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Genie ZX-135/70 with Jib-Extend User Manual

Genie ZX-135/70 with Jib-Extend
65 pages
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Operator's Manual
ZX
-
135/70
CE
with Jib-Extend
TM
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1272823GT
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Genie ZX-135/70 with Jib-Extend Specifications

General IconGeneral
Turntable Rotation360° continuous
Platform Rotation160°
Gradeability45%
Maximum Platform Height135 ft
Engine Power74 hp
Fuel TypeDiesel
Stowed Height (ft)10 ft
Max Working Height141 ft
Platform Height135 ft
Max Horizontal Reach70 ft
Platform Capacity600 lbs
Machine Width8 ft 2 in
Stowed Height10 ft
Drive Speed - Stowed3.5 km/h
Jib Length12 ft
Horizontal Reach70 ft
Platform Capacity (lbs)600 lbs
Drive Speed3.5 km/h
Stowed Length43 ft 2 in / 13.16 m
Stowed Width8 ft 2 in

Summary

Introduction

About this manual

General information about the operator's manual and its purpose.

Intended Use

Primary purpose of the machine for lifting personnel.

Bulletin Distribution and Compliance

Information on safety bulletins and compliance with regulations.

Introduction and Operating Pre-conditions

Contacting the Manufacturer

How and why to contact Genie for inquiries and support.

Transfer of Machine Ownership

Process for updating owner information to receive updates.

Essential Operating Pre-conditions

Essential conditions that must be met before operating the machine safely.

Safety Signage and Hazard Classification

Safety Sign Maintenance

Instructions for maintaining and cleaning safety signs on the machine.

Hazard Classification System

Explanation of hazard symbols, color coding, and signal words.

Symbol and Hazard Pictorials Definitions

Common Hazard Pictorials

Definitions for crush, electrocution, tip-over, and explosion hazards.

Operational and Safety Pictorials

Definitions for manuals, battery, fire, and smoking hazard symbols.

Symbol and Hazard Pictorials Definitions (Continued)

Platform and Load Pictorials

Definitions for tie-down, lifting, capacity, and wind speed symbols.

System and Hazard Pictorials

Definitions for recovery, ether, voltage, and environmental hazard symbols.

General Safety and Decal Locations

Safety Decal Locations

Diagram showing the placement of key safety decals on the machine.

General Safety and Additional Decals

Additional Safety Decals

More safety decals and their locations on the machine.

General Safety and Hazard Awareness Decals

Decals for Safety and Hazard Awareness

Decals indicating hazards like tip-over, tires, and explosion.

Personal Safety

Personal Fall Protection Requirements

Mandatory use of safety belts or harnesses and proper attachment.

Work Area Safety: Electrical and Stability

Electrocution Hazards and Clearance

Safety measures for electrical power lines and minimum clearance distances.

Tip-over Hazards and Capacity Limits

Precautions against tip-over by managing platform capacity and occupants.

Work Area Safety: Slopes and Wind

Slope Operation and Tilt Alarms

Importance of level surfaces and understanding tilt alarm signals.

Wind Condition Precautions

Safety guidelines for operating in high winds and gusty conditions.

Work Area Safety: Driving and Components

Driving, Obstructions, and Modifications

Safe driving on terrain, avoiding structures, and prohibiting modifications.

Load Placement and Component Integrity

Rules for load placement and maintaining machine component specifications.

Work Area Safety: Loads and Slopes

Load Placement and Surface Stability

Prohibiting fixed loads and operating on unstable or moving surfaces.

Slope Operation Hazards and Ratings

Hazards related to slope operation and machine slope rating limitations.

Work Area Safety: Falls and Collisions

Fall Hazards and Platform Integrity

Requirements for fall protection and maintaining a clear platform.

Collision Hazards and Obstructions

Awareness of blind spots, tailswing, and overhead obstructions.

Work Area Safety: Bodily Injury and Fire

Bodily Injury Hazards

Warnings about hydraulic leaks, air leaks, and accessing compartments.

Explosion and Fire Hazards

Safety measures for flammable substances and refueling operations.

Work Area Safety: Machine Condition and Batteries

Machine Condition and Component Safety

Procedures for handling damaged machines and component-specific hazards.

Battery Safety and Hazards

Precautions for battery handling, including burn and explosion risks.

Work Area Safety: Welding and Lockout

Welder and Weld Line Safety

Safety guidelines for using welding equipment and connecting weld lines.

