Terex Genie Z-25J Operator's Manual
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Terex Genie Z-25J Operator's Manual

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Operator's Manual
Z
-45/25J
®
IC Power
Serial Number Range
from Z4525D-8000
AUS
Australia
with
Maintenance
Information
Original Instructions
Eighth Edition
First Printing
Part No. 1320357GT

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Summary of Contents for Terex Genie Z-25J

  • Page 1 Operator's Manual Serial Number Range -45/25J ® from Z4525D-8000 Australia IC Power with Maintenance Information Original Instructions Eighth Edition First Printing Part No. 1320357GT...

  • Page 2: Table Of Contents

    Maintenance ............52 Specifications ............56 Copyright © 2012 Terex Corporation Eighth Edition: First Printing, February 2023 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 -45/25J Part No.

  • Page 3: Introduction

    Eighth 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 Operator's Manual Eighth Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level, jib boom Platform level swtich up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 Eighth 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 Operator's Manual Eighth 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

    Eighth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Electrocution hazard Maintain required Explosion hazard Explosion hazard Collision hazard clearance Runaway hazard Tip-over hazard Crush hazard Color coded Wind speed direction arrows Manual force Maximum capacity...
  • Page 8 Operator's Manual Eighth 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

    Eighth Edition • First Printing Operator's Manual General Safety Gener al Safety Part No. 1320357GT -45/25J ®...
  • Page 10 Operator's Manual Eighth Edition • First Printing General Safety -45/25J Part No. 1320357GT ®...
  • Page 11 Eighth Edition • First Printing Operator's Manual General Safety Part No. 1320357GT -45/25J ®...
  • Page 12 Operator's Manual Eighth Edition • First Printing General Safety -45/25J Part No. 1320357GT ®...

  • Page 13: Personal Safety

    Eighth 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 14: Work Area Safety

    Operator's Manual Eighth Edition • First Printing Work Area Safety Work Ar ea Safety Tip-over Hazards Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity or the not provide protection from contact with or maximum platform capacity of the platform proximity to electrical current.
  • Page 15 Eighth Edition • First Printing Operator's Manual 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 16 Operator's Manual Eighth Edition • First Printing Work Area Safety Do not contact adjacent structures with the boom. Do not place ladders or scaffolds in the platform or Do not tie the boom or platform to adjacent against any part of this structures.
  • Page 17 Eighth Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating safety belt or harness in of the machine.
  • Page 18 Operator's Manual Eighth Edition • First Printing 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 19 Eighth 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 20 Operator's Manual Eighth Edition • First Printing 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 21 Eighth 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 22 Operator's Manual Eighth Edition • First Printing Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 23: Legend

    Eighth Edition • First Printing Operator's Manual Legend Legend Platform controls Foot switch Primary boom Manual storage container Secondary boom Sliding mid-rail 10 Ground controls Lanyard anchorage points 11 Steer tire Jib boom (Z-45/25J) 12 LPG tank (if equipped) Platform 13 Non-steer tire Part No.

  • Page 24: Controls

    Operator's Manual Eighth Edition • First Printing 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 25 Eighth Edition • First Printing Operator's Manual Controls Ground Control Panel Engine idle (rpm) select switch 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 26 Operator's Manual Eighth Edition • First Printing 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 27 Eighth Edition • First Printing Operator's Manual Controls Platform Control Panel Horn button Platform control box heater (if equipped) Platform level switch 10 Generator switch (if equipped) Platform rotate switch 11 Aircraft protection override switch (if equipped) Jib boom up/down switch (if equipped) 12 Red Emergency Stop button Platform overload indicator light 13 Dual axis proportional control handle for drive...
  • Page 28 Operator's Manual Eighth Edition • First Printing Controls 14 Drive enable indicator light 19 Gasoline/LPG models: Fuel select switch 15 Drive enable switch 20 Proportional control handle for secondary boom up/down function 16 Diesel models: Glow plug switch 21 Primary boom extend/retract switch 17 Engine idle (rpm) select switch 22 Dual axis proportional control handle for primary Turtle: foot switch activated low idle...
  • Page 29 Eighth Edition • First Printing Operator's Manual 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 30 Operator's Manual Eighth Edition • First Printing 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 31 Eighth Edition • First Printing Operator's Manual 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 32: Inspections

