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

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Operator's Manual

-135/70

from ZX135H-4001

ANSI/CSA
North

America

South

America

Asia

with Jib - Extend

with
Maintenance
Information

Original Instructions
Second Edition
Third Printing
Part No. 1272822GT

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

Page 1: ...perator s Manual ZX 135 70 from ZX135H 4001 ANSI CSA North America South America Asia with Jib Extend with Maintenance Information Original Instructions Second Edition Third Printing Part No 1272822GT...

Page 2: ...rk Area Safety 16 Legend 26 Controls 27 Inspections 36 Operating Instructions 57 Transport and Lifting Instructions 71 Maintenance 74 Specifications 78 Copyright 2012 by Terex Corporation Second Editi...

Page 3: ...Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s resp...

Page 4: ...ine movement Platform level Platform rotate Jib boom up down Primary boom up down Turntable rotate Secondary boom raise extend Secondary boom retract lower Primary boom extend retract Jib boom extend...

Page 5: ...d movement Drive steer secondary boom raise extend and secondary boom retract lower Interlocked functions Elevated drive speed Elevated drive in an off level condition Drive enable when the boom is ro...

Page 6: ...ction indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com Contacting the Manufacturer At times it may be necessary to contact Genie...

Page 7: ...ons You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Safety Sign Maintenance Replace any missing or damaged safety signs Keep...

Page 8: ...ep 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...

Page 9: ...ions Part No 1272822GT ZX 135 70 7 Fire hazard No smoking Explosion hazard No step Lanyard anchorage points Platform tie down instructions Lifting tie down instructions Tie down point Lifting point Wi...

Page 10: ...sure rating for air line to platform Tire specifications Runaway hazard Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Retract lower secondary 3 Retract prima...

Page 11: ...Second Edition Third Printing Operator s Manual General Safety Part No 1272822GT ZX 135 70 9 General Safety...

Page 12: ...Operator s Manual Second Edition Third Printing General Safety 10 ZX 135 70 Part No 1272822GT...

Page 13: ...Second Edition Third Printing Operator s Manual General Safety Part No 1272822GT ZX 135 70 11...

Page 14: ...Operator s Manual Second Edition Third Printing General Safety 12 ZX 135 70 Part No 1272822GT...

Page 15: ...Second Edition Third Printing Operator s Manual General Safety Part No 1272822GT ZX 135 70 13...

Page 16: ...Operator s Manual Second Edition Third Printing General Safety 14 ZX 135 70 Part No 1272822GT...

Page 17: ...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 gov...

Page 18: ...form 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...

Page 19: ...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 sou...

Page 20: ...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 replac...

Page 21: ...ing 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 down...

Page 22: ...machine is in the stowed position and the platform is at ground level Hazards related with the specific product application of exiting at height have been considered in the design of the machine for f...

Page 23: ...rbon 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 c...

Page 24: ...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...

Page 25: ...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 we...

Page 26: ...cal 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 with the welding powe...

Page 27: ...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...

Page 28: ...26 ZX 135 70 Part No 1272822GT Legend 1 Square end tire 2 Ground controls 3 Secondary boom 4 Primary boom 5 Jib boom 6 Platform 7 Circle end tire 8 Platform controls 9 Sliding mid rail 10 Manual stora...

Page 29: ...e 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 platfor...

Page 30: ...elect button to select the engine speed When the arrow above the rabbit is lit the engine is in high idle speed When the arrow above the turtle is lit the engine is in low idle speed 7 LCD readout scr...

Page 31: ...tform out of level P22 and platform level controls do not work Refer to the operating instructions Recovery key position should be used only by trained and authorized personnel 18 Platform rotate righ...

Page 32: ...Operator s Manual Second Edition Third Printing Controls 30 ZX 135 70 Part No 1272822GT Platform Control Panel 1 2 3 4 5 6 7 8 9 22 24 25 28 23 26 27...

Page 33: ...Second Edition Third Printing Operator s Manual Controls Part No 1272822GT ZX 135 70 31 STOP 18 10 11 14 12 13 15 16 17 20 19 21...

Page 34: ...light if equipped Move the generator switch to turn the generator on Move the switch again to turn the generator off 8 Auxiliary power switch with indicator light Use auxiliary power if the primary p...

Page 35: ...f Pull out the red Emergency Stop button to the on position to operate the machine 18 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive funct...

Page 36: ...om of the rocker switch and the jib boom will extend 23 Dual axis proportional control handle for jib boom up down and platform rotate left right functions Move the control handle up and the jib boom...

Page 37: ...le for primary boom up down and turntable rotate left right functions Move the control handle up and the primary boom will raise Move the control handle down and the primary boom will lower Move the c...

