Operator`s Manual - Genie Industries
Contents
1. weighted Ground clearance center 15 5 in 39 4 cm Ground clearance minimum 11 5 in 29 2 cm Controls 12V DC proportional Weight See Serial Label 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 160 degrees AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions System voltage 12V Tire size 4WD amp 2WD RT 355 55 D625 Tire size High Flotation 33 16LL 500 10 ply Maximum slope rating stowed position 2WD Counterweight uphill 30 17 Counterweight downhill 25 14 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 25 14 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Fuel tank capacity 17 gallons 64 4 liters Floor loading information Tire load maximum 8800 lbs 3992 kg Tire contact pressure 50 psi 3 51 kg cm2 345 kPa Occupied floor pressure 2WD 196 psf 957 kg m2 9 38 kPa Occupied floor pressure 4WD 198 psf 967 kg m2 9 48 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specific2. 9 in 4 5 m Turning radius inside 5 ft 6 in 1 7 m Turntable rotation 355 Turntable tailswing 0 in 0 cm Drive speed stowed 5 mph 8 0 km h 40 ft 5 5 sec 12 2 m 5 5 sec Drive speed 0 6 mph 1 km h booms raised 40 ft 45 sec 12 2 m 45 sec Airborne noise emissions 73 dB Maximum sound level at normal operating workstations A weighted Ground clearance center 15 5 in 39 4 cm Ground clearance minimum 11 5 in 29 2 cm Controls 12V DC proportional Weight See Serial Label 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 amp 2WD RT 355 55 D625 Tire size High Flotation 33 16LL 500 10 ply Maximum slope rating stowed position 2WD Counterweight uphill 30 17 Counterweight downhill 25 14 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 25 14 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Fuel tank capacity 17 gallons 64 4 liters Floor loading information Tire load maximum 8000 lbs 3629 kg Tire contact pressure 50 psi 3 51 kg cm2 345 kPa Occupied
3. 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 Do not press down the foot switch and test each machine function Result The machine functions should not operate Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 21 Test Drive and Braking 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 Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 31 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
4. Inspection 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 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as 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 If damage or any unauthorized 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 mainte
5. 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 See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the machine There are four lifting points on the chassis Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis Y Axis Z 45 25 47 in 42 in 1 19 m 1 06 m Z 45 25J 49 in 44 5 in 1 24 m 1 13 m TRANSPORT AND LIFTING INSTRUCTIONS X Axis Y Axis Operator s Manual Third Edition Second Printing 34 Z 45 25 Z 45 25J Part No 110015 Decals Part No Decal Description Quantity 25994 Caution Component Damage Hazard 1 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 28164 Notice Hazardous Materials 1 28165 Notice Foot Switch 1 28171 Label No Smoking 1 28174 Label Power to Platform 230V 2 28175 Caution Comp
6. floor pressure 2WD 187 psf 913 kg m2 8 95 kPa Occupied floor pressure 4WD 190 psf 928 kg m2 9 10 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors 1 Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 39 SPECIFICATIONS Operator s Manual Third Edition Second Printing 40 Z 45 25 Z 45 25J Part No 110015 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 Width 7 ft 6 in 2 29 m Length stowed 22 ft 5 in 6 83 m Maximum load capacity 500 lbs 227 kg Maximum wind speed 28 mph 12 5 m s Wheelbase 6 ft 8 in 2 0 m Turning radius outside 14 ft 9 in 4 5 m Turning radius inside 5 ft 6 in 1 7 m Turntable rotation 355 Turntable tailswing 0 in 0 cm Drive speed stowed 5 mph 8 0 km h 40 ft 5 5 sec 12 2 m 5 5 sec Drive speed 0 6 mph 1 km h booms raised 40 ft 45 sec 12 2 m 45 sec Airborne noise emissions 73 dB Maximum sound level at normal operating workstations A
7. loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation SPECIFICATIONS Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 45 SPECIFICATIONS Distributed By California Proposition 65 WARNING 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 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica 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
8. of wood 144 inches 3 6 m Run 144 inches 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 3 grade 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting section run rise Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 29 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 drive 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 Drive Speed Select Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Engine Idle Select rpm When the foot switch is not pressed the engine will idle at the lowest rpm Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle Generator if equipped To start the generator move the generator toggle switch to the on position Plug a pow
9. put back into service Operator s Manual Third Edition Second Printing 18 Z 45 25 Z 45 25J Part No 110015 Function Tests 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 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 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 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 19 FUNCTION TESTS Test the Tilt Sensor 9 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 10 Open the engine side turntable cover and locate t
