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First Edition • Seventh Printing

Operator's Manual

Transport and Lifting Instructions

Part No. 160567

ZX-135/70 61

Securing to Truck or Trailer for
Transit

Always use the turntable rotation lock pin each
time the machine is transported.

Turntable rotation lock pin

Turn the key switch to the off position and remove
the key before transporting.

Inspect the entire machine for loose or unsecured
items.

Securing the Chassis

Use chains of ample load capacity.

Use a minimum of 6 chains.

Adjust the rigging to prevent damage to the chains.

Securing the Platform

Place a block under the platform rotator. Do not
allow the block to contact the platform cylinder.

Secure the platform with a nylon strap placed
through the lower platform support. Do not use
excessive downward force when securing the
boom section.

Summary of Contents for X-135/70

Page 1: ...or s Manual Serial Number Range ZX 135 70 from ZX13513 2001 ANSI CSA North America South America Asia With Jib Extend with Jib Extend with Maintenance Information First Edition Seventh Printing Part No 160567 ...

Page 2: ...Work Area Safety 13 Legend 22 Controls 23 Inspections 31 Operating Instructions 48 Transport and Lifting Instructions 60 Maintenance 63 Specifications 67 Copyright 2012 by Terex Corporation First Edition Seventh Printing September 2015 Genie and ZX are registered trademarks of Terex South Dakota Inc in the U S A and many other countries These machines comply with ANSI SIA 92 5 CSA B 354 4 ...

Page 3: ...nded 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...

Page 4: ... 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 ...

Page 5: ...e 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 se...

Page 6: ...rd 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 ancho...

Page 7: ...e specifications 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 Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Retract lower secondary 3 Retract primary Platform downhill 1 Retract primary 2 Ret...

Page 8: ...rgy starting aids on machines equipped with glow plugs Electrocution BurnHazard Failure to disconnect all the batteries before performing service on this machine may result in death or serious injury Disconnect all the batteries before performing service on this machine WARNING 97865 B 1261816 or 1261817 229356 or 230977 1261816 or 1261817 Lug NutTorque Dry bolts 320 ft lbs 433 9Nm Foam FilledTire...

Page 9: ...First Edition Seventh Printing Operator s Manual General Safety Part No 160567 ZX 135 70 7 ...

Page 10: ...ion BurnHazard Failure to disconnect all the batteries before performing service on this machine may result in death or serious injury Disconnect all the batteries before performing service on this machine WARNING 97865 B Tip over Hazard Altering or disabling angle sensor can result in machine tip over Machine tip over will result in death or serious injury DANGER Do not move alter or disable angl...

Page 11: ...First Edition Seventh Printing Operator s Manual General Safety Part No 160567 ZX 135 70 9 ...

Page 12: ...Operator s Manual First Edition Seventh Printing General Safety 10 ZX 135 70 Part No 160567 ...

Page 13: ...First Edition Seventh Printing Operator s Manual General Safety Part No 160567 ZX 135 70 11 ...

Page 14: ... 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...

Page 15: ...f 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 600 lbs 272 kg Ma...

Page 16: ...e primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Retract lower the secondary boom 3 Lower the primary boom Do not raise the boom when wind speeds may exceed 28 mph 12 5 m s If wind speeds exceed 28 mph 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 i...

Page 17: ...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 m...

Page 18: ...itions and adequate traction See Driving on a Slope in the Operating Instructions section 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 w...

Page 19: ...s must comply with employer job site and governmental rules regarding use of personal protective equipment 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 loc...

Page 20: ...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 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 eac...

Page 21: ...will reduce rated platform capacity and must be factored into total platform load The pipe cradle assembly weighs 21 lbs 9 5 kg The maximum capacity of the pipe cradle assembly is 200 lbs 91 kg The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform Center the load within the perimeter of the platform Secure the load to the plat...

Page 22: ...rate unless you are adequately instructed and are aware of all hazards associated with lifting panels Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Maximum vertical height of panels 4 ft 1 2 m Maximum wind speed 15 mph 6 7 m sec Maximum panel area 32 sq ft 3 m2 Welder Safety Read understand and obey all warnings and instructions provided...

Page 23: ...rate 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 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that t...

Page 24: ...ting Legend 22 ZX 135 70 Part No 160567 Legend 1 Square end tire 2 Ground controls 3 Secondary boom 4 Primary boom 5 Jib boom 6 Platform 7 Platform controls 8 Sliding mid rail 9 Manual storage container 10 Lanyard anchorage points 11 Foot switch ...

Page 25: ...utton and the turntable will rotate right 2 Turntable rotate left button Press the turntable rotate left button and the turntable will rotate left 3 Secondary boom up extend and down retract buttons Push the secondary boom up extend button and the secondary boom will raise and then extend Push the secondary boom down retract button and the secondary boom will retract and then lower ...

Page 26: ...ff ground platform selection Turn the key switch to the off position and the machine will be off Turn the key switch to the ground position and the ground controls will operate Turn the key switch to the platform position and the platform controls will operate 11 Engine start button Press the engine start button to start the engine 12 Jib boom up down buttons Press the jib boom up button and the j...

