Terex Genie Z-45 Operator's Manual
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Terex Genie Z-45 Operator's Manual

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Operator's Manual
Z
-45/25J
®
Serial Number Range
from Z4525D-3958
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Sixth Edition
First Printing
Part No. 1299167GT

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Summary of Contents for Terex Genie Z-45

  • Page 1 Operator's Manual Serial Number Range -45/25J ® from Z4525D-3958 ANSI/CSA North America South America Asia with Maintenance Information Original Instructions Sixth Edition First Printing Part No. 1299167GT...

  • Page 2: Table Of Contents

    11 Maintenance ..........63 12 Specifications ..........67 Copyright © 2012 Terex Corporation Sixth Edition: First Printing, September 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI/SAIA A92.20...

  • Page 3: Introduction

    Sixth Edition • First Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for 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.
  • Page 4 Sixth Edition • First Printing Operator's Manual 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.
  • Page 5 Sixth Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Sixth Edition • First Printing Operator's Manual 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.
  • Page 7 Sixth Edition • First Printing Operator's Manual Introduction Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 8: Symbol And Hazard Pictorials Definitions

    Sixth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Read the operator’s Crush hazard Keep away from Fire extinguisher Overhead obstruction moving parts manual Electrocution hazard Maintain required Tip-over hazard Manual force Tip-over hazard clearance...
  • Page 9 Sixth Edition • First Printing Operator's Manual 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 &...
  • Page 10 Sixth Edition • First Printing Operator's Manual 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.

  • Page 11: General Safety

    Sixth Edition • First Printing Operator's Manual General Safety Gener al Safety ® Part No. 1299167GT -45/25J...
  • Page 12 Sixth Edition • First Printing Operator's Manual General Safety ® -45/25J Part No. 1299167GT...
  • Page 13 Sixth Edition • First Printing Operator's Manual General Safety ® Part No. 1299167GT -45/25J...
  • Page 14 Sixth Edition • First Printing Operator's Manual General Safety ® -45/25J Part No. 1299167GT...
  • Page 15 Sixth Edition • First Printing Operator's Manual General Safety ® Part No. 1299167GT -45/25J...
  • Page 16 Sixth Edition • First Printing Operator's Manual General Safety ® -45/25J Part No. 1299167GT...
  • Page 17 Sixth Edition • First Printing Operator's Manual General Safety ® Part No. 1299167GT -45/25J...
  • Page 18 Sixth Edition • First Printing Operator's Manual General Safety ® -45/25J Part No. 1299167GT...

  • Page 19: Personal Safety

    Sixth Edition • First Printing Operator's Manual 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.

  • Page 20: Work Area Safety

    Sixth Edition • First Printing Operator's Manual Work Area Safety Wor k 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.
  • Page 21 Sixth Edition • First Printing Operator's Manual Work Area Safety If the tilt alarm sounds Do not raise or extend the with the platform boom unless the machine downhill: is on a firm, level surface. Retract the primary boom. Lower the secondary boom.
  • Page 22 Sixth Edition • First Printing Operator's Manual 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.
  • Page 23 Sixth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Do not transport tools and materials unless they are evenly distributed and can be safely handled Occupants must wear a by person(s) in the platform. safety belt or harness in Do not use the machine on a moving or mobile accordance with surface or vehicle.
  • Page 24 Sixth Edition • First Printing Operator's Manual 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.
  • Page 25 Sixth Edition • First Printing Operator's Manual 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.
  • Page 26 Sixth Edition • First Printing Operator's Manual 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...
  • Page 27 Sixth Edition • First Printing Operator's Manual Work Area Safety Pipe Cradle Safety Read, understand, and obey all warnings and instructions provided with the pipe cradles. Do not exceed the rated platform capacity. The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform load.

  • Page 28: Legend

    Sixth Edition • First Printing Operator's Manual Legend Leg end Primary boom Foot switch Secondary boom Manual storage container 10 Ground controls Sliding mid-rail 11 Steer tire Lanyard anchorage points 12 LPG tank (if equipped) Jib boom (Z-45/25J) 13 Non-steer tire Platform Platform controls ®...

  • Page 29: Controls

    Sixth Edition • First Printing Operator's Manual 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.
  • Page 30 Sixth Edition • First Printing Operator's Manual Controls LCD readout screen 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.
  • Page 31 Sixth Edition • First Printing Operator's Manual 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.
  • Page 32 Sixth Edition • First Printing Operator's Manual Controls Platform Control Panel ® -45/25J Part No. 1299167GT...
  • Page 33 Sixth Edition • First Printing Operator's Manual Controls ® Part No. 1299167GT -45/25J...
  • Page 34 Sixth Edition • First Printing Operator's Manual Controls Platform Control Panel Platform overload indicator light Horn button Light flashing indicates the platform is overloaded. The engine will stop and no Press this button and the horn will sound. functions will operate. Remove weight until the Release the button and the horn will stop.
  • Page 35 Sixth Edition • First Printing Operator's Manual 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.
  • Page 36 Sixth Edition • First Printing Operator's Manual Controls 20 Gasoline/LPG models: Fuel select switch Move the fuel select switch to the gasoline position to select gasoline. Move the fuel select switch to the LPG position to select LPG. 21 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary...

