Terex Genie Z-45/25 Bi-Energy User manual

Operator’s Manual
Fourth Edition
First Printing
Part No. 114340
Serial Number Range
after 00000
with
Maintenance
Information
Z-45 25
IC Power
Z-45 25J
Z-51 30 J
CE

Operator's Manual
Z-45/25 • Z-45/25J • Z-51/30J PartNo.114340
Fourth Edition • First Printing
Important
Read,understandandobeythesesafetyrulesand
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. If you have any questions, call Genie Industries.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 8
Work Area Safety....................................................... 9
Legend ...................................................................... 15
Controls .................................................................... 16
Inspections ............................................................... 23
OperatingInstructions............................................... 34
TransportandLiftingInstructions .............................. 40
Maintenance ............................................................. 43
Specifications ........................................................... 47
Contact us:
Internet:www.genielift.com
E-mail:[email protected]
Copyright © 1998 by Genie Industries
First Edition: Seventh Printing, May 2002
Second Edition: Second Printing, August 2004
Third Edition: Second Printing, October 2005
Fourth Edition: First Printing, March 2007
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
Printed on recycled paper
Printed in U.S.A.

Operator'sManualFourth Edition · First Printing
PartNo.114340 Z-45/25 • Z-45/25J • Z-51/30J 1
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis 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:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

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2 Z-45/25 • Z-45/25J • Z-51/30J PartNo.114340
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorserious injury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor ormoderate injury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

Operator'sManualFourth Edition · First Printing
PartNo.114340 Z-45/25 • Z-45/25J • Z-51/30J 3
CrushHazard ExplosionHazard FireHazard ExplosionHazard Electrocution
Hazard
FallHazard CrushHazard Tip-overHazard
Symbol and Hazard Pictorials Definitions
Tip-overHazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface. Keepawayfrom movingparts. Keepawayfrom path of moving
platform.
Onlytrained
maintenance
personnelshould
access
compartments.
Nosmoking.
Noflame.
Stopengine. Platformuphill:
1 Lowerprimary
2 Lowersecondary
3 Retractprimary
Platformdownhill:
1 Retract primary
2 Lowersecondary
3 Lowerprimary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.

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4 Z-45/25 • Z-45/25J • Z-51/30J PartNo.114340
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform Replacetires with
tires of same
specification.
Tie-down
instructions Tie-down instructions

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PartNo.114340 Z-45/25 • Z-45/25J • Z-51/30J 5
General Safety
Safety signs and locations

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6 Z-45/25 • Z-45/25J • Z-51/30J PartNo.114340
General Safety
Safety signs and locations

Operator'sManualFourth Edition · First Printing
PartNo.114340 Z-45/25 • Z-45/25J • Z-51/30J 7
General Safety
Safety signs and locations

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8 Z-45/25 • Z-45/25J • Z-51/30J PartNo.114340
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.