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Genie Z-45, Z-25J manual

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Table of contents for the manual

  • Page 1

    Operator’s Manual Z-45 25 Fourth Edition First Printing Part No. 114339 Serial Number Range after 00000 with Maintenance Information IC Power Z-45 25J ANSI/CSA North America South America Asia AUS Australia[...]

  • Page 2

    Operator's Manual Z-45/25 • Z-45/25J P ar t No . 114339 Fourth Edition • First Printing Impor tant 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[...]

  • Page 3

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 1 Introduction 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 operator'[...]

  • Page 4

    Operator's Manual Fourth Edition · First Printing 2 Z-45/25 • Z-45/25J P ar t No . 114339 Intended Use This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site. Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all [...]

  • Page 5

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 3 Crush Hazard Burn Hazard Fire Hazard Explosion Hazard Electrocution Hazard Fall Hazard Crush Hazard Tip-over Hazard Symbol and Hazard Pictorials Definitions Tip-over Hazard Electrocution Hazard Maintain required clearance. Read the operator’s manual.[...]

  • Page 6

    Operator's Manual Fourth Edition · First Printing 4 Z-45/25 • Z-45/25J P ar t No . 114339 Lanyard attachment point Symbol and Hazard Pictorials Definitions Wheel load Voltage rating for power to platform Pressure rating for air line to platform Replace tires with tires of same specification. Tie-down instructions Tie-down instructions[...]

  • Page 7

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 5 Safety signs and locations General Safety[...]

  • Page 8

    Operator's Manual Fourth Edition · First Printing 6 Z-45/25 • Z-45/25J P ar t No . 114339 General Safety Safety signs and locations[...]

  • Page 9

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 7 Safety signs and locations General Safety[...]

  • Page 10

    Operator's Manual Fourth Edition · First Printing 8 Z-45/25 • Z-45/25J P ar t No . 114339 General Safety Safety signs and locations[...]

  • Page 11

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 9 General Safety Safety signs and locations[...]

  • Page 12

    Operator's Manual Fourth Edition · First Printing 10 Z-45/25 • Z-45/25J P ar t No . 114339 General Safety Safety signs and locations[...]

  • Page 13

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 11 P ersonal Safety Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in [...]

  • Page 14

    Operator's Manual Fourth Edition · First Printing 12 Z-45/25 • Z-45/25J P ar t No . 114339 W ork Area Safety 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 wi[...]

  • Page 15

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 13 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 while the [...]

  • Page 16

    Operator's Manual Fourth Edition · First Printing 14 Z-45/25 • Z-45/25J P ar t No . 114339 W ork Area Safety Z-45/25 and Z-45/25J Narrow Base Models: Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight and proper counterweight configuration are critical to stability. Z-45/25 and Z-45/25J models equi[...]

  • Page 17

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 15 Operation on Slopes Hazards 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 Pla[...]

  • Page 18

    Operator's Manual Fourth Edition · First Printing 16 Z-45/25 • Z-45/25J P ar t No . 114339 Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations. 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 pl[...]

  • Page 19

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 17 W ork Area Safety 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. Do n[...]

  • Page 20

    Operator's Manual Fourth Edition · First Printing 18 Z-45/25 • Z-45/25J P ar t No . 114339 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. Explosion Hazard Keep s[...]

  • Page 21

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 19 Legend 1 Foot switch 2 Manual storage container 3 Sliding mid-rail 4 Lanyard anchorage point 5 Jib boom (Z-45/25J and Z-51/30) 6 Platform 7 Platform controls 8 Primary boom 9 Secondary boom 1 0 Ground controls 1 1 Steer tire 1 2 LPG tank (if equipped)[...]

  • Page 22

    Operator's Manual Fourth Edition · First Printing 20 Z-45/25 • Z-45/25J P ar t No . 114339 Controls 1 3 6 Drive speed select switch 7 Diesel models: 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 Platf[...]

  • Page 23

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 21 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 Not used 1 4 Machine not level indicator light (if[...]

  • Page 24

    Operator's Manual Fourth Edition · First Printing 22 Z-45/25 • Z-45/25J P ar t No . 114339 Platform Control Panel 1 Horn button Push the horn button and the horn will sound. Release the horn button and the horn will stop. 2 Platform level switch Move the platform level switch up and the level of the platform will raise. Move the platform le[...]

  • Page 25

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 23 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 Move the control handle in the direction indicated by the blue arrow on the control panel and[...]

