Terex Genie ZX-135/70 Operator's Manual
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Terex Genie ZX-135/70 Operator's Manual

With jib - extend
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Operator's Manual
ZX
-135/70
®
with Jib - Extend
Serial Number Range
from ZX135H-4001
®
CE
with
Maintenance
Information
Original Instructions
Third Edition
Third Printing
Part No. 1272823GT

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Summary of Contents for Terex Genie ZX-135/70

  • Page 1 Operator's Manual Serial Number Range -135/70 ® from ZX135H-4001 with Jib - Extend ® with Maintenance Information Original Instructions Third Edition Third Printing Part No. 1272823GT...

  • Page 2: Table Of Contents

    Specifications ............74 Copyright © 2011 by Terex Corporation Third Edition: Third Printing, October 2020 Genie and "ZX" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with Complies with EC Directive 2006/42/EC See EC Declaration of Conformity ®...

  • Page 3: Introduction

    Third Edition• Third Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Third Edition• Third Printing Operator's Manual Introduction Platform controls symbology and related Primary boom extend/retract machine movement: Platform level Jib boom extend/retract Platform rotate Jib boom up/down Axle extend Primary boom up/down Turntable rotate Axle retract Drive forward/reverse Secondary boom raise/extend Secondary boom retract/lower ®...
  • Page 5 Third Edition• Third Printing Operator's Manual Introduction Steer right/left Ground controls symbology and related machine movement: Platform level, jib boom up/down, primary boom Square end steer extend/retract, primary boom up/down, secondary boom raise/extend, and secondary boom retract/lower. Circle end steer Turntable rotate, platform rotate, and jib boom extend/retract.
  • Page 6 Third Edition• Third Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 7 Third Edition• Third Printing Operator's Manual Introduction 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.
  • Page 8 Third Edition• Third Printing Operator's Manual Introduction 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.

  • Page 9: Symbol And Hazard Pictorials Definitions

    Third Edition• Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Crush hazard Keep away from Crush hazard Overhead Collision hazard moving parts obstruction Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Read the operator’s...
  • Page 10 Third Edition• Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Fire hazard No smoking Explosion hazard No step Lanyard anchorage points Platform tie-down Lifting & tie down instructions Tie-down point Lifting point instructions Wind speed Maximum capacity Manual force Wheel load Weight of welder reduces capacity...
  • Page 11 Third Edition• Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Do not use ether or Voltage rating for Pressure rating for air Tire specifications Runaway hazard other high energy power to platform line to platform starting aids on machines equipped with glow plugs.

  • Page 12: General Safety

    Third Edition• Third Printing Operator's Manual General Safety Gener al Safety ® -135/70 Part No. 1272823GT...
  • Page 13 Third Edition• Third Printing Operator's Manual General Safety ® Part No. 1272823GT -135/70...
  • Page 14 Third Edition• Third Printing Operator's Manual General Safety ® -135/70 Part No. 1272823GT...

  • Page 15: Personal Safety

    Third Edition• Third Printing Operator's Manual Personal Safety Pers onal 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 16: Work Area Safety

    Third Edition• Third Printing Operator's Manual Work Area Safety Wor k Ar ea 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 17 Third Edition• Third 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. Retract/lower the secondary boom.
  • Page 18 Third Edition• Third Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Use extreme care and in 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 19 Third 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 machine.
  • Page 20 Third Edition• Third Printing Operator's Manual 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 rotating the turntable.
  • Page 21 Third Edition• Third 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 22 Third Edition• Third Printing Operator's Manual Work Area Safety Damaged Machine Hazards Contact Alarm Safety Do not use a damaged or malfunctioning machine. Read, understand and obey all warnings and instructions provided with the contact alarm. Conduct a thorough pre-operation inspection of the machine and test all functions before each Do not exceed the rated platform capacity.
  • Page 23 Third Edition• Third Printing Operator's Manual Work Area Safety Battery Safety Pipe Cradle Safety Read, understand, and obey all warnings and Burn Hazards instructions provided with the pipe cradles. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective pipe cradle assembly and the weight in the pipe clothing and eye wear when...
  • Page 24 Third Edition• Third Printing Operator's Manual Work Area Safety Panel Cradle Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the panel cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 25 Third Edition• Third Printing Operator's Manual Work Area Safety Weld Line to Platform 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 26: Legend

    Third Edition• Third Printing Operator's Manual Legend Leg end Square-end tire Circle-end tire Ground controls Platform controls Secondary boom Sliding mid-rail Primary boom 10 Manual storage container Jib boom 11 Lanyard anchorage points Platform 12 Foot switch ® -135/70 Part No. 1272823GT...

