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Second Edition • Third Printing

Operator's Manual

Maintenance

Part No. 1258936

ZX-135/70 61

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.

Содержание Genie ZX-135/70

Страница 1: ...Operator s Manual Serial Number Range ZX 135 70 from ZX13515 2559 CE With Jib Extend with Jib Extend with Maintenance Information Original Instructions Second Edition Third Printing Part No 1258936...

Страница 2: ...Safety 10 Legend 18 Controls 19 Inspections 28 Operating Instructions 46 Transport and Lifting Instructions 55 Maintenance 58 Specifications 62 Copyright 2011 by Terex Corporation Second Edition Third...

Страница 3: ...ded 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 paramo...

Страница 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 thi...

Страница 5: ...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 avoi...

Страница 6: ...d 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...

Страница 7: ...fications 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 Retract lower seconda...

Страница 8: ...Operator s Manual Second Edition Third Printing General Safety 6 ZX 135 70 Part No 1258936 General Safety...

Страница 9: ...Second Edition Third Printing Operator s Manual General Safety Part No 1258936 ZX 135 70 7...

Страница 10: ...Operator s Manual Second Edition Third Printing General Safety 8 ZX 135 70 Part No 1258936...

Страница 11: ...ccupants 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 gover...

Страница 12: ...lectrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the...

Страница 13: ...ate Identify the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering The recovery mode shou...

Страница 14: ...o not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace...

Страница 15: ...platform Do not use the machine on a moving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Operation on Slopes Hazards Do not drive the machine on a sl...

Страница 16: ...atform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Collision Hazards Be a...

Страница 17: ...bon 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 ca...

Страница 18: ...e 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 contro...

Страница 19: ...ailable for instant use per OSHA regulation 1926 352 d Weld Line to Platform Safety Read understand and obey all warnings and instructions provided with the welding power unit Do not connect weld lead...

Страница 20: ...ng Legend 18 ZX 135 70 Part No 1258936 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 containe...

Страница 21: ...7 LCD readout screen 8 Red Emergency Stop button 9 Glow plug button 10 Key switch for off ground platform selection 11 Engine start button 12 Jib boom up down buttons 13 Platform level up down button...

Страница 22: ...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 screen a low fuel indicator b...

Страница 23: ...d 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 right button Press the platfo...

Страница 24: ...tor switch with indicator light if equipped 8 Emergency power switch 9 Diesel models Glow plug switch with indicator light Gasoline LPG models Choke switch with indicator light 10 Engine start switch...

Страница 25: ...ghts Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed 22 Thumb rocker for jib boom extend retract function 23 Dua...

Страница 26: ...ove the generator switch to turn the generator on Move the switch again to turn the generator off 8 Emergency power switch with indicator light Use emergency power if the primary power source engine f...

Страница 27: ...onal control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated by the blue a...

Страница 28: ...1 Drive select switch with indicator lights Move the drive select switch to choose drive setting The indicator light next to the current setting will be on 22 Thumb rocker for jib boom extend retract...

Страница 29: ...slowly move the drive control handle off center 26 Thumb rocker switch for primary boom extend retract function Push the top of the rocker switch and primary boom will retract Push the bottom of the...

Страница 30: ...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 pro...

Страница 31: ...ce 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 fi...

Страница 32: ...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...

Страница 33: ...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 arr...

Страница 34: ...d 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...

Страница 35: ...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...

Страница 36: ...y 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 bu...

Страница 37: ...rm 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...

Страница 38: ...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 rock...

Страница 39: ...he 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 di...

Страница 40: ...color coded direction 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 t...

Страница 41: ...jib boom extended and the primary boom extended exceeds 15 cm s immediately tag and remove the machine from service 83 Retract the primary boom and the jib boom Test Drive Tilt Cutout 84 Press down t...

Страница 42: ...tilt 99 Retract the jib boom to the stowed position or drive in the opposite direction Result The machine should drive 100Return to level ground and stow the jib boom 101With the boom fully stowed dr...

Страница 43: ...n to level ground and extend the jib boom approximately 30 cm 114Drive 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...

Страница 44: ...itch or thumb rocker switch Result No boom and steer functions should operate 123Move and hold the function override switch 124Activate each function control handle toggle switch or thumb rocker switc...

Страница 45: ...tor 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 an...

Страница 46: ...l Read the Manual 2 97757 Label Hydraulic Oil Level 1 97815 Label Lower Mid rail 1 Part No Decal Description Qty 114248 Label Tip over Hazard Tilt Alarm 1 114249 Label Tip over Hazard Tires 4 114251 L...

Страница 47: ...Second Edition Third Printing Operator s Manual Inspections Part No 1258936 ZX 135 70 45...

Страница 48: ...e 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...

Страница 49: ...oggle 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 c...

Страница 50: ...ch on and activate the desired function The drive function 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...

Страница 51: ...xt 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 contr...

Страница 52: ...incline symbol To determine the 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 1 m long tape...

Страница 53: ...e Idle Select rpm Select the engine idle rpm by pressing the engine idle select switch The indicator light next to the current setting will be on Turtle symbol low idle Rabbit symbol high idle Check E...

Страница 54: ...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...

Страница 55: ...generation mode is running No service required Machine Not Level Indicator Light If the tilt alarm sounds when the platform is raised the Machine Not Level indicator light will come on and the drive f...

Страница 56: ...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 Selec...

Страница 57: ...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 labe...

Страница 58: ...tion 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...

Страница 59: ...nt 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 if equipped Remove all loose items on the machi...

Страница 60: ...ols appear at the beginning of 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...

Страница 61: ...z 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 c...

Страница 62: ...hen 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...

Страница 63: ...rly 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 Mac...

Страница 64: ...tage 12V Tire size 445 65 D22 5 or 445D50 710 18 ply FF Weight 20 457 kg Machine weights vary with option configurations See serial label for specific machine weight Airborne noise emissions Sound pre...

Страница 65: ...Second Edition Third Printing Operator s Manual Specifications Part No 1258936 ZX 135 70 63 ZX 135 70 Range of Motion Chart ZX 135 70 Part No 1258936 Operator s Manual Second Edition Third Printing...

Страница 66: ...Distributed By www genielift com...

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