Operator’s Manual Z-45/25 ANSI/CSA Z-45/25J North America South America DC Power Asia Bi-Energy Power AUS Australia with Maintenance Information Fourth Edition Second Printing Part No. 114344
Operator's Manual Fourth Edition • Second Printing Important Copyright © 1999 by Genie Industries Read, understand and obey these safety rules and Fourth Edition: Second Printing, April 2012 operating instructions before operating this machine. Only trained and authorized personnel shall be \"Genie\" and \"Z\" are registered trademarks of permitted to operate this machine. This manual should Genie Industries in the U.S.A. and many other be considered a permanent part of your machine and countries. should remain with the machine at all times. If you have any questions, call Genie Industries. These machines comply with ANSI/SIA 92.5 Contents CAN B.354.4 Page Printed on recycled paper Introduction ................................................................ 1 Symbol and Hazard Pictorials Definitions ................... 3 Printed in U.S.A. General Safety ........................................................... 5 Personal Safety ........................................................ 11 Work Area Safety ...................................................... 12 Legend ...................................................................... 20 Controls .................................................................... 21 Inspections ............................................................... 28 Operating Instructions ............................................... 44 Transport and Lifting Instructions .............................. 51 Maintenance ............................................................. 54 Specifications ........................................................... 57 Contact us: Internet: http://www.genielift.com E-mail: [email protected] Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Introduction Owners, Users and Operators: Danger Genie appreciates your choice of our machine for Failure to obey the instructions and your application. Our number one priority is user safety rules in this manual will safety, which is best achieved by our joint efforts. result in death or serious injury. We feel that you make a major contribution to safety if you, as the equipment users and Do Not Operate Unless: operators: You learn and practice the principles of safe 1 Comply with employer, job site and machine operation contained in this operator's governmental rules. manual. 2 Read, understand and follow the instructions 1 Avoid hazardous situations. in this and other manuals supplied with this machine. Know and understand the safety rules before going on to the next section. 3 Use good safe work practices in a commonsense way. 2 Always perform a pre-operation inspection. 4 Only have trained/certified operators, directed 3 Always perform function tests prior to use. by informed and knowledgeable supervision, running the machine. 4 Inspect the workplace. If there is anything in this manual that is not clear 5 Only use the machine as it was intended. or which you believe should be added, please contact us. You read, understand and obey the manufacturer's instructions and safety rules— Internet: www.genieind.com safety and operator's manuals and machine decals. Email: [email protected] 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.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 1
Operator's Manual Fourth Edition • Second Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words This machine is intended to be used only to lift to identify the following: personnel, along with their tools and materials to an aerial work site. Red Safety alert symbol—used to alert Orange you to potential personal injury Safety Sign Maintenance Yellow hazards. Obey all safety messages that follow this symbol Replace any missing or damaged safety signs. Blue to avoid possible injury or death. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use Indicates a hazardous situation solvent-based cleaners because they may damage which, if not avoided, will result in the safety sign material. death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates a hazardous situation which, if not avoided, could result in property damage. 2 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Crush Hazard Electrocution Fire Hazard Explosion Hazard Burn Hazard Hazard Fall Hazard Crush Hazard No Open Flames Tip-over Hazard No Smoking Voltage rating for Pressure rating for Electrocution Disconnect Batteries used as power to platform air line to platform Hazard batteries counterweight Explosion Hazard Do not use ether Maintain required Keep away from Only trained or other high clearance path of moving maintenance energy starting platform personnel should aids on machines access equipped with compartments glow plugs Recovery procedure if tilt alarm sounds while elevated. 3 3 Platform uphill: Platform downhill: Platform Platform Chassis 1 Lower primary 1 Retract primary tie-down tie-down tie-down 2 Lower secondary 2 Lower secondary instructions, jib instructions, no jib instructions 3 Retract primary 3 Lower primary Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 3
Operator's Manual Fourth Edition • Second Printing Symbol and Hazard Pictorials Definitions Grounded AC Replace damaged Lanyard Wheel load Read the attachment point operator’s manual 3-wire outlet only wires and cords No smoking Keep away from Keep off this Replace tires with Bodily Injury No flame. moving parts surface Stop engine same tire Hazard Stay clear of belts Maximum Maximum Manual Maximum Wind and fan when platform capacity engine is running Force Speed Burn hazard 4 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual General Safety Safety signs and locations 31060 114390 28177 28161 31060 28161 43595 WARNING 43595 31060 31787 31788 Crush Hazard DANGER DANGER Contact with moving parts can 43595 result in death or serious 31787 injury. Tip-over Hazard DANGER Altering or disabling limit Keep away from moving parts. switches can result in machine tip-over. Machine 28161 C tip-over will result in death or serious injury. 114390 Do not alter or disable limit DANGER switch(s). 31060 C 28177 WARNING Crush Hazard Death or serious injury may result from platform crushing personnel against boom. Keep away from 31788 path of moving platform. 28177 C DANGER Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 5
Operator's Manual Fourth Edition • Second Printing 114389 General Safety Safety signs and locations 114389 114397 114389 DANGER 28236 28236 WARNING Read and understand Operator's Manual, Responsibilities Manual and Safety Manual and all safety signs before using or maintaining machine. Improper operation or If you do not understand the maintenance can result in serious injury or death. information in the manuals, consult your supervisor, the owner or the manufacturer. 28236 D 114397 DANGER 6 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Safety signs and locations General Safety 31060 43595 28181 DANGER DANGER WARNING Tip-over Hazard Fall Hazard Altering or disabling limit Death or serious injury may result switches can result in from climbing or riding on boom. machine tip-over. Machine tip-over will result in death Keep off this surface. 28181 C or serious injury. Do not alter or disable limit 114390 28177 switch(s). WARNING 31060 C Crush Hazard 28175 Death or serious injury may result WARNING from platform crushing DANGER personnel against boom. 31060 Keep away from 28175 path of moving 114390 platform. 28177 C 43595 43595 28181 28177 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 7
