Table Of ContentOperator's Manual Second Edition • Fifth Printing
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this 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, call Genie.
Contents
Page
Introduction................................................................ 1
Symbols and Hazard Pictorials Definitions................. 3
General Safety........................................................... 5
Personal Safety........................................................11
Work Area Safety......................................................12
Legend......................................................................20
Controls ....................................................................21
Inspections...............................................................29
Operating Instructions...............................................46
Transport and Lifting Instructions..............................58
Maintenance .............................................................61
Specifications...........................................................64
Contact us: Copyright © 2005 by Terex Corporation
Second Edition: Fifth Printing, September 2015
Internet: http://www.genielift.com
e-mail: [email protected] "Genie" and "Z" are registered trademarks of
Terex South Dakota in the U.S.A. and many
other countries.
These machines comply with
ANSI/SIA 92.5
CAN B.354.4
Printed on recycled paper
Printed in U.S.A.
Z-135/70 Part No. 114474
Second Edition · Fifth Printing Operator's Manual
Introduction
Owners, Users and Operators:
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.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators: Danger
1 Comply with employer, job site and
Failure to obey the instructions and
governmental rules.
safety rules in this manual will
2 Read, understand and follow the instructions
result in death or serious injury.
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
Do Not Operate Unless:
commonsense way.
4 Only have trained/certified operators, directed You learn and practice the principles of safe
by informed and knowledgeable supervision, machine operation contained in this operator's
running the machine. manual.
If there is anything in this manual that is not clear 1 Avoid hazardous situations.
or which you believe should be added, please
Know and understand the safety rules before
contact us.
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 work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Part No. 114474 Z-135/70 1
Operator's Manual Second Edition · Fifth Printing
Introduction
Hazard Classification Intended Use
Genie uses symbols, color coding and signal words This machine is intended to be used only to lift
to identify the following: personnel, along with their tools and materials to an
aerial work site.
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety Safety Sign Maintenance
messages that follow this symbol
to avoid possible injury or death.
Replace any missing or damaged safety signs.
Indicates a hazardous situation Keep operator safety in mind at all times. Use mild
which, if not avoided, will result in soap and water to clean safety signs. Do not use
Red death or serious injury. solvent-based cleaners because they may damage
the safety sign material.
Indicates a hazardous situation
which, if not avoided, could result
Orange in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
Yellow
in minor or moderate injury.
Indicates a hazardous situation
which, if not avoided, could result
Blue in property damage.
2 Z-135/70 Part No. 114474
Second Edition · Fifth Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Crush Hazard Keep away from Electrocution Disconnect battery. Fall Hazard
moving parts. Hazard
Keep away from
Keep off this
Crush Hazard path of moving Tip-over Hazard Read the operator’s
surface.
platform. manual.
Tip-over Hazard Rated platform Electrocution Maintain required
capacity Hazard clearance.
Read service
Explosion Hazard No smoking. manual Only trained
No flame. maintenance
Stop engine. personnel should
access
compartments
Recovery procedure if tilt alarm sounds
while elevated.
3
3
Tip-over Hazard Explosion Hazard Do not use ether
or other high
energy starting
Platform uphill: Platform downhill: aids on machines
1 Lower primary 1 Retract primary equipped with
2 Retract/lower 2 Retract/lower glow plugs.
secondary secondary
3 Retract primary 3 Lower primary
Part No. 114474 Z-135/70 3
Operator's Manual Second Edition · Fifth Printing
Symbol and Hazard Pictorials Definitions
Lanyard Wheel load Voltage rating for Pressure rating for Tire specification
attachment point power to platform air line to platform
Avoid contact. Tie-down Tie-down Weight of welder Wind speed
instructions instructions reduces capacity
Fire Hazard Fire extinguisher
Accesss by
No step. Do not jump-start trained and
this battery. authorized
personnel only
4 Z-135/70 Part No. 114474
Second Edition · Fifth Printing Operator's Manual
General Safety
Safety signs and
locations
28177 114258 97865 114390
97602
1263543 1263543 82237
28161
97715
or 229356
97715
or 230977
or 229356
or 230977
97715 or 229356 or 230977 28177 1263543
WARNING WARNING
DANGER
Lug Nut Torque
Dry bolts:
Tip-over Hazard 420 ft-lbs /
Failure to replace tires with tires 569.5 Nm Crush Hazard
of same specification will result Lubricated bolts: Death or serious
in death or serious injury. 320 ft-lbs / injury may result
433.9 Nm
Do not use air-filled tires. from platform
Fmoaacmhi-nfiell esdta tbirielitsy .are critical to cpreursshoinnngel tIhmisp reoqpueirp mopeenrta ctiaonn roers mulat iinnt edneaanthc eo rof aAuctcheosrsiz beyd tpraeirnseodn naenld only.
Dtiroe sn owti rthe ptilraecse o faf cdtioffreyr-einnsttalled against boom. serious injury.
specification or ply rating.
T44ir5e/ S65iz De22.5, 18 ply Foam-filled 97715 B Kpaetehp o af wmaoyv ifnrogm
platform.
114258 28161
114390 28177 C
DANGER DANGER WARNING
Burn Hazard No smoking. No Crush Hazard
Fuel and fumes flame. Stop Contact with moving parts can
can explode engine. result in death or serious
and burn. injury.
