Operator`s Manual - Genie Industries
Contents
1. DECALS 59631 44981 38110 38112 27564 32700 or 72443 28174 230V 38111 28157 52947 31060 or 82279 or 28235 115V 52632 ss R 31060 2 05026 Z Serial Plate A iz py 28181 ZN 28161 No 52672 a 31784 Ground Controls Side 31508 haul 44980 31788 or 43658 52787 31787 5 Platform 33952 OO eae EEN 52946 27207 iia A 32700 27204 JL Lar 40434 52969 Ne 28236 27206 Y j l TI 28176 age i i d Bi i 30080 31787 28165 02 87 Drive 33550 adie Chassi 44981 31060 assis m 27206 27205 28163 or 62070 44986 9_ o Non 28175 8 28171 fe H Ground 28164 E i Controls 27564 d Side 28161 i wy Shading indicates decal is hidden from view i e under 31784 52672 52672 31784 28161 28177 covers PartNo 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC 25 Operator s Manual First Edition Fifth Printing Specifications Model Height working maximum Height platform maximum Height stowed maximum Horizontal reach maximum Width Length stowed Maximum load capacity 6 foot platform Wheelbase Turning radius outside Turning radius inside Turntable rotation degrees2. Genie Z 45 25 DC 8 Genie Z 45 25J DC 23 Operator s Manual First Edition Fifth Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions Part No Decal Description Quantity 27204 Arrow Blue 1 27205 Arrow Yellow 1 27206 Triangle Blue 2 27207 Triangle Yellow 2 27564 Danger Electrocution Hazard 2 28157 Label Dexron 1 28161 Warning Crushing Hazard 3 28163 Notice Max Side Force 150 lbs 667N 1 28164 Notice Hazardous Materials 1 28165 Notice Foot Switch 1 28171 Label No Smoking 1 28174 Label Power to Platform 230V 2 28175 Caution Compartment Access 1 28176 Notice Missing Manuals 1 28177 Warning Platform Rotate 2 28181 Warning No Step or Ride 1 28235 Label Power to Platform 115V 2 28236 Warning Failure To Read 1 30080 Notice Maximum Load 1 31060 Danger Tip over Hazard Interlock 3 31508 Notice Power to Charger 1 31784 Label Tire Pressure 4 31786 Notice Connection Diagram 2 31787 Danger Tip over Hazard 2 31788 Danger Battery Safety 2 32700 Danger Safety Rules 2 24 Genie Z 45 25 DC amp Genie Z 45 25J DC Part No 33550 33952 38110 38111 38112 40434 43658 43663 44980 44981 44986 52631 52632 52664 52672 52787 52946 52947 52969 62070 62926 62927 72443 72444 82279 Decal Description Safety Tape Danger
3. M 7 of p F Operators Manual with Maintenance Information Part No 52700 2 45 25 DC 2 45 25J DC Operators Manual First Edition Fifth Printing CEE CANE 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 EE LY EE AE E T T 1 CONTOS PA in E Syeustdudietelemoreineeeiacaenncinas 7 Pre operation Inspection esaae ozna ozna azasa ane 10 Maintenance esueeaa aaa aaa aaa a aaa aaa aaa zaw aaaazaaanai ia 12 FUNCION ICS Sza kc dni od AEG 14 Workplace Inspection s aaaaaa aaa aaasaaaeazacanai 19 Operating Instructions s aau ea a zana aa aaaaaacazianii 20 Transport Instructions aeeaae aaa zana aaa a aaaazacanai 23 BISZCZY 24 SDEGIICALUON S aaa iR O WE RZ O EE a 26 Contact US Copyright 1999 by Genie Industries First Edition Fifth Printing April 2002 Internet http www genielift com E mail techpub genieind com Genie and Z are registered trademarks of Genie Industries in the U S A and many other countries These machines comply with ANSI SIA 92 5 1992 2 Printed on recycled paper Printe
4. 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel and tools to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine 20 Genie Z 45 25 DC 8 Genie Z 45 25J DC 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 f
5. 3200 psi 221 bar 9 14 5 LT 30 7 in 17 8 cm 8 gallons 30 3 liters 1 Outreach specification with platform rotated 90 degrees 50 ft 50 ft 15 2m Ema 15 2 m 40 ft AO ft 12 2m 12 2m 30 ft 30 ft 9 1 m _ 9 1 m 20 ft 20 ft 6 1m 6 1m 10 ft 10 ft 3m oft LOH O sm oft O 40 Om Om oft 5ft 15 ft 25 ft O ft Om 1 5m 4 6m 7 6m Om 1 5 5 ft 5 m Continuous improvementofourproductsisaGenie policy Product specifications are subjecttochangewithoutnotice or obligation Part No 52700 Genie Scandinavia Phone 46 31575100 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 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 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 617 3375 1002 Genie China Phone 486 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie J apan Phone 81 3 3453 608
6. Turntable tailswing Power source Drive speed stowed Drive speed booms raised Z 45 25 DC Z 45 25J DC no jib jib 51 ft 5 in 51 ft 3 in 15 7 m 15 6 m 45 ft 5 in 45 ft 3 in 13 8 m 13 8 m 6 ft 7 in 6 ft 7 in 2 0m 2 0m 124 ft 6 in 25 ft3 in 17 5 m 7 7 m 5 ft 9 in 5 ft 9 in 1 8m 1 8m 18 ft 22 ft 3 in 5 5m 6 8 m 500 Ibs 500 Ibs 227 kg 227 kg 6 ft 8 in 6 ft 8 in 2 0m 2 0m Oft Oft Om Om 5 ft 5 ft 1 5m 1 5m 359 359 0 in O in 0 cm 0 cm 8 Group 4H 6V 315AH Batteries 3 0 mph 3 0 mph 4 8 km h 4 8 km h 40 f 9 sec 40 ft 9 sec 12 2 m 9 sec 12 2 m 9 sec 0 6 mph 0 6 mph 1 km h 1 km h 40 ft 45 sec 40 ft 45 sec 12 2 m 45 sec 12 2 m 45 sec Airborne noise emissions 73 dB 73 dB Maximum sound level at normal operating workstations A weighted Weight 26 See Serial Plate Machine weights vary with option configurations Genie Z 45 25 DC amp Genie Z 45 25J DC Model Z 45 25 DC no jib Platform dimensions 6 foot 72 in x 30 in length x width Platform leveling self leveling Platform rotation Controls AC outlet in platform standard Hydraulic pressure maximum 3200 psi boom functions 221 bar Tire size 2WD Industrial Gradeability stowed 2WD 30 Ground clearance 7 in minimum 17 8 cm Hydraulic tank capacity 8 gallons 30 3 liters Z 45 25J DC jib 72 in x 30 in 1 8mx 76cm 1 8mx 76cm self leveling 180 degrees 160 degrees 24V DC proportional standard