Operator's Manual Fourth Edition • Second Printing General Safety 31508 114258 Safety signs and locations DANGER 31788 DANGER 28162 28175 WARNING WARNING 97602 WARNING 31787 114390 DANGER DANGER 114390 (Bi-Energy) 28175 (Bi-Energy) 114258 (Bi-Energy) 97602 (Bi-Energy) 28162 (Bi-Energy) 31508 31788 31787 8 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual General Safety Safety signs and locations 114252 82544 114249 82472 82487 82548 82481 114345 82487 114252 82548 114345 114249 82602 82487 114248 82601 or 82612 82602 114249 114248 114249 A 114252 82612 82472 82544 82601 82481 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 9
Operator's Manual Fourth Edition • Second Printing General Safety Safety signs and locations 114251 82481 82473 114251 A 114334 82544 114249 114249 A 114252 82548 114391 114247 114345 114391 A 82544 (Bi-Energy) 114252 (Bi-Energy) 82473 (Bi-Energy) 114251 (Bi-Energy) 114391 (Bi-Energy) 82473 82544 114334 82481 114249 82548 114249 114345 114247 10 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Fall Protection Personal Safety 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 the platform. 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.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 11
Operator's Manual Fourth Edition • Second Printing Work Area Safety 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. proximity to electrical current. Maximum platform capacity 500 lbs 227 kg 440 lbs Maximum platform capacity 200 kg Machine equipped with 2 Aircraft Protection Package Maximum occupants Maintain required clearances from electrical power The weight of options and accessories, such as lines and apparatus in accordance with applicable pipe cradles, panel cradles and welders, will reduce governmental regulations and the following chart. the rated platform capacity and must be factored into the total platform load. See the decals on the Line Voltage Required Clearance options and accessories. 0 to 50KV 10 ft 3.0 m 50 to 200KV 15 ft 4.6 m If using accessories, read, understand and obey 200 to 350KV 20 ft 6.1 m the decals and instructions with the accessory. 350 to 500KV 25 ft 7.6 m 500 to 750KV 35 ft 10.6 m Do not alter or disable the limit switches. 750 to 1000KV 45 ft 13.7 m Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight and proper counterweight configuration are critical to stability. Do not raise or extend the boom unless the machine is on a firm, level surface. Allow for platform movement, electrical line sway or Do not depend on the tilt alarm as a level indicator. sag and beware of strong or gusty winds. The tilt alarm sounds in the platform only when the machine is on a severe slope. Keep away from the machine if it contacts energized power lines. Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off. Do not operate the machine during lightning or storms. Do not use the machine as a ground for welding. 12 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Work Area Safety If the tilt alarm sounds while the boom is lowered: Do not operate the machine in strong or gusty Do not extend, rotate or raise the boom above winds. Do not increase the surface area of the horizontal. Move the machine to a firm, level platform or the load. Increasing the area exposed to surface before raising the platform. the wind will decrease machine stability. If the tilt alarm sounds when the platform is raised: Use extreme care and slow speeds while driving Use extreme caution. Identify the condition of the the machine in the stowed position across uneven boom on the slope as shown below. Follow the terrain, debris, unstable or slippery surfaces and steps to lower the boom before moving to a firm, near holes and drop-offs. level surface. Do not rotate the boom while Do not drive the machine on or near uneven terrain, lowering. unstable surfaces or other hazardous conditions with the boom raised or extended. If the tilt alarm sounds with Do not push off or pull toward any object outside of the platform uphill: the platform. 1 Lower the primary boom. 3 Maximum allowable side force - ANSI & CSA 2 Lower the secondary 150 lbs / 667 N boom. Maximum allowable manual force - AUS 3 Retract the primary 90 lbs / 400 N boom. If the tilt alarm sounds with the platform downhill: 1 Retract the primary boom. 2 Lower the secondary 3 boom. 3 Lower the primary boom. Do not raise the boom when wind speeds may exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 13
Operator's Manual Fourth Edition • Second Printing Work Area Safety Do not alter or disable machine components that in Do not use the platform controls to free a platform any way affect safety and stability. that is caught, snagged or otherwise prevented Do not replace items critical to machine stability from normal motion by an adjacent structure. All with items of different weight or specification. personnel must be removed from the platform Do not modify or alter an aerial work platform before attempting to free the platform using the without prior written permission from the ground controls. manufacturer. Mounting attachments for holding tools or other materials onto the platform, toeboards Do not use batteries that weigh less than the or guard rail system can increase the weight in the original equipment. Batteries are used as platform and the surface area of the platform or the counterweight and are critical to machine stability. load. Each battery must weigh a minimum of Do not place or attach overhanging loads to any 105 lbs / 47.6 kg. Each battery box including part of this machine. batteries must weigh a minimum of 530 lbs / 240.4 kg. Do not place ladders or scaffolds in the platform or against any part of this machine. Do not use the machine as a crane. Do not transport tools and materials unless they are evenly distributed and can be safely handled by Do not push the machine or other objects with the person(s) in the platform. boom. Do not use the machine on a moving or mobile surface or vehicle. Do not contact adjacent structures with the boom. Be sure all tires are in good condition and lug nuts are properly tightened. Do not tie the boom or platform to adjacent structures. Do not place loads outside the platform perimeter. 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 Platform downhill 30% (17°) Platform uphill 20% (11°) Side slope 25% (14°) Note: Slope rating is subject to ground conditions and adequate traction. See Driving on a Slope in the Operating Instructions section. 14 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the Be aware of the boom position and tailswing when anchor provided in the rotating the turntable. platform. Check the work area for overhead obstructions or Do not sit, stand or climb on the platform guard other possible hazards. rails. Maintain a firm footing on the platform floor at all times. Do not climb down from the platform when raised. Be aware of crushing hazards when grasping the platform guard rail. Keep the platform floor clear of debris. Operators must comply with employer, job site and Lower the platform entry mid-rail or close the entry governmental rules regarding the use of personal gate before operating. protective equipment. Do not enter or exit the platform unless the Observe and use the color-coded direction arrows machine is in the stowed position and the platform on the platform controls and drive chassis for drive is at ground level. and steer functions. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 15