  • Page 37: Inspections

    Sixth Edition • First Printing Operator's Manual 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...
  • Page 38 Sixth Edition • First Printing Operator's Manual Inspections Pre-operation Inspection  Fuel and hydraulic tanks  Drive and turntable motors and drive hubs  Be sure that the operator’s, safety, and  Wear pads responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 39 Sixth Edition • First Printing Operator's Manual 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 40 Sixth Edition • First Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of Turn the key switch to hazards. platform control. Pull out the platform red Emergency Turn the key switch to ground control.
  • Page 41 Sixth Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Platform Controls 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.
  • Page 42 Sixth Edition • First Printing Operator's Manual 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...
  • Page 43 Sixth Edition • First Printing Operator's Manual 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.
  • Page 44 Sixth Edition • First Printing Operator's Manual 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 2 ft / 58 Rotate the turntable until the primary boom 61 cm.
  • Page 45 Sixth Edition • First Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test Aircraft Protection Package (if equipped) 71 Start the engine from the platform controls. Note: Two people may be required to perform this 72 Drive the right steer tire up onto a 6 in/15 cm test.
  • Page 46 Sixth Edition • First Printing Operator's Manual 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.
  • Page 47 Sixth Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 48 Sixth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Label – Low Sulfur Fuel (diesel 133278 Determine whether the decals on your machine models)* have words or symbols. Use the appropriate 160516 Ground Control Panel with LCD inspection to verify that all decals are legible and screen*...
  • Page 49 Sixth Edition • First Printing Operator's Manual Inspections ® Part No. 1299167GT -45/25J...
  • Page 50 Sixth Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Label – Electrocution/Burn Hazard Symbols 133205 Danger, Warning – Tip-over Hazard, 161162 Determine whether the decals on your machine CE, Aircraft Protection* have words or symbols. Use the appropriate 214932 Ground Control Panel inspection to verify that all decals are legible and...
  • Page 51 Sixth Edition • First Printing Operator's Manual Inspections ® Part No. 1299167GT -45/25J...

  • Page 52: Operating Instructions

    Sixth Edition • First Printing Operator's Manual 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, safety, and responsibilities manuals.
  • Page 53 Sixth Edition • First Printing Operator's Manual Operating Instructions Models with automatic glow plugs: Starting the Engine The LCD screen will display the glow Gasoline/LPG models plug symbol when the automatic glow plugs are on. At the ground controls, turn the key switch to the desired position.
  • Page 54 Sixth Edition • First Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
  • Page 55 Sixth Edition • First Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 56 Sixth Edition • First Printing Operator's Manual 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.
  • Page 57 Sixth Edition • First Printing Operator's Manual Operating Instructions Drive Enable Tilt Sensor Activation Settings Model Chassis Angle Chassis Angle (front Light on indicates that the boom (side to side) to back) has moved just past either non- steer wheel and the drive Z-45J IC 4.5°...
  • Page 58 Sixth Edition • First Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Engine Idle Select (rpm) When the foot switch is not pressed, the engine If the tilt alarm sounds when the will idle at the lowest rpm. platform is raised, the Machine Not Level indicator light will come on ...
  • Page 59 Sixth Edition • First Printing Operator's Manual 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.
  • Page 60 Sixth Edition • First Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) After Each Use The contact alarm is designed to alert ground 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 Retract and lower the boom to the stowed movement, sounding an alarm and flashing...

  • Page 61: Transport And Lifting Instructions

    Reverse the procedures described to re-engage the brakes. Note: Towing the Genie Z-45/25 or the Z-45/25J is not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. ®...
  • Page 62 Sixth Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform - Z-45/25J Securing to Truck or Trailer for 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.
  • Page 63 Sixth Edition • First Printing Operator's Manual 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. ...
  • Page 64 Sixth Edition • First Printing Operator's Manual Transport and Lifting Instructions Attach the rigging only to the designated lifting Lifting Instructions 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).

  • Page 65: Maintenance

    Sixth Edition • First Printing Operator's Manual Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 66 Sixth Edition • First Printing Operator's Manual 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.
  • Page 67 Sixth Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 68 Sixth Edition • First Printing Operator's Manual 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.

  • Page 69: Specifications

    Sixth Edition • First Printing Operator's Manual Specifications Specific ati ons Ambient operating temperature -20° F to 120° F Z-45/25J -29° C to 49° C Height, working maximum 52 ft 1 in 16.05 m AC outlet in platform standard Height, platform maximum 46 ft 1 in 14.05 m Hydraulic pressure, maximum...
  • Page 70 Sixth Edition • First Printing Operator's Manual Specifications Z-45/25J Range of motion chart Z®-45/25J Part No. 1299167GT Operator's M anual Si xth Editi on • First Printi ng ® -45/25J Part No. 1299167GT...

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Genie z-25j

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