114258 A
82237
DANGER
Keep away from moving parts.
97602 97865 28161 C
WARNING
WARNING
Electrocution
Hazard
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serious injury. 82237 B performing service on this
machine may result in
Do not use ether or death or serious injury.
Explosion Hazard other high energy
Death or serious injury can starting aids on Disconnect all the batteries
result from the use of ether or machines equipped before performing service on
other high energy starting with glow plugs. this machine.
aids. 97602 B
97865 B
Part No. 114474 Z-135/70 5
Operator's Manual Second Edition · Fifth Printing
General Safety
Safety signs and locations
(cid:2)(cid:3)(cid:4)(cid:5)(cid:6)(cid:5)(cid:7)
Bodily Injury Hazard
Failure to use pipe cradle assembly according to instructions and safety rules
below and in operator's and responsibilities manual could result in death or
serious injury.
Do not exceed rated platform capacity. Secure load to platform.
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Center load within perimeter of platform. 72875 C
WARNING
Bodily Injury Failure to use panel cradles according to instructions and safety rules
Hazard below and in operator's and responsibilities manual could result in death
or serious injury.
Do not exceed rated platform Weight of panel cradles and loadDo not cause a horizontal force
capacity. Combined weight in panel cradles may limit or side load to machine by
of cradles, panels, maximum number of occupants raising or lowering a fixed or
occupants, tools and any in platform to one person. overhanging load.
oexthceere edq ruaitpemd ecnatp macuistyt .not SSeeccuurree pcraandelel(ss )t oto p plalatftoforrmm. Mpaanxeimlsu: m4 fvt e/ r1ti.c2a ml height of
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DANGER
3
•Stop all movement. P1laLtfoowrme ru pprhimill:ary boom.
2Retract/lower secondary boom.
3Retract primary boom.
Tip-over Hazard 3
If tilt-alarm
sounds, unit is on •Read operator's Platform downhill:
a severe slope. manual before 1Retract primary boom.
Death or serious attempting to move 2Retract/lower secondary boom.
injury will result. machine. 133236 A 3Lower primary boom.
6 Z-135/70 Part No. 114474
Second Edition · Fifth Printing Operator's Manual
General Safety
Safety signs and locations
31788 28177 52865 97865 114389
DANGER WARNING WARNING DANGER
WARNING
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Dinejuartyh m oar ys ererisouulst tpmheaerc fboharimntteein rmigea ssy eb rreevfsiocureel to inn this
from platform death or serious injury.
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DO NOTOPERATE equipment if you do not 97865 B
understand the information in the manuals. Keep away from
Cmoannsuufaltc ytuoruerr .supervisor, the owner or the path of moving
platform.
31788 C
114390 281737 C1060 28181
DANGER DANGER WARNING
Tip-over Hazard
Altering or disabling limit
switches can result in machine
tip-over. Machine tip-over will
result in death or serious injury.
Dswoi tncoht( sa)l.ter or disable limit FDfroaemlal tH hca loizmra bsrdienrgio ours riindjiunrgy omna byo roemsu.lt
31060 C
97875 1263543
WARNING
Keep off this surface. 28181 C
28161 82314
Improper operation or maintenance of Access by trained and
this equipment can result in death or authorized personnel only. WARNING
serious injury. DANGER
Tip-over Hazard
82237 Acaltne rriensgu oltr i nd imsaabclhininge a tnipg-loe vseern.sor
97715 or 229356 or 230977 DANGER Mdeaacthhi noer stiepr-ioovuesr iwnjiull rrye.sult in
Do not move, alter or disable
DANGER Lug Nut Torque angle sensor. 82314 B
Dry bolts: Crush Hazard
Tip-over Hazard 420 ft-lbs / Contact with moving parts can
FoiDFmnofaoa dasi clnmaeuhomari-tnetf ieuhe ltl s eossoedtp rra aeetsbiicpreriel-ilirfftasiiyilo cc.laeuaerdte st iti oicirrnnerejis tsuwi c.rwiaylil.lt rthoe stiurelts Lu534b632r930ic.. 59fat -tNNlebmmds b/olts: EHCecrseoenlaosemreznuicoratpltgaturro oidcisznnct e ieuwnddntjeiiuottahsrny tch.a onr Awcovitmohi pde8o nc2neo2ern3gnt7iatz s ce .Btd rinejsuurylt. in death or serious
Do not replace factory-installed
tsT4irp4iere5esc/ S6iwf5iizci tDeaht 2itoi2rne.5 so, r1o p8f ld pyi lfryfae Ftrieonnagtm.-filled 97715 B Keep away fr2o81m61 mCoving parts.
97865
82314
1263543
31060
31060
1263543
97875
28161
114389
52865
97715 97715
114390 1263543 28181 28177
or 229356 or 229356
31788 or 230977 or 230977 82237
Part No. 114474 Z-135/70 7
Operator's Manual Second Edition · Fifth Printing
General Safety
Safety signs and locations
82548 114251 133079 133067
1263542
1263542
82472
114249
114249
82472
114251 1263542
114251 A
82472 B
133079 133067
133179 A
82548 114249
114249 A
8 Z-135/70 Part No. 114474
Description:Failure to use pipe cradle assembly according to instructions and safety 52865. 97875. Tip-over Hazard. Altering or disabling limit switches can
