Genie Z-135 70 Aerial Work Platform Operator's Manual

Operator's Manual
Second Edition • Third Printing
Important
Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual
should be considered a permanent part of your
machine and should remain with the machine at all
times. If you have any questions, call Genie.
Contents
Page
Introduction ................................................................ 1
Symbols and Hazard Pictorials Definitions ................. 3
General Safety ........................................................... 5
Personal Safety ......................................................... 7
Work Area Safety ....................................................... 8
Legend ...................................................................... 16
Controls .................................................................... 17
Inspections ............................................................... 25
Operating Instructions ............................................... 38
Transport and Lifting Instructions .............................. 49
Maintenance ............................................................. 52
Specifications ........................................................... 55
Contact us:
Copyright © 2005 by Terex Corporation
Second Edition: Third Printing, January 2013
Internet: http://www.genielift.com
e-mail: [email protected]
"Genie" and "Z" are registered trademarks of
Terex South Dakota in the U.S.A. and many
other countries.
Printed on recycled paper
Printed in U.S.A.
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Introduction
Owners, Users and Operators:
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
Danger
Failure to obey the instructions and
safety rules in this manual will
result in death or serious injury.
Do Not Operate Unless:
4 Only have trained/certified operators, directed
by informed and knowledgeable supervision,
running the machine.
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
1 Avoid hazardous situations.
Internet: www.genielift.com
2 Always perform a pre-operation inspection.
E-mail: [email protected]
3 Always perform function tests prior to use.
Know and understand the safety rules before
going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and work site regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
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Introduction
Hazard Classification
Intended Use
Genie uses symbols, color coding and signal words
to identify the following:
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
2
Red
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Orange
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Yellow
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Blue
Indicates a hazardous situation
which, if not avoided, could result
in 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.
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Symbol and Hazard Pictorials Definitions
Crush Hazard
Keep off this
surface.
Tip-over Hazard
Explosion Hazard
Keep away from
moving parts.
Electrocution
Hazard
Crush Hazard
Rated platform
capacity
No smoking.
No flame.
Stop engine.
Disconnect battery.
Fall Hazard
Keep away from
path of moving
platform.
Tip-over Hazard
Read the operator’s
manual.
Electrocution
Hazard
Maintain required
clearance.
Read service
manual
Only trained
maintenance
personnel should
access
compartments
Recovery procedure if tilt alarm sounds
while elevated.
Tip-over Hazard
Explosion Hazard
Platform uphill:
1 Lower primary
2 Retract/lower
secondary
3 Retract primary
Part No. 114475
Platform downhill:
1 Retract primary
2 Retract/lower
secondary
3 Lower primary
Z-135/70
Do not use ether
or other high
energy starting
aids on machines
equipped with
glow plugs.
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Symbol and Hazard Pictorials Definitions
Lanyard
attachment point
Avoid contact.
Wheel load
Tie-down
instructions
Voltage rating for
power to platform
Tie-down
instructions
Fire Hazard
No step.
4
Pressure rating for
air line to platform
Tire specification
Weight of welder
reduces capacity
Wind speed
Fire extinguisher
Do not jump-start
this battery.
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General Safety
Safety signs and locations
133179 A
272 kg
+
<=
82546 B
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272 kg
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General Safety
Safety signs and locations
133179 A
133180 A
6
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Operator's Manual
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.
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Work Area Safety
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
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
applicable
governmental
regulations and the
following chart.
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.
Do not operate the machine during lightning or
storms.
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.
Maximum platform capacity
272 kg
Maximum occupants
Line Voltage
0 to 50KV
3.0 m
50 to 200KV
4.6 m
200 to 350KV
6.1 m
350 to 500KV
7.6 m
500 to 750KV
10.6 m
750 to 1000KV
13.7 m
8
2
Required Clearance
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will reduce
the rated platform capacity and must be subtracted
from the platform capacity. See the decals with the
options and accessories.
If using accessories, read, understand and obey
the decals, manuals and instructions with the
accessory.
