Genie X-135/70 Operator's Manual

ZX

-

Operator's Manual

With Jib Extend

with Jib-Extend™

135/70

Serial Number Range

from ZX13513-2001

ANSI/CSA
North America
South America
Asia

with
Maintenance
Information

First Edition
Seventh Printing
Part No. 160567

Operator's Manual First Edition • Seventh Printing

Front Matter

Contents

Introduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 4

General Safety ...................................................... 6

Personal Safety ................................................... 12

Work Area Safety ................................................ 13

Legend ................................................................ 22

Controls ............................................................... 23

Inspections .......................................................... 31

Operating Instructions ......................................... 48

Transport and Lifting Instructions ....................... 60

Maintenance ....................................................... 63

Specifications ...................................................... 67

ZX-135/70 Part No. 160567

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

First Edition • Seventh Printing Operator's Manual

Introduction

Introduction

About this manual

Intended Use

Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.

This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.

Product Identification

The machine serial number is located on the serial
label.

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
specific machines using the machine model and
serial number.

Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.

To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

Part No. 160567 ZX-135/70 1

Operator's Manual First Edition • Seventh Printing

Introduction

Contacting the Manufacturer

At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:

Accident reporting

Questions regarding product applications and
safety

Standards and regulatory compliance information

Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies 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.

Know and understand the safety rules
before going on to the next section.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

 You read, understand and obey the

manufacturer’s instructions and safety
rules—safety and operator’s manuals and
machine decals.

 You read, understand and obey employer’s

safety rules and worksite regulations.

 You read, understand and obey all applicable

governmental regulations.

 You are properly trained to safely operate the

machine.

2 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

NOTICE

Introduction

Safety Sign Maintenance

Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.

Hazard Classification

Decals on this machine use symbols, color coding
and signal words to identify the following:

Safety alert symbol—used to alert
you to potential personal injury

DANGER

WARNING

CAUTION

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 serious injury.

Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.

Indicates a property damage
message.

Part No. 160567 ZX-135/70 3

Operator's Manual First Edition • Seventh Printing

Symbol and Hazard Pictorials Definitions

Symbol and Hazard Pictorials Definitions

Crush hazard

Keep away from
moving parts

Electrocution hazard

Maintain required
clearance

Electrocution hazard Avoid contact Disconnect battery

Crush hazard Overhead obstruction Collision hazard

Tip-over hazard Tip-over hazard Tip-over hazard

Read the operator’s
manual

Read the service
manual

No smoking

Explosion hazard

No flame
Stop engine

Fire hazard No smoking Explosion hazard No step

4 ZX-135/70 Part No. 160567

Explosion hazard Burn hazard Fire extinguisher

Lanyard anchorage
points

First Edition • Seventh Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Platform tie-down
instructions

Wind speed Maximum capacity

Lifting & tie down instructions Tie-down point Lifting point

Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.

Recovery procedure if tilt alarm sounds while
elevated.

Voltage rating for
power to platform

+

+

Weight of welder
reduces capacity

Wheel load Tire specifications

Pressure rating for air
line to platform

Color Coded
Direction Arrows

Runaway Hazard

Platform uphill:

1 Lower primary
2 Retract/lower

secondary

3 Retract primary

Part No. 160567 ZX-135/70 5

Platform downhill:

1 Retract primary
2 Retract / lower

secondary

3 Lower primary

Access by trained
and authorized
personnel only

Operator's Manual First Edition • Seventh Printing

General Safety

General Safety

229356 or 230977 or

1261816 or 1261817

114258

978651263543 9760282237

114390

1263543

229356 or 230977

or 1261816 or 1261817

229356 or 230977

1261816 or 1261817

DANGER

Tip-over Hazard

Failure to replace tires with tires
of same specification will result
in death or ser ious injury.

Do not use air-filled tires.
Foam-filled tire s are cr itical to
mach ine st abili ty.

Do no t repla ce facto ry-i nstall ed
tires with tires of different
specificati on or ply rating.

Tire Size
445D50/710, 18 ply Foam-f illed

Lug Nut Torque

Dry bolts:

320 ft-lb s /

433.9 Nm

Foam-Fi lle d Ti re,
Min imum N ew
Weight:

850 lbs / 386 kg

1261816 A

82237

DANGER

Electrocution
Hazard
Contact with
energized
components can
result in death or
serious injury.

Avoid contact
with energized
components.

82237 B

114258

DANGER

Burn Hazard
Fuel and fumes
can explode
and burn.

No smoking. No
flame. Stop
engine.

114258 A

114390

1263543

97865

WARNING

Electrocution/BurnHazard
Failure to disconnect all
the batteries before
performingservice on this
machine may result in
death or serious injury.

Disconnect all the batteries
before performing service on
this machine.

97865 B

97602

WARNING

Explosion Hazard
Death or serious injury can
result from the use of ether or
other high energy starting
aids.

DANGER

Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.

97602 B

6 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

General Safety

Part No. 160567 ZX-135/70 7

Operator's Manual First Edition • Seventh Printing

General Safety

1263543

31060

DANGER

Tip-over Hazard
Altering or disabling limit

switches can result in machine
tip-over. Machine tip-over will
result in death or serious injury.

Do not alter or disable limit
switch(s).

229356 or 230977 or
1261816 or 1261817

DANGER

Tip-over Hazard

Failure to replace tires with tires
of same spec ifica tion wi ll resul t
in death or ser ious injury.

Do not use air-filled tires.
Foam-filled tires are cr itical to
mach ine st abili ty.

Do not replace factory-installed
tires wit h tires of dif ferent
specificati on or ply rating.

Tire Size
445D50/710, 18 ply Foam-f illed

31060

31060 C

Lug Nut Torque

Dry bolts:

320 ft-lb s /

433.9 Nm

Foam-Fi lle d Ti re,
Minimum New
Weight:

850 lbs / 386 kg

1261816 A

31788

52865

1263543

DANGER

Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness

Keep all open flames and sparks away. Wear
personal protective equipment, including face
shield, gloves and long sleeve shirt.

READ MANUALS
Read all manuals prior to operation.

DO NOT OPERATE equipment if you do not
understand the information in the manuals.

Consult your supervisor, the owner or the
manufacturer.

31788 C

WARNING

114390

DANGER

82237

Electrocution
Hazard
Contact with
energized
components can
result in death or
serious injury.

82314

DANGER

Avoid contact
with energized
components.

82237 B

DANGER

Tip-over Hazard
Altering or disabling angle sensor
can result inmachine tip-over.
Machine tip-over will result in
death or serious injury.

Do notmove, alter or disable
angle sensor.

97865

WARNING

Electrocution/BurnHazard
Failure to disconnectall
the batteries before
performingservice on this
machine may result in
death or serious injury.

Disconnect all the batteries
before performing service on
this machine.