Lockout Procedures After Use

Steps for securing the machine after operation to prevent unauthorized use.

Legend: Machine Component Identification

Machine Component Identification

Visual guide to the main parts of the aerial work platform.

Controls: Ground Control Panel Overview

Ground Control Panel Overview

Visual layout of the ground control panel and its components.

Controls: Ground Panel Functions and Indicators

Ground Control Panel Functions

Explanation of buttons for boom, turntable, and axle operations.

LCD Readout Screen Indicators

Meaning of indicators displayed on the LCD screen.

Controls: Boom, Platform, and System Functions

Boom and Platform Control Functions

Controls for jib boom, platform leveling, and primary boom.

System Controls and Enable Functions

Explanation of circuit breakers, alarms, and speed enable functions.

Controls: Platform Control Panel Overview

Platform Control Panel Overview

Visual layout of the platform control panel and its components.

Controls: Platform Indicators and Drive Handle

Platform Control Functions and Indicators

Description of horn, level indicators, overload lights, and engine status.

Drive and Steer Control Handle

Operation of the proportional control handle for driving and steering.

Controls: Advanced Platform Functions

Platform Control Functions (Continued)

Controls for emergency power, choke, engine start, and idle select.

Controls: Platform Indicators and Drive/Steer

Platform Indicators and System Status

Lights for overload, power, engine fault, low fuel, and system faults.

Drive, Steer, and Axle Control Functions

Controls for drive select, steer mode, and axle functions.

Controls: Axle, Drive, Boom, and Leveling

Axle and Drive Control Functions

Switches and handles for axle extension/retraction and drive enable.

Boom and Platform Level Controls

Proportional controls for boom movement and platform leveling.

Inspections: Pre-operation Procedures

Pre-operation Inspection Procedure

Steps and importance of conducting a pre-operation inspection.

Inspections: Pre-operation and Function Test Fundamentals

Pre-operation Inspection Fundamentals

The purpose and responsibility of operator's pre-operation checks.

Essential Inspection Before Operation

Conditions requiring inspection before operation.

Inspections: Pre-operation Checklist

Pre-operation Inspection Checklist

Comprehensive list of items to check during a pre-operation inspection.

Inspections: Function Test Fundamentals

Function Test Fundamentals

The purpose of function tests and operator responsibilities.

Essential Function Tests Before Operation

Conditions requiring function tests before operation.

Inspections: Ground Control and Axle Tests

Ground Controls and Emergency Stop Testing

Testing emergency stop and axle functions from ground controls.

Extendable Axle Function Testing

Verifying axle extension/retraction with boom operations.

Inspections: Turntable, Axle, and Boom Tests

Turntable and Axle Steering Tests

Testing turntable rotation and axle steering modes.

Boom Functionality Tests

Testing primary and secondary boom raise, lower, extend, and retract.

Inspections: Machine Functions and Tilt Sensors

Machine Function and Emergency Control Tests

Testing all functions and emergency controls.

Tilt Sensor Functionality Testing

Verifying the accuracy of tilt sensors on the turntable and platform.

Inspections: Operating Envelope and Boom Tests

Operating Envelope and Boom Angle Tests

Testing boom angles relative to gravity and status.

Secondary Boom Operation Tests

Testing secondary boom up/extend and down/retract functions.

Inspections: Platform Controls and Foot Switch

Platform Control Tests

Testing horn, emergency stop, tilt alarm, and foot switch.

Platform Functionality Tests

Testing all machine functions with the foot switch engaged.

Inspections: Steering and Braking Systems

Steering Mode and Function Testing

Testing square-end, circle-end, and crab steering modes.

Drive and Braking System Tests

Testing the drive system and braking effectiveness.

Inspections: Steering and Slope Braking

Steering Mode and Slope Braking Tests

Testing steering modes and drive braking on slopes.

Drive and Slope Braking Performance

Verifying drive function and braking performance on various slopes.

Inspections: Drive System and Speed Limits

Drive Enable System Testing

Testing the drive enable system and its interaction with boom position.

Limited Drive Speed Testing

Testing drive speed limits under various boom conditions.

Inspections: Speed Limits and Tilt Cutout

Drive Speed Limits and Tilt Cutout

Testing speed limits with boom extension and tilt cutout on slopes.

