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Terex Z4525XCF-101 Operator's Manual

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Operator's Manual
Z
-45 XC™
®
Serial Number Range
from Z4525XCF-101
AUS
Australia
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1301594GT

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Summary of Contents for Terex Z4525XCF-101

  • Page 1 Operator's Manual Serial Number Range -45 XC™ ® from Z4525XCF-101 Australia with Maintenance Information Original Instructions First Edition Second Printing Part No. 1301594GT...

  • Page 2: Table Of Contents

    Maintenance ............62 Specifications ............66 Copyright © 2019 by Terex Corporation First Edition: Second Printing, June 2022 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 1418.10 ®...

  • Page 3: Introduction

    First Edition • Second Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Second Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 First Edition • Second Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual First Edition • Second Printing 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-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Read the operator’s Fire extinguisher Overhead obstruction moving parts manual Electrocution hazard Maintain required Tip-over hazard Manual force Tip-over hazard clearance Electrocution hazard...
  • Page 8 Operator's Manual First Edition • Second Printing Symbol and Hazard Pictorials Definitions Weight of welder No smoking. Explosion hazard Collision hazard Corrosive acid. reduces capacity No flame. Stop engine. Wheel load Tire specifications No smoking Overhead Explosion hazard obstruction Platform tie-down Lifting and tie down Lanyard anchorage Support the platform...
  • Page 9 First Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Maximum capacity Runaway hazard Color coded Voltage rating for Pressure rating for air direction arrows power to platform line to platform Recovery procedure if tilt alarm sounds while elevated.

  • Page 10: General Safety

    Operator's Manual First Edition • Second Printing General Safety General Safety These decals are model, option or configuration specific. ® -45 XC ™ Part No. 1301594GT...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety These decals are model, option or configuration specific. Part No. 1301594GT ® -45 XC ™...
  • Page 12 Operator's Manual First Edition • Second Printing General Safety 114390 1263543 97865 97602 *219484 31788 *1295957 1267121 52865 114390 97602 1263543 31788 97865 *219484 *219484 *1295957 52865 *1295957 1267121 ® -45 XC ™ Part No. 1301594GT...

  • Page 13: Personal Safety

    First Edition • Second Printing Operator's Manual Personal Safety 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.

  • Page 14: Work Area Safety

    Operator's Manual First Edition • Second Printing Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety If the platform load is greater than 664 lbs/301 kg, Do not depend on the tilt alarm as a level indicator. or 604 lbs/274 kg with Aircraft Protection Package The tilt alarm sounds in the platform only when the do not move the platform into the unrestricted machine is on a severe slope.
  • Page 16 Operator's Manual First Edition • Second Printing Work Area Safety Do not raise the boom Do not push off or pull when wind speeds may toward any object outside exceed 28 mph/12.5 m/s. of the platform. If wind speeds exceed Maximum allowable 28 mph/12.5 m/s when the manual force:...
  • Page 17 First Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 18 Operator's Manual First Edition • Second Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 21 First Edition • Second Printing Operator's Manual Work Area Safety Contact Alarm Safety Panel Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the contact alarm. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 22 Operator's Manual First Edition • Second Printing Work Area Safety Pipe Cradle Safety Welder Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 23 First Edition • Second Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 24: Legend

    Operator's Manual First Edition • Second Printing Legend Legend Foot switch Platform controls Manual storage container Primary boom Sliding mid-rail 10 Secondary boom Lanyard anchorage points 11 Ground controls Swing gate 12 Steer tire Jib boom 13 Non-steer tire Platform ®...

  • Page 25: Controls

    First Edition • Second Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 26 Operator's Manual First Edition • Second Printing Controls Ground Control Panel Engine idle (rpm) select switch Diesel models: Oil pressure light Move the engine idle select switch to the turtle position for foot switch activated low idle. Light on and engine stopped: Tag the machine Move the engine idle select switch to the rabbit and remove from service.
  • Page 27 First Edition • Second Printing Operator's Manual Controls 18 Function enable button 14 Platform rotate switch Press and hold the function enable button to Move the platform rotate switch to the right enable the functions on the ground control and the platform will rotate to the right. Move panel to operate.
  • Page 28 Operator's Manual First Edition • Second Printing Controls Platform Control Panel ® -45 XC ™ Part No. 1301594GT...
  • Page 29 First Edition • Second Printing Operator's Manual Controls Part No. 1301594GT ® -45 XC ™...
  • Page 30 Operator's Manual First Edition • Second Printing Controls Platform Control Panel Restricted range of motion indicator light (if equipped) Horn button Light on indicates that the range of motion is Press this button and the horn will sound. restricted. Release the button and the horn will stop. Unrestricted range of motion indicator light Platform level switch Light on indicates that the range of motion is...
  • Page 31 First Edition • Second Printing Operator's Manual Controls 12 Work light switch (if equipped) 15 Drive speed select switch Move the work light switch up to activate the Machine on incline symbol: Low range lights. Move the work light switch down to turn operation for inclines.
  • Page 32 Operator's Manual First Edition • Second Printing Controls 24 Dual axis proportional control handle for 21 Models with LCD screen: Engine shut-down primary boom up/down and turntable rotate indicator light left/right functions Light on indicates that the engine has shut Move the control handle up down.
  • Page 33 First Edition • Second Printing Operator's Manual Controls Platform Control Panel With LCD Display Part No. 1301594GT ® -45 XC ™...
  • Page 34 Operator's Manual First Edition • Second Printing Controls ® -45 XC ™ Part No. 1301594GT...
  • Page 35 First Edition • Second Printing Operator's Manual Controls Platform Control Panel with LCD Platform overload indicator light Display Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the Press this button and the horn will sound.
  • Page 36 Operator's Manual First Edition • Second Printing Controls 12 Work light switch (if equipped) 14 Dual axis proportional control handle for drive and steer functions. Move the work light switch up to activate the lights. Move the work light switch down to turn Proportional control handle for drive function off the lights.
  • Page 37 First Edition • Second Printing Operator's Manual Controls 15 Drive speed select switch 22 Proportional control handle for secondary boom up/down function Machine on incline symbol: Low range operation for inclines. Move the control handle Machine on level surface symbol: High range up and the secondary operation for maximum drive speed.

