Operator's Manual

Serial Number Range

Z®-45/25J from Z4525D-3958

CE

IC Power

with
Maintenance
Information

Original Instructions
Eighth Edition
Third Printing
Part No. 1311642GT
Operator's Manual Eighth Edition • Third Printing

Front Matter

Manufacturer:
Contents
Terex Global GmbH
Introduction ............................................................1
Bleicheplatz 2
Schaffhausen, 8200 Symbol and Hazard Pictorials Definitions ..............5
Switzerland General Safety .......................................................8
Personal Safety ................................................... 12
EU Authorized representative:
Work Area Safety ................................................ 13
Genie Industries B.V. Legend ................................................................ 22
Boekerman 5
4751 XK OUD GASTEL Controls ............................................................... 23
The Netherlands Inspections .......................................................... 31
Operating Instructions ......................................... 44
UK Authorized representative:
Transport and Lifting Instructions ....................... 53
Genie UK Limited Maintenance ....................................................... 57
The Maltings
Specifications ...................................................... 61
Wharf Road
Grantham
NG31 6BH
UK

Copyright © 2020 by Terex Corporation

Eighth Edition: Third Printing, June 2023
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Supply of Machinery (Safety) Regulations 2008

Z®-45/25J Part No. 1311642GT

Eighth Edition • Third Printing Operator's Manual

Introduction
Intr oducti on

About this manual Intended Use and Familiarization

Genie appreciates your choice of our machine for Guide
your application. Our number one priority is user The intended use of this machine is to lift
safety, which is best achieved by our joint efforts. personnel, including tools, and materials to an
This book is an operation and daily maintenance aerial work site. Before operating the machine, it’s
manual for the user or operator of a Genie the operator’s responsibility to read and
machine. understand this familiarization guide.
This manual should be considered a permanent
 Each person must be trained to operate a
part of your machine and should remain with the
Mobile Elevating Work Platform (MEWP).
machine at all times. If you have any questions,
contact Genie.  Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Product Identification
 Only trained and authorized personnel should
The machine serial number is located on the serial be permitted to operate the machine.
label.
 The operator is responsible to read,
Serial number Serial label understand, and obey the manufacturer’s
stamped on chassis (located under cover) instructions and safety rules provided in the
Operator’s Manual.
 The Operator’s Manual is located in the
manual storage container, at the platform.
 For specific product applications, see
Contacting The Manufacturer.

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Introduction
Platform controls symbology and related Ground controls symbology and related
machine movement: machine movement:
Platform level swtich Platform level, jib boom
up/down, primary boom
extend/retract, primary
boom up/down, and
secondary boom
Platform rotate switch retract/lower.

Turntable rotate and

Jib boom up/down platform rotate

Primary boom up/down

Sequential functions and movement:

• Drive and steer.
Interlocked functions:
Turntable rotate
• Elevated drive speed.
• Elevated drive in an off-level condition.
• Drive enable when the boom is rotated past the
Primary boom extend/retract non-steer wheels.
switch
• All platform and ground controls.
Limitations of use:

Secondary boom up/down • The intended use of this machine is to lift

personnel, including tools, and materials to an
aerial work site.
• Do not elevate the platform unless the machine
Drive forward/reverse is on firm level ground.
Stability enhancing means:
• Foam filled tires.

Steer right/left

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Introduction

Bulletin Distribution and Contacting the Manufacturer

Compliance At times it may be necessary to contact Genie.
Safety of product users is of paramount When you do, be ready to supply the model
importance to Genie. Various bulletins are used by number and serial number of your machine, along
Genie to communicate important safety and with your name and contact information. At
product information to dealers and machine minimum, Genie should be contacted for:
owners. Accident reporting
The information contained in the bulletins is tied to Questions regarding product applications and
specific machines using the machine model and safety
serial number.
Standards and regulatory compliance information
Distribution of bulletins is based on the most
current owner on record along with their Current owner updates, such as changes in
associated dealer, so it is important to register machine ownership or changes in your contact
your machine and keep your contact information information. See Transfer of Ownership, below.
up to date.
To ensure safety of personnel and the reliable Transfer of Machine Ownership
continued operation of your machine, be sure to
comply with the action indicated in a respective Taking a few minutes to update owner information
bulletin. will ensure that you receive important safety,
maintenance and operating information that
To view any open bulletins for your machine, visit applies to your machine.
us on the web at www.genielift.com.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

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Introduction

Safety Sign Maintenance

Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may
damage the safety sign material.
Danger
Hazard Classification
Failure to obey the instructions and
Decals on this machine use symbols, color coding,
safety rules in this manual will result and signal words to identify the following:
in death or serious injury.
Safety alert symbol—used to alert
you to potential personal injury
Do Not Operate Unless: hazards. Obey all safety
messages that follow this symbol
 You learn and practice the principles of safe to avoid possible injury or death.
machine operation contained in this operator’s
manual. Indicates a hazardous situation
which, if not avoided, will result in
1 Avoid hazardous situations. death or serious injury.
Know and understand the safety rules
before going on to the next section. Indicates a hazardous situation
which, if not avoided, could result
2 Always perform a pre-operation inspection. in death or serious injury.
3 Always perform function tests prior to use.
Indicates a hazardous situation
4 Inspect the workplace. which, if not avoided, could result
in minor or moderate injury.
5 Only use the machine as it was intended.
 You read, understand and obey the Indicates a property damage
manufacturer’s instructions and safety rules— message.
safety and operator’s manuals and machine
decals.
 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.

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Symbol and Hazard Pictorials Definitions

Symbol and H az ard Pictorials Definiti ons

Crush hazard Keep away from Read the operator’s Fire extinguisher Overhead obstruction
moving parts manual

Electrocution hazard Maintain required Tip-over hazard Manual force Tip-over hazard
clearance

Electrocution hazard Avoid contact Disconnect battery Lifting point Wind speed

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Symbol and Hazard Pictorials Definitions

Weight of welder No smoking. Explosion hazard Collision hazard Corrosive acid.

reduces capacity No flame.
Stop engine.

Wheel load Tire specifications No smoking Overhead Explosion hazard

obstruction

Platform tie-down Lifting and tie down Lanyard anchorage Support the platform Tie-down point
instructions instructions points or boom during
maintenance

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Symbol and Hazard Pictorials Definitions

Maximum capacity Runaway hazard Color coded Voltage rating for Pressure rating for air
direction arrows power to platform line to platform
Recovery procedure if tilt alarm sounds while
elevated.

Platform uphill: Platform downhill: Access by trained Auxiliary lowering Read the service
1 Lower primary. 1 Retract primary. and authorized manual
2 Lower secondary. 2 Lower secondary. personnel onlyl
3 Retract primary. 3 Lower primary.

Do not use ether or Crush hazard Platform overloaded Fire hazard

other high energy
starting aids on
machines equipped
with glow plugs.

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General Safety
Gener al Safety

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General Safety

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General Safety

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General Safety

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Personal Safety
Pers onal Safety

Personal Fall Protection

Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in 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.

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Work Area Safety

Work Ar ea Safety

Electrocution Hazards Keep away from the

machine if it contacts
This machine is not electrically insulated and will energized power lines.
not provide protection from contact with or Personnel on the ground
proximity to electrical current. or in the platform must not
touch or operate the
Obey all local and machine until energized
governmental regulations power lines are shut off.
regarding required
clearance from electrical
power lines. At a minimum, Do not operate the machine during lightning or
the required clearance storms.
contained in the chart
below must be followed. Do not use the machine as a ground for welding.

Tip-over Hazards
Line Voltage Required Clearance Occupants, equipment and materials shall not
exceed the maximum platform capacity.
0 to 50KV 10 ft 3.05 m
50 to 200KV 15 ft 4.60 m Maximum platform capacity 500 lbs 227 kg
200 to 350KV 20 ft 6.10 m Maximum occupants 2
350 to 500KV 25 ft 7.62 m Maximum capacity 440 lbs 200 kg
500 to 750KV 35 ft 10.67 m Machine equipped with
Aircraft Protection Package
750 to 1000KV 45 ft 13.72 m
The weight of options and accessories, such as
Allow for platform movement, electrical line sway pipe cradles, panel cradles and welders, will
or sag, and beware of strong or gusty winds. reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.

