Genie TZ-20 Setup guide

Genie TZ-34/20 Part No. 133554
Operator's Manual Fourth Edition • Fourth Printing
Copyright © 2003 by Terex
Fourth Edition: Fourth Printing, October 2014
"Terex" is a registered trademark of Terex USA, LLC in the USA
and many other countries.
These machines comply with
ANSI A92.2
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Printed on recycled paper
Printed in U.S.A.
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.
Contact us:
Internet: http://www.genielift.com
e-mail: [e-mail]
Contents
Introduction........................................................... 1
Symbol and Hazard Pictorials Definitions............. 4
General Safety...................................................... 6
Work Area Safety................................................ 14
Legend................................................................ 19
Controls .............................................................. 20
Inspections ......................................................... 22
Operating Instructions ........................................ 34
Transport and Lifting Instructions ....................... 38
Maintenance....................................................... 40
Specifications ..................................................... 44
Reporting Safety Defects.................................... 46

Part No. 133554 Genie TZ-34/20 1
Operator’s Manual
Fourth Edition • Fourth Printing
About this manual
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.
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Bulletin Distribution and
Compliance
Safety of product users is of 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 te action indicated in a respective
bulletin.
Introduction

2 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
Contacting the Manuafacturer
At times it may be necessary to contact Terex.
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, Terex 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.
Introduction

Part No. 133554 Genie TZ-34/20 3
Operator’s Manual
Fourth Edition • Fourth Printing
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 hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
DANGER
Indicates a hazardous situation
that if not avoided, will result in
death or serious injury.
WARNING
Indicates a hazardous situation
that if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation
that if not avoided, could result in
minor or moderate injury.
NOTICE
Indicates information considered
important, but not hazard related
(e.g. messages related to property
damage)
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.v
Introduction

4 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
Read the
operator’s
manual.
Electrocution/burn
hazard.
Crushing Hazard.
Corrosive acid.
No smoking. Explosion/burn
hazard.
Crushing hazard. Stay clear of
moving platform.
Crushing hazard. Keep away from
moving parts.
Wear protective
clothing.
Only trained
personnel.
Fall Hazard Keep off boom. Do not expose to
water or rain.

Part No. 133554 Genie TZ-34/20 5
Operator’s Manual
Fourth Edition • Fourth Printing
Symbol and Hazard Pictorials Definitions
Corrosive acid. Explosion hazard. Crushing hazard. No flame. Crushing hazard.
Stay clear of
moving machinery.
Electrocution
hazard.
Maintain required
clearance.
Injection Hazard. Do not check for
hydraulic leaks
with hands.
Tip-over Hazard.

6 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
General Safety
82505 A
Crushing Hazard.
Contact with moving
parts will cause death
or serious injury.
Keep clear of elevated
components.
Crushing hazard.
Lowering the outriggers or tires
onto a person's foot can result
in serious injury.
82506 B
Keep clear of outriggers and
tires before lowering.
WARNING
82506
82506
1263140
1263140
46262
46262
43617
43617
82505
82505
82479
82479
Electrocution Hazard
Death or injury can result from contacting electric
power lines.
Always contact the electric power line owner. The
electric power shall be disconnected or the power
lines moved or insulated before machine operations
begin. 1263140 A
DANGER
Maintain required clearance.
LineVoltage Required Clearance
0 to 300V Avoid Contact
300V to 50KV 10 ft 3.05 m
50KV to 200KV 15 ft 4.60 m
200KV to 350KV 20 ft 6.10 m
350KV to 500KV 25 ft 7.62 m
500KV to 750KV 35 ft 10.67 m
750KV to 1000KV 45 ft 13.72 m
Manifold Side / Platform End TZ-34