  • Page 38: Inspections

    Operator's Manual First Edition • Second Printing Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 39 First Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection  Contact alarm (if equipped)  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Generator (if equipped) responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 40 Operator's Manual First Edition • Second Printing Inspections 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 41 First Edition • Second Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of Turn the key switch to hazards. platform control. Pull out the platform red Emergency Turn the key switch to ground control.
  • Page 42 Operator's Manual First Edition • Second Printing Inspections At the Platform Controls Test Machine Functions 24 Press down the foot switch. Test Emergency Stop 25 Activate each machine function control handle 15 Turn the key switch to platform control and or toggle switch.
  • Page 43 First Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 33 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 44 Operator's Manual First Edition • Second Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 36 Press down the foot switch. 46 Press down the foot switch. 37 Raise the primary boom approximately 2 ft / 47 With the boom fully stowed, drive the machine 61 cm.
  • Page 45 First Edition • Second Printing Operator's Manual Inspections 55 With the boom fully stowed, drive the machine 64 Drive the machine onto a slope where the onto a slope where the chassis pitch angle is chassis roll angle is greater than 4.5°. greater than 4.5°.
  • Page 46 Operator's Manual First Edition • Second Printing Inspections Test the Oscillating Axle Test Aircraft Protection Package (if equipped) 71 Drive the right steer tire up onto a 6 in/15 cm block or curb. Note: Two people may be required to perform this test.
  • Page 47 First Edition • Second Printing Operator's Manual Inspections 87 Operate each machine function. Test the Contact Alarm (if equipped) Result: All machine functions should not 83 Do not activate the foot switch and press on operate. the contact alarm cable to release the actuator from the switch socket.
  • Page 48 Operator's Manual First Edition • Second Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces ...
  • Page 49 First Edition • Second Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description Use the pictures on the next page to verify that all 215527 Instructions – Ford Engine Specifications (MSG-425) decals are legible and in place. 218053 Label –...
  • Page 50 Operator's Manual First Edition • Second Printing Inspections 31060 35526 29104 114258 82366 219485* 1280819 219486* 825579 1274536 114390 1280820 219952 1283345 218529 218053 *219484 218054 *1295957 1305354 1283744 72086 82243 52475 1278542 1278982 114397 1267121 *219484 1305354 72086 *1295957 218559 28160 52475...

  • Page 51: Operating Instructions

    First Edition • Second Printing Operator's Manual Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Starting the Engine Emergency Stop At the ground controls, turn the key switch to Push in the red Emergency Stop button to the off position at the ground controls or the platform the desired position.
  • Page 53 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 54 Operator's Manual First Edition • Second Printing Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
  • Page 55 First Edition • Second Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the boom use the following procedure. has moved just past either non- steer wheel and the drive You will need: function has been interrupted.
  • Page 56 Operator's Manual First Edition • Second Printing Operating Instructions Engine Idle Select (rpm) Machine Not Level Indicator Light To select engine idle (rpm), move the switch to the If the tilt alarm sounds when the turtle symbol or the rabbit symbol. platform is raised, the Machine Not Level indicator light will come on When the foot switch is not pressed, the engine...
  • Page 57 First Edition • Second Printing Operator's Manual Operating Instructions Platform Capacity Selection Platform Capacity Selection with Aircraft Protection Range of motion is controlled automatically based on platform load. Range of motion is controlled automatically based on platform load. Unrestricted Range of Motion: When the platform load is less than 661 lbs - Unrestricted Range of Motion: When 1,000 lbs/301 - 454 kg, the restricted...
  • Page 58 Operator's Manual First Edition • Second Printing Operating Instructions Tilt Sensor Activation Settings When the Machine On Incline indicator light is on and the tilt Z-45 XC alarm sounds, the following functions are affected; drive Platform Load: 660 lbs/300 kg functions are disabled.
  • Page 59 First Edition • Second Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Contact Alarm (if equipped) The contact alarm is designed to alert ground If the platform bumper comes personnel when an operator makes contact with into contact with an object, the the platform control panel, interrupting boom machine will shut down and no movement, sounding an alarm and flashing...
  • Page 60 Operator's Manual First Edition • Second Printing Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 61: Transport And Lifting Instructions

    First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  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.
  • Page 62 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform - Z-45 XC, Z-45 HF Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 63 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 64: Maintenance

    Operator's Manual First Edition • Second Printing Maintenance Check the Engine Oil Level Maintenance Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 65 First Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 66 Operator's Manual First Edition • Second Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 67 First Edition • Second Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, 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 68: Specifications

    Operator's Manual First Edition • Second Printing Specifications Specifications Z-45 XC Platform dimensions, 6 foot 183 cm x 76 cm Platform leveling self-leveling Height, working maximum 15.86 m Platform rotation 160° Height, platform maximum 13.86 m AC outlet in platform standard Height, stowed maximum 2.25 m...
  • Page 69 First Edition • Second Printing Operator's Manual Specifications Z-45 XC Range of Motion Chart Z-45 XC Range of Motion Chart with Aircraft Protection Z®-45 XC™ Part No. 1301594GT Operator's Manual First Edition • Second Printing Part No. 1301594GT ® -45 XC ™...

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Genie z-45 xc

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