7. 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 DC 8 Genie Z 45 25J DC 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 Symbol Legend Indicates that a specific result is expected after performing a series of steps Part No 52700 First Edition Fifth Printing Operator s Manual 1 Select a test area that is firm level and free of obstruction At the Ground Controls 2 Turnthe key switch to ground control 3 Pull out the red Emergency Stop button to the on position Result The beacon if equipped should flash Test Emergency Stop 4 Push in the red Emergency Stop button to the off position Result All functions
8. Tilt Alarm Label Travel Alarm Warning Brake Release Caution Brake Release Label Lanyard Anchorage Label Power to Charger 230V Notice Function Enable Label Power to Charger 115V Label Airline to Platform Notice Max Manual Force 90 Ibs 400N Platform Control Panel Ground Control Panel Label Controller Status Indicator Light Danger Tip over Notice Charger Operating Instructions Notice Operating Instructions Platform Notice Operating Instructions Ground Cosmetic Genie Boom Cosmetic DC Power Cosmetic Genie Z 45 25J Cosmetic Genie Z 45 25 Platform Control Panel Ground Control Panel Platform Control Panel Quantity 1 1 Part No 52700 First Edition Fifth Printing Operator s Manual
9. 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 After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the non steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use 5 Chock the wheels 6 Charge the batteries if necessary 22 Genie Z 45 25 DC 8 Genie Z 45 25J DC Part No 52700 First Edition Fifth Printing Operator s Manual Transport Instructions Observe and Obey M The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight M 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 Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport U
10. maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 30 Lower the primary boom to the stowed position 31 Raise the secondary boom approximately 2 feet 61 cm PartNo 52700 FUNCTION TESTS 32 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 33 Lower the secondary boom to the stowed position 34 Extend the primary boom approximately 1 foot 30 cm 35 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 36 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 DC 8 Genie Z 45 25J DC 17 Operator s Manual First Edition Fifth Printing FUNCTIONTESTS Test the Drive Enable System 37 Press down the foot switch and lower the boom to the stowed position 38 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 39 Move the drive control handle off center
11. should not operate 5 Pull out the red Emergency Stop button to the on position Testthe Machine Functions 6 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 notoperate 7 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate 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 52700 FUNCTION TESTS Test the Tilt Sensor 8 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 9 Openthenon ground controls side turntable cover and locate the tilt sensor to the right of the hydraulic pump 10 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 11 Turn the key switch to ground control 12 Pull out the red Emergency Stop button to the on position 13 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Note To conserve battery pow
12. the direction identified 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 23 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The teer wheels should turn in the direction that the yellow triangles point on the drive chassis Part No 52700 First Edition Fifth Printing Operator s Manual Test Drive and Braking 24 Press down the foot switch 25 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 26 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 Test Limited Drive Speed 27 Press down the foot switch 28 Raise the primary boom approximately 2 feet 61 cm 29 Slowly move the drive control handle to the full drive position Result The
13. the platform or against any part of this machine A Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Operator s Manual First Edition Fifth 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 It is recommended that operators wear an approved hard hat when operating the machine Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times a Do not climb down from the platform when raised Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating 4 Genie Z 45 25 DC 8 Genie Z 45 25J DC Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position when rotating the turntable Check work area for overhead obstructions or other possible hazards A e A _ R p N Be aware of crushing hazard when grasping the platform guard rail Observe and use color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below Is clear of pers
14. 0V 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 2 Genie Z 45 25 DC 8 Genie Z 45 25J DC Tip over Hazards Occupants and equipment shall not exceed the maximum platform capacity 500 Ibs Maximum platform capacity 227 kg Maximum occupants 2 Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a firm level surface before raising the platform Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be remo
15. 2 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 5511 41 665 754 Genie Holland Phone 31 183 581 102 Fax 31183 581 566
