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Operator's Manual

Eighth Edition • First Printing

Maintenance

60

Z

®

-45/25J

Part No. 1311642GT

Maintenance

Observe and Obey:



Only routine maintenance items specified in
this manual shall be performed by the
operator.



Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer’s specifications
and the requirements specified in the
responsibilities manual.



Use only Genie approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

Indicates that tools will be required to
perform this procedure.

Indicates that new parts will be required to
perform this procedure.

Indicates that a cold engine is required
before performing this procedure.

Check the Engine Oil Level

Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.

Note: Check the oil level with the engine off.

1

Check the oil level dipstick. Add oil as needed.

Deutz D2011 L03i Engine

Oil type

15W-40

Oil type - cold conditions

5W-40

Deutz D2.9 L4 Engine

Oil type

15W-40

Oil type - cold conditions

5W-40

Kubota D-1105-E4B Engine

Oil type

10W-30

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Summary of Contents for Genie Z-45/25J Bi-Energy

Page 1: ...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 ...

Page 2: ... 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 ot...

Page 3: ... 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...

Page 4: ...vel 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 intend...

Page 5: ...f 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 Sta...

Page 6: ...ways 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 tr...

Page 7: ...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 inju...

Page 8: ...Symbol and Hazard 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 ...

Page 9: ...lder 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 ...

Page 10: ...ure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Lower secondary 3 Retract primary Platform downhill 1 Retract primary 2 Lower secondary 3 Lower 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 g...

Page 11: ...Eighth Edition First Printing Operator s Manual General Safety Part No 1311642GT Z 45 25J 9 General Safety ...

Page 12: ...Operator s Manual Eighth Edition First Printing General Safety 10 Z 45 25J Part No 1311642GT For Kubota only ...

Page 13: ...Eighth Edition First Printing Operator s Manual General Safety Part No 1311642GT Z 45 25J 11 ...

Page 14: ...Operator s Manual Eighth Edition First Printing General Safety 12 Z 45 25J Part No 1311642GT For Kubota only ...

Page 15: ...Eighth Edition First Printing Operator s Manual General Safety Part No 1311642GT Z 45 25J 13 ...

Page 16: ...Operator s Manual Eighth Edition First Printing General Safety 14 Z 45 25J Part No 1311642GT ...

Page 17: ... 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...

Page 18: ... 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 maxi...

Page 19: ...Lower the secondary boom 3 Retract the primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Lower the secondary boom 3 Lower 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 s...

Page 20: ...r 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 f...

Page 21: ... 14 Side slope 25 14 Note Slope rating is subject to ground conditions with one person in the platform and adequate traction Additional platform weight may reduce slope rating 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 ...

Page 22: ...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 other factors ...

Page 23: ...pen 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 Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection...

Page 24: ...ety Read understand and obey all warnings and instructions provided with the contact alarm Do not exceed the rated platform capacity The weight of the contact alarm assembly will reduce the rated platform capacity and must be subtracted from the total platform load The contact alarm assembly weighs 10 lbs 4 5 kg Be sure the contact alarm is securely installed Lockout After Each Use 1 Select a safe...

Page 25: ...e load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from all energized electrical conductors Panel Cradle Safety Bodily injury hazard Failure to use the Genie Panel Cradle according to the instructions and safety rules listed here and in the Operator s and Responsibilities Manual could result in serious injury Read understand and obey all warni...

Page 26: ...Part No 1311642GT Legend 1 Foot switch 2 Manual storage container 3 Sliding mid rail 4 Lanyard anchorage points 5 Jib boom Z 45 25J 6 Platform 7 Platform controls 8 Primary boom 9 Secondary boom 10 Ground controls 11 Steer tire 12 LPG tank if equipped 13 Non steer tire ...

Page 27: ...tation can be used in the event of an emergency to rescue an incapacitated person in the platform When the ground control station is selected the platform controls are inoperable including the E stop switch The Z 45 25J machines will have one of these two styles of ground control panels The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to b...

Page 28: ...h to either side and activate the desired function 9 Platform rotate switch Move the platform rotate switch to the right and the platform will rotate to the right Move the platform rotate switch to the left and the platform will rotate to the left 10 Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level switch down and the level of...