Operator's Manual Fourth Edition • Second Printing Work Area Safety Do not lower the boom unless the area below is Explosion and Fire Hazards clear of personnel and obstructions. All models: Limit travel speed according to the condition of the Charge the battery only in an open, well-ventilated ground surface, congestion, slope, location of area away from sparks, flames and lighted tobacco. personnel, and any other factors which may cause collision. Do not operate the machine in hazardous locations Do not operate a boom in the path of any crane or locations where potentially flammable or unless the controls of the crane have been locked explosive gases or particles may be present. out and/or precautions have been taken to prevent any potential collision. Bi-Energy models: No stunt driving or horseplay while operating a Do not start the engine if you smell or detect liquid machine. petroleum gas (LPG), gasoline, diesel fuel or other explosive substances. Do not refuel the machine with the engine running. Refuel the machine only in an open, well-ventilated area away from sparks, flames and lighted tobacco. Do not spray ether into engines equipped with glow plugs. 16 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Component Damage Hazard All models: All models: Do not operate the machine with a hydraulic oil or Do not use the machine as a ground for welding. air leak. An air leak or hydraulic leak can penetrate and/or burn skin. Bi-Energy models: Do not use any battery or charger greater than 12V Improper contact with components under any cover to jump-start the engine. will cause serious injury. Only trained maintenance personnel should access compartments. Access by the operator is only advised when performing a pre-operation inspection. All compartments must remain closed and secured during operation. Bi-Energy models: When the engine is running, operate the machine in a well-ventilated area to avoid carbon monoxide poisoning. Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine. Be sure all maintenance has been performed as specified in this manual and the appropriate service manual. Be sure all decals are in place and legible. Be sure the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located on the platform. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 17
Operator's Manual Fourth Edition • Second Printing Work Area Safety Battery Safety Component Damage Hazards Burn Hazards Do not use any battery charger greater than 48V to charge the batteries. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Both battery packs must be charged together. Avoid spilling or contacting battery acid. Neutralize Disconnect the battery pack plug before removing battery acid spills with baking soda and water. the battery pack. The battery pack must remain in the upright position. Electrocution Hazards Do not expose the batteries or the charger to water or rain. Connect the battery charger to a grounded, AC 3-wire electrical Explosion Hazards outlet only. Keep sparks, flames and Inspect daily for damaged cord, lighted tobacco away cables and wires. Replace from batteries. Batteries damaged items before emit an explosive gas. operating. The battery pack cover must remain off during Avoid electrical shock from contact with battery the entire charging cycle. terminals. Remove all rings, watches and other Do not contact the jewelry. battery terminals or the cable clamps with tools Tip-over Hazard that may cause sparks. Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability. Each battery must weigh a minimum of 105 lbs / 47.6 kg. Each battery box including batteries must weigh a minimum of 530 lbs / 240.4 kg. Lifting Hazard Use a forklift to remove or install the battery packs. 18 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Lockout After Each Use Work Area Safety 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. 4 Turn the key switch to the off position and remove the key to secure from unauthorized use. 5 Chock the wheels. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 19
Operator's Manual Fourth Edition • Second Printing Legend 8 7 6 Z-45/25 7 6 9 Z-45/25J 10 11 5 12 4 13 14 3 2 1 1 Foot switch 8 Primary boom 2 Manual storage container 9 Secondary boom 3 Sliding mid-rail 10 Ground controls 4 Lanyard anchorage point 11 Power to charger (between tires) 5 Jib boom (Z-45/25J) 12 Steer tire 6 Platform 13 Battery box 7 Platform controls 14 Non-steer tire 20 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual 7 Controls 89 10 6 11 5 4 5 3 2 12 1 13 18 17 16 15 5 14 Ground Control Panel 8 Key switch for platform/off/ground selection 9 Red Emergency Stop button 1 Platform rotate switch 10 Not used 11 Hour meter 2 Turntable rotate switch 12 Bi-Energy models: Glow plug switch 13 Function enable switch 3 Primary boom up/down switch 14 Bi-Energy models: Engine start switch 15 Secondary boom up/down switch 4 Primary boom extend/retract switch 16 10A breaker for control electrical circuits 17 Z-45/25J: Jib boom up/down switch 5 Used for optional equipment 18 Platform level switch 6 Bi-Energy models: Engine idle (rpm) select switch • turtle: low idle • rabbit: high idle and quickest battery charging 7 Auxiliary power switch Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 21