16. Result The drive function should not operate 40 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 f controls and the drive chassis to identify the direction of 4 travel Yellow 18 Genie Z 45 25 DC amp Genie Z 45 25J DC Test Auxiliary Controls 41 Pull out the red Emergency Stop button to the on position 42 Press down the foot switch 43 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power Test the Lift Drive Select Function if equipped 44 Press down the foot switch 45 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 46 Repair any malfunctions before operating the machine Part No 52700 First Edition Fifth Printing Operator s Manual Workplace Inspection Workplace Inspection Be
17. ails 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 with auxiliary power Part No 52700 First Edition Fifth Printing Operator s Manual Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position To Position Platform 1 Hold the function enable switch to either side 2 Movethe appropriate toggle switch according to the markings on the control panel 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 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 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 p
18. ast the drive speed limit switch PartNo 52700 OPERATINGINSTRUCTIONS To Steer 1 Press down the foot switch 2 Turnthe steer wheels with the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 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 Genie Z 45 25 DC 8 Genie Z 45 25J DC 21 Operator s Manual First Edition Fifth Printing OPERATINGINSTRUCTIONS 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 Controller Fault Indicator Light
19. aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris Do Not Operate Unless overhead obstructions and high voltage M You learn and practice the principles of safe conductors machine operation contained in this operator s hazardous locations manual inadequate surface support to withstand all load 1 Avoid hazardous situations forces imposed by the machine 2 Always perform a pre operation wind and weather conditions inspection the presence of unauthorized personnel 3 Always perform function tests prior to use 7 other possible unsafe conditions 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 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 PartNo 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC 19 Operator s Manual First Edition Fifth Printing Operating Instructions 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
20. charge indicator PartNo 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC 9 Operator s Manual First Edition Fifth Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine 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 and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machi
21. d in U S A Genie Z 45 25 DC amp Genie Z 45 25J DC Part No 52700 First Edition Fifth 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 a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine PartNo 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC 1 Operator s Manual First Edition Fifth 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 R 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 30
22. dous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information 6 Genie Z 45 25 DC 8 Genie Z 45 25J DC Part No 52700 First Edition Fifth Printing Operator s Manual Controls AUXILIARY STO P POWER O 5 O ilOS H Ox OF O s 3 Q JRE FUNCTION ENABLE r AMP w 8 9 OO Ground Control Panel 1 Platform rotate switch 9 Hourmeter 2 Turntable rotate switch 10 Function enable switch 3 Primary boom up down switch 11 Secondary boom up down switch 4 Primary boom extend retract switch 12 10A breaker for control electrical circuits 5 notused 13 Z 45 25J DC models Jib boom up down switch 6 Auxiliary power switch 14 Platform level switch 7 Key switch for platform off ground selection 8 Red Emergency Stop button PartNo 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC 7 Operator s Manual First Edition Fifth Printing CONTROLS Platform Control Panel an A N HORN z 01 Horn button Auxiliary power switch Drive enable indica
23. el If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps PartNo 52700 MAINTENANCE 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 AWARNING 2 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 Industrial tire 100 psi 6 9 bar Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Genie Z 45 25 DC 8 Genie Z 45 25J DC 13 Operator s Manual First Edition Fifth Printing Function Tests Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual
24. er test each function through a partial cycle Result All boom functions should operate Genie Z 45 25 DC 8 Genie Z 45 25J DC 15 Operator s Manual First Edition Fifth Printing FUNCTIONTESTS At the Platform Controls Test Emergency Stop 14 Push in the platform red Emergency Stop button to the off position 15 Activate each machine function control handle or toggle switch Result No functions should operate 16 Pull out the red Emergency Stop button to the on position Test the Horn 17 Push the horn button Result The horn should sound Test the Foot Switch 18 Do not press down the foot switch and test each machine function Result The machine functions should not operate 16 Genie Z 45 25 DC 8 Genie Z 45 25J DC Test Machine Functions 19 Press down the foot switch 20 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 21 Press down the foot switch 22 Depress the thumb rocker switch on top of the drive control handle in
