Z135 Operators Manual
Contents
1. 40434 28161 97716 97716 97715 97715 82422 82841 d 97885 27205 7 97890 65278 97864 i L 3 33952 i a E gr815 n A 28176 dnd 9 EET 28174 ia afi Lamm Ir m e or 28235 27204 NX 28236 65278 l 28165 27204 ELISTE 39998 d 44981 27206 97875 97887 or 44986 d 25994 27206 97865 97757 1000084 82840 V 82314 re a 31060 31060 4x e 97891 BB TLLA pA 28174 or 28235 bow 97875 SH i i E m a 28161 97890 Real 97885 Ee 27564 97715 28175 97889 97716 28181 40434 28164 97716 Seriallabel 100257 97715 44981 28177 Genio PartNo 82800 Z 135 70 37 Operator s Manual DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in First Edition Third Printing HERE du TI place Part No Description Quantity Part No Description Quantity 27204 Arrow Blue 2 82602 Danger Max Side Force 667 N ANSI 1 27205 Arrow Yellow 2 82604 Danger Max Manual2. 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 84 Retract the primary boom and the jib boom Test Auxiliary Controls 85 Push in the red Emergency Stop button to the off position to shut off the engine 86 Pull out the red Emergency Stop button to the on position 8 Press down the foot switch 88 Simultaneously press and hold the auxiliary power button and activate each function control handle toggle switch or button Note To conserve battery power test each function through a partial cycle O Result All boom and steer functions should operate Genie A TEREX COMPANY 24 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Do Not Operate Unless V 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 Inspectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals 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 Itis th
3. Genie Operator s Manual with Maintenance Information First Edition Third Printing Part No 82800 Z 135 70 Operator s Manual First Edition Third Printing i 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 Industries Contents Page Safety Rules sssssssssssseeeeeeeeerrtns 1 eoi e 8 E e po 11 Pre operation Inspection seeseeesesss 12 Malint nanee E 14 Function Tests ssssssssseeeen 17 Workplace Inspection sese 25 Operating Instructions esee 26 Transport and Lifting Instructions 33 Decals ote e t eem serius 36 Specifications ssssssssssseeeeneet 40 Copyright 2005 by Genie Industries Contact us First Edition Third Printing August 2006 oa Genie and Z are registered trademarks of Internet http www genielift com Genie Industries in the U S A and many other e mail techpub genieind com countries These machines comp
4. In cold climates the LCD readout screen will need to warm up before the display appears 4 Start the engine See Operating Instructions section Test Emergency Stop 5 Pushin the red Emergency Stop button to the off position Result The engine should turn 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 Atthe 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 Genie Part No 82800 A TEREX COMPANY Z 135 70 17 Operator s Manual First Edition Third Printing FUNCTION TESTS 8 Pushandhold a function enable speed select button and press the secondary boom raise extend button O 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 axl
5. Force 400 N CE 1 27206 Triangle Blue 2 82607 Caution No Step 2 27207 Triangle Yellow 2 82671 Label Weld Line to Platform 2 28159 Label Diesel 1 82840 Ground Control Panel 1 28171 Label No Smoking 1 82841 Platform Control Panel 1 28174 Label Power to Platform 230V 2 82924 Caution Shut off Valves 1 28235 Label Power to Platform 115V 2 97705 Cosmetic Genie Z 135 70 1 40434 Label Lanyard Anchorage 3 97716 Label Wheel Load 4 44981 Label Air Line to Platform 2 97757 Label Hydraulic Oil Level 1 82422 Label Driving Lights 1 97815 Label Lower Mid Rail 1 82472 Warning Crushing Hazard 2 97889 Cosmetic Z 135 2 82473 Caution Compartment Access 1 97891 Cosmetic Genie Z 135 1 82487 Label Read the Manual 2 100257 Label Transport Diagram 2 82544 Danger Electrocution Hazard 2 1000054 Label Drive Enable Patch 1 82546 Notice Max Capacity 272 kg 1 82548 Warning Platform Rotate 2 Genie 38 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual DECALS 82548 97716 28159 82473 82544 28171 97705 97889 97716 e N 40434 D C F gt g 82472 ai 82422 1000054 a 82841 82607 7 js 97815 272
6. If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Genie Part No 82800 A TEREX COMPANY Z 135 70 15 Operator s Manual First Edition Third Printing MAINTENANCE Check the Engine Coolant Level Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life An 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 fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be in the NORMAL range Bodily injury hazard Fluids in the AWARNING radiator are under pressure and extremely hot Use caution when removing cap and adding fluids 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 Genie A TEREX