Page 27: ...the jib boom will extend Press the jib boom retract button and the jib boom will retract 21 High speed function enable button Press the high speed function enable button to enable the functions on the ground control panel to operate at high speed 22 Low speed function enable button Press the low speed function enable button to enable the functions on the ground control panel to operate at low spee...

Page 28: ...Operator s Manual First Edition Seventh Printing Controls 26 ZX 135 70 Part No 160567 Platform Control Panel 1 2 3 4 5 6 7 8 9 22 24 25 28 23 26 27 ...

Page 29: ...First Edition Seventh Printing Operator s Manual Controls Part No 160567 ZX 135 70 27 STOP 18 10 11 14 12 13 15 16 17 20 19 21 ...

Page 30: ...wer if the primary power source engine fails Simultaneously move the emergency power switch and activate the desired function The indicator light will be on when emergency power is being used 9 Diesel models Glow plug button with indicator light Press the glow plug button and hold for 3 to 5 seconds The glow plug indicator light will be on when the glow plugs are being used Diesel models Automatic...

Page 31: ... will steer to the left Move the control handle in the direction indicated by the yellow triangle and the machine will steer to the right OR Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Press the left side of the...

Page 32: ...ile the axles are retracting and stay on when the axles are fully retracted 25 Drive enable switch with indicator light Light on indicates that the primary boom has moved past either circle end wheel and the drive function is turned off To drive move the drive enable switch and slowly move the drive control handle off center 26 Thumb rocker switch for primary boom extend retract function Push the ...

Page 33: ...n is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthori...

Page 34: ...nce section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit switches and horn Rotation sensors Ste...

Page 35: ...e the machine as it was intended 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 tagged and removed from service Repairs to the machine may o...

Page 36: ...h the axles retracted 7 At the ground controls push and hold a function enable speed select button and push the primary boom up button Result The primary boom should not raise On the LCD screen the arrow next to the extend axle symbol will flash The boom should not raise unless the axles are extended 8 Push and hold a function enable speed select button and press the secondary boom raise extend bu...

Page 37: ...ld extend The indicator light will flash while the axles are moving and stay on when the axles are fully extended 13 Return to the ground controls Turn the key switch to ground control 14 Push and hold a function enable speed select button and push the primary boom up button and then the primary boom down button Result The primary boom should raise and lower normally 15 Push and hold a function en...

Page 38: ...o the off position to shut off the engine 21 Pull out the red Emergency Stop button to the on position 22 Simultaneously push and hold the emergency power button and push each boom function button Note To conserve battery power test each function through a partial cycle Result All boom functions should operate 23 Start the engine Test the Tilt Sensor 24 Press one of the LCD screen control buttons ...

Page 39: ...ly press the 2 LCD screen control buttons shown to activate status mode 31 Press the LCD screen control buttons shown until SEC BOOM ANGLE is displayed 32 Press and hold the secondary boom up extend button Result The secondary boom should raise and the LCD screen should display the secondary boom angle in degrees The secondary boom should raise and then extend The secondary boom should not extend ...

Page 40: ...arm should sound at the platform controls Test the Foot Switch 39 Push in the platform red Emergency Stop button to the off position 40 Pull out the red Emergency Stop button to the on position and do not start the engine 41 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 42 Do not press down the foot sw...

Page 41: ...h and choose circle end yellow arrow steer 51 Press down the foot switch 52 Slowly move the control handle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The circle end wheels should turn in the direction that the blue triangles point on the drive chassis 53 Slowly move the drive contr...

Page 42: ...the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The square end wheels should turn in the direction that the yellow triangles point on the drive chassis The circle end wheels should turn in the direction that the blue triangles point on the drive chassis Test Drive and Braking 62 Press down...

Page 43: ... arrows on the platform controls and the drive chassis to identify the direction of travel If the drive control handle is not moved within two seconds of moving the drive enable toggle switch the drive function will not operate Test Limited Drive Speed 69 Press down the foot switch 70 Raise the primary boom to 5 above horizontal 71 Slowly move the drive control handle to the full drive position Re...

Page 44: ...d 6 inches 15 cm per second If the drive speed with the jib boom extended and the primary boom extended exceeds 6 inches 15 cm per second immediately tag and remove the machine from service 83 Retract the primary boom and the jib boom Test Emergency Controls 84 Push in the red Emergency Stop button to the off position to shut off the engine 85 Pull out the red Emergency Stop button to the on posit...

Page 45: ...ator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situation...

Page 46: ...evel 1 97815 Label Lower Mid rail 1 97865 Warning Electrocution Hazard 2 97875 Warning Weld Line to Platform option 2 114258 Danger Explosion Hazard 1 Part No Decal Description Qty 114390 Danger Electrocution Hazard 3 1261816 Danger Tire Specifications Foam Filled 4 1261817 Danger Tire Specifications Solid Rubber 4 128953 Instructions Deutz Engine Specs 1 133163 Label Function Override Aircraft Pr...

