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

Operator's Manual
Z
-
45/25 AUS
Australia
Z
-
45/25J
Z
-
51/30J
IC Power
with
Maintenance
Information
Seventh Edition
First Printing
Part No. 219414

Operator's Manual Seventh Edition • First Printing
Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 5
General Safety ...................................................... 7
Personal Safety................................................... 10
Work Area Safety................................................ 11
Legend ................................................................ 18
Controls............................................................... 19
Inspections.......................................................... 27
Operating Instructions......................................... 38
Transport and Lifting Instructions ....................... 44
Maintenance ....................................................... 47
Specifications...................................................... 51
Copyright © 2012 Terex Corporation
Seventh Edition: First Printing, June 2013
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

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 1
Introducti on
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.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
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.
Sequence number
stamped on chassis
Serial label
(located under cover)

Operator's Manual Seventh Edition • First Printing
Introduction
2 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
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.

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 3
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.

Operator's Manual Seventh Edition • First Printing
Introduction
4 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
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.
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.
DANGER
WARNING
CAUTION
NOTICE

Seventh Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 5
Symbol and Hazard P ictorials Definiti ons
Electrocution hazard Maintain required
clearance
Explosion hazard Explosion hazard Collision hazard
Runaway Hazard Tip-over hazard Crush hazard Color Coded
Direction Arrows
Wind speed
Side force Maximum capacity Voltage rating for
power to platform
Pressure rating for
air line to platform
Replace tires with
tires of same
specification.

Operator's Manual Seventh Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
Recovery procedure if tilt alarm sounds while
elevated.
Read the operator’s
manual
No smoking
No flame
Stop engine
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs
Platform uphill:
1Lower primary.
2Lower secondary
3Retract primary
Platform downhill:
1Retract primary.
2Lower secondary.
3Lower primary.
Lanyard attachment
point
Wheel load

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 7
General Safety
218557
or 218558
114390 219486
114258
218857
or 218558
31060
114258
218857
218558
219486
31060
114390
or 218484
or 218484
219484

Operator's Manual Seventh Edition • First Printing
General Safety
8 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
114390 219487
218550
or 218551
218559
28236
31060
218549
114397
218555
218551
114397
218559
218555
31060
28236
114390
219487

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 9
114390
97602
31060
31788
28175
218857 218558
114390
28175 97602
218557
or 218558
or 219484
219484
31060
218557
or 218558
or 219484
31788

Operator's Manual Seventh Edition • First Printing
Personal Safety
10 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
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.
All PFPE must comply with applicable governmen-
tal regulations, and must be inspected and used
in accordance with the PFPE manufacturer’s
instructions.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 11
WorkArea Safety
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 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 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 or the
maximum platform capacity of the platform
extension.
Maximum platform capacity 227 kg
Machine equipped with Aircraft
Protection Package
200 kg
Maximum occupants 2
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.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
12 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
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 while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the
boom on the slope as shown below. 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 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.
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.
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.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 13
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 – 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.
Do not use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight and
proper counterweight configuration are critical to
stability.
Do not modify or alter an aerial 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.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, air-filled
tires are properly inflated and lug nuts are properly
tightened.
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.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
14 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or
operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 15
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any othe
r
factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
Bodily Injury Hazard
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
16 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
to jump-start the engine.
Do not use the machine as a ground for welding.
Do not operate the machine in locations where
extremely high magnetic fields may be present.
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.
Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Retract and lower the boom to the stowed
position.
3Rotate the turntable so that the boom is
between the non-steer wheels.
4Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5Chock the wheels.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 17
Panel Cradle Safety
Read, understand and obey all warnings and
instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.
The panel cradle assembly weighs 30 lbs /
13.6 kg.
The maximum capacity of the panel cradles is
250 lbs / 113 kg.
The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Maximum vertical height of panels: 4 ft / 1.2 m
Maximum wind speed:15 mph / 6.7 m/sec
Maximum panel area: 32 sq ft / 3 m2
Pipe Cradle Safety
Read, understand and obey all warnings and
instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
The pipe cradle assembly weighs 21 lbs / 9.5 kg.
The maximum capacity of the pipe cradle
assembly is 200 lbs / 91 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
Center the load within the perimeter of the
platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhanging load.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.

Operator's Manual Seventh Edition • First Printing
Legend
18 Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414
Legend
1Foot switch
2Manual storage container
3Sliding mid-rail
4Lanyard anchorage point
5Jib boom (Z-45/25J & Z-51/30J)
6Platform
7Platform controls
8Primary boom
9Secondary boom
10 Ground controls
11 Steer tire
12 LPG tank (if equipped)
13 Non-steer tire