7. Push 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 Genie 20 Z 135 70 At the Platform Controls Test Emergency Stop 35 Turn the key switch to platform control 36 Push in the platform red Emergency Stop button to the off position Result The engine should turn off and no functions should operate 37 Pull out the red Emergency Stop button and restart the engine Test the Horn 38 Push the horn button Result The horn should sound Test the Tilt Sensor Alarm 39 Push a button such as the engine RPM button or the fuel select button Result The alarm should sound at the platform controls Part No 82800 First Edition Third Printing Operator s Manual Test the Foot Switch 40 Push in the platform red Emergency Stop button to the off position 41 Pull out the red Emergency Stop button to the on position but do not start the engine 42 Press down the foot switch and attempt to start the engine by pushing the engine start button Result The engine should not start 43 Do not press down the foot switch and restart the engine 44 Do not press down the foot switch and test each machine function Result No machine functions should operate Test Machine Functions 45 Press down the foot switch 46 Activate each machine function control han
8. Slowly move the drive steer 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 O Result The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis 55 Push the steer mode select button for crab steer FR oe 56 Press down the foot switch 57 Slowly move the drive steer 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 58 Slowly move the drive steer 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 59 Push the steer mode e o O e Emu button for coordinated steer 60 Press down the foot switch 61 Slowly move the drive steer 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 circ
9. 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 Genie A TEREX COMPANY 26 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Starting the Engine 1 At the ground controls turn the key switch to the desired position Deutz models 2 Pressthe glow plug button The glow plugs will turn on for 30 seconds 3 Press the engine start button The engine start button can be pressed 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 and Cummins models 2 Pressand hold the glow plug button 3 Press the engine start button 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 befor
10. must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions 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 circle end wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use 5 Chock the wheels Genie A TEREX COMPANY 32 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Transport and Lifting Instructions Observe and Obey M Genie Industries 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 M Genie customers needing to containerize any lift or Genie product should source a qualified freightforwarder with expertise in preparing loading and securing construction and lifting equipment for international shipment M Only qualified aerial lift operators should move the machine on or off the truck KI The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded
11. the turntable rotation lock pin each time the machine is transported Secure the platform with a nylon strap placed through the lower platform support Do not use excessive downward force when securing the boom section Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 6 chains Adjust the rigging to prevent damage to the chains Truck Bed 25 w 6 4 Secondary boom width Jib boom width 26 in 16in 66 cm 42 ft 5 in 41 cm P 12 97 m J o EY nU 4 ft 4 in 131m L 10fti0in 3 3m Genie A TEREX COMPANY 34 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instructions Fully lower and retract the primary and secondary boom Fully lower and retract the jib boom Remove all loose items on the machine Determine the center of gravity of your machine using the picture on this page Observe and Obey Attach the rigging only to the designated lifting points on the machine There are four lifting points on the chassis M Only qualified riggers should rig and lift the machine M Be sure the crane capacity loading surfaces and straps or lines are
12. 0 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 5511 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
13. 07 y s o 82487 ANS A EE 28174 27204 ME aE or 28235 82607 82546 27204 5 d 44981 ete 82671 82604 or 82602 27205 27206 Serial label 97891 82671 28174 or 28235 44981 82472 82924 82544 100257 82487 97757 97716 82473 97889 40434 Genie Part No 82800 Z 135 70 39 Operator s Manual First Edition Third Printing Specifications Z 135 70 Platform leveling self leveling Height working maximum 141 ft 42 9 m Platform rotation 160 Height platform maximum 135 ft 41 1 m AC outlet in platform standard Height stowed maximum 10 ft 1 in 3 1m Hydraulic pressure maximum 2900 psi Horizontal reach maximum 69 ft 9 in 21 3m panmi unetons see Width axles retracted 8 ft 1 in 2 5m Hydraulic itu a eri SiO ps auxiliary power unit 218 bar Width axles extended 12 ft 11 in 3 9 m System voltage 12V Length stowed 42 ft 5 in 12 9 m d Tire size 18 22 5 18 ply FF Maximum load capacity 600 Ibs 272 kg 7 Fuel tank capacity 40 gallons 151 liters Maximum wind speed 28 mph 12 5 m s Weight See Serial Label Wheelbase axles extended 13 ft 6 in 4 1m Machine weights vary with option configurations Wheelbase axles retracted 15ft 6 in 4 7m Airborne noise emissions 113 dB L Maximum sound level at normal operating workstations Ground clearance 20 in 51 cm A weighted Turning rac
