Operator`s Manual
Contents
1. DECALS 28174 44981 27564 32700 or 28285 82366 52597 58045 72444 31060 52664 40434 62926 or Serial Plate 62927 52672 28177 82635 31784 28181 28161 72833 27907 283 2 52672 Ground Controls Side 29635 31784 31787 31786 Platform 97907 f 33952 44980 T 52597 or 43658 T i 82279 97204 X lt A 32700 52969 P l 28236 31508 Sait 28176 27206 CE T 30080 i ni 59787 Drive 44981 31786 Chassis 28163 or 31060 Shading indicates 44986 2 206 decal is hidden from 2 205 view2. oft LOH 0 oft 5ft 15 ft 25 ft Om 1 5m 4 6m 7 6 m Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 35 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 Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany 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 55 5666 5242 Fax 52 55 5666 3241 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 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 10 220 7911 Fax 31 10 220 6642
3. d F ie Operator s Manual Anr ae with Maintenance Information Part No 82596 Z 45 25 Z 45 25J Bi Energy Power Operator s Manual Second Edition Second Printing 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 SUE AIER E E E E TT 1 CONTOS eriein E E 8 Pre operation Inspection cccceceeeeeeeeeeeeeeeeseeeesees 11 Maintenance ecccseececeesecceeeeeeeeeceeeeeseaeeeseeeeeeueeenanes 13 FUNCUON CSS ananeng a 16 Workplace Inspection c ccceceeeeeseeeeeeeeeeeeeeeaeeeens 21 Operating Instructions cccccceeeeeeeeeeeeeeeeeeaeeeeeeeaes 22 Transport and Lifting Instructions ccceeeeeeeee 27 DOCA ee E 30 Specifications ssc secincssadeiviasvexededsececcsunedeae ieseercdneaaveacseds 34 Contact us Internet http www genielift com E mail techpub genieind com Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Copyright 1999 by Genie Industries First Edition Fifth Printing April 2002 Second Edition Second Printing August 2004 Genie and Z are registered trademarks of Genie Industries in the U S A and many other countries The
4. i e under covers 62068 281 59 SI Q D Q 28175 28171 Sy ee Ni r o G 40434 28164 at N JJ 27964 FF T NN i l 28162 ir 28161 ay 28177 Engine 72833 82635 82635 97602 Side 31784 28372 52672 31784 28161 52437 Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 31 Operator s Manual Second Edition e Second Printing ee Nl 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 Part No Decal Description Quantity 27204 Arrow Blue 1 72444 Ground Control Panel 1 27205 Arrow Yellow 1 82279 Platform Control Panel 1 27206 Triangle Blue 2 82472 Warning Crushing Hazard 3 27207 Triangle Yellow 2 82473 Caution Compartment Access 1 28159 Label Diesel 1 82481 Danger Battery Safety 2 28174 Label Power to Platform 230V 2 82487 Label Operating Instructions 2 28235 Label Power to Platform 115V 2 82544 Danger Electrocution Hazard 2 40434 Label Lanyard Anchorage 3 82545 Danger Max Capacity 227 kg 1 43658 Label Power to Charger 230V 1 82548 Warning Platform Rotate 2 44980 Label Power to Charger 115V 1 82602 Danger Max Manual Force 667N 1 44981 Label Air Line to Platform 2 82604 Danger Max Manual Force 400N 1 52969 Cosmetic Genie Boom 1 82634 Label Tire Pressure 4 62068 Cosmetic Bi Energy 1
5. 82635 Label Wheel Load 4 62926 Cosmetic Genie Z 45 25J 1 82647 Label Drive Enable Patch 1 62927 Cosmetic Genie Z 45 25 1 32 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Part No 82596 Second Edition e Second Printing Operator s Manual DECALS 44981 82544 82487 Ground aes Controls 28174 or SILE 28235 N 72444 62926 or Serial Plate 62927 82635 or 82634 82472 82635 82634 44980 27207 or 43658 82481 82647 82279 IN C j 27207 A oN 82487 A j N 52969 N 7 a 21206 X H Ea iem 82545 82481 i 27206 82602 or 27209 Shading indicates 62068 decal is hidden from view i e under covers 20159 Q Jo gt ff A ran i 40434
6. Z 45 25J Bi Energy Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position when rotating turntable Operators must comply with employer job site and governmental rules regarding the use of personal protective equipment Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guardrail Observe and use color coded direction arrows on the platform controls and drive chassis for drive and steer functions 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 Part No 82596 Second Edition e Second Printing Operator s Manual 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 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 When the engine Is running operate the machine in a well ventilated area to avoid carbon monoxide poisoning Improper contact with components under any cover will cause serious injury
7. level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark 14 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Charging the batteries with the engine does not fully charge the batteries Periodically use the AC battery charger to fully charge the batteries Perform this test after fully charging the batteries 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion Remove the battery vent caps 4 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps Part No 82596 Second Edition e Second Printing Operator s Manual MAINTENANCE Check the Tire Pressure Scheduled Maintenance The scheduled maintenance items must be completed by a person trained and qualified to perform maintenance on this machine according to Tip over hazard An ove
8. Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 7 Operator s Manual Second Edition Second Printing Controls Platform Control Panel 1 Hornbutton Auxiliary power switch Drive enable indicator light Drive enable switch Z 45 25J Bi Energy models Jib boom up down switch O A W PDP DRIVE ENABLE OPERATION Light on indicates that boom has moved past a non steer tire and drive function is turned off To drive hold drive enable switch to the side and slowly move drive control handle Machine may drive in opposite direction that the drive and steer controls are moved Use color coded direction arrows on this panel and drive chassis to identify the direction machine will travel 20 6 Platform rotate switch 7 Platform level switch 8 Optional equipment 9 Glow plug switch 10 Engine start switch 8 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Part No 82596 Second Edition e Second Printing Operator s Manual CONTROLS STOP G Q Coa HZS lt i CREEP 4 t lol Ll 11 Engine idle rpm select switch 15 Proportional control handle for drive function and Rabbit amp Foot Switch foot switch activated thumb rocker for steer function high idle e Tune lowide 16 Boom function speed controller Rabbit high idle and quickest battery 17 Primary boom extend retract switch charging 18 Primary boom up down switch 12 Platform overload indicator light
9. 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 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 Part No 82596 SAFETY RULES Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Do not spray ether into engines equipped with glow plugs 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 Bi Energy amp Z 45 25J Bi Energy Service Manual Be sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are comp
10. angles 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 the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the booms are raised Part No 82596 Second Edition e Second Printing Operator s 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 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 Engine Idle Select rpm Select the engine idle speed rpm using the symbols on the control panel Engine idle speed does not affect machine function speed y Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle and slow battery charging Rabbit symbol high idle an
11. boom and platform function toggle switch Result All boom and platform functions should operate through 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 82596 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 the tilt sensor to the right of the hydraulic pump 11 Press down one side of the tilt sensor and hold for 5 seconds Result The alarm located in the platform should sound Test Auxiliary Controls 12 Turn the key switch to ground control 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 f Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 17 Operator s Manual Second Edition Second Printing FUNCTION TESTS At the Platform Controls Test Emergency Stop 15 Push in the platform red Emergency Stop button to the off position 16 Activate each machi
12. buttons are pulled out to the on position 3 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 In cold conditions hold the glow plug switch to either side and then start the engine In extreme cold conditions 20 F 6 C and below hold the glow plug switch to either side for 10 seconds and then start the engine Warm the engine use low idle for 5 minutes to prevent hydraulic system damage Part No 82596 OPERATINGINSTRUCTIONS Emergency Stop Push in either the 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 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 platform 4 Simultaneously hold the auxiliary power switch on and activate the desired function The drive function will not operate wit
13. cond Printing L Limit switches alarms and horn Ll Nuts bolts and other fasteners Li Platform entry mid rail gate I Beacon and alarms if equipped Check entire machine for d Cracks in welds or structural components Li 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 I After you complete your inspection be sure that all compartment covers are in place and secured Part No 82596 Second Edition e Second Printing Operator s Manual 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 Part No 82596 Maintenance Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper h
14. d Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 105 pounds 47 6 kg Each battery box including batteries must weigh a minimum of 530 pounds 240 4 kg Lifting Hazard Use a forklift to remove or install the battery packs Part No 82596 Second Edition e Second Printing Operator s Manual a ee 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 ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A 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 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 Part No 82596
15. d quickest battery charging At high idle the engine supplies enough power for charging and for machine functions At low idle machine functions will use battery power Part No 82596 OPERATINGINSTRUCTIONS Machine Not Level Indicator Light if equipped A 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 aa Platform Overload Indicator Light if equipped A Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Controller Fault Indicator Light On If the controller fault indicator light is on push in the red Emergency Stop button wait a few seconds and pull out the red Emergency Stop button to reset the system If the light stays on tag and remove the machine from service Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 25 Operator s Manual Second Edition e Second Printing I OPERATINGINSTRUCTIONS Fall Protection After Each Use Personal fall protection equipment PFPE is 1 Select a safe parking location firm level required when operating this machine surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed All PFPE must comply with applicable position governmental regulations and must be inspected and used in accordance with the PFPE 3 Rotate the turntable so that the b
