Genie Z-45/25 User manual

Third Edition
Second Printing
Part No. 110015
Operator’s Manual
with Maintenance Information
Bi-Energy PowerIC Power

Operator's Manual Third Edition · Second Printing
Z-45/25•Z-45/25J PartNo.110015
Copyright © 1998 by Genie Industries
First Edition: Seventh Printing, May 2002
Second Edition: Second Printing, August 2004
Third Edition: Second Printing, October 2005
"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,understandand obey thesesafetyrules 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 Rules .............................................................. 1
Legend ....................................................................... 8
Controls ..................................................................... 9
Pre-operationInspection ........................................... 12
Maintenance ............................................................. 14
Function Tests.......................................................... 18
WorkplaceInspection................................................ 24
OperatingInstructions............................................... 25
Transportand LiftingInstructions .............................. 31
Decals ...................................................................... 34
Specifications ........................................................... 38
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 1
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 andsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperly trained tosafelyoperate the
machine.

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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
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Feet Meters
0to300V AvoidContact
300Vto50KV 10 3.1
50KVto200KV 15 4.6
200KVto350KV 20 6.1
350KVto500KV 25 7.6
500KVto750KV 35 10.7
750KVto1000KV 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
energizedpowerlines. Personnelonthegroundor
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.
Donotoperate themachineduring lightningor
storms.
Tip-over Hazards
Occupants,equipmentandmaterials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipecradles, panelcradles andwelders,willreduce
the rated platform capacity and must be factored
into the total platform load. See the decals on the
options.
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.
Donotrotatetheboom while lowering. Move the
machine to a firm, level surface before raising the
platform.

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PartNo.110015 Z-45/25•Z-45/25J 3
SAFETY RULES
Do not use the platform controls to free a platform
thatis caught,snaggedor otherwiseprevented
from normal motion by an adjacent structure. All
personnelmustbe removedfromthe platform
before attempting to free the platform using the
groundcontrols.
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 stowed position across uneven
terrain,debris,unstable or slippery surfacesand
nearholesanddrop-offs.
Do not alter or disable the limit switches.
Donotdrive the machine onornear uneven terrain,
unstablesurfacesorotherhazardousconditions
withtheboom raisedorextended.
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
Counterweight uphill 30% (17°)
Counterweight downhill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Counterweight uphill 45% (24°)
Counterweight downhill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not push off or pull toward any object outside
of the platform.
Maximum allowable
side force - ANSI and CSA
150 lbs / 667 N
Maximum allowable
manual force - CE and
Australia
90 lbs / 400 N
Do not alter or disable machine components that in
any way affect safety and stability.

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4 Z-45/25•Z-45/25J PartNo.110015
SAFETY RULES
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
toolsorothermaterials 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 transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
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.
Be sure all tires are in good condition, air-filled tires
areproperlyinflatedandlugnutsareproperly
tightened.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Z-45/25andZ-45/25JNarrowBaseModels:
Do not use air-filled tires. These machines are
equippedwithfoam-filledtires.Wheelweightand
propercounterweightconfigurationarecriticalto
stability.
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.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
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.

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 5
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beawareoftheboom position when rotating the
turntable.
Checkthe work areafor overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazards whengraspingthe
platformguardrail.
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.
SAFETY RULES
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Observeandusethecolor-codeddirectionarrows
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
outand/or precautions havebeen taken toprevent
any potential collision.
Nostunt driving orhorseplay whileoperatinga
machine.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-startthe engine.
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,dieselfuel orother
explosive substances.
Donotrefuel themachinewith theenginerunning.
Refuel the machine and charge the battery only in
anopen, well-ventilatedarea awayfromsparks,
flames and lighted tobacco.
Donotoperate themachinein hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Donot sprayetherinto enginesequipped withglow
plugs.

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Damaged Machine Hazards
Donotuse adamagedor malfunctioningmachine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureall maintenancehasbeen performed as
specified in this manual and the
Genie Z-45/25 &
GenieZ-45/25JServiceManual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and inthestorage
containerlocatedon theplatform.
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.
Alwaysoperatethe machine inawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontact withcomponentsunder anycover
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.
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.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 7
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.

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8 Z-45/25•Z-45/25J PartNo.110015
Legend
1 Foot switch
2 Manualstoragecontainer
3 Slidingmid-rail
4 Lanyardanchoragepoint
5 Jibboom(Z-45/25J)
6 Platform
7 Platformcontrols
8 Primaryboom
9 Secondaryboom
10 Groundcontrols
11 Steertire
12 LPGtank(ifequipped)
13 Non-steertire
Z-45/25
Z-45/25J

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 9
Controls
GroundControlPanel
1 Platform level switch
2 Platform rotate switch
3 Z-45/25J models only: Jib boom up/down switch
4 Turntablerotateswitch
5 Primaryboomup/downswitch
6 Primaryboom extend/retractswitch
7 Gasoline/LPG models: Fuel select switch
8 Platformoverloadindicatorlight(ifequipped)
9 Auxiliarypower switch
10 Gasoline/LPGmodels:Checkenginelight
Diesel models: Oil pressure light
11 Key switch for platform/off/ground selection
12 RedEmergencyStopbutton
13 Hourmeter
14 Dieselmodels:Watertemperaturelight
15 Diesel models:Glowplug switch (ifequipped)
16 Functionenableswitch
17 Engine start switch
18 15A breaker for engine electrical circuits
19 Secondaryboomup/downswitch
20 15A breaker for control electrical circuits