14. 2 Axle extend button with indicator light 28 Axle retract button with indicator light 29 Thumb rocker switch for primary boom extend retract function 30 Dual axis proportional control handle for primary boom up down andturntable rotate left right functions Part No 82800 A TEREX COMPANY Z 135 70 Operator s Manual First Edition Third Printing CONTROLS OS MG CE ORO eG Nu Ground Control Panel Primary boom down button D Primary boom extend retract buttons Primary boom up button Not used LCD screen control buttons LCD readout screen Red Emergency Stop button Glow plug button Key switch for off ground platform selection e ON DOO CO 268000 10 Engine start button 11 Engine speed select button 12 Auxiliary power button 13 High speed function enable button 14 Low speed function enable button 15 20A circuit breaker for system circuit 16 Alarm 17 Platform level up down buttons Genie S S wa C Q eG OO 18 Jib boom extend retract buttons 19 Jib boom up down buttons 20 Secondary boom up extend and down retract buttons 21 Platform rotate left right buttons 22 Turntable
15. 70 Part No 82800 First Edition Third Printing Operator s Manual O ey SPECIFICATIONS Z 135 70 Range of Motion oo 32 30 ft 50 ft 70 ft 9 1m 152m 21 3m La 34 Genie A TEREX COMPANY Part No 82800 Z 135 70 41 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 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 91
16. COMPANY 16 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Do Not Operate Unless MI 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 andunderstand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals 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 Function Tests 1 Select a test area that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground control 3 Pulloutthe red Emergency Stop button to the on position Result The LCD screen will come on and display no error messages The beacon if equipped should flash Note
17. M Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial plate for the machine weight MI 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 slope or side slope rating See Driving on a Slope in the Operating Instructions section MI If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling Disengage Release the wheel brakes by turning over all four drive hub disconnect Engage 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 Genie Part No 82800 A TEREX COMPANY Z 135 70 33 Operator s Manual First Edition Third Printing l TRANSPORT ANDLIFTING INSTRUCTIONS Securing to Truck or Trailer for Securing the Platform Transit Place a block under the platform rotator Do not l allow the block to contact the platform cylinder Always use
18. NSOR X DIRECTION appears Result The LCD screen should display the angle in degrees 26 Push one of the LCD screen control buttons until TURNTABLE LEVEL SENSOR Y DIRECTION appears Result The LCD screen should display the angle in degrees 2 Push one of the LCD screen control buttons until PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees Genie Part No 82800 A TEREX COMPANY Z 135 70 19 Operator s Manual First Edition Third Printing FUNCTION TESTS Testthe Operating Envelope 28 Push one of the LCD screen control buttons shown until 4 el PRI BOOM ANGLE TO GRAVITY is displayed 29 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 30 Lower the primary boom 31 Simultaneously push the 2 LCD screencontrol zz buttons shown to activate status mode 32 Push one of the LCD screen control buttons shown until 4 el SEC BOOM ANGLE is displayed 33 Push 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 34
19. Safety if equipped 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 leads to the twist lock connectors at the turntable and platform Genie A TEREX COMPANY 6 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Battery Safety Burn 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 Explosion Hazard Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas Electrocution Hazard Avoid contact with electrical terminals Part No 82800 Genie Z 135 70 7 SAFETY RULES Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A ha
