Terex Z4525XCF-101 User manual

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

Operator's Manual First Edition • Second Printing
Z®-45 XC™Part No. 1301594GT
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 5
General Safety ...................................................... 8
Personal Safety................................................... 11
Work Area Safety................................................ 12
Legend ................................................................ 22
Controls............................................................... 23
Inspections.......................................................... 36
Operating Instructions......................................... 49
Transport and Lifting Instructions ....................... 59
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

First Edition • Second Printing Operator's Manual
Introduction
Part No. 1301594GT Z®-45 XC™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.
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 First Edition • Second Printing
Introduction
2 Z®-45 XC™Part No. 1301594GT
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 (if equipped).
Restricted operating envelope:
•1,000 lbs/454 kg platform capacity. (if
equipped)

First Edition • Second Printing Operator's Manual
Introduction
Part No. 1301594GT Z®-45 XC™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 First Edition • Second Printing
Introduction
4 Z®-45 XC™Part No. 1301594GT
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.
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.

First Edition • Second Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1301594GT Z®-45 XC™5
Symbol and Hazard Pic torials Definiti ons
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

Operator's Manual First Edition • Second Printing
Symbol and Hazard Pictorials Definitions
6 Z®-45 XC™Part No. 1301594GT
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 and tie down
instructions
Lanyard anchorage
points
Support the platform
or boom during
maintenance
Tie-down point

First Edition • Second Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1301594GT Z®-45 XC™7
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:
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 glow plugs.
Crush hazard

Operator's Manual First Edition • Second Printing
General Safety
8 Z®-45 XC™Part No. 1301594GT
General Safety
* These decals are model, option or configuration specific.

First Edition • Second Printing Operator's Manual
General Safety
Part No. 1301594GT Z®-45 XC™9
* These decals are model, option or configuration specific.

Operator's Manual First Edition • Second Printing
General Safety
10 Z®-45 XC™Part No. 1301594GT
97865
114390
1263543
31788
97602
114390 1263543
31788 97602
97865
*219484
*1295957
*219484
*1295957 1267121
1267121
*219484
*1295957
52865
52865

First Edition • Second Printing Operator's Manual
Personal Safety
Part No. 1301594GT Z®-45 XC™11
Personal Safet y
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 First Edition • Second Printing
Work Area Safety
12 Z®-45 XC™Part No. 1301594GT
Work Area Safet y
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 follo
wed.
Line Voltage
Required Clearance
0
to 50KV 10 f
t
3.05
m
5
0 to 200KV 15 f
t
4.60
m
20
0 to 350KV 20 f
t
6.10
m
35
0 to 500KV 25 f
t
7.62
m
50
0 to 750KV 35 f
t
10.67
m
75
0 to 1000KV 45 f
t
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
Unrestricted range of motion
660 l
bs
300 k
g
Maximum occupants
2
Maximum platform capacity
Restricted range of motion
1000 l
bs
454 k
g
Maximum occupants
3
Maximum platform capacity
Unrestricted range of motion
Machine equipped with Aircraft
Protection Package
600 l
bs
273 k
g
Maximum
occupants
2
Maximum platform capacity
Restricted range of motion
Machine equipped with Aircraft
Protection Package
940 l
bs
427 k
g
Maximum occupants
3

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1301594GT Z®-45 XC™13
If the platform load is greater than 664 lbs/301 kg,
or 604 lbs/274 kg with Aircraft Protection Package
do not move the platform into the unrestricted
range of motion zone.
Do not exceed the maximum platform capacity.
Do not attach a platform rated at 660 lbs/300 kg
(unrestricted range of motion) or 1000 lbs/454 kg
(restricted range of motion) to machines with any
other rated load. See the serial label for the
maximum rated load.
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 surfac
e.
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:
1
Lower the primary
boom.
2
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.

Operator's Manual First Edition • Second Printing
Work Area Safety
14 Z®-45 XC™Part No. 1301594GT
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.
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.
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.

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1301594GT Z®-45 XC™15
Do not place or attach
fixed or overhanging loads
to any part of t
his
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 the tires are in good condition and the lug
nuts tightened.
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, 4WD
Platform downhill
45%
(24°)
Platform uphill
25%
(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.

Operator's Manual First Edition • Second Printing
Work Area Safety
16 Z®-45 XC™Part No. 1301594GT
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.
Hazards related with the specific product
application of exiting at height have been
considered in the design of the machine, for
further information contact Genie (see section
Contacting the Manufacturer).
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.
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.

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1301594GT Z®-45 XC™17
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lowe
r 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 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 First Edition • Second Printing
Work Area Safety
18 Z®-45 XC™Part No. 1301594GT
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 manual is complete, legible,
and in the storage container located on the
machine.
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.