Genie Z-45/25 Operator's Manual
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Genie Z-45/25 Operator's Manual

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

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Summary of Contents for Genie Z-45/25

  • Page 1 Operator's Manual Serial Number Range Z-45/25 from Z452513A-47001 ANSI/CSA North America Z-45/25J South America Asia IC Power with Maintenance Information Fifth Edition Fourth Printing Part No. 218568...

  • Page 2: Table Of Contents

    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...

  • Page 3: Introduction

    This book is an operation and daily maintenance manual for the user or operator of a Genie Bulletin Distribution and machine. Compliance...
  • Page 4 Fifth Edition • Fourth Printing Introduction 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...
  • Page 5  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. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 6 Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. Z-45/25 • Z-45/25J Part No. 218568...

  • Page 7: Symbol And Hazard Pictorials Definitions

    Tip-over hazard Crush hazard Color Coded Wind speed Direction Arrows Side force Maximum capacity Voltage rating for Pressure rating for Replace tires with power to platform air line to platform tires of same specification. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 8 No flame 1 Lower primary. 1 Retract primary. starting aids on 2 Lower secondary 2 Lower secondary. Stop engine machines equipped 3 Retract primary 3 Lower primary. with glow plugs Lanyard attachment Wheel load point Z-45/25 • Z-45/25J Part No. 218568...

  • Page 9: General Safety

    Fifth Edition • Fourth Printing Operator's Manual General Safety 31060 General Safety 114390 219485 114258 218857 or 218558 or 218484 218857 or 218558 or 218484 218857 114390 31060 218558 114258 219485 219484 Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 10 Operator's Manual Fifth Edition • Fourth Printing General Safety 218559 218549 218551 114390 114397 218559 218555 31060 114390 218549 or 218551 28236 31060 114397 218555 28236 Z-45/25 • Z-45/25J Part No. 218568...
  • Page 11 Fifth Edition • Fourth Printing Operator's Manual General Safety Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 12 Operator's Manual Fifth Edition • Fourth Printing General Safety Z-45/25 • Z-45/25J Part No. 218568...
  • Page 13 Fifth Edition • Fourth Printing Operator's Manual General Safety 114252 114248 219958 219957 133067 219953 or 219955 82487 133067 219958 219953 114248 114248 219955 219957 82487 114252 Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 14 Operator's Manual Fifth Edition • Fourth Printing General Safety Z-45/25 • Z-45/25J Part No. 218568...

  • Page 15: Personal Safety

    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. Part No. 218568 Z-45/25 • Z-45/25J...

  • Page 16: Work Area Safety

    Do not operate the machine during lightning or storms. Do not use the machine as a ground for welding. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 17 Do not use the machine as a crane. boom. Do not push the machine or other objects with the Lower the secondary boom. boom. Do not contact adjacent structures with the boom. Lower the primary boom. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 18 All weight in the platform and the surface area of the personnel must be removed from the platform platform or the load. before attempting to free the platform using the ground controls. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 19 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. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 20 No stunt driving or horseplay while operating a machine. Operators must comply with employer, job site and governmental rules regarding use of personal protective equipment. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 21 Improper contact with components under any Be sure all maintenance has been performed as cover will cause serious injury. Only trained specified in this manual and the appropriate Genie maintenance personnel should access service manual. compartments. Access by the operator is only Be sure all decals are in place and legible.
  • Page 22 Chock the wheels. Explosion Hazards Keep sparks, flames and lighted tobacco away from batteries. Batteries emit explosive gas. Electrocution Hazard Avoid contact with electrical terminals. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 23 Do not cause a horizontal force or side load to Maximum panel area: 32 sq ft / 3 m machine by raising or lowering a fixed or overhanging load. Electrocution Hazard: Keep pipes away from all energized electrical conductors. Part No. 218568 Z-45/25 • Z-45/25J...

  • Page 24: Legend

    Primary boom Foot switch Secondary boom Manual storage container 10 Ground controls Sliding mid-rail 11 Steer tire Lanyard anchorage point 12 LPG tank (if equipped) Jib boom (Z-45/25J) 13 Non-steer tire Platform Platform controls Z-45/25 • Z-45/25J Part No. 218568...