25. er fasteners Platform entry mid rail gate U U U U EL LL Beacon and alarms if equipped 4 E PRE OPERATION INSPECTION Check entire machine for 1 Cracks in welds or structural components I 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 Be sure that both battery packs are in place and properly connected After you complete your inspection be sure that all compartment covers are in place and secured Part No 52700 Genie Z 45 25 DC amp Genie Z 45 25J DC 11 Operator s Manual First Edition Fifth Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure 12 Genie Z 45 25 DC 8 Genie Z 45 25J DC Check the Hydrau
26. lic 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 reservoir on the hydraulic power unit Result The hydraulic oil level should be within the FULL and ADD marks on the hydraulic reservoir Hydraulic oil specifications Hydraulic oil type Dexron equivalent Part No 52700 First Edition Fifth Printing Operator s Manual 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 AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 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 3 Remove the battery vent caps 4 Check the battery acid lev
27. ne may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual 10 Genie Z 45 25 DC 8 Genie Z 45 25J DC Part No 52700 First Edition Fifth Printing Operator s Manual Pre operation Inspection 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 in place and legible See Decals section m Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section m 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 and improperly installed or missing parts 1 Electrical components wiring and electrical cables M Hydraulic power unit hoses fittings cylinders and manifolds Hydraulic tanks Drive and turntable motors and torque hubs Boom wear pads Tires and wheels Limit switches alarms and horn Nuts bolts and oth
28. onnel and obstructions Limit travel soeed according to condition of ground surface congestion slope location of personnel and any other factors which may cause collision Part No 52700 First Edition Fifth 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 Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Component Damage Hazards Do not use the machine as a ground for welding 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 batteries 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 Part No 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC SAFETY RULES Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation in
29. se the tie points on the drive chassis for anchoring down to the transport surface Use the rotator guard under the platform to secure the boom from side to side movement Do not use excessive downward force when securing the boom section Use chains or straps of ample load capacity Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Part No 52700 Free wheel Configuration for Winching 1 Chock the wheels to prevent the machine from rolling 2 Releasethe non steer wheel brakes by turning over the drive hub disconnect caps see below Machines with remote brake switch Plug the switch into the adaptor at the ground control box Apply the remote brake release switch while winching the machine 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 Chockthe wheels to prevent the machine from rolling 2 Apply the non steer wheel brakes by turning over the drive hub disconnect caps see below Towing a Genie Z 45 25 DC or a Z 45 25J DC machine is not recommended If the machine must be towed do not exceed 2 mph 3 2 km h Disengage Position Engage Position
30. spection 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 DC amp 45 25J DC 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 Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazard Keep sparks flames and lighted tobacco away from battery Batteries emit explosive gas Electrocution Hazard Avoid contact with electrical terminals Operators Manual First Edition Fifth Printing CEE CANE SAFETY RULES Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the A DANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazar
31. tor light Drive enable switch Z 45 25J DC models Jib boom up down switch Platform rotate switch AUXILIARY POWER O O 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 JIB BOOM PLATFORM ROTATE PLATFORM LEVEL Pad e amp R gt Hi E c Z r TURNTABLE ROTATE SECONDARY BOOM PRIMARY BOOM LEFT RIGHT UP DOWN UP DOWN 3 7 Platform level switch 8 notused 9 RedEmergency Stop button 10 Proportional control handle for drive function and thumb rocker for steer function 11 Boom function speed controller 12 Primary boom extend retract switch Genie Z 45 25 DC 8 Genie Z 45 25J DC Part No 52700 First Edition Fifth Printing Operator s Manual CONTROLS GLOW PLUG ENGINE START ENGINE RPM EMERGENCY STOP R leje 470 start 0 OO OO C t 4 woos m CREEP 4 D R l E PRIMARY BOOM EXTEND RETRACT BOOM FUNCTION SPEED H A gt vy STEER 12 W Go 13 Primary boom up down switch 14 Secondary boom up down switch 15 Turntable rotate left right switch 16 Battery
32. ved from the platform before attempting to free the platform using the ground controls Part No 52700 First Edition Fifth 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 stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended Do not push off or pull toward any object outside of the platform Maximum allowable 150 Ibs side force ANSI amp CSA 667 N Maximum allowable 90 Ibs side force CE 400 N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine Stability with items of different weight or specification Part No 52700 Genie Z 45 25 DC 8 Genie Z 45 25J DC SAFETY RULES Do not modify or alter an aerial work platform Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Do not place or attach overhanging loads to any part of this machine Do not place ladders or scaffolds in
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