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
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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
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31060
28236
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219487