20. al to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in the oil level that might indicate the presence of hydraulic system problems 1 Be sure that the engine is off and the boom is in the stowed position 2 Visually inspect the sight gauge located on the side of the hydraulic oil tank O Result The hydraulic oil level should be between the two marks on the decal next to the sight gauge Add oil as needed Maximum oil level Minimum oil level Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent MAINTENANCE Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Besure that the battery hold down bar is in place and secure 4 Remove the battery vent caps 5 Check the battery acid level
21. ator 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 Genie A TEREX COMPANY Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Pre operation Inspection C1 Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform C1 Be sure that all decals are legible and in place See Decals section L Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section L Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section L Check fo
22. dle toggle switch or button Result All functions should operate through a full cycle FUNCTION TESTS Testthe Steering 47 Push the steer mode select button x 2 O 2 end blue arrow steer 48 Press down the foot switch 49 Slowly move the drive steer 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 50 Slowly move the drive steer 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 Push the steer mode select button for circle end yellow arrow steer 5 52 Press down the foot switch 53 Slowly move the drive steer 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 O Result The circle end wheels should turn in the direction that the blue triangles point on the drive chassis Genie Part No 82800 A TEREX COMPANY Z 135 70 21 Operator s Manual First Edition Third Printing FUNCTION TESTS 54
23. e foot switch 2 Select the steer mode by pressing a steer mode button The indicator light next to the current steer mode will be on 3 Slowly move the drive steer control handle in the direction indicated by the blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn Genie A TEREX COMPANY 28 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual OPERATINGINSTRUCTIONS To Drive Driving on a slope 1 Press down the foot switch p Determine the uphill downhill and side slope ratings 2 Increase speed Slowly move the drive for the machine and determine the slope grade steer control handle in the direction N Maximum slope rating indicated by the blue or yellow arrows ES counterweightuphill gradeability Decrease speed Slowly move the drive steer ese control handle toward center Maximum slope rating Stop Return the drive steer control handle to x POHHIIWeIH downhill center or release the foot switch 307149 Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Maximum side slope rating 25 14 De Machine travel speed is restricted when the boom is raised or extended Note Slope rating is subject to gro
24. e operating to prevent hydraulic system damage In extreme cold conditions O 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 OPERATING INSTRUCTIONS 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 a system fault To remove the fault hold the auxiliary power button and activate the secondary boom up function until the secondary boom begins extending Emergency Stop Push in either the ground or platform red Emergency Stop button to the off position to stop all functions and turn the engine off Repair any function that operates when the red Emergency Stop button is pushed in to the off position Selecting and operating the ground controls will override the platform red Emergency Stop button 1 Turn the key switch to ground or platform control Auxiliary Controls Use auxiliary power if the primary power source engine fails 2 Pullout the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platform 4 Simultaneously hold the auxiliary power button and activate the desired function Genie Part No 82800 A TEREX COMPANY Z 135 70 27 Operator s Manual First Editi
25. e 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 82800 Genie Z 135 70 25 Workplace Inspection Workplace Inspection 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 Operator s Manual First Edition Third Printing Operating Instructions Do Not Operate Unless M 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 Fundamentals 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