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Operator's Manual
Work Area Safety
Do not raise or extend
the boom unless the
machine is on a firm,
level surface.
Do not depend on the
tilt alarm as a level
indicator. The tilt alarm
sounds in the platform
only when the machine
is on a severe slope.
If the tilt alarm sounds
while the boom is
lowered: 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. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the platform uphill:
Do not raise the boom
when wind speeds may
exceed 12.5 m/s. If
wind speeds exceed
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.
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 dropoffs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
1 Lower the primary boom.
2 Retract/lower the secondary
boom.
3 Retract the primary boom.
If the tilt alarm sounds with the
platform downhill:
1 Retract the primary
boom.
2 Retract/lower the
secondary boom.
3 Lower the primary
boom.
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Work Area Safety
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside
of the platform.
Do not use air-filled tires. These machines are
equipped with foam-filled tires. Wheel weight is
critical to stability.
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 place or attach
overhanging loads to
any part of this
machine.
Maximum allowable
manual force - CE
400 N
Do not place ladders or
scaffolds in the
platform or against any
part of this machine.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not transport tools
and materials unless
they are evenly
distributed and can be
safely handled by
person(s) in the
platform.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace factory-installed tires with tires of
different specification or ply rating.
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.
10
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.
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Work Area Safety
Operation on Slopes Hazards
Fall Hazards
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.
Occupants must wear a
safety belt or harness
in accordance with
governmental
regulations. Attach the
lanyard to the anchor
provided in the
platform.
Maximum slope rating, stowed position
Platform downhill
45% (24°)
Platform uphill
30% (17°)
Side slope
25% (14°)
Do not sit, stand or
climb on the platform
guard rails. Maintain a
firm footing on the
platform floor at all
times.
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions Section.
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.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
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Work Area Safety
No stunt driving or
horseplay while
operating a machine.
Collision Hazards
Do not lower the boom
unless the area below
is clear of personnel
and obstructions.
Be aware of limited sight distance and blind spots
when driving or operating.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any
other factors which
may cause collision.
Be aware of the boom position and tailswing when
rotating the turntable.
Be aware of machine length when operating. The
machine is 12.9 m long.
Check the work area for
overhead obstructions
or other possible
hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply
with employer, job site
and governmental rules
regarding the use of
personal protective
equipment.
Observe and use the
color-coded direction
arrows on the platform
controls and drive
chassis for drive and
steer functions.
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 a
pre-operation inspection. All compartments must
remain closed and secured during operation.
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.
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Work Area Safety
Explosion and Fire Hazards
Component Damage 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 with 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 use any battery or charger greater than 12V
to jump-start the engine. Apply jumper cables to the
starter and controls battery, not the auxiliary power
batteries.
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.
Battery Safety
Burn Hazards
Do not spray ether into engines equipped with glow
plugs.
Batteries contain acid.
Always wear protective
clothing and eye wear
when working with
batteries.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Avoid spilling or
contacting battery acid.
Neutralize battery acid
spills with baking soda
and water.
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 Genie
service manual.
Explosion Hazard
Keep sparks, flames
and lighted tobacco
away from batteries.
Batteries emit
explosive gas.
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.
Electrocution Hazard
Avoid contact with electrical terminals.
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Work Area Safety
Pipe Cradle Safety
Panel Cradle Safety
Read, understand and obey all warnings and
instructions provided with the pipe cradles.
Read, understand and obey all warnings and
instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.
The pipe cradle assembly weighs 9.5 kg.
The panel cradle assembly weighs 13.6 kg.
The maximum capacity of the pipe cradle assembly
is 91 kg.
The maximum capacity of the panel cradles is
113 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.
Center the load within the perimeter of the platform.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhanging load.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhanging load.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Maximum vertical height of panels: 1.2 m
Maximum wind speed: 6.7 m/sec
Maximum panel area: 3 m2
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
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Work Area Safety
Welder Safety
Weld Line to Platform Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
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 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 and the welder is properly grounded.
Do not operate unless the weld cables are properly
connected.
The weight of the welder will reduce the rated
platform capacity and must be factored into the
total platform load. The welder power supply weighs
34 kg.
