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Genie Z-45/25J manual

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Table of contents for the manual

  • Page 1

    First Edition Seventh Printing Part No. 52421 Operator’ s Manual with Maintenance Information[...]

  • Page 2

    Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Copyright © 1998 by Genie Industries First Edition: Seventh Printing, May 2002 "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[...]

  • Page 3

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 1 Operator's Manual First Edition · Seventh Printing Safety Rules Danger F ailure to obe y the instr uctions and saf ety r ules in this man ual will result in death or ser ious injury . Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this o[...]

  • Page 4

    2 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing SAFETY RULES Electrocution Hazar ds 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 acco[...]

  • Page 5

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 3 Operator's Manual First Edition · Seventh 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[...]

  • Page 6

    4 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing SAFETY RULES 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 t[...]

  • Page 7

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 5 Operator's Manual First Edition · Seventh Printing Do not lower the boom unless the area below is clear of personnel and obstructions. Limit travel speed according to condition of ground surface, congestion, slope, location of personnel, and any other factors which may cause collision. Do [...]

  • Page 8

    6 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing 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 follo[...]

  • Page 9

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 7 Operator's Manual First Edition · Seventh Printing Contr ols 5 7 8 6 2 1 3 4 9 10 11 12 13 14 15 16 17 18 19 Ground Control Panel 1 Platform rotate switch 2 Turntable rotate switch 3 Primary boom up/down switch 4 Primary boom extend/retract switch 5 Gasoline/LPG models: Fuel select switch [...]

  • Page 10

    8 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing 1 3 6 Drive speed select switch 7 Glow plug switch 8 Engine start switch 9 Engine idle (rpm) select switch 1 0 Gasoline/LPG models: Gasoline/LPG select switch Platform Control Panel 1 Horn button 2 Platform level switch 3 Platform rotate [...]

  • Page 11

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 9 Operator's Manual First Edition · Seventh Printing CONTROLS 1 1 Red Emergency Stop button 1 2 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 1 3 used for optional equipment 1 4 Drive [...]

  • Page 12

    10 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh 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. Know and[...]

  • Page 13

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 11 Operator's Manual First Edition · Seventh Printing PRE-OPERATION INSPECTION Pre-operation Inspection o Be sure that the operator ’ s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform. o Be sure that all decals are legible and[...]

  • Page 14

    12 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh 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 manufacture[...]

  • Page 15

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 13 Operator's Manual First Edition · Seventh Printing Deutz Engine F3L 1011F Oil viscosity requirements below 60 ° F / 15.5 ° C (synthetic) 5W -30 -10 ° F to 90 ° F / -23 ° C to 32 ° C 10W-40 above -4 ° F / -34 ° C 15W-40 Engine oil should have properties of API classification CC/SE,[...]

  • Page 16

    14 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Chec k the Engine Coolant Level - Ford and P erkins 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 damage engine [...]

  • Page 17

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 15 Operator's Manual First Edition · Seventh Printing Chec k the Tire Pressure Bodily injury hazard. An over- inflated tire can explode, which can result in death or serious injury. Tip-over hazard. Do not use temporary flat tire repair products. This procedure does not need to be performed [...]

  • Page 18

    16 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Function T ests 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 mach[...]

  • Page 19

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 17 Operator's Manual First Edition · Seventh Printing FUNCTION TESTS Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position. Turn the key switch to platform control. 10 Open the engine side turntable cover and locate the tilt sensor to the right of the hydr[...]

  • Page 20

    18 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing FUNCTION TESTS Test Machine Functions 2 5 Press down the foot switch. 2 6 Activate each machine function control handle or toggle switch. Result: All boom/platform functions should operate through a full cycle. Machines equipped with Pla[...]

  • Page 21

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 19 Operator's Manual First Edition · Seventh Printing Test Drive and Braking 3 1 Press down the foot switch. 3 2 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 posit[...]

  • Page 22

    20 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing FUNCTION TESTS Test Limited Drive Speed Z-45/25 & Z-45/25J Standard Base Models ANSI and CSA Z-45/25 & Z-45/25J Narrow Base Models before serial number 19081 4 0 Move the lift/drive select switch to the lift position (if equipped[...]