Operator's Manual Fourth Edition • Second Printing Controls Ground Control Panel 8 Key switch for platform/off/ground selection 1 Platform rotate switch Turn the key switch to the platform position and the platform controls will operate. Turn the key Move the platform rotate switch to the off position and the machine will switch to the right and the be off. Turn the key switch to the ground platform will rotate to the position and the ground controls will operate. right. Move the platform rotate switch to the left and 9 Red Emergency Stop button the platform will rotate to the left. Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red 2 Turntable rotate switch Emergency Stop button to the on position to operate the machine. Move the switch to the right and the turntable will move to the 10 Not used right. Move the switch to the left and the turntable will move 11 Hour meter to the left. The hour meter displays the number of hours the 3 Primary boom up/down switch machine has operated. Move the switch up and the 12 Bi-Energy models: Glow plug switch primary boom will raise. Move the switch down and the Move the glow plug switch to either side and primary boom will lower. hold for 3 to 5 seconds before starting the engine. 4 Primary boom extend/retract switch 13 Function enable switch Move the switch to the left Move the function enable switch to either side to and the boom will extend. enable the functions on the ground control panel Move the switch to the right to operate. and the boom will retract. 14 Bi-Energy models: Engine start switch 5 Used for optional equipment Move the engine start switch to either side to 6 Bi-Energy models: Engine idle (rpm) select start the engine. switch 15 Secondary boom up/down Move the switch to the left (turtle) for low idle. switch Move the switch to the right (rabbit) for high idle and quickest battery charging. Move the switch up and the secondary boom will raise. 7 Auxiliary power switch Move the switch down and the secondary boom will lower. Use auxiliary power if the primary power source fails. Simultaneously hold the auxiliary power switch to either side and activate the desired function. 22 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual 16 10A breaker for control electrical circuits. Controls 17 Z-45/25J: Jib boom up/down switch Move the switch up and the jib boom will raise. Move the switch down and the jib boom will lower. 18 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. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 23
Operator's Manual Fourth Edition • Second Printing Controls 2 3 45 6 7 1 21 8 20 19 18 Platform Control Panel 8 Used for optional equipment 1 Horn button 2 Auxiliary power switch 9 Bi-Energy models: Glow plug switch 3 Drive enable indicator light 4 Drive enable switch 10 Bi-Energy models: Engine start switch 5 Z-45/25J: Jib boom up/down switch 6 Platform rotate switch 11 Bi-Energy models: 7 Platform level switch Engine idle (rpm) select switch • Rabbit & Foot Switch: foot switch activated high idle • Turtle: low idle • Rabbit: high idle and quickest battery charging 24 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual 8 9 10 11 12 13 Controls 14 17 16 15 12 Not used 18 Primary boom up/down switch 13 Machine not level indicator light 19 Secondary boom up/down switch 14 Red Emergency Stop button 20 Turntable rotate switch 15 Proportional control handle for drive function and 21 Battery charge indicator thumb rocker for steer function 16 Boom function speed controller 17 Primary boom extend/retract switch Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 25
Operator's Manual Fourth Edition • Second Printing Controls Platform Control Panel 7 Platform level switch 1 Horn button Move the platform level switch up and the level of Push the horn button and the horn will sound. the platform will raise. Move Release the horn button and the horn will stop. the platform level switch down and the level of the 2 Auxiliary power switch platform will lower. Use auxiliary power if the primary power source 8 Used for optional equipment fails. Simultaneously hold the auxiliary power switch 9 Bi-Energy models: Glow plug switch to either side and activate the desired function. Move the glow plug switch to either side and 3 Drive enable indicator light hold for 3 to 5 seconds before starting the engine. Light on indicates that the boom has moved just past either non-steer wheel and drive function 10 Bi-Energy models: Engine start switch has been interrupted. Move the engine start switch to either side to 4 Drive enable switch start the engine. To drive when the drive enable light is on, hold 11 Bi-Energy models: Engine idle (rpm) select the drive enable switch to either side and slowly switch move the drive control handle off center. Be aware that the machine may move in the Move the switch to the left (rabbit & foot switch) opposite direction that the drive and steer for foot switch activated high idle. controls are moved. Move the switch to the center (turtle) for low idle. 5 Z-45/25J: Jib boom up/down switch Move the switch to the right (rabbit) for high idle and quickest battery charging. Move the switch up and the jib boom will raise. Move the 12 Not used. switch down and the jib boom will lower. 13 Machine not level indicator light 6 Platform rotate switch The machine not level indicator light will come on when the tilt alarm sounds. Move the platform rotate switch to the right and the 14 Red Emergency Stop button platform will rotate to the right. Move the platform Push in the red Emergency Stop button to the rotate switch to the left off position to stop all functions. Pull out the red and the platform will rotate Emergency Stop button to the on position to to the left. operate the machine. 26 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Controls 15 Proportional control handle for drive function and 20 Turntable rotate switch thumb rocker for steer function Move the switch to the right and Move the control handle in the direction the turntable will move to the indicated by the blue arrow on the control panel right. Move the switch to the left and the machine will drive forward. Move the and the turntable will move to the control handle in the direction indicated by the left. yellow arrow and the machine will drive backwards. 21 Battery charge indicator Press the left side of the thumb rocker and the The battery charge indicator displays the charge machine will steer to the left. Press the right level of the batteries. side of the thumb rocker and the machine will steer to the right. 16 Boom function speed controller Turn the dial to increase or decrease the speed of the machine functions. 17 Primary boom extend/retract switch Move the switch down and the primary boom will extend. Move the switch up and the primary boom will retract. 18 Primary boom up/down switch Move the switch up and the primary boom will raise. Move the switch down and the primary boom will lower. 19 Secondary boom up/down switch Move the switch up and the secondary boom will raise. Move the switch down and the secondary boom will lower. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 27