10. the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the booms are raised OPERATING INSTRUCTIONS Operator s Manual Third Edition Second Printing 28 Z 45 25 Z 45 25J Part No 110015 OPERATING INSTRUCTIONS Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating counterweight uphill gradeability 2WD 30 17 4WD 45 24 Maximum slope rating counterweight downhill 25 14 Maximum side slope rating 25 14 Note Slope rating is subject to ground conditions and adequate traction Be sure the boom is below horizontal and the platform is between the non steer wheels Move the drive speed select switch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope 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 While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example Piece
11. the machine on any slope it is able to climb Test the Drive Enable System 32 Press down the foot switch and lower the boom to the stowed position 33 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 34 Move the drive control handle off center Result The drive function should not operate 35 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 to identify the direction of travel FUNCTION TESTS Blue Yellow Operator s Manual Third Edition Second Printing 22 Z 45 25 Z 45 25J Part No 110015 FUNCTION TESTS Test Limited Drive Speed Standard Base Models 36 Press down the foot switch 37 Raise the primary boom approximately 2 feet 61 cm 38 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 39 Lower the primary boom to the stowed position 40 Raise the secondary boom approxim
12. 00000 Notice Operating Instructions 2 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 35 DECALS Drive Chassis Platform Shading indicates decal is hidden from view i e under covers Ground Controls Side Engine Side Operator s Manual Third Edition Second Printing 36 Z 45 25 Z 45 25J Part No 110015 Decals 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 Quantity 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 28174 Label Power to Platform 230V 2 28235 Label Power to Platform 115V 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 62947 Cosmetic IC Power 4 x 2 1 62948 Cosmetic IC Power 4 x 4 1 72442 Ground Control
13. Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
14. Panel 1 82238 Platform Control Panel 1 Part No Decal Description Quantity 82472 Warning Crushing Hazard 3 82473 Caution Compartment Access 1 82487 Label Read the Manual 2 82544 Danger Electrocution Hazard 3 82545 Danger Maximum Load 227 kg 1 82548 Warning Platform Rotate 2 82587 Label Tire Pressure High Flotation Tires 4 82602 Danger Max Side Force 667 N 1 82604 Danger Max Manual Force 400 N 1 82633 Label Tire Pressure RT Tires 4 82646 Label Drive Enable Patch 1 97815 Label Lower Mid rail CE models 1 114023 Label Wheel Load Z 45 25 4 114024 Label Wheel Load Z 45 25J 4 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 37 DECALS Platform Shading indicates decal is hidden from view i e under covers Ground Controls Side Engine Side Drive Chassis Operator s Manual Third Edition Second Printing 38 Z 45 25 Z 45 25J Part No 110015 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 Horizontal reach maximum 125 ft 17 62 m Width 7 ft 6 in 2 29 m Length stowed 18 ft 3 in 5 56 m Maximum load capacity 500 lbs 227 kg Maximum wind speed 28 mph 12 5 m s Wheelbase 6 ft 8 in 2 0 m Turning radius outside 14 ft
15. Third Edition Second Printing Part No 110015 Operator s Manual with Maintenance Information Bi Energy Power IC Power Operator s Manual Third Edition Second Printing Z 45 25 Z 45 25J Part No 110015 Copyright 1998 by Genie Industries First Edition Seventh Printing May 2002 Second Edition Second Printing August 2004 Third Edition Second Printing October 2005 Genie and Z are registered trademarks of Genie Industries in the U S A and many other countries These machines comply with ANSI SIA 92 5 1992 Printed on recycled paper Printed in U S A Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety Rules 1 Legend 8 Controls 9 Pre operation Inspection 12 Maintenance 14 Function Tests 18 Workplace Inspe
16. aily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 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 Operator s Manual Third Edition Second Printing 16 Z 45 25 Z 45 25J Part No 110015 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 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 p
17. artment Access 1 28176 Notice Missing Manuals 1 28177 Warning Platform Rotate 2 28181 Warning No Step or Ride 1 28235 Label Power to Platform 115V 2 28236 Warning Failure To Read 1 30080 Notice Maximum Load 500 lbs 227 kg 1 31060 Danger Tip over Hazard Interlock 3 32728 Label Generator option 1 33952 Danger Tilt Alarm 1 40434 Label Lanyard Anchorage Point 3 Part No Decal Description Quantity 43595 Danger Tip over Hazard Tires 4 44981 Label Air Line to Platform 2 44986 Notice Max Manual Force 90 lbs 400N 1 52607 Label Test Switch 1 52672 Danger Tip over Hazard Tires 4 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 62948 Cosmetic IC Power 4 x 4 1 65301 Notice Foam Filled Tire Specs 4 72442 Ground Control Panel 1 72847 Notice Hi Flotation Tire Specs 4 82238 Platform Control Panel 1 82366 Label Chevron Rykon 1 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 97887 Notice Max Side Force 150 lbs 667N 1 97890 Danger Safety Rules 2 114023 Label Wheel Load Z 45 25 4 114024 Label Wheel Load Z 45 25J 4 10