16. esult The drive function should not operate 44 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 Blue fT controls and the drive chassis to identify the q direction of travel Yellow 20 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Test Auxiliary Controls 45 Shut the engine off 46 Pull out the red Emergency Stop button to the on position 47 Press down the foot switch 48 Simultaneously hold 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 Test the Lift Drive Select Function if equipped 49 Press down the foot switch 50 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 Part No 82596 Second Edition e Second Printing Operator s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the followin
17. f C 9 82544 82472 ay 82473 Engine 82634 82635 82635 82634 82472 82548 Side Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 33 Operator s Manual Second Edition Second Printing Specifications Model Z 45 25 Bi Energy no jib Height working maximum 51 ft 5 in 15 7 m Height platform maximum 45 ft 5 in 13 8 m Height stowed maximum 6 ft 7 in 2 0m Horizontal reach maximum 124 ft 6 in 17 5 m Width 5 ft 9 in 1 8m Length stowed 18 ft 5 5m Maximum load capacity 500 Ibs 227 kg Wheelbase 6 ft 8 in 2 0m Turning radius inside 4 ft 6 in 1 3 m Turning radius outside 15 ft 4 6m Turntable rotation degrees 359 Turntable tailswing O in 0 cm Power source 8 Group 4H 6V 315AH Batteries with Kubota Z482 E engine Drive speed stowed 3 0 mph 4 8 km h 40 ft 9 sec 12 2 m 9 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 Weight See Serial Plate Machine weights vary with option configurations 72 in x 30 in 1 8 m x 76 cm Platform dimensions 6 foot length x width Platform leveling self leveling Platform rotation 160 Controls 24V DC proportional AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions 34 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy System voltage 48V Tire size 2WD Industrial 9 14 5 LT Gradeabilit
18. g Inspect the entire machine for loose or unsecured items Securing the Chassis Use the tie points on the drive chassis for anchoring down to the transport surface Use chains or straps of ample load capacity Use a minimum of 4 chains Adjust the rigging to prevent damage to the chains Truck bed NO X f 28 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 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 po l 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 Part No 82596 Second Edition e Second Printing Operator s Manual TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instructions Fully lower and retract the boom Fully lower the jib if equipped Remove all loose items from the machine Dete
19. g hazardous situations 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 3 Always perform function tests prior to use 4 Inspect the 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 lt 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 82596 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 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 21 Operator s Manual Second Edition Second Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this ope
20. h auxiliary power Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 23 Operator s Manual Second Edition e Second Printing OPERATINGINSTRUCTIONS Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 2 Move the appropriate toggle switch according to the markings on the control panel To Position Platform 1 Hold the function enable switch to either side The 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 24 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Operation from Platform 1 Turn the key switch to platform control 2 Pullout both ground and platform red Emergency Stop buttons to the on position 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 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 Press down the foot switch 2 Turn the steer wheels with the thumb rocker switch located on top of the drive control handle Use the color coded direction tri
21. if equipped Arep PER 19 Secondary boom up down switch 13 Machine not level indicator light if equipped oneeguipped 20 Turntable rotate left right switch 14 Red Emergency Stop button gene yop 21 Battery charge indicator Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 9 Operator s Manual Second Edition e Second Printing CONTROLS O 0O OF D O Q E nos TOFORO O ot OAO ORO Oa DL DO O STOP O i 00009 9 SO eQ a MeO 8 WY Ground Control Panel J Ooo A W N Platform rotate switch Turntable rotate switch Primary boom up down switch Primary boom extend retract switch Not used Engine idle rom select switch turtle low idle rabbit high idle and quickest battery charging 7 Auxiliary power switch 8 Key switch for platform off ground selection 9 Red Emergency Stop button 10 Platform overload indicator light if equipped 11 Hour meter 12 Glow plug switch 13 Function enable switch 14 Engine start switch 15 Secondary boom up down switch 16 10A breaker for control electrical circuits 17 Z 45 25J Bi energy models Jib boom up down switch 18 Platform level switch Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Part No 82596 Second Edition e Second Printing Operator s Manual Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contai