26. enerator button with indicator light option 10 Auxiliary power button with indicator light 11 Glow plug button with indicator light 12 Engine start button with indicator light 13 Steer mode select buttons with indicator lights Genie 14 Engine idle rpm select button with indicator lights Rabbit amp Foot Switch foot switch activated high idle Turtle low idle Rabbit high idle 15 Platform overload indicator light if equipped 16 Not used 17 Fault indicator light 18 Low fuel indicator light 19 Check engine indicator light 20 Red Emergency Stop button A TEREX COMPANY Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual CONTROLS 21 Power indicator light 22 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function 23 Single axis proportional control handle for secondary boom up extend and down retractfunction 24 Drive select button with indicator lights Machine on incline symbol Lowrange operation for inclines Machine on level surface symbol High range operation for maximum drive speed 25 Thumb rocker for jib boom extend retract function 26 Dual axis proportional control handle for jib boom up down and platform rotate left right functions Genie D
27. es are extended 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 Push and hold a function enable speed select button and push the turntable rotate right button O 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 push the extend axle button 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 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 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 16 Result The secondary boom should raise and extend and retract and lower normally 17 Push and hold a function enable speed select button and push the primary boom exte
28. ion is required by the operator Lower Retract Secondary Boom indicator light flashing Lower retract the secondary boom until the indicator light is off ESO Lower Primary Boom indicator light flashing Lower the primary boom until the indicator light is off Gro ZO WED O Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing 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 Genie Part No 82800 A TEREX COMPANY Z 135 70 31 Operator s Manual First Edition Third Printing OPERATING INSTRUCTIONS Generator if equipped Tooperate the generator press the generator button The indicator light will come on and the engine will continue to run Plug power tools into the power to plattorm GFCI outlet To turn off the generator push the generator button The indicator light will turn off Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE
29. ith 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 in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Do not spray ether into engines equipped with glow plugs 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 that the operator s safety and responsibilities manuals are complete legible and in the storage container located in 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 Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning 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 the pre operation inspection All compartments must remain closed and secured during operation Weld Line to Platform
30. ius axles extended Maximum slope rating stowed position inside 7 ft 6 in 2 3m P 9 P outside 18 ft 6 in 5 6M QCounterweight uphill 45 24 Turning radius axles retracted Counterweight downhill 30 179 inside 18 ft 1 in 5 1m outside 25 ft 6 in 7 8m Side slope 25 14 Turntable rotation 360 continuous Turntable tailswing secondary boom lowered 14 ft 4 3m Turntable tailswing secondary boom raised 2 ft 7 in 78 cm Drive speed stowed 3 0 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Drive speed 0 7 mph 1 1 km h raised or extended 40 ft 40 sec 12 2 m 40 sec Drive speed 0 4 mph 0 6 km h raised and extended 40 ft 68 sec 12 2 m 68 sec Controls 12V DC proportional 72 in x 30 in 1 8m x 76 cm Platform dimensions 6 foot length x width Note Slope rating is subject to ground conditions and adequate traction Floor loading information Tire load maximum 25 000 lbs 11 340 kg Tire contact pressure 130 psi 9 14 kg cm 896 kPa Occupied floor pressure 204 psf 996 kg m 9 76 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Platform dimensions 8 foot 96 in x 36 in Continuous improvement of our products is a Genie length x width 2 4mx 91cm policy Product specifications are subject to change without notice or obligation Genie A TEREX COMPANY 40 Z 135
31. king 1 97716 Label Wheel Load 4 28174 Label Power to Platform 230V 2 97757 Label Hydraulic Oil Level 1 28175 Caution Compartment Access 2 97864 Caution Collision Hazard 1 28176 Notice Missing Manuals 1 97865 Warning Electrocution Hazard 2 28177 Warning Collision Hazard 2 97875 Warning Weld Lines to Platform 2 28181 Warning No Step or Ride 1 97885 Notice Operating Instructions 2 28235 Label Power to Platform 115V 2 97887 Notice Max Side Force 150 Ibs 667 N 28236 Warning Failure To Read 1 ANSIA USA 31060 Danger Tip over Hazard 2 29930 Danger General Safety 2 32998 Notice Max Capacity 600 lbs 272 kg 1 102188 Notice Engine Specifications Cummins 1 33952 Danger Tip over Hazard 1 pees e a ete 40434 Label Lanyard Anchorage 3 2 99 Sosels Merle 44981 Label Air Line to Platform p ingens abe a anspor Diagram 2 44986 Notice Max Manual Force 1000083 Notice Start and Controls Battery 1 90 Ibs 400 N Australia 1 1000084 Caution Auxiliary Batteries 1 65278 Caution No Step 2 Shading indicates decal is hidden from view i e under covers Genie A TEREX COMPANY 36 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual 28177 28175 28159 28171 97865 27564 97576 DECALS 97889 97705 97708 1000083 97602 or 97603 or 102188