97865 B

97875

82314 B

97865

82314
31060

1263543

31788

114390

8 ZX-135/70 Part No. 160567

229356 or 230977 or

1261816 or 1261817

1263543

52865

229356 or 230977 or

1261816 or 1261817

82237

97875

First Edition • Seventh Printing Operator's Manual

General Safety

Part No. 160567 ZX-135/70 9

Operator's Manual First Edition • Seventh Printing

General Safety

10 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

General Safety

Part No. 160567 ZX-135/70 11

Operator's Manual First Edition • Seventh Printing

Personal Safety

Personal Safety

Personal Fall Protection

Personal fall protection equipment (PFPE) is
required when operating this machine.

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’s instructions.

12 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Work Area Safety

Work Area Safety

Electrocution Hazards

Tip-over Hazards

This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.

Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a
minimum, the required
clearance contained in the
chart below must be
followed.

Line Voltage Required Clearance

0 to 50KV 10 ft 3.05 m

50 to 200KV 15 ft 4.60 m

200 to 350KV 20 ft 6.10 m

350 to 500KV 25 ft 7.62 m

500 to 750KV 35 ft 10.67 m

750 to 1000KV 45 ft 13.72 m

Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.

Occupants, equipment and materials shall not
exceed the maximum platform capacity.

Maximum platform capacity

Maximum occupants

600 lbs 272 kg

The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.

If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.

Do not raise or extend the
boom unless the machine
is on a firm, level surface.

2

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
machine until energized
power lines are shut off.

Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.

Do not operate the machine during lightning or
storms.

Do not use the machine as a ground for welding.

Part No. 160567 ZX-135/70 13

Operator's Manual First Edition • Seventh Printing

Work Area Safety

If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.

If the tilt alarm sounds when the platform is raised,
use extreme caution. 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 should be used only by trained
and authorized personnel.

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.

If the tilt alarm sounds
with the platform downhill:

1 Retract the primary

boom.

2 Retract/lower the

secondary 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 increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.

Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.

Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.

Do not use the machine as a crane.

Do not push the machine or other objects with the
boom.

3 Lower the primary

boom.

14 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Work Area Safety

Do not contact adjacent structures with the boom.

Do not tie the boom or platform to adjacent
structures.

Do not place loads outside the platform perimeter.

Do not push off or pull
toward any object outside
of the platform.

Maximum allowable
side force – ANSI & CSA

150 lbs / 667 N

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 replace factory-installed tires with tires of
different specification or ply rating.

Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.

Do not place or attach
fixed or overhanging loads
to any part of this
machine.

Do not place ladders or
scaffolds in the platform or
against any part of this
machine.

Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an 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 transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the 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.

Part No. 160567 ZX-135/70 15

Operator's Manual First Edition • Seventh Printing

Work Area Safety

Operation on Slopes Hazards

Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.

Maximum slope rating, stowed position

Platform downhill 45% (24°)

Platform uphill 30% (17°)

Side slope 25% (14°)

Note: Slope rating is subject to ground conditions
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 when raised.

Keep the platform floor clear of debris.

Lower the platform 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.

16 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

r

Work Area Safety

Collision Hazards

Be aware of limited sight
distance and blind spots
when driving or
operating.

Be aware of the boom position and tailswing when
rotating the turntable.

Be aware of machine length when operating. The
machine is 42 ft 5 inches / 12.9 m long.

Check the work area for
overhead obstructions or
other possible hazards.

Be aware of crushing
hazards when grasping
the platform guard rail.

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, location of
personnel, and any othe
factors which may cause
collision.

Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.

No stunt driving or horseplay while operating a
machine.

Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.

Part No. 160567 ZX-135/70 17

Operator's Manual First Edition • Seventh Printing

Work Area Safety

Bodily Injury Hazard

Always operate the machine in a well-ventilated
area to avoid carbon 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 cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.

Do not refuel the machine with the engine running.

Refuel the machine and charge the battery only in
an open, well-ventilated area away from sparks,
flames 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.

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 each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.

Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
service manual.

Be sure all decals are in place and legible.

Be sure the operator's, safety and responsibilities
manuals are complete, 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 controls battery, not the emergency
power batteries.

Do not use the machine as a ground for welding
unless the machine is equipped with the weld line
to platform option and it is properly connected.

Do not spray ether into engines equipped with
glow plugs.

18 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Work Area Safety

Battery Safety

Burn Hazards

Explosion Hazards

Batteries contain acid.
Always wear protective
clothing and eye wear when
working with batteries.

Avoid spilling or contacting
battery acid. Neutralize
battery acid spills with
baking soda and water.

Keep sparks, flames and
lighted tobacco away from
batteries. Batteries emit
explosive gas.

Pipe Cradle Safety

Read, understand and obey all warnings and
instructions provided with the pipe cradles.

Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles 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 platform.

Do not obstruct the entrance or the exit of the
platform.

Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.

Electrocution Hazard

Avoid contact with electrical terminals.

Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhanging load.

Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.

Electrocution Hazard: Keep pipes away from all
energized electrical conductors.

Part No. 160567 ZX-135/70 19

Operator's Manual First Edition • Seventh Printing

Work Area Safety

Panel Cradle Safety

Read, understand and obey all warnings and
instructions provided with the panel cradles.

Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.

The panel cradle assembly weighs 30 lbs /

13.6 kg.

The maximum capacity of the panel cradles is
250 lbs / 113 kg.

The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.

Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.

Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.

Welder Safety

Read, understand and obey all warnings and
instructions provided with the welding power unit.

Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.

Do not operate unless the weld cables are properly
connected and the welder is properly grounded.

The weight of the welder will reduce the rated
platform capacity and must be factored into the
total platform load. The welder power supply
weighs 75 lbs / 34 kg.

Do not operate the welder unless a fire
extinguisher is immediately available for instant
use, per OSHA regulation 1926.352(d).

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

2

Maximum panel area: 32 sq ft / 3 m

20 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Work Area Safety

Weld Line to Platform Safety

Read, understand and obey all warnings and
instructions provided with the welding power unit.

Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.

Do not operate 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 the boom is

between the non-steer wheels.

4 Turn the key switch to the off position and

remove the key to secure from unauthorized
use.

Part No. 160567 ZX-135/70 21

Operator's Manual First Edition • Seventh Printing

Legend

Legend

1 Square-end tire
2 Ground controls
3 Secondary boom
4 Primary boom
5 Jib boom

7 Platform controls
8 Sliding mid-rail
9 Manual storage container
10 Lanyard anchorage points
11 Foot switch

6 Platform

22 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Controls

Controls

Ground Control Panel

1 Turntable rotate right button

Press the turntable rotate right button and the
turntable will rotate right.

2 Turntable rotate left button

Press the turntable rotate left button and the
turntable will rotate left.

Part No. 160567 ZX-135/70 23

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.

Operator's Manual First Edition • Seventh Printing

Controls

4 Primary boom up/down buttons

10 Key switch for off/ground/platform selection

Press the primary boom up button and the
boom will raise. Press the primary boom down
button and the boom will lower.

5 LCD screen control buttons
6 Engine speed select button

Press the engine speed select 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 screen

abc de

a low fuel indicator
b engine oil pressure indicator
c water temperature indicator
d emergency power indicator
e high engine rpm indicator
f hour meter

8 Red Emergency Stop button

Push in the red Emergency Stop button to the
off position to stop all functions and turn the
engine off. Pull out the red Emergency Stop
button to the on position to operate the
machine.

