Terex Genie Z-45/25 Operator's Manual
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Terex Genie Z-45/25 Operator's Manual

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Operator's Manual
Z-45/25
Z-45/25J
Z-51/30J
IC Power
AUS
Australia
with
Maintenance
Information
Seventh Edition
First Printing
Part No. 219414

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Summary of Contents for Terex Genie Z-45/25

  • Page 1 Operator's Manual Z-45/25 Australia Z-45/25J Z-51/30J IC Power with Maintenance Information Seventh Edition First Printing Part No. 219414...

  • Page 2: Table Of Contents

    Maintenance ............47 Specifications ............51 Copyright © 2012 Terex Corporation Seventh Edition: First Printing, June 2013 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS 1418.14 Z-45/25 •...

  • Page 3: Introduction

    Seventh Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Seventh Edition • First Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for: Accident reporting Questions regarding product applications and...
  • Page 5 Seventh Edition • First Printing Operator's Manual Introduction Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury. Do Not Operate Unless:  You learn and practice the principles of safe machine operation contained in this operator’s manual.
  • Page 6 Operator's Manual Seventh Edition • First Printing 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: Symbol And Hazard Pictorials Definitions

    Seventh Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Maintain required Electrocution hazard Explosion hazard Explosion hazard Collision hazard clearance Runaway Hazard Tip-over hazard Crush hazard Color Coded Wind speed Direction Arrows Side force Maximum capacity Voltage rating for...
  • Page 8 Operator's Manual Seventh Edition • First Printing Symbol and Hazard Pictorials Definitions Recovery procedure if tilt alarm sounds while elevated. Read the operator’s No smoking Do not use ether or Platform uphill: Platform downhill: manual other high energy No flame 1 Lower primary.

  • Page 9: General Safety

    Seventh Edition • First Printing Operator's Manual General Safety General Safety 31060 114390 219486 114258 218857 or 218558 or 218484 218557 or 218558 218857 or 218484 114390 31060 218558 114258 219486 219484 Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J...
  • Page 10 Operator's Manual Seventh Edition • First Printing General Safety 218559 218549 218551 114390 219487 114397 219487 218559 218555 31060 114390 218550 or 218551 28236 31060 114397 218555 28236 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414...
  • Page 11 Seventh Edition • First Printing Operator's Manual General Safety 114390 31060 218857 218558 219484 31788 28175 97602 31060 114390 97602 31788 28175 218557 218557 or 218558 or 218558 or 219484 or 219484 Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J...

  • Page 12: Personal Safety

    Operator's Manual Seventh Edition • First Printing Personal Safety Personal 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.

  • Page 13: Work Area Safety

    Seventh Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Tip-over Hazards This machine is not electrically insulated and will Occupants, equipment and materials shall not not provide protection from contact with or exceed the maximum platform capacity or the proximity to electrical current.
  • Page 14 Operator's Manual Seventh Edition • First Printing Work Area Safety Do not depend on the tilt alarm as a level indicator. Do not raise the boom The tilt alarm sounds in the platform only when the when wind speeds may machine is on a severe slope.
  • Page 15 Seventh Edition • First Printing Operator's Manual Work Area Safety Do not tie the boom or platform to adjacent Do not place ladders or structures. scaffolds in the platform or against any part of this Do not place loads outside the platform perimeter. machine.
  • Page 16 Operator's Manual Seventh Edition • First Printing Work Area Safety Operation on Slopes Hazards Do not climb down from the platform when raised. Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine.
  • Page 17 Seventh Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Be aware of crushing hazards when grasping Always operate the machine in a well-ventilated the platform guard rail. area to avoid carbon monoxide poisoning. Do not operate the machine with a hydraulic oil or air leak.
  • Page 18 Operator's Manual Seventh Edition • First Printing Work Area Safety Explosion Hazards Damaged Machine Hazards Keep sparks, flames and Do not use a damaged or malfunctioning machine. lighted tobacco away from Conduct a thorough pre-operation inspection of the batteries. Batteries emit machine and test all functions before each work explosive gas.
  • Page 19 Seventh Edition • First Printing Operator's Manual Work Area Safety Panel Cradle Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the panel cradles. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.

  • Page 20: Legend

    Operator's Manual Seventh Edition • First Printing Legend Legend Primary boom Foot switch Secondary boom Manual storage container 10 Ground controls Sliding mid-rail 11 Steer tire Lanyard anchorage point 12 LPG tank (if equipped) Jib boom (Z-45/25J & Z-51/30J) 13 Non-steer tire Platform Platform controls Z-45/25 •...