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Work Area Safety

Do not raise or extend the If the tilt alarm sounds

boom unless the machine with the platform
is on a firm, level surface. downhill:
1 Retract the primary
boom.
2 Lower the
secondary 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
Do not depend on the tilt alarm as a level indicator. the boom is raised, lower
The tilt alarm sounds in the platform only when the the boom and do not
machine is on a severe slope. continue to operate the
machine.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the Do not operate the machine in strong or gusty
boom on the slope as shown in the tilt alarm winds. Do not increase the surface area of the
procedure. Follow the steps to lower the boom platform or the load. Increasing the area exposed
before moving to a firm, level surface. Do not to the wind will decrease machine stability.
rotate the boom while lowering.
Use extreme care and
If the tilt alarm sounds slow speeds while driving
with the platform uphill: the machine in the stowed
position across uneven
1 Lower the primary terrain, debris, unstable or
boom. slippery surfaces and near
2 Lower the holes and drop-offs.
secondary boom.
3 Retract the primary
boom. Do not drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the boom raised or extended.

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Work Area Safety

Do not use the machine as a crane. Do not use the platform controls to free a platform
that is caught, snagged, or otherwise prevented
Do not push the machine or other objects with the from normal motion by an adjacent structure. All
boom. personnel must be removed from the platform
Do not contact adjacent structures with the boom. before attempting to free the platform using the
ground controls.
Do not tie the boom or platform to adjacent
structures. Do not modify or alter a mobile elevating work
platform without prior written permission from the
Do not place loads outside the platform perimeter. manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
Do not push off or pull toeboards, or guard rail system can increase the
toward any object outside weight in the platform and the surface area of the
of the platform. platform or the load.

Maximum allowable Do not place or attach

manual force - fixed or overhanging loads
90 lbs / 400 N to any part of this
machine.

Do not alter or disable machine components that

in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification. Do not place ladders or
scaffolds in the platform or
Do not replace factory-installed tires with tires of against any part of this
different specification or ply rating. machine.
Z-45/25J models equipped with Aircraft
Protection Package: Do not use air-filled tires.
These machines are equipped with foam-filled
tires. Wheel weight is critical to stability.

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Work Area Safety

Do not transport tools and materials unless they Fall Hazards

are evenly distributed and can be safely handled
by person(s) in the platform. Occupants must wear a
safety belt or harness in
Do not use the machine on a moving or mobile accordance with
surface or vehicle. governmental regulations.
Attach the lanyard to the
Be sure all tires are in good condition, air-filled anchor provided in the
tires are properly inflated and lug nuts are properly
platform.
tightened.
Do not sit, stand, or climb
Operation on Slopes Hazards on the platform guard rails.
Maintain a firm footing on
Do not drive the machine on a slope that exceeds the platform floor at all
the maximum uphill, downhill or side slope rating times.
of the machine. Slope rating applies only to
machines in the stowed position.

Maximum slope rating, stowed position, 2WD

Platform downhill 30% (17°) Do not climb down from the
Platform uphill 25% (14°) platform when raised.
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24°)
Platform uphill 25% (14°)
Side slope 25% (14°)

Note: Slope rating is subject to ground conditions Keep the platform floor clear of debris.
with one person in the platform and adequate
Lower the platform entry mid-rail or close the entry
traction. Additional platform weight may reduce
gate before operating.
slope rating. See Driving on a Slope in the
Operating Instructions section. Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Hazards related with the specific product
application of exiting at height have been
considered in the design of the machine, for
further information contact Genie (see section
Contacting the Manufacturer).

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Work Area Safety

Collision Hazards Observe and use the color-coded direction arrows

on the platform controls and drive chassis for drive
Be aware of limited sight and steer functions.
distance and blind spots
when driving or operating. Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Be aware of the boom position and tailswing when
rotating the turntable.

Check the work area for

overhead obstructions or
other possible hazards.
Limit travel speed
according to the condition
of the ground surface,
congestion, slope, location
of personnel, and any
other factors which may
cause collision.
Be aware of crushing
hazards when grasping the
platform guard rail.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
Operators must comply with employer, job site,
and governmental rules regarding use of personal
protective equipment.

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Work Area Safety

Bodily Injury Hazard Damaged Machine Hazards

Always operate the machine in a well-ventilated Do not use a damaged or malfunctioning machine.
area to avoid carbon monoxide poisoning.
Conduct a thorough pre-operation inspection of
Do not operate the machine with a hydraulic oil or the machine and test all functions before each
air leak. An air leak or hydraulic leak can penetrate work shift. Immediately tag and remove from
and/or burn skin. service a damaged or malfunctioning machine.
Improper contact with components under any Be sure all maintenance has been performed as
cover will cause serious injury. Only trained specified in this manual and the appropriate Genie
maintenance personnel should access service manual.
compartments. Access by the operator is only
advised when performing a pre-operation Be sure all decals are in place and legible.
inspection. All compartments must remain closed Be sure the operator's manual is complete, legible,
and secured during operation. and in the storage container located on the
machine.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid Component Damage Hazards
petroleum gas (LPG), gasoline, diesel fuel or other Do not use any battery or charger greater than
explosive substances. 12V to jump-start the engine.
Do not refuel the machine with the engine running. Do not use the machine as a ground for welding.
Refuel the machine and charge the battery only in Do not operate the machine in locations where
an open, well-ventilated area away from sparks, extremely high magnetic fields may be present.
flames and lighted tobacco.
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.

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Work Area Safety

Battery Safety Contact Alarm Safety

Read, understand and obey all warnings and
Burn Hazards instructions provided with the contact alarm.
Batteries contain acid. Do not exceed the rated platform capacity. The
Always wear protective weight of the contact alarm assembly will reduce
clothing and eye wear when the rated platform capacity and must be subtracted
working with batteries. from the total platform load.
Avoid spilling or contacting The contact alarm assembly weighs 10 lbs/4.5 kg.
battery acid. Neutralize
battery acid spills with Be sure the contact alarm is securely installed.
baking soda and water.

Explosion Hazards
Keep sparks, flames, and
lighted tobacco away from
batteries. Batteries emit
explosive gas.

Electrocution Hazard
Avoid contact with electrical terminals.

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Work Area Safety

Pipe Cradle Safety Panel Cradle Safety

Read, understand, and obey all warnings and Bodily injury hazard. Failure to
instructions provided with the pipe cradles. use the Genie Panel Cradle
according to the instructions and
Do not exceed the rated platform capacity. The
safety rules listed here and in
pipe cradle assembly and the weight in the pipe
the Operator's Manual could
cradles will reduce rated platform capacity and
result in serious injury.
must be factored into total platform load.
The pipe cradle assembly weighs 21 lbs/9.5 kg. Read, understand and obey all warnings and
instructions provided with the panel cradle.
The maximum capacity of the pipe cradle
assembly is 200 lbs/91 kg. Do not exceed the rated platform capacity. The
combined weight of the cradle, panels, occupants,
The weight of the pipe cradle assembly and the tools and any other equipement must not exceed
load in the pipe cradles may limit the maximum rated capacity.
number of occupants in platform.
The panel cradle assembly weighs 30 lbs/13.6 kg.
Center the load within the perimeter of the
platform. The maximum capacity of the panel cradle is
250 lbs/113 kg.
Secure the load to the platform.
The weight of the panel cradle and the load in the
Do not obstruct the entrance or the exit of the panel cradle may limit the maximum number of
platform. occupants in the platform to one person.

Do not obstruct the ability to operate the platform Secure the panel(s) to the platform railing using
controls or the red Emergency Stop button. the straps provided.
Do not operate unless you are adequately Do not operate unless you are adequately
instructed and are aware of all of the hazards instructed and are aware of all hazards associated
associated with movement of the platform with an with lifting panels.
overhanging load.
Do not cause a horizontal force or side load to
Do not cause a horizontal force or side load to machine by raising or lowering a fixed or
machine by raising or lowering a fixed or overhanging load.
overhanging load.
Maximum vertical height of panels: 4 ft/1.2 m.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors. Maximum wind speed: 15 mph/6.7 m/sec.
Maximum panel area: 32 sq ft/3 m2.

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Work Area Safety

Lockout After Each Use

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.