9 Glow plug button (if equipped with manual

glow plugs)

Push the glow plug button and hold for 3 to
5 seconds.

f

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 jib boom
will raise. Press the jib boom down button and
the jib boom will lower.

13 Platform level up/down buttons

Press the platform level up button and the
level of the platform will raise. Press the
platform level down button and the level of the
platform will lower.

14 Primary boom extend/retract buttons

Press the primary boom extend button and the
primary boom will extend. Press the primary
boom retract button and the primary boom will
retract.

15 20A circuit breaker for system circuit
16 Alarm
17 Bypass/recovery key switch

Bypass key position to be used only to level
the platform if the ground control display
shows platform 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.

24 ZX-135/70 Part No. 160567

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Controls

18 Platform rotate right button

Press the platform rotate right button and the
platform will rotate right.

19 Platform rotate left button

Press the platform rotate left button and the
platform will rotate left.

20 Jib boom extend/retract buttons

Press the jib boom extend button and 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 speed.

23 Emergency power button

Use emergency power if the primary power
source (engine) fails.
Simultaneously hold the emergency power
button and activate the desired function.

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Operator's Manual First Edition • Seventh Printing

Controls

1

2 3 4 5

6 7 8 9

22242528 232627

Platform Control Panel

26 ZX-135/70 Part No. 160567

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Controls

10 11 1412 13 15 16 17

STOP

!

21

20

19

18

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Operator's Manual First Edition • Seventh Printing

Controls

Platform Control Panel

1 Horn button

Press this button and the horn will sound.
Release the button and the horn will stop.

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.

2 Platform not level indicator light

Level the platform until the light is off. The
platform level toggle switch will only work in
the direction that will level the platform.

3 Machine on incline indicator light

Light on indicates all functions have stopped.
See the instructions in the Operating
Instructions section.

4 Lower primary boom indicator light

Lower the primary boom until the light is off.

5 Lower / retract secondary boom indicator light

Lower/retract the secondary boom until the
light is off.

6 Used for optional equipment
7 Generator switch with indicator light (if

equipped)

Move 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) fails.
Simultaneously move the emergency power
switch and activate the desired function. The
indicator light will be on when emergency
power is being used.

Diesel models: Automatic glow plug indicator
light

Amber light indicates glow plugs are on.

Gasoline/LPG models: Choke button with
indicator light

Press the choke button and hold for 3 to
5 seconds. The choke indicator light will be on
when the choke is being used.

10 Engine start switch with indicator light

Move the engine start switch and the engine
will start. The engine start indicator light will be
on when the switch is Moved.

11 Engine idle select switch with indicator light:

Move this switch to select
engine idle setting. Rabbit
symbol light on indicates high
idle is selected. Turtle symbol
light on indicates low idle is
selected.

12 Not used
13 Power indicator light

Light on indicates the machine is on.

14 Check engine indicator light

Light on indicates an engine fault.

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Controls

15 Low fuel indicator light

19 Steer mode select switch with indicator lights

Light on indicates the machine is low on fuel.

16 Fault indicator light

Light on indicates a system fault.

17 Red Emergency Stop button

Push in the red Emergency Stop button to the
off position to stop all functions and turn the
engine off. 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
function and thumb rocker for steer function.

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. Move the control handle
in the direction indicated by the blue triangle
and the machine 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
thumb rocker and the machine will steer to the
left. Press the right side of the thumb rocker
and the machine will steer to the right.

Move the steer
mode select switch
to choose steer
mode.
The indicator light
next to the current
steer mode will be
on.

20 Single axis proportional control handle for

secondary boom up/extend and down/retract
function

Move the control
handle up and the
secondary boom will
raise and then extend.
Move the control
handle down and the
secondary boom will
retract and then lower.

21 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.

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Operator's Manual First Edition • Seventh Printing

Controls

22 Thumb rocker for jib boom extend/retract

function

Push the top of the rocker
switch and the jib boom will
retract. Push the bottom 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 will
raise. Move the control
handle down and the jib
boom will lower. Move
the control handle to the
left and the platform will
rotate to the left. Move
the control handle to the
right and the platform will
rotate to the right.

24 Axle extend/retract switch with indicator lights

Move the axle select
switch to choose an axle
setting. The indicator
light will flash while the
axles are extending and
stay on when the axles
are fully extended. The
indicator light will flash
while 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 top of the rocker
switch and primary boom
will retract. Push the
bottom of the rocker switch
and the primary boom will
extend.

27 Dual axis proportional control handle 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 control handle to
the left and the turntable
will rotate to the left. Move
the control handle to the
right and the turntable will
rotate to the right.

28 Platform level switch

Move the platform level
switch up and the level of the
platform will raise. Move the
platform level switch down
and the level of the platform
will lower.

30 ZX-135/70 Part No. 160567

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Inspections

Inspections

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s
manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation

inspection.

Know and understand the pre-operation
inspection before going on to the next
section.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

Pre-operation Inspection
Fundamentals

It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.

The pre-operation inspection is a visual inspection
performed by the operator prior to each work shift.
The inspection 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 unauthorized variation from
factory delivered condition is discovered, the
machine must be tagged and removed from
service.

Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer’s specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on to
the function tests.

Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer’s specifications and
the requirements listed in the responsibilities
manual.

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Inspections

Pre-operation Inspection

 Be sure that the operator’s, safety and

responsibilities manuals are complete, legible
and in the storage container located in the
platform.

 Be sure that all decals are legible and in place.

See Inspections section.

 Check for hydraulic oil leaks and proper oil

level. Add oil if needed. See Maintenance
section.

 Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See
Maintenance section.

 Check for engine oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

 Check for engine coolant leaks and proper

level of coolant. Add coolant if needed. See
Maintenance section.

 Steer and axle sensors
 Alarms and beacons (if equipped)
 Nuts, bolts and other fasteners
 Platform entry mid-rail or gate
 Lanyard anchorage points

Check entire machine for:

 Cracks in welds or structural components
 Dents or damage to machine
 Excessive rust, corrosion or oxidation

 Be sure that all structural and other critical

components are present and all associated
fasteners and pins are in place and properly
tightened.

 After you complete your inspection, be sure

that all compartment covers are in place and
latched.

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

32 ZX-135/70 Part No. 160567

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Inspections

Function Test Fundamentals

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s
manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to

use.

Know and understand the function tests
before going on to the next section.

4 Inspect the workplace.

5 Only use the machine as it was intended.

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 only be made by a qualified service
technician, according to the manufacturer’s
specifications.

After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.

Part No. 160567 ZX-135/70 33

Operator's Manual First Edition • Seventh Printing

Inspections

At the Ground Controls

1 Select a test area that is firm, level and free of

obstruction.

2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to the

on position.

Result: The beacons (if equipped) should

flash.

4 Start the engine. See Operating Instructions

section.