  • Page 21: Controls

    Seventh Edition • First Printing Operator's Manual Controls Controls 00009.9 Ground Control Panel 11 Secondary boom up/down switch Gasoline/LPG select switch: Check engine light Diesel models: Oil pressure light 12 Turntable rotate switch 15A breaker for engine electrical circuits 13 Emergency lowering switch Hour meter 14 Platform rotate switch Key switch for platform/off/ground selection...
  • Page 22 Operator's Manual Seventh Edition • First Printing Controls Engine idle (rpm) select switch Ground Control Panel Move the engine idle select switch to the turtle Gasoline/LPG models: Check engine light position for foot switch activated low idle. Diesel models: Oil pressure light Move the engine idle select switch to the rabbit Light on and engine stopped: Tag the machine position for foot switch activated high idle.
  • Page 23 Seventh Edition • First Printing Operator's Manual Controls 15 Jib boom up/down switch Move the jib boom switch up and the jib boom will raise. Move the jib boom switch down and the jib boom will lower. 16 Platform level switch Move the platform level switch up and the level of the platform will raise.
  • Page 24 Operator's Manual Seventh Edition • First Printing Controls Platform Control Panel Platform control box heater (if equipped) Horn button 10 Generator switch (if equipped) Platform level switch 11 Aircraft protection override switch (if equipped) Platform rotate switch 12 Red Emergency Stop button Jib boom up/down switch (if equipped) 13 Dual axis proportional control handle for drive Platform overload indicator light...
  • Page 25 Seventh Edition • First Printing Operator's Manual Controls 214933 A 19 Gasoline/LPG models: Gasoline/LPG select 14 Drive enable indicator light switch 15 Drive enable switch 20 Proportional control handle for secondary boom 16 Diesel models: Glow plug switch up/down function 17 Engine idle (rpm) select switch 21 Primary boom extend/retract switch Turtle: foot switch activated low idle...
  • Page 26 Operator's Manual Seventh Edition • First Printing Controls Platform overload indicator light Platform Control Panel Light flashing indicates the platform is Horn button 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 27 Seventh 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 28 Operator's Manual Seventh Edition • First Printing Controls 20 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. 21 Primary boom extend/retract switch Move the primary boom extend/retract switch up and the primary boom will...

  • Page 29: Inspections

    Seventh Edition • First Printing Operator's Manual Inspections Inspections 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 Do Not Operate Unless: performed by the operator prior to each work shift. The inspection is designed to discover if anything ...
  • Page 30 Operator's Manual Seventh Edition • First Printing Inspections  Tires and wheels Pre-operation Inspection  Engine and related components  Be sure that the operator’s, safety and  Limit switches and horn responsibilities manuals are complete, legible  Alarms and beacons (if equipped) and in the storage container located in the platform.
  • Page 31 Seventh 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 32 Operator's Manual Seventh Edition • First Printing Inspections Test the Tilt Sensor At the Ground Controls Turn the key switch to Select a test area that is firm, level and free of platform control. Pull out obstruction. the platform red Emergency Turn the key switch to ground control.
  • Page 33 Seventh Edition • First Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 19 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 15 Turn the key switch to platform control and 20 Pull out the red Emergency Stop button to the restart the engine.
  • Page 34 Operator's Manual Seventh Edition • First Printing Inspections Test the Steering Test Drive and Braking 26 Press down the foot switch. 29 Press down the foot switch. 27 Press the thumb rocker switch on top of the 30 Slowly move the drive control handle in the drive control handle in the direction indicated direction indicated by the blue arrow on the by the blue triangle on the control panel OR...
  • Page 35 Seventh Edition • First Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 32 Press down the foot switch and lower the 36 Press down the foot switch. boom to the stowed position. 37 Raise the primary boom approximately 2 ft / 33 Rotate the turntable until the primary boom 61 cm.
  • Page 36 Operator's Manual Seventh Edition • First Printing Inspections Test the Oscillating Axle (if equipped) Test Aircraft Protection Package (if equipped) 46 Start the engine from the platform controls. 54 Extend the primary boom approximately 47 Drive the right steer tire up onto a 6 in / 15 cm 1 ft / 30 cm.
  • Page 37 Seventh 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 38 219487 Label – Platform Overload 62926 Cosmetic – Genie Z-45/25J 219488 Label – Transport Diagram, Z-45 62927 Cosmetic – Genie Z-45/25 823488 Instructions – Perkins Engine 62947 Cosmetic – IC Power 4 x 2 Specifications 62948 Cosmetic – IC Power 4 x 4 Shading indicates decal is hidden from view, i.e.
  • Page 39 Seventh Edition • First Printing Operator's Manual Inspections 214933 31060 62926 82366 218561 218557 114390 219486 77398 52607 214932 or 62927 or 218562 or 218558 or 219483 or 219484 28158 or 28159 114258 133278 219488 218557 or 218558 or 219484 218561 or 218562 or 219483...

