Terex Genie Z-45/25 Operator's Manual
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Also See for Genie Z-45/25:
- Service manual (213 pages) ,
- Operator's manual (58 pages) ,
- Service and repair manual (143 pages)
Related Manuals for Terex Genie Z-45/25
Summary of Contents for Terex Genie Z-45/25
- Page 1 Operator’s Manual Z-45 25 Z-45 25J Z-51 30 J IC Power with Maintenance Information Fourth Edition First Printing Part No. 114340...
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Page 2: Table Of Contents
Operator's Manual Fourth Edition • First Printing Important Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. -
Page 3: Introduction
Fourth Edition · First Printing Operator's Manual Introduction Owners, Users and Operators: Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. We feel that you make a major contribution to safety if you, as the equipment users and operators: Danger... - Page 4 Operator's Manual Fourth Edition · First Printing Introduction Hazard Classification Intended Use Genie uses symbols, color coding and signal words This machine is intended to be used only to lift to identify the following: personnel, along with their tools and materials to an aerial work site.
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Page 5: Symbol And Hazard Pictorials Definitions
Fourth Edition · First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Crush Hazard Explosion Hazard Fire Hazard Explosion Hazard Electrocution Hazard Electrocution Fall Hazard Crush Hazard Tip-over Hazard Tip-over Hazard Hazard Keep off this Keep away from Maintain required Keep away from Only trained surface. - Page 6 Operator's Manual Fourth Edition · First Printing Symbol and Hazard Pictorials Definitions Lanyard Wheel load Voltage rating for Pressure rating for Replace tires with power to platform air line to platform attachment point tires of same specification. Tie-down Tie-down instructions instructions Z-45/25 •...
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Page 7: General Safety
Fourth Edition · First Printing Operator's Manual General Safety Safety signs and locations Part No. 114340 Z-45/25 • Z-45/25J • Z-51/30J... - Page 8 Operator's Manual Fourth Edition · First Printing General Safety Safety signs and locations Z-45/25 • Z-45/25J • Z-51/30J Part No. 114340...
- Page 9 Fourth Edition · First Printing Operator's Manual General Safety Safety signs and locations Part No. 114340 Z-45/25 • Z-45/25J • Z-51/30J...
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Page 10: Personal Safety
Operator's Manual Fourth Edition · First Printing Personal Safety 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 11: Work Area Safety
Fourth Edition · First Printing Operator's Manual Work Area Safety Do not use the machine as a ground for welding. Electrocution Hazards Do not operate the machine during lightning or This machine is not electrically insulated and will storms. not provide protection from contact with or proximity to electrical current. - Page 12 Operator's Manual Fourth Edition · First Printing Work Area Safety Do not raise or extend the boom unless the Do not raise the boom when wind speeds may machine is on a firm, level surface. exceed 12.5 m/s. If wind speeds exceed 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.
- Page 13 Fourth Edition · First Printing Operator's Manual Work Area Safety Do not push off or pull Do not place or attach overhanging loads to any toward any object outside part of this machine. of the platform. Maximum allowable manual force 400 N Do not alter or disable machine components that in any way affect safety and stability.
- Page 14 Operator's Manual Fourth Edition · First Printing 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 of safety belt or harness in the machine.
- Page 15 Fourth Edition · First Printing Operator's Manual Work Area Safety Do not operate a boom in the path of any crane Collision Hazards unless the controls of the crane have been locked out and/or precautions have been taken to prevent Be aware of limited sight any potential collision.
- Page 16 Operator's Manual Fourth Edition · First Printing Work Area Safety Battery Safety Explosion and Fire Hazards Do not start the engine if you smell or detect liquid Burn Hazards petroleum gas (LPG), gasoline, diesel fuel or other explosive substances. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries.
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Page 17: Legend
Fourth Edition · First Printing Operator's Manual Legend 1 Foot switch 8 Primary boom 2 Manual storage container 9 Secondary boom 3 Sliding mid-rail 10 Ground controls 4 Lanyard anchorage point 11 Steer tire 5 Jib boom (Z-45/25J and Z-51/30J) 12 LPG tank (if equipped) 6 Platform 13 Non-steer tire... -
Page 18: Controls
Operator's Manual Fourth Edition · First Printing Controls Platform Control Panel 6 Drive speed select switch 7 Diesel models: Glow plug switch 1 Horn button 8 Engine start switch 2 Platform level switch 9 Engine idle (rpm) select switch 3 Platform rotate switch 10 Gasoline/LPG models: Gasoline/LPG 4 Z-45/25J and Z-51/30J: Jib boom up/down select switch... - Page 19 Fourth Edition · First Printing Operator's Manual Controls 16 Drive enable switch 11 Red Emergency Stop button 17 Proportional control handle for secondary boom 12 Dual axis proportional control handle for drive up/down function and steer functions OR Proportional control handle for drive function 18 Primary boom extend/retract switch and thumb rocker for steer function 19 used for optional equipment...
