Operator’s Manual Z-45 25 Z-45 25J ANSI/CSA North America South America Asia IC Power AUS Australia with Maintenance Information Fourth Edition First Printing Part No.
Operator's Manual Fourth Edition • First Printing Important Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries. Contents Page Introduction ................................................................
Fourth Edition · First Printing Operator's Manual Introduction Owners, Users and Operators: Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: 1 Comply with employer, job site and governmental rules. 2 Read, understand and follow the instructions in this and other manuals supplied with this machine.
Operator's Manual Fourth Edition · First Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words to identify the following: This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site. Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Fourth Edition · First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Crush Hazard Burn Hazard Fire Hazard Explosion Hazard Electrocution Hazard Fall Hazard Crush Hazard Tip-over Hazard Tip-over Hazard Electrocution Hazard Keep off this surface. Keep away from moving parts. Maintain required clearance. Keep away from path of moving platform. Only trained maintenance personnel should access compartments. Recovery procedure if tilt alarm sounds while elevated.
Operator's Manual Fourth Edition · First Printing Symbol and Hazard Pictorials Definitions 4 Lanyard attachment point Wheel load Tie-down instructions Tie-down instructions Voltage rating for power to platform Z-45/25 • Z-45/25J Pressure rating for air line to platform Replace tires with tires of same specification. Part No.
Fourth Edition · First Printing Operator's Manual General Safety Safety signs and locations Part No.
Operator's Manual Fourth Edition · First Printing General Safety Safety signs and locations 6 Z-45/25 • Z-45/25J Part No.
Fourth Edition · First Printing Operator's Manual General Safety Safety signs and locations Part No.
Operator's Manual Fourth Edition · First Printing General Safety Safety signs and locations 8 Z-45/25 • Z-45/25J Part No.
Fourth Edition · First Printing Operator's Manual General Safety Safety signs and locations Part No.
Operator's Manual Fourth Edition · First Printing General Safety Safety signs and locations 10 Z-45/25 • Z-45/25J Part No.
Fourth Edition · First Printing Operator's Manual Personal Safety Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.
Operator's Manual Fourth Edition · First Printing Work Area Safety Do not use the machine as a ground for welding. Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Do not operate the machine during lightning or storms. Tip-over Hazards Occupants, equipment and materials shall not exceed the maximum platform capacity.
Fourth Edition · First Printing Operator's Manual Work Area Safety Do not raise or extend the boom unless the machine is on a firm, level surface. Do not raise the boom when wind speeds may exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine. Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load.
Operator's Manual Fourth Edition · First Printing Work Area Safety Do not push the machine or other objects with the boom. Do not contact adjacent structures with the boom. Do not tie the boom or platform to adjacent structures. Do not place loads outside the platform perimeter. Do not push off or pull toward any object outside of the platform. Maximum allowable side force - ANSI & CSA 150 lbs / 667 N Do not alter or disable machine components that in any way affect safety and stability.
Fourth Edition · First Printing Operator's Manual Work Area Safety Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform. Do not use the machine on a moving or mobile surface or vehicle. Be sure all tires are in good condition, air-filled tires are properly inflated and lug nuts are properly tightened.
Operator's Manual Fourth Edition · First Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times. Be aware of limited sight distance and blind spots when driving or operating.
Fourth Edition · First Printing Operator's Manual Work Area Safety Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision. No stunt driving or horseplay while operating a machine. Do not lower the boom unless the area below is clear of personnel and obstructions.
Operator's Manual Fourth Edition · First Printing Work Area Safety Battery Safety Burn Hazards Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water. Explosion Hazard Keep sparks, flames and lighted tobacco away from batteries. Batteries emit explosive gas. Electrocution Hazard Avoid contact with electrical terminals.
Fourth Edition · First Printing Operator's Manual Legend 1 Foot switch 8 Primary boom 2 Manual storage container 9 Secondary boom 3 Sliding mid-rail 10 Ground controls 4 Lanyard anchorage point 11 Steer tire 5 Jib boom (Z-45/25J and Z-51/30) 12 LPG tank (if equipped) 6 Platform 13 Non-steer tire 7 Platform controls Part No.
Operator's Manual Fourth Edition · First Printing Controls 1 2 3 4 19 20 5 18 17 Platform Control Panel 6 Drive speed select switch 1 Horn button 7 Diesel models: Glow plug switch 2 Platform level switch 8 Engine start switch 3 Platform rotate switch 9 Engine idle (rpm) select switch 4 Z-45/25J: Jib boom up/down switch 10 Gasoline/LPG models: Gasoline/LPG select switch 5 Auxiliary power switch 20 Z-45/25 • Z-45/25J Part No.
