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

Operator's Manual
Serial Number Range
Z®-45/25J
from Z4525D-3958
CE
with
Maintenance
Information
Original Instructions
Eighth Edition
First Printing
Part No. 1311642GT

Operator's Manual Eighth Edition • First Printing
Z®-45/25J Part No. 1311642GT
Front Matter
Manufacturer:
Terex South Dakota, Inc.
500 Oakwood Road
Watertown, SD 57201, USA
EU Authorized representative:
Genie Industries B.V.
Boekerman 5
4751 XK OUD GASTEL
The Netherlands
Contents
Introduction........................................................... 1
Symbol and Hazard Pictorials Definitions............. 6
General Safety...................................................... 9
Personal Safety................................................... 15
Work Area Safety................................................ 16
Legend................................................................ 24
Controls............................................................... 25
Inspections.......................................................... 33
Operating Instructions......................................... 47
Transport and Lifting Instructions ....................... 56
Maintenance ....................................................... 60
Specifications...................................................... 64
Copyright © 2020 by Terex Corporation
Eighth Edition: First Printing, July 2021
Genie and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity

Eighth Edition • First Printing Operator's Manual
Introduction
Part No. 1311642GT Z®-45/25J 1
Introduction
About this manual
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.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number
stamped on chassis
Serial label
(located under cover)
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual Eighth Edition • First Printing
Introduction
2 Z®-45/25J Part No. 1311642GT
Platform controls symbology and related
machine movement:
Platform level swtich
Platform rotate switch
Jib boom up/down
Primary boom up/down
Turntable rotate
Primary boom extend/retract
switch
Secondary boom up/down
Drive forward/reverse
Steer right/left
Ground controls symbology and related
machine movement:
Platform level, jib boom
up/down, primary boom
extend/retract, primary
boom up/down, and
secondary boom
retract/lower.
Turntable rotate and
platform rotate
Sequential functions and movement:
•Drive and steer.
Interlocked functions:
•Elevated drive speed.
•Elevated drive in an off-level condition.
•Drive enable when the boom is rotated past the
non-steer wheels.
•All platform and ground controls.
Limitations of use:
•The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
•Do not elevate the platform unless the machine
is on firm level ground.
Stability enhancing means:
•Foam filled tires.

Eighth Edition • First Printing Operator's Manual
Introduction
Part No. 1311642GT Z®-45/25J 3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register
your machine and keep your contact information
up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
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
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Operator's Manual Eighth Edition • First Printing
Introduction
4 Z®-45/25J Part No. 1311642GT
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.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety rules—
safety and operator’s manuals and machine
decals.
You read, understand and obey employer’s
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
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.

Eighth Edition • First Printing Operator's Manual
Introduction
Part No. 1311642GT Z®-45/25J 5
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.

Operator's Manual Eighth Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 Z®-45/25J Part No. 1311642GT
Symbol andHazard Pictorials Definitions
Crush hazard
Keep away from
moving parts
Read the
operator’s
manual
Fire extinguisher
Overhead
obstruction
Electrocution
hazard
Maintain required
clearance
Tip-over hazard
Manual force
Tip-over hazard
Electrocution
hazard
Avoid contact
Disconnect
battery
Lifting point
Wind speed

Eighth Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1311642GT Z®-45/25J 7
Weight of welder
reduces capacity
No smoking.
No flame.
Stop engine.
Explosion hazard
Collision hazard
Corrosive acid.
Wheel load
Tire specifications
No smoking
Overhead
obstruction
Explosion hazard
Platform tie-down
instructions
Lifting & tie down
instructions
Lanyard
anchorage points
Support the
platform or boom
during
maintenance
Tie-down point

Operator's Manual Eighth Edition • First Printing
Symbol and Hazard Pictorials Definitions
8 Z®-45/25J Part No. 1311642GT
Maximum capacity
Runaway hazard
Color coded
direction arrows
Voltage rating for
power to platform
Pressure rating for
air line to platform
Recovery procedure if tilt alarm sounds
while elevated.
Platform uphill:
1Lower primary.
2Lower secondary.
3Retract primary.
Platform downhill:
1Retract primary.
2Lower secondary.
3Lower primary.
Access by trained
and authorized
personnel onlyl
Emergency
lowering
Read the service
manual
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
Crush hazard

Eighth Edition • First Printing Operator's Manual
General Safety
Part No. 1311642GT Z®-45/25J 9
GeneralSafety

Operator's Manual Eighth Edition • First Printing
General Safety
10 Z®-45/25J Part No. 1311642GT
For Kubota only

Eighth Edition • First Printing Operator's Manual
General Safety
Part No. 1311642GT Z®-45/25J 11

Operator's Manual Eighth Edition • First Printing
General Safety
12 Z®-45/25J Part No. 1311642GT
For Kubota only

Eighth Edition • First Printing Operator's Manual
General Safety
Part No. 1311642GT Z®-45/25J 13

Operator's Manual Eighth Edition • First Printing
General Safety
14 Z®-45/25J Part No. 1311642GT

Eighth Edition • First Printing Operator's Manual
Personal Safety
Part No. 1311642GT Z®-45/25J 15
PersonalSafety
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.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

Operator's Manual Eighth Edition • First Printing
Work Area Safety
16 Z®-45/25J Part No. 1311642GT
Work AreaSafety Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart
below must be followed.
Line Voltage
Required Clearance
0 to 50KV
10 ft
3.05 m
50 to 200KV
15 ft
4.60 m
200 to 350KV
20 ft
6.10 m
350 to 500KV
25 ft
7.62 m
500 to 750KV
35 ft
10.67 m
750 to 1000KV
45 ft
13.72 m
Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.
Keep away from the
machine if it contacts
energized power lines.
Personnel on the ground
or in the platform must not
touch or operate the
machine until energized
power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity
500 lbs
227 kg
Maximum occupants
2
Maximum capacity
Machine equipped with
Aircraft Protection Package
440 lbs
200 kg
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.

Eighth Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1311642GT Z®-45/25J 17
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the
boom on the slope as shown in the tilt alarm
procedure. Follow the steps to lower the boom
before moving to a firm, level surface. Do not
rotate the boom while lowering.
If the tilt alarm sounds
with the platform uphill:
1Lower the primary
boom.
2Lower the
secondary boom.
3Retract the primary
boom.
If the tilt alarm sounds
with the platform
downhill:
1Retract the primary
boom.
2Lower the
secondary boom.
3Lower the primary
boom.
Do not raise the boom
when wind speeds may
exceed 28 mph/12.5 m/s.
If wind speeds exceed
28 mph/12.5 m/s when
the boom is raised, lower
the boom and do not
continue to operate the
machine.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.
Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven
terrain, unstable surfaces or other hazardous
conditions with the boom raised or extended.

Operator's Manual Eighth Edition • First Printing
Work Area Safety
18 Z®-45/25J Part No. 1311642GT
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
manual force - 90 lbs /
400 N
Do not alter or disable machine components that
in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
Z-45/25J models equipped with Aircraft
Protection Package: Do not use air-filled tires.
These machines are equipped with foam-filled
tires. Wheel weight is critical to stability.
Do not use the platform controls to free a platform
that is caught, snagged, or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not modify or alter a mobile elevating work
platform without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.
Do not place or attach
fixed or overhanging loads
to any part of this
machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.