Terex ZX13515-2558 Operator's Manual
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Terex ZX13515-2558 Operator's Manual

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Operator's Manual
ZX-135/70
Serial Number Range
from ZX13513-2001
to ZX13515-2558
CE
with
Maintenance
Information
Original Instructions
First Edition
Fourth Printing
Part No. 160568

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Summary of Contents for Terex ZX13515-2558

  • Page 1 Operator's Manual Serial Number Range ZX-135/70 from ZX13513-2001 to ZX13515-2558 with Maintenance Information Original Instructions First Edition Fourth Printing Part No. 160568...

  • Page 2: Table Of Contents

    Copyright © 2011 by Terex Corporation First Edition: Fourth Printing, September 2015 Genie and "ZX" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity ZX-135/70 Part No.

  • Page 3: Introduction

    First Edition • Fourth Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Fourth Printing Introduction 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: Danger Accident reporting...
  • Page 5 First Edition • Fourth Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual First Edition • Fourth Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush hazard Keep away from Crush hazard Overhead obstruction Collision hazard moving parts Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact...
  • Page 7 First Edition • Fourth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Platform tie-down Lifting & tie down instructions Tie-down point Lifting point instructions Wind speed Maximum capacity Weight of welder Wheel load Tire specifications reduces capacity Recovery procedure if tilt alarm sounds while elevated Platform uphill: Platform downhill:...

  • Page 8: General Safety

    Operator's Manual First Edition • Fourth Printing General Safety General Safety ZX-135/70 Part No. 160568...
  • Page 9 First Edition • Fourth Printing Operator's Manual General Safety Part No. 160568 ZX-135/70...
  • Page 10 Operator's Manual First Edition • Fourth Printing General Safety ZX-135/70 Part No. 160568...

  • Page 11: Personal Safety

    First Edition • Fourth 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 12: Work Area Safety

    Operator's Manual First Edition • Fourth 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 13 First Edition • Fourth Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with boom unless the machine the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 14 Operator's Manual First Edition • Fourth Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 15 First Edition • Fourth 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 of machine.
  • Page 16 Operator's Manual First Edition • Fourth 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 governmental regulations. operating. Attach the lanyard to the Be aware of the boom position and tailswing when anchor provided in the...
  • Page 17 First Edition • Fourth 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 18 Operator's Manual First Edition • Fourth 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 the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 19 First Edition • Fourth Printing Operator's Manual Work Area Safety Welder Safety Weld Line to Platform Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the welding power unit. instructions provided with the welding power unit. Do not connect weld leads or cables unless the Do not connect weld leads or cables unless the welding power unit is turned off at the platform...

  • Page 20: Legend

    Operator's Manual First Edition • Fourth Printing Legend Legend Platform controls Square-end tire Sliding mid-rail Ground controls Manual storage container Secondary boom 10 Lanyard anchorage points Primary boom 11 Foot switch Jib boom Platform ZX-135/70 Part No. 160568...

