Genie Z-45/25, Operator'S Manual

Page 1: ...Second Edition First Printing Part No 82595 Operator s Manual with Maintenance Information DC Power ...

Page 2: ...derstand 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 machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page Safety 1 Controls 8 Pre operationInspection 11 Ma...

Page 3: ...ituations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals You read understand and obey employ...

Page 4: ...off Do not use the machine as a ground for welding Do not operate the machine during lightning or storms Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity Maximum platform capacity 500 lbs 227 kg Maximum occupants 2 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 t...

Page 5: ... force CE 90 lbs 400 N Do not alter or disable machine components that in any way affect safety and stability Do not alter or disable the limit switches Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or othe...

Page 6: ...eforeoperating Component Damage Hazard Do not use the machine as a ground for welding Collision Hazards Be aware of limited sight distance and blind spots whendrivingoroperating Be aware of the boom position when rotating the turntable Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Operators must comply wit...

Page 7: ...on inspection All compartments must remain closed and secured during operation Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the batteries only in an open well ventilated area away from sparks flames and lighted toba...

Page 8: ... imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without saf...

Page 9: ...e cable clamps with tools that may cause sparks Component Damage Hazards Do not use any battery charger greater than 48V to charge the batteries Both battery packs must be charged together Disconnect the battery pack plug before removing the battery pack Electrocution Hazards Connect the battery charger to a grounded AC3 wireelectrical outlet only Inspect daily for damaged cord cables and wires Re...

Page 10: ... 10 Machine not level indicator light if equipped 11 Red Emergency Stop button 12 Proportional control handle for drive function and thumb rocker for steer function Platform Control Panel 1 Hornbutton 2 Auxiliary power switch 3 Drive enable indicator light 4 Drive enable switch 5 Z 45 25J DC models Jib boom up down switch 6 Platform rotate switch 2 Controls 5 6 7 15 16 8 4 17 18 3 ...

Page 11: ... Manual Second Edition First Printing CONTROLS 13 Boom function speed controller 14 Primary boom extend retract switch 15 Primary boom up down switch 16 Secondary boom up down switch 17 Turntable rotate switch 18 Battery charge indicator 8 8 8 12 13 8 9 10 11 14 ...

Page 12: ...itch 3 Primary boom up down switch 4 Primary boom extend retract switch 5 Not used 6 Auxiliary power switch 7 Key switch for platform off ground selection 8 Red Emergency Stop button 9 Platform overload indicator light if equipped 10 Hourmeter 11 Function enable switch 12 Secondary boom up down switch 13 10A breaker for control electrical circuits 14 Z 45 25J DC models Jib boom up downswitch 15 Pl...

Page 13: ...designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves 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 If damage or any unauthorized v...

Page 14: ...ng components or areas for damage improperly installed or missing parts and unauthorizedmodifications o Electrical components wiring and electrical cables o Hydraulic power unit hoses fittings cylinders and manifolds o Hydraulic tanks o Drive and turntable motors and torque hubs o Boom wear pads o Tires and wheels o Limit switches alarms and horn o Nuts bolts and other fasteners o Platform entry m...

Page 15: ...inning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure 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 inspec...

Page 16: ... water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps MAINTENANCE Check the Tire Pressure Tip overhazard Anover inflated tire can explode which may compromise machine stability and cause the machine to tip over Tip over hazard The use of temporary flat tire repair products may lead to tire failure which could compromise machine stability and cause the machine to tip...

Page 17: ...airs 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 hazard...

Page 18: ... a test area that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground control 3 Pull out the red Emergency Stop button to the on position Result The beacon if equipped should flash Test Emergency Stop 4 Push in the red Emergency Stop button to the off position Result All functions should not operate 5 Pull out the red Emergency Stop button to the on positio...

Page 19: ... All boom platform functions should operate through a full cycle Note Control the speed of boom functions by adjusting the boom function speed controller Drive and steer functions are not affected by the boom function speed controller Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed...

Page 20: ...b Test Limited Drive Speed 27 Press down the foot switch 28 Raise the primary boom approximately 2 feet 61 cm 29 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 30 Lower the primary boom to the stowed position 31 Raise the secondary boom approximately 2 feet 61 cm 32 Slo...