Connect the positive lead to the twist-lock
connector at the turntable and platform.
Do not operate the welder unless a fire extinguisher
is immediately available for instant use, per OSHA
regulation 1926.352(d).
Clamp the negative lead to the ground post at the
turntable and platform.
Lockout 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 non-steer wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chock the wheels.
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Legend
1 Square-end tire
8 Sliding mid-rail
2 Ground controls
9 Manual storage container
3 Secondary boom
10 Lanyard anchorage point
4 Primary boom
11 Foot switch
5 Jib boom
6 Platform
7 Platform controls
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Operator's Manual
Controls
Z-135 machines will
have one of these
two styles of ground
control panel. The
descriptions in this
section and the
instructions in the
Function Test and
Operating
Instructions sections
apply to both panels,
unless specifically
noted.
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Controls
Ground Control Panel
7 Platform level up/down buttons
Push the platform level up button and the level
of the platform will raise. Push the platform level
down button and the level of the platform will
lower.
1 LCD readout screen
a
b
c
d
e
a
low fuel indicator
b
engine oil pressure indicator
c
water temperature indicator
d
auxiliary power indicator
e
high engine rpm indicator
f
hour meter
f
8 Primary boom extend/retract buttons
Push the primary boom extend button and the
primary boom will extend. Push the primary
boom retract button and the primary boom will
retract.
9 20A circuit breaker for system circuit
10 Alarm
11 Platform rotate left/right buttons
2 Red Emergency Stop button
Push in red Emergency Stop button to the off
position to stop all functions and turn the engine
off. Pull out the red Emergency Stop button to
the on position to operate the machine.
Push the platform rotate left button and the
platform will rotate to the left. Push the platform
rotate right button and the platform will rotate to
the right.
12 Jib boom extend/retract buttons
3 Glow plug button
Push the jib boom extend button and the jib
boom will extend. Push the jib boom retract
button and the jib boom will retract.
Push the glow plug button and hold for 3 to 5
seconds.
13 High speed function enable button
4 Key switch for off/ground/platform selection
Push the high speed function enable switch to
enable the functions on the ground control panel
to operate at high speed.
Turn the key switch to the off position and the
machine will be off. Turn the key switch to the
ground position and the ground controls will
operate. Turn the key switch to the platform
position and the platform controls will operate.
14 Low speed function enable button
Push the low speed function enable switch to
enable the functions on the ground control panel
to operate at low speed.
5 Engine start button
Push the engine start button and the engine will
start.
15 Emergency/Auxiliary power button
6 Jib boom up/down buttons
Use emergency/auxiliary power if the primary
power source (engine) fails.
Simultaneously push the emergency/auxiliary
power button and activate the desired function.
Push the jib boom up button and the jib boom
will raise. Push the jib boom down button and
the jib boom will lower.
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Controls
16 Turntable rotate left/right buttons
Push the turntable rotate left button and the
turntable will rotate to the left. Push the
turntable rotate right button and the turntable will
rotate to the right.
17 Secondary boom up/extend and down/retract
buttons
Push the secondary boom up/extend button and
the secondary boom will raise and then extend.
Push the secondary boom down/retract button
and the secondary boom will retract and then
lower.
18 Primary boom up/down buttons
Push the primary boom up button and the
primary boom will raise. Push the primary boom
down button and the primary boom will lower.
19 LCD screen control buttons
20 Engine speed select button
Push the engine speed select button to select
the engine speed. When the arrow above the
rabbit is lit, the engine is in high idle speed.
When the arrow above the turtle is lit, the engine
is in low idle speed.
21 Primary boom down button
Push the primary boom down button and the
primary boom will lower.
22 Primary boom up button
Push the primary boom up button and the
primary boom will raise.
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Controls
Z-135 machines will have
one of these two styles of
platform control panel.
The descriptions in this
section and the
instructions in the
Function Test and
Operating Instructions
sections apply to both
panels, unless
specifically noted.