  • Page 26

    Operator's Manual Fourth Edition · First Printing 24 Z-45/25 • Z-45/25J P ar t No . 114339 Controls Ground Control Panel 1 Platform level switch 2 Platform rotate switch 3 Z-45/25J: Jib boom up/down switch 4 Turntable rotate switch 5 Primary boom up/down switch 6 Primary boom extend/retract switch 7 Gasoline/LPG models: Fuel select switch 8[...]

  • Page 27

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 25 Ground Control Panel 1 Platform level switch Move the platform level switch up and the level of the platform will raise. Move the platform level switch down and the level of the platform will lower. 2 Platform rotate switch Move the platform rotate sw[...]

  • Page 28

    Operator's Manual Fourth Edition · First Printing 26 Z-45/25 • Z-45/25J P ar t No . 114339 Controls 1 1 Key switch for platform/off/ground selection Turn the key switch to the platform position and the platform controls will operate. Turn the key switch to the off position and the machine will be off. Turn the key switch to the ground posit[...]

  • Page 29

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 27 Inspections 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 understand the pre-operati[...]

  • Page 30

    Operator's Manual Fourth Edition · First Printing 28 Z-45/25 • Z-45/25J P ar t No . 114339 Inspections Pre-operation Inspection ! Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform. ! Be sure that all decals are legible and in place. See Decals sectio[...]

  • Page 31

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 29 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. K[...]

  • Page 32

    Operator's Manual Fourth Edition · First Printing 30 Z-45/25 • Z-45/25J P ar t No . 114339 Inspections Test the Tilt Sensor 9 Turn the key switch to platform control. Pull out the platform red Emergency Stop button to the on position. 1 0 Open the engine side turntable cover and locate the tilt sensor to the right of the hydraulic pump. 1 1[...]

  • Page 33

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 31 Inspections At the Platform Controls Test Emergency Stop 1 5 Turn the key switch to platform control and restart the engine. 1 6 Push in the platform red Emergency Stop button to the off position. Result: The engine will shut off after 2 or 3 seconds.[...]

  • Page 34

    Operator's Manual Fourth Edition · First Printing 32 Z-45/25 • Z-45/25J P ar t No . 114339 Blue Y ellow Test Drive and Braking 2 9 Press down the foot switch. 3 0 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 35

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 33 Inspections Test Limited Drive Speed - Standard Base Models 3 6 Press down the foot switch. 3 7 Raise the primary boom approximately 2 feet / 61 cm. 3 8 Slowly move the drive control handle to the full drive position. Result: The maximum achievable dr[...]

  • Page 36

    Operator's Manual Fourth Edition · First Printing 34 Z-45/25 • Z-45/25J P ar t No . 114339 Inspections Test the Oscillate Axle (oscillating axle-equipped models) 4 6 Start the engine from the platform controls. 4 7 Drive the right steer tire up onto a 6 inch / 15 cm block or curb. Result: The three remaining tires should stay in firm contac[...]

  • Page 37

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 35 W orkplace Inspection Be aware of and avoid the following hazardous situations: · drop-offs or holes · bumps, floor obstructions or debris · sloped surfaces · unstable or slippery surfaces · overhead obstructions and high voltage conductors · ha[...]

  • Page 38

    Operator's Manual Fourth Edition · First Printing 36 Z-45/25 • Z-45/25J P ar t No . 114339 Inspection for Decals with W or ds Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Inspections Part No. Decal Description Quantity 25994 Notice - Co[...]

  • Page 39

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 37 Inspections Drive Chassis Platform Shading indicates decal is hidden from view, i.e. under covers Ground Controls Side Engine Side[...]

  • Page 40

    Operator's Manual Fourth Edition · First Printing 38 Z-45/25 • Z-45/25J P ar t No . 114339 Part No. Decal Description Quantity 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 27206 Triangle - Blue 2 27207 Triangle - Yellow 2 28158 Label - Unleaded 1 28159 Label - Diesel 1 28160 Label - Liquid Petroleum Gas 1 28174 Label - Power to Platform, 230[...]

  • Page 41

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 39 Drive Chassis Platform Shading indicates decal is hidden from view, i.e. under covers Ground Controls Side Engine Side Inspections[...]

  • Page 42

    Operator's Manual Fourth Edition · First Printing 40 Z-45/25 • Z-45/25J P ar t No . 114339 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 perform functio[...]