Test Emergency Stop

5 Push in the red Emergency Stop button to the

off position.

Result: The engine should shut off and no

functions should operate.

6 Pull out the red Emergency Stop button to the

on position and restart the engine.

Test the Extendable Axles

Note: Start this test with 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 button.

Result: The secondary boom should not raise.

On the LCD screen, the arrow next to the
extend axle symbol will flash. The secondary
boom should not raise unless the axles are
extended.

9 Push and hold a function enable/speed select

button and press the primary boom extend
button.

Result: The primary boom should not extend.

On the LCD screen, the arrow next to the
extend axle symbol will flash. The primary
boom should not extend unless the axles are
extended.

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Inspections

10 Push and hold a function enable/speed select

button and push the turntable rotate left button.

Result: The turntable should rotate 15° and

then stop. The turntable should not rotate
more than 15° unless the axles are extended.

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.

11 Push and hold a function enable/speed select

button and push the turntable rotate right
button.

Result: The turntable should return to center,

rotate 15° to the right and then stop. The
turntable should not rotate more than 15°
unless the axles are extended.

12 Turn the key switch to platform control. At the

platform controls, move the drive control
handle in the forward direction and move the
extend axle toggle switch.

Result: The machine should drive 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 control.

15 Push and hold a function enable/speed select

button and push the secondary boom
raise/extend button and then the secondary
boom lower/retract button.

Result: The secondary boom should raise and

extend and retract and lower normally.

16 Push and hold a function enable/speed select

button and push the primary boom extend
button and then the primary boom retract
button.

Result: The primary boom should extend and

retract normally.

17 Push and hold a function enable/speed select

button and push the turntable rotate left button
and then the turntable rotate right button.

Result: The turntable should rotate normally.

Part No. 160567 ZX-135/70 35

Operator's Manual First Edition • Seventh Printing

Inspections

Test Machine Functions

Test the Tilt Sensor

18 Do not press and hold a function enable/speed

select button. Attempt to activate each boom
and platform function button.

Result: No boom and platform functions should

operate.

19 Press and hold a function enable/speed select

button and activate each boom and platform
function button.

Result: All boom and platform functions should

operate through a full cycle. The descent
alarm should sound while the boom is
lowering.

Test Emergency Controls

20 Push in the red Emergency Stop button to 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.

24 Press one of the LCD

screen control buttons until
TURNTABLE LEVEL
SENSOR X-DIRECTION
appears.

Result: The LCD screen should display the

angle in degrees.

25 Press the LCD screen control buttons until

TURNTABLE LEVEL SENSOR Y-DIRECTION
appears.

Result: The LCD screen should display the

angle in degrees.

26 Press the LCD screen control buttons until

PLATFORM LEVEL SENSOR DEGREES
appears.

Result: The LCD screen should display the

angle in degrees.

Note: To conserve battery power, test each
function through a partial cycle.

Result: All boom functions should operate.

23 Start the engine.

36 ZX-135/70 Part No. 160567

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Inspections

Test the Operating Envelope

27 Press the LCD screen

control buttons shown until
PRI BOOM ANGLE TO
GRAVITY is displayed.

28 Raise the primary boom and observe the LCD

screen.

Result: The primary boom should raise and the

LCD screen should display the primary boom
angle in degrees.

29 Lower the primary boom.
30 Simultaneously 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 until it is fully raised.

33 Press and hold the secondary boom

down/retract button.

Result: The secondary boom should fully

retract and then lower. The secondary boom
should not lower unless it is fully retracted.

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Operator's Manual First Edition • Seventh Printing

Inspections

At the Platform Controls

Test Emergency Stop

Test the Foot Switch

39 Push in the platform red Emergency Stop

button to the off position.

34 Turn the key switch to platform control.
35 Push in the platform red Emergency Stop

button to the off position.

Result: The engine should shut off and no

functions should operate.

36 Pull out the red Emergency Stop button and

restart the engine.

Test the Horn

37 Press the horn button.

Result: The horn should sound.

Test the Tilt Sensor Alarm

38 Move a toggle switch, such as the engine idle

select switch.

Result: The alarm should sound at the platform

controls.

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 switch and restart

the engine.

Result: The engine should start.

43 Do not press down the foot switch and test

each machine function.

Result: No functions should operate.

Test Machine Functions

44 Press down the foot switch.
45 Activate each function control handle, toggle

switch or thumb rocker switch.

Result: All functions should operate through a

full cycle.

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Inspections

Test the Steering

46 Move the steer

mode select switch
and choose
square-end (blue
arrow) steer.

47 Press down the foot switch.
48 Slowly move the drive control handle in the

direction indicated by the blue triangle on the
control panel OR press the thumb rocker
switch in the direction indicated by the blue
triangle.

Result: The square-end wheels should turn in

the direction that the blue triangles point on the
drive chassis.

49 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 square-end wheels should turn in

the direction that the yellow triangles point on
the drive chassis.

50 Move the steer

mode select switch
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 control handle in the

direction indicated by the blue triangle on the
control panel OR press the thumb rocker
switch in the direction indicated by the blue
triangle.

Result: The circle-end wheels should turn in

the direction that the yellow triangles point on
the drive chassis.

54 Move the steer

mode select switch
and choose crab
steer.

55 Press down the foot switch.
56 Slowly move the drive control handle in the

direction indicated by the blue triangle on the
control panel OR press the thumb rocker
switch in the direction indicated by the blue
triangle.

Result: All wheels should turn in the direction

that the blue triangles point on the drive
chassis.

Part No. 160567 ZX-135/70 39

Operator's Manual First Edition • Seventh Printing

Inspections

57 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: All wheels should turn in the direction

that the yellow triangles point on the drive
chassis.

58 Move the steer

mode select switch
and choose
coordinated steer.

59 Press down the foot switch.
60 Slowly move the drive control handle in the

direction indicated by the blue triangle on the
control panel OR press the thumb rocker
switch in the direction indicated by the blue
triangle.

Result: The square-end wheels should turn in

the direction that the blue triangles point on the
drive chassis. The circle-end wheels should
turn in the direction that the yellow triangles
point on the drive chassis.

Test Drive and Braking

62 Press down the foot switch.
63 Slowly move the drive control handle in the

direction indicated by the blue arrow on the
control panel until the machine begins to move,
then return the handle to the center position.

Result: The machine should move in the

direction that the blue arrow points on the drive
chassis, then come to an abrupt stop.

64 Slowly move the control handle in the direction

indicated by the yellow arrow on the control
panel until the machine begins to move, then
return the handle to the center position.

Result: The machine should move in the

direction that the yellow arrow points on the
drive chassis, then come to an abrupt stop.

Note: The brakes must be able to hold the
machine on any slope it is able to climb.

61 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 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.

40 ZX-135/70 Part No. 160567

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Inspections

Test the Drive Enable System

Test Limited Drive Speed

65 Press down the foot switch and lower the

boom to the stowed position.

66 Rotate the turntable until the primary boom

moves past one of the circle-end tires.