  • Page 25: Controls

    Fifth Edition • Fourth Printing Operator's Manual Controls Controls The Z-45/25 and Z-45/25J machines will have one of these two styles of ground control panels. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted.
  • Page 26 14 Primary boom extend/retract switch Move the primary boom extend/retract switch to the right and the primary boom will retract. Move the boom extend/retract switch to the left and the primary boom will extend. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 27 24 hours. 24 Gasoline/LPG models: Fuel select switch Move the fuel select switch to the gasoline position to select gasoline. Move the fuel select swtich to the LPG posiiton to select LPG. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 28 13 Dual axis proportional control handle for boom Not used up/down and turntable rotate left/right functions Machine not level indicator light OR Proportional control handle for drive function Emergency lowering switch and thumb rocker for steer function Drive speed select switch Z-45/25 • Z-45/25J Part No. 218568...
  • Page 29 22 Primary boom extend/retract switch Turtle: foot switch activated low idle 23 Dual axis proportional control handle for boom Rabbit: foot switch activated high idle up/down and turntable rotate left/right functions 18 Engine start switch Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 30 Move Move and hold the aircraft protection override the jib boom switch switch to operate the machine when the down and the jib boom platform bumper is against an object. will lower. Not used Z-45/25 • Z-45/25J Part No. 218568...
  • Page 31 Press the right side of the thumb rocker 19 Models with LCD screen: Engine shut-down and the machine will steer to the right. indicator light Light on indicates that the engine has shut down. Contact service personnel. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 32 Move the control handle to the right and the turntable will rotate to the right. Move the control handle to the left and the turntable will rotate to the left. Z-45/25 • Z-45/25J Part No. 218568...

  • Page 33: Inspections

    Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 34 Maintenance section.  After you complete your inspection, be sure that all compartment covers are in place and  Z-45/25 RT and Z-45/25J RT model with latched. air-filled tires: Check for proper tire pressure. Add air if needed. See Maintenance section.
  • Page 35 Push in the red Emergency Stop button to the off position. Result: The engine will shut off after 2 to 3 seconds. Pull out the red Emergency Stop button to the on position and restart the engine. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 36 11 Press down one side of the tilt sensor. Test the Horn Result: The alarm, located in the platform, 18 Press the horn button. should sound. Result: The horn should sound. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 37 Result: No functions should operate. drive chassis. Test Machine Functions 24 Press down the foot switch. 25 Activate each machine function control handle or toggle switch. Result: All boom and platform functions should operate through a full cycle. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 38 Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction of travel. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 39 If the drive speed with the primary boom auxiliary power. raised, the secondary boom raised or the primary boom extended exceeds 1 ft / 30 cm per second, immediately tag and remove the machine from service. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 40 Result: No boom and steer functions should operate. 57 Move and hold the aircraft protection override switch. 58 Activate each function control handle or toggle switch. Result: All boom and steer functions should operate. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 41 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. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 42 Danger, Warning – Tip-over, Crush 28176 Label – Missing Manuals Hazard 28235 Label – Power to Platform, 115V 218561 Label – Wheel Load, Z-45/25 28236 Warning – Improper Operation 218562 Label – Wheel Load, Z-45/25J 31060 Danger – Tip-over Hazard, Limit Switch 219485 Notice –...
  • Page 43 218557 52865 or 97548 218557 77399 52475 72086 serial 28160 218561 77399 38149 or 218558 or 822004 or 218558 218561 label 28174 or 218562 or 219484 or 822131 or 219484 or 218562 or 28235 Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 44 Platform Control Panel 27206 Triangle – Blue 215526 Label – Belt Routing (MSG 425) 27207 Triangle – Yellow 218561 Label – Wheel Load, Z-45/25 28158 Label – Unleaded 218562 Label – Wheel Load, Z-45/25J 28159 Label – Diesel 219488 Label – Transport Diagram, Z-45 28160 Label –...
  • Page 45 28174 133067 or 28235 82481 40434 215526 82473 72086 52475 219950 serial or 219951 label 82240 218561 219950 218561 28174 or 218483 or 219951 114249 28160 114249 or 218562 52475 72086 or 28235 44981 Part No. 218568 Z-45/25 • Z-45/25J...