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Legend
Legend

1 Foot switch 8 Primary boom

2 Manual storage container 9 Secondary boom
3 Sliding mid-rail 10 Ground controls
4 Lanyard anchorage points 11 Steer tire
5 Jib boom (Z-45/25J) 12 LPG tank (if equipped)
6 Platform 13 Non-steer tire
7 Platform controls

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Controls
Controls

The ground control station is to be used as a means to raise the platform for storage purposes and for
function tests. The ground control station can be used in the event of an emergency to rescue an
incapacitated person in the platform. When the ground control station is selected, the platform controls are
inoperable, including the E-stop switch.
The Z-45/25J machines will have one of these two styles of ground control panels. The descriptions in this
section and the instructions in the Function Test and Operating Instructions apply to both panels, unless
specifically noted.

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Controls

1 LCD readout screen 9 Platform rotate switch

Screen displays hour meter, voltage, oil Move the platform rotate switch to the right
pressure and coolant temperature. Screen and the platform will rotate to the right. Move
also displays fault codes and other service the platform rotate switch to the left and the
information. platform will rotate to the left.
2 Engine start switch 10 Platform level switch
Move the engine start switch to either side to Move the platform level switch up and the level
start the engine. of the platform will raise. Move the platform
3 Not used level switch down and the level of the platform
will lower.
4 Not used
11 Platform overload indicator light
5 Engine idle (rpm) select switch
12 Light flashing indicates the platform is
Move the engine idle select switch to the turtle overloaded. The engine will stop and no
position for foot switch activated low idle. functions will operate. Remove weight until the
Move the engine idle select switch to the rabbit light goes off and then restart the engine.
position for foot switch activated high idle.
13 Function enable button
6 Not used
Press and hold the function enable button to
7 Turntable rotate switch enable the functions on the ground control
panel to operate.
Move the turntable rotate switch to the right
and the turntable will rotate to the right. Move 14 Jib boom up/down switch
the turntable rotate switch to the left and the
turntable will rotate to the left. Move the jib boom switch up and the jib boom
will raise. Move the jib boom switch down and
8 Auxiliary power switch the jib boom will lower.
Use auxiliary power if the primary power 15 Primary boom extend/retract switch
source (engine) fails.
Simultaneously hold the auxiliary power switch Move the primary boom extend/retract switch
to either side and activate the desired function. to the right and the primary boom will retract.
Move the boom extend/retract switch to the left
and the primary boom will extend.

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Controls

16 Key switch for platform/off/ground selection 22 Hour meter

Turn the key switch to the platform position The hour meter displays the number of hours
and the platform controls will operate. Turn the the machine has operated.
key switch to the off position and the machine
23 Deutz, Kubota and Perkins Diesel Models:
will be off. Turn the key switch to the ground
Glow plug switch (if equipped)
position and the ground controls will operate.
Move the glow plug switch to either side and
17 Red Emergency Stop button
hold for 3 to 5 seconds.
Push in the red Emergency Stop button to the
24 Not used
off position to stop all functions and turn the
engine off. Pull out the red Emergency Stop
button to the on position to operate the
machine.
18 Primary boom up/down switch
Move the primary boom up/down switch up
and the boom will raise. Move the primary
boom up/down switch down and the boom will
lower.
19 15A breaker for engine electrical circuits
20 15A breaker for control electrical circuits
21 Secondary boom up/down switch
Move the secondary boom up/down switch up
and the secondary boom will raise. Move
secondary boom up/down switch down and
the secondary boom will lower.

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Controls

Platform Control Panel

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Controls

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Controls

Platform Control Panel 6 Machine not level indicator light

1 Horn button The machine not level indicator light will come
on when the tilt alarm sounds.
Press this button and the horn will sound.
Release the button and the horn will stop. 7 Auxiliary power switch

2 Platform level switch Use auxiliary power if the primary power

source (engine) fails.
Move the platform level Simultaneously hold the auxiliary power switch
switch up and the level to either side and activate the desired function.
of the platform will raise. 8 Drive speed select switch
Move the platform level
switch down and the Machine on incline symbol: Low range
level of the platform will operation for inclines.
lower. Machine on level surface symbol: High range
operation for maximum drive speed.
3 Platform rotate switch
9 Platform control box heater (if equipped)
Move the platform rotate Move the heater switch up to turn on the
switch to the right and the platform control box heater. Move the heater
platform will rotate to the switch down to turn off the platform control box
right. Move the platform heater.
rotate switch to the left
and the platform will rotate 10 Generator switch (if equipped)
to the left. Move the generator switch up to activate the
4 Jib boom up/down switch generator. Move the switch down to turn off
the generator.
Move the jib boom switch
up and the jib boom will
raise. Move the jib boom
switch down and the jib
boom will lower.

5 Platform overload indicator light

Light flashing indicates the platform is
overloaded. The engine will stop and no
functions will operate. Remove weight until the
light goes off and then restart the engine.

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Controls

11 Aircraft protection override switch (if equipped) 14 Drive enable indicator light
Move and hold the aircraft protection override Light on indicates that the boom has moved
switch to operate the machine when the just past either non-steer wheel and drive
platform bumper is against an object. function has been interrupted.
12 Red Emergency Stop button 15 Drive enable switch
Push in the red Emergency Stop button to the To drive when the drive enable light is on, hold
off position to stop all functions and turn the the drive enable switch to either side and
engine off. Pull out the red Emergency Stop slowly move the drive control handle off
button to the on position to operate the center. Be aware that the machine may move
machine. in the opposite direction that the drive and
steer controls are moved.
13 Dual axis proportional control handle for drive
and steer functions. 16 Diesel models: Glow plug switch
OR
Move the glow plug switch to either side and
Proportional control handle for drive function
hold for 3 to 5 seconds.
and thumb rocker for steer function.
Or for models with LCD readout screen, light
Move the control handle in the direction
on indicates that glow plugs are on. Start
indicated by the blue arrow on the control
engine when light goes off.
panel and the machine will drive forward.
Move the control handle in the direction 17 Engine idle (rpm) select switch
indicated by the yellow arrow and the machine
Move the engine idle select switch to the turtle
will drive backwards. Move the control handle
position for foot switch activated low idle.
in the direction indicated by the blue triangle
Move the engine idle select switch to the rabbit
and the machine will steer to the left. Move the
position for foot switch activated high idle.
control handle in the direction indicated by the
yellow triangle and the machine will steer to 18 Engine start switch
the right.
OR Move the engine start switch to either side to
Move the control handle in the direction start the engine.
indicated by the blue arrow on the control 19 Models with LCD screen: Engine shut-down
panel and the machine will drive forward. indicator light
Move the control handle in the direction
indicated by the yellow arrow and the machine Light on indicates that the engine has shut
will drive backwards. Press the left side of the down. Contact service personnel.
thumb rocker and the machine will steer to the
left. Press the right side of the thumb rocker
and the machine will steer to the right.

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Controls

20 Not used
21 Proportional control handle for secondary
boom up/down function

Move the control handle

up and the secondary
boom will raise. Move the
control handle down and
the secondary boom will
lower.

22 Primary boom extend/retract switch

Move the primary boom

extend/retract switch up and
the primary boom will
retract. Move the boom
extend/retract switch down
and the primary boom will
extend.

23 Dual axis proportional control handle for

primary boom up/down and turntable rotate
left/right functions

Move the control handle up

and the primary boom will
raise. Move the control
handle down and the
primary boom will lower.

Move the control handle to

the right and the turntable
will rotate to the right. Move
the control handle to the left
and the turntable will rotate
to the left.

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Inspections
Ins pections

Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
Do Not Operate Unless: The inspection is designed to discover if anything
is apparently wrong with a machine before the
 You learn and practice the principles of safe operator performs the function tests.
machine operation contained in this operator’s
manual. The pre-operation inspection also serves to
1 Avoid hazardous situations. determine if routine maintenance procedures are
required. Only routine maintenance items specified
2 Always perform a pre-operation in this manual may be performed by the operator.
inspection.
Refer to the list on the next page and check each
Know and understand the pre-operation of the items.
inspection before going on to the next
section. If damage or any unauthorized variation from
factory delivered condition is discovered, the
3 Always perform function tests prior to use. machine must be tagged and removed from
4 Inspect the workplace. service.
5 Only use the machine as it was intended. 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.