Operator's Manual Fourth Edition • Second Printing Inspections Do Not Operate Unless: Pre-operation Inspection Fundamentals You learn and practice the principles of safe machine operation contained in this operator's It is the responsibility of the operator to perform a manual. pre-operation inspection and routine maintenance. 1 Avoid hazardous situations. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. 2 Always perform a pre-operation The inspection is designed to discover if anything inspection. is apparently wrong with a machine before the operator performs the function tests. Know and understand the pre-operation inspection before going on to the next The pre-operation inspection also serves to section. determine if routine maintenance procedures are required. Only routine maintenance items specified 3 Always perform function tests prior to use. in this manual may be performed by the operator. 4 Inspect the workplace. Refer to the list on the next page and check each of the items. 5 Only use the machine as it was intended. If damage or any unauthorized variation from factory delivered condition is discovered, the machine must be tagged and removed from service. Repairs 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 again before going on to the function tests. Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual. 28 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection Fuel tank (if equipped) Be sure that the operator’s, safety and Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the Platform entry mid-rail or gate platform. Check entire machine for: Be sure that all decals are legible and in place. See Inspections section. Cracks in welds or structural components Check for hydraulic oil leaks and proper oil level. Dents or damage to machine Add oil if needed. See Maintenance section. Excessive rust, corrosion or oxidation Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See Be sure that all structural and other critical Maintenance section. components are present and all associated fasteners and pins are in place and properly Bi-Energy models: Check for engine oil leaks tightened. and proper fluid level. Add oil if needed. See Maintenance section. Be sure that both battery packs are in place and properly connected. Bi-Energy models: Check for engine coolant leaks and proper fluid level. Add coolant if After you complete your inspection, be sure that needed. See Maintenance section. all compartment covers are in place and latched. Check the following components or areas for damage, improperly installed or missing parts and unauthorized modifications: Electrical components, wiring and electrical cables Hydraulic hoses, fittings, cylinders and manifolds Hydraulic tank Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Limit switches and horn Alarms and beacons (if equipped) Engine and related components (if equipped) Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 29
Operator's Manual Fourth Edition • Second Printing Inspections Do Not Operate Unless: Function Test Fundamentals You learn and practice the principles of safe The function tests are designed to discover any machine operation contained in this operator's malfunctions before the machine is put into service. manual. The operator must follow the step-by-step instructions to test all machine functions. 1 Avoid hazardous situations. A malfunctioning machine must never be used. If 2 Always perform a pre-operation malfunctions are discovered, the machine must be inspection. tagged and removed from service. Repairs to the machine may only be made by a qualified service 3 Always perform function tests prior to technician, according to the manufacturer's use. specifications. Know and understand the function tests After repairs are completed, the operator must before going on to the next section. perform a pre-operation inspection and function tests again before putting the machine into service. 4 Inspect the workplace. 5 Only use the machine as it was intended. 30 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections 1 Select a test area that is firm, level and free of Test the Tilt Sensor obstruction. 10 Pull out the platform red Emergency Stop button At the Ground Controls to the on position. Turn the key switch to platform control. 2 Turn the key switch to ground control. 11 Open the turntable cover on the 3 Pull out the red Emergency Stop button to side opposite the ground controls the on position. and locate the tilt sensor. Result: The beacon (if equipped) should flash. 12 Press down one side of the tilt sensor. 4 Bi-Energy models: Start the engine. See Operating Instructions section. Result: The alarm, located in the platform, should sound. Test Emergency Stop Test Auxiliary Controls 5 Push in the red Emergency Stop button to the off position. 13 Turn the key switch to ground control. Result: The engine (if equipped) should turn off. 14 Pull out the red Emergency Stop button to the on position. 6 Activate each machine function control handle or toggle switch. 15 Simultaneously hold the auxiliary power switch on and activate each Result: No functions should operate. boom function toggle switch. 7 Pull out the red Emergency Stop button to Note: To conserve battery power, test each the on position. function through a partial cycle. Test Machine Functions and Descent Alarm Result: All boom functions should operate. 8 Do not hold the function enable switch to either side. Attempt to activate each boom and platform function toggle switch. Result: All boom and platform functions should not operate. 9 Hold the function enable switch to either side and activate each boom and platform function toggle switch. Result: All boom and platform functions should operate through a full cycle. The descent alarm should sound while the boom is lowering. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 31
Operator's Manual Fourth Edition • Second Printing Inspections At the Platform Controls Test the Steering 16 Turn the key switch to platform control. 27 Press down the foot switch. 17 Pull out the red Emergency Stop button to 28 Press the thumb rocker switch on top of the the on position. drive control handle in the direction indicated by the blue triangle on the control panel. 18 Bi-Energy models: Start the engine. See Operating Instructions section. Result: The steer wheels should turn in the direction that the blue triangles point on the Test Emergency Stop drive chassis. 19 Turn the key switch to platform control. 29 Press the thumb rocker switch in the direction indicated by the yellow triangle on the control 20 Push in the platform red Emergency Stop button panel. to the off position. Result: The steer wheels should turn in the Result: The engine (if equipped) should turn off. direction that the yellow triangles point on the drive chassis. 21 Activate each machine function control handle or toggle switch. Test Drive and Braking Result: No functions should operate. 30 Press down the foot switch. 22 Pull out the red Emergency Stop button. 31 Slowly move the drive control handle in the direction indicated by the blue arrow on the Test the Horn control panel until the machine begins to move, then return the handle to the center position. 23 Push the horn button. Result: The machine should move in the Result: The horn should sound. direction that the blue arrow points on the drive chassis, then come to an abrupt stop. Test the Foot Switch 32 Slowly move the drive control handle in the 24 Do not press down the foot switch. Test each direction indicated by the yellow arrow on the machine function. control panel until the machine begins to move, then return the handle to the center position. Result: The machine functions should not operate. Result: The machine should move in the direction that the yellow arrow points on the Test Machine Functions and Descent Alarm drive chassis, then come to an abrupt stop. 25 Press down the foot switch. Note: The brakes must be able to hold the machine on any slope it is able to climb. 