  • Page 27: Controls

    Third Edition• Third Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 28 Third Edition• Third Printing Operator's Manual Controls Ground Control Panel LCD readout screen 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 29 Third 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 30 Third Edition• Third Printing Operator's Manual Controls Platform Control Panel ® -135/70 Part No. 1272823GT...
  • Page 31 Third Edition• Third Printing Operator's Manual Controls ® Part No. 1272823GT -135/70...
  • Page 32 Third Edition• Third Printing Operator's Manual Controls Platform Control Panel Diesel models: Glow plug button with indicator light Horn button Press the glow plug button and hold for 3 to Press this button and the horn will sound. 5 seconds. The glow plug indicator light will be Release the button and the horn will stop.
  • Page 33 Third Edition• Third Printing Operator's Manual Controls 15 Low fuel indicator light 19 Steer mode select switch with indicator lights Light on indicates the machine is low on fuel. Move the steer 16 Fault indicator light mode select switch to choose steer Light on indicates a system fault.
  • Page 34 Third Edition• Third Printing Operator's Manual Controls 23 Dual axis proportional control handle for jib 26 Thumb rocker switch for primary boom boom up/down and platform rotate left/right extend/retract function functions Push the top of the rocker Move the control handle switch and primary boom up and the jib boom will will retract.

  • Page 35: Inspections

    Third Edition• Third Printing Operator's Manual Inspections Ins pections 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 36 Third Edition• Third Printing Operator's Manual Inspections Pre-operation Inspection  Steer and axle sensors  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 37 Third Edition• Third Printing Operator's Manual 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 38 Third Edition• Third Printing Operator's Manual Inspections At the Ground Controls Test the Extendable Axles Note: Start this test with the axles retracted. Select a test area that is firm, level and free of hazards. At the ground controls, push and hold a function enable/speed select button and push Turn the key switch to ground control.
  • Page 39 Third Edition• Third Printing Operator's Manual 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 and push the primary boom up button button. and then the primary boom down button. Result: The turntable should rotate 15°...
  • Page 40 Third 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 41 Third Edition• Third Printing Operator's Manual Inspections Test the Operating Envelope At the Platform Controls 27 Press the LCD screen Test Emergency Stop control buttons shown until PRI BOOM ANGLE TO 34 Turn the key switch to platform control. GRAVITY is displayed. 35 Push in the platform red Emergency Stop button to the off position.
  • Page 42 Third Edition• Third Printing Operator's Manual Inspections Test the Foot Switch Test the Steering 39 Push in the platform red Emergency Stop 46 Move the steer button to the off position. mode select switch and choose 40 Pull out the red Emergency Stop button to the square-end (blue on position and do not start the engine.
  • Page 43 Third Edition• Third Printing Operator's Manual Inspections 53 Slowly move the drive control handle in the 58 Move the steer direction indicated by the blue triangle on the mode select switch control panel OR press the thumb rocker and choose switch in the direction indicated by the blue coordinated steer.
  • Page 44 Third Edition• Third Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 62 Press down the foot switch. 65 Press down the foot switch and lower the boom to the stowed position. 63 Slowly move the drive control handle in the direction indicated by the blue arrow on the 66 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 45 Third Edition• Third Printing Operator's Manual Inspections Test Limited Drive Speed 77 Slowly move the drive control handle to the full drive position. 69 Press down the foot switch. Result: The maximum achievable drive speed 70 Raise the primary boom to 5° above with the secondary boom raised should not horizontal.
  • Page 46 Third Edition• Third Printing Operator's Manual Inspections Test Drive Tilt Cutout 92 Return to level ground and stow the boom. 84 Press down the foot switch. 93 With the boom fully stowed, drive the machine onto a slope where the chassis angle is 85 With the boom fully stowed, drive the machine greater than 4.5°...
  • Page 47 Third Edition• Third Printing Operator's Manual Inspections 99 Retract the jib boom to the stowed position or 106 Drive the machine onto a slope where the drive in the opposite direction. chassis angle is greater than 4.5° along the X- Axis (side to side).
  • Page 48 Third Edition• Third Printing Operator's Manual Inspections Test the Contact Alarm (if equipped) 112 Lower the secondary boom to the stowed position or drive in the opposite direction. 122 Do not activate the foot switch and press on the contact alarm cable to release the actuator Result: The alarm should turn off and the from the switch socket.
  • Page 49 Third Edition• Third Printing Operator's Manual Inspections Test Aircraft Protection Package 126 Operate each machine function. (if equipped) Result: All machine functions should not Note: Two people may be required to perform this operate. test. 127 Insert the actuator into the switch socket. 129 Move the yellow bumper at the bottom of the Result: The lights and horn will turn off.
  • Page 50 Third 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 51 Third Edition• Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols Label – Electrocution Hazard 133067 Label – Function Override (Aircraft 133163 Use the pictures on the next page to verify that all Protection Package)* decals are legible and in place.
  • Page 52 Third Edition• Third Printing Operator's Manual Inspections ® -135/70 Part No. 1272823GT...