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Controls
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Controls
Platform Control Panel
9 Glow plug control with indicator light
1 Horn button
Move the switch or push the button to activate
the glow plugs.
Press the button and the horn will sound.
Release the button and the horn will stop.
10 Engine start control with indicator light
2 Platform not level indicator light
Move the switch or push the button and the
engine will start. The indicator light will be on
when the switch is moved or the button is
pushed.
Level the platform until the light is off. The
switch will only work in the direction that will
level the platform.
11 Engine idle control with indicator light
3 Machine on incline indicator light
Move the switch or push the button to select
engine idle setting. The indicator light next to
the current engine idle setting will be on.
Light on indicates all functions have stopped.
See the instructions in the Operating
Instructions section.
12 Platform overload indicator light
4 Lower primary boom indicator light
Light flashing indicates the platform is
overloaded. The engine will stop and no
functions will operate. Remove weight from the
platform until the light goes off.
Lower the primary boom until the light is off.
5 Lower / retract secondary boom indicator light
Lower/retract the secondary boom until the light
is off.
13 Power indicator light
Light on indicates the machine is on.
6 Used for optional equipment
14 Check engine indicator light
7 Generator control with indicator light
(if equipped)
Light on indicates an engine fault.
Move the switch or push the button to turn the
generator on. Move the switch again or release
the button to turn the generator off.
8 Emergency/auxiliary power control with indicator
light
Use emergency/auxiliary power if the primary
power source (engine) fails.
15 Low fuel indicator light
Light on indicates the machine is low on fuel.
16 Fault indicator light
Light on indicates a system fault.
17 Red Emergency Stop button
Move and hold the switch, or push and hold the
button. Activate the desired function. The
indicator light will be on when emergency/
auxiliary power is being used.
22
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Push in the red Emergency Stop button to the
off position to stop all functions and turn the
engine off. Pull out the red Emergency Stop
button to the on position to operate the
machine.
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Controls
21 Drive control with indicator lights
18 Dual axis proportional control handle for drive
and steer functions OR Proportional control
handle for drive function and thumb rocker for
steer function.
Move the switch or push the button to choose
the drive setting. The indicator light next to the
current setting will be on.
Move the control handle in the direction
indicated by the blue arrow on the control panel
and the machine will drive forward. Move the
control handle in the direction indicated by the
yellow arrow and the machine will drive
backwards. Move the control handle in the
direction indicated by the blue triangle and the
machine will steer to the left. Move the control
handle in the direction indicated by the yellow
triangle and the machine will steer to the right.
22 Thumb rocker for jib boom extend/retract
function
Push the top of the rocker switch and the jib
boom will retract. Push the bottom of the rocker
switch and the jib boom will extend.
23 Dual axis proportional control handle for jib boom
up/down and platform rotate left/right functions
Move the control handle up and the jib boom will
raise. Move the control handle down and the jib
boom will lower. Move the control handle to the
left and the platform will rotate to the left. Move
the control handle to the right and the platform
will rotate to the right.
OR
Move the control handle in the direction
indicated by the blue arrow on the control panel
and the machine will drive forward. Move the
control handle in the direction indicated by the
yellow arrow and the machine will drive
backwards. Press the left side of the thumb
rocker and the machine will steer to the left.
Press the right side of the thumb rocker and the
machine will steer to the right.
24 Axle extend/retract switch with indicator lights
Move the axle select switch to chose an axle
setting. The indicator light will flash while the
axles are extending and stay on when the axles
are fully extended. The indicator light will flash
while the axles are retracting and stay on when
the axles are fully retracted.
19 Steer mode control with indicator lights
Move the switch or push the button to choose
steer mode.
25 Drive enable control with indicator light
The indicator light next to the current steer mode
will be on.
20 Single axis proportional control handle for
secondary boom up/extend and down/retract
function
Light on indicates that the primary boom has
moved past either circle-end wheel and the drive
function is turned off. To drive, move the drive
enable switch or push the drive enable button
and slowly move the drive/steer control handle
off center.
Move the control handle up and the secondary
boom will raise and then extend. Move the
control handle down and the secondary boom
will retract and then lower.