22. lete legible and in the storage container located on the platform Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 5 Operator s Manual Second Edition Second Printing SAFETY RULES 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 The battery pack must remain in an upright position Do not expose the batteries or the charger to water orrain Explosion Hazards Keep sparks flames and lighted tobacco away from batteries Batteries emit an explosive gas e N l The battery pack cover must remain off during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks 6 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Component Damage Hazards Do not use any battery charger greater than 48V to charge the batteries Both battery packs must be charged together Disconnect the battery pack plug before removing the battery pack Electrocution Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cord cables and wires Replace damaged items before operating ir Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Tip over Hazar
23. n Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 34 Lower the primary boom to the stowed position 35 Raise the secondary boom approximately 2 feet 61 cm 36 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 37 Lower the secondary boom to the stowed position 38 Extend the primary boom approximately 1 foot 30 cm 39 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 40 Retract the boom 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 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 19 Operator s Manual Second Edition Second Printing FUNCTION TESTS Test the Drive Enable System 41 Press down the foot switch and lower the boom to the stowed position 42 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 43 Move the drive control handle off center R
24. ne function control handle or toggle switch Result No functions should operate 17 Pull out the red Emergency Stop button to the on position 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 test each machine function Result The machine functions should not operate 18 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Test Machine Functions 23 Press down the foot switch 24 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle Note Control the speed of boom functions by adjusting the boom function speed controller Drive and steer functions are not affected by the boom function speed controller 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 25 Press down the foot switch 26 Depress the thumb rocker switch on top of the drive control handle in the direction iden
25. ned 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 lt 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 maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifica
26. ned 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 Part No 82596 Second Edition e Second Printing Operator s 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 The beacon if equipped should flash 4 Start the engine See Operating Instructions section Test Emergency Stop 5 Push inthe red Emergency Stop button to the off position Result The engine should turn off and all functions should not operate 6 Pull out the red Emergency Stop button to the on position Test the Machine Functions 7 Donothold 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
27. ng while the machine is being loaded M 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 Vl The machine must be on a level surface or secured before releasing the brakes M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Part No 82596 Free wheel Configuration for Winching 1 Chock the wheels to prevent the machine from rolling Disengage 2 Release the non Position steer wheel brakes by turning over the drive hub disconnect caps Engage Position 3 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions After the machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Apply the non steer wheel brakes by turning over the drive hub disconnect caps Towing a Genie Z 45 25 Bi Energy or a Z 45 25J Bi Energy machine is not recommended If the machine must be towed do not exceed 2 mph 3 2 km h Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 27 Operator s Manual Second Edition e Second Printing TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Turn the key switch to the off position and remove the key before transportin
28. o 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 Part No 82596 Second Edition e Second Printing Operator s 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 the 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 AN A K Di NJ 0 S Do not alter or disable machine components that in any way affect safety and stability Maximum allowable side force ANSI amp CSA 150 Ibs 667 N Maximum allowable side force CE 90 Ibs 400 N Do not replace items critical to machine stability with items of different weight or specification Part No 82596 SAFETY RULES 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
