Genie Z-45/25 User manual

Second Edition
First Printing
Part No. 82595
Operator’s Manual
with Maintenance Information
DC Power

Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition · First Printing
Copyright © 1999 by Genie Industries
First Edition: Fifth Printing, April 2002
Second Edition: First Printing, June 2003
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
These machines comply with
ANSI/SIA 92.5-1992.
Printed on recycled paper
Printed in U.S.A.
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you
have any questions, call Genie Industries.
Contents
Page
Safety ........................................................................ 1
Controls ..................................................................... 8
Pre-operationInspection ........................................... 11
Maintenance ............................................................. 13
Function Tests .......................................................... 15
WorkplaceInspection ................................................ 20
OperatingInstructions ............................................... 21
Transport and Lifting Instructions .............................. 25
Decals ...................................................................... 28
Specifications ........................................................... 32
Contact us:
Internet:http://www.genielift.com
E-mail: [email protected]

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 1
Operator's ManualSecond Edition · First 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 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
governmentalregulations.
You are properly trained to safely operate the
machine.

2 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition · First 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 Approach Distance
Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.1
50KV to 200KV 15 4.6
200KV to 350KV 20 6.1
350KV to 500KV 25 7.6
500KV to 750KV 35 10.7
750KV to 1000KV 45 13.7
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not use the machine as a ground for welding.
Do not operate the machine during lightning or
storms.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
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 removed from the platform
before attempting to free the platform using the
ground controls.

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 3
Operator's ManualSecond Edition · First 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, 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
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 alter or disable the limit switches.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform, toeboards
or guard rail system can increase the 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 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.

4 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition · First Printing
SAFETY RULES
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
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
gatebeforeoperating.
Component Damage Hazard
Do not use the machine as a ground for welding.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position when rotating the
turntable.
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazards when grasping the
platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protectiveequipment.
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.

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 5
Operator's ManualSecond Edition · First Printing
SAFETY RULES
Observe and use color-coded direction arrows on
the platform controls and drive chassis for drive
and steer functions.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Improper contact with components under any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operation inspection. All compartments must
remain closed and secured during operation.
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.
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 DC
& Z-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.

6 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
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—usedtoindicate operation
ormaintenanceinformation.
SAFETY RULES

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 7
Operator's ManualSecond Edition ·First Printing
SAFETY RULES
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eye wear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
The battery pack must remain in the upright
position.
Do not expose the batteries or the charger to water
or rain.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit an
explosive gas.
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.
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
damageditems before
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
original equipment. Batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 88 lbs / 40 kg. Each
battery box including batteries must weigh a
minimum of 452 lbs / 205 kg.
Lifting Hazard
Use a forklift to remove or install the battery packs.

8 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
1
7 Platform level switch
8 Not used
9 Platform overload indicator light (if equipped)
10 Machine not level indicator light (if equipped)
11 Red Emergency Stop button
12 Proportional control handle for drive function and
thumb rocker for steer function
Platform Control Panel
1 Hornbutton
2 Auxiliary power switch
3 Drive enable indicator light
4 Drive enable switch
5 Z-45/25J DC models: Jib boom
up/down switch
6 Platform rotate switch
2
Controls
56 7
15168
4
1718
3

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 9
Operator's ManualSecond Edition ·First Printing
CONTROLS
13 Boom function speed controller
14 Primary boom extend/retract switch
15 Primary boom up/down switch
16 Secondary boom up/down switch
17 Turntable rotate switch
18 Battery charge indicator
8 8 8
1213
8 9 10 11
14

10 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
CONTROLS
5
7 86
2
1
3
4
9
10
5
5
11
5512131415
GroundControl Panel
1 Platform rotate switch
2 Turntable rotate switch
3 Primary boom up/down switch
4 Primary boom extend/retract switch
5 Not used
6 Auxiliary power switch
7 Key switch for platform/off/ground selection
8 Red Emergency Stop button
9 Platform overload indicator light (if equipped)
10 Hourmeter
11 Function enable switch
12 Secondary boom up/down switch
13 10A breaker for control electrical circuits
14 Z-45/25J DC models: Jib boom
up/downswitch
15 Platform level switch
5

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 11
Operator's ManualSecond Edition ·First Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
Knowandunderstandthepre-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-operationinspectionandroutinemaintenance.
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 specifications and
the requirements listed in the responsibilities
manual.

12 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
PRE-OPERATIONINSPECTION
Pre-operation Inspection
oBe sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
oBe sure that all decals are in place and legible.
See Decals section.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
oCheck 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
unauthorizedmodifications:
o Electrical components, wiring and electrical
cables
oHydraulic power unit, hoses,
fittings, cylinders and manifolds
oHydraulic tanks
oDrive and turntable motors and torque hubs
oBoom wear pads
oTires and wheels
oLimit switches, alarms and horn
oNuts, bolts and other fasteners
oPlatform entry mid-rail/gate
oBeacon and alarms (if equipped)
Check entire machine for:
oCracks in welds or structural components
oDents or damage to machine
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
oBe sure that both battery packs are in place and
properly connected.
oAfter you complete your inspection, be sure that
all compartment covers are in place and
secured.

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 13
Operator's ManualSecond Edition ·First Printing
Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the meaning
below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be required to
perform this procedure.
Check the Hydraulic Oil Level
Maintaining the hydraulic oil at the proper level is
essential to machine operation. Improper hydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.
1 Be sure that the boom is in the stowed position,
then visually inspect the 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 Chevron Rykon
Premium MV equivalent

14 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
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
hazardousconditions.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
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 level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
5 Install the vent caps.
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.
Bodily injury hazard. An over-
inflated tire can explode and may
cause death or serious injury.
This procedure does not need to
be performed on machines
equipped with foam-filled tires.
1 Check each tire with an air pressure gauge and
add air as needed.
Tire pressure 100 psi 6.9 bar
Scheduled Maintenance
Maintenanceperformedquarterly, 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.

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 15
Operator's ManualSecond Edition ·First Printing
Function Tests
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into
service. The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If
malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
machine may only be made by a qualified service
technician, according to the manufacturer's
specifications.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to
use.
Knowandunderstandthefunctiontests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

16 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
FUNCTIONTESTS
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 Open the turntable cover on
the side opposite the
ground controls 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,
shouldsound.
TestAuxiliaryControls
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 power, test each
function through a partial cycle.
Result: All boom functions should operate.
1 Select a test area that is firm, level and free of
obstruction.
At the Ground Controls
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to
the on position.
Result: The beacon (if equipped) should flash.
TestEmergencyStop
4 Push in the red Emergency Stop button to the
off position.
Result: All functions should not operate.
5 Pull out the red Emergency Stop button to
the on position.
TesttheMachineFunctions
6 Do not hold the function enable
switch to either side. Attempt to
activate each boom and platform
function toggle switch.
Result: All boom and platform functions should
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.

PartNo.82595 Genie Z-45/25 DC & Genie Z-45/25J DC 17
Operator's ManualSecond Edition ·First Printing
FUNCTIONTESTS
At the Platform Controls
TestEmergencyStop
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.
TesttheHorn
17 Push the horn button.
Result: The horn should sound.
TesttheFootSwitch
18 Do not press down the foot switch and test each
machine function.
Result: The machine functions should not
operate.
TestMachineFunctions
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 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 steer wheels should turn in the
direction that the yellow triangles point on the
drive chassis.

18 Genie Z-45/25 DC & Genie Z-45/25J DC PartNo.82595
Operator's Manual Second Edition ·First Printing
FUNCTIONTESTS
TestDriveandBraking
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.
TestLimitedDrive 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 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.
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.