  • Page 21: Controls

    First Edition • Fourth Printing Operator's Manual Controls Controls Ground Control Panel Glow plug button 16 Alarm Turntable rotate right button 10 Key switch for 17 Bypass/recovery key switch Turntable rotate left button off/ground/platform selection 18 Platform rotate right button Secondary boom up/extend 11 Engine start button and down/retract buttons...
  • Page 22 Operator's Manual First Edition • Fourth Printing Controls LCD readout screen Ground Control Panel Turntable rotate right button Press the turntable rotate right button and the turntable will rotate right. a low fuel indicator Turntable rotate left button b engine oil pressure indicator Press the turntable rotate left button and the c water temperature indicator turntable will rotate left.
  • Page 23 First Edition • Fourth Printing Operator's Manual Controls 12 Jib boom up/down buttons 18 Platform rotate right button Press the jib boom up button and the jib boom Press the platform rotate right button and the will raise. Press the jib boom down button and platform will rotate right.
  • Page 24 Operator's Manual First Edition • Fourth Printing Controls Platform Control Panel Generator switch with 11 Engine idle select switch with Horn button indicator light (if equipped) indicator light: Platform not level indicator  Rabbit: high idle Emergency power switch light ...
  • Page 25 First Edition • Fourth Printing Operator's Manual Controls 15 16 STOP 21 Drive select switch with 24 Axle extend/retract switch 18 Dual axis proportional control indicator lights with indicator lights handle for drive and steer functions Machine on incline symbol: 25 Drive enable switch with OR Proportional control Low range operation for...
  • Page 26 Operator's Manual First Edition • Fourth Printing Controls Platform Control Panel Emergency power switch with indicator light Use emergency power if the primary power Horn button source (engine) fails. Press this button and the horn will sound. Simultaneously move the emergency power Release the button and the horn will stop.
  • Page 27 First Edition • Fourth Printing Operator's Manual Controls 12 Platform overload indicator light 18 Dual axis proportional control handle for drive and steer functions Light flashing indicates the platform is OR Proportional control handle for drive overloaded. The engine will stop and no function and thumb rocker for steer function.
  • Page 28 Operator's Manual First Edition • Fourth Printing Controls 19 Steer mode select switch with indicator lights 22 Thumb rocker for jib boom extend/retract function Move the steer mode select switch Push the top of the rocker to choose steer switch and the jib boom will mode.
  • Page 29 First Edition • Fourth Printing Operator's Manual Controls 24 Axle extend/retract switch with indicator lights 27 Dual axis proportional control handle for primary boom up/down and turntable rotate Move the axle select left/right functions switch to choose an axle setting. The indicator Move the control handle up light will flash while the and the primary boom will...

  • Page 30: Inspections

    Operator's Manual First Edition • Fourth 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 31 First Edition • Fourth Printing Operator's Manual Inspections  Steer and axle sensors Pre-operation Inspection  Alarms and beacons (if equipped)  Be sure that the operator’s, safety and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible ...
  • Page 32 Operator's Manual First Edition • Fourth 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 33 First Edition • Fourth Printing Operator's Manual Inspections Test the Extendable Axles At the Ground Controls Note: Start this test with the axles retracted. Select a test area that is firm, level and free of obstruction. At the ground controls, push and hold a function enable/speed select button and push Turn the key switch to ground control.
  • Page 34 Operator's Manual First Edition • Fourth Printing Inspections 10 Push and hold a function enable/speed select 14 Push and hold a function enable/speed select button and push the turntable rotate left button. button and push the primary boom up button and then the primary boom down button.
  • Page 35 First Edition • Fourth Printing Operator's Manual Inspections Test Machine Functions Test the Tilt Sensor 18 Do not press and hold a function enable/speed 24 Press one of the LCD select button. Attempt to activate each boom screen control buttons until and platform function button.
  • Page 36 Operator's Manual First Edition • Fourth Printing Inspections 32 Press and hold the secondary boom up/extend Test the Operating Envelope button. 27 Press the LCD screen Result: The secondary boom should raise and control buttons shown until the LCD screen should display the secondary PRI BOOM ANGLE TO boom angle in degrees.
  • Page 37 First Edition • Fourth Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 39 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 34 Turn the key switch to platform control. 40 Pull out the red Emergency Stop button to the on position and do not start the engine.
  • Page 38 Operator's Manual First Edition • Fourth Printing Inspections 51 Press down the foot switch. Test the Steering 52 Slowly move the control handle in the direction 46 Move the steer indicated by the yellow triangle on the control mode select switch panel OR press the thumb rocker switch in the and choose direction indicated by the yellow triangle.
  • Page 39 First Edition • Fourth Printing Operator's Manual Inspections 57 Slowly move the control handle in the direction Test Drive and Braking indicated by the yellow triangle on the control 62 Press down the foot switch. panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 40 Operator's Manual First Edition • Fourth Printing Inspections Test the Drive Enable System Test Limited Drive Speed 65 Press down the foot switch and lower the 69 Press down the foot switch. boom to the stowed position. 70 Raise the primary boom to 5° above 66 Rotate the turntable until the primary boom horizontal.
  • Page 41 First Edition • Fourth Printing Operator's Manual Inspections 77 Slowly move the drive control handle to the full 81 Extend the primary boom 1.2 m. drive position. 82 Slowly move the drive control handle to the full Result: The maximum achievable drive speed drive position.
  • Page 42 Operator's Manual First Edition • Fourth Printing Inspections Test Emergency Controls Test Aircraft Protection Package (if equipped) 84 Push in the red Emergency Stop button to the off position to shut off the engine. 88 Move the gray bumper at the bottom of the platform 10 cm in any direction.
  • Page 43 First Edition • Fourth Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 44 Operator's Manual First Edition • Fourth Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 114248 Label – Tip-over Hazard, Tilt Alarm 114249 Label – Tip-over Hazard, Tires Use the pictures on the next page to verify that all 114251 Label –...
  • Page 45 First Edition • Fourth Printing Operator's Manual Inspections Part No. 160568 ZX-135/70...

