Genie Z-135/70 User manual

Operator's Manual Second Edition • Fourth Printing
Z-135/70 PartNo.114474
Copyright © 2005 by Terex Corporation
Second Edition: Fourth Printing, January 2015
"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.
Important
Read,understandandobeythesesafetyrulesand
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
GeneralSafety ........................................................... 5
PersonalSafety ........................................................ 11
Work Area Safety...................................................... 12
Legend ...................................................................... 20
Controls .................................................................... 21
Inspections ............................................................... 29
OperatingInstructions ............................................... 46
TransportandLiftingInstructions .............................. 58
Maintenance ............................................................. 61
Specifications ........................................................... 64
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]

Operator'sManualSecond Edition · Fourth Printing
PartNo.114474 Z-135/70 1
Introduction
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructionsandsafetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and work site regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis 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:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.

Operator'sManual Second Edition · Fourth Printing
2 Z-135/70 PartNo.114474
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
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-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminorormoderate injury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

Operator'sManualSecond Edition · Fourth Printing
PartNo.114474 Z-135/70 3
Symbol and Hazard Pictorials Definitions
ExplosionHazard
Electrocution
Hazard FallHazard
CrushHazard
Tip-overHazard
Tip-overHazard
Tip-overHazard Electrocution
Hazard Maintainrequired clearance.
Readtheoperator’s
manual.
Keep off this
surface.
Keepawayfrom
path of moving
platform.
Nosmoking.
Noflame.
Stopengine.
Do not use ether
orotherhigh
energystarting
aids on machines
equippedwith
glowplugs.
Readservice
manual
Ratedplatform
capacity
Platformuphill:
1 Lowerprimary
2 Retract/lower
secondary
3 Retractprimary
Platformdownhill:
1 Retract primary
2 Retract/lower
secondary
3 Lowerprimary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.
Onlytrained
maintenance
personnelshould
access
compartments
CrushHazard Keepawayfrom
movingparts.
ExplosionHazard
Disconnectbattery.

Operator'sManual Second Edition · Fourth Printing
4 Z-135/70 PartNo.114474
Symbol and Hazard Pictorials Definitions
Lanyard
attachmentpoint Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform
Avoid contact. Tie-down
instructions Tie-down instructions
Fireextinguisher
Weightofwelder
reducescapacity Windspeed
No step. Donotjump-start
this battery.
FireHazard
Tirespecification
Accesss by
trainedand
authorized
personnelonly

Operator'sManualSecond Edition · Fourth Printing
PartNo.114474 Z-135/70 5
Safety signs and
locations
General Safety
Improper operation or maintenance of
this equipment can result in death or
serious injury.
WARNING
Access by trained and
authorized personnel only.
114390
114258 97865
1263543
28177
97715
or 229356
or 230977
97715
or 229356
or 230977
97602
28161
82237
28177
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
LugNutTorque
Dry bolts:
420 ft-lbs /
569.5Nm
Lubricatedbolts:
320 ft-lbs /
433.9Nm
Tip-overHazard
Failure to replace tires with tires
ofsame specification will result
in death or serious injury.
Do not use air-filled tires.
Foam-filled tires are critical to
machinestability.
Donot replace factory-installed
tires with tires of different
specification or ply rating.
Tire Size
445/65D22.5,18plyFoam-filled
DANGER
97715 B
97715 or 229356 or 230977
114258
Burn Hazard
Fuel and fumes
can explode
and burn.
DANGER
No smoking. No
flame. Stop
engine.
114258 A
Electrocution/BurnHazard
Failure to disconnect all
the batteries before
performing service on this
machine may result in
death or serious injury.
Disconnect all the batteries
before performing service on
this machine.
WARNING
97865 B
97865
114390
DANGER
Electrocution
Hazard
Contact with
energized
components can
result in death or
serious injury. 82237 B
DANGER
Avoid contact
with energized
components.
82237
97602
Explosion Hazard
Death or serious injury can
result from the use of ether or
other high energy starting
aids.
97602 B
WARNING
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
28161
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
1263543
1263543