Fourth Edition · First Printing Operator's Manual Controls 7 16 8 15 9 14 10 13 11 12 11 Red Emergency Stop button 16 Drive enable switch 12 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 17 Proportional control handle for secondary boom up/down function 19 Used for optional equipment 13 Not used 14 Machine not level indicator light (if equipped) 15 Drive enable indicator light Part N
Operator's Manual Fourth Edition · First Printing Controls 6 Drive speed select switch Platform Control Panel 1 Horn button Push the horn button and the horn will sound. Release the horn button and the horn will stop. 2 Platform level switch 7 Glow plug switch Move the platform level switch up and the level of the platform will raise. Move the platform level switch down and the level of the platform will lower. Move the glow plug switch to either side and hold for 3 to 5 seconds.
Fourth Edition · First Printing Operator's Manual Controls 12 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward. Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards.
Operator's Manual Fourth Edition · First Printing Controls Ground Control Panel 1 Platform level switch 11 Key switch for platform/off/ground selection 2 Platform rotate switch 12 Red Emergency Stop button 3 Z-45/25J: Jib boom up/down switch 13 Hour meter 4 Turntable rotate switch 14 Diesel models: Water temperature light 5 Primary boom up/down switch 15 Diesel models: Glow plug switch (if equipped) 6 Primary boom extend/retract switch 16 Function enable switch 7 Gasoline/LPG models: Fuel sel
Fourth Edition · First Printing Operator's Manual Controls Ground Control Panel 1 Platform level switch Move the platform level switch up and the level of the platform will raise. Move the platform level switch down and the level of the platform will lower. 2 Platform rotate switch Move the platform rotate switch to the right and the platform will rotate to the right. Move the platform rotate switch to the left and the platform will rotate to the left.
Operator's Manual Fourth Edition · First Printing Controls 11 Key switch for platform/off/ground selection Turn the key switch to the platform position and the platform controls will operate. Turn the key switch to the off position and the machine will be off. Turn the key switch to the ground position and the the ground controls will operate. 12 Red Emergency Stop button Push in red Emergency Stop button to the off position to stop all functions and turn the engine off.
Fourth Edition · First Printing Operator's Manual Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operation inspection before going on to the next section.
Operator's Manual Fourth Edition · First Printing Inspections Pre-operation Inspection ! Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform. ! Be sure that all decals are legible and in place. See Decals section. ! Check for engine oil leaks and proper oil level. Add oil if needed. See Maintenance section. ! Check for hydraulic oil leaks and proper oil level. Add oil if needed. See Maintenance section.
Fourth Edition · First Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. A malfunctioning machine must never be used.
Operator's Manual Fourth Edition · First Printing Inspections 1 Select a test area that is firm, level and free of obstruction. At the Ground Controls 2 Turn the key switch to ground control. 3 Pull out the red Emergency Stop button to the on position. Result: The beacon (if equipped) should flash. 4 Start the engine. See Operating Instructions section. Test the Tilt Sensor 9 Turn the key switch to platform control. Pull out the platform red Emergency Stop button to the on position.
Fourth Edition · First Printing Operator's Manual Inspections At the Platform Controls Test Machine Functions Test Emergency Stop 24 Press down the foot switch. 15 Turn the key switch to platform control and restart the engine. 25 Activate each machine function control handle or toggle switch. 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 Emergency Stop button and restart the engine.
Operator's Manual Fourth Edition · First Printing Inspections 34 Move the drive control handle off center. Test Drive and Braking Result: The drive function should not operate. 29 Press down the foot switch. 30 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.
Fourth Edition · First Printing Operator's Manual Inspections Test Limited Drive Speed - Narrow Base Models Test Limited Drive Speed - Standard Base Models 36 Press down the foot switch. 36 Press down the foot switch. 37 Raise the primary boom approximately 2 feet / 61 cm. 37 Raise the primary boom approximately 2 feet / 61 cm. 38 Slowly move the drive control handle to the full drive position.
Operator's Manual Fourth Edition · First Printing Inspections Test the Oscillate Axle (oscillating axle-equipped models) Test the Lift/Drive Select Function (if equipped) 46 Start the engine from the platform controls. 54 Press down the foot switch. 47 Drive the right steer tire up onto a 6 inch / 15 cm block or curb. 55 Move the drive control handle off center and activate a boom function toggle switch. Result: The three remaining tires should stay in firm contact with the ground.
Fourth Edition · First Printing Operator's Manual Inspections Workplace Inspection Be aware of and avoid the following hazardous situations: Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual.
Operator's Manual Fourth Edition · First Printing Inspections Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Decal Description Part No.
Fourth Edition · First Printing Operator's Manual Inspections Ground Controls Side Drive Chassis Platform Engine Side Shading indicates decal is hidden from view, i.e. under covers Part No.
Operator's Manual Fourth Edition · First Printing Inspections Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No. Decal Description 27204 Arrow - Blue 27205 Quantity Part No.
Fourth Edition · First Printing Operator's Manual Inspections Ground Controls Side Drive Chassis Platform Engine Side Shading indicates decal is hidden from view, i.e. under covers Part No.
Operator's Manual Fourth Edition · First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations.