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Inspections

Pre-operation Inspection  Fuel and hydraulic tanks

 Drive and turntable motors and drive hubs
 Be sure that the operator’s manual is
complete, legible and in the storage container  Wear pads
located in the platform.
 Tires and wheels
 Be sure that all decals are legible and in place.
 Engine and related components
See Inspections section.
 Limit switches and horn
 Check for hydraulic oil leaks and proper oil
level. Add oil if needed. See Maintenance  Alarms and beacons (if equipped)
section.
 Nuts, bolts and other fasteners
 Check for battery fluid leaks and proper fluid
 Platform entry mid-rail or gate
level. Add distilled water if needed. See
Maintenance section. Check entire machine for:
 Check for engine oil leaks and proper oil level.  Cracks in welds or structural components
Add oil if needed. See Maintenance section.
 Dents or damage to machine
 Check for engine coolant leaks and proper
level of coolant. Add coolant if needed. See  Excessive rust, corrosion or oxidation
Maintenance section.  Verify that all structural and other critical
 Model with air-filled tires: Check for proper tire components are present and all associated
pressure. Add air if needed. See Maintenance fasteners and pins are in place and properly
section. tightened.

Check the following components or areas for  After you complete your inspection, be sure
damage, improperly installed, or missing parts and that all compartment covers are in place and
unauthorized modifications: latched.

 Electrical components, wiring, and

electrical cables
 Hydraulic hoses, fittings, cylinders, and
manifolds

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Inspections

Function Test Fundamentals

The function tests are designed to discover any
malfunctions before the machine is put into
service. The operator must follow the step-by-step
instructions to test all machine functions.
A malfunctioning machine must never be used. If
Do Not Operate Unless: malfunctions are discovered, the machine must be
tagged and removed from service. Repairs to the
 You learn and practice the principles of safe machine may only be made by a qualified service
machine operation contained in this operator’s technician, according to the manufacturer’s
manual. specifications.
1 Avoid hazardous situations. After repairs are completed, the operator must
2 Always perform a pre-operation inspection. perform a pre-operation inspection and function
tests again before putting the machine into
3 Always perform function tests prior to service.
use.
Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

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Inspections

At the Ground Controls Test the Tilt Sensor

1 Select a test area that is firm, level and free of 9 Turn the key switch to
hazards. platform control. Pull out the
platform red Emergency
2 Turn the key switch to ground control.
Stop button to the on
3 Pull out the red Emergency Stop button to the position.
on position.
10 Open the engine side
Result: The beacon (if equipped) should flash. turntable cover and locate
the tilt sensor to the right of
4 Start the engine. See Operating Instructions
the hydraulic pump.
section.
11 Press down one side of the tilt sensor.
Test Emergency Stop
Result: The alarm, located in the platform,
5 Push in the red Emergency Stop button to the should sound.
off position.
Result: The engine will shut off after 2 to Test Auxiliary Controls
3 seconds. 12 Turn the key switch to ground control and shut
6 Pull out the red Emergency Stop button to the the engine off.
on position and restart the engine. 13 Pull out the red Emergency Stop button to the
on position.
Test Machine Functions
14 Simultaneously hold the auxiliary
7 Do not push and hold the power switch on and activate each
function enable button. boom function toggle switch.
Attempt to activate each
boom and platform function Note: To conserve battery power, test each
toggle switch. function through a partial cycle.

Result: No boom and platform functions Result: All boom functions should operate.
should operate.
8 Press and hold the function enable button 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.

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Inspections

At the Platform Controls Test Machine Functions

24 Press down the foot switch.
Test Emergency Stop
25 Activate each machine function control handle
15 Turn the key switch to platform control and or toggle switch.
restart the engine.
Result: All boom and platform functions should
16 Push in the platform red Emergency Stop operate through a full cycle.
button to the off position.
Result: The engine will shut off after 2 to Test the Steering
3 seconds. 26 Press down the foot switch.
17 Pull out the red Emergency Stop button and 27 Press the thumb rocker switch on top of the
restart the engine. drive control handle in the direction indicated
by the blue triangle on the control panel OR
Test the Horn slowly move the control handle in the direction
indicated by the blue triangle.
18 Press the horn button.
Result: The steer wheels should turn in the
Result: The horn should sound.
direction that the blue triangles point on the
drive chassis.
Test the Foot Switch
28 Press the thumb rocker switch in the direction
19 Push in the platform red Emergency Stop
indicated by the yellow triangle on the control
button to the off position. panel OR slowly move the control handle in
20 Pull out the red Emergency Stop button to the the direction indicated by the yellow triangle.
on position and do not start the engine. Result: The steer wheels should turn in the
21 Press down the foot switch and attempt to direction that the yellow triangles point on the
start the engine by moving the start toggle drive chassis.
switch to either side.
Result: The engine should not start.
22 Do not press down the foot switch and restart
the engine.
Result: The engine should start.
23 Do not press down the foot switch and test
each machine function.
Result: No functions should operate.

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Inspections
Test Drive and Braking Test Drive Tilt Cutout
29 Press down the foot switch. 32 Press down the foot switch.
30 Slowly move the drive control handle in the 33 With the boom fully stowed, drive the machine
direction indicated by the blue arrow on the onto a slope where the chassis pitch angle is
control panel until the machine begins to greater than 2.5°.
move, then return the handle to the center
Result: The machine should continue to drive.
position.
34 Return to level ground and raise the primary
Result: The machine should move in the
boom to an out of stowed position
direction that the blue arrow points on the
(approximately 10° above horizontal).
drive chassis, then come to an abrupt stop.
35 Drive the machine onto a slope where the
31 Slowly move the control handle in the direction
chassis pitch angle is greater than 2.5°.
indicated by the yellow arrow on the control
panel until the machine begins to move, then Result: The machine should stop once the
return the handle to the center position. machine reaches 2.5° of chassis tilt and the
alarm should sound at the platform controls.
Result: The machine should move in the
direction that the yellow arrow points on the 36 Lower the primary boom to the stowed position
drive chassis, then come to an abrupt stop. or drive in the opposite direction.
Note: The brakes must be able to hold the Result: The machine should drive.
machine on any slope it is able to climb.
37 Return to level ground and extend the primary
boom approximately 1.6 ft / 0.5 m.
38 Drive the machine onto a slope where the
chassis pitch angle is greater than 2.5°.
Result: The machine should stop once the
machine reaches 2.5° of chassis tilt and the
alarm should sound at the platform controls.

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Inspections
39 Retract the primary boom to the stowed 48 Lower the primary boom to the stowed position
position or drive in the opposite direction. or drive in the opposite direction.
Result: The machine should drive. Result: The machine should drive.
40 Return to level ground and stow the boom. 49 Return to level ground and extend the primary
boom approximately 1.6 ft / 0.5 m.
41 With the boom fully stowed, drive the machine
onto a slope where the chassis pitch angle is 50 Drive the machine onto a slope where the
greater than 2.5°. chassis roll angle is greater than 4.5°.
Result: The machine should continue to drive. Result: The machine should stop once the
machine reaches 4.5° of chassis tilt and the
42 Return to level ground and raise the
alarm should sound at the platform controls.
secondary boom to an out of stowed position
(approximately 15° above horizontal). 51 Retract the primary boom to the stowed
position or drive in the opposite direction.
43 Drive the machine onto a slope where the
chassis pitch angle is greater than 2.5°. Result: The machine should drive.
Result: The machine should stop once the 52 Return to level ground and stow the boom.
machine reaches 2.5° of chassis tilt and the
53 With the boom fully stowed, drive the machine
alarm should sound at the platform controls.
onto a slope where the chassis roll angle is
44 Lower the secondary boom to the stowed greater than 4.5°.
position or drive in the opposite direction.
Result: The machine should continue to drive.
Result: The machine should drive.
54 Return to level ground and raise the
45 With the boom fully stowed, drive the machine secondary boom to an out of stowed position
onto a slope where the chassis pitch angle is (approximately 15° above horizontal).
greater than 2.5°.
55 Drive the machine onto a slope where the
Result: The machine should continue to drive. chassis roll angle is greater than 4.5°.
46 Return to level ground and raise the primary Result: The machine should stop once the
boom to an out of stowed position machine reaches 4.5° of chassis tilt and the
(approximately 10° above horizontal). alarm should sound at the platform controls.
47 Drive the machine onto a slope where the 56 Lower the secondary boom to the stowed
chassis roll angle is greater than 4.5°. position or drive in the opposite direction.
Result: The machine should stop once the Result: The machine should drive.
machine reaches 4.5° of chassis tilt and the
alarm should sound at the platform controls.