29. oom is between manufacturer s instructions the non steer wheels r 4 Turn the key switch to the off position and Charging the Batteries remove the key to secure from unauthorized Use the engine or the AC battery charger to Eee recharge the batteries 5 Chock the wheels Charging the Batteries with the Engine 6 Charge the batteries if necessary Running the engine will automatically charge the batteries At high idle the engine supplies enough power for charging and for machine functions At low idle machine functions will use battery power All lift and drive functions can be operated while the engine Is running The battery charge indicator will reset when the engine has been turned off for 2 3 minutes Charging the batteries with the engine does not fully charge the batteries Periodically use the AC battery charger to fully charge the batteries Charging the Batteries with the AC Charger Be sure the engine is not running Use the AC battery charger included with the machine for overnight charging The charger shuts off automatically Periodically use the AC battery charger to fully charge the batteries 26 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Part No 82596 Second Edition e Second Printing Operator s Manual Transport and Lifting Instructions Observe and Obey MI The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolli
30. or guard rail system can increase the weight in the platform and the surface area of the platform or the load e AY 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 Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 105 pounds 47 6 kg Each battery box including batteries must weigh a minimum of 530 pounds 240 4 kg Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 3 Operator s Manual Second Edition Second Printing SAFETY RULES 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 A i Keep the platform floor clear of debris hm aa Lower the platform entry mid rail or close the entry gate before operating 4 Genie Z 45 25 Bi Energy amp Genie
31. plicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase ApproachDistance 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 1357 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 Bi Energy amp Genie Z 45 25J Bi Energy Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity 500 Ibs Maximum platform capacity 227 kg Maximum occupants 2 Z 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 D
32. r Ride Label Power to Platform 115V Warning Failure To Read Caution Component Damage Hazard Notice Maximum Load 500 lbs 227 kg Danger Tip over Hazard Interlock Notice Power to Charger Label Tire Pressure Notice Connection Diagram Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Quantity NINI N Part No 31787 31788 32700 33952 40434 43658 44980 44981 44986 52437 92597 92664 52672 52787 52969 62068 62926 62927 12444 72833 82279 82366 82635 97602 Second Edition Second Printing Decal Description Quantity Danger Tip over Hazard 2 Danger Battery Safety 2 Danger General Safety 2 Danger Tilt Alarm 1 Label Lanyard Anchorage 3 Label Power to Charger 230V 1 Label Power to Charger 115V 1 Label Air Line to Platform 2 Notice Max Manual Force 90 Ibs 400N Notice Kubota Diesel Engine Spec Notice Operating Instructions Label Controller Status Indicator Light Danger Tip over Notice Charger Operating Instructions Cosmetic Genie Boom Cosmetic Bi Energy Cosmetic Genie Z 45 25J Cosmetic Genie Z 45 25 Ground Control Panel Label Open Platform Control Panel Label Chevron Rykon Label Wheel Load Warning Explosion Hazard Part No 82596 Second Edition e Second Printing a ee Operator s Manual
33. r inflated the procedures found in the service manual for this tire can explode which may machine compromise machine stability and cause the machine to tip over Machines that have been out of service for more l than three months must receive the quarterly Tip over hazard The use of inspection before placing the machine back into temporary flat tire repair products service may lead to tire failure which could compromise machine stability and cause the machine to tip over AWARNING 2 09 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 pressure 100 psi 6 9 bar Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 15 Operator s Manual Second Edition Second Printing E unction Tests 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 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 Bi Energy amp Genie Z 45 25J Bi Energy Fundamentals The function tests are desig
34. rator 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 lt 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 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 22 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Part No 82596 Second Edition e Second Printing Operator s Manual Introduction This machine can be operated with or without the engine running Starting the Engine 1 Atthe ground controls turn the key switch to the desired position 2 Besure both ground and platform control red Emergency Stop
35. rmine the center of gravity of your machine using the picture on this page Observe and Obey Attach the rigging only to the designated lifting MI Only qualified riggers should rig and lift the points on the machine There are four lifting points machine on the chassis M Be sure the crane capacity loading surfaces Adjust the rigging to prevent damage to the and straps or lines are sufficient to withstand machine and to keep the machine level the machine weight See the serial plate for the machine weight 41 in 1 04 m Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 29 Operator s Manual Decals 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 2 204 2 205 2 206 2 207 2 564 28159 28161 28162 28163 28164 28165 28171 28174 28175 28176 28177 28181 28235 28236 28372 30080 31060 31508 31784 31786 30 Decal Description Arrow Blue Arrow Yellow Triangle Blue Triangle Yellow Danger Electrocution Hazard Label Diesel Warning Crushing Hazard Warning Crushing Hazard Notice Max Side Force 150 lbs 667N Notice Hazardous Materials Notice Foot Switch Label No Smoking Label Power to Platform 230V Caution Compartment Access Notice Missing Manuals Warning Platform Rotate Warning No Step o