  • Page 43

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 41 Operating Instructions Starting the Engine 1 At the ground controls, turn the key switch to the desired position. 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position. Gasoline/LPG models 3 Choose fue[...]

  • Page 44

    Operator's Manual Fourth Edition · First Printing 42 Z-45/25 • Z-45/25J P ar t No . 114339 Operating Instructions Operation from Ground 1 Turn the key switch to ground control. 2 Pull out the red Emergency Stop button to the on position. 3 Gasoline/LPG models: Choose fuel by moving the fuel select switch to the desired position. 4 Start the[...]

  • Page 45

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 43 Operating Instructions Driving on a slope Determine the uphill, downhill and side slope ratings for the machine and determine the slope grade. Maximum slope rating, platform downhill (gradeability): 2WD: 30% (17°) 4WD: 45% (24°) Maximum slope rating[...]

  • Page 46

    Operator's Manual Fourth Edition · First Printing 44 Z-45/25 • Z-45/25J P ar t No . 114339 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 control handle[...]

  • Page 47

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 45 Operating Instructions 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. Air craft Protection P ack age (if equipped) If[...]

  • Page 48

    Operator's Manual Fourth Edition · First Printing 46 Z-45/25 • Z-45/25J P ar t No . 114339 T ranspor t and Lifting Instructions 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 pr[...]

  • Page 49

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 47 Securing to T ruc k or T railer f or T ransit Always use the turntable rotation lock pin each time the machine is transported. Turn the key switch to the off position and remove the key before transporting. Inspect the entire machine for loose or unse[...]

  • Page 50

    Operator's Manual Fourth Edition · First Printing 48 Z-45/25 • Z-45/25J P ar t No . 114339 Observe and Obey: Only qualified riggers should rig and lift the machine. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See the serial label for the machine weight. T ranspor t and Lif[...]

  • Page 51

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 49 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 speci[...]

  • Page 52

    Operator's Manual Fourth Edition · First Printing 50 Z-45/25 • Z-45/25J P ar t No . 114339 Maintenance 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 l[...]

  • Page 53

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 51 Maintenance Check the Batteries Proper battery condition is essential to good engine performance and operational safety. Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions. Electrocut[...]

  • Page 54

    Operator's Manual Fourth Edition · First Printing 52 Z-45/25 • Z-45/25J P ar t No . 114339 Maintenance Scheduled Maintenance Maintenance performed quarterly, 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[...]

  • Page 55

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 53 Specifications Standard Base Models Z-45/25 (no jib) Height, working maximum 51 ft 11 in 16 m Height, platform maximum 45 ft 11 in 14 m Height, stowed maximum 6 ft 11 in 2.11 m Horizontal reach maximum 1 25 ft 1 7.62 m Width 7 ft 6 in 2.29 m Length, s[...]

  • Page 56

    Operator's Manual Fourth Edition · First Printing 54 Z-45/25 • Z-45/25J P ar t No . 114339 Specifications Standard Base Models Z-45/25J (jib) Height, working maximum 52 ft 2 in 16.07 m Height, platform maximum 46 ft 2 in 14.07 m Height, stowed maximum 6 ft 11 in 2.1 m Horizontal reach maximum 25 ft 1 in 7.6 m Width 7 ft 6 in 2.29 m Length, [...]

  • Page 57

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 55 Narrow Base Models Z-45/25 (no jib) Height, working maximum 51 ft 6 in 15.9 m Height, platform maximum 45 ft 6 in 13.9 m Height, stowed maximum 6 ft 7 in 2.05 m Horizontal reach maximum 1 25 ft 1 7.62 m Width 5 ft 10.3 in 1.79 m Length, stowed 18 ft 3[...]

  • Page 58

    Operator's Manual Fourth Edition · First Printing 56 Z-45/25 • Z-45/25J P ar t No . 114339 Narrow Base Models Z-45/25J (jib) Height, working maximum 51 ft 9 in 15.9 m Height, platform maximum 45 ft 9 in 13.9 m Height, stowed maximum 6 ft 7 in 2.0 m Horizontal reach maximum 25 ft 1 in 7.7 m Width 5 ft 10.3 in 1.79 m Length, stowed 22 ft 5 in[...]

  • Page 59

    Operator's Manual Fourth Edition · First Printing P ar t No . 114339 Z-45/25 • Z-45/25J 57 Z-45/25J Range of Motion Z-45/25 Range of Motion Specifications[...]