Terex Genie ZX13515-2559 User manual

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

Operator's Manual Second Edition • Third Printing
ZX-135/70 Part No. 1258936
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 4
General Safety ...................................................... 6
Personal Safety..................................................... 9
Work Area Safety................................................ 10
Legend ................................................................ 18
Controls............................................................... 19
Inspections.......................................................... 28
Operating Instructions......................................... 46
Transport and Lifting Instructions ....................... 55
Maintenance ....................................................... 58
Specifications...................................................... 62
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

Second Edition • Third Printing Operator's Manual
Introduction
Part No. 1258936 ZX-135/70 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.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
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.

Operator's Manual Second Edition • Third Printing
Introduction
2 ZX-135/70 Part No. 1258936
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.
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.

Second Edition • Third Printing Operator's Manual
Introduction
Part No. 1258936 ZX-135/70 3
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.
DANGER
WARNING
CAUTION
NOTICE

Operator's Manual Second Edition • Third Printing
Symbol and Hazard Pictorials Definitions
4 ZX-135/70 Part No. 1258936
Symbol and Hazard P ictorials Definiti ons
Crush hazard Keep away from
moving parts
Crush hazard Overhead obstruction Collision hazard
Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard
Electrocution hazard Avoid contact Disconnect battery Read the operator’s
manual
Read the service
manual
Explosion hazard No smoking.
No flame.
Stop engine.
Explosion hazard Burn hazard Fire extinguisher
Fire hazard No smoking Explosion hazard No step Lanyard anchorage
points

Second Edition • Third Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1258936 ZX-135/70 5
Platform tie-down
instructions
Lifting & tie down instructions Tie-down point Lifting point
Wind speed Maximum capacity Weight of welder
reduces capacity
Wheel load Tire specifications
Recovery procedure if tilt alarm sounds while
elevated
Platform uphill:
1Lower primary
2Retract/lower
secondary
3Retract primary
Platform downhill:
1Retract primary
2Retract / lower
secondary
3Lower primary
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
Voltage rating for
power to platform
Pressure rating for
air line to platform
Color Coded
Direction Arrows
Runaway Hazard Access by trained
and authorized
personnel only
Manual force
+
+

Operator's Manual Second Edition • Third Printing
General Safety
6 ZX-135/70 Part No. 1258936
General Safety

Second Edition • Third Printing Operator's Manual
General Safety
Part No. 1258936 ZX-135/70 7

Operator's Manual Second Edition • Third Printing
General Safety
8 ZX-135/70 Part No. 1258936

Second Edition • Third Printing Operator's Manual
Personal Safety
Part No. 1258936 ZX-135/70 9
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.
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 Second Edition • Third Printing
Work Area Safety
10 ZX-135/70 Part No. 1258936
WorkArea Safety
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 followed.
Line Voltage Required Clearance
0 to 50KV 3.05 m
50 to 200KV 4.60 m
200 to 350KV 6.10 m
350 to 500KV 7.62 m
500 to 750KV 10.67 m
750 to 1000KV 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 272 kg
Maximum occupants 2
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.

Second Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1258936 ZX-135/70 11
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
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 while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. The machine not level
indicator light will come on and the drive function in
one or both directions will not operate. Identify the
condition of the boom on the slope as shown
below. Follow the steps to lower the boom before
moving to a firm, level surface. Do not rotate the
boom while lowering.
The recovery mode should be used only by trained
and authorized personnel.
If the tilt alarm sounds with
the platform uphill:
1Lower the primary
boom.
2Lower the secondary
boom.
3Retract the primary
boom.
If the tilt alarm sounds with
the platform downhill:
1Retract the primary
boom.
2Lower the secondary
boom.
3Lower the primary
boom.
Do not raise the boom
when wind speeds may
exceed 12.5 m/s. If wind
speeds exceed 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.

Operator's Manual Second Edition • Third Printing
Work Area Safety
12 ZX-135/70 Part No. 1258936
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 – CE
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 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 use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight is
critical to stability.
Do not modify or alter an aerial 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.

Second Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1258936 ZX-135/70 13
Do not place or attach
fixed or overhanging loads
to any part of this
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
Platform downhill 45% (24°)
Platform uphill 30% (17°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.

Operator's Manual Second Edition • Third Printing
Work Area Safety
14 ZX-135/70 Part No. 1258936
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.
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.
Be aware of machine length when operating. The
machine is 12.9 m long.
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.

Second Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1258936 ZX-135/70 15
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 othe
r
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 Second Edition • Third Printing
Work Area Safety
16 ZX-135/70 Part No. 1258936
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, safety and responsibilities
manuals are 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. Apply jumper cables to
the starter and controls battery, not the auxiliary
power batteries.
Do not use the machine as a ground for welding
unless the machine is equipped with the weld line
to platform option and it is properly connected.
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.

Second Edition • Third Printing Operator's Manual
Work Area Safety
Part No. 1258936 ZX-135/70 17
Welder Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected and the welder is properly grounded.
The weight of the welder will reduce the rated
platform capacity and must be factored into the
total platform load. The welder power supply
weighs 34 kg.
Do not operate the welder unless a fire
extinguisher is immediately available for instant
use, per OSHA regulation 1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected.
Connect the positive lead to the twist-lock
connector at the turntable and platform.
Clamp the negative lead to the ground post at the
turntable and platform.
Lockout After Each Use
1Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2Retract and lower the boom to the stowed
position.
3Rotate the turntable so that the boom is
between the non-steer wheels.
4Turn the key switch to the off position and
remove the key to secure from unauthorized
use.

Operator's Manual Second Edition • Third Printing
Legend
18 ZX-135/70 Part No. 1258936
Legend
1Square-end tire
2Ground controls
3Secondary boom
4Primary boom
5Jib boom
6Platform
7Platform controls
8Sliding mid-rail
9Manual storage container
10 Lanyard anchorage points
11 Foot switch