  • Page 53: Operating Instructions

    Third Edition• Third Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons 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 54 Third 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 55 Third Edition• Third Printing Operator's Manual 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 56 Third Edition• Third Printing Operator's Manual Operating Instructions To Steer Operation from Ground Press down the foot switch. Turn the key switch to ground control. Select the steer mode by moving the steer Pull out the red Emergency Stop button to the mode switch.
  • Page 57 Third Edition• Third Printing Operator's Manual Operating Instructions Driving on a slope Tilt Sensor Activation Settings Determine the uphill, downhill and side slope Chassis Angle Max Height Max Reach ratings for the machine and determine the slope (front to back) grade.
  • Page 58 Third Edition• Third Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the primary use the following procedure. boom has moved past either circle-end wheel and the drive You will need: function is turned off.
  • Page 59 Third Edition• Third Printing Operator's Manual Operating Instructions Engine Idle Select (rpm) If the tilt alarm sounds with the platform uphill: Select the engine idle (rpm) by pressing the engine idle select Lower the primary boom. switch. The indicator light next to Retract/lower the the current setting will be on.
  • Page 60 Third Edition• Third Printing Operator's Manual Operating Instructions Standstill Regeneration The DPF standstill regeneration cannot begin until the engine has been run for at least two When the LCD screen displays the message minutes and the coolant temperature has "Regen Required" and the Regeneration lamp is reached 35°C.
  • Page 61 Third Edition• Third Printing Operator's Manual Operating Instructions The LCD screen displays the message 13 If the Regeneration process has begun NOTICE: ALL FUNCTIONS WILL BE successfully, the LCD screen displays the LOCKED. REGEN WILL TAKE APPROX. 1 message REGEN TIME REMAINING. HOUR.
  • Page 62 Third Edition• Third 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 LEVEL >...
  • Page 63 Third Edition• Third Printing Operator's Manual Operating Instructions Platform Overload Indicator Light LCD Screen (if equipped) The LCD screen displays hour meter, voltage, oil Light flashing indicates the pressure and coolant temperature. The screen platform is overloaded and no also displays fault codes and other service functions will operate.
  • Page 64 Third Edition• Third Printing Operator's Manual Operating Instructions Aircraft Protection Package (if equipped) Machine Not Level Indicator Light If the platform bumper comes If the tilt alarm sounds when the into contact with an object, the platform is raised, the Machine Not machine will shut down and no Level indicator light will come on functions will operate.
  • Page 65 Third Edition• Third Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Pipe Cradle Instructions The contact alarm is designed to alert ground The pipe cradle assembly consists of 2 pipe personnel when an operator makes contact with cradles positioned at either side of the platform the platform control panel, interrupting boom and mounted to the guardrails with U-bolts.
  • Page 66 Third Edition• Third Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation  Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
  • Page 67 Third Edition• Third Printing Operator's Manual Operating Instructions Panel Cradle Assembly Installation of Padding Apply the warning decal to the front of each Install the 2 pieces of padding on the platform panel cradle (if needed). rails. Position the padding to protect the panels from contact with the platform rails.
  • Page 68 Third Edition• Third Printing Operator's Manual 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 69: Transport And Lifting Instructions

    Third Edition• Third Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 70 Third Edition• Third Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 71 Third Edition• Third Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 72: Maintenance

    Third Edition• Third Printing Operator's Manual Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 73 Third 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 74 Third Edition• Third Printing Operator's Manual 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 75 Third 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 76: Specifications

    Third Edition• Third Printing Operator's Manual Specifications Specific ati ons Ambient operating -20° F to 120° F Model ZX-135/70 temperature -29° C to 49° C Height, working maximum 141 ft 43.15 m Note: Low end of temperature range requires the use of Height, platform maximum 135 ft 41.15 m...
  • Page 77 Third Edition• Third Printing Operator's Manual Specifications ZX-135 Range of Motion Chart Max Height Max Reach 135 ft 41.1 m 0 ft 115 ft 35.1 m 10 ft 3.0 m 95 ft 29.0 m 30 ft 9.1 m 75 ft 22.9 m 50 ft 15.2 m...
  • Page 78 Third Edition• Third Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

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