Result: The drive enable

indicator light should come on
and remain on while the boom
is anywhere in the range
shown.

67 Move the drive control handle off center.

Result: The drive function should not operate.

68 Move the drive enable toggle switch and

slowly move the drive control handle off
center.

Result: The drive function should operate.

Note: When the drive enable system is in use, the
machine may drive in the opposite direction that
the drive and steer control handle is moved.

Use the 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 toggle switch,
the drive function will not operate.

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.

Result: The maximum achievable drive speed

with the primary boom raised should not
exceed 1 ft / 30 cm per second.

Note: The machine will travel 40 ft / 12 m in
40 seconds.

72 Lower the primary boom to the stowed

position.

73 Extend the primary boom 4 ft / 1.2 m.
74 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the primary boom extended should not
exceed 1 ft / 30 cm per second.

Note: The machine will travel 40 ft / 12 m in
40 seconds.

75 Retract the primary boom to the stowed

position.

76 Raise the secondary boom to 5° above

horizontal.

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Operator's Manual First Edition • Seventh Printing

Inspections

77 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the secondary boom raised should not
exceed 1 ft / 30 cm per second.

Note: The machine will travel 40 ft / 12 m in
40 seconds.

78 Lower the secondary boom to the stowed

position.

79 Extend the jib boom 1 ft / 30 cm.
80 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the jib boom extended should not exceed
1 ft / 30 cm per second.

If the drive speed with the primary or secondary
boom raised or extended or the jib boom extended
exceeds 1 ft / 30 cm per second, immediately tag
and remove the machine from service.

81 Extend the primary boom 4 ft / 1.2 m.
82 Slowly move the drive control handle to the full

drive position.

Result: The maximum achievable drive speed

with the jib boom extended and the primary
boom extended should not exceed 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 position.

86 Press down the foot switch.
87 Simultaneously move and hold the emergency

power switch and activate each function
control handle, toggle switch or thumb rocker
switch.

Note: To conserve battery power, test each
function through a partial cycle.

Result: All boom and steer functions should

operate.

Test Aircraft Protection Package
(if equipped)

Note: Two people may be required to perform this
test.

88 Move the yellow bumper at the bottom of the

platform 4 inches / 10 cm in any direction.

89 Activate each function control handle, toggle

switch or thumb rocker switch.

Result: No boom and steer functions should

operate.

90 Move and hold the function override switch.
91 Activate each function control handle, toggle

switch or thumb rocker switch.

Result: All boom and steer functions should

operate.

42 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Inspections

Workplace Inspection Checklist

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s
manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

Know and understand the workplace
inspection before going on to the next
section.

5 Only use the machine as it was intended.

Workplace Inspection
Fundamentals

Be aware of and avoid the following hazardous
situations:

 drop-offs or holes
 bumps, floor obstructions or debris
 sloped surfaces
 unstable or slippery surfaces
 overhead obstructions and high voltage

conductors

 hazardous locations
 inadequate surface support to withstand all

load forces imposed by the machine

 wind and weather conditions
 the presence of unauthorized personnel
 other possible unsafe conditions

The workplace inspection helps the operator
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.

Part No. 160567 ZX-135/70 43

Operator's Manual First Edition • Seventh Printing

Inspections

Inspection for Decals with Words

Use the pictures on the next page to verify that all
decals are legible and in place.

Below is a numerical list with quantities and
descriptions.

Part No. Decal Description Qty

27204 Arrow – Blue 2

27205 Arrow – Yellow 2

27206 Triangle – Blue 4

27207 Triangle – Yellow 4

28159 Label – Diesel 1

28174 Label – Power to Platform, 230V 2

28176 Label – Missing Manuals 1

28235 Label – Power to Platform, 115V 2

28236 Warning – Improper Operation 1

31060 Danger – Tip-over Hazard, Limit Switch 2

31788 Danger – Explosion/Burn Hazard 1

40434 Label – Lanyard Anchorage Point 8

44981 Label – Air Line to Platform (option) 2

52475 Label – Transport Tie Down 6

52865 Warning – Annual Inspection Record 1

65278 Caution – No Step 6

72086 Label – Lifting Point 4

72875 Warning – Pipe Cradle (option) 2

82237 Danger – Electrocution Hazard (option) 4

82314 Danger – Tip-over Hazard 1

82366 Label – Chevron Rando 1

82410 Warning – Panel Cradle (option) 2

82862 Danger – Fire Extinguisher, Welder

(option)

97579 Danger – Tip-over Welder (option) 1

97602 Warning – Explosion Hazard 1

97757 Label – Hydraulic Oil Level 1

97815 Label – Lower Mid-rail 1

97865 Warning – Electrocution Hazard 2

97875 Warning – Weld Line to Platform

(option)

114258 Danger – Explosion Hazard 1

Part No. Decal Description Qty

114390 Danger – Electrocution Hazard 3

1261816 Danger – Tire Specifications,

Foam Filled

1261817 Danger – Tire Specifications,

Solid Rubber

128953 Instructions – Deutz Engine Specs 1

133163 Label – Function Override

(Aircraft Protection Package)

133236 Danger – Tip-over Hazard 1

160424 Cosmetic – ZX-135/70 1

160425 Cosmetic – ZX-135/70 1

160575 Danger – Maximum Capacity, Wind &

Side Force

160580 Warning – Slope Rating 1

160654 Label – Fuse and Relay Panel Layout 1

160682 Label – Wheel Load 4

160683 Label – Transport Diagram 2

218559 Danger, Warning – Tip-over, Crush

Hazard

219485 Notice – Operating Instructions 1

219974 Platform Control Panel 1

229356 Danger – Tire Specifications,

Low Profile

230977 Danger – Tire Specifications,

Solid Rubber

230985 Ground Control Panel 1

824615 Instructions – Deutz Engine Specs, T4 1

826345 Label – Ultra Low Sulfur Fuel Only

(diesel models)

1000083 Notice – Start and Controls Battery 1

1255369 Instructions – Perkins 1104D 1

1

1257237 Instructions – Perkins Tier 4 1

1262903 Instructions – Perkins 1

1263543 Warning – Compartment Access 5

1263544 Bypass Key Switch 1

1263545 Instructions – Bypass Key Switch 1

2

Shading indicates decal is hidden from view, i.e.

under covers

4

4

1

1

1

4

4

1

44 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Inspections

1000083

97865
72086
28159
114258

826345
160682
40434

229356

or 230977
1263543
160683
27207
27205
65278

65278
52475
27207
27204

65278
52475

27204
27206
52475
65278

27205
27206
82366

1263545

72086
1263543

31060

219485
230985

1263543

or 1261816 or 1261817

160424

160654

65278

52475
27207

160575
160580

97815

65278
27206

52475

1263543

114390

82237

97602

128953

or 1255369

or 824615

or 1257237

160682

229356
or 230977
or 1261816
or 1261817

133163
219974
218559

133236
114390

28174

or 28235

28176

28236
97579
44981
82862
97875
97757
31788

114390

82314
72086
31060

160425

28174 or 28235

97875

1263544

97865
72875

82410

Part No. 160567 ZX-135/70 45

160682

229356
or 230977
or 1261816
or 1261817

52865

& serial

label

160683

44981

1263543

229356
or 230977
or 1261816
or 1261817

160682

82237

40434

Operator's Manual First Edition • Seventh Printing

Inspections

Inspection for Decals with
Symbols

Use the pictures on the next page to verify that all
decals are legible and in place.