32. l handle to the full drive position O Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds Genie Part No 82800 A TEREX COMPANY Z 135 70 23 Operator s Manual First Edition Third Printing FUNCTION TESTS 76 Retract the primary boom to the stowed position 7 Raise the secondary boom to 5 above horizontal 78 Slowly move the drive control handle to the full drive position O Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds 79 Lower the secondary boom to the stowed position 80 Extend the jib boom 1 foot 30 cm 81 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 foot 30 cm per second If the drive speed with the primary or secondary boom raised or extended or the jib boom extended exceeds 1 foot 30 cm per second immediately tag and remove the machine from service 82 Extend the primary boom 4 feet 1 2 m 83 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
33. le end wheels should turn in the direction that the yellow triangles point on the drive chassis 62 Slowly move the drive steer 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 Genie A TEREX COMPANY 22 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Test Drive and Braking 63 Press down the foot switch 64 Slowly move the drive steer 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 O Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 65 Slowly move the drive steer 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 O 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 Test the Drive Enable Sy
34. ly with ANSI SIA 92 5 1992 2 Printed on recycled paper Printed in U S A Genie A TEREX COMPANY 2 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless VI 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Genie A TEREX COMPANY Part No 82800 Z 135 70 1 Operator s Manual First Edition Third Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current S R E Q sS E PEE Maintain safe distances from electrical power li
35. mental rules regarding the use of personal protective equipment 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 circle and square markings and the color coded direction arrows on the platform controls and drive chassis for drive and steer functions SAFETY RULES 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 other 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 Component Damage Hazards Do not use any battery or charger greater than 12V DC to jump start the engine 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 Genie Part No 82800 A TEREX COMPANY Z 135 70 5 Operator s Manual First Edition Third Printing SAFETY RULES 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 w
36. nd button and then the primary boom retract button O Result The primary boom should extend and retract normally 18 Push and hold a function enable speed select button and push the turntable rotate left button and then the turntable rotate right button O Result The turntable should rotate normally Genie A TEREX COMPANY 18 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Test the Machine Functions 19 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 20 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 if equipped should sound while the boom is lowering Test Auxiliary Controls 21 Push in the red Emergency Stop button to the off position to turn off the engine 22 Pull out the red Emergency Stop button to the on position Note To conserve battery power test each function through a partial cycle 23 Simultaneously push and hold the auxiliary power button and push each boom function button Result All boom functions should operate 24 Start the engine FUNCTION TESTS Test the Tilt Sensor 25 Push one of the LCD screen control buttons until TURNTABLELEVEL 4 el SE
37. nes and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance 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 Allow for platform movement electrical line sway or sag and beware of strong or gusty winds 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 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 Before performing service on this machine disconnect the batteries under both turntable covers Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity 600 Ibs Maximum platform capacity 272 kg Maximum occupants 2 The weight of options and accessories such as pipe cradles panel cradles and welders will reduce the rated platform capacity and must be factored into the total platform load See the decals with the options and accessories Do not raise or extend the boom unless the machine is on a firm level surface Umm Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the