Part No. 133554 Genie TZ-34/20 7
Operator’s Manual
Fourth Edition • Fourth Printing
General Safety
82506 46262
43617
1263140
82558
82558
28175
28175
Crushing hazard.
Lowering the outriggers or tires
onto a person's foot can result
in serious injury.
82506 B
Keep clear of outriggers and
tires before lowering.
WARNING
82506
1263140
43617
Electrocution Hazard
Death or injury can result from contacting electric
power lines.
Always contact the electric power line owner. The
electric power shall be disconnected or the power
lines moved or insulated before machine operations
begin. 1263140 A
DANGER
Maintain required clearance.
LineVoltage Required Clearance
0 to 300V Avoid Contact
300V to 50KV 10 ft 3.05 m
50KV to 200KV 15 ft 4.60 m
200KV to 350KV 20 ft 6.10 m
350KV to 500KV 25 ft 7.62 m
500KV to 750KV 35 ft 10.67 m
750KV to 1000KV 45 ft 13.72 m
82558 B
Injection Hazard
Escaping fluid under pressure can
penetrate skin, causing serious injury.
Relieve pressure before disconnecting
hydraulic lines. Keep away from leaks
and pin holes. Use a piece of cardboard
or paper to search for leaks. Do not use
hand.
Fluid injected into skin must be
surgically removed within a few hours
by a doctor familiar with this type of
injury or gangrene will result.
WARNING
Compartment access
is restricted.
Contact with
components under
any cover may result
in serious injury.
Only trained maintenance personnel
should access compartments. Access
by operator is only advised when
performing Pre-operation Inspection.All
compartments must remain closed and
secured during operation.
28175 H
WARNING
46262
Hydraulic tank side Side / Hitch End TZ-34

8 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
General Safety
Crushing hazard.
Lowering the outriggers or tires
onto a person's foot can result
in serious injury.
82506 B
Keep clear of outriggers and
tires before lowering.
WARNING
28161
28161 28161
82506
82506 82506
72832 72832
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
Front and Rear view outriggers
82505
72832
DANGER
Do not alter or
disable limit switch.
72832 D
Tip-over hazard.
Machine tip-over will
result in death or
serious injury.
82505 A
Crushing Hazard.
Contact with moving
parts will cause death
or serious injury.
Keep clear of elevated
components.
82505

Part No. 133554 Genie TZ-34/20 9
Operator’s Manual
Fourth Edition • Fourth Printing
General Safety
Keep off this surface.
WARNING
Fall Hazard
Death or serious injury may result
from climbing or riding on boom.
28181 C
TZ-34/20
®
TZ-34/20
®
Boom and Platform Views
62707
62707
82505
82505
82409
82409
28181
28181
28236
82423
28177
28177
28236
28177
Explosion Hazards
Do not start engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel machine with engine running.
Electrocution Hazards
This machine is not electrically
insulated and will not provide
protection from contact with or
proximity to electrical current.
Maintain safe distances from
electrical power lines and
apparatus in accordance with
applicablegovernmental
regulations and the following
chart.
Minimum Safe Approach Distance
Voltage Distance
Phase to Phase Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72
Fall Hazards
Occupants must wear a safety
belt or harness in accordance
with governmentalregulations.
Attach lanyard to anchor
provided in 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.
Lower platform entry mid-rail or close entry gate before
operating.
Collision Hazard
Be aware of crushing hazard when grasping platform
guard rail.
Check work area for overheadobstructions or other
possible hazards.
Do not lower the boom unless the area below is clear of
personnel and obstructions.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in the appropriate operator's and service
manuals.
Be sure all decals are in place and legible.
Be sure safety, operator’s and responsibilities manuals
are complete, legible and in the storage container
located on the platform.
Improper Use Hazard
The operator is responsible for safe machine
operation.This includes:
1 Avoid hazardous situations.
2 Alwaysperform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect work place.
5 Only use the machine as it was intended.
Do not operate unless:
You read, understand and obey:
- manufacturer’s instructions and safety rules —
safety and operator's manuals and decals
- employer’s safety rules
- applicablegovernmental regulations
You are properly trained to safely operate this
machine.
Tip-over Hazards
Do not exceed rated load
capacity.
Do not raise boom unless all
fouroutriggers are lowered,
footpads are in firm contact
with ground and machine is
level.
Do not raise boom unless machine is level.Do not set
machine up on a surface where it cannot be leveled
using only the outriggers.
Do not set the machine up unless it is on a firm
surface Avoid drop-offs, holes, unstable or slippery
surfaces and other possible hazardous conditions.
Do not depend on tilt alarm as
a level indicator. Tilt alarm
sounds only when machine is
on a severe slope.
Do not operate machine in
strong or gusty winds. Do not
increase surface area of
platform or load. Increasing
area exposed to wind will
decrease machine stability.
Do not place ladders or
scaffolds in platform or against
any part of this machine.
Do not alter or disable machine
components that in any way
affect safety and stability.
Be sure all tires are in good condition, air-filled tires
are properly inflated and lug nuts are properly
tightened.
Do not push off or pull toward any object outside of
the platform.
Do not place or attach overhanging loads to any part
of platform.
Failure to read, understand and obey the
operator's manual and the following safety
rules will result in death or serious injury.
82423B
DANGER
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
Read and understand Operator's
Manual, Responsibilities Manual and
Safety Manual and all safety signs
before using or maintaining machine.
If you do not understand the
information in the manuals, consult
your supervisor, the owner or the
manufacturer. 28236 D
WARNING
Improper operation or
maintenance can result in
serious injury or death.
82423