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Inspections
Test the Drive Enable System Test Limited Drive Speed
57 Press down the foot switch and lower the 61 Press down the foot switch.
boom to the stowed position.
62 Raise the primary boom approximately
58 Rotate the turntable until the primary boom 2 ft / 61 cm.
moves past one of the non-steer wheels.
63 Slowly move the drive control handle to the full
Result: The drive enable drive position.
indicator light should Result: The maximum achievable drive speed
come on and remain on with the primary boom raised should not
while the boom is exceed 1 ft / 30 cm per second.
anywhere in the range
shown. 64 Lower the primary boom to the stowed
position.
59 Move the drive control handle off center.
65 Raise the secondary boom approximately
Result: The drive function should not operate. 2 ft / 61 cm.
60 Move and hold the drive enable toggle switch 66 Slowly move the drive control handle to the full
to either side and slowly move the drive drive position.
control handle off center.
Result: The maximum achievable drive speed
Result: The drive function should operate. with the secondary boom raised should not
exceed 1 ft / 30 cm per second.
Note: When the drive enable system is in use, the
machine may drive in the opposite direction that 67 Lower the secondary boom to the stowed
the drive and steer control handle is moved. position.

Use the color-coded direction 68 Extend the primary boom approximately

arrows on the platform controls 1 ft / 30 cm.
and the drive chassis to identify 69 Slowly move the drive control handle to the full
the direction of travel. drive position.
Result: The maximum achievable drive speed
with the primary boom extended should not
exceed 1 ft / 30 cm per second.
70 Retract the boom to the stowed position.
If the drive speed with the primary boom
raised, the secondary boom raised or the
primary boom extended exceeds 1 ft / 30 cm
per second, immediately tag and remove the
machine from service.

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Inspections
Test the Oscillating Axle (if equipped) Test Aircraft Protection Package
71 Start the engine from the platform controls.
(if equipped)

72 Drive the right steer tire up onto a 6 in/15 cm Note: Two people may be required to perform this
block or curb. test.

Result: The three remaining tires should stay 79 Extend the primary boom approximately
in firm contact with the ground. 1 ft/30 cm.

73 Drive the left steer tire up onto a 6 in/15 cm 80 Move the yellow bumper at the bottom of the
block or curb. platform 4 inches/10 cm in any direction.

Result: The three remaining tires should stay 81 Activate each function control handle or toggle
in firm contact with the ground. switch.

74 Drive both steer tires up onto a 6 in/15 cm Result: No boom and steer functions should
block or curb. operate.

Result: The non-steer tires should stay in firm 82 Move and hold the aircraft
contact with the ground. protection override switch.

Test Auxiliary Controls

75 Shut the engine off.
83 Activate each function control handle or toggle
76 Pull out the red Emergency Stop button to the switch.
on position.
Result: All boom and steer functions should
77 Press down the foot switch. operate.
78 Simultaneously hold the auxiliary
power switch on and activate each
boom function toggle switch.

Note: To conserve battery power, test each

function through a partial cycle.
Result: All boom functions should operate.
Drive functions should not operate with
auxiliary power.

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Inspections
Test the Contact Alarm (if equipped) 88 Operate each machine function.
84 Do not activate the foot switch and press on Result: All machine functions should not
the contact alarm cable to release the actuator operate.
from the switch socket.
89 Insert the actuator into the switch socket.
Result: The contact alarm lights will not flash
and the machine horn will not sound. Result: The lights and horn will turn off.

85 Activate the foot switch by pressing the foot 90 Operate each machine function.
switch down. Result: All machine functions should operate.
Result: The contact alarm lights will flash and
the machine horn will sound.
86 Insert the actuator into the switch socket.
Result: The lights and horn will turn off.
87 Activate the foot switch by pressing the foot
switch down and press on the contact alarm
cable to release the actuator from the switch
socket.
Result: The contact alarm lights will flash and
the machine horn will sound.
1 actuator
2 contact alarm cable
3 flashing alarm
4 switch socket

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Inspections

Workplace Inspection Checklist

Be aware of and avoid the following hazardous
situations:
 drop-offs or holes
 bumps, floor obstructions, or debris

Do Not Operate Unless:  sloped surfaces

 You learn and practice the principles of safe  unstable or slippery surfaces
machine operation contained in this operator’s  overhead obstructions and high voltage
manual. conductors
1 Avoid hazardous situations.  hazardous locations
2 Always perform a pre-operation inspection.  inadequate surface support to withstand all
3 Always perform function tests prior to use. load forces imposed by the machine

4 Inspect the workplace.  wind and weather conditions

Know and understand the workplace  the presence of unauthorized personnel

inspection before going on to the next  other possible unsafe conditions
section.
5 Only use the machine as it was intended.

Workplace Inspection
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.

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Inspections

Inspection for Decals with Part No. Decal Description Qty

Symbols 214932 Ground Control Panel 1
214933 Platform Control Panel 1
Determine whether the decals on your machine
have words or symbols. Use the appropriate 218562 Label – Wheel Load, Z-45/25J 4
inspection to verify that all decals are legible and 219952 Label – Emergency Lowering 1
in place. 219488 Label – Transport Diagram 1

Below is a numerical list with quantities and 219954 Label – Tip-over Hazard 1
descriptions. 219956 Label – Platform Overload 1
219957 Label – Runaway Hazard, Slope 1
Part No. Decal Description Qty
219958 Label – Tip-over, Crush Hazard 1
27204 Arrow – Blue 1 823766 Platform Control Panel, models with 1
27205 Arrow – Yellow 1 LCD screen
27206 Triangle – Blue 2 1263542 Label – Compartment Access 2
27207 Triangle – Yellow 2 1272242 Label – Machine Registration 1
28158 Label – Unleaded* 1 1278542 Label – Contact Alarm Weight 1
28159 Label – Diesel* 1 1278982 Label – Actuator Switch Socket 1
28174 Label – Power to Platform, 230V* 2 1281175 Label – Lanyard Anchorage Point, Fall 8
28235 Label – Power to Platform, 115V* 2 Restrained*
44981 Label – Air Line to Platform (option)* 2 1286130 Label – Emission Information, Z45IC, 1
China III*
52475 Label – Transport Tie-down 4
1286362 Label – Crush Hazard, Service 1
72086 Label – Lifting Point 4
1296345 Label – Emission Information, Z45IC, 1
82240 Label – 105 dB 1 Ina III, D2.9*
82481 Label – Battery/Charger Safety 1 1301030 Label – Diesel, Stage V 1
82487 Label – Read the Manual*** 6 1304217 Label – Explosion Hazard 1
97815 Label – Lower Mid-rail 1 1312068 Label – Emission Information, Kubota 1
114248 Label – Tip-over Hazard, Tilt Alarm 1 D1105, Z45IC
114249 Label – Tip-over Hazard, Tires 4 Shading indicates decal is hidden from view, i.e.
114251 Label – Explosion Hazard 1 under covers
114252 Label – Tip-over Hazard, Limit 3 * These decals are model, option or configuration
Switches specific.
133067 Label – Electrocution Hazard 3 *** These decals are installed on both sides of chassis
and are model, option, or configuration specific.
133205 Label – Electrocution/Burn Hazard 1
161162 Danger, Warning – Tip-over Hazard, 1
Aircraft Protection*

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Inspections

219952 133067 82487

1263542
*44981
114251
*28174 *28158
1286362
*28235 *28159

219488 114252 114252

72086 27207
52475 27206
218562 27204
218562 214932
72086
114249 52475

27206
72086 114252
52475 27207
27205 *1304217
218562
72086
52475
114249
218562

1263542

1301030
*1296345
82481 *1286130
133205 *1312068
82240
133067 1272242
114248
219956
219958
219957
1281175 *44981
*28174
133067
*28235
*219954
*161162
82487
***82487

***82487 *214933
97815 1278542 1278982 *823766

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Operating Instructions
Operati ng Instr ucti ons

Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator’s responsibility to follow all the
safety rules and instructions in the operator’s
manual.