- Page 20 Operator's Manual Fourth Edition · First Printing Controls Platform Control Panel 6 Drive speed select switch Machine on incline symbol: Low range operation 1 Horn button for inclines. Push the horn button and the horn will sound. Machine on level surface symbol: High range Release the horn button and the horn will stop.
- Page 21 Fourth Edition · First Printing Operator's Manual Controls 12 Dual axis proportional control handle for drive 16 Drive enable switch and steer functions To drive when the drive enable light is on, hold OR Proportional control handle for drive function the drive enable switch to either side and slowly and thumb rocker for steer function move the drive control handle off center.
- Page 22 Operator's Manual Fourth Edition · First Printing Controls Ground Control Panel 1 Platform level switch 11 Key switch for platform/off/ground selection 2 Platform rotate switch 12 Red Emergency Stop button 3 Z-45/25J and Z-51/30J: Jib boom up/down 13 Hour meter switch 14 Diesel models: Water temperature light 4 Turntable rotate switch...
- Page 23 Fourth Edition · First Printing Operator's Manual Controls Ground Control Panel 6 Primary boom extend/retract switch 1 Platform level switch Move the primary boom extend/retract switch to the Move the platform level right and the boom will switch up and the level of retract.
- Page 24 Operator's Manual Fourth Edition · First Printing Controls Turn the key switch to the platform position and Move the engine start switch to either side to the platform controls will operate. Turn the key start the engine. switch to the off position and the machine will 18 15A breaker for engine electrical circuits be off.
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Page 25: Inspections
Fourth Edition · First Printing Operator's Manual 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 You learn and practice the principles of safe is apparently wrong with a machine before the... - Page 26 Operator's Manual Fourth Edition · First Printing Inspections Pre-operation Inspection ! Engine and related components ! Be sure that the operator’s, safety and ! Limit switches and horn responsibilities manuals are complete, legible and in the storage container located in the ! Alarms and beacons (if equipped) platform.
- Page 27 Fourth 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
- Page 28 Operator's Manual Fourth Edition · First Printing Inspections 1 Select a test area that is firm, level and free of Test the Tilt Sensor obstruction. 9 Turn the key switch to At the Ground Controls platform control. Pull out the platform red Emergency Stop 2 Turn the key switch to ground control.
- Page 29 Fourth Edition · First Printing Operator's Manual 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.
- Page 30 Operator's Manual Fourth Edition · First Printing Inspections Test Drive and Braking 34 Move the drive control handle off center. Result: The drive function should not operate. 29 Press down the foot switch. 35 Move and hold the drive enable toggle switch to 30 Slowly move the drive control handle in the either side and slowly move the drive control direction indicated by the blue arrow on the...
- Page 31 Fourth Edition · First Printing Operator's Manual Inspections Test Limited Drive Speed - Standard Base Test Limited Drive Speed - Narrow Base Models Models 36 Press down the foot switch. 36 Press down the foot switch. 37 Raise the primary boom approximately 61 cm. 37 Raise the primary boom approximately 61 cm.
- Page 32 Operator's Manual Fourth Edition · First Printing Inspections Test the Oscillate Axle Test the Lift/Drive Select Function (oscillating axle-equipped models) (if equipped) 46 Start the engine from the platform controls. 54 Press down the foot switch. 55 Move the drive control handle off center and 47 Drive the right steer tire up onto a 15 cm block activate a boom function toggle switch.
- Page 33 Fourth Edition · First Printing Operator's Manual Inspections Workplace Inspection 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 ·...
- Page 34 Label - Wheel Load, Z-45/25J 62926 Cosmetic - Genie Z-45/25J 114114 Label - Transport Diagram 62927 Cosmetic - Genie Z-45/25 114247 Label - Fall Hazard 62947 Cosmetic - IC Power 4 x 2 114248 Label - Tip-over Hazard, Tilt Alarm...
- Page 35 Fourth Edition · First Printing Operator's Manual Inspections Ground Controls Side Drive Platform Chassis Engine Side Shading indicates decal is hidden from view, i.e. under covers Part No. 114340 Z-45/25 • Z-45/25J • Z-51/30J...
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Page 36: Operating Instructions
Operator's Manual Fourth Edition · First Printing 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. Do Not Operate Unless: Using the machine for anything other than lifting personnel, along with their tools and materials, to... - Page 37 Fourth Edition · First Printing Operator's Manual Operating Instructions Starting the Engine In extreme cold conditions, -18°C and below, machines should be equipped with optional cold start kits. Attempting to start the engine when 1 At the ground controls, turn the key switch to temperatures are below -18°C may require the use the desired position.