  • Page 40: Operating Instructions

    Operator's Manual Seventh Edition • First Printing Operating Instructions Operating Instructions 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 41 Seventh Edition • First Printing Operator's Manual Operating Instructions All models Starting the Engine If the engine fails to start after 15 seconds of At the ground controls, turn the key switch to cranking, determine the cause and repair any the desired position.
  • Page 42 Operator's Manual Seventh Edition • First Printing Operating Instructions Emergency Power Operation from Platform Use emergency power if the primary power source Turn the key switch to platform control. (engine) fails. Pull out both ground and platform red Emergency Stop buttons to the on position. Turn the key switch to ground or platform control.
  • Page 43 Seventh Edition • First Printing Operator's Manual Operating Instructions To Drive To determine the slope grade: Press down the foot switch. Measure the slope with a digital inclinometer OR use the following procedure. Increase speed: Slowly move the drive control handle off center.
  • Page 44 Operator's Manual Seventh Edition • First Printing Operating Instructions Drive Enable Engine Idle Select (rpm) When the foot switch is not pressed, the engine Light on indicates that the boom will idle at the lowest rpm. has moved just past either non-steer wheel and the drive ...
  • Page 45 Seventh Edition • First Printing Operator's Manual Operating Instructions Check Engine Light Control Box Heater (if equipped) Light on and engine stopped: Tag Move the control box heater switch up the machine and remove from to activate the heater. service. Light on and engine still running: Contact service personnel within After Each Use...

  • Page 46: Transport And Lifting Instructions

    Reverse the procedures described to re-engage for the serial label location. 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. Z-45/25 • Z-45/25J • Z-51/30J...
  • Page 47 Seventh Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform – Z-45/25 Securing to Truck or Trailer for Transit Make sure the platform is in the stowed position. Secure the platform with a nylon strap placed over Always use the turntable rotation lock pin each the platform mount near the platform rotator (see time the machine is transported.
  • Page 48 Operator's Manual Seventh Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 49: Maintenance

    Seventh Edition • First Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential Observe and Obey: to good engine performance and service life. Operating the machine with an improper oil level ...
  • Page 50 Operator's Manual Seventh Edition • First Printing Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Ford and Perkins Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 51 Seventh Edition • First Printing Operator's Manual Maintenance Check the Batteries Check the Tire Pressure Proper battery condition is essential to good Tip-over hazard. An over-inflated tire can machine performance and operational safety. explode which may compromise machine Improper fluid levels or damaged cables and stability and cause the machine to tip over.
  • Page 52 Operator's Manual Seventh Edition • First Printing 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 53: Specifications

    Seventh Edition • First Printing Operator's Manual Specifications Specifications Z-45/25 (no jib) Airborne noise emissions Height, working maximum 15.97 m Sound pressure level at ground 87 dBA workstation Height, platform maximum 13.97 m Sound pressure level at platform 82 dBA Height, stowed maximum 2.13 m workstation...
  • Page 54 Operator's Manual Seventh Edition • First Printing Specifications Z-45/25J (jib) Airborne noise emissions Height, working maximum 16.05 m Sound pressure level at ground 87 dBA workstation Height, platform maximum 14.05 m Sound pressure level at platform 82 dBA Height, stowed maximum 2.13 m workstation Horizontal reach, maximum...
  • Page 55 Seventh Edition • First Printing Operator's Manual Specifications Z-51/30J (jib) Airborne noise emissions Height, working maximum 17.42 m Sound pressure level at ground 86 dBA workstation Height, platform maximum 15.59 m Sound pressure level at platform 79 dBA Height, stowed maximum 2.13 m workstation Horizontal reach, maximum...
  • Page 56 Operator's Manual Seventh Edition • First Printing Specifications Z-45/25 Range of Motion Chart Z-45/25J Range of Motion Chart Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414...
  • Page 57 Seventh Edition • First Printing Operator's Manual Specifications Z-51/30J Range of Motion Chart 18 m 16 m 14 m 12 m 10 m -1 m -2 m 10 m Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414 Operator's Manual Seventh Edition • First Printing Part No.
  • Page 58 www.genielift.com...

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Genie z-45/25jGenie z-51/30j

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