Do Not Operate Unless: Using the machine for anything other than lifting
personnel, along with their tools and materials, to
 You learn and practice the principles of safe an aerial work site is unsafe and dangerous.
machine operation contained in this operator’s
manual. Only trained and authorized personnel should be
permitted to operate a machine. If more than one
1 Avoid hazardous situations. operator is expected to use a machine at different
2 Always perform a pre-operation inspection. times in the same work shift, they must all be
qualified operators and are all expected to follow
3 Always perform function tests prior to use. all safety rules and instructions in the operator’s
4 Inspect the workplace. manual. That means every new operator should
perform a pre-operation inspection, function tests,
5 Only use the machine as it was and a workplace inspection before using the
intended. machine.

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Operating Instructions

Starting the Engine All models

If the engine fails to start after 15 seconds of
Diesel models cranking, determine the cause and repair any
malfunction. Wait 60 seconds before trying to start
1 At the ground controls, turn the key switch to
the desired position. again.
In cold conditions, 20°F/-6°C and below, warm the
2 Be sure both ground and platform control red
Emergency Stop buttons are pulled out to the engine for 5 minutes before operating to prevent
on position. hydraulic system damage.
In extreme cold conditions, 0°F/-18°C and below,
Models with glow plug toggle switch: machines should be equipped with optional cold
3 Move the glow plug switch to either side and start kits. Attempting to start the engine when
hold for 3 to 5 seconds. temperatures are below 0°F/-18°C may require the
use of a booster battery.
4 Move the engine start toggle switch to either
side. If the engine fails to start or dies, the Gasoline/LPG models: In cold conditions,
restart delay will disable the start switch for 20°F/-6°C and below, the machine should be
3 seconds. started on gasoline and warmed for 2 minutes,
then switched to LPG. Warm engines can be
Models with automatic glow plugs:
started on LPG.
5 The LCD screen will display the glow
plug symbol when the automatic glow
plugs are on.

6 When the automatic glow plug symbol turns

off, move the engine start toggle switch to
either side. If the engine fails to start or dies,
the restart delay will disable the start switch for
3 seconds.

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Operating Instructions

Emergency Stop Operation from Ground

Push in the red Emergency Stop button to the off 1 Turn the key switch to ground control.
position at the ground controls or the platform
2 Pull out the red Emergency Stop button to the
controls to stop all machine functions and turn the
on position.
engine off.
3 Start the engine.
Repair any function that operates when either red
Emergency Stop button is pushed in.
To Position Platform
Selecting and operating the ground controls will
1 Push and hold the function
override the platform red Emergency Stop button.
enable button.

Auxiliary Power
2 Move the appropriate toggle switch according
Use auxiliary power if the primary power source to the markings on the control panel.
(engine) fails.
Drive and steer functions are not available from
1 Turn the key switch to ground or platform the ground controls.
control.
2 Pull out the red Emergency Stop button to the
on position.
3 Press down the foot switch when using the
controls from the platform.

4 Simultaneously hold the auxiliary

power switch to either side and
activate the desired function.

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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 control
Emergency Stop buttons to the on position. handle off center.

3 Start the engine. Do not press down the foot Decrease speed: Slowly move the control
switch when starting the engine. handle toward center.
Stop: Return the control handle to center or
To Steer release the function enable switch.
1 Press down the foot switch. Use the color-coded direction arrows on the
2 Slowly move the drive control handle in the platform controls and the drive chassis to identify
direction indicated by blue or yellow triangles the direction the machine will travel.
OR press the thumb rocker switch located on Machine travel speed is restricted when the boom
top of the drive control handle. is raised.
Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the wheels will turn.

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Operating Instructions
Driving on a slope To determine the slope grade:
Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR
ratings for the machine and determine the slope use the following procedure.
grade.
You will need:
Maximum slope rating, platform
downhill (gradeability): • carpenter’s level
2WD: 30% (17°) • straight piece of wood, at least 3 feet/1 m long
4WD: 45% (24°)
• tape measure
Maximum slope rating, platform
uphill: Lay the piece of wood on the slope.
25% (14°)
At the downhill end, lay the level on the top edge
Maximum side slope rating:
of the piece of wood and lift the end until the piece
25% (14°)
of wood is level.
While holding the piece of wood level, measure
Note: Slope rating is subject to ground conditions the vertical distance from the bottom of the piece
with one person in the platform and adequate of wood to the ground.
traction. Additional platform weight may reduce
slope rating. The term gradeability applies to the Divide the tape measure distance (rise) by the
counterweight uphill configuration only. length of the piece of wood (run) and multiply by
100.
Be sure the boom is below horizontal and the
platform is between the circle-end wheels. Example:
Move the drive speed select switch to machine on
incline symbol.

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 slope or side
slope rating, then the machine must be winched or
transported up or down the slope. See Transport
and Lifting section.

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Operating Instructions
Drive Enable Tilt Sensor Activation Settings
Light on indicates that the boom Model Chassis Angle Chassis Angle (front
has moved just past either non- (side to side) to back)
steer wheel and the drive Z-45J IC 4.5° 2.5°
function has been interrupted.
When the Machine On Incline
indicator light is on and the tilt
alarm sounds, the following
functions are affected; drive
functions are disabled.
To drive, hold the drive enable switch to either side
and slowly move the drive control handle off Follow the Boom lowering
center. procedure (see Operating
Instructions) to restore drive
Be aware that the machine may move in the function.
opposite direction that the drive and steer controls
are moved. While operating from the platform
with the machine on the out of
Always use the color-coded direction arrows on
stowed position, on a slope, and
the platform controls and the drive chassis to
the tilt alarm sounds. The
identify the direction the machine will travel.
following functions are affected: lift
functions are disabled.
To Position Platform
1 Press down the foot switch. Follow the Boom lowering
procedure (see Operating
2 Slowly move the appropriate function control instruction) to restore lift function.
handle or toggle switch or press the
appropriate button according to the markings
on the control panel. Generator (if equipped)
To start the generator, move
Drive Speed Select the generator toggle switch to
the on position.
Plug a power tool into the
power to platform GFCI outlet.
• Machine on incline symbol: Low range
To turn off the generator, move the generator
operation for inclines
toggle switch to the off position.
• Machine on level surface symbol: High range
operation for maximum drive speed. Note: Machine functions will not operate while the
generator is running and the foot switch is not
pressed down. When the foot switch is pressed
down, the generator will turn off and the machine
functions will operate.

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Operating Instructions
Machine Not Level Indicator Light Engine Idle Select (rpm)
If the tilt alarm sounds when the When the foot switch is not pressed, the engine
platform is raised, the Machine Not will idle at the lowest rpm.
Level indicator light will come on
and the drive function in one or • Turtle symbol: Foot
both directions will not operate. switch activated low idle
Identify the condition of the boom • Rabbit symbol: Foot
on the slope as shown below. switch activated high idle
Follow the steps to lower the boom
before moving to a firm, level If foot switch activated low idle or high idle do not
surface. Do not rotate the boom work, contact service personnel within 24 hours.
while lowering.
Foot switch activated idle settings are disabled by
If the tilt alarm sounds certain fault codes.
with the platform uphill:
Check Engine Light
1 Lower the primary
boom. Light on and engine stopped: Tag
the machine and remove from
2 Lower the
service.
secondary boom.
3 Retract the primary Light on and engine still running:
boom. Contact service personnel within
24 hours.
If the tilt alarm sounds
with the platform
downhill: Platform Overload Indicator Light

1 Retract the primary Light flashing indicates the

boom. platform is overloaded. The
engine will stop and no
2 Lower the functions will operate.
secondary boom.
Remove weight from the
3 Lower the primary platform until the light goes off
boom. and then restart the engine.