36. rotation degrees 359 Turntable tailswing O in 0 cm Power source 8 Group 4H 6V 315AH Batteries with Kubota Z482 E engine Drive speed stowed 3 0 mph 4 8 km h 40 ft 9 sec 12 2 m 9 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 Weight See Serial Plate Machine weights vary with option configurations 72 in x 30 in 1 8mx 76cm Platform dimensions 6 foot length x width Platform leveling self leveling Platform rotation 160 Controls 24V DC proportional AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions Part No 82596 SPECIFICATIONS System voltage 48V Tire size 2WD Industrial 9 14 5 LT Gradeability stowed 2WD 30 Ground clearance 7 in 17 8 cm minimum Fuel tank capacity 9 gallons 34 1 liters Floor Loading Information GVW Rated Load 17 100 Ibs 7756 kg Axle load maximum 12 700 lbs 5759 kg Wheel load maximum 7400 Ibs 3355 kg Localized pressure per tire 100 psi 7 03 kg cm 690 kPa Occupied pressure 323 psf 15 45 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors 50 ft 15 2m 40 ft 12 2 m 30 ft 9 1m io 20 ft 6 1m
37. se machines comply with ANSI SIA 92 5 1992 Printed on recycled paper Printed in U S A Part No 82596 Second Edition Second Printing Operator s Manual 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 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 apre 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 the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 1 Operator s Manual Second Edition e Second 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 Maintain safe distances from electrical power lines and apparatus in accordance with ap
38. tified by the blue triangle on the control panel Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 2 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Part No 82596 Second Edition e Second Printing Operator s Manual Test Drive and Braking 28 Press down the foot switch 29 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 30 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 82596 FUNCTION TESTS Test Limited Drive Speed 31 Press down the foot switch 32 Raise the primary boom approximately 2 feet 61 cm 33 Slowly move the drive control handle to the full drive positio
39. tions and the requirements listed in the responsibilities manual Part No 82596 Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 11 Operator s Manual a a E PRE OPERATION INSPECTION Pre operation Inspection LI LI Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper fluid level Add oil if needed See Maintenance section Check for engine coolant leaks and proper fluid level Add coolant if needed See Maintenance section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section 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 LI Electrical components wiring and electrical cables LI Hydraulic power unit hoses fittings cylinders and manifolds Generator belts and related components Fuel and hydraulic tanks Drive and turntable motors and torque hubs Boom wear pads Tires and wheels Coo ood oO Engine and related components Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy Second Edition e Se
40. y stowed 2WD 30 Ground clearance minimum 7 in 17 8 cm Fuel tank capacity 9 gallons 34 1 liters Floor Loading Information GVW Rated Load 16 200 Ibs 7348 kg Axle load maximum 12 300 Ibs 5577 kg Wheel load maximum 7400 Ibs 3355 kg Localized pressure per tire 100 psi 7 03 kg cm 690 kPa Occupied pressure 309 psf 14 80 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 50 ft 15 2 m n 40 ft 12 2 m 30 ft 9 1 m a 20 ft 6 1m 10 ft 3m Wo lo o ot OLEO 0 oft 5ft 15 ft 25 ft Om 1 5m 4 6m 7 6 m Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Part No 82596 Second Edition e Second Printing Operator s Manual Model Z 45 25J Bi Energy jib Height working maximum 51 ft 3 in 15 6 m Height platform maximum 45 ft 3 in 13 8 m Height stowed maximum 6 ft 7 in 2 0m Horizontal reach maximum 25 ft 3 in 7 7 m Width 5 ft 9 in 1 8m Length stowed 22 ft 3 in 6 8m Maximum load capacity 500 Ibs 227 kg Wheelbase 6 ft 8 in 2 0m Turning radius inside 4 ft 6 in 1 3 m Turning radius outside 15 ft 4 6m Turntable
41. ydraulic 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 the boom is in the stowed position then visually inspect the oil level in the hydraulic tank Result The hydraulic oil level should be within the FULL and ADD marks on the hydraulic tank Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Genie Z 45 25 Bi Energy amp Genie Z 45 25J Bi Energy 13 Operator s Manual Second Edition Second Printing 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 Check the oil level with the engine off 1 Check the oil level dipstick Add oil as needed Result The oil level should be at the FULL mark on the dipstick Kubota Engine Z482 E Oil viscosity requirements 10W 30 Engine oil should have properties of API classification CC SE CD SE CC SF or CD SF grades Units ship with 10W 40 SG CC Check the Engine Coolant Level 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
Download Pdf Manuals
Related Search