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Controls
26 Thumb rocker switch for primary boom extend/
retract function
Push the top of the rocker switch and primary
boom will retract. Push the bottom of the rocker
switch and the primary boom will extend.
27 Dual axis proportional control handle for primary
boom up/down and turntable rotate left/right
functions
Move the control handle up and the primary
boom will raise. Move the control handle down
and the primary boom will lower. Move the
control handle to the left and the turntable will
rotate to the left. Move the control handle to the
right and the turntable will rotate to the right.
28 Platform level switch
Move the switch up and the level of the platform
will raise. Move the switch down and the level of
the platform will lower.
29 Not used
30 Axle extend button with indicator light
Push the axle extend button to extend the axles.
The indicator light will flash while the axles are
extending and stay on when the axles are fully
extended.
31 Axle retract button with indicator light
Push the axle retract button to retract the axles.
The indicator light will flash while the axles are
retracting and stay on when the axles are fully
retracted.
24
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Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
Do Not Operate Unless:
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.
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
operator 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.
Part No. 114475
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Operator's Manual
Second Edition · Third Printing
Inspections
Pre-operation Inspection
R Steer and axle sensors
R Be sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
R Alarms and beacons (if equipped)
R Nuts, bolts and other fasteners
R Be sure that all decals are legible and in place.
See Inspections for Decals section.
R Platform entry mid-rail or gate
Check entire machine for:
R Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
R Cracks in welds or structural components
R Dents or damage to machine
R Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
R Excessive rust, corrosion or oxidation
R Check for engine coolant leaks and proper level
of coolant. Add coolant if needed. See
Maintenance section.
R Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
R Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
R After you complete your inspection, be sure that
all compartment covers are in place and
latched.
Check the following components or areas for
damage, improperly installed or missing parts and
unauthorized modifications:
R Electrical components, wiring and
electrical cables
R Hydraulic hoses, fittings, cylinders and
manifolds
R Fuel and hydraulic tanks
R Drive and turntable motors and drive hubs
R Boom wear pads
R Tires and wheels
R Engine and related components
R Limit switches and horn
R Rotation sensors
26
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
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 Pull out the red Emergency Stop button to
the on position.
Do Not Operate Unless:
Result: The LCD screen will come on and
display no error messages. The beacon (if
equipped) should flash.
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
Note: In cold climates, the LCD readout screen will
need to warm up before the display appears.
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
4 Start the engine. See Operating Instructions
section.
3 Always perform function tests prior to
use.
Test Emergency Stop
Know and understand the function tests
before going on to the next section.
5 Push in the red Emergency Stop button to the
off position.
Result: The engine should turn off and no
functions should operate.
4 Inspect the workplace.
5 Only use the machine as it was intended.
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.
Function Test 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.
7 At the ground controls, push and hold a function
enable/speed select button and push the
primary boom up button.
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.
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.
After repairs are completed, the operator must
perform a pre-operation inspection and function
tests again before putting the machine into service.
Part No. 114475
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Operator's Manual
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Inspections
12 Turn the key switch to platform control. At the
platform controls, press and hold the foot switch
and move the drive control handle in the forward
direction.
8 Push and hold a function enable/speed select
button and press the secondary boom raise/
extend button.
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.
13 Activate the extend axle function.
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.
9 Push and hold a function enable/speed select
button and press the primary boom extend
button.
14 Return to the ground controls. Turn the key
switch to ground control.
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 axles are extended.
15 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.
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.
16 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.
11 Push and hold a function enable/speed select
button and push the turntable rotate right button.
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.
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 extend
button and then the primary boom retract button.
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.
Result: The turntable should rotate normally.
28
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Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
Test the Machine Functions
Test the Tilt Sensor
19 Do not press and hold a function enable/speed
select button. Attempt to activate each boom
and platform function button.
25 Push one of the LCD
screen control buttons until
TURNTABLE LEVEL
SENSOR X-DIRECTION
appears.
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 Emergency/Auxiliary Controls
21 Push in the red Emergency Stop button to the
off position to turn off the engine.