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Operating Instructions
Aircraft Protection Package (if equipped) LCD Screen (if equipped)
If the platform bumper comes The LCD screen displays hour
into contact with an object, the meter, voltage, oil pressure and
machine will shut down and no coolant temperature. The screen
functions will operate. also displays fault codes and
other service information.
1 Start the engine.
2 Press down the foot switch. Deutz, Kubota and Perkins engines

3 Move and hold the aircraft Flashing red lights: contact service personnel.
protection override switch.
Flashing green lights: contact service personnel
4 Move the appropriate within 24 hours.
function control handle or
toggle switch to move the
machine away from aircraft
components.

Control Box Heater (if equipped)

Move the control box heater switch up
to activate the heater.

Engine Shut-down indicator light (if

equipped)
Light on: Tag and remove the machine
from service.

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Operating Instructions
Contact Alarm (if equipped) After Each Use
The contact alarm is designed to alert ground 1 Select a safe parking location—firm level
personnel when an operator makes contact with surface, clear of obstruction and traffic.
the platform control panel, interrupting boom
2 Retract and lower the boom to the stowed
movement, sounding an alarm and flashing
position.
warning lights.
3 Rotate the turntable so that the boom is
When the contact alarm cable is tripped, the lift
between the non-steer wheels.
and drive functions are disabled at the platform.
The audio and visual warnings will activate alerting 4 Turn the key switch to the off position and
others that assistance may be needed. These remove the key to secure from unauthorized
notifications will continue until the system is reset. use.
1 The contact alarm cable is tripped, releasing 5 Chock the wheels.
the actuator from the switch socket.
2 Insert the actuator into the switch socket to Machine Storage
turn off flashing lights and audio alarm. Properly preparing and stowing the machine for
extended storage will make it easier to put the
machine back into service.
1 See After Each Use section for basic machine
stowing instructions.
2 Store the machine in a dry and well-ventilated
location. Be sure machine is clean and dry.
3 Perform a complete Pre-Operation Inspection.
Models with Engines: fill the fuel tank.
4 Refer to the Scheduled Maintenance section in
the appropriate Service Manual, and complete
1 actuator each lubrication procedure.
2 contact alarm cable
5 Remove and store the battery.
3 flashing alarm
4 switch socket 6 Models with Engines: Refer to the OEM
engine manual for additional extended storage
procedures. As needed, start and run the
engine for 10 minutes.

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Transport and Lifting Instructions

Trans port and Lifti ng Instr ucti ons

 Be sure the turntable is secured with the

turntable rotation lock before transporting. Be
sure to unlock the turntable for operation.
 Do not drive the machine on a slope that
exceeds the uphill, downhill or side slope
rating. See Driving on a Slope in the Operating
Observe and Obey: Instructions section.
 Genie provides this securement information as  If the slope of the transport vehicle bed
a recommendation. Drivers are solely exceeds the uphill or downhill maximum slope
responsible for making sure machines are rating, the machine must be loaded and
properly secured and the correct trailer is unloaded using a winch as described in the
selected. brake release operation. See the
Specifications section for the slope ratings.
 Genie customers needing to containerize any
lift or Genie product should source a qualified
freight forwarder with expertise in preparing, Free-wheel Configuration for
loading and securing construction and lifting
equipment for international shipment.
Winching
Chock the wheels to prevent the machine from
 Only qualified mobile elevating work platform rolling.
operators should move the machine on or off
the truck. 2WD models: Release Disengage
 The transport vehicle must be parked on a the non-steer wheel
level surface. brakes by turning over
the drive hub
 The transport vehicle must be secured to disconnect caps.
prevent rolling while the machine is being
loaded. 4WD models: Release
the wheel brakes by Engage
 Be sure the vehicle capacity, loading surfaces turning over all four
and chains or straps are sufficient to withstand drive hub disconnect
the machine weight. Genie lifts are very heavy caps.
relative to their size. See the serial label for
the machine weight. See the inspections Be sure the winch line is properly secured to the
section for the serial label location. drive chassis tie points and the path is clear of all
obstructions.
Reverse the procedures described to re-engage
the brakes.
Note: Towing the Genie Z-45/25J is not
recommended. If the machine must be towed, do
not exceed 2 mph / 3.2 km/h.

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Transport and Lifting Instructions

Securing to Truck or Trailer for Securing the Platform - Z-45/25J

Transit Make sure the jib and platform are in the stowed
position.
Always use the turntable rotation lock pin each
time the machine is transported. 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.

1 Turntable rotation lock pin

Turn the key switch to the off position and remove
the key before transporting.
Inspect the entire machine for loose or unsecured
items.

Securing the Chassis

Use chains of ample load capacity.
Use a minimum of 4 chains or straps.
Adjust the rigging to prevent damage to the
chains.

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Transport and Lifting Instructions

Observe and Obey:

 Only qualified riggers should rig the machine.
 Only certified crane operators should lift the
machine and only in accordance with the
applicable crane regulations.
 Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial label for
the machine weight.

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Transport and Lifting Instructions

Lifting Instructions Attach the rigging only to the designated lifting

points on the machine. There are four lifting points
Fully lower and retract the boom. Fully lower the on the machine, one on each axle.
jib (if equipped). Remove all loose items on the
machine. Adjust the rigging to prevent damage to the
machine and to keep the machine level.
Determine the center of gravity of your machine
using the table and the picture on this page. Center of gravity X Axis Y Axis
Z-45/25J 47.3 in 44 in
120 cm 112 cm

1 Y Axis

2 X Axis

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Maintenance
Maintenanc e

Check the Engine Oil Level

Maintaining the proper engine oil level is essential

to good engine performance and service life.
Operating the machine with an improper oil level
Observe and Obey: can damage engine components.
 Only routine maintenance items specified in
Note: Check the oil level with the engine off.
this manual shall be performed by the
operator. 1 Check the oil level dipstick. Add oil as needed.
 Scheduled maintenance inspections shall be Deutz D2011 L03i Engine
performed by qualified service technicians,
according to the manufacturer’s specifications. Oil type 15W-40
Oil type - cold conditions 5W-40
 Dispose of material in accordance with
governmental regulations. Deutz D2.9 L4 Engine
Oil type 15W-40
 Use only Genie approved replacement parts.
Oil type - cold conditions 5W-40
Maintenance Symbols Legend Kubota D-1105-E4B Engine
The following symbols have been used in this Oil type 10W-30
manual to help communicate the intent of the Perkins 403J-11 Engine
instructions. When one or more of the symbols
Oil type 10W-30
appear at the beginning of a maintenance
procedure, it conveys the meaning below. Perkins 403EA-11 Engine
Oil type 10W-30
Indicates that tools will be required to
perform this procedure. Perkins 404D-22 Engine
Oil type 15W-40
Oil type - cold conditions 5W-40
Indicates that new parts will be required to
perform this procedure.

Indicates that a cold engine is required

before performing this procedure.

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Maintenance

Diesel Fuel Requirements Check the Hydraulic Oil Level

Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is
the use of a good quality fuel. The use of a good essential to machine operation. Improper hydraulic
quality fuel will give the following result: long oil levels can damage hydraulic components. Daily
engine life and acceptable exhaust emissions checks allow the inspector to identify changes in
levels. oil level that might indicate the presence of
hydraulic system problems.
Minimum diesel fuel requirements for each engine
are listed below. 1 Be sure that the boom is in the stowed
position.
Deutz D2011 L03i Engine
2 Visually inspect the sight gauge located on the
Fuel Type Low Sulfur Diesel (LSD) side of the hydraulic oil tank.
Deutz D2.9 L4 Engine
Result: The hydraulic oil level should be within
Fuel Type Ultra Low Sulfur Diesel (ULSD) the top 2 inches / 5 cm of the sight gauge.
Kubota D-1105-E4B Engine 3 Add oil as needed. Do not overfill.
Fuel Type Low Sulfur Diesel (LSD) or
Ultra Low Sulfur Diesel (ULSD) Hydraulic oil specifications

Perkins 403J-11 Engine Hydraulic oil type Chevron Rando HD equivalent

Fuel Type Ultra Low Sulfur Diesel (ULSD)

Perkins 403EA-11 Engine
Fuel Type Ultra Low Sulfur Diesel (ULSD)
Perkins 404D-22 Engine
Fuel Type Low Sulfur Diesel (LSD)

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Maintenance

Check the Engine Coolant Level – Check the Batteries

Liquid Cooled Models

Proper battery condition is essential to good

Maintaining the engine coolant at the proper level machine performance and operational safety.
is essential to engine service life. Improper coolant Improper fluid levels or damaged cables and
level will affect the engine’s cooling capability and connections can result in component damage and
damage engine components. Daily checks will hazardous conditions.
allow the inspector to identify changes in coolant Electrocution hazard. Contact with hot or live
level that might indicate cooling system problems. circuits may result in death or serious injury.
Burn hazard. Beware of hot engine parts and Remove all rings, watches and other jewelry.
coolant. Contact with hot engine parts and/or Bodily injury hazard. Batteries contain acid.
coolant may cause severe burns. Avoid spilling or contacting battery acid.
Burn hazard. Do not remove the radiator cap if Neutralize battery acid spills with baking soda
the engine has been running. Contact with and water.
pressurized coolant may cause severe burns. 1 Put on protective clothing and eye wear.
Allow engine to cool before removing the
radiator cap. 2 Be sure that the battery cable connections are
tight and free of corrosion.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed. 3 Be sure that the battery hold-down brackets
are in place and secure.
Result: The fluid level should be at the FULL
mark on the tank or visible in the sight gauge. Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.