18. ately 2 feet 61 cm 41 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 42 Lower the secondary boom to the stowed position 43 Extend the primary boom approximately 1 foot 30 cm 44 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 45 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 tag and remove the machine from service Test Limited Drive Speed Narrow Base Models 36 Press down the foot switch 37 Raise the primary boom approximately 2 feet 61 cm 38 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 6 in 15 cm per second 39 Lower the primary boom to the stowed position 40 Raise the secondary boom approximately 2 feet 61 cm 41 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 6 in 15 cm per second 42 Lower the secondary boom to the stowed position 43 Extend the prima
19. ations are subject to change without notice or obligation SPECIFICATIONS Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 41 SPECIFICATIONS Operator s Manual Third Edition Second Printing 42 Z 45 25 Z 45 25J Part No 110015 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 Height stowed maximum 6 ft 7 in 2 05 m Horizontal reach maximum 125 ft 17 62 m Width 5 ft 10 3 in 1 79 m Length stowed 18 ft 3 in 5 56 m Maximum load capacity 500 lbs 227 kg Maximum wind speed 28 mph 12 5 m s Wheelbase 6 ft 8 in 2 0 m Turning radius outside 14 ft 4 3 m Turning radius inside 6 ft 1 8 m Turntable rotation 355 Turntable tailswing 0 in 0 cm Drive speed stowed 5 mph 8 0 km h 40 ft 5 5 sec 12 2 m 5 5 sec Drive speed 0 4 mph 64 km h booms raised 40 ft 68 sec 12 2 m 68 sec Airborne noise emissions 73 dB Maximum sound level at normal operating workstations A weighted Ground clearance center 9 5 in 24 1 cm Ground clearance minimum 7 5 in 19 1 cm Controls 12V DC proportional Weight See Serial Label 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 sta
20. capacity 500 lbs 227 kg Maximum wind speed 28 mph 12 5 m s Wheelbase 6 ft 8 in 2 0 m Turning radius outside 14 ft 4 3 m Turning radius inside 6 ft 1 8 m Turntable rotation 355 Turntable tailswing 0 in 0 cm Drive speed stowed 5 mph 8 0 km h 40 ft 5 5 sec 12 2 m 5 5 sec Drive speed 0 4 mph 64 km h booms raised 40 ft 68 sec 12 2 m 68 sec Airborne noise emissions 73 dB Maximum sound level at normal operating workstations A weighted Ground clearance center 9 5 in 24 1 cm Ground clearance minimum 7 5 in 19 1 cm Controls 12V DC proportional Weight See Serial Label 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 160 degrees AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions System voltage 12V Tire size 2WD Industrial Foam filled only 9 14 5 LT Maximum slope rating stowed position Counterweight uphill 30 17 Counterweight downhill 25 14 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Fuel tank capacity 17 gallons 64 4 liters Floor loading information Tire load maximum 8800 lbs 3992 kg Tire contact pressure 100 psi 7 03 kg cm2 689 kPa Occupied floor pressure 328 psf 1601 kg m2 15 70 kPa Note Floor
21. ce 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 Add oil as needed Perkins 404C 22 Engine Oil type 15W 40 Oil type cold conditions 5W 40 Ford LRG 425 EFI Engine EPA Compliant Oil type 10W 40 Oil type cold conditions 5W 30 Deutz F3L 2011 Engine Oil type 15W 40 Oil type cold conditions 5W 30 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 15 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 Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge 2 Add oil as needed Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent 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 D
22. ction 24 Operating Instructions 25 Transport and Lifting Instructions 31 Decals 34 Specifications 38 Contact us Internet http www genielift com E mail techpub genieind com Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 1 Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals You read understand and obey employer s safety rules and worksite regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Operator s Manual Third Edition Second Pr
23. cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power Test the Lift Drive Select Function if equipped 54 Press down the foot switch 55 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 56 Repair any malfunctions before operating the machine FUNCTION TESTS Operator s Manual Third Edition Second Printing 24 Z 45 25 Z 45 25J Part No 110015 Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions 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 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next
24. er tool into the power to platform GFCI outlet To turn off the generator move the generator toggle switch to the off position Note Machine functions will not operate while the generator is running and the foot switch is not pressed down When the foot switch is pressed down the generator will turn off and the machine functions will operate Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Machine Not Level Indicator Light if equipped Light on indicates the machine is not level The tilt alarm will be sounding when this light is on Move the machine to a firm level surface OPERATING INSTRUCTIONS Operator s Manual Third Edition Second Printing 30 Z 45 25 Z 45 25J Part No 110015 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 Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and
25. 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 3 SAFETY RULES 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 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 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
26. he desired position 4 Start the engine 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 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 Press down the foot switch 2 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel To Steer 1 Press down the foot switch 2 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 triangles on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 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
27. he 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 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 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 opera
