Terex Genie ZX13515-2559 Operator's Manual
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Terex Genie ZX13515-2559 Operator's Manual

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Operator's Manual
ZX-135/70
With Jib Extend
with Jib-Extend™
Serial Number Range
from ZX13515-2559
CE
with
Maintenance
Information
Original Instructions
Second Edition
Third Printing
Part No. 1258936

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Summary of Contents for Terex Genie ZX13515-2559

  • Page 1 Operator's Manual Serial Number Range ZX-135/70 from ZX13515-2559 With Jib Extend with Jib-Extend™ with Maintenance Information Original Instructions Second Edition Third Printing Part No. 1258936...

  • Page 2: Table Of Contents

    Copyright © 2011 by Terex Corporation Second Edition: Third 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

    Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Read the operator’s Read the service...
  • Page 7 Second Edition • Third 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 Second Edition • Third Printing General Safety General Safety ZX-135/70 Part No. 1258936...
  • Page 9 Second Edition • Third Printing Operator's Manual General Safety Part No. 1258936 ZX-135/70...
  • Page 10 Operator's Manual Second Edition • Third Printing General Safety ZX-135/70 Part No. 1258936...

  • Page 11: Personal Safety

    Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Bodily Injury Hazard 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 Second Edition • Third 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 Second Edition • Third Printing Operator's Manual Work Area Safety Welder Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the welding power unit. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not connect weld leads or cables unless the position.

  • Page 20: Legend

    Operator's Manual Second Edition • Third 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. 1258936...

  • Page 21: Controls

    Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third Printing Controls Emergency power switch with indicator light Platform Control Panel 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 Second Edition • Third 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 10° above 66 Rotate the turntable until the primary boom horizontal.
  • Page 41 Second Edition • Third Printing Operator's Manual Inspections 77 Slowly move the drive control handle to the full Test Drive Tilt Cutout drive position. 84 Press down the foot switch. Result: The maximum achievable drive speed 85 With the boom fully stowed, drive the machine with the secondary boom raised should not onto a slope where the chassis angle is exceed 30 cm/s.
  • Page 42 Operator's Manual Second Edition • Third Printing Inspections 92 Return to level ground and stow the boom. 101 With the boom fully stowed, drive the machine onto a slope where the chassis angle is 93 With the boom fully stowed, drive the machine greater than 4.5°...
  • Page 43 Second Edition • Third Printing Operator's Manual Inspections 109 With the boom fully stowed, drive the machine Test Emergency Controls onto a slope where the chassis angle is 117 Push in the red Emergency Stop button to the greater than 4.5° along the X-Axis (side to off position to shut off the engine.
  • Page 44 Operator's Manual Second Edition • Third Printing Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 121 Move the yellow bumper at the bottom of the platform 10 cm in any direction. 122 Activate each function control handle, toggle switch or thumb rocker switch.
  • Page 45 Second Edition • Third 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 46 Operator's Manual Second Edition • Third 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 47 Second Edition • Third Printing Operator's Manual Inspections Part No. 1258936 ZX-135/70...

  • Page 48: Operating Instructions

    Operator's Manual Second Edition • Third 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 49 Second Edition • Third 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 50 Operator's Manual Second Edition • Third 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 51 Second Edition • Third 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 52 Operator's Manual Second Edition • Third 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 53 Second Edition • Third Printing Operator's Manual Operating Instructions Drive Enable Check Engine Light Light on indicates that the primary Light on and engine stopped: Tag the boom has moved past either machine and remove from service. circle-end wheel and the drive Light on and engine still running: function is turned off.
  • Page 54 Operator's Manual Second Edition • Third Printing 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 55 Second Edition • Third Printing Operator's Manual Operating Instructions LCD Screen (if equipped) Machine Not Level Indicator Light The LCD screen displays hour meter, voltage, oil If the tilt alarm sounds when the pressure and coolant temperature. The screen platform is raised, the Machine also displays fault codes and other service Not Level indicator light will come information.
  • Page 56 Operator's Manual Second Edition • Third Printing Operating Instructions Aircraft Protection Package (if equipped) After Each Use Select a safe parking location—firm level If the platform bumper comes surface, clear of obstruction and traffic. into contact with an object, the machine will shut down and no Retract and lower the boom to the stowed functions will operate.

  • Page 57: Transport And Lifting Instructions

    Second Edition • Third 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 58 Operator's Manual Second Edition • Third 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 59 Second Edition • Third 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 60: Maintenance

    Operator's Manual Second Edition • Third 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 61 Second Edition • Third 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 62 Operator's Manual Second Edition • Third 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 63 Second Edition • Third 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 64: Specifications

    Operator's Manual Second Edition • Third Printing 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 65 Second Edition • Third Printing Operator's Manual Specifications ZX-135/70 Range of Motion Chart ZX-135/70 Part No. 1258936 Operator's Manual Second Edition • Third Printing Part No. 1258936 ZX-135/70...
  • Page 66 www.genielift.com...

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