    Operator's Manual Eighth Edition • First Printing 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 33 Eighth 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 manual is  Wear pads complete, legible and in the storage container located in the platform.
  • Page 34 Operator's Manual Eighth Edition • First Printing 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 35 Eighth Edition • First Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Turn the key switch to Select a test area that is firm, level and free of platform control. Pull out the hazards. platform red Emergency Turn the key switch to ground control.
  • Page 36 Operator's Manual Eighth Edition • First Printing Inspections At the Platform Controls Test the Foot Switch 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 37 Eighth Edition • First Printing Operator's Manual 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 38 Operator's Manual Eighth Edition • First Printing 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 33 Rotate the turntable until the primary boom 2 ft / 61 cm.
  • Page 39 Eighth Edition • First Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test Aircraft Protection Package (if equipped) 46 Start the engine from the platform controls. Note: Two people may be required to perform this 47 Drive the right steer tire up onto a 6 in/15 cm test.
  • Page 40 Operator's Manual Eighth Edition • First Printing 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 You learn and practice the principles of safe ...
  • Page 41 Eighth Edition • First Printing Operator's Manual Inspections Decal Inspection Part No. Decal Description 160516 Ground Control Panel with LCD Use the pictures on the next page to verify that all screen* decals are legible and in place. 214932 Ground Control Panel* Below is a numerical list with quantities and 214933 Platform Control Panel*...
  • Page 42 Operator's Manual Eighth Edition • First Printing Inspections 114390 114258 219952 825579 219486 *77398 *28158 *28159 *133278 *44981 *826345 *28174 *28235 1263543 1267121 *77399 31060 31060 219488 *214932 1264307 72086 *160516 27207 52475 27206 *82366 27204 218562 218562 *218557 *218558 72086 *219484 52475...

  • Page 43: Operating Instructions

    Eighth 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 manual.
  • Page 44 Operator's Manual Eighth Edition • First Printing Operating Instructions Starting the Engine All models 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 45 Eighth 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 46 Operator's Manual Eighth Edition • First Printing Operating Instructions Operation from Platform To Drive 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 47 Eighth Edition • First Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Measure the slope with a digital inclinometer OR Determine the uphill, downhill and side slope use the following procedure. ratings for the machine and determine the slope grade.
  • Page 48 Operator's Manual Eighth Edition • First Printing Operating Instructions Tilt Sensor Activation Settings Drive Enable Light on indicates that the boom Model Chassis Angle Chassis Angle (front (side to side) to back) has moved just past either non- steer wheel and the drive 4.5°...
  • Page 49 Eighth Edition • First Printing Operator's Manual Operating Instructions Engine Idle Select (rpm) Machine Not Level Indicator Light When the foot switch is not pressed, the engine Light on indicates machine is not will idle at the lowest rpm. level. The tilt alarm will be sounding when this light is on.
  • Page 50 Operator's Manual Eighth Edition • First Printing Operating Instructions Platform Overload Indicator Light Lockout After Each Use Light flashing indicates the Select a safe parking location—firm level platform is overloaded and no surface, clear of obstruction and traffic. functions will operate. Retract and lower the boom to the stowed position.

  • Page 51: Transport And Lifting Instructions

    Eighth Edition • First Printing Operator's Manual 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. ...
  • Page 52 Operator's Manual Eighth Edition • First Printing 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.
  • Page 53 Eighth Edition • First Printing Operator's Manual 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 54: Maintenance

    Operator's Manual Eighth Edition • First Printing 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.
  • Page 55 Eighth Edition • First Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Diesel Fuel Requirements Maintaining the hydraulic oil at the proper level is Satisfactory engine performance is dependent on essential to machine operation. Improper hydraulic the use of a good quality fuel. The use of a good oil levels can damage hydraulic components.
  • Page 56 Operator's Manual Eighth Edition • First Printing 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 57 Eighth Edition • First Printing Operator's Manual Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Tip-over hazard. An over-inflated tire can this machine according to the procedures found in explode which may compromise machine the service manual for this machine.

  • Page 58: Specifications

    Operator's Manual Eighth Edition • First Printing Specifications Specific ati ons AC outlet in platform standard Z-45/25J (jib) Hydraulic pressure, maximum 221 bar Height, working maximum 16.05 m (boom functions) Height, platform maximum 14.05 m System voltage Height, stowed maximum 2.13 m Tire size, 4WD &...
  • Page 59 Eighth Edition • First Printing Operator's Manual Specifications Z-45/25J Range of Motion Chart Z®-45/25J Part No. 1320357GT Operator's M anual Eighth Editi on • First Printing Part No. 1320357GT -45/25J ®...

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