Page 21: ...he machine may drive in the opposite direction that the drive and steer control handle is moved Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel TestAuxiliaryControls 41 Pull out the red Emergency Stop button to the on position 42 Press down the foot switch 43 Simultaneously hold the auxiliary power switch on and activate each ...

Page 22: ... 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 Alwaysperformapre operation inspection 3 Always perform function tests prior to use 4 Inspecttheworkplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The ...

Page 23: ...one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Emergency Stop Push i...

Page 24: ...ss down the foot switch 2 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch To Steer 1 Press down the foot switch 2 Turn the steer wheels with the thumb ro...

Page 25: ...he machine from service Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off OPERATINGINSTRUCTIONS Machine Not Level Indicator Light if equipped Light on indicates the machine is not level The tilt alarm will be sounding when this light is on Move the machine to a fir...

Page 26: ...nect the battery charger to a grounded AC circuit 6 Turn the battery charger on 7 The charger will indicate when the battery is fully charged 8 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic s...

Page 27: ...rntable rotation lock before transporting Be sure to unlock the turntable for operation Free wheel Configuration for Winching 1 Chock the wheels to prevent the machine from rolling 2 Release the non steer wheel brakes by turning over the drive hub disconnect caps 3 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions After the machine...

Page 28: ... transport surface Use chains or straps of ample load capacity Use a minimum of 4 chains Adjust the rigging to prevent damage to the chains Securing the Platform Z 45 25 Make sure the platform is in the stowed position Secure the platform with a nylon strap placed over the platform mount near the platform rotator see below Do not use excessive downward force when securing the boom section Securing...

Page 29: ...ent to withstand the machine weight See the serial plate for the machineweight Lifting Instructions Fully lower and retract the boom Fully lower the jib if equipped Remove all loose items on the machine Determine the center of gravity of your machine using the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the chassis A...

Page 30: ...86 Notice Connection Diagram 2 31787 Danger Tip over Hazard 2 31788 Danger Battery Safety 2 32700 Danger Safety Rules 2 Part No Decal Description Quantity 33952 Danger Tilt Alarm 1 40434 Label Lanyard Anchorage 3 43658 Label Power to Charger 230V 1 44980 Label Power to Charger 115V 1 44981 Label Air Line to Platform 2 44986 Notice Max Manual Force 90 lbs 400N 1 52664 Label Controller Status Indica...

Page 31: ...No 82595 Genie Z 45 25 DC Genie Z 45 25J DC 29 Operator s Manual Second Edition First Printing DECALS Ground Controls Side Drive Chassis Platform Shading indicates decal is hidden from view i e under covers ...

Page 32: ...8 Label Power to Charger 230V 1 44980 Label Power to Charger 115V 1 44981 Label Air Line to Platform 2 52969 Cosmetic Genie Boom 1 62070 Cosmetic DC Power 1 62926 Cosmetic Genie Z 45 25J 1 62927 Cosmetic Genie Z 45 25 1 Part No Decal Description Quantity 72444 Ground Control Panel 1 82279 Platform Control Panel 1 82472 Warning Crushing Hazard 3 82473 Caution Compartment Access 1 82481 Danger Batte...

Page 33: ...No 82595 Genie Z 45 25 DC Genie Z 45 25J DC 31 Operator s Manual Second Edition First Printing DECALS Ground Controls Side Drive Chassis Platform Shading indicates decal is hidden from view i e under covers ...

Page 34: ... weighted Weight See Serial Plate Machine weights vary with option configurations Platform dimensions 6 foot 72 in x 30 in length x width 1 8 m x 76 cm Platform leveling self leveling Platform rotation 180 degrees Controls 24V DC proportional AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions System voltage 48V Tire size 2WD Industrial 9 14 5 LT Gradeability ...

Page 35: ...rating workstations A weighted Weight See Serial Plate Machine weights vary with option configurations Platform dimensions 6 foot 72 in x 30 in length x width 1 8 m x 76 cm Platform leveling self leveling Platform rotation 180 degrees Controls 24V DC proportional AC outlet in platform standard Hydraulic pressure maximum 3200 psi 221 bar boom functions System voltage 48V Tire size 2WD Industrial 9 ...

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