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Maintenance

Scheduled Maintenance
Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on
this machine according to the procedures found in
the service manual for this machine.
Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.
Obey all local and governmental regulations
regarding the disposal and decommissioning of
the machine at the end of its lifetime. Refer to the
appropriate Genie service manual for additional
information.

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Specifications
Specific ati ons

Z-45/25J Ambient operating temperature -20° F to 120° F

Height, working maximum -29° C to 49° C
51 ft 6 in 15.86 m
AC outlet in platform standard
Height, platform maximum 45 ft 6 in 13.86 m
Hydraulic pressure, maximum 3,200 psi 221 bar
Height, stowed maximum 7 ft 2.13 m
(boom functions)
Horizontal reach, maximum 24 ft 8 in 7.52 m
System voltage 12V
Width, standard tires 7 ft 6 in 2.29 m
Tire size, 4WD & 2WD RT 315/55 D20
Width, high flotation tires 8 ft 5 in 2.56 m
Tire size, High Floatation 33/16LL500
Length, stowed 21 ft 10 in 6.65 m
Airborne noise emissions
Maximum load capacity 500 lbs 227 kg
Sound pressure level at platform
Maximum load capacity, 440 lbs 200 kg 82 dBA
workstation
Models with Aircraft Protection
Package Sound pressure level at ground
87 dBA
workstation
Maximum wind speed 28 mph 12.5 m/s
Guaranteed sound power level 105 dBA
Wheelbase 6 ft 8 in 2.03 m
Maximum slope rating, stowed position, 2WD
Turning radius (outside) 14 ft 9 in 4.5 m
Platform downhill 30% (17°)
Turning radius (inside) 5 ft 6 in 1.68 m
Platform uphill 25% (14°)
Turntable rotation 355°
Side slope 25% (14°)
Turntable tailswing 0 in 0 cm
Drive speed, stowed 4.5 mph 7.2 km/h Maximum slope rating, stowed position, 4WD

Drive speed, stowed, Kubota 3.1 mph 5.0 km/h Platform downhill 45% (24°)

Drive speed, stowed, Perkins 2.6 mph 4.2 km/h Platform uphill 25% (14°)

Drive speed, booms raised 0.9 ft/s 0.3 m/s Side slope 25% (14°)

Ground clearance, center 14.8 in 37.5 cm Note: Slope rating is subject to ground conditions with
one person in the platform and adequate traction.
Ground clearance, axle 10.5 in 26.7 cm Additional platform weight may reduce slope rating.
Controls 12V DC proportional Maximum allowable Refer to "Tilt Sensor
Weight chassis inclination Activation Settings" section
2WD 14,063 lbs 6,379 kg Hydraulic tank capacity 22 gallons 83 liters
4WD 14,363 lbs 6,515 kg
Fuel tank capacity 17 gallons 64.4 liters
(Machine weights vary with option configurations. See
serial label for specific machine weight.) Floor loading information
Platform dimensions 48 in x 30 in 122 cm x 76 cm Tire load maximum 8,050 lbs 3,651 kg
(length x width) 4 foot Tire contact pressure 60 psi 414 kPa
Platform dimensions 60 in x 30 in 152 cm x 76 cm Occupied floor pressure 186 psf 909 kg/m2
(length x width) 5 foot (2WD) 8.92 kPa
Platform dimensions 72 in x 30 in 183 cm x 76 cm Occupied floor pressure 190 psf 930 kg/m2
(length x width) 6 foot (4WD) 9.12 kPa
Platform leveling self-leveling Note: Floor loading information is approximate and does
Platform rotation 160° not incorporate different option configurations. It should
be used only with adequate safety factors.
Total vibration value to which the hand/arm system is
subjected does not exceed 2.5 m/s2. Continuous improvement of our products is a Genie
Highest root mean square value of weighted policy. Product specifications are subject to change
acceleration to which the whole body is subjected does without notice or obligation.
not exceed 0.5 m/s2.

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Specifications
Z-45/25J Range of motion chart

Maximum platform capacity

1 500 lbs 227 kg
Maximum platform capacity, models with Aircraft Protection Package

1 440 lbs 200 kg

Horizontal Values Vertical Values

2 0 ft 0m 6 -5 ft -1.5 m

3 5 ft 1.5 m 7 0 ft 0m

4 15 ft 4.6 m 8 10 ft 3m

5 25 ft 7.6 m 9 20 ft 6.1 m

10 30 ft 9.1 m

11 40 ft 12.2 m

12 50 ft 15.2 m

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Specifications

Contents of EC Declaration of Conformity - 1

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Directives:
1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard
EN280 as described in EC type-examination certificate <variable field> issued by:
<notified body's name>

<notified body's number>

2. EC Directive EMC: 2014/30/EU, under consideration of harmonized European standard EN 61000-6-
2 and EN 61000-6-4
3. EC Directive 2000/14/EC, Noise Directive, under consideration of Annex V and harmonized standard
EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie Industries B.V
Boekerman 5,
4751 XK Oud Gastel,
The Netherlands

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of EC Declaration of Conformity - 2

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Directives:
1. EC Directive 2006/42/EC, Machinery Directive, Conformity assessment procedure: art.12 (3) (a), with
the application of European Harmonized Standard EN 280:2013+A1:2015.
2. EC Directive EMC: 2014/30/EU, under consideration of harmonized European standard EN 61000-6-
2 and EN 61000-6-4
3. EC Directive 2000/14/EC, Noise Directive, under consideration of Annex V and harmonized standard
EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie Industries B.V
Boekerman 5,
4751 XK Oud Gastel,
The Netherlands

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of UK Declaration of Conformity - 1

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Legislation:
1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI
2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type-
examination certificate <variable field> issued by:
<notified body's name>

<notified body's number>

2. Electromagnetic Compatibility Regulations 2016 (SI 2016/1091) as amended (SI 2017/1206, SI
2019/696) under consideration of designated standard EN 61000-6-2 and EN 61000-6-4
3. Noise Emissions in the Environment by Equipment for use Outdoors Regulations 2001 (SI 2001/1701)
as amended (SI 2001/3958, SI 2005/3525, 2015/98) under consideration of Annex V and designated
standard EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie UK Ltd
The Maltings
Wharf Road
Grantham
NG31 6BH

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of UK Declaration of Conformity - 2

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Legislation:
1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI
2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11. (2) (a) with reference
to designated standard EN 280:2013+A1:2015
2. Electromagnetic Compatibility Regulations 2016 (SI 2016/1091) as amended (SI 2017/1206, SI
2019/696) under consideration of designated standard EN 61000-6-2 and EN 61000-6-4
3. Noise Emissions in the Environment by Equipment for use Outdoors Regulations 2001 (SI 2001/1701)
as amended (SI 2001/3958, SI 2005/3525, 2015/98) under consideration of Annex V and designated
standard EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie UK Ltd
The Maltings
Wharf Road
Grantham
NG31 6BH

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

Z®-45/25J Part No. 1311642GT Operator's M anual Eighth Editi on • T hird Printi ng

66 Z®-45/25J Part No. 1311642GT