  • Page 23

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 21 Operator's Manual First Edition · Seventh Printing 4 2 Raise the primary boom approximately 2 feet / 61 cm. 4 3 Move the lift/drive select switch to the drive position (if equipped). 4 4 Slowly move the drive control handle to the full drive position. Result: The maximum achievable drive [...]

  • Page 24

    22 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing FUNCTION TESTS Test Auxiliary Controls 6 2 Shut the engine off. 6 3 Pull out the red Emergency Stop button to the on position. 6 4 Move the lift/drive select switch to the lift position (if equipped). 6 5 Press down the foot switch. 6 6 [...]

  • Page 25

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 23 Operator's Manual First Edition · Seventh Printing W orkplace Inspection W orkplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris · overhead obstructions and high voltage conductors · hazardous locations[...]

  • Page 26

    24 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Operating Instructions 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 p[...]

  • Page 27

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 25 Operator's Manual First Edition · Seventh Printing A uxiliary Controls Use auxiliary power if the primary power source (engine) fails. 1 Turn the key switch to ground or platform control. 2 Pull out the red Emergency Stop button to the on position. 3 Move the lift/drive select switch to t[...]

  • Page 28

    26 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing OPERATING INSTRUCTIONS To Position Platform 1 Hold the function enable switch to either side. 2 Move the appropriate toggle switch according to the markings on the control panel. Drive and steer functions are not available from the groun[...]

  • Page 29

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 27 Operator's Manual First Edition · Seventh Printing OPERATING INSTRUCTIONS Drive Enable Light on indicates that the boom has moved just past either non-steer wheel and the drive function has been interrupted. To drive, hold the drive enable switch to either side and slowly move the drive c[...]

  • Page 30

    28 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Check Engine Light (if equipped) Light on and engine stopped: Tag the machine and remove from service. Light on and engine still running: Contact service personnel within 24 hours. Stopping the Engine Push in the red Emergency Stop butto[...]

  • Page 31

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 29 Operator's Manual First Edition · Seventh Printing Free-wheel Configuration for Winching Chock the wheels to prevent the machine from rolling. Release the non-steer wheel brakes by turning over the drive hub disconnect caps (see below). Be sure the winch line is properly secured to the dr[...]

  • Page 32

    30 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Decals Part No. Decal Description Quantity 25994 Caution - Component Damage Hazard 1 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 27206 Triangle- Blue 2 27207 Triangle - Yellow 2 27564 Danger - Electrocution Hazard 2 28157 Label - Dexron [...]

  • Page 33

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 31 Operator's Manual First Edition · Seventh Printing DECALS Drive Chassis Platform Shading indicates decal is hidden from view, i.e. under covers Ground Controls Side Engine Side[...]

  • Page 34

    32 Genie Z-45/25 & Genie Z-45/25J P ar t No . 52421 Operator's Manual First Edition · Seventh Printing Specifications Standard Base Models Z-45/25 Z-45/25J (no jib) (jib) Height, working maximum 51 ft 8 in 51 ft 6 in 15.74 m 15.69 m Height, platform maximum 45 ft 8 in 45 ft 6 in 13.9 m 13.8 m Height, stowed maximum 6 ft 10 in 6 ft 10 in 2[...]

  • Page 35

    P ar t No. 52421 Genie Z-45/25 & Genie Z-45/25J 33 Operator's Manual First Edition · Seventh Printing Narrow Base Models Z-45/25 Z-45/25J (no jib) (jib) Controls 12V DC proportional Weight See Serial Plate (Machine weights vary with option configurations) Platform dimensions, 6 foot 72 in x 30 in 72 in x 30 in (length x width) 1.8 m x 76 [...]

  • Page 36

    Genie North America Genie Australia Pty Ltd. Genie China Genie Malaysia Genie Japan Genie Korea Genie Africa Genie Latin America Phone T oll Free Fax Phone + Fax + Phone + Fax + Phone + Fax + Phone + Fax + Phone + Fax + Phone + Fax + Phone + Fax + 425.881.1800 USA and Canada 800.536.1800 425.883.3475 61 7 3375 1660 61 7 3375 1002 86 21 53852570 86 [...]