Terex Z4525F-62000 Operator's Manual
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Terex Z4525F-62000 Operator's Manual

Terex Z4525F-62000 Operator's Manual

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Operator's Manual
Z
-45J
®
DC Power
Bi-Energy Power
Serial Number Range
from Z4525F-62000
from Z4525D-8000
AUS
Australia
with
Maintenance
Information
Original Instructions
Seventh Edition
Second Printing
Part No. 1307435GT

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Summary of Contents for Terex Z4525F-62000

  • Page 1 Operator's Manual Serial Number Range -45J ® from Z4525F-62000 from Z4525D-8000 Australia DC Power Bi-Energy Power with Maintenance Information Original Instructions Seventh Edition Second Printing Part No. 1307435GT...

  • Page 2: Table Of Contents

    Maintenance ............56 Specifications ............59 Copyright © 1999 Terex Corporation Seventh Edition: Second Printing, March 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 1418.10 ®...

  • Page 3: Introduction

    Seventh Edition • Second Printing Operator's Manual Introduction Introduction 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 Seventh Edition • Second Printing Introduction Platform controls symbology and related Secondary boom up/down machine movement: Platform level Drive forward/reverse Platform rotate Jib boom up/down Steer right/left Primary boom up/down Turntable rotate Primary boom extend/retract ® ® -45J DC • Z -45J Bi-Energy Part No.
  • Page 5 Seventh Edition • Second Printing Operator's Manual Introduction Ground controls symbology and related Sequential functions and movement: machine movement: • Drive and steer. Platform level Interlocked functions: • Elevated drive speed. • Elevated drive in an off-level condition. Platform rotate •...
  • Page 6 Operator's Manual Seventh Edition • Second Printing 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 7 Seventh Edition • Second 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 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Seventh Edition • Second Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 9 Seventh Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Support the platform or boom during maintenance Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 10 Operator's Manual Seventh Edition • Second Printing Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Read the operator’s Access by trained...

  • Page 11: General Safety

    Seventh Edition • Second Printing Operator's Manual General Safety General Safety Z-45 DC, Z-45 BE ® ® Part No. 1307435GT -45J DC • Z -45J Bi-Energy...
  • Page 12 Operator's Manual Seventh Edition • Second Printing General Safety Z-45 BE ® ® -45J DC • Z -45J Bi-Energy Part No. 1307435GT...
  • Page 13 Seventh Edition • Second Printing Operator's Manual General Safety Z-45 DC ® ® Part No. 1307435GT -45J DC • Z -45J Bi-Energy...
  • Page 14 Operator's Manual Seventh Edition • Second Printing General Safety Z-45 DC, Z-45 BE These decals are model, option or configuration specific. ® ® -45J DC • Z -45J Bi-Energy Part No. 1307435GT...

  • Page 15: Personal Safety

    Seventh Edition • Second Printing Operator's Manual 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 16: Work Area Safety

    Operator's Manual Seventh Edition • Second Printing Work Area Safety Work Area 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 17 Seventh Edition • Second Printing Operator's Manual Work Area Safety Do not use air-filled tires. These machines are If the tilt alarm sounds when the platform is raised, equipped with foam-filled tires. Wheel weight and use extreme caution. The Machine Not Level proper counterweight configuration are critical to indicator light will come on and the drive function stability.
  • Page 18 Operator's Manual Seventh Edition • Second Printing Work Area Safety Do not raise the boom Do not modify or alter a mobile elevating work when wind speeds may platform without prior written permission from the exceed 28 mph/12.5 m/s. manufacturer. Mounting attachments for holding If wind speeds exceed tools or other materials onto the platform, 28 mph/12.5 m/s when...
  • Page 19 Seventh Edition • Second Printing Operator's Manual Work Area Safety Fall Hazards Do not use batteries that weigh less than the original equipment. Batteries are used as Occupants must wear a counterweight and are critical to machine stability. safety belt or harness in Each battery must weigh a minimum of accordance with 105 lbs / 47.6 kg.
  • Page 20 Operator's Manual Seventh Edition • Second 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 21 Seventh Edition • Second Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Bodily Injury Hazard All models: All models: Charge the battery only in an open, well-ventilated Do not operate the machine with a hydraulic oil or area away from sparks, flames and lighted air leak.
  • Page 22 Operator's Manual Seventh Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. Always wear protective the machine and test all functions before each clothing and eye wear when working with work shift.
  • Page 23 Seventh Edition • Second Printing Operator's Manual Work Area Safety Lockout After Each Use Component Damage Hazard Do not use any battery charger greater than 48V Select a safe parking location—firm level to charge the batteries. surface, clear of obstruction and traffic. Both battery packs must be charged together.