Below is a numerical list with quantities and
descriptions.

Part No. Decal Description Qty

27204 Arrow – Blue 2

27205 Arrow – Yellow 2

27206 Triangle – Blue 4

27207 Triangle – Yellow 4

28159 Label – Diesel 1

28174 Label – Power to Platform, 230V 2

28235 Label – Power to Platform, 115V 2

40434 Label – Lanyard Anchorage Point 8

44981 Label – Air Line to Platform (option) 2

52475 Label – Transport Tie Down 6

65278 Caution – No Step 6

72086 Label – Lifting Point 4

82473 Label – Compartment Access 2

82481 Label – Battery/Charger Safety 1

82487 Label – Read the 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 – Function Override

(Aircraft Protection Package)

133205 Label – Electrocution/Burn Hazard 2

160424 Cosmetic – ZX-135/70 1

160425 Cosmetic – ZX-135/70 1

160577 Label – Maximum Capacity, Wind &

Side Force

160579 Label – Slope Rating 1

160682 Label – Wheel Load 4

160683 Label – Transport Diagram 2

219958 Label – Tip-over, Crush Hazard 1

219974 Platform Control Panel 1

230985 Ground Control Panel 1

1263542 Label – Compartment Access 5

1263544 Bypass Key Switch 1

1263545 Instructions – Bypass Key Switch 1

Shading indicates decal is hidden from view, i.e.

under covers

1

1

46 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Inspections

160424

133205

72086

28159

114251

160682

40434

114249

1263542

160683

27207
27205
65278

65278
52475
27207
27204

1253542

65278
52475
27207
160577
133067

97815

133067

160682
114249

133163

219974
219958

160579
114248

28174

or 28235

65278
52475
27204
27206
52475
65278

27205
27206

72086

114252

230985

1263542
1263544

133205

82487

82487

160682

114249

serial

label

65278
27206
52475

160683

44981

1263542

114249

160682

82487

44981

82487

97757
1263542
1263545

82481

133067
114252

72086

114252
160425

28174 or 28235

40434

Part No. 160567 ZX-135/70 47

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Operating Instructions

Fundamentals

Do Not Operate Unless:

 You learn and practice the principles of safe

machine operation contained in this operator’s
manual.

1 Avoid hazardous situations.

2 Always perform a pre-operation inspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was

intended.

The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the 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 machine at different
times in the same work shift, they must all be
qualified operators and are all expected to follow
all safety rules and instructions in the operator’s,
safety and responsibilities manuals. That means
every new operator should perform a pre-operation
inspection, function tests, and a workplace
inspection before using the machine.

48 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Operating Instructions

Starting the Engine

1 At the ground controls, turn the key switch to

the desired position.

2 Be sure both ground and platform control red

Emergency Stop buttons are pulled out to the
on position.

Deutz models

1 Diesel models with glow plug button: Push the

glow plug button.

Diesel models with automatic glow plugs:
Amber light will be on when glow plugs are on.

2 Move the engine start toggle switch

to either side. The engine start
switch can be moved at any time
while the glow plugs are on. If the
engine fails to start or dies, the
restart delay will disable the start
switch for 3 seconds.

Perkins models

1 Move the glow plug switch to either side and

hold.

2 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 hydraulic system damage.

In extreme cold conditions, 0°F / -18°C and below,
machines should be equipped with optional cold
start kits. Attempting to start the engine when
temperatures are below 0°F / -18°C may require
the use of a booster battery.

If the machine is stored for long
periods of time in low
temperatures (below 32°F / 0°C)
with the secondary boom raised
and extended, the engine may
not start due to system fault.

To remove the fault, move and hold the emergency
power switch and activate the secondary boom up
function until the secondary boom begins
extending.

Part No. 160567 ZX-135/70 49

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Emergency Stop

Push in the red Emergency Stop button to the off
position at the ground controls or the platform
controls to stop all machine functions and turn the
engine off.

Repair any function that operates when either red
Emergency Stop button is pushed in.

Selecting and operating the ground controls will
override the platform red Emergency Stop button.

Emergency Power

Use emergency power if the primary power source
(engine) fails.

1 Turn the key switch to ground or platform

control.

2 Pull out the red Emergency Stop button to the

on position.

3 Press down the foot switch when using the

controls from the platform.

4 Simultaneously hold the

emergency power switch 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 when the axles are fully
extended or retracted.

The axles can only be retracted if the primary and
secondary booms are fully lowered and retracted
and the platform is between the circle-end wheels.

Operation from Ground

1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to the

on position.

3 Start the engine.

To Position Platform

1 Push and hold a

function enable/speed
select button.

50 ZX-135/70 Part No. 160567

2 Push the appropriate

function button
according to the
markings on the control
panel.

Drive and steer functions are not available from the
ground controls.

First Edition • Seventh Printing Operator's Manual

Operating Instructions

Operation from Platform

1 Turn the key switch to platform control.

To Drive

1 Press down the foot switch.

2 Pull out both ground and platform red

Emergency Stop buttons to the on position.

3 Start the engine. Do not press down the foot

switch when starting the engine.

To Position Platform

1 Press down the foot switch.
2 Slowly move the appropriate function control

handle or thumb rocker switch or toggle switch
according to the markings on the control panel.

To Steer

1 Press down the foot switch.
2 Select the steer mode by moving the steer

mode switch. The indicator light next 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.

2 Increase speed: Slowly move the drive

control handle in the direction
indicated by the blue or yellow arrows.

Decrease speed: Slowly move the
drive control handle toward center.

Stop: Return the drive control handle
to center or release the foot switch.

Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.

Machine travel speed is restricted when the boom
is raised or extended.

Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the wheels will turn.

Part No. 160567 ZX-135/70 51

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Driving on a slope

To determine the slope grade:

Determine the uphill, downhill and side slope
ratings for the machine and determine the slope
grade.

Maximum slope rating, platform
downhill (gradeability):

45% (24°)

Maximum slope rating, platform
uphill:

30% (17°)

Maximum side slope rating:

25% (14°)

Note: Slope rating is subject to ground conditions
and adequate traction.The term gradeability
applies to the counterweight 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.

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 distance from the bottom of the piece of
wood to the ground.

Divide the tape measure distance (rise) by the
length of the piece of wood (run) and multiply by

100.

Example:

52 ZX-135/70 Part No. 160567

Piece of wood = 144 inches (3.6 m)

Run = 144 inches (3.6 m)

Rise = 12 inches (0.3 m)

12 in ÷ 144 in = 0.083 x 100 = 8.3% grade

0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade

If the slope exceeds the maximum slope or side
slope rating, then the machine must be winched or
transported up or down the slope. See Transport
and Lifting section.