10 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
General Safety
82544
82544
82481
82481
82475
82475
82487
82487
97590
97590
Manifold Side / Platform End TZ-34
82475 C
82487 C
82481 B
97590 A
82544 B

Part No. 133554 Genie TZ-34/20 11
Operator’s Manual
Fourth Edition • Fourth Printing
General Safety
82614
82614
82481
82481
82475
82475
82544
82544
82560
82560
Hydraulic tank side Side / Hitch End TZ-34
82614C
82560 B
82475 C
82544 B
82481 B

12 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
General Safety
82472
Front and Rear view outriggers
82475
82475 C
82472 B
82472 82472
82475 82475
Front and Rear view outriggers
82614
82614
82614 C

Part No. 133554 Genie TZ-34/20 13
Operator’s Manual
Fourth Edition • Fourth Printing
General Safety
TZ-34/20
®
Boom and Platform Views
82614
82487
82548
82548
82548
82614
82614 C
82487
82487 C
82548 B

14 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
Electrocution 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 3.05 m
>50 to 200KV 4.60 m
>200 to 350KV 6.10 m
>350 to 500KV 7.62 m
>500 to 750KV 10.67 m
>750 to 1000KV 13.72 m
over 1000KV see below
For power lines over 1000kV, the minimum
clearance distance must be established by
the utility owner or operator or by a registered
professional engineer who is a qualified person
with respect to electrical power transmission and
distribution.
Allow for platform movement, electrical line sway
or sag and beware of strong or gusty winds.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Keep away from the machine if it contacts
energized power lines. Personnel must not touch
or operate the machine until energized power lines
are shut off.
Do not operate an AC powered machine or a DC
battery charger unless using a 3-wire grounded
extension cord connected to a grounded AC
circuit. Do not alter or disable 3-wire grounded
plugs.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum capacity - without optional platform rotate
ANSI/CSA models - 2 occupants 227 kg
CE models - 2 occupants 200 kg
Maximum capacity - with optional platform rotate
ANSI/CSA models - 2 occupants 209 kg
CE models - 1 occupant 181 kg
Work Area Safety

Part No. 133554 Genie TZ-34/20 15
Operator’s Manual
Fourth Edition • Fourth Printing
Do not raise the boom unless the machine is level.
Do not set the machine up on a surface where it
cannot be leveled using only the outriggers.
Do not raise the boom unless all four outriggers
are lowered, the footpads are in firm contact with
the ground and the machine is level.
Do not set the machine up unless it is on a firm
surface. Avoid drop-offs, holes, unstable or
slippery surfaces and other possible hazardous
conditions.
Do not move the machine when the boom is
raised.
Do not adjust or stow the outriggers when the
boom is raised.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds only when the machine is on
a severe slope.
When the tilt alarm sounds, immediately lower
the boom and adjust the outriggers to level the
machine.
Do not alter or disable the limit switches.
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.
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 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 transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not place ladders or scaffolds in the platform or
against any part of this machine.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are properly inflated and in good
condition and lug nuts are properly tightened.
Do not use the platform as a crane.
Work Area Safety