  • Page 24: Legend

    Operator's Manual Seventh Edition • Second Printing Legend Legend Foot switch Primary boom Manual storage container Secondary boom Sliding mid-rail 10 Ground controls Lanyard anchorage points 11 Power to charger (between steer tires) Jib boom 12 Steer tire Platform 13 Battery box Platform controls 14 Non-steer tire ®...

  • Page 25: Controls

    Seventh Edition • Second 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 26 Operator's Manual Seventh Edition • Second Printing Controls Ground Control Panel Bi-Energy models: Engine idle (rpm) select switch Platform rotate switch Move the switch to the left (turtle) for low idle. Move the platform rotate Move the switch to the right (rabbit) for high switch to the right and the idle and quickest battery charging.
  • Page 27 Seventh Edition • Second Printing Operator's Manual Controls 13 Function enable switch Move the function enable switch to either side to enable the functions on the ground control panel to operate. 14 Bi-Energy models: Engine start switch Move the engine start switch to either side to start the engine.
  • Page 28 Operator's Manual Seventh Edition • Second Printing Controls Platform Control Panel Horn button Bi-Energy models: Glow plug switch Auxiliary power switch 10 Bi-Energy models: Engine start switch Drive enable indicator light 11 Bi-Energy models: Engine idle (rpm) select switch Drive enable switch Rabbit &...
  • Page 29 Seventh Edition • Second Printing Operator's Manual Controls 12 Platform overload indicator light 17 Primary boom extend/retract switch 13 Machine not level indicator light 18 Primary boom up/down switch 14 Red Emergency Stop button 19 Secondary boom up/down switch 15 Proportional control handle for drive function and 20 Turntable rotate switch thumb rocker for steer function 21 Battery charge indicator...
  • Page 30 Operator's Manual Seventh Edition • Second Printing Controls Platform Control Panel Platform level switch Move the platform level Horn button switch up and the level of Press this button and the horn will sound. the platform will raise. Release the button and the horn will stop. Move the platform level switch down and the Auxiliary power switch with cover...
  • Page 31 Seventh Edition • Second Printing Operator's Manual Controls 14 Red Emergency Stop button 18 Primary boom up/down switch Push in the red Emergency Stop button to the Move the switch up and the off position to stop all functions. Pull out the primary boom will raise.

  • Page 32: Inspections

    Operator's Manual Seventh Edition • Second Printing 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 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 Seventh Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection Check entire machine for: ❑ Cracks in welds or structural components ❑ Be sure that the operator’s manual is ❑ Dents or damage to machine complete, legible and in the storage container located in the platform.
  • Page 34 Operator's Manual Seventh Edition • Second 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 35 Seventh Edition • Second Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of 10 Turn the key switch to hazards. platform control. Pull out the platform red Emergency Turn the key switch to ground control.
  • Page 36 Operator's Manual Seventh Edition • Second Printing Inspections At the Platform Controls Test Machine Functions and Descent Alarm 17 Pull out the red Emergency Stop button to the 24 Press down the foot switch. on position. 25 Activate each machine function control handle 18 Bi-Energy models: Start the engine.
  • Page 37 Seventh Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 33 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 38 Operator's Manual Seventh Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 36 Press down the foot switch. 46 Press down the foot switch. 37 Raise the primary boom approximately 47 With the boom fully stowed, drive the machine 3 ft/91 cm.
  • Page 39 Seventh Edition • Second Printing Operator's Manual Inspections 53 Return to level ground and stow the boom. 61 Return to level ground and extend the primary boom approximately 1.6 ft / 0.5 m. 54 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 62 Drive the machine onto a slope where the greater than 4.5°.
  • Page 40 Operator's Manual Seventh Edition • Second Printing Inspections Test the Contact Alarm (if equipped) Test Auxiliary Lowering 69 Do not activate the foot switch and press on 76 Pull out the red Emergency Stop button to the the contact alarm cable to release the actuator on position.
  • Page 41 Seventh Edition • Second 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 Do Not Operate Unless: ❑ sloped surfaces ❑ unstable or slippery surfaces ...
  • Page 42 Operator's Manual Seventh Edition • Second Printing Inspections Decal Inspection - Bi-Energy Part No. Decal Description Models with Words 114117 Notice – Battery Connection Diagram 114258 Danger – No Smoking Use the pictures on the next page to verify that all 114343 Label –...
  • Page 43 Seventh Edition • Second Printing Operator's Manual Inspections Z-45 BE 1299743 31787 1299743 31060 114025 114025 1299743 27206 **72086 28372 27207 27207 72833 27206 27205 **52475 1299743 27204 31788 31788 31787 31508 31785 133286 114117 31785 1299744 **72086 1263543 114390 28162 114025 114117...
  • Page 44 Operator's Manual Seventh Edition • Second Printing Inspections Decal Inspection - DC Models Part No. Decal Description with Words 82366 Label – Chevron Rando* 97815 Label – Lower Mid-rail Use the pictures on the next page to verify that all 114025 Label –...
  • Page 45 Seventh Edition • Second Printing Operator's Manual Inspections Z-45 DC 1299743 31787 1299743 31060 114025 1299743 114025 27206 **72086 28372 27207 27207 72833 27205 **52475 27206 1299743 27204 31788 31788 31787 31508 ***48732 31785 *133286 ***48731 *44980 114117 31785 1299744 **72086 114117 114025...