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.
27 Push one of the LCD screen control buttons until
PLATFORM LEVEL SENSOR DEGREES
appears.
Result: The LCD screen should display the
angle in degrees.
22 Pull out the red Emergency Stop button to the
on position.
23 Simultaneously push and hold the
emergency/auxiliary power button
and push each boom function button.
Note: To conserve battery power, test
each function through a partial cycle.
Result: All boom functions should operate.
24 Start the engine.
Part No. 114475
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Operator's Manual
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Inspections
Test the Operating Envelope
At the Platform Controls
28 Push one of the LCD screen
control buttons shown until
PRI BOOM ANGLE TO
GRAVITY is displayed.
Test Emergency Stop
35 Turn the key switch to platform control.
36 Push in the platform red Emergency Stop button
to the off position.
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.
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
31 Simultaneously push the 2
LCD screen control buttons
shown to activate status
mode.
38 Push the horn button.
Result: The horn should sound.
Test the Tilt Sensor Alarm
32 Push one of the LCD screen
control buttons shown until
SEC BOOM ANGLE is
displayed.
39 Push a button or move a switch, such as the
engine idle control.
Result: The alarm should sound at the platform
controls.
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 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.
30
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
Test the Foot Switch
Test the Steering
40 Push in the platform red Emergency Stop button
to the off position.
47 Select square-end (blue arrow) steer.
Push the square-end (blue arrow)
steer button or move the steer mode
switch.
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.
Result: The engine should not start.
43 Do not press down the foot switch and restart
the engine.
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.
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 handle,
toggle switch or button.
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.
Result: All functions should operate through a
full cycle.
51 Select circle-end (yellow arrow) steer.
Push the circle-end (yellow arrow) steer
button or move the steer mode switch.
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.
Result: The circle-end wheels should turn in the
direction that the blue triangles point on the
drive chassis.
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Operator's Manual
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Inspections
54 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 circle-end wheels should turn in the
direction that the yellow triangles point on the
drive chassis.
55 Select crab steer. Push the crab steer
button or move the steer mode switch.
59 Select coordinated steer. Push the
coordinated steer button or move the
steer mode switch.
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 circle-end wheels should turn
in the direction that the yellow triangles point on
the drive chassis.
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.
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.
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: 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.
Result: All wheels should turn in the direction
that the yellow triangles point on the drive
chassis.
32
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
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.
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.
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.
Result: The machine should move in the
direction that the yellow arrow points on the
drive chassis, then come to an abrupt stop.
Use the color-coded
direction arrows on the
platform controls and the
drive chassis to identify the
direction of travel.
Blue
Yellow
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.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
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
30 cm per second.
Test the Drive Enable System
66 Press down the foot switch and lower the booms
to the stowed position.
Note: The machine will travel 12 m in 40 seconds.
73 Lower the primary boom to the stowed position.
67 Rotate the turntable until the primary boom
moves past one of the circle-end tires.
74 Extend the primary boom 1.2 m.
75 Slowly move the drive control handle to the full
drive position.
Result: The drive enable
indicator light should come
on while the boom is
anywhere in the range
shown.
Result: The maximum achievable drive speed
with the primary boom extended should not
exceed 30 cm per second.
68 Move the drive/steer control handle off center.
Note: The machine will travel 12 m in 40 seconds.
Result: No drive function should operate.
69 Push the drive enable button or move the drive
enable switch, and slowly move the drive/steer
control handle off center.
Result: The drive function should operate.
Part No. 114475
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Operator's Manual
Second Edition · Third Printing
Inspections
76 Retract the primary boom to the stowed position.
Test Emergency/Auxiliary Controls
77 Raise the secondary boom to 5° above
horizontal.
85 Push in the red Emergency Stop button to the
off position to shut off the engine.
78 Slowly move the drive control handle to the full
drive position.
86 Pull out the red Emergency Stop button to
the on position.
Result: The maximum achievable drive speed
with the secondary boom raised should not
exceed 30 cm per second.
87 Press down the foot switch.
Note: The machine will travel 12 m in 40 seconds.