38. o not replace factory installed tires with tires of different specification or ply rating Do not place or attach overhanging loads to any part of this machine EN Do not place ladders or scaffolds in the platform or against any part of this machine 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 all tires are in good condition and lug nuts are properly tightened Genie A TEREX COMPANY 4 Z 135 70 Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchorage point 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 A v s gt A 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 Part No 82800 First Edition Third Printing Operator s Manual Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of 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 Operators must comply with employer job site and govern
39. on Third Printing OPERATING INSTRUCTIONS To Extend and Retract Axles 1 Turn the key switch to platform control 2 Atthe platform controls press down the foot switch and move the drive control handle in either direction and push the appropriate axle button O O Ja 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 Pulloutthe red Emergency Stop button to the on position 3 Startthe engine To Position Platform 1 Push and hold a function enable speed select button 2 Pushthe appropriate function button according to the markings on the control panel Drive steer and axle functions are not available from the ground controls ol o Operation from Platform 1 Turn the key switch to platform control 2 Pullout 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 toggle switch or press the appropriate button according to the markings on the control panel To Steer 1 Press down th
40. platform only when the machine is on a severe slope Genie A TEREX COMPANY 2 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual If the tilt alarm sounds 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 to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a firm level surface before raising the platform 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 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 Ka pa NO 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 SAFETY RULES Do not drive the machine on or near uneven
41. r engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section B L Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for M damage improperly installed or missing parts and unauthorized modifications I Electrical components wiring and electrical cables 11 Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Tires and wheels C D CO O O Engine and related components Genie A TEREX COMPANY PartNo 82800 Z 135 70 PRE OPERATION INSPECTION O Limit switches 14 Rotation sensors 11 Steer and axle sensors L4 Alarms and beacons if equipped 11 Pins nuts bolts and other fasteners Q1 Platform entry mid rail or gate Check entire machine for 1 Cracks in welds or structural components HQ Dents or damage to machine Qj 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 13 Operator s Manual First Edition Third Printing Maintenance Observe and Obey m Only routine maintenance items specified in this manual shall be performed b
42. rotate left right buttons A TEREX COMPANY Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Legend o EFFI SUA A Q i l pe iS 1 Square endtire 8 Sliding mid rail 2 Groundcontrols 9 Manualstorage container 3 Secondary boom 10 Lanyard anchorage point 4 Primaryboom 11 Foot switch 5 Jibboom 6 Platform 7 Platform controls Genie A TEREX COMPANY PartNo 82800 Z 135 70 11 Operator s Manual First Edition Third Printing Pre operation Inspection Do Not Operate Unless M 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 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 oper
43. stem 66 Press down the foot switch and lower the booms to the stowed position 67 Rotate the turntable until the primary boom moves past one of the circle end tires Result The drive enable indicator light should come on while the boom is anywhere in the range shown 68 Move the drive steer control handle off center O Result No drive function should operate FUNCTION TESTS 69 Push the drive enable button and slowly move the drive steer 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 Blue 1 direction arrows on the platform controls and the lt drive chassis to identify the direction of travel Yelow If the drive steer control handle is not moved within two seconds of pushing the drive enable button the drive function will not operate Test Limited Drive Speed 70 Press down the foot switch 71 Raise the primary boom to 5 above horizontal 72 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 foot 30 cm per second Note The machine will travel 40 feet 12 m in 40 seconds 73 Lower the primary boom to the stowed position 74 Extend the primary boom 4 feet 1 2 m 75 Slowly move the drive contro