  • Page 46: Operating Instructions

    Operator's Manual First Edition • Fourth Printing 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 47 First Edition • Fourth Printing Operator's Manual Operating Instructions Perkins models Starting the Engine Move the glow plug switch to either side and At the ground controls, turn the key switch to hold. the desired position. Move the engine start toggle switch to either Be sure both ground and platform control red side.
  • Page 48 Operator's Manual First Edition • Fourth Printing Operating Instructions Emergency Stop To Extend and Retract Axles Push in the red Emergency Stop button to the off Turn the key switch to platform control. position at the ground controls or the platform At the platform controls, controls to stop all machine functions and turn the press down the foot switch...
  • Page 49 First Edition • Fourth Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the drive Pull out both ground and platform red control handle in the direction Emergency Stop buttons to the on position.
  • Page 50 Operator's Manual First Edition • Fourth Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 51 First Edition • Fourth Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the primary Select the engine idle (rpm) by boom has moved past either pressing the engine idle select circle-end wheel and the drive switch.
  • Page 52 Operator's Manual First Edition • Fourth Printing Operating Instructions Operating Envelope Indicator Lights If the tilt alarm sounds with the platform uphill: The operating envelope indicator lights will come on to notify the operator that a function has been Lower the primary interrupted and/or an action is required by the boom.
  • Page 53 First Edition • Fourth Printing Operator's Manual Operating Instructions Platform Out of Level (P22 code) Platform Out of Level (Platform Level > 15 Degrees Fault) Bypass key position to be used to level the platform if ground control display shows platform If ground control display shows PLATFORM out of level (P22) and platform level controls do not LEVEL >...
  • Page 54 Operator's Manual First Edition • Fourth 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 55: Transport And Lifting Instructions

    First Edition • Fourth 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 56 Operator's Manual First Edition • Fourth Printing Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Use a minimum of 6 chains. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 57 First Edition • Fourth Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 58: Maintenance

    Operator's Manual First Edition • Fourth Printing Maintenance Maintenance 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 Observe and Obey: can damage engine components.
  • Page 59 First Edition • Fourth Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 60 Operator's Manual First Edition • Fourth Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 61: Specifications

    First Edition • Fourth Printing Operator's Manual Specifications Specifications Model System voltage ZX-135/70 Tire size 445/65 D22.5 Height, working maximum 42.9 m or 445D50/710, 18 ply FF Height, platform maximum 41.4 m Weight 20,457 kg Height, stowed maximum 3.1 m (Machine weights vary with option configurations.
  • Page 62 Operator's Manual First Edition • Fourth Printing Specifications ZX-135/70 Range of Motion Chart ZX-135/70 Part No. 160568 Operator's Manual First Edition • Fourth Printing ZX-135/70 Part No. 160568...
  • Page 63 www.genielift.com...

This manual is also suitable for:

Zx13513-2001Genie zx-135/70

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