16 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
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.
Collision Hazards
The machine must be on a level surface or
secured before releasing the parking brake.
Do not attempt to manually move a machine
unless it is on a firm, level surface. Use the parking
brake to control the speed of the machine while
pushing it.
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazards when grasping the
platform guard rail.
Do not lower the boom unless the area below is
clear of personnel and obstructions.
Be aware of boom position when rotating the
turntable.
Operators must comply with employer, job site
and governmental rules regarding use of personal
protective equipment.
Do not place loads outside the platform perimeter.
Do not place or attach overhanging loads to any
part of the platform.
Maximum allowable manual force, CE 400 N
Do not push off or pull
toward any object outside
of the platform.
Do not push the machine
or other objects with the
boom.
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.
DC models: Do not use batteries that weigh less
than the original equipment. Four batteries are
used as counterweight and are critical to machine
stability. Each battery must weigh 65 pounds /
29.5 kg.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Fall Hazards
Occupants must wear a
safety belt or harness and
comply with applicable
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Work Area Safety

Part No. 133554 Genie TZ-34/20 17
Operator’s Manual
Fourth Edition • Fourth Printing
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 the
machine.
Explosion and Fire Hazards
Do not operate the machine in hazardous
locations or locations where potentially flammable
or explosive gases or particles may be present.
Component Damage Hazards
Do not use the machine as a ground for welding.
Do not fully lower the booms unless the booms are
aligned with the tongue. The primary boom must
be lowered into the chassis cradle.
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
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 platform.
Bodily Injury Hazard
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.
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.
Make sure your tow vehicle is properly maintained
and capable of towing this machine.
Be sure the hitch is properly and securely attached
to your tow vehicle.
Do not overload your tow vehicle. Observe the
manufacturer’s Gross Vehicle Weight Rating
(GVWR).
Be sure all lights, mirrors and hitch components
conform to federal and local regulations.
Be sure that all driving lights are operational.
Be sure the tires are properly inflated.
Do not tow the machine unless the boom is
lowered into both cradles and the hold-down
latches are securely locked in place. There is a
mast cradle on the chassis and a mid-pivot cradle
on the tongue of the machine.
Do not load cargo on the machine. The TZ is not
designed to carry any extra cargo.
Be sure the safety chains (if required) are securely
attached to the tow vehicle. Cross the chains
under the hitch. This will create a cradle to catch
the tongue of the trailer if it becomes disconnected
from the tow vehicle.
Work Area Safety

18 Genie TZ-34/20 Part No. 133554
Operator’s Manual Fourth Edition • Fourth Printing
Battery Safety - DC Models
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazards
Keep sparks, flames and
lighted tobacco away
from batteries. Batteries
emit an explosive gas.
The covers should be
open during the entire
charging cycle.
Do not contact the battery terminals or the cable
clamps with tools that may cause sparks.
Component Damage Hazards
Do not use any battery charger greater than 24V
to charge the batteries.
Do not expose the batteries or the charger to
water or rain.
Electrocution Hazards
Connect the battery charger to
a grounded,
AC 3-wire electrical outlet only.
Inspect daily for damaged
cord, cables and wires.
Replace damaged items before
operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the
original equipment. Four batteries are used as
counterweight and are critical to machine stability.
Each battery must weigh 65 pounds / 29.5 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Work Area Safety
Do not tow the machine on public roads unless it
meets all governmental regulations for towing.
Do not exceed 60 mph / 97 km/h. Obey all local
and national towing speed laws.
Be sure to chock the wheels of the trailer when
parking on a hill.