28. hey 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 Operator s Manual Third Edition Second Printing 26 Z 45 25 Z 45 25J Part No 110015 OPERATING INSTRUCTIONS In extreme cold conditions 0 F 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Gasoline LPG models In cold conditions 20 F 6 C and below the machine should be started on gasoline and warmed for 2 minutes then switched to LPG Warm engines can be started on 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 Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platf
29. ight in the platform and the surface area of the platform or the load Do not place or attach overhanging loads to any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Do not replace factory installed tires with tires of different specification or ply rating Z 45 25 and Z 45 25J Narrow Base Models Do not use air filled tires These machines are equipped with foam filled tires Wheel weight and proper counterweight configuration are critical to stability Do not 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 Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times Do not climb down from the platform when raised Keep the platform f
30. inting 2 Z 45 25 Z 45 25J Part No 110015 SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 1 50KV to 200KV 15 4 6 200KV to 350KV 20 6 1 350KV to 500KV 25 7 6 500KV to 750KV 35 10 7 750KV to 1000KV 45 13 7 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 Do not operate the machine during lightning or storms Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity Maximum platform capacity 500 lbs 227 kg Maximum occupants 2 The weight of options and accessories such as pipe cradles panel cradles and welders will reduce the rated platform capacity and must be factored into the total platform load See the decals on the options Do not raise or extend the boom unless the machine is on a
31. llow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information Operator s Manual Third Edition Second Printing 8 Z 45 25 Z 45 25J Part No 110015 Legend 1 Foot switch 2 Manual storage container 3 Sliding mid rail 4 Lanyard anchorage point 5 Jib boom Z 45 25J 6 Platform 7 Platform controls 8 Primary boom 9 Secondary boom 10 Ground controls 11 Steer tire 12 LPG tank if equipped 13 Non steer tire Z 45 25 Z 45 25J Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 9 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 light Diesel 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 circui
32. loor clear of debris Lower the platform entry mid rail or close the entry gate before operating Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 5 Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of the boom position when rotating the turntable Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Do not lower the boom unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision SAFETY RULES Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions 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 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 Explosion and Fire Hazards Do not start the engine if
33. 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 31 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 Transport Instructions Observe and Obey The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructi
34. nance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 13 PRE OPERATION INSPECTION 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 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 Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Engine and related components Limit switche
35. ndard Hydraulic pressure maximum 3200 psi 221 bar boom functions System voltage 12V Tire size 2WD Industrial Foam filled only 9 14 5 LT Maximum slope rating stowed position Counterweight uphill 30 17 Counterweight downhill 25 14 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Fuel tank capacity 17 gallons 64 4 liters Floor loading information Tire load maximum 8000 lbs 3629 kg Tire contact pressure 100 psi 7 03 kg cm2 689 kPa Occupied floor pressure 324 psf 1582 kg m2 15 51 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors 1 Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 43 SPECIFICATIONS Operator s Manual Third Edition Second Printing 44 Z 45 25 Z 45 25J Part No 110015 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 Horizontal reach maximum 25 ft 1 in 7 7 m Width 5 ft 10 3 in 1 79 m Length stowed 22 ft 5 in 6 8 m Maximum load
36. offs Do not alter or disable the limit switches Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position 2WD Counterweight uphill 30 17 Counterweight downhill 25 14 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 25 14 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Do not push off or pull toward any object outside of the platform Maximum allowable side force ANSI and CSA 150 lbs 667 N Maximum allowable manual force CE and Australia 90 lbs 400 N Do not alter or disable machine components that in any way affect safety and stability Operator s Manual Third Edition Second Printing 4 Z 45 25 Z 45 25J Part No 110015 SAFETY RULES Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the we
37. ons section If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described Disengage Position Engage Position Transport and Lifting Instructions Operator s Manual Third Edition Second Printing 32 Z 45 25 Z 45 25J Part No 110015 Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items 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 over the platform mount near the platform rotator see below Do not use excessive downward force when securing the boom section TRANSPORT AND LIFTING INSTRUCTIONS Securing the Platform Z 45 25J Make sure the jib and platform are in the stowed position 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 33 Observe and Obey