26 Activate each machine function control handle or toggle switch. Result: All boom and platform functions should operate through a full cycle. The descent alarm should sound while the boom is lowering. 32 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 33 Press down the foot switch 37 Press down the foot switch. and lower the boom to the stowed position. 38 Raise the primary boom approximately 3 feet / 90 cm. 34 Rotate the turntable until the boom moves past one 39 Slowly move the drive control handle to the full of the non-steer wheels. drive position. Result: The drive enable indicator light should Result: The maximum achievable drive speed come on and remain on while the boom is with the primary boom raised should not exceed anywhere in the range shown. 1 foot / 30 cm per second. 35 Move the drive control handle off center. 40 Lower the primary boom to the stowed position. Result: The drive function should not operate. 41 Raise the secondary boom approximately 3 feet / 91 cm. 36 Move and hold the drive enable toggle switch to either side and slowly move the drive control 42 Slowly move the drive control handle to the full handle off center. drive position. Result: The drive function should operate. Result: The maximum achievable drive speed with the secondary boom raised should not Note: When the drive enable system is in use, the exceed 1 foot / 30 cm per second. machine may drive in the opposite direction that the drive and steer control handle is moved. 43 Lower the secondary boom to the stowed position. Use the color-coded direction Blue arrows on the platform 44 Extend the primary boom approximately controls and the drive chassis 2 feet / 60 cm. to identify the direction of travel. 45 Slowly move the drive control handle to the full drive position. Yellow Result: The maximum achievable drive speed with the primary boom extended should not exceed 1 foot / 30 cm per second. 46 Retract the boom. If the drive speed with the primary boom raised, the secondary boom raised or the primary boom extended exceeds 1 foot / 30 cm per second, immediately tag and remove the machine from service. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 33
Operator's Manual Fourth Edition • Second Printing Inspections Test Auxiliary Controls 47 Pull out the red Emergency Stop button to the on position. 48 Press down the foot switch. 49 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch. Note: To conserve battery power, test each function through a partial cycle. Result: All boom and steer functions should operate. Drive functions should not operate with auxiliary power. 34 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections Do Not Operate Unless: Workplace Inspection You learn and practice the principles of safe Be aware of and avoid the following hazardous machine operation contained in this operator's situations: manual. • drop-offs or holes 1 Avoid hazardous situations. • bumps, floor obstructions or debris • sloped surfaces 2 Always perform a pre-operation • unstable or slippery surfaces inspection. • overhead obstructions and high voltage 3 Always perform function tests prior to use. conductors • hazardous locations 4 Inspect the workplace. • inadequate surface support to withstand all load Know and understand the workplace forces imposed by the machine inspection before going on to the next • wind and weather conditions section. • the presence of unauthorized personnel • other possible unsafe conditions 5 Only use the machine as it was intended. Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation. It should be performed by the operator prior to moving the machine to the workplace. 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.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 35
Operator's Manual Fourth Edition • Second Printing Inspections DC Models - Inspection for Decals with Words 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. Part No. Decal Description Quantity Part No. Decal Description Quantity 27204 27205 Arrow - Blue 1 44986 Instructions - Maximum Manual Force, 27206 AUS, 90 lbs / 400 N 27207 Arrow - Yellow 1 1 28161 28165 Triangle - Blue 2 48731 Label - FM Approval (option) 1 28174 28175 Triangle - Yellow 2 48732 Label - EE Rating (option) 2 28176 28177 Warning - Crushing Hazard 1 52664 Label - Controller Status Indicator Light 1 28181 28235 Instructions - Foot Switch 1 52865 Warning - Annual Service Inspection 1 28236 28372 Label - Power to Platform, 230V 2 52947 Instructions - Operating Instructions, 30080 Ground Controls 1 31060 31508 Warning - Compartment Access 1 52969 Cosmetic - Genie Boom 1 31785 Label - Missing Manuals 1 62070 Cosmetic - DC Power 1 31787 31788 Warning - Platform Rotate 2 62926 Cosmetic - Genie Z-45/25J 1 32728 40434 Warning - Fall Hazard 1 62927 Cosmetic - Genie Z-45/25 1 43595 43658 Label - Power to Platform, 115V 2 65301 Label - Tire Specifications 4 44248 Warning - Improper Operation 1 72444 Ground Control Panel 1 44980 44981 Notice - Battery Cables 2 72833 Label - Open 2 Instructions - Maximum Capacity, 1 72867 Label - Lights (option) 1 500 lbs / 227 kg Danger - Tip-over Hazard, Interlock 3 82279 Platform Control Panel 1 Danger - Electrocution Hazard, AC 82366 Label - Chevron Rykon 1 Power Supply 1 97815 Label - Lower Mid-rail 1 Instructions - Battery Charger 2 97887 Instructions - Maximum Side Force, ANSI & CSA, 150 lbs / 667 N Danger - Tip-over Hazard, Batteries 2 1 Danger - Battery Safety 2 114025 Label - Wheel Load 4 Label - AC Inverter (option) 1 114114 Label - Transport Diagram 2 Label - Lanyard Anchorage 3 114117 Instructions - Battery Connection 2 Danger - Tip-over Hazard, Tires 4 114350 Label - AC Inverter Power (option) 2 Label - Power to Charger, 230V 1 114389 Danger - Safety Rules 2 Instructions - Maximum Capacity, 114390 Danger - Electrocution Hazard 2 440 lbs / 200 kg (Aircraft Protection option) 1 114397 Danger - Tilt Alarm 1 Label - Power to Charger, 115V 1 1000001 Instructions - Operating Instructions, Platform Controls Label - Air Line to Platform (option) 2 1 36 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections Ground 31060 62926 114390 114389 52664 Controls or 62927 28161 82366 52947 72444 Side 48731 40434 52865 28181 Serial Label 28177 43595 65301 27207 Chassis 72833 31788 Platform 31787 114025 31785 Shading indicates 28372 114117 decal is hidden from 48732 27207 view, i.e. under covers 114114 44980 or 43595 43658 65301 27204 114025 52969 82279 31508 72867 27206 32728 31788 114397 31787 1000001 31785 114117 114389 31060 97815 27206 28236 27205 30080 or 62070 44248 28165 31060 28176 44981 28175 114390 97887 or 43595 44986 65301 114025 28174 or 28235 28372 114114 65301 44981 28174 or 114350 72833 48732 43595 114025 114350 28235 40434 40434 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 28177 37