44. sufficient to withstand the machine weight See the serial plate for the machine weight Adjust the rigging to prevent damage to the machine and to keep the machine level Genie A TEREX COMPANY Part No 82800 Z 135 70 35 Operator s Manual First Edition Third Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity Part No Description Quantity 25994 Caution Component Damage Hazard 1 82314 Danger Tip over Hazard 1 27204 Arrow Blue 2 82422 Label Driving Lights 1 27205 Arrow Yellow 2 82840 Ground Control Panel 1 27206 Triangle Blue 2 82841 Platform Control Panel 1 27207 Triangle Yellow 2 97576 Notice Engine Specifications Deutz 1 27564 Danger Electrocution Hazard 2 97602 Warning Explosion Hazard 1 28159 Label Diesel 1 97603 Notice Engine Specifications Perkins 1 28161 Warning Crushing Hazard 2 97705 Cosmetic Genie Z 135 70 1 28164 Notice Hazardous Materials 1 97708 Label Fuse and Relay Panel Layout 1 28165 Notice Foot Switch 1 97715 Danger Notice Tire Specifications 4 28171 Label No Smo
45. terrain unstable surfaces or other hazardous conditions with the boom raised or extended 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 Counterweight uphill 45 24 Counterweight downhill 30 17 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Maximum allowable side force ANSI and CSA 150 Ibs 667 N F M ENS Do not alter or disable machine components that in any way affect safety and stability Maximum allowable manual force CE and Australia 90 Ibs 400 N Do not push off or pull toward any object outside of the platform Do not replace items critical to machine stability with items of different weight or specification Genie Part No 82800 A TEREX COMPANY Z 135 70 3 Operator s Manual First Edition Third Printing SAFETY RULES 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 use air filled tires This machine is equipped with foam filled tires Wheel weight is critical to stability D
46. the primary boom has moved past either circle end wheel and the drive function is turned off To drive push the drive enable button and slowly move the drive steer control handle off center If the drive steer control handle is not moved within two seconds of pushing the drive enable button the drive function will not operate Release and push the drive enable button 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 Genie A TEREX COMPANY 30 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Engine Idle Select rpm Select the engine idle rpm by pressing the select button The indicator light next to the current setting will be on Rabbit and foot switch symbol foot switch activated high idle Turtle symbol low idle Rabbit symbol high idle Check Engine Light Cty Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours 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 act
47. und 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 Genie A TEREX COMPANY Part No 82800 Z 135 70 29 Operator s Manual First Edition Third Printing OPERATING INSTRUCTIONS To determine the slope grade 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 uM run m rise X 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 uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See the Transport and Lifting section Drive Enable Light on indicates that
48. y the operator mi Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure EE Check the Engine Oil Level 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 Check the oil level with the engine off 1 Checkthe engine oil dipstick Add oil as needed Perkins 1104C 44 Engine Oil type 15W 40 Oil type cold conditions 10W 30 Deutz BF4L2011 Engine Oil type 15W 40 Oil type cold conditions 5W 30 Cummins B4 5C80 Engine Oil type 15W 40 Oil type cold conditions 10W 30 Genie A TEREX COMPANY 14 Z 135 70 Part No 82800 First Edition Third Printing Operator s Manual Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essenti
49. zardous situation which if not avoided could result in death or serious injury gt Yellow with safety alert symbol ACAUTION used to indicate the presence ofa A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information Operator s Manual Controls First Edition Third Printing DRIVE ENABLE OPERATION Light on indicates that boom has moved past a circle end tire and drive function is turned off To drive push drive enable button and slowly move drive control handle Machine may drive in opposite direction that drive and steer controls are moved Use color coded direction arrows on this panel and drive chassis to identify the direction machine will travel When drive enable light is on axles cannot retract Platform Control Panel 1 2 Platform level toggle switch Platform not level indicator light Machine not level indicator light Lower primary boom indicator light Lower retract secondary boom indicator light Drive enable button with indicator light Horn button 8 Usedforoptional equipment 9 G
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