- Page 38 Operator's Manual Fourth Edition · First Printing Operating Instructions Operation from Ground To Position Platform 1 Press down the foot switch. 1 Turn the key switch to ground control. 2 Slowly move the appropriate function control 2 Pull out the red Emergency Stop button to handle or toggle switch according to the the on position.
- Page 39 Fourth Edition · First Printing Operator's Manual Operating Instructions Driving on a slope Lay the piece of wood on the slope. Determine the uphill, downhill and side slope ratings At the downhill end, lay the level on the top edge of for the machine and determine the slope grade.
- Page 40 Operator's Manual Fourth Edition · First Printing Operating Instructions Drive Enable Generator (if equipped) Light on indicates that the To start the generator, boom has moved just past move the generator toggle either non-steer wheel and the switch to the on position. drive function has been interrupted.
- Page 41 Fourth Edition · First Printing Operator's Manual Operating Instructions Check Engine Light (if equipped) Light on and engine stopped: Tag the machine and remove from service. Light on and engine still running: Contact service personnel within 24 hours. Aircraft Protection Package (if equipped) If the platform bumpers come in contact with aircraft components, the machine will shut down...
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Page 42: Transport And Lifting Instructions
Reverse the procedures described to re-engage the machine weight. brakes. Be sure the turntable is secured with the Note: Towing the Genie Z-45/25, Z-45/25J or turntable rotation lock before transporting. Be Z-51/30J is not recommended. If the machine must sure to unlock the turntable for operation. - Page 43 Fourth 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. Always use the turntable rotation lock pin each time Secure the platform with a nylon strap placed over the machine is transported.
- Page 44 Operator's Manual Fourth 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.
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Page 45: Maintenance
Fourth Edition · First Printing Operator's Manual Maintenance 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 this Note: Check the oil level with the engine off. - Page 46 Operator's Manual Fourth 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 Maintaining the engine coolant at the proper level is essential to machine operation.
- Page 47 Fourth Edition · First Printing Operator's Manual Maintenance Check the Batteries Check the Tire Pressure Proper battery condition is essential to good engine Tip-over hazard. An over-inflated tire can performance and operational safety. Improper fluid explode which may compromise machine levels or damaged cables and connections can stability and cause the machine to tip over.
- Page 48 Operator's Manual Fourth 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.
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Page 49: Specifications
Fourth Edition · First Printing Operator's Manual Specifications Standard Base Models Z-45/25 (no jib) AC outlet in platform standard Height, working maximum 16 m Hydraulic pressure, maximum 221 bar (boom functions) Height, platform maximum 14 m System voltage Height, stowed maximum 2.11 m Tire size, 4WD &... - Page 50 Operator's Manual Fourth Edition · First Printing Specifications Standard Base Models Z-45/25J (jib) AC outlet in platform standard Height, working maximum 16.07 m Hydraulic pressure, maximum 221 bar (boom functions) Height, platform maximum 14.07 m System voltage Height, stowed maximum 2.1 m Tire size, 4WD &...
- Page 51 Fourth Edition · First Printing Operator's Manual Specifications Narrow Base Models Z-45/25 (no jib) AC outlet in platform standard Height, working maximum 15.9 m Hydraulic pressure, maximum 221 bar (boom functions) Height, platform maximum 13.9 m System voltage Height, stowed maximum 2.05 m Tire size, 2WD Industrial Horizontal reach maximum...
- Page 52 Operator's Manual Fourth Edition · First Printing Specifications Narrow Base Models Z-45/25J (jib) AC outlet in platform standard Height, working maximum 15.9 m Hydraulic pressure, maximum 221 bar (boom functions) Height, platform maximum 13.9 m System voltage Height, stowed maximum 2.0 m Tire size, 2WD Industrial Horizontal reach maximum...
- Page 53 Fourth Edition · First Printing Operator's Manual Specifications Z-51/30J AC outlet in platform standard Height, working maximum 17.6 m Hydraulic pressure, maximum 221 bar (boom functions) Height, platform maximum 15.6 m System voltage Height, stowed maximum 2.16 m Tire size, 4WD 355/55 D625, foam-filled Horizontal reach maximum 9.25 m...
- Page 54 Operator's Manual Fourth Edition · First Printing Specifications Z-51/30 Range of Motion Chart Z-45/25J Range of Motion Chart Z-45/25 Range of Motion Chart Z-45/25 • Z-45/25J • Z-51/30J Part No. 114340...
- Page 55 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China...