  • Page 46: Operating Instructions

    That means 4 Inspect the workplace. every new operator should perform a pre-operation inspection, function tests, and a workplace 5 Only use the machine as it was inspection before using the machine. intended. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 47 Move the engine start toggle switch to either to LPG. Warm engines can be started on LPG. side. If the engine fails to start or dies, the restart delay will disable the start switch for 3 seconds. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 48 Pull out the red Emergency Stop button to the ground controls. on position. Press down the foot switch when using the controls from the platform. Simultaneously hold the emergency power switch to either side and activate the desired function. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 49 Use the color-coded direction arrows on the  tape measure platform controls and the drive chassis to identify the direction the machine will travel. Machine travel speed is restricted when the booms are raised. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 50 See Transport and Lifting section.  Machine on incline symbol: Low range operation for inclines  Machine on level surface symbol: High range operation for maximum drive speed Z-45/25 • Z-45/25J Part No. 218568...
  • Page 51 Rabbit symbol: Foot switch activated high idle If foot switch activated low idle or high idle do not work, contact service personnel within 24 hours. Foot switch activated idle settings are disabled by certain fault codes. Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 52 Restart the engine Flashing red lights: contact service personnel. Flashing green lights: contact service personnel within 24 hours. Deutz engine Flashing red lights: contact service personnel. Flashing green lights: contact service personnel within 24 hours. Z-45/25 • Z-45/25J Part No. 218568...

  • Page 53: Transport And Lifting Instructions

    Genie lifts are very heavy relative to their size. See the serial label for the Note: Towing the Genie Z-45/25 or the Z-45/25J is machine weight. See the inspections section not recommended. If the machine must be towed, for the serial label location.
  • Page 54 Operator's Manual Fifth Edition • Fourth Printing Transport and Lifting Instructions Securing the Platform – Z-45/25 Securing to Truck or Trailer for Transit Make sure the platform is in the stowed position. Secure the platform with a nylon strap placed over...
  • Page 55 X Axis Y Axis and straps or lines are sufficient to withstand the machine weight. See the serial label for the Z-45/25, Z-45/25J 47.3 in 44 in machine weight. 120 cm 112 cm Y Axis Part No. 218568 Z-45/25 • Z-45/25J...

  • Page 56: Maintenance

    Oil type - cold conditions 5W-40 responsibilities manual. Perkins 404F-22 Engine  Use only Genie approved replacement parts. Oil type 15W-40 Oil type - cold conditions 25W-40 Maintenance Symbols Legend Ford MSG-425 EFI Engine...
  • Page 57 Add oil as needed. Do not overfill. Fuel Type Low Sulfur Diesel (LSD) Hydraulic oil specifications Deutz D2.9 L4 Engine Hydraulic oil type Chevron Rando HD equivalent Fuel Type Ultra Low Sulfur Diesel (ULSD) Part No. 218568 Z-45/25 • Z-45/25J...
  • Page 58 Result: The fluid level should be at the FULL Note: Adding terminal protectors and a corrosion mark on the tank or visible in the sight gauge. preventative sealant will help eliminate the corrosion on the battery terminals and cables. Z-45/25 • Z-45/25J Part No. 218568...
  • Page 59 Add air as needed. Tire specifications Models with Aircraft Foam-filled Only Protection Package Rough terrain tire 60 psi / Tire size: 315/55 D20 3.5 bar High flotation tires 38 psi / Tire size: 33/16LL500 2.6 bar Part No. 218568 Z-45/25 • Z-45/25J...

  • Page 60: Specifications

    72 in x 30 in 183 cm x be used only with adequate safety factors. 6 foot (length x width) 76 cm Continuous improvement of our products is a Genie Platform leveling self-leveling policy. Product specifications are subject to change Platform rotation 180°...
  • Page 61 6123 kg be used only with adequate safety factors. Machine weights vary with option configurations. Continuous improvement of our products is a Genie Platform dimensions, 72 in x 30 in 183 cm x 76 cm policy. Product specifications are subject to change 6 foot without notice or obligation.

  • Page 62: Z-45/25 • Z-45/25J Part No

    Operator's Manual Fifth Edition • Fourth Printing Specifications Z-45/25 Range of Motion Z-45/25J Range of Motion Chart 50 ft 50 ft 50 ft 50 ft 15.2 m 15.2 m 15.2 m 15.2 m 40 ft 40 ft 40 ft 40 ft 12.2 m...

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Z45/25j

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