Page 47: ...44981 40434 65278 65278 27204 27205 44981 114390 97875 97875 160425 160682 97815 160683 31788 133163 97579 82862 82366 82237 72875 82410 229356 or 230977 218559 160575 114390 160580 65278 52475 1263543 160683 72086 160424 160682 114258 28159 97865 1000083 160654 114390 82237 27206 27207 52475 52475 65278 65278 52475 65278 52475 826345 229356 or 230977 or 1261816 or 1261817 or 1261816 or 1261817 22...

Page 48: ...Manual 2 82487 Label Read the Manual pipe cradle 2 82487 Label Read the Manual panel cradle 2 Part No Decal Description Qty 97757 Label Hydraulic Oil Level 1 97815 Label Lower Mid rail 1 114248 Label Tip over Hazard Tilt Alarm 1 114249 Label Tip over Hazard Tires 4 114251 Label Explosion Hazard 1 114252 Label Tip over Hazard Limit Switches 3 133067 Label Electrocution Hazard 3 133163 Label Functio...

Page 49: ...el 133205 28174 or 28235 44981 40434 44981 1263542 133067 160425 160682 160683 82481 82487 82487 114249 114249 114249 219958 114248 1263542 160683 72086 160424 160682 114251 28159 133205 133067 114249 27207 27204 27206 27206 27205 27207 65278 65278 27204 27205 65278 52475 27206 27207 52475 52475 65278 65278 52475 65278 52475 133163 114252 97815 160577 133067 1253542 1263542 1263542 1263545 1263544...

Page 50: ...he operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a...

Page 51: ... Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hyd...

Page 52: ...h on and activate the desired function The drive functions will not operate with emergency power To Extend and Retract Axles 1 Turn the key switch to platform control 2 At the platform controls press down the foot switch and move the drive control handle in either direction and move the axle switch in the appropriate direction The indicator light will flash while the axles are moving and stay on w...

Page 53: ...ext to the current steer mode will be on 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slo...

Page 54: ...e slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the vertical d...

Page 55: ...ve enable switch again Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel When the drive enable light is on the axles cannot retract Engine Idle Select rpm Select the engine idle rpm by pressing the engine...

Page 56: ... Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing If the tilt alarm sounds with the platform uphill 1 Lower the primary boom 2 Retract lower the secondary boom 3 Retract the primary boom 4 Move the machine to a firm level surface If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Retract lower the secondary boom 3 ...

Page 57: ...om service until the fault has been corrected by a qualified service technician Platform Out of Level Platform Level 15 Degrees Fault If ground control display shows PLATFORM LEVEL 15 DEGREES FAULT and the platform level controls do not work the machine will need to be recovered by trained and authorized personnel or a qualified service technician Generator if equipped To operate the generator mov...

Page 58: ...t switch 3 Move and hold the aircraft protection override switch 4 Move the appropriate function control handle or toggle switch to move the machine away from aircraft components After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the non steer whee...

Page 59: ...rve and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on the platform floor Be sure the platform is level before installing a pipe cradle Pipe Cradle Installation 1 Install a pipe cradle on each side of the platform Refer to the illustration on the left Mak...

Page 60: ...es may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 200 lbs 90 7 kg Pipe Cradle Assembly Weight 21 lbs 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to the front of each panel cradle if needed 2 Install rubber bumper 1 in the panel cradle base See the illustration 3 Secure the bumper with 2 high profile lock nuts and 2 washers Panel Cradle ...

Page 61: ... one side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly end plate should be able to slide on the platform rail Panel Cradle Operation 1 Secure both panel cradles to the platform 2 Place the load so that it rests in both panel cradles 3 Center the load on...

Page 62: ...e is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight 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 e...

Page 63: ...ition and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 6 chains Adjust the rigging to prevent damage to the chains Securing the Platform Place a block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed th...

Page 64: ... to withstand the machine weight See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the machine There are four lifting points on the machine o...

Page 65: ...a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the mac...

Page 66: ...tz TD2 9L Engine Fuel Type Ultra Low Sulfur Diesel ULSD Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed...

Page 67: ... degas tank are under pressure and extremely hot Use caution when removing cap and adding fluids Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or seri...

Page 68: ...erly 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 69: ... Platform rotation 160 AC outlet in platform standard Fuel tank capacity 40 gallons 151 liters Hydraulic pressure maximum boom functions 2 900 psi 203 bar Hydraulic pressure maximum emergency power unit 3 100 psi 218 bar System voltage 12V Tire size 445 65 D22 5 or 445D50 710 18 ply FF Weight 45 100 lbs 20 457 kg Machine weights vary with option configurations See serial label for specific machine...

Page 70: ...Operator s Manual First Edition Seventh Printing Specifications 68 ZX 135 70 Part No 160567 ZX 135 70 Range of Motion Chart ZX 135 70 Part No 160567 Operator s Manual First Edition Seventh Printing ...

Page 71: ...stributed By www genielift com California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

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