Page 29: ...gency Stop button to the on position to operate the machine 18 Primary boom up down switch Move the primary boom up down switch up and the boom will raise Move the primary boom up down switch down and the boom will lower 19 15A breaker for engine electrical circuits 20 15A breaker for control electrical circuits 21 Secondary boom up down switch Move the secondary boom up down switch up and the sec...

Page 30: ...Operator s Manual Eighth Edition First Printing Controls 28 Z 45 25J Part No 1311642GT Platform Control Panel ...

Page 31: ...Eighth Edition First Printing Operator s Manual Controls Part No 1311642GT Z 45 25J 29 ...

Page 32: ...light Light flashing indicates the platform is overloaded The engine will stop and no functions will operate Remove weight until the light goes off and then restart the engine 6 Machine not level indicator light The machine not level indicator light will come on when the tilt alarm sounds 7 Auxiliary power switch Use auxiliary power if the primary power source engine fails Simultaneously hold the ...

Page 33: ...anel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Press the left side of the thumb rocker and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right 14 Drive enable indicator light Light on indicates that the boom has moved just past either ...

Page 34: ...the primary boom extend retract switch up and the primary boom will retract Move the boom extend retract switch down and the primary boom will extend 23 Dual axis proportional control handle for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boom will raise Move the control handle down and the primary boom will lower Move the control handl...

Page 35: ...on is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthor...

Page 36: ...Add coolant if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit swit...

Page 37: ...se the machine as it was intended 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 malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may ...

Page 38: ... functions should operate 8 Press and hold the function enable button and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle The descent alarm should sound while the boom is lowering Test the Tilt Sensor 9 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 10 Open ...

Page 39: ...ch and restart the engine Result The engine should start 23 Do not press down the foot switch and test each machine function Result No functions should operate Test Machine Functions 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch Result All boom and platform functions should operate through a full cycle Test the Steering 26 Press down the foot switc...

Page 40: ...old the machine on any slope it is able to climb Test Drive Tilt Cutout 32 Press down the foot switch 33 With the boom fully stowed drive the machine onto a slope where the chassis pitch angle is greater than 2 5 Result The machine should continue to drive 34 Return to level ground and raise the primary boom to an out of stowed position approximately 10 above horizontal 35 Drive the machine onto a...

Page 41: ... slope where the chassis roll angle is greater than 4 5 Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 48 Lower the primary boom to the stowed position or drive in the opposite direction Result The machine should drive 49 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 50 Drive the machin...

Page 42: ...n of travel Test Limited Drive Speed 61 Press down the foot switch 62 Raise the primary boom approximately 2 ft 61 cm 63 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 1 ft 30 cm per second 64 Lower the primary boom to the stowed position 65 Raise the secondary boom approximately 2 ft 61 cm 66...

Page 43: ...ed Emergency Stop button to the on position 77 Press down the foot switch 78 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate Drive functions should not operate with auxiliary power Test Aircraft Protection Package if equipped Note Two pe...

Page 44: ...machine horn will sound 86 Insert the actuator into the switch socket Result The lights and horn will turn off 87 Activate the foot switch by pressing the foot switch down and press on the contact alarm cable to release the actuator from the switch socket Result The contact alarm lights will flash and the machine horn will sound 88 Operate each machine function Result All machine functions should ...

Page 45: ...rator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situatio...

Page 46: ...l Explosion Hazard 1 114252 Label Tip over Hazard Limit Switches 3 133067 Label Electrocution Hazard 2 Part No Decal Description Qty 133205 Label Electrocution Burn Hazard 1 161162 Danger Warning Tip over Hazard CE Aircraft Protection 1 214932 Ground Control Panel 1 214933 Platform Control Panel 1 218562 Label Wheel Load Z 45 25J 4 219952 Label Emergency Lowering 1 219488 Label Transport Diagram Z...

Page 47: ...Eighth Edition First Printing Operator s Manual Inspections Part No 1311642GT Z 45 25J 45 ...

