Terex Genie Z-135/70 User manual

Safety Notice 140019
North America
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
1 of 2
THIS SAFETY NOTICE CONTAINS INFORMATION ABOUT MANDATORY CHANGES OR CHECKS
RELATED TO THE SAFE USE OF OUR PRODUCT.
Issue:
Date: January 22, 2015
Models and Serial Numbers
Affected:
Z-135/70: Z13505-101 to Z13513-1863
Zx-135/70: Z13513-2002, Z13513-2008
ZX13513-2001 to ZX13515-2563
Subject: Platform Leveling
Allowable Hours: 60 minutes
Issue:
Genie Industries has become aware of instances where the platform leveling valve, utilized in the above
referenced machines, malfunctions due to contamination of the hydraulic oil. A platform leveling valve that
malfunctions can cause the platform to become unlevel.
Actions Required:
1Locate all machines within the models and serial ranges referenced above.
2Order the Platform Leveling Valve Kit PN 1261518.
3Using the installation instructions included in the kit, install the Leveling Valve Kit on your machine.
Installation of the kit must take place as soon as possible but no later than 30 days from receipt of
the kit.
4Fill out and sign the completion form attached to the installation instructions and return to Genie. This will
serve as verification that you have completed this Safety Notice.
Continued Use Instructions:
All machine operators and users must be notified of these continued use requirements.
The machine may remain in service until this Safety Notice is completed by following the requirements below:
If platform becomes unlevel, do the following:
aImmediately disengage the foot switch.
Note: Do not re-engage the foot switch. Re-engaging the foot switch can cause the platform to move
further out of level.
bShut off the engine.
cRemove the operator from the platform.
dLower the platform using the ground controls.
eTag and remove the machine from service until this Safety Notice has been completed.

Safety Notice 140019
North America
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
2 of 2
To order parts:
Machine owners with a valid Genie account can contact the Terex AWP Parts Department to place an order
through one of the following:
Genie Website
http://www.gogenielift.com
Fax: [phone]
Phone: [phone]
Machine owners without a valid Genie account can contact their nearest Terex AWP dealership or Terex AWP
Service Centers for assistance.
Search for your nearest Terex AWP dealership by visiting our website at:
http://www.genielift.com/dealersearch/
Warranty:
The labor and travel miles required to perform this Safety Notice are covered under the provisions of our LIMITED
PRODUCT WARRANTY statement. Warranty claims can be submitted online, by paper claims, fax or email. If
you need more information about filing a warranty claim, please contact Terex AWP Warranty Department at:
Email: [email protected]
United States: 1-800-536-1800
Canada: 1-425-881-1800
All other locations: 001-425-881-1800
Genie and local industry standards (e.g. ANSI, CSA) requires that the seller of a Genie machine report to Genie
the model and serial number of each machine sold, as well as the name, address, and telephone number of the
new owner, within 60 days of the sale. Genie, OSHA and local industry standards, also require that the
manufacturer’s Safety Notice be completed. It is your responsibility to communicate this important information to
all machine owners and applicable branches. If you require additional copies of this Safety Notice or have any
questions, please contact Genie Product Support at:
United States: 1-800-536-1800
Canada: 1-425-881-1800
All other locations: 001-425-881-1800
Enclosures:
Machine List
New Owner Update Form
NORTH AMERICA Terex Aerial Work Platforms , 18340NE 76th Str eetRedmond WA 98052, Ph: 800-536- 1800, 425-881-1800
140019
SafetyNotice

Safety Notice 140019
New Owner Update Form
(for updating machine owner information only)
Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial number of each
machine sold, as well as the name, address, and telephone number of the new owner, within 60 days of the sale.
If you have sold a machine, list new owner's name, address and phone number, for each machine.
List complete model and serial number (ex. Z13506-317 or ZX13514-2249).
New Owner Information:
Machine 1 Machine 2 Machine 3
Model*
Serial Number *
Owner Name*
Address 1*
Address 2
City/State/Zip*
Phone Number*
Contact Person
* Required fields
Seller Information:
Date:
Company Name:
Account #:
Address:
(street):
(city):
(state, zip code):
Phone #:
List any machines that could not be inspected or repaired because of the following:
Model & Serial Number Scrapped Exported Stolen Other (explain)
- - - -
- - - -
- - - -
- - - -
- - - -
Fax to: United States: 1 877-738-7530 Latin America: + 55 11 3246-9760
Canada: 1 425-498-7530
Central America: + 1 425 498 7530
Mexico: 1 425-498-7530
Asia-Pacific: + 1 425 498 7530
Carribean: + 1 425 498 7530 All other locations: + 1 425 498 7530

