Genie Z-45/25 User manual

Operator's Manual
Serial Number Range
Z
-
45/25 from Z452513A
-
47001 ANSI/CSA
North America
South America
Asia
Z
-
45/25J
IC Power
with
Maintenance
Information
Fifth Edition
Fourth Printing
Part No. 218568

Operator's Manual Fifth Edition • Fourth Printing
Z-45/25 • Z-45/25J Part No. 218568
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 5
General Safety ...................................................... 7
Personal Safety................................................... 13
Work Area Safety................................................ 14
Legend ................................................................ 22
Controls............................................................... 23
Inspections.......................................................... 31
Operating Instructions......................................... 44
Transport and Lifting Instructions ....................... 51
Maintenance ....................................................... 54
Specifications...................................................... 58
Copyright © 2012 Terex Corporation
Fifth Edition: Fourth Printing, July 2013
Genie and "Z" are registered trademarks of
Terex South Dakota, Inc. in the U.S.A. and many other
countries.
These machines comply with
ANSI/SIA A92.5
CAN B.354.4

Fifth Edition • Fourth Printing Operator's Manual
Introduction
Part No. 218568 Z-45/25 • Z-45/25J 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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,
contact Genie.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
Sequence number
stamped on chassis
Serial label
(located under cover)

Operator's Manual Fifth Edition • Fourth Printing
Introduction
2 Z-45/25 • Z-45/25J Part No. 218568
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Fifth Edition • Fourth Printing Operator's Manual
Introduction
Part No. 218568 Z-45/25 • Z-45/25J 3
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.

Operator's Manual Fifth Edition • Fourth Printing
Introduction
4 Z-45/25 • Z-45/25J Part No. 218568
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Hazard Classification
Decals on this machine use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
DANGER
WARNING
CAUTION
NOTICE

Fifth Edition • Fourth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 218568 Z-45/25 • Z-45/25J 5
Symbol and Hazard P ictorials Definiti ons
Electrocution hazard Maintain required
clearance
Explosion hazard Explosion hazard Collision hazard
Runaway Hazard Tip-over hazard Crush hazard Color Coded
Direction Arrows
Wind speed
Side force Maximum capacity Voltage rating for
power to platform
Pressure rating for
air line to platform
Replace tires with
tires of same
specification.

Operator's Manual Fifth Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
6 Z-45/25 • Z-45/25J Part No. 218568
Recovery procedure if tilt alarm sounds while
elevated.
Read the operator’s
manual
No smoking
No flame
Stop engine
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs
Platform uphill:
1Lower primary.
2Lower secondary
3Retract primary
Platform downhill:
1Retract primary.
2Lower secondary.
3Lower primary.
Lanyard attachment
point
Wheel load

Fifth Edition • Fourth Printing Operator's Manual
General Safety
Part No. 218568 Z-45/25 • Z-45/25J 7
General Safety
218857
or 218558
114390 219485
114258
218857
or 218558
31060
114258
218857
218558
219485
31060
114390
or 218484
or 218484
219484

Operator's Manual Fifth Edition • Fourth Printing
General Safety
8 Z-45/25 • Z-45/25J Part No. 218568
114390
218549
or 218551
218559
28236
31060
218549
114397
218555
218551
114397
218559
218555
31060
28236
114390

Fifth Edition • Fourth Printing Operator's Manual
General Safety
Part No. 218568 Z-45/25 • Z-45/25J 9

Operator's Manual Fifth Edition • Fourth Printing
General Safety
10 Z-45/25 • Z-45/25J Part No. 218568

Fifth Edition • Fourth Printing Operator's Manual
General Safety
Part No. 218568 Z-45/25 • Z-45/25J 11
114252
133067
219953
or 219955
219953
219955
114248
219958
114248
219957
82487
219958
219957
82487 114252
133067
114248

Operator's Manual Fifth Edition • Fourth Printing
General Safety
12 Z-45/25 • Z-45/25J Part No. 218568

Fifth Edition • Fourth Printing Operator's Manual
Personal Safety
Part No. 218568 Z-45/25 • Z-45/25J 13
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

Operator's Manual Fifth Edition • Fourth Printing
Work Area Safety
14 Z-45/25 • Z-45/25J Part No. 218568
WorkArea Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m
200 to 350KV 20 ft 6.10 m
350 to 500KV 25 ft 7.62 m
500 to 750KV 35 ft 10.67 m
750 to 1000KV 45 ft 13.72 m
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 operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
Maximum capacity
Machine equipped with
Aircraft Protection Package
440 lbs 200 kg
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.

Fifth Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. 218568 Z-45/25 • Z-45/25J 15
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 while the boom is lowered:
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. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds
with the platform uphill:
1Lower the primary
boom.
2Lower the secondary
boom.
3Retract the primary
boom.
If the tilt alarm sounds
with the platform downhill:
1Retract the primary
boom.
2Lower the secondary
boom.
3Lower the primary
boom.
Do not raise the boom
when wind speeds may
exceed 28 mph /
12.5 m/s. If wind speeds
exceed 28 mph / 12.5 m/s
when the boom is raised,
lower the boom and do
not continue to operate
the machine.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.
Use extreme care and
slow speeds while driving
the machine in 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 use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.

Operator's Manual Fifth Edition • Fourth Printing
Work Area Safety
16 Z-45/25 • Z-45/25J Part No. 218568
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
side force – ANSI & CSA
150 lbs / 667 N
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Z-45/25J models equipped with Aircraft
Protection Package: Do not use air-filled tires.
These machines are equipped with foam-filled tires.
Wheel weight is critical to stability.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not place or attach
fixed or overhanging
loads to any part of this
machine.
Do not place ladders or
scaffolds in the platform
or against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, air-filled
tires are properly inflated and lug nuts are properly
tightened.
Do not 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.

Fifth Edition • Fourth Printing Operator's Manual
Work Area Safety
Part No. 218568 Z-45/25 • Z-45/25J 17
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.

Operator's Manual Fifth Edition • Fourth Printing
Work Area Safety
18 Z-45/25 • Z-45/25J Part No. 218568
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or
operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not 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 othe
r
factors which may cause
collision.
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.