Operator's Manual Fourth Edition • Second Printing Inspections Bi-Energy Models - Inspection for Decals with Words 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. Part No. Decal Description Quantity Part No. Decal Description Quantity 27204 27205 Arrow - Blue 1 44981 Label - Air Line to Platform (option) 2 27206 27207 Arrow - Yellow 1 44986 Instructions - Maximum Manual Force, 28159 AUS, 90 lbs / 400 N 28161 Triangle - Blue 2 1 28162 28165 Triangle - Yellow 2 52664 Label - Controller Status Indicator Light 1 28174 28175 Label - Diesel 1 52865 Warning - Annual Service Inspection 1 28176 28177 Warning - Crushing Hazard 1 52969 Cosmetic - Genie Boom 1 28181 28235 Warning - Cushing Hazard 1 62068 Cosmetic - Bi-Energy 1 28236 28372 Instructions - Foot Switch 1 62926 Cosmetic - Genie Z-45/25J 1 30080 Label - Power to Platform, 230V 2 62927 Cosmetic - Genie Z-45/25 1 31060 31508 Warning - Compartment Access 1 65301 Label - Tire Specifications 4 31785 Label - Missing Manuals 1 72444 Ground Control Panel 1 31787 31788 Warning - Platform Rotate 2 72833 Label - Open 2 32728 40434 Warning - Fall Hazard 1 72867 Label - Lights (option) 1 43595 43658 Label - Power to Platform, 115V 2 82279 Platform Control Panel 1 44248 Warning - Improper Operation 1 82366 Label - Chevron Rykon 1 44980 Notice - Battery Cables 2 97602 Warning - Explosion Hazard 1 Instructions - Maximum Capacity, 97815 Label - Lower Mid-rail 1 500 lbs / 227 kg 1 97887 Instructions - Maximum Side Force, 150 lbs / 667 N Danger - Tip-over Hazard, Interlock 3 1 Danger - Electrocution Hazard, AC 110282 Instructions - Kubota Engine Specs 1 Power Supply 1 114025 Label - Wheel Load 4 Instructions - Battery Charger 2 114114 Label - Transport Diagram 2 Danger - Tip-over Hazard, Batteries 2 114117 Instructions - Battery Connection 2 Danger - Battery Safety 2 114258 Danger - No Smoking 1 Label - AC Inverter (option) 1 114350 Label - AC Inverter Power (option) 2 Label - Lanyard Anchorage 3 114389 Danger - Safety Rules 2 Danger - Tip-over Hazard, Tires 4 114390 Danger - Electrocution Hazard 2 Label - Power to Charger, 230V 1 114397 Danger - Tilt Alarm 1 Instructions - Maximum Capacity, 1000027 Instructions - Operating Instructions 2 440 lbs / 200 kg (Aircraft Protection option) 1 Label - Power to Charger, 115V 1 38 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Inspections Ground 31060 62926 114390 114389 52664 Controls or 62927 28161 82366 1000027 72444 Side 40434 52865 Chassis Serial Label 28181 Platform 43595 28177 Shading indicates 65301 decal is hidden from 72833 27207 view, i.e. under covers 31788 114025 31787 28372 31785 114117 114114 27207 43595 44980 or 65301 43658 114025 27204 52969 82279 31508 72867 27206 32728 31788 114397 31787 31785 1000027 114117 114389 31060 97815 27206 28236 27205 62068 30080 or 44248 114390 28165 31060 28176 28175 44981 28159 114258 97887 or 110282 44986 28162 97602 28174 or 28235 114350 40434 40434 28177 65301 43595 72833 114114 65301 44981 28174 or 114025 28372 43595 114025 114350 28235 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 39
Operator's Manual Fourth Edition • Second Printing Inspections DC Models - Inspection for Decals with Symbols 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. Part No. Decal Description Quantity Part No. Decal Description Quantity 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 82548 Label - Platform Rotate 2 27206 Triangle - Blue 2 27207 Triangle - Yellow 2 82601 Label - Maximum Capacity, 227 kg 1 28174 Label - Power to Platform, 230V 2 28235 Label - Power to Platform, 115V 2 82602 Label - Max Manual Force, 667 N 1 40434 Label - Lanyard Anchorage 3 44981 Label - Air Line to Platform 2 82612 Label - Maximum Capacity, 200 kg 52969 Cosmetic - Genie Boom 1 (Aircraft Protection Package) 62070 Cosmetic - DC Power 1 1 62926 Cosmetic - Genie Z-45/25J 1 62927 Cosmetic - Genie Z-45/25 1 82647 Label - Drive Enable Patch 1 72867 Label - Lights (option) 1 82472 Label - Crushing Hazard 1 97815 Label - Lower Mid-rail 1 82473 Warning - Compartment Access 1 82481 Label - Battery Safety 2 72444 Ground Control Panel 1 82487 Label - Read the Manual 2 82544 Label - Electrocution Hazard 2 82279 Platform Control Panel 1 114025 Label - Wheel Load 4 114247 Label - Fall Hazard 1 114248 Label - Tilt Alarm 1 114249 Label - Tip-over Hazard, Tires 4 114252 Label - Tip-over Hazard 3 114334 Label - Electrocution Hazard, AC 1 Power Supply 114114 Label - Transport Diagram 2 114345 Label - Tip-over Hazard, Batteries 2 40 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual 114252 62926 or 82544 Inspections 62927 82472 82487 Ground Controls 40434 Chassis Side 82548 Platform 72444 114247 Shading indicates Serial Plate decal is hidden from 27207 view, i.e. under covers 114249 82481 114025 114345 27207 114114 27204 114249 43658 114025 or 44980 52969 82279 114334 82647 27206 72867 82481 82487 114345 114248 114252 97815 27206 82601 or 27205 82612 62070 44981 82602 114252 82473 28174 82544 or 28235 114025 40434 82548 114249 114249 28174 44981 114114 114025 or 28235 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 41
Operator's Manual Fourth Edition • Second Printing Inspections Bi-Energy Models - Inspection for Decals with Symbols 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. Part No. Decal Description Quantity Part No. Decal Description Quantity 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 82601 Label - Maximum Capacity, 227 kg 1 27206 Triangle - Blue 2 27207 Triangle - Yellow 2 82602 Label - Max Side Force, 667 N 1 28159 Label - Diesel 1 28174 Label - Power to Platform, 230V 2 82612 Label - Maximum Capacity, 200 kg 28235 Label - Power to Platform, 115V 2 (Aircraft Protection Package) 40434 Label - Lanyard Anchorage 3 1 44981 Label - Air Line to Platform 2 52969 Cosmetic - Genie Boom 1 82647 Label - Drive Enable Patch 1 62068 Cosmetic - Bi-Energy 1 62926 Cosmetic - Genie Z-45/25J 1 97815 Label - Lower Mid-rail 1 62927 Cosmetic - Genie Z-45/25 1 72867 Label - Lights (option) 1 72444 Ground Control Panel 1 82472 Label - Crushing Hazard 1 82473 Warning - Compartment Access 1 82279 Platform Control Panel 1 82481 Label - Battery Safety 2 82487 Label - Read the Manual 2 114025 Label - Wheel Load 4 82544 Label - Electrocution Hazard 2 82548 Label - Platform Rotate 2 114247 Label - Fall Hazard 1 114248 Label - Tilt Alarm 1 114249 Label - Tip-over Hazard, Tires 4 114251 Label - No Smoking 1 114252 Label - Tip-over Hazard 3 114334 Label - Electrocution Hazard, AC 1 Power Supply 114114 Label - Transport Diagram 2 114345 Label - Tip-over Hazard, Batteries 2 114391 Label - Crushing Hazard 1 42 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual 114252 62926 or 82544 Inspections 62927 82472 82487 Ground Controls 40434 Chassis Side 82548 Platform 72444 114247 Shading indicates Serial Plate decal is hidden from 27207 view, i.e. under covers 114249 82481 114025 114345 27207 114114 27204 114249 43658 114025 or 44980 52969 82279 114334 82647 27206 72867 82487 82481 114248 114345 97815 114252 82601 or 27206 82612 27205 44981 62068 82602 82544 28174 114252 or 28235 82473 28159 40434 114251 114391 82548 114249 114249 28174 44981 114025 114114 114025 or 28235 Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 43