38. orm 4 Simultaneously hold auxiliary power switch on and activate the desired function The drive and steer functions will not operate with auxiliary power 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 If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds Diesel models 3 Move the glow plug switch to either side and hold for 3 to 5 seconds 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 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 the engine for 5 minutes before operating to prevent hydraulic system damage Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 27 Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to t
39. reventative sealant will help eliminate corrosion on the battery terminals and cables Check the Tire Pressure Tip over hazard An over inflated tire can explode which may compromise machine stability and cause the machine to tip over Tip over hazard The use of temporary flat tire repair products may lead to tire failure which could compromise machine stability and cause the machine to tip over Bodily injury hazard An over inflated tire can explode and may cause death or serious injury This procedure does not need to be performed on machines equipped with foam filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire specifications 2WD Models 4WD Models Narrow base models Foam filled Industrial tire Only Standard base models Industrial tire 100 psi Tire size 9 14 5 LT 6 9 bar Standard base models 50 psi 50 psi Rough terrain tire 3 5 bar 3 5 bar Tire size 355 55D625 14 ply MAINTENANCE Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 17 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
40. ry boom approximately 1 foot 30 cm 44 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 6 in 15 cm per second 45 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 6 in 15 cm cm per second immediately tag and remove the machine from service Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 23 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 in firm 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 in firm 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 firm contact with the ground Test Auxiliary Controls 50 Shut the engine off 51 Pull out the red Emergency Stop button to the on position 52 Press down the foot switch 53 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
41. s 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 critical components are present and all associated fasteners and pins are in place and properly tightened After you complete your inspection be sure that all compartment covers are in place and latched Operator s Manual Third Edition Second Printing 14 Z 45 25 Z 45 25J Part No 110015 Maintenance Observe and Obey Only routine maintenance items specified in this manual shall be performed by the operator 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 before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performan
42. 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 25 Operating Instructions 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 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 along with their tools and materials 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 t
43. te through a full cycle The descent alarm if equipped should sound while the boom is lowering Operator s Manual Third Edition Second Printing 20 Z 45 25 Z 45 25J Part No 110015 FUNCTION TESTS Test Machine Functions 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle Test the Steering 26 Press down the foot switch 27 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 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 28 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 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 Emergency Stop button and restart the engine Test the
44. ts 19 Secondary boom up down switch 20 15A breaker for control electrical circuits Operator s Manual Third Edition Second Printing 10 Z 45 25 Z 45 25J Part No 110015 1 3 6 Drive speed select switch 7 Diesel models Glow plug switch 8 Engine start switch 9 Engine idle rpm select switch 10 Gasoline LPG models Gasoline LPG select 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 17 18 20 19 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 11 CONTROLS 11 Red Emergency Stop button 12 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 13 Platform overload indicator light if equipped 14 Machine not level indicator light if equipped 15 Drive enable indicator light 11 7 8 9 10 12 16 15 16 Drive enable switch 17 Proportional control handle for secondary boom up down function 18 Primary boom extend retract switch 19 used for optional equipment 20 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions 13 14 Operator s Manual Third Edition Second Printing 12 Z 45 25 Z 45 25J Part No 110015 Pre operation
45. us injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation 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 Operator s Manual Third Edition Second Printing Part No 110015 Z 45 25 Z 45 25J 7 Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Ye
46. you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Do not spray ether into engines equipped with glow plugs Operator s Manual Third Edition Second Printing 6 Z 45 25 Z 45 25J Part No 110015 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 the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Improper contact with components under any cover will cause serio
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