Installation Instructions
Platform Level Update
Z
-
135/70
ZX
-
135/70
Part No. 1261248
Rev A

Instructions Rev A
Introduction
2 Platform Level Update Part No. 1261248
Introducti on
Introducti on
Observe and Obey:
This procedure shall be completed by a person
trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Starting Installation:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
Indicates that a specific result is expected after
performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
Note: These installation instructions only apply
to the Genie models listed on the front cover,
as required by Safety Notice 140019.
If you have any further questions regarding these
instructions or need assistance, please contact
Genie Product Support at one of the following
telephone numbers:
United States: 800-536-1800
Canada: 425-881-1800
Europe: UK + 44 1476 584 333
France + 33 237 260 986
Germany + 49 4221 491 821
Iberica + 34 935 725 090
Italy + 39 075 941 8132
Scandinavia + 46 3157 5154
Other locations + 31 653 221 908
Middle East: + 97 143 391 800 or
+ 97 150 459 7937
Australia: + 61 7 3456 4444
All other locations + 1-425-881-1800

Rev A Instructions
Introduction
Part No. 1261248 Platform Level Update 3
Tools Required:
Mild cleaning solvent
Soft clean cloth
7/16 inch wrench
9/16 inch wrench
5/8 inch wrench
11/16 inch wrench
1 1/8 inch wrench
7/16 inch socket
Ratchet
Torx T40 security bit
Components of Kit 1261518
Screw, HHC, 1/4-20 x 1.75
Genie part number 6637
Qty. 2
Flat washer, 1/4
Genie part number 6638
Qty. 2
Flange nut, 1/4-20
Genie part number 18504
Qty. 2
Fitting, 90°, -4, ORFS
Genie part number 48904
Qty. 1
Fitting, -4, ORFS
Genie part number 48905
Qty. 1
Fitting, run tee, -4, ORFS
Genie part number 48906
Qty. 2
Proportional valve
Genie part number 107816
Qty. 1
Manifold mounting bracket
Genie part number 1260641
Qty. 1
Flow control manifold
Genie part number 1261078
Qty. 1
Hose assembly
Genie part number 1261517
Qty. 2
Installation instructions
Genie part number 1261248
Qty. 1

Instructions Rev A
Procedure
4 Platform Level Update Part No. 1261248
Procedure
Note: Perform this procedure on a flat level surface,
with the boom and jib in the stowed position.
1Locate and disconnect the black negative
battery cable from the engine battery.
2Using a mild cleaning solvent, clean the
platform manifold and hose ends. Refer to
illustration 1.
1platform manifold
2manifold mounting bracket
3Tag and disconnect the harness from the
platform manifold.
4Tag and disconnect the hydraulic hoses from
the platform manifold. Cap the fittings and plug
the hoses.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
5Remove the platform manifold from the
mounting bracket. Set the manifold and
retaining fasteners aside.
6Remove the manifold mounting bracket from
the platform. Set the retaining fasteners aside
and discard the manifold mounting bracket.
Note: Refer to the illustration included with
these instructions for component location.
7Attach manifold mounting bracket (Genie part
number 1260641) to the platform using the
retaining fasteners set aside in step 6.
1manifold mounting bracket
8Attach the flow control manifold (Genie part
number 1261078) to the manifold mounting
bracket using the provided retaining fasteners
(Genie part numbers 6637, 6638 and 18504).
9Install the provided fitting (Genie part number
48905) into port 1 of the flow control manifold
and securely torque to 14 ft-lbs / 19 Nm.
1
2
WARNING
1

