Genie Z45/25J Operator's Manual
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Genie Z45/25J Operator's Manual

Self-propelled servicing platform
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Summary of Contents for Genie Z45/25J

  • Page 2: Table Of Contents

    Copyright © 2003 by Genie Industries Second Edition: Fifth Printing, December 2012 Internet: http://www.genielift.com "Genie" and "Z" are registered trademarks of E-mail: techpub@genieind.com 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.

  • Page 3: Safe Operation In Hazardous Locations

    Second Edition • Fifth Printing Operator's Manual Safe Operation in Hazardous Locations Only trained and authorized personnel shall be permitted to operate this machine in hazardous locations. Do not enter hazardous locations unless the engine and charger switches are off. Do not enter hazardous locations unless the Danger thermometer reads below 348°F.

  • Page 4: Safety Rules

    Operator's Manual Second Edition • Fifth 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.
  • Page 5 Second Edition • Fifth Printing Operator's Manual SAFETY RULES Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity or the proximity to electrical current.
  • Page 6 Operator's Manual Second Edition • Fifth Printing SAFETY RULES If the tilt alarm sounds: Do not use air-filled tires. These machines are Do not extend, rotate or raise the boom above equipped with foam-filled tires. Wheel weight and horizontal. Move the machine to a firm, level proper counterweight configuration are critical to surface before raising the platform.
  • Page 7 Second Edition • Fifth Printing Operator's Manual SAFETY RULES Do not place or attach fixed or overhanging loads to Fall Hazards any part of 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.
  • Page 8 Operator's Manual Second Edition • Fifth Printing SAFETY RULES Collision Hazards 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 Be aware of limited sight any potential collision.
  • Page 9 Second Edition • Fifth Printing Operator's Manual SAFETY RULES manuals are complete, legible and in the storage container located on the platform. Explosion and Fire Hazards Auxiliary Platform Safety Do not charge the batteries in hazardous locations. (if equipped) Do not operate the engine while the machine is in hazardous locations.
  • Page 10 Operator's Manual Second Edition • Fifth Printing SAFETY RULES Battery Safety Component Damage Hazards Do not use any battery charger greater than 48V to Burn Hazards charge the batteries. Batteries contain acid. Always wear protective Both battery packs must be charged together. clothing and eye wear when working with batteries.
  • Page 11 Second Edition • Fifth Printing Operator's Manual SAFETY RULES 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.

  • Page 12: Controls

    Operator's Manual Second Edition • Fifth Printing Controls Platform Control Panel 1 Horn button 7 Platform level switch 2 Auxiliary power switch 8 Function override switch 3 Drive enable indicator light 9 Glow plug switch 4 Drive enable switch 10 Engine start switch 5 Jib boom up/down switch 11 Engine idle (rpm) select switch 6 Platform rotate switch...
  • Page 13 Second Edition • Fifth Printing Operator's Manual CONTROLS · Rabbit & Foot Switch: foot switch activated 16 Boom function speed controller high idle 17 Primary boom extend/retract switch · Turtle: low idle · Rabbit: high idle and quickest battery charging 18 Primary boom up/down switch 12 Drive lights switch 19 Secondary boom up/down switch...
  • Page 14 Operator's Manual Second Edition • Fifth Printing CONTROLS Ground Control Panel 9 Red Emergency Stop button 1 Platform rotate switch 10 Hour meter 2 Turntable rotate switch 11 Glow plug switch 3 Primary boom extend/retract switch 12 Function enable switch 4 Primary boom up/down switch 13 Engine start switch 5 Engine idle (rpm) select switch...

  • Page 15: Pre-Operation Inspection

    Second Edition • Fifth Printing Operator's Manual Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. 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 Do Not Operate Unless: is apparently wrong with a machine before the...
  • Page 16 Operator's Manual Second Edition • Fifth Printing PRE-OPERATION INSPECTION Pre-operation Inspection Platform entry mid-rail Be sure that the operator's, safety and Beacon and alarms responsibilities manuals are complete, legible and in the storage container located on the Auxiliary platform components platform.

  • Page 17: Maintenance

    Second Edition • Fifth Printing Operator's Manual Maintenance Check the Batteries Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and Observe and Obey: connections can result in component damage and hazardous conditions.
  • Page 18 Operator's Manual Second Edition • Fifth Printing MAINTENANCE Check the Engine Oil Level Check the Hydraulic Oil Level Maintaining the proper engine oil level is essential Maintaining the hydraulic oil at the proper level is to good engine performance and service life. essential to machine operation.

