safety Tape Danger Tilt Alarm Label Lanyard Anchorage Point Danger Tip over Hazard Tires Notice Function Enable Notice Operating Instructions Lift Drive Select option Airline to Platform Notice Max Manual Force 90 lbs 400N Notice Ford Engine Spec LRG 425 EFI Platform Control Panel
39. u 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 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 Using the machine for anything other than lifting personnel and tools 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 24 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Besure both ground and platform control red Emergency Stop buttons are pulled out to the on position 3 G
40. ual First Edition Seventh Printing OPERATING INSTRUCTIONS 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 Stopping the Engine Push in the red Emergency Stop button and turn the key switch to the off position 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 28 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual Transport Instructions Observe and Obey MI The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand machine weight See the serial plate for the machine weight M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Use the tie point
41. up down switch Diesel models Glow plug switch option Primary boom extend retract switch ie nete ERAEN CN Gasoline LPG models Fuel select switch 14 Engine start switch Auxiliary power switch 15 15A breaker for engine electrical circuits Key switch for platform off ground selection 16 Secondary boom up down switch Red Emergency Stop button 17 15A breaker for control electrical circuits O DOAN OO OO fF W ND Gasoline LPG models Check engine light 18 Z 45 25J models only Jib boom up down switch Diesel models Oil pressure light 19 Platform level switch 10 Hour meter Part No 52421 Genie Z 45 25 amp Genie Z 45 25J 7 Operators Manual First Edition Seventh Printing CONTROLS HORN PLATFORM LEVEL PLATFORM ROTATE JIB BOOM ME DRIVE SPEED P k r s BOOM ej d EXTEND TURNTABLE TURNTABLE ROTATE ROTATE SECONDARY z BOOM M DOWN Platform Control Panel 6 Drive speed select switch 1 Horn button 7 Glow plug switch Platform level switch 8 Engine start switch Platform rotate switch 9 Engine idle rom select switch Z 45 25J models only Jib boom up down switch 10 Gasoline LPG models Gasoline LPG select switch an A O ND Auxiliary power switch 8 Genie Z 45 25 amp Genie Z 45 25J Part No 52421 First Edition Seventh Printing Operators Manual CONTROLS GLOW PLUG ENGINE START ENGINE RPM FUEL SELECT STOP DRIVE ENABLE OPERATION ote on a that boom has moved past a non steer tire and a drive
42. y Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M 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 M 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 M You are properly trained to safely operate the machine Part No 52421 Genie Z 45 25 amp Genie Z 45 25J 1 Operators 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 N O b 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 7 750
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