Genie Z-45/25 Setup guide

Second Edition
Second Printing
Part No. 82596
Operator’s Manual
with Maintenance Information
Bi-Energy Power

GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596
Operator's Manual Second Edition · Second Printing
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.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandandobeythesesafetyrulesand
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you
have any questions, call Genie Industries.
Contents
Page
Safety ........................................................................ 1
Controls ..................................................................... 8
Pre-operationInspection ........................................... 11
Maintenance ............................................................. 13
Function Tests.......................................................... 16
WorkplaceInspection................................................ 21
OperatingInstructions............................................... 22
Transportand LiftingInstructions .............................. 27
Decals ...................................................................... 30
Specifications ........................................................... 34
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 1
Operator's ManualSecond Edition • Second Printing
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.

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Operator's Manual Second Edition • 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.
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 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 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.
Tip-over Hazards
Occupants,equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 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.
Donot rotate the boom whilelowering. Move the
machine to a firm, level surface before raising the
platform.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 3
Operator's ManualSecond Edition • Second Printing
SAFETY RULES
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,unstableor slippery surfaces and
nearholesanddrop-offs.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesor otherhazardousconditions
withthe boom raised or extended.
Do not push off or pull toward any object outside
of the platform.
Maximum allowable
side force - ANSI & CSA
150 lbs / 667 N
Maximum allowable
side force - CE
90 lbs / 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.
Do not modify or alter an aerial work platform
withoutprior writtenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor 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 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)intheplatform.
Be sure all tires are in good condition, air-filled tires
areproperlyinflated andlug nutsareproperly
tightened.
Do not use batteries that weigh less than the
originalequipment. Batteriesareused 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.

4 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596
Operator's Manual Second Edition • Second Printing
SAFETY RULES
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchorprovidedinthe
platform.
Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform floor at
all times.
Do not climb down from the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gatebeforeoperating.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beawareofboompositionwhenrotatingturntable.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Checkthe work area for overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazards whengrasping the
platformguardrail.
Observeandusecolor-codeddirectionarrowson
the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom unless the area below is
clearof personnelandobstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 5
Operator's ManualSecond Edition • Second Printing
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.
Nostunt driving or horseplaywhileoperatinga
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/orburnskin.
Whenthe engine isrunning,operate the machinein
awell-ventilatedareatoavoidcarbonmonoxide
poisoning.
Impropercontact with componentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
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
petroleumgas (LPG), gasoline, diesel fuel or other
explosive substances.
Donot refuel the machine with the engine running.
Refuel the machine and charge the battery only in
anopen, well-ventilatedareaaway from sparks,
flames and lighted tobacco.
Donot operate the machine in hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Donot spray etherintoengines equipped with glow
plugs.
Damaged Machine Hazards
Donot use a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
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&Z-45/25JBi-Energy Service Manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocated on the platform.
SAFETY RULES

6 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596
Operator's Manual Second Edition • Second Printing
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworkingwithbatteries.
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
andlightedtobacco
awayfrom batteries.
Batteries emit an
explosive gas.
The battery pack cover
mustremain off during
theentirecharging
cycle.
Do not contact the battery terminals or the cable
clamps with tools that may cause sparks.
Component Damage Hazards
Do not use any battery charger greater than 48V to
chargethebatteries.
Both battery packs must be charged together.
Disconnectthe battery pack plug before removing
the battery pack.
Electrocution Hazards
Connect the battery charger to a
grounded,AC3-wireelectrical
outlet only.
Inspect daily for damaged cord,
cablesandwires. Replace
damageditemsbefore
operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the
originalequipment. Batteriesareused 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.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 7
Operator's ManualSecond Edition • Second Printing
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—usedtoindicateoperation
ormaintenanceinformation.
SAFETY RULES

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Operator's Manual Second Edition • Second Printing
13
6 Platform rotate switch
7 Platform level switch
8 Optionalequipment
9 Glowplug switch
10 Engine start switch
PlatformControlPanel
1 Hornbutton
2 Auxiliarypower switch
3 Driveenableindicatorlight
4 Driveenableswitch
5 Z-45/25JBi-Energy models: Jib boom
up/down switch
2
Controls
56 7
18198
4
2021