  • Page 19: Function Tests

    Second Edition • Fifth Printing Operator's Manual 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 20 Operator's Manual Second Edition • Fifth Printing FUNCTION TESTS 1 Select a test area that is firm, level and free of 14 Hold the function enable switch to either side obstruction. and activate each boom and platform function toggle switch. At the Ground Controls Result: All boom and platform functions should 2 Turn the key switch to ground control.
  • Page 21 Second Edition • Fifth Printing Operator's Manual FUNCTION TESTS At the Platform Controls Test Machine Functions 32 Press down the foot switch. Test Emergency Stop 33 Activate each machine function control handle 21 Push in the platform red Emergency Stop button or toggle switch.
  • Page 22 Operator's Manual Second Edition • Fifth Printing FUNCTION TESTS Test Drive and Braking Test Limited Drive Speed 37 Press down the foot switch. 40 Press down the foot switch. 38 Slowly move the drive control handle in the 41 Raise the primary boom approximately direction indicated by the blue arrow on the 2 feet / 61 cm.
  • Page 23 Second Edition • Fifth Printing Operator's Manual FUNCTION TESTS Test the Drive Enable System Test Auxiliary Controls 50 Press down the foot switch and lower the boom 54 Shut the engine off. to the stowed position. 55 Pull out the red Emergency Stop button to 51 Rotate the turntable until the primary boom the on position.

  • Page 24: Workplace Inspection

    Operator's Manual Second Edition • Fifth Printing Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris Do Not Operate Unless: · sloped surfaces You learn and practice the principles of safe ·...

  • Page 25: Operating Instructions

    Second Edition • Fifth Printing Operator's Manual Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to...
  • Page 26 Operator's Manual Second Edition • Fifth Printing OPERATING INSTRUCTIONS Operating the Machine in Introduction Hazardous Locations This machine can be operated with or without the engine running. Read, understand and obey the following instructions before entering a Class 1, Division 2, Starting the Engine Group D hazardous location: 1 At the ground controls, turn the key switch to...
  • Page 27 Second Edition • Fifth Printing Operator's Manual OPERATING INSTRUCTIONS Emergency Stop Operation from Platform Push in either the ground or platform red 1 Turn the key switch to platform control. Emergency Stop button to the off position to stop 2 Pull out both ground and platform red all functions and turn the engine off.
  • Page 28 Operator's Manual Second Edition • Fifth Printing OPERATING INSTRUCTIONS Driving on a slope While holding the piece of wood level, measure the vertical distance from the bottom of the piece of Determine the uphill, downhill and side slope ratings wood to the ground. for the machine and determine the slope grade.
  • Page 29 Second Edition • Fifth Printing Operator's Manual OPERATING INSTRUCTIONS Drive Enable Auxiliary Platform Operation Light on indicates that the boom To Raise Platform has moved just past either non- steer wheel and the drive function 1 Pull out the two pins that secure the auxiliary has been interrupted.
  • Page 30 Operator's Manual Second Edition • Fifth Printing OPERATING INSTRUCTIONS 8 Unfold the auxiliary platform to the fully upright Machine Not Level Indicator position. Light 9 Secure the four pins at the toeboard. Light on indicates the machine is not 10 Secure the four pins at the mid-rail. level.
  • Page 31 Second Edition • Fifth Printing Operator's Manual OPERATING INSTRUCTIONS Controller Fault Indicator Charging the Batteries Light On Do not charge the batteries in hazardous locations. If the controller fault indicator light is on, push in Use the engine or the AC battery charger to the red Emergency Stop button, wait a few seconds recharge the batteries.
  • Page 32 Operator's Manual Second Edition • Fifth Printing OPERATING INSTRUCTIONS After Each Use 1 Select a safe parking location—firm level surface, clear of obstruction and traffic. 2 Retract and lower the boom to the stowed position. 3 Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 33: Transport And Lifting Instructions

    Second Edition • Fifth Printing Operator's Manual Transport and Lifting Instructions Free-wheel Configuration for Winching 1 Chock the wheels to prevent the machine from rolling. Disengage Position 2 Release the non-steer wheel brakes by turning Observe and Obey: over the drive hub Engage disconnect caps.
  • Page 34 Operator's Manual Second Edition • Fifth Printing TRANSPORT AND LIFTING INSTRUCTIONS Securing to Truck or Trailer for Securing the Platform - Z-45/25J Transit Make sure the jib and platform are in the stowed position. Always chock the machine wheels in preparation for transport.
  • Page 35 Second Edition • Fifth Printing Operator's Manual TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items from the machine. Be sure the auxiliary platform (if equipped) is fully stowed and all retaining pins are in place. See Operating Instructions section.

  • Page 36: Decals

    Operator's Manual Second Edition • Fifth Printing Decals Decal Inspection Part No. Decal Description Quantity 48731 Label - FMRC Approval Use the pictures on the next page to verify that all decals are legible and in place. 48732 Label - EE Approval Below is a numerical list with quantities and 52437 Notice - Kubota Diesel Engine Spec...
  • Page 37 Second Edition • Fifth Printing Operator's Manual DECALS Ground Controls Side Platform Drive Chassis Shading indicates decal is hidden from view, i.e. under covers Engine Side Part No. 114047 Self-Propelled Servicing Platform...

  • Page 38: Specifications

    24 in x 18 in (length x width) 61 cm x 46 cm Platform leveling self-leveling Continuous improvement of our products is a Genie policy. Product specifications are subject to change Platform rotation 160° without notice or obligation. Self-Propelled Servicing Platform...

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