79 Lower the secondary boom to the stowed
position.
88 Activate the emergency/auxiliary controls. Move
and hold the switch or push and hold the button.
Activate each function control handle, switch or
button.
Note: To conserve battery power, test each
function through a partial cycle.
80 Extend the jib boom 30 cm.
Result: All boom and steer functions should
operate.
81 Slowly move the drive control handle to the full
drive position.
Test Aircraft Protection Package (if equipped)
Result: The maximum achievable drive speed
with the jib boom extended should not exceed
30 cm per second.
89 Move the gray bumper at the bottom of the
platform 4 inches / 10 cm in any direction.
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 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.
90 Activate each function control handle or toggle
switch or button.
Result: All boom and steer functions should not
operate.
91 Activate the function override. Move and hold
the switch or push and hold the button.
92 Activate each function control handle or toggle
switch or button.
Result: All boom and steer functions should
operate.
If the drive speed with the jib boom extended and
the primary boom extended exceeds 15 cm per
second, immediately tag and remove the machine
from service.
84 Retract the primary boom and the jib boom.
34
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
·
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
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the 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.
It is the 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. 114475
Z-135/70
35
Operator's Manual
Second Edition · Third Printing
Inspections
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
place.
Part No. Description
Quantity
Part No. Description
Quantity
27204
Arrow - Blue
2
82840
Ground Control Panel
1
27205
Arrow - Yellow
2
82841
Platform Control Panel
1
27206
Triangle - Blue
2
97705
Cosmetic - Genie Z-135/70
1
27207
Triangle - Yellow
2
97716
Label - Wheel Load
4
28159
Label - Diesel
1
97757
Label - Hydraulic Oil Level
1
28174
Label - Power to Platform, 230V
2
97815
Label - Lower Mid-Rail
1
28235
Label - Power to Platform, 115V
2
97889
Cosmetic - Z-135
2
40434
Label - Lanyard Anchorage
3
97891
Cosmetic - Genie Z-135
1
44981
Label - Air Line to Platform
2
114247
Label - Fall Hazard
1
65278
Label - No Step
2
114248
Label - Tip-over Hazard
1
82246
Label - 113 dB
1
114249
Label - Tire Specifications
4
82422
Label - Driving Lights
1
114251
Label - No Smoking
1
82472
Label - Crushing Hazard
2
114252
Label - Tip-over Hazard
3
82473
Label - Compartment Access
2
133067
Label - Electrocution Hazard
2
82481
Label - Battery Safety
1
133180
Label - Battery Damage
1
82487
Label - Read the Manual
2
133205
Label - Electrocution/Burn Hazard
2
82487
Label - Read the Manual, Pipe Cradle
1
230386
Label - Emergency Lowering
1
82487
Label - Read the Manual, Panel Cradle
1
230985
Ground Control Panel
1
82546
Notice - Max. Capacity, 272 kg
1
230987
Ground Control Panel Key Switch
1
82548
Label - Platform Rotate
2
233130
Platform Control Panel
1
82604
Label - Max. Side Force, 400N
1
1000054 Label - Drive Enable Patch
1
1000257 Label - Transport Diagram
2
Shading indicates decal is hidden from view, i.e.
under covers
36
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Inspections
Part No. 114475
Z-135/70
37
Operator's Manual
Second Edition · Third Printing
Operating Instructions
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.
Do Not Operate Unless:
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.
38
Using the machine for anything other than lifting
personnel, along with their tools and materials, to
an aerial work site 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.
Z-135/70
Part No. 114475
Second Edition · Third Printing
Operator's Manual
Operating Instructions
Deutz models
If the machine is stored for long
periods of time in low temperatures
(below 0°C) with the secondary
boom raised and extended, the
engine may not start due to a
system fault.
2 Activate the glow plugs. Push the button or
move the switch. The glow plugs will turn on for
30 seconds.
To remove the fault, hold the auxiliary power button
and activate the secondary boom up function until
the secondary boom begins extending.
3 Start the engine. Press the button
or move the switch.