First Edition • Seventh Printing Operator's Manual

Operating Instructions

Drive Enable

Engine Idle Select (rpm)

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/steer control handle off center.

If the drive/steer control handle is not moved within
two seconds of moving the drive enable switch, the
drive function will not operate. Release and move
the drive 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.

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 Engine Light

Light on and engine stopped: Tag the
machine and remove from service.

Light on and engine still running:
Contact service personnel within
24 hours.

Part No. 160567 ZX-135/70 53

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Operating Envelope Indicator Lights

The operating envelope indicator lights will come
on to notify the operator that a function has been
interrupted and/or an action is required by the
operator.

Lower/Retract Secondary
Boom indicator light
flashing: Lower/retract the
secondary boom until the
indicator light is off.

Lower Primary Boom
indicator light flashing:
Lower the primary boom
until the indicator light is
off.

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 Lower the primary

boom

4 Move the machine to a

firm, level surface.

Platform Not Level
indicator light flashing: The
tilt alarm will be sounding
when this light is flashing.
The Platform Level toggle
switch will only work in the
direction that will level the
platform. Level the
platform until the indicator
light is off.

54 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

P22

Operating Instructions

Platform Out of Level (P22 code)

Bypass key position to be used to level the
platform if ground control display shows platform
out of level (P22) and platform level controls do not
work.

To operate:

1 Turn the engine off.
2 Turn the main key switch to ground control.

Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.

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, move the generator
switch. The indicator light will come on and the
engine will continue to run.

3 Turn the

bypass/recovery key
switch to the bypass
position.

P22

4 Using emergency power, operate the platform

level button to level the platform.

5 Turn the bypass/recovery key switch to the run

position.

6 Remove the key from the bypass/recovery key

switch and insert the key into the main key
switch.

7 Push in and then pull out the red Emergency

Stop button.

8 If the P22 code is still visible, tag and remove

the machine from service until the fault has
been corrected by a qualified service
technician.

Plug a power tool into the power to platform GFCI
outlet.

To turn off the generator, move the generator
switch. The indicator light will turn off.

LCD Screen (if equipped)

The LCD screen displays hour meter, voltage, oil
pressure and coolant temperature. The screen
also displays fault codes and other service
information.

Perkins Engine

Machines equipped with Perkins 854F-34T Diesel
engines have a regeneration mode that should run
automatically when needed.

LCD will display REGEN FORCED and WARNING
HIGH EXHAUST SYSTEM TEMP when the
regeneration mode is running. No service required.

Part No. 160567 ZX-135/70 55

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Aircraft Protection Package (if equipped)

After Each Use

If the platform bumper comes
into contact with an object, the
machine will shut down and no
functions 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
machine away from aircraft
components.

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 wheels.

4 Turn the key switch to the off position and

remove the key to secure from unauthorized
use.

56 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Operating Instructions

Pipe Cradle Instructions

Observe and Obey:

The pipe cradle assembly consists of 2 pipe
cradles positioned at either side of the platform
and mounted to the guardrails with U-bolts.

 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.
Make sure the bottom of the pipe cradle tube
rests on the platform floor.

2 Install two U-bolts from the outside of the

platform rails through each pipe cradle mount.

3 Secure each U-bolt with 2 washers and 2 nuts.

a strap
b U-bolts
c pipe cradle mount
d upper platform railing
e pipe cradle weldment
f middle platform railing
g flat washers
h nylock nuts

Part No. 160567 ZX-135/70 57

Operator's Manual First Edition • Seventh Printing

Operating Instructions

Pipe Cradle Operation

Panel Cradle Assembly

1 Be sure the pipe cradle assembly and

installation 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
parallel with the length of the platform.

3 Center the load in the pipe cradles.
4 Secure the load to each pipe cradle. Pass the

nylon strap over the load. Depress the buckle
and slide the strap through. Tighten the strap.

5 Gently push and pull on the load to make sure

the pipe cradles and load are secure.

6 Keep the load secured when the machine is

moving.

Tip-over hazard. The weight of the pipe cradle

assembly and the load in the pipe cradles will
reduce the rated platform capacity of the
machine and must be factored into the total
platform load.

Tip-over hazard. The weight of the pipe cradle

assembly and the load in the pipe cradles may
limit the maximum number of occupants in the
platform.

Maximum Pipe Cradle Capacity

All models

Pipe Cradle Assembly Weight

200 lbs

90.7 kg

21 lbs

9.5 kg

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 Installation

1 Insert the hook piece through the slots in the

panel cradle base.

2 Hook the panel cradle to the bottom platform

tube in the desired location.

3 Install rubber bumper 2 through the panel

cradle base and the hook piece. See the
illustration.

4 Secure with 2 low profile lock nuts.
5 If the panel cradle is installed at a platform

floor support tube, insert the U-bolt through the
floor, around the tube and into the panel cradle
base.

6 Secure the U-bolt with 2 nuts and 2 washers.

Proceed to step 9.

7 If the 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, around the tube and into the panel cradle
base.

58 ZX-135/70 Part No. 160567

9 Repeat above for the second set of parts.

First Edition • Seventh Printing Operator's Manual

Operating Instructions

Installation of Padding

1 Install the 2 pieces of padding on the platform

rails. Position the padding to protect the panels
from contact with the platform rails.

Installation of Strap

1 Open the clamp and install it around a vertical

platform rail tube.

2 Insert a bolt with a washer through 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 the platform.
4 Secure the load to the platform using the strap.

Tighten the strap.

rubber
bumper 1

decal

hook piece

padding

rubber

bumper 2

U-bolt

mounting

slots

panel

cradle

base

Part No. 160567 ZX-135/70 59

clamp

hook

Operator's Manual First Edition • Seventh Printing

Transport and Lifting Instructions

Transport and Lifting Instructions

Observe and Obey:

 Genie provides this securement information as

a recommendation. Drivers are solely
responsible for making sure machines are
properly secured and the correct trailer is
selected pursuant to US Department of
Transportation regulations, other localized
regulations, and their company policy.

 Genie customers needing to containerize any

lift or Genie product should source a qualified
freight forwarder with expertise in preparing,
loading and securing construction and lifting
equipment for international shipment.

 Only qualified aerial lift operators should move

the machine on or off the truck.

 The transport vehicle must be parked on a

level surface.

 The transport vehicle must be secured to

prevent rolling while 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 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

exceeds the uphill, downhill or side slope
rating. See Driving on a Slope in the Operating
Instructions section.

 If the slope of the transport vehicle bed

exceeds the maximum slope rating, the
machine must be loaded and unloaded using a
winch as described in the brake release
operation.

Free-wheel Configuration for
Winching

Chock the wheels to prevent the machine from
rolling.

Release the wheel
brakes by turning
over all four drive hub
disconnect caps.

Be sure the winch
line is properly
secured to the drive
chassis tie points and
the path is clear of all
obstructions.