Fourth Edition · First Printing Operator's Manual Operating Instructions Starting the Engine 1 At the ground controls, turn the key switch to the desired position. 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position. Gasoline/LPG models 3 Choose fuel by moving the fuel select switch to the desired position. 4 Move the engine start toggle switch to either side.
Operator's Manual Fourth Edition · First Printing Operating Instructions Operation from Ground To Position Platform 1 Turn the key switch to ground control. 1 Press down the foot switch. 2 Pull out the red Emergency Stop button to the on position. 2 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel. 3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position. To Steer 4 Start the engine.
Fourth Edition · First Printing Operator's Manual Operating Instructions Driving on a slope Lay the piece of wood on the slope. Determine the uphill, downhill and side slope ratings for the machine and determine the slope grade. At the downhill end, lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level.
Operator's Manual Fourth Edition · First Printing Operating Instructions Drive Enable Generator (if equipped) Light on indicates that the boom has moved just past either non-steer wheel and the drive function has been interrupted. To start the generator, move the generator toggle switch to the on position. To drive, hold the drive enable switch to either side and slowly move the drive control handle off center.
Fourth Edition · First Printing Operator's Manual 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. Aircraft Protection Package (if equipped) If the platform bumpers come in contact with aircraft components, the machine will shut down and no functions will operate. Move the function override toggle switch to either side to operate the machine.
Operator's Manual Fourth Edition · First Printing Transport and Lifting Instructions Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating. See Driving on a Slope in the Operating Instructions section. Observe and Obey: Genie Industries provides this securement information as a recommendation.
Fourth Edition · First Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Transit Securing the Platform - Z-45/25 Always use the turntable rotation lock pin each time the machine is transported. Secure the platform with a nylon strap placed over the platform mount near the platform rotator (see below). Do not use excessive downward force when securing the boom section. Make sure the platform is in the stowed position.
Operator's Manual Fourth Edition · First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Only qualified riggers should rig and lift the machine. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight.
Fourth Edition · First Printing Operator's Manual Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level can damage engine components. Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator.
Operator's Manual Fourth Edition · First Printing Maintenance Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems. 1 Be sure that the boom is in the stowed position, then visually inspect the sight gauge located on the side of the hydraulic oil tank.
Fourth Edition · First Printing Operator's Manual Maintenance Check the Tire Pressure Check the Batteries Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocution hazard. Contact with hot or live circuits may result in death or serious injury. Remove all rings, watches and other jewelry. Bodily injury hazard. Batteries contain acid.
Operator's Manual Fourth Edition · First Printing Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service. 52 Z-45/25 • Z-45/25J Part No.
Fourth Edition · First Printing Operator's Manual Specifications Standard Base Models Z-45/25 (no jib) Height, working maximum 51 ft 11 in 16 m Height, platform maximum 45 ft 11 in 14 m Height, stowed maximum 6 ft 11 in 2.11 m 125 Horizontal reach maximum Width Length, stowed Maximum load capacity ft 17.62 m 7 ft 6 in 2.29 m 18 ft 3 in 5.56 m 500 lbs 227 kg Maximum load capacity Models with Aircraft Protection Package 440 lbs 200 kg Maximum wind speed 28 mph 12.
Operator's Manual Fourth Edition · First Printing Specifications Standard Base Models Z-45/25J (jib) Height, working maximum 52 ft 2 in 16.07 m Height, platform maximum 46 ft 2 in 14.07 m Height, stowed maximum 6 ft 11 in 2.1 m Horizontal reach maximum 25 ft 1 in 7.6 m 7 ft 6 in 2.29 m 22 ft 5 in 6.83 m 500 lbs 227 kg Width Length, stowed Maximum load capacity Maximum load capacity Models with Aircraft Protection Package 440 lbs 200 kg Maximum wind speed 28 mph 12.
Fourth Edition · First Printing Operator's Manual Specifications Narrow Base Models Z-45/25 (no jib) Height, working maximum 51 ft 6 in 15.9 m Height, platform maximum 45 ft 6 in 13.9 m 6 ft 7 in 2.05 m Height, stowed maximum 125 Horizontal reach maximum Width ft 17.62 m standard Hydraulic pressure, maximum 3200 psi (boom functions) 221 bar System voltage 12V Tire size, 2WD Industrial Foam-filled only 9-14.5 LT 5 ft 10.3 in 1.
Operator's Manual Fourth Edition · First Printing Specifications Narrow Base Models Z-45/25J (jib) Height, working maximum 51 ft 9 in 15.9 m Height, platform maximum 45 ft 9 in 13.9 m Height, stowed maximum 6 ft 7 in 2.0 m 25 ft 1 in 7.7 m 5 ft 10.3 in 1.79 m 22 ft 5 in 6.8 m 500 lbs 227 kg Horizontal reach maximum Width Length, stowed Maximum load capacity Maximum load capacity Models with Aircraft Protection Package 440 lbs 200 kg Maximum wind speed 28 mph 12.
Fourth Edition · First Printing Operator's Manual Specifications Z-45/25J Range of Motion Part No.