Rev A Instructions
Procedure
Part No. 1261248 Platform Level Update 5
10 Install the provided fitting (Genie part number
48904) into port 2 of the flow control manifold
and securely torque to 14 ft-lbs / 19 Nm.
Note: The fitting must be in the downward position.
1port 2
2port 1
11 Attach the platform manifold set aside in
step 5 to the manifold mounting bracket.
12 Remove the 90° fittings from pressure port (P)
and tank port (T) of the platform manifold and
discard.
13 Install the provided run tee (Genie part number
48906) into pressure port (P). Do not tighten at
this time.
14 Connect the 90° end of hose (Genie part
number 1261517) to the bottom of the run tee
of port (P). Connect the loose end of the hose
to port 1 of the flow control manifold (Genie
part number 1261078). Do not tighten at this
time.
15 Connect the pressure hose removed in
step 4 to the side of the run tee of port (P).
Torque the run tee to 14 ft-lbs / 19 Nm. Torque
all hose ends to 10 ft-lbs / 13.6 Nm.
16 Install the provided run tee (Genie part number
48906) into tank port (T). Do not tighten at this
time.
17 Connect the 90° end of hose (Genie part
number 1261517) to the bottom of the run tee
of port (T). Connect the loose end of the hose
to port 2 of the flow control manifold (Genie
part number 1261078). Do not tighten at the
time.
18 Connect the tank hose removed in step 4 to
the side of the run tee of port (T). Torque the
run tee to 14 ft-lbs / 19 Nm. Torque all hose
ends to 10 ft-lbs / 13.6 Nm.
19 Loosen and rotate the four 90° fittings on the
platform manifold as shown in the illustration.
20 Remove the coils from the platform level
proportional valve. Set the coils aside, discard
the nut and spacer.
Note: This is the bottom valve on the platform
manifold.
21 Remove the proportional valve and discard.
22 Install proportional valve (Genie part number
107816) and torque to 20 ft-lbs / 27 Nm.
23 Install the coils removed in step 20 using the
provided spacer and nut. Torque the nut
to 5 ft-lbs / 6.8 Nm.
24 Connect the platform level hoses (PLU and
PLD) removed in step 4 to the platform
manifold. Torque the hose ends to 10 ft-lbs /
13.6 Nm.
25 Connect the platform rotate hoses (PRR and
PRL) removed in step 4 to the platform
manifold. Torque the hose ends to 10 ft-lbs /
13.6 Nm.
1
2

Instructions Rev A
Procedure
6 Platform Level Update Part No. 1261248
26 Connect the harness that was disconnected in
step 3 to the platform manifold.
1green/black and brown
2green and brown
3orange/black and brown
4orange and brown
27 Connect the black negative battery cable to the
engine battery.
28 Start the machine and operate platform level
and platform rotate through one full cycle.
Check for leaks at the platform manifolds.
29 Perform function test. Refer to the Operator's
Manual located on your machine.
30 Return the machine to service.
31 Fill out and sign the attached completion form
and fax or email to Terex AWP Warranty
Department. This will serve as verification that
you have completed Safety Notice 140019.
3
2
4
1

Rev A Instructions
Illustration
Part No. 1261248 Platform Level Update 7
Illustration
1Platform manifold
2Platform rotate valve
3Platform level valve
4Run tee, (P) port
5Mounting bracket
6Run tee (T) port
7Flow control manifold
7
6
2
3
1
4
5

Instructions
8 Platform Level Update Part No. 1261248
This page intentionally left blank.

Safety Notice 140019
Completion Form
Your signature on this form will verify that you have completed Safety Notice 140019 on the machines listed below.
Please note that this is not a Warranty Claim Form. A Warranty Claim Form must be submitted to the
Terex AWP Warranty Department for reimbursement under the provisions of our standard warranty terms
and conditions.
Fax to:
United States: 1 877-738-7530 France: + 33 237 260 998
Canada: 1 425-498-7530 Germany: + 49 4221 491 820
Australia: + 61 733751002 Italy: + 39 075 941 8146
All other locations: + 1-425-498-7530 Iberica: + 34 935 725 080
Scandinavia + 46 3157 5104
Middle East: + 97 143 990 382
All other locations: + 31 165 510 826
Email to: [email protected]
Date:
Company Name:
Account # (if applicable):
Address:
(street):
(city):
(state, zip code):
Phone:
Please list the complete serial number (ex. Z13506-317 or ZX13514-2249)
Serial Number: Serial Number:
Print (service manager) Signature Date
Instructions PartN o. 1261248
Rev A
Platform Lev el Update