Page 48: ...Operator s Manual Eighth Edition First Printing Inspections 46 Z 45 25J Part No 1311642GT For Kubota only ...

Page 49: ...he operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a...

Page 50: ...s are on 6 When the automatic glow plug symbol turns off move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds All models If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 20 F 6 C and ...

Page 51: ...y power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform 4 Simultaneously hold the auxiliary power switch to either side and activate the desired function Operation from Ground 1 Turn the key switch to ground control 2 Pull o...

Page 52: ...ow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control handle toward center Stop Return the control...

Page 53: ...itch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holdi...

Page 54: ...gh range operation for maximum drive speed Tilt Sensor Activation Settings Model Chassis Angle side to side Chassis Angle front to back Z 45J IC 4 5 2 5 When the Machine On Incline indicator light is on and the tilt alarm sounds the following functions are affected drive functions are disabled Follow the Boom lowering procedure see Operating Instructions to restore drive function While operating f...

Page 55: ...latform downhill 1 Retract the primary boom 2 Lower the secondary boom 3 Lower the primary boom 4 Engine Idle Select rpm When the foot switch is not pressed the engine will idle at the lowest rpm Turtle symbol Foot switch activated low idle Rabbit symbol Foot switch activated high idle If foot switch activated low idle or high idle do not work contact service personnel within 24 hours Foot switch ...

Page 56: ...e function control handle or toggle switch to move the machine away from aircraft components Control Box Heater if equipped Move the control box heater switch up to activate the heater Engine Shut down indicator light if equipped Light on Tag and remove the machine from service LCD Screen if equipped The LCD screen displays hour meter voltage oil pressure and coolant temperature The screen also di...

Page 57: ... others that assistance may be needed These notifications will continue until the system is reset 1 The contact alarm cable is tripped releasing the actuator from the switch socket 2 Insert the actuator into the switch socket to turn off flashing lights and audio alarm 1 actuator 2 contact alarm cable 3 flashing alarm 4 switch socket After Each Use 1 Select a safe parking location firm level surfa...

Page 58: ...ifts are very heavy relative to their size See the serial label for the machine weight See the inspections section for the serial label location 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 See Driving on a Slope in the Ope...

Page 59: ...before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 4 chains or straps Adjust the rigging to prevent damage to the chains For diagram refer to the Lifting Instructions Securing the Platform Z 45 25J Make sure the jib and platform are in the stowed position Secure the platform with a nylon strap placed o...

Page 60: ...nd Obey Only qualified riggers should rig the machine Only certified crane operators should lift the machine and only in accordance with the applicable crane regulations Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial label for the machine weight ...

Page 61: ... items on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the machine one on each axle Adjust the rigging to prevent damage to the machine and to keep the machine level Center of gravity X Axis Y Axis Z 45 25J 47 3 in 120 cm 44 in 112 cm ...

Page 62: ...e or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good e...

Page 63: ...E4B Engine Fuel Type Low Sulfur Diesel LSD or Ultra Low Sulfur Diesel ULSD Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the bo...

Page 64: ...l in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark on the tank or visible in the sight gauge Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with ho...

Page 65: ...terly 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 the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service ...

Page 66: ...ient operating temperature 20 F to 120 F 29 C to 49 C AC outlet in platform standard Hydraulic pressure maximum boom functions 3200 psi 221 bar System voltage 12V Tire size 4WD 2WD RT 315 55 D20 Tire size High Floatation 33 16LL500 Airborne noise emissions Sound pressure level at platform workstation 82 dBA Sound pressure level at ground workstation 87 dBA Guaranteed sound power level 105 dBA Tota...

Page 67: ...ifications Part No 1311642GT Z 45 25J 65 Z 45 25J Range of motion chart Horizontal Values Vertical Values 2 0 ft 0 m 6 5 ft 1 5 m 3 5 ft 1 5 m 7 0 ft 0 m 4 15 ft 4 6 m 8 10 ft 3 m 5 25 ft 7 6 m 9 20 ft 6 1 m 10 30 ft 9 1 m 11 40 ft 12 2 m 12 50 ft 15 2 m ...

Page 68: ... engine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specif...

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