Fourth Edition • Second Printing Operator's Manual Operating Instructions Battery and Charger Instructions Charging the Batteries with the AC Charger Observe and Obey: 1 Be sure the batteries are connected before Do not use external charger or booster batteries. charging the batteries. Charge the batteries in a well-ventilated area. Use proper AC input voltage for charging as 2 Open the battery compartment. The indicated on the charger. compartment should remain open for the entire Use only Genie authorized batteries and charging cycle. charger. Do not operate the machine with the battery Maintenance-free batteries charger plugged in. 1 Connect the battery charger to a grounded AC Charging the Batteries circuit. Use the engine (if equipped) or the AC battery 2 The charger will indicate when the battery is fully charger to recharge the batteries. charged. Charging the Batteries with the Engine Standard Batteries (Bi-Energy models) 1 Remove the battery vent caps and check the Running the engine will automatically charge the battery acid level. If necessary, add only batteries. At high idle, the engine supplies enough enough distilled water to cover the plates. Do power for charging and for machine functions. At not overfill prior to the charge cycle. low idle, machine functions will use battery power. 2 Replace the battery vent caps. All lift and drive functions can be operated while the engine is running. 3 Connect the battery charger to a grounded AC circuit. The battery charge indicator will reset when the engine has been turned off for 2-3 minutes. 4 The charger will indicate when the battery is fully charged. Charging the batteries with the engine does not fully charge the batteries. Periodically, use the AC 5 Check the battery acid level when the charging battery charger to fully charge the batteries. cycle is complete. Replenish with distilled water to the bottom of the fill tube. Do not overfill. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 49
Operator's Manual Fourth Edition • Second Printing Operating Instructions Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings. 2 Fill each cell with battery acid (electrolyte) until the level is sufficient to cover the plates. Do not fill to maximum level until the battery charge cycle is complete. Overfilling can cause the battery acid to overflow during charging. Neutralize battery acid spills with baking soda and water. 3 Install the battery vent caps. 4 Charge the battery. 5 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. 50 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 Transport and Lifting Instructions Observe and Obey: Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating. Genie Industries provides this securement See Driving on a Slope in the Operating information as a recommendation. Drivers are Instructions section. solely responsible for making sure machines are properly secured and the correct trailer is If the slope of the transport vehicle bed exceeds selected pursuant to US Department of the uphill or downhill maximum slope rating, the Transportation regulations, other localized machine must be loaded and unloaded using a regulations, and their company policy. winch as described. See the Specifications section for the slope ratings. Genie customers needing to containerize any lift or Genie product should source a qualified Free-wheel Configuration for freight forwarder with expertise in preparing, Winching loading and securing construction and lifting equipment for international shipment. Chock the wheels to prevent the machine from rolling. Only qualified aerial lift operators should move the machine on or off the truck. Release the non-steer Disengage wheel brakes by The transport vehicle must be parked on a level turning over the drive surface. hub disconnect caps. The transport vehicle must be secured to Be sure the winch line Engage prevent rolling while the machine is being is properly secured to loaded. the drive chassis tie points and the path is Be sure the vehicle capacity, loading surfaces clear of all and chains or straps are sufficient to withstand obstructions. the machine weight. Genie lifts are very heavy relative to their size. See the serial label for the Reverse the procedures described to re-engage the machine weight. brakes. Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 51