Operator's Manual Fourth Edition • Second Printing Operating Instructions Do Not Operate Unless: Fundamentals You learn and practice the principles of safe The Operating Instructions section provides machine operation contained in this operator's instructions for each aspect of machine operation. manual. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, 1 Avoid hazardous situations. safety and responsibilities manuals. 2 Always perform a pre-operation Using the machine for anything other than lifting inspection. personnel, along with their tools and materials, to an aerial work site is unsafe and dangerous. 3 Always perform function tests prior to use. Only trained and authorized personnel should be 4 Inspect the workplace. permitted to operate a machine. If more than one operator is expected to use a machine at different 5 Only use the machine as it was intended. 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. 44 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Operating Instructions Introduction Auxiliary Controls Bi-Energy models can be operated with or without Use auxiliary power if the primary power source the engine running. fails. Starting the Engine 1 Turn the key switch to ground or platform control. 1 At the ground controls, turn the key switch to the desired position. 2 Pull out the red Emergency Stop button to the on position. 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the 3 Press down the foot switch when operating the on position. auxiliary controls from the platform. 3 Move the engine start toggle switch 4 Simultaneously hold the auxiliary to either side. If the engine fails to power switch on and activate the start or dies, the restart delay will desired function. disable the start switch for 3 seconds. The drive function will not operate with auxiliary power. If the engine fails to start after 15 seconds of cranking, determine the cause and repair any Operation from Ground malfunction. Wait 60 seconds before trying to start again. 1 Turn the key switch to ground control. In cold conditions, hold the glow plug switch to 2 Pull out the red Emergency Stop button to either side for 3 to 5 seconds and then start the the on position. engine. To Position Platform In extreme cold conditions, 20°F / -6°C and below, hold the glow plug switch to either side for 10 1 Hold the function enable switch to seconds and then start the engine. Warm the either side. engine (use low idle) for 5 minutes to prevent hydraulic system damage. 2 Move the appropriate toggle switch according to the markings on the control panel. Emergency Stop Drive and steer functions are not available from the Push in either the ground or platform red ground controls. Emergency Stop button to the off position to stop all machine functions. Repair any function that operates when the red Emergency Stop button is pushed in. Selecting and operating the ground controls will override the platform red Emergency Stop button. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 45
Operator's Manual Fourth Edition • Second Printing Operating Instructions Operation from Platform To Drive 1 Turn the key switch to platform control. 1 Press down the foot switch. 2 Pull out both ground and platform red 2 Increase speed: Slowly move the drive control Emergency Stop buttons to the on position. handle off center. To Position Platform Decrease speed: Slowly move the drive control handle toward center. 1 Set the boom function speed controller to the desired speed. Stop: Return the drive control handle to center or release the foot switch. Note: Drive and steer functions are not affected by the boom function speed controller. Use the color-coded direction arrows on the platform controls and the drive chassis to identify 2 Press down the foot switch. the direction the machine will travel. 3 Move the appropriate toggle switch according to Machine travel speed is restricted when the boom the markings on the control panel. is raised or extended. To Steer Drive Enable 1 Press down the foot switch. Light on indicates that the boom has moved just past 2 Turn the steer wheels with the thumb rocker either non-steer wheel and switch located on top of the drive control drive function has been handle. interrupted. Use the color-coded direction triangles on the To drive, hold the drive enable switch to either side platform controls and the drive chassis to identify and slowly move the drive control handle off center. the direction the wheels will turn. Be aware that the machine may move in the opposite direction that the drive and steer controls are moved. Always use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel. 46 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
Fourth Edition • Second Printing Operator's Manual Operating Instructions Driving on a Slope To determine the slope grade: Determine the uphill, downhill and side slope ratings for the machine and determine the slope grade. Measure the slope with a digital inclinometer OR use the following procedure. Maximum slope rating, platform downhill (gradeability): You will need: 30% (17°) carpenter’s level Maximum slope rating, platform uphill: straight piece of wood, at least 3 feet / 1 m long 20% (11°) tape measure Maximum side slope rating: 25% (14°) Lay the piece of wood on the slope. Note: Slope rating is subject to ground conditions At the downhill end, lay the level on the top edge of and adequate traction. The term gradeability applies the piece of wood and lift the end until the piece of to the platform downhill configuration only. wood is level. Be sure the boom is below horizontal and the While holding the piece of wood level, measure the platform is between the non-steer wheels. vertical distance from the bottom of the piece of wood to the ground. Divide the tape measure distance (rise) by the length of the piece of wood (run) and multiply by 100. Example: run rise Piece of wood = 144 inches (3.6 m) Run = 144 inches (3.6 m) Rise = 12 inches (0.3 m) 12 in 144 in = 0.083 x 100 = 8.3% grade 0.3 m 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum uphill, downhill or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 47
Operator's Manual Fourth Edition • Second Printing Operating Instructions AC Inverter (if equipped) The inverter supplies power to the platform when external AC power is removed. Plug the power-to-platform cable on the machine into the inverter power cable. To activate the inverter, move the platform toggle switch in either direction. All boom functions will operate while the inverter is in use. Machine Not Level Indicator Light Light on indicates the machine is not level. The tilt alarm will be sounding when this light is on. Move the machine to a firm level surface. Aircraft Protection Package (if equipped) If the platform bumpers come in contact with aircraft components, the machine will shut down and no functions will operate. Move the function override toggle switch to either side to operate the machine. 48 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy Part No.114344
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