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Genie ZX-135/70 with Jib-Extend Operator's Manual

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See also: Service & Repair Manual , Service Manual
Operator's Manual
ZX-135/70
with Jib-Extend
TM
CE
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1272823GT

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Summary of Contents for Genie ZX-135/70 with Jib-Extend

  • Page 1 Operator's Manual ZX-135/70 with Jib-Extend with Maintenance Information Original Instructions Third Edition First Printing Part No. 1272823GT...

  • Page 2: Table Of Contents

    Maintenance ............58 Specifications ............61 Copyright © 2011 by Terex Corporation Third Edition: First Printing, March 2017 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...

  • Page 3: Introduction

    This book is an operation and daily maintenance manual for the user or operator of a Genie Bulletin Distribution and machine. Compliance...
  • Page 4 Third Edition • First 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...
  • Page 5 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing General Safety 82472 133205 133067 General Safety 114249 114249 A 114252 82481 114252 A 82481 B 1256425 1263542 82487 82487 B 1263542 133067 82487 114252 82472 114252 82481 133205 1263542 1263542 114249 114249 1256425 ZX-135/70 Part No.
  • Page 9 Third Edition • First Printing Operator's Manual General Safety Part No. 1272823GT ZX-135/70...
  • Page 10 Operator's Manual Third Edition • First Printing General Safety ZX-135/70 Part No. 1272823GT...

  • Page 11: Personal Safety

    Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 14 Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Be sure all maintenance has been performed as Avoid spilling or contacting specified in this manual and the appropriate Genie battery acid. Neutralize service manual. battery acid spills with baking Be sure all decals are in place and legible.
  • Page 19 Third Edition • First 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 Third Edition • First 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. 1272823GT...

  • Page 21: Controls

    Third Edition • First Printing Operator's Manual Controls Controls Ground Control Panel Part No. 1272823GT ZX-135/70...
  • Page 22 Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Controls Platform Control Panel ZX-135/70 Part No. 1272823GT...
  • Page 25 Third Edition • First Printing Operator's Manual Controls 15 16 STOP Part No. 1272823GT ZX-135/70...
  • Page 26 Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Controls 22 Thumb rocker for jib boom extend/retract 19 Steer mode select switch with indicator lights function Move the steer Push the top of the rocker mode select switch switch and the jib boom will to choose steer retract.
  • Page 29 Third Edition • First 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 light Move the control handle up will flash while the axles and the primary boom will...

  • Page 30: Inspections

    Operator's Manual Third Edition • First 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 Third Edition • First Printing Operator's Manual Inspections  Platform load cell Pre-operation Inspection  Steer and axle sensors  Be sure that the operator’s, safety and  Alarms and beacons (if equipped) responsibilities manuals are complete, legible  Nuts, bolts and other fasteners and in the storage container located in the platform.
  • Page 32 Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Inspections Test the Drive Enable System Test Limited Drive Speed 65 Press down the foot switch and lower the boom 69 Press down the foot switch. to the stowed position. 70 Raise the primary boom to 10° above 66 Rotate the turntable until the primary boom horizontal.
  • Page 41 Third Edition • First 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 greater exceed 30 cm/s.
  • Page 42 Operator's Manual Third Edition • First 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 greater 93 With the boom fully stowed, drive the machine than 4.5°...
  • Page 43 Third Edition • First 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 greater 117 Push in the red Emergency Stop button to the than 4.5° along the X-Axis (side to side). off position to shut off the engine.
  • Page 44 Operator's Manual Third Edition • First Printing Inspections Test the Lift/Drive Select Function 125 Press down the foot switch. 126 Move the drive control handle off center and activate a boom function toggle switch. Result: No boom functions should operate. The machine will move in the direction indicated on the control panel.
  • Page 45 Third Edition • First 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 44981 Label — Air Line to Platform (option) 230985 Ground Control Panel 52475 Label — Transport Tie Down 1255581 Cosmetic — Genie 65278 Caution — No Step 1263542 Label — Compartment Access 72086 Label — Lifting Point 1263544 Bypass Key Switch 82247 Label —...
  • Page 47 Third Edition • First Printing Operator's Manual Inspections 133067 1255581 133205 1256425 82481 1263542 72086 160424 72086 114251 28159 1279245 40434 1271132 1279245 114249 114249 1263542 160683 133163 27207 27207 219974 27205 27205 65278 65278 218558 65278 65278 219956 52475 52475 114248 27207...

  • Page 48: Operating Instructions

    Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Operator's Manual Operating Instructions Operation from Platform To Drive Turn the key switch to platform control. Press down the foot switch. Pull out both ground and platform red Increase speed: Slowly move the drive Emergency Stop buttons to the on position. control handle in the direction indicated by the blue or yellow arrows.
  • Page 52 Operator's Manual Third Edition • First 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 Third Edition • First 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 Third Edition • First Printing Operating Instructions Platform Out of Level (P22 code) If the tilt alarm sounds with the platform uphill: Bypass key position to be used to level the platform Lower the primary if ground control display shows platform out of level boom.
  • Page 55 HIGH EXHAUST SYSTEM TEMP when the overloaded. For information on how to reset this regeneration mode is running. No service required. message, please consult the appropriate Genie Service Manual. Part No. 1272823GT ZX-135/70...
  • Page 56 Operator's Manual Third Edition • First Printing Operating Instructions Aircraft Protection Package If the tilt alarm sounds with the platform uphill: (if equipped) Lower the primary If the platform bumper comes boom. into contact with an object, the Lower the secondary machine will shut down and no boom.

  • Page 57: Transport And Lifting Instructions

    Winching  Genie customers needing to containerize any lift or Genie product should source a qualified Chock the wheels to prevent the machine from freight forwarder with expertise in preparing, rolling. loading and securing construction and lifting equipment for international shipment.
  • Page 58 Operator's Manual Third Edition • First 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 Third Edition • First 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

    Dispose of material in accordance with Oil type 15W-40 governmental regulations. Oil type - cold conditions 5W-30  Use only Genie approved replacement parts. Perkins 854F-34T Engine Oil type 15W-40 Maintenance Symbols Legend Oil type - cold conditions 5W-30 The following symbols have been used in this Deutz TD2.9L Engine...
  • Page 61 Third Edition • First 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 Third Edition • First 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: Specifications

    It should Hydraulic pressure, maximum 218 bar be used only with adequate safety factors. (auxiliary power unit) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 1272823GT ZX-135/70...
  • Page 64 Operator's Manual Third Edition • First Printing Specifications ZX-135/70 Range of Motion Chart ZX-135/70 Part No. 1272823GT Operator's Manual Third Edition • First Printing ZX-135/70 Part No. 1272823GT...
  • Page 65 www.genielift.com...

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