Operator's Manual Fourth Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer Securing the Platform - Z-45/25 for Transit Make sure the platform is in the stowed position. Secure the platform with a nylon strap placed over Always use the turntable lock pin the platform mount near the platform rotator (see rotation lock pin each time below). Do not use excessive downward force when the machine is securing the boom section. transported. The lock pin is located under the Securing the Platform - Z-45/25J turntable on the hydraulic Make sure the jib and platform are in the stowed tank side of the machine. position. Secure the platform with a nylon strap placed over Turn the key switch to the off position and remove the platform mount near the platform rotator (see the key before transporting. below). Do not use excessive downward force when securing the boom section. Inspect the entire machine for loose or unsecured items. Securing the Chassis Use chains of ample load capacity. Use a minimum of 4 chains. Adjust the rigging to prevent damage to the chains. 52 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 Transport and Lifting Instructions Observe and Obey: Lifting Instructions Only qualified riggers should rig and lift the Fully lower and retract the boom. Fully lower the jib. machine. Remove all loose items on the machine. Be sure the crane capacity, loading surfaces Use the turntable rotation lock to secure the and straps or lines are sufficient to withstand turntable. the machine weight. See the serial label for the machine weight. 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. Adjust the rigging to prevent damage to the machine and to keep the machine level. X Axis 44 in 1.1 m Y Axis 41 in 1.0 m Y Axis X Axis Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 53
Operator's Manual Fourth Edition • Second Printing Maintenance Check the Batteries Observe and Obey: Proper battery condition is essential to good machine performance and operational safety. Only routine maintenance items specified in this Improper fluid levels or damaged cables and manual shall be performed by the operator. connections can result in component damage and Scheduled maintenance inspections shall be hazardous conditions. completed by qualified service technicians, according to the manufacturer's specifications Electrocution hazard. Contact with hot or live and the requirements specified in the circuits may result in death or serious injury. responsibilities manual. Remove all rings, watches and other jewelry. Use only Genie approved replacement parts. Bodily injury hazard. Batteries contain acid. Maintenance Symbols Legend Avoid spilling or contacting battery acid. Neutralize The following symbols have been used in this battery acid spills with baking soda and water. manual to help communicate the intent of the instructions. When one or more of the symbols 1 Put on protective clothing and eye wear. appear at the beginning of a maintenance procedure, it conveys the meaning below. 2 Be sure that the battery cable connections are tight and free of corrosion. Indicates that tools will be required to perform this procedure. 3 Be sure that the battery hold-down brackets are in place and secure. Indicates that new parts will be required to perform this procedure. Standard Batteries 4 Remove the battery vent caps. 5 Check the battery acid level. If needed, replenish with distilled water to the bottom of the battery fill tube. Do not overfill. 6 Install the vent caps. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. Indicates that a cold motor or pump will be required to perform this procedure. 54 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 Maintenance Check the Hydraulic Oil Level Check the Engine Oil Level (Bi-Energy models) Maintaining the hydraulic oil at the proper level is Maintaining the proper engine oil level is essential essential to machine operation. Improper hydraulic to good engine performance and service life. oil levels can damage hydraulic components. Daily Operating the machine with an improper oil level checks allow the inspector to identify changes in oil can damage engine components. level that might indicate the presence of hydraulic system problems. Note: Check the oil level with the engine off. 1 With the boom is in the stowed position, visually 1 Check the oil level dipstick. The oil level should inspect the oil level in the hydraulic tank. The be at the FULL mark on the dipstick. hydraulic oil level should be within the FULL and ADD marks on the hydraulic reservoir. 2 Add oil as needed. 2 Add oil as needed. Kubota Engine Z482-E Hydraulic oil specifications Oil viscosity requirements 10W-30 Hydraulic oil type Chevron Rykon Engine oil should have properties of API classification Premium MV equivalent CC/SE, CD/SE, CC/SF or CD/SF grades. Units ship with 10W-40 SG/CC Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 55