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1 3
6 Drive speed select switch
7 Diesel models: Glow plug switch
8 Engine start switch
9 Engine idle (rpm) select switch
10 Gasoline/LPGmodels:Gasoline/LPG
select switch
PlatformControlPanel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 Z-45/25J models only: Jib boom up/down switch
5 Auxiliarypower switch
2
CONTROLS
4 5 6
171820 19

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 11
CONTROLS
11 RedEmergencyStopbutton
12 Dualaxisproportionalcontrolhandlefordrive
and steer functions
ORProportionalcontrolhandlefordrivefunction
and thumb rocker for steer function
13 Platformoverloadindicatorlight(ifequipped)
14 Machine not levelindicatorlight (if equipped)
15 Driveenableindicatorlight
117 8 9 10
1216 15
16 Driveenableswitch
17 Proportionalcontrolhandleforsecondaryboom
up/downfunction
18 Primary boomextend/retract switch
19 usedforoptionalequipment
20 Dualaxisproportionalcontrolhandleforprimary
boom up/down and turntable rotate
left/rightfunctions
13
14

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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.
Thepre-operationinspection 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.
Thepre-operationinspectionalsoserves 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.
Ifdamage orany unauthorizedvariation from
factory delivered condition is discovered, the
machinemustbe taggedand 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.

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PartNo.110015 Z-45/25•Z-45/25J 13
PRE-OPERATION INSPECTION
Pre-operation Inspection
oBe sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheckforengine coolant leaks andproperlevel
of coolant. Add coolant if needed. See
Maintenancesection.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
oZ-45/25RTandZ-45/25J RT models: Check for
proper tire pressure. Add air if needed. See
Maintenancesection.
Checkthefollowing componentsorareas for
damage,improperly installedormissing partsand
unauthorizedmodifications:
oElectricalcomponents,wiringand
electrical cables
oHydraulic hoses, fittings, cylinders and
manifolds
oFuel and hydraulic tanks
oDriveand turntablemotorsanddrivehubs
oBoomwearpads
oTiresandwheels
oEngineandrelatedcomponents
oLimit switches and horn
oAlarmsandbeacons(ifequipped)
oNuts, bolts and other fasteners
oPlatformentrymid-rail or gate
Checkentiremachine for:
oCracks in welds or structural components
oDentsor damagetomachine
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
oAfter you complete your inspection, be sure that
all compartment covers are in place and
latched.

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14 Z-45/25•Z-45/25J PartNo.110015
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
responsibilitiesmanual.
MaintenanceSymbolsLegend
Thefollowingsymbols havebeen
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
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.
Indicates that a cold engine is required
beforeperformingthisprocedure.
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
1 Check the oil dipstick. Add oil as needed.
Perkins 404C-22 Engine
Oil type 15W-40
Oil type - cold conditions 5W-40
Ford LRG-425 EFI Engine (EPA Compliant)
Oil type 10W-40
Oil type - cold conditions 5W-30
Deutz F3L 2011 Engine
Oil type 15W-40
Oil type - cold conditions 5W-30

Operator's ManualThird Edition · Second Printing
PartNo.110015 Z-45/25•Z-45/25J 15
Check the Hydraulic Oil Level
Maintaining the hydraulic oil at the proper level is
essentialtomachineoperation.Improperhydraulic
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 sight gauge located on
the side of the hydraulic oil tank.
Result: The hydraulic oil level should be within
the top 2 inches / 5 cm of the sight gauge.
2 Add oil as needed.
Hydraulic oil specifications
Hydraulic oil type Chevron Rykon
Premium MV equivalent
MAINTENANCE
Check the Engine Coolant Level
- Ford and Perkins Models
Maintaining the engine coolant at the proper level is
essential to engine service life. Improper coolant
level will affect the engine's cooling capability and
damageenginecomponents.Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.
Burnhazard.Bewareofhotengine
parts and coolant. Contact with hot
enginepartsand/orcoolantmay
causesevere burns.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed.
Result: The fluid level should be at the
FULLmark.
Donotremove the radiator cap.

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Check the Batteries
Proper battery condition is essential to good engine
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultinenginecomponentdamageandhazardous
conditions.
Electrocutionhazard. Contactwith
hot or live circuits may 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.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down bracket is
secure.
4 Remove the battery vent caps.
5 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
6 Install the vent caps.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
Check the Tire Pressure
Tip-overhazard.Anover-inflated
tire can explode which may
compromisemachinestability and
cause the machine to tip over.
Tip-overhazard.The use of
temporaryflattirerepairproducts
may lead to tire failure which could
compromisemachinestability and
cause the machine to tip over.
Bodily injury hazard. An over-
inflated tire can explode and may
cause death or serious injury.
Thisproceduredoes notneedto
beperformedonmachines
equippedwithfoam-filledtires.
1 Checkeachtire with an air pressuregaugeand
addairasneeded.
Tire specifications 2WD Models 4WD Models
Narrow base models Foam-filled
Industrial tire Only
Standard base models
Industrial tire 100 psi /
Tire size: 9-14.5 LT 6.9 bar
Standard base models 50 psi / 50 psi /
Rough terrain tire 3.5 bar 3.5 bar
Tire size: 355/55D625 14 ply
MAINTENANCE

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PartNo.110015 Z-45/25•Z-45/25J 17
MAINTENANCE
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedand qualifiedto performmaintenance onthis
machineaccordingto the proceduresfound 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.

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FunctionTests
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.