Drive Tilt Cutout Testing

Verifying machine response to slopes and tilt limits.

Inspections: Tilt Cutout, Emergency Controls, and Aircraft Protection

Drive Tilt Cutout and Emergency Control Tests

Testing tilt cutout and emergency controls.

Aircraft Protection Package Testing

Testing the functionality of the aircraft protection package.

Inspections: Lift/Drive Select Function

Lift/Drive Select Function Test

Testing the selection between lift and drive modes.

Inspections: Workplace Safety

Workplace Inspection Checklist

A checklist to identify and avoid workplace hazards.

Workplace Inspection Fundamentals

The importance of inspecting the work area before operation.

Inspections: Workplace Inspection Pre-requisite

Essential Workplace Inspection Before Operation

Conditions requiring workplace inspection before operation.

Inspections: Decal Verification

Decal Inspection and Verification

Checking all decals for legibility and proper placement.

Operating Instructions: Fundamentals

Operating Instructions Fundamentals

Importance of following safety rules and instructions.

Essential Operating Knowledge Before Use

Conditions requiring operational knowledge before use.

Operating Instructions: Engine Starting

Starting the Engine

Step-by-step guide to starting the engine for Deutz and Perkins models.

Operating Instructions: Emergency and Positioning

Emergency Stop and Controls

Using Emergency Stop and emergency power controls.

Axle Extension and Platform Positioning

Procedures for extending axles and positioning the platform.

Operation from Ground Controls

Steps for operating the machine from the ground controls.

Operating Instructions: Platform Operations

Operation from Platform Controls

Steps for operating the machine from the platform.

Steering and Driving Operations

Procedures for steering and driving the machine using platform controls.

Operating Instructions: Slope Driving

Driving on Slopes and Grade Determination

Safety and procedures for operating on inclines and calculating slope.

Operating Instructions: Drive System and Indicators

Drive Enable and Engine Idle Select

Functionality of drive enable and engine idle select systems.

Operating Envelope Indicator Lights

Interpretation of lights indicating function interruptions or required actions.

Operating Instructions: Platform Faults and Protection

Platform Out of Level and Overload Procedures

Steps for handling platform level faults and overload conditions.

Aircraft Protection Package and Post-Use Procedures

Operation of aircraft protection and after-use steps.

Operating Instructions: Advanced Platform Faults and Generator

Platform Level Faults and Overload Recovery

Procedures for specific platform faults and overload recovery.

Generator and LCD Screen Information

Operation of the generator and interpretation of the LCD screen.

Operating Instructions: Aircraft Protection and Tilt Alarms

Aircraft Protection Package Operation

Operation and shutdown of the aircraft protection system.

Machine Not Level Indicator and Tilt Alarm

Understanding the machine not level indicator and tilt alarm.

Tilt Alarm Response Procedures

Steps to take when the tilt alarm sounds with platform uphill or downhill.

Transport and Lifting Instructions: General Guidelines

General Transport and Lifting Guidelines

Observe and obey rules for securement and transport.

Free-wheel Configuration for Winching

Procedure for configuring the machine for winching by releasing brakes.

Transport and Lifting Instructions: Securing for Transit

Securing Machine for Transit

Instructions for securing the chassis and platform to a truck or trailer.

Transport and Lifting Instructions: Lifting Procedures

Safe Lifting Procedures

Guidelines for rigging, center of gravity, and lifting points.

Maintenance: Guidelines and Engine Oil

Maintenance Guidelines and Symbols

Operator responsibilities, symbols, and approved parts.

Engine Oil Level Check

Procedure for checking engine oil levels for different engine models.

Maintenance: Fuel and Hydraulic Oil

Diesel Fuel Requirements

Minimum fuel specifications for various engine types.

Hydraulic Oil Level Check

Procedure for checking and maintaining hydraulic oil levels.

Maintenance: Coolant, Batteries, and Scheduling

Engine Coolant and Battery Checks

Procedures for checking engine coolant and battery condition.

Scheduled Maintenance Requirements

Information on periodic maintenance performed by qualified technicians.

Specifications: Machine Data

Machine Specifications and Dimensions

Key technical data including height, reach, capacity, and dimensions.

Slope Ratings, Drive Speeds, and Load Info

Specifications for slope ratings, drive speeds, and floor loading.

Specifications: Operational Range

Range of Motion Chart

Visual diagram illustrating the machine's operational envelope.

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