Reverse the procedures described to re-engage
the brakes.

Note: The pump free-wheel valve should always
remain closed.

60 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Transport and Lifting Instructions

Securing to Truck or Trailer for
Transit

Securing the Chassis

Use chains of ample load capacity.

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

1 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.

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.

Part No. 160567 ZX-135/70 61

Operator's Manual First Edition • Seventh Printing

Transport and Lifting Instructions

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.

Observe and Obey:

 Only qualified riggers should rig the machine.
 Only certified crane operators should lift the

machine and only in accordance with the
applicable crane regulations.

 Be sure the crane capacity, loading surfaces

and straps or lines are sufficient to withstand
the machine weight. See the serial label for the
machine weight.

Attach the rigging only to the designated lifting
points on the machine. There are four lifting points
on the machine, one on each axle.

Adjust the rigging to prevent damage to the
machine and to keep the machine level.

Center of gravity X Axis Y Axis

ZX-135/70

72.75 in

1.85 m

40.5 in

1.03 m

62 ZX-135/70 Part No. 160567

First Edition • Seventh Printing Operator's Manual

Maintenance

Maintenance

Check the Engine Oil Level

Observe and Obey:

 Only routine maintenance items specified in

this manual shall be performed by the
operator.

 Scheduled maintenance inspections shall be

completed by qualified service technicians,
according to the manufacturer’s specifications
and the requirements specified in the
responsibilities manual.

 Use only Genie approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in this
manual to help communicate the intent of the
instructions. When one or more of the symbols
appear at the beginning of a maintenance
procedure, it conveys the meaning below.

Indicates that tools will be required to
perform this procedure.

Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.

Note: Check the oil level with the engine off.

1 Check the oil level dipstick. Add oil as needed.

Perkins 1104D-44T Engine

Oil type 15W-40

Oil type - cold conditions 10W-30

Deutz TD2011 L04i Engine

Oil type 15W-40

Oil type - cold conditions 5W-30

Perkins 854F-34T Engine

Oil type 15W-40

Oil type - cold conditions 5W-30

Deutz TD2.9L Engine

Oil type 15W-40

Oil type - cold conditions 5W-30

Indicates that new parts will be required to
perform this procedure.

Indicates that a cold engine is required
before performing this procedure.

Part No. 160567 ZX-135/70 63

Operator's Manual First Edition • Seventh Printing

Maintenance

Diesel Fuel Requirements

Satisfactory engine performance is dependent on
the use of a good quality fuel. The use of a good
quality fuel will give the following result: long
engine life and acceptable exhaust emissions
levels.

Minimum diesel fuel requirements for each engine
are listed below.

Perkins 1104D-44T Engine

Fuel Type Low Sulfur Diesel (LSD)

Perkins 854F-34T Engine

Fuel Type Ultra Low Sulfur Diesel (ULSD)

Deutz TD2011 L04i Engine

Fuel Type Low Sulfur Diesel (LSD)

Deutz 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 position

and the engine is off.

2 Visually inspect the sight gauge located on the

side of the hydraulic oil tank.

Result: The hydraulic oil level should be

between the two marks on the decal next to
the sight gauge.

3 Add oil as needed. Do not overfill.

Maximum oil level

Minimum oil level

Hydraulic oil specifications

Hydraulic oil type Chevron Rando HD equivalent

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Maintenance

Check the Engine Coolant Level –
Liquid Cooled Models

Maintaining the engine coolant at the proper level
is essential to engine service life. Improper coolant
level will affect the engine’s cooling capability and
damage engine components. Daily checks will
allow the inspector to identify changes in coolant
level that might indicate cooling system problems.

1 Check the coolant fluid level. Add fluid as

needed.

Result (Deutz TD2.9L engine): The fluid level

should be visible in the sight gauge on the
degas tank.

Result (all other engine models): The fluid

level should be in the NORMAL range.

Bodily Injury Hazard. Fluids in the radiator and

in the 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 serious injury.
Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.

Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda
and water.

1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are

tight and free of corrosion.

3 Be sure that the battery hold-down brackets

are in place and secure.

Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.

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Maintenance

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.

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Specifications

Specifications

Model

ZX-135/70

Height, working maximum 141 ft 42.9 m

Height, platform maximum 135 ft 41.4 m

Height, stowed maximum 10 ft 1 in 3.1 m

Horizontal reach, maximum 69 ft 9 in 21.3 m

Width, axles retracted 8 ft 1 in 2.5 m

Width, axles extended 16 ft 6 in 5 m

Length, stowed 42 ft 5 in 12.9 m

Maximum load capacity 600 lbs 272 kg

Maximum wind speed 28 mph 12.5 m/s

Wheelbase, axles extended 7 ft 3 in 2.2 m

Wheelbase, axles retracted 16 ft 6 in 5 m

Ground clearance 15 in 38 cm

Turning radius, axles extended

Inside 9 ft 11 in 3 m

Outside 20 ft 7 in 6.3 m

Turning radius, axles retracted

Inside 24 ft 1 in 7.3 m

Outside 28 ft 1 in 8.6 m

Turntable rotation (degrees) 360° continuous

Turntable tailswing,

14 ft 4.3 m

secondary boom lowered

Turntable tailswing,

2 ft 7 in 0.74 m

secondary boom raised

Controls 12V DC proportional

Platform dimensions, 6 foot

72 x 30 in 182 x 76 cm

(length x width)

Platform dimensions, 8 foot

96 x 36 in 244 x 91 cm

(length x width)

Platform leveling self-leveling

Platform rotation 160°

AC outlet in platform standard

Fuel tank capacity 40 gallons 151 liters

Hydraulic pressure, maximum

2,900 psi 203 bar

(boom functions)

Hydraulic pressure, maximum

3,100 psi 218 bar

(emergency power unit)

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 weight.)

Maximum slope rating, stowed position, 4WD

Counterweight uphill 45% 24°

Counterweight downhill 30% 17°

Side slope 25% 14°

Note: Slope rating is subject to ground conditions and
adequate traction.

Drive speeds

Drive speed, stowed 3.0 mph

40ft/9.1 sec

Drive speed, raised or
extended

Drive speed, raised and
extended

0.7 mph

40 ft/40 sec

0.4mph

40 ft/68 sec

4.8 km/h

12.2 m/9.1 sec

1.1 km/h

12.2m/40 sec

0.6 km/h

12.2 m/68 sec

Floor loading information

Tire load maximum 22,000 lbs 9,979 kg

Tire contact pressure 82 psi 5.77 kg / cm

566 kPa

Occupied floor pressure 289 psf 1,411 kg / m

13.84 kPa

Note: Floor loading information is approximate and does
not incorporate different option configurations. It should
be used only with adequate safety factors.

Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

2

2

Part No. 160567 ZX-135/70 67

Operator's Manual First Edition • Seventh Printing

Specifications

ZX-135/70 Range of Motion Chart

ZX-135/70 Part No. 160567 Operator's Manual Fi rst Edition • Sevent h Printing

68 ZX-135/70 Part No. 160567

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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