Operator's Manual Fourth Edition • Second Printing Maintenance Check the Engine Coolant Level Scheduled Maintenance (Bi-Energy models) Maintenance performed quarterly, annually and Maintaining the engine coolant at the proper level is every two years must be completed by a person essential to engine service life. Improper coolant trained and qualified to perform maintenance on this level will affect the engine's cooling capability and machine according to the procedures found in the damage engine components. Daily checks will service manual for this machine. allow the inspector to identify changes in coolant level that might indicate cooling system problems. Machines that have been out of service for more than three months must receive the quarterly Burn hazard. Beware of hot engine parts and inspection before they are put back into service. coolant. Contact with hot engine parts and/or coolant may cause severe burns. Note: Do not remove the radiator cap. 1 Check the fluid level in the coolant recovery tank. The fluid level should be at the FULL mark. 2 Add fluid as needed. 56 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 Specifications Model Z-45/25 DC (no jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 6 in 15.8 m Height, platform maximum 45 ft 6 in 13.8 m Platform dimensions, 5 foot 60 in x 30 in (length x width) 1.5 m x 76 cm Height, stowed maximum 6 ft 7 in 2.0 m Platform dimensions, 4 foot 48 in x 30 in (length x width) 1.2 m x 76 cm Horizontal reach maximum 125 ft 17.6 m Width 5 ft 10.3 in 1.79 m Platform leveling self-leveling Length, stowed 18 ft 3 in 5.56 m Platform rotation 180° Maximum load capacity 500 lbs 227 kg Controls 24V DC proportional Maximum wind speed 28 mph 12.5 m/s AC outlet in platform standard Wheelbase 6 ft 8 in 2.0 m Hydraulic pressure, maximum 3200 psi 221 bar (boom functions) Turning radius (inside) 6 ft 1.8 m System voltage 48V Turning radius (outside) 14 ft 4.3 m Tire size, 2WD Industrial 9-14.5 LT Foam-filled only Turntable rotation 355° Turntable tailswing 0 in 0 cm Fuel tank capacity 9 gallons 34.1 liters Power source 8 Group 903, L-16, Maximum slope rating, stowed position 6V 390AH Batteries Platform downhill 30% (17°) Drive speed, stowed 3.0 mph 4.8 km/h 40 ft/9 sec 12.2 m/9 sec Platform uphill 20% (11°) Drive speed, 0.6 mph 1 km/h Side slope 25% (14°) booms raised 40 ft/45 sec 12.2 m/45 sec Note: Slope rating is subject to ground conditions and adequate traction. Airborne noise emissions 73 dB Maximum sound level at normal operating workstations Floor loading information (A-weighted) Ground clearance, center 9.5 in 24.1 cm Tire load, maximum 8100 lbs 3674 kg Ground clearance, minimum 7.5 in 19.1 cm Tire contact pressure 100 psi 7.03 kg/cm2 689 kPa Weight 15,350 lbs 6963 kg Occupied floor pressure 297 psf 1450 kg/m2 14.22 kPa (Machine weights vary with option configurations. See serial label for specific machine weight.) Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors. 1 Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy. 57 Product specifications are subject to change without notice or obligation. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Operator's Manual Fourth Edition • Second Printing Specifications Model Z-45/25J DC (jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 9 in 15.9 m Height, platform maximum 45 ft 9 in 13.9 m Platform dimensions, 5 foot 60 in x 30 in (length x width) 1.5 m x 76 cm Height, stowed maximum 6 ft 7 in 2.0 m Platform dimensions, 4 foot 48 in x 30 in (length x width) 1.2 m x 76 cm Horizontal reach maximum 25 ft 1 in 7.7 m Width 5 ft 10.3 in 1.79 m Platform leveling self-leveling Length, stowed 22 ft 5 in 6.83 m Platform rotation 160° Maximum load capacity 500 lbs 227 kg Controls 24V DC proportional Maximum wind speed 28 mph 12.5 m/s AC outlet in platform standard Wheelbase 6 ft 8 in 2.0 m Hydraulic pressure (maximum) 3200 psi 221 bar (boom functions) Turning radius (inside) 6 ft 1.8 m System voltage 48V Turning radius (outside) 14 ft 4.3 m Tire size, 2WD Industrial 9-14.5 LT Foam-filled only Turntable rotation 355° Turntable tailswing 0 in 0 cm Fuel tank capacity 9 gallons 34.1 liters Power source 8 Group 903, L-16, Maximum slope rating, stowed position 6V 390AH Batteries Platform downhill 30% (17°) Drive speed, stowed 3.0 mph 4.8 km/h 40 ft/9 sec 12.2 m/9 sec Platform uphill 20% (11°) Drive speed, 0.6 mph 1 km/h Side slope 25% (14°) booms raised 40 ft/45 sec 12.2 m/45 sec Note: Slope rating is subject to ground conditions and adequate traction. Airborne noise emissions 73 dB Maximum sound level at normal operating workstations Floor loading information (A-weighted) Ground clearance, center 9.5 in 24.1 cm Tire load, maximum 8100 lbs 3674 kg Ground clearance, minimum 7.5 in 19.1 cm Tire contact pressure 100 psi 7.03 kg/cm2 689 kPa Weight 16,300 lbs 7394 kg Occupied floor pressure 315 psf 1538 kg/m2 15.08 kPa (Machine weights vary with option configurations. See serial label for specific machine weight.) Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. 58 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 Specifications Model Z-45/25 Bi-Energy (no jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 6 in 15.8 m Height, platform maximum 45 ft 6 in 13.8 m Platform dimensions, 5 foot 60 in x 30 in (length x width) 1.5 m x 76 cm Height, stowed maximum 6 ft 7 in 2.0 m Platform dimensions, 4 foot 48 in x 30 in (length x width) 1.2 m x 76 cm Horizontal reach maximum 125 ft 17.6 m Width 5 ft 10.3 in 1.79 m Platform leveling self-leveling Length, stowed 18 ft 3 in 5.56 m Platform rotation 180° Maximum load capacity 500 lbs 227 kg Controls 24V DC proportional Maximum wind speed 28 mph 12.5 m/s AC outlet in platform standard Wheelbase 6 ft 8 in 2.0 m Hydraulic pressure, maximum 3200 psi 221 bar (boom functions) Turning radius (inside) 6 ft 1.8 m System voltage 48V Turning radius (outside) 14 ft 4.3 m Tire size, 2WD Industrial 9-14.5 LT Foam-filled only Turntable rotation 355° Turntable tailswing 0 in 0 cm Fuel tank capacity 9 gallons 34.1 liters Power source 8 Group 903, L-16, Maximum slope rating, stowed position 6V 390AH Batteries with Kubota Z482-E engine Platform downhill 30% (17°) Drive speed, stowed 3.0 mph 4.8 km/h Platform uphill 20% (11°) 40 ft/9 sec 12.2 m/9 sec Side slope 25% (14°) Drive speed, 0.6 mph 1 km/h Note: Slope rating is subject to ground conditions and booms raised adequate traction. 40 ft/45 sec 12.2 m/45 sec Airborne noise emissions 73 dB Floor loading information Maximum sound level at normal operating workstations (A-weighted) Tire load, maximum 8100 lbs 3674 kg Ground clearance, center 9.5 in 24.1 cm Tire contact pressure 100 psi 7.03 kg/cm2 689 kPa Ground clearance, minimum 7.5 in 19.1 cm Weight 15,850 lbs 7189 kg Occupied floor pressure 306 psf 1494 kg/m2 14.65 kPa (Machine weights vary with option configurations. See serial label for specific machine weight.) Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors. 1 Outreach specification with platform rotated 90 degrees Continuous improvement of our products is a Genie policy. 59 Product specifications are subject to change without notice or obligation. Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy
Operator's Manual Fourth Edition • Second Printing Specifications Model Z-45/25J Bi-Energy (jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 9 in 15.9 m Height, platform maximum 45 ft 9 in 13.9 m Platform dimensions, 5 foot 60 in x 30 in (length x width) 1.5 m x 76 cm Height, stowed maximum 6 ft 7 in 2.0 m Platform dimensions, 4 foot 48 in x 30 in (length x width) 1.2 m x 76 cm Horizontal reach maximum 25 ft 1 in 7.7 m Width 5 ft 10.3 in 1.79 m Platform leveling self-leveling Length, stowed 22 ft 5 in 6.83 m Platform rotation 160° Maximum load capacity 500 lbs 227 kg Controls 24V DC proportional Maximum wind speed 28 mph 12.5 m/s AC outlet in platform standard Wheelbase 6 ft 8 in 2.0 m Hydraulic pressure (maximum) 3200 psi 221 bar (boom functions) Turning radius (inside) 6 ft 1.8 m System voltage 48V Turning radius (outside) 14 ft 4.3 m Tire size, 2WD Industrial 9-14.5 LT Foam-filled only Turntable rotation 355° Turntable tailswing 0 in 0 cm Fuel tank capacity 9 gallons 34.1 liters Power source 8 Group 903, L-16, Maximum slope rating, stowed position 6V 390AH Batteries with Kubota Z482-E engine Platform downhill 30% (17°) Drive speed, stowed 3.0 mph 4.8 km/h Platform uphill 20% (11°) 40 ft/9 sec 12.2 m/9 sec Side slope 25% (14°) Drive speed, 0.6 mph 1 km/h Note: Slope rating is subject to ground conditions and booms raised adequate traction. 40 ft/45 sec 12.2 m/45 sec Airborne noise emissions 73 dB Floor loading information Maximum sound level at normal operating workstations (A-weighted) Tire load, maximum 8100 lbs 3674 kg Ground clearance, center 9.5 in 24.1 cm Tire contact pressure 100 psi 7.03 kg/cm2 689 kPa Ground clearance, minimum 7.5 in 19.1 cm Weight 16,800 lbs 7620 kg Occupied floor pressure 325 psf 1587 kg/m2 15.56 kPa (Machine weights vary with option configurations. See serial label for specific machine weight.) Note: Floor loading information is approximate and does not incorporate different option configurations. It should be used only with adequate safety factors. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. 60 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 Range of motion - models without jib Specifications Range of motion - models with jib Part No.114344 Z-45/25 DC • Z-45/25J DC • Z-45/25 Bi-Energy • Z-45/25J Bi-Energy 61
Search