  • Page 46: Operating Instructions

    Operator's Manual Seventh Edition • Second 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 manual.
  • Page 47 Seventh Edition • Second Printing Operator's Manual Operating Instructions Introduction Emergency Stop Bi-Energy models can be operated with or without Push in the red Emergency Stop button to the off the engine running. position at the ground controls or the platform controls to stop all machine functions and turn the Starting the Engine engine off.
  • Page 48 Operator's Manual Seventh Edition • Second Printing Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 49 Seventh Edition • Second Printing Operator's Manual Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
  • Page 50 Operator's Manual Seventh Edition • Second Printing Operating Instructions To determine the slope grade: Tilt Sensor Activation Settings Measure the slope with a digital inclinometer OR Model Chassis Angle Chassis Angle (side to side) (front to back) use the following procedure. Z-45J DC 4.5°...
  • Page 51 Seventh Edition • Second Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Contact Alarm (if equipped) The contact alarm is designed to alert ground If the tilt alarm sounds when the personnel when an operator makes contact with platform is raised, the Machine Not the platform control panel, interrupting boom Level indicator light will come on...
  • Page 52 Operator's Manual Seventh Edition • Second Printing Operating Instructions Aircraft Protection Package (if equipped) Lockout After Each Use If the platform bumpers come into contact with Select a safe parking location—firm level aircraft components, the machine will shut down surface, clear of obstruction and traffic. and no functions will operate.
  • Page 53 Seventh Edition • Second Printing Operator's Manual Operating Instructions Bi-Energy models: Charging the Batteries with the Engine Running the engine will automatically charge the batteries. At high idle, the engine supplies enough power for charging and for machine functions. At low idle, machine functions will use battery power.
  • Page 54 Operator's Manual Seventh Edition • Second Printing Operating Instructions Standard Batteries Dry Battery Filling and Charging Instructions Remove the battery vent caps and check the battery acid level. If necessary, add only Remove the battery vent caps and enough distilled water to cover the plates. Do permanently remove the plastic seal from the not overfill prior to the charge cycle.

  • Page 55: Transport And Lifting Instructions

    Seventh Edition • Second Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  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.
  • Page 56 Operator's Manual Seventh Edition • Second 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 57 Seventh Edition • Second 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. Use the turntable rotation lock to secure the Observe and Obey: turntable.

  • Page 58: Maintenance

    Operator's Manual Seventh Edition • Second Printing Maintenance Maintenance Check the Batteries Proper battery condition is essential to good machine performance and operational safety. Improper fluid levels or damaged cables and Observe and Obey: connections can result in component damage and ...
  • Page 59 Seventh Edition • Second Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Oil Level (Bi- Energy models) Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the proper engine oil level is essential oil levels can damage hydraulic components.
  • Page 60 Operator's Manual Seventh Edition • Second Printing Maintenance Check the Engine Coolant Level Scheduled Maintenance (Bi-Energy models) 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 Maintaining the engine coolant at the proper level the service manual for this machine.

  • Page 61: Specifications

    Seventh Edition • Second Printing Operator's Manual Specifications Specifications Z-45J DC (jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 9 in 15.9 m Platform dimensions, 5 foot 60 in x 30 in Height, platform maximum 45 ft 9 in...
  • Page 62 Operator's Manual Seventh Edition • Second Printing Specifications Z-45J Bi-Energy (jib) Platform dimensions, 6 foot 72 in x 30 in (length x width) 1.8 m x 76 cm Height, working maximum 51 ft 9 in 15.9 m Platform dimensions, 5 foot 60 in x 30 in Height, platform maximum 45 ft 9 in...
  • Page 63 Seventh Edition • Second Printing Operator's Manual Specifications Z-45J Range of motion chart Max Height Max Reach 50 ft 15.2 m 0 ft 40 ft 12.2 m 5 ft 1.5 m 30 ft 9.1 m 15 ft 4.6 m 20 ft 6.1 m 25 ft 7.6 m...

This manual is also suitable for:

Genie z-45j bi-energyGenie z-45j dcZ4525d-8000

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