Page 38: ...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 pr...

Page 39: ...on 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 c...

Page 40: ...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 ste...

Page 41: ...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 arro...

Page 42: ...and the axles should 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 contr...

Page 43: ...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 auxiliary power button and push each boom function button Note...

Page 44: ...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 b...

Page 45: ...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...

Page 46: ...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 roc...

Page 47: ...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 d...

Page 48: ...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 driv...

Page 49: ...ds 6 inches 15 cm per second immediately tag and remove the machine from service 83 Retract the primary boom and the jib boom Test Drive Tilt Cutout 84 Press down the foot switch 85 With the boom full...

Page 50: ...chassis angle is greater than 4 5 along the Y Axis front to back Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 99 Retr...

Page 51: ...condary boom to approximately 5 above horizontal 111Drive the machine onto a slope where the chassis angle is greater than 4 5 along the X Axis side to side Result The machine should stop once the mac...

Page 52: ...from the switch socket Result The contact alarm lights will not flash and the machine horn will not sound 123Activate the foot switch by pressing the foot switch down Result The contact alarm lights w...

Page 53: ...1 Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction 2 Activate each function control handle toggle switch or thumb rocker switch Result No boom and steer functions...

Page 54: ...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 a...

Page 55: ...Protection Package 1 133236 Danger Tip over Hazard 1 160576 Danger Maximum Capacity Wind Manual Force 1 Part No Decal Description Qty 160580 Warning Slope Rating 1 160683 Label Transport Diagram 2 16...

Page 56: ...683 1281174 72086 28159 114258 97865 1000083 826345 160424 114390 82237 1263543 1255581 1255581 31788 72875 82410 1279245 52865 44981 160683 1263543 28174 28235 1261816 1279245 1263543 31788 72086 127...

Page 57: ...el Explosion Hazard 1 114252 Label Tip over Hazard Limit Switches 5 133067 Label Electrocution Hazard 3 Part No Decal Description Qty 133163 Label Function Override Aircraft Protection Package 1 13320...

Page 58: ...1 97815 133163 218558 160578 133067 160579 28235 1279245 114249 1279245 114249 1263542 160683 1281174 1281175 72086 28159 114251 133205 160424 133067 1256425 1263542 1255581 1255581 82481 82487 82487...

Page 59: ...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 wit...

Page 60: ...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...

Page 61: ...ch on and activate the desired function The drive function will not operate with auxiliary power To Extend and Retract Axles 1 Turn the key switch to platform control 2 At the platform controls press...

Page 62: ...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 cont...

Page 63: ...eight uphill configuration only Be sure the boom is below horizontal and the platform is between the circle end wheels Move the drive speed select switch to machine on incline symbol To determine the...

Page 64: ...ansport and Lifting section Tilt Sensor Activation Settings Chassis Angle front to back Max Height Max Reach 5 126 ft 38 4 m 71 ft 21 6 m 2 135 ft 41 1 m 70 ft 21 3 m When the Machine On Incline indic...

Page 65: ...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...

Page 66: ...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 s...

Page 67: ...from 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...

Page 68: ...ns will operate 1 Start the engine 2 Press down the foot switch 3 Move and hold the aircraft protection override switch 4 Move the appropriate function control handle or toggle switch to move the mach...

Page 69: ...te alerting others that assistance may be needed These notifications will continue until the system is reset 1 The contact alarm cable is tripped releasing the actuator from the switch socket 2 Insert...

Page 70: ...ion instructions have been followed properly and that the pipe cradles are secured to the platform railings 2 Place the load so that it rests in both pipe cradles The length of the load should be para...

Page 71: ...panel cradle is not installed at a platform floor support tube use the aluminum tube provided 8 Place the tube between the panel cradle and the platform floor Insert the U bolt through the floor arou...

Page 72: ...rface 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 wheels 4 Turn the key switch to the off posi...

Page 73: ...the machine 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...

Page 74: ...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...

Page 75: ...ent 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 Determin...

Page 76: ...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...

Page 77: ...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...

Page 78: ...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 s...

Page 79: ...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 Ma...

Page 80: ...ht 46 500 lbs 21 092 kg Machine weights vary with option configurations See serial label for specific machine weight Ambient operating temperature 20 F to 120 F 29 C to 49 C Note Low end of temperatur...

Page 81: ...tion Chart Max Height Max Reach 1 135 ft 41 1 m 10 0 ft 0 m 2 115 ft 35 1 m 11 10 ft 3 0 m 3 95 ft 29 0 m 12 30 ft 9 1 m 4 75 ft 22 9 m 13 50 ft 15 2 m 5 55 ft 16 8 m 14 70 ft 21 3 m 6 35 ft 10 7 m 7...

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