Operator'sManual Second Edition · Fourth Printing
6 Z-135/70 PartNo.114474
General Safety
Safety signs and locations
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
seriousinjury.
Do not exceed rated platform capacity.
Pipe cradle assembly and weight in pipe
cradles will reduce rated platform capacity
and must be factored into total platform
load.
Pipe cradle assembly weighs 25 lbs (11kg).
Maximum capacity of pipe cradle assembly
is 200 lbs (91 kg).
Weight of pipe cradle assembly and load in
pipe cradles may limit maximum number of
occupants in platform.
Centerload withinperimeter ofplatform.
Secure load to platform.
Do not obstruct entrance/exit of platform.
Do not obstruct ability to operate platform
controls or Emergency Stop button.
Donot operateunless youare adequately
instructedandare awareof allhazards
associated with movement of platform
withoverhangingload.
Do not cause a horizontal force or side
load to machine by raising or lowering a
fixedor overhangingload.
WARNING
72875 C
Do not cause a horizontal force
or side load to machine by
raisingor loweringa fixedor
overhangingload.
Maximum vertical height of
panels: 4 ft / 1.2 m
Maximumwind speed:
15 mph / 6.7 m/sec
Maximumpanelarea:
32 sq. ft / 3 m
2
Donot exceedrated platform
capacity.Combinedweight
of cradles, panels,
occupants, tools and any
otherequipment mustnot
exceed rated capacity.
Panelcradle assembly
weighs 30 lbs / 13.6 kg.
Maximum capacity of panel
cradles is 250 lbs / 113 kg.
Weightof panelcradles andload
in panel cradles may limit
maximumnumber ofoccupants
in platform to one person.
Secure cradles to platform.
Securepanel(s) toplatform
railingusing strapsprovided.
Donot operateunless youare
adequatelyinstructedand are
awareof allhazards associated
with lifting panels.
WARNING
82410 C
Bodily Injury
Hazard Failureto usepanel cradlesaccording toinstructions and safetyrules below and in operator's and responsibilities manual could result in death
or serious injury.
Tip-over Hazard
If tilt-alarm
sounds, unit is on
a severe slope.
Death or serious
injury will result.
133236 A
DANGER
Platformuphill:
1 Lowerprimaryboom.
2 Retract/lowersecondary boom.
3 Retractprimaryboom.
Platformdownhill:
1 Retractprimary boom.
2 Retract/lowersecondary boom.
3 Lowerprimaryboom.
3
3
• Read operator's
manual before
attempting to move
machine.
• Stop all movement.

Operator'sManualSecond Edition · Fourth Printing
PartNo.114474 Z-135/70 7
Safety signs and locations
General Safety
31060
31060
52865
97865
82314
28161
114389
28177
28181
1263543
114390
97875
31788 82237
28177
31060
Crush Hazard
Death or serious
injury may result
from platform
crushing
personnel
against boom.
WARNING
28177 C
Keep away from
path of moving
platform.
114390
DANGER
DANGER
114389
WARNING
52865
97875
Tip-over Hazard
Altering or disabling limit
switches can result in machine
tip-over. Machine tip-over will
result in death or serious injury.
DANGER
Do not alter or disable limit
switch(s).
31060 C
28181
Keep off this surface.
WARNING
Fall Hazard
Death or serious injury may result
from climbing or riding on boom.
28181 C
DANGER
Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
31788 C
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
Electrocution/BurnHazard
Failure to disconnect all
the batteries before
performing service on this
machine may result in
death or serious injury.
Disconnect all the batteries
before performing service on
this machine.
WARNING
97865 B
97865
Electrocution
Hazard
Contact with
energized
components can
result in death or
serious injury.
82237 B
DANGER
Avoid contact
with energized
components.
82237
28161
28161 C
Crush Hazard
Contact with moving parts can
result in death or serious
injury.
WARNING
Keep away from moving parts.
Tip-over Hazard
Altering or disabling angle sensor
can result in machine tip-over.
Machine tip-over will result in
death or serious injury.
DANGER
Do not move, alter or disable
angle sensor.
82314 B
82314
97715
or 229356
or 230977
LugNutTorque
Dry bolts:
420 ft-lbs /
569.5Nm
Lubricatedbolts:
320 ft-lbs /
433.9Nm
Tip-overHazard
Failure to replace tires with tires
ofsamespecification willresult
in death or serious injury.
Do not use air-filled tires.
Foam-filled tires are critical to
machinestability.
Donotreplace factory-installed
tires with tires of different
specification or ply rating.
Tire Size
445/65D22.5, 18ply Foam-filled
DANGER
97715 B
97715 or 229356 or 230977
97715
or 229356
or 230977
Improper operation or maintenance of
this equipment can result in death or
serious injury.
WARNING
Access by trained and
authorized personnel only.
1263543
1263543
1263543

Operator'sManual Second Edition · Fourth Printing
8 Z-135/70 PartNo.114474
General Safety
Safety signs and locations
133067
114251 133079
82548
114249
114249
82472
82548
114251
133067
82472
114251 A
82472 B
114249
114249 A
133179 A
133079
1263542
1263542
1263542