Terex Genie ZX-135/70, Operator'S Manual

Page 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...

Page 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...

Page 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...

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 thi...

Page 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...

Page 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...

Page 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...

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

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

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

Page 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...

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