Emergency Stop
The engine start button can be
pressed at any time while the glow
plugs are on.
Push in either the ground or platform red
Emergency Stop button to the off position to stop
all functions and turn the engine off.
Perkins and Cummins models
Repair any function that operates when the red
Emergency Stop button is pushed in to the off
position.
Starting the Engine
1 At the ground controls, turn the key switch to
the desired position.
2 Activate the glow plugs for 3-5 seconds. Push
and hold the button or move and hold the
switch.
3 Start the engine. Press the button or move and
hold the switch.
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, -6°C and below, warm the engine
for 5 minutes before operating to prevent hydraulic
system damage.
In extreme cold conditions, -18°C and below,
machines should be equipped with optional cold
start kits. Attempting to start the engine when
temperatures are below -18°C may require the use
of a booster battery.
Part No. 114475
Selecting and operating the ground controls will
override the platform red Emergency Stop button.
Emergency/Auxiliary Power
Use emergency/auxiliary power if the primary power
source (engine) fails.
1 Turn the key switch to ground or platform
control.
2 Pull out the red Emergency Stop button to the
on position.
3 Press down the foot switch when operating the
emergency/auxiliary controls from the platform.
4 Move and hold the switch or push
and hold the button. Activate the
desired function. The indicator light
will be on when emergency power
is being used.
Z-135/70
39
Operator's Manual
Second Edition · Third Printing
Operating Instructions
To Extend and Retract Axles
To Position Platform
1 Turn the key switch to platform control.
1 Push and hold a function enable/speed select
button.
2 At the platform controls, press down the foot
switch and move the drive control handle in
either direction. Activate the extend axle
function or the retract axle function. Move the
switch or push the button.
2 Push the appropriate function button according
to the markings on the control panel.
Drive, steer and axle functions are not available
from the ground controls.
The indicator light will flash while the axles are
moving and stay on when the axles are fully
extended or retracted.
Operation from Platform
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.
1 Turn the key switch to platform control.
Operation from Ground
3 Start the engine. Do not press down the foot
switch when starting the engine.
1 Turn the key switch to ground control.
2 Pull out the red Emergency Stop button to
the on position.
3 Start the engine.
40
2 Pull out both ground and platform red
Emergency Stop buttons to the on position.
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.
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Operator's Manual
Operating Instructions
To Steer
Driving on a slope
1 Press down the foot switch.
Determine the uphill, downhill and side slope ratings
for the machine and determine the slope grade.
2 Select the steer mode. Move the switch or push
the button. The indicator light next to the current
steer mode will be on.
Maximum slope rating,
counterweight uphill (gradeability):
45% (24°)
Maximum slope rating,
counterweight downhill:
30% (17°)
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.
Maximum side slope rating:
25% (14°)
Note: Slope rating is subject to ground 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.
To Drive
Select the machine on incline drive setting.
1 Press down the foot switch.
2 Increase speed: Slowly move the drive/
steer control handle in the direction
indicated by the blue or yellow arrows.
Decrease speed: Slowly move the drive/steer
control handle toward center.
Stop: Return the drive/steer control handle to
center or release the foot switch.
Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.
Machine travel speed is restricted when the boom
is raised or extended.
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Operating Instructions
To determine the slope grade:
Drive Enable
Measure the slope with a digital inclinometer OR
use the following procedure.
Light on indicates that the
primary boom has moved past
either circle-end wheel and the
drive function is turned off.
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.
To drive, activate the drive enable function and
slowly move the drive/steer control handle off
center. Push the drive enable button or move the
drive enable switch.
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.
If the drive/steer control handle is not moved within
two seconds of activating the drive enable function,
the drive function will not operate. Release and
activate the drive enable function again.
While holding the piece of wood level, measure the
vertical distance from the bottom of the piece of
wood to the ground.
Be aware that the machine may move in the
opposite direction that the drive and steer controls
are moved.
Divide the tape measure distance (rise) by the
length of the piece of wood (run) and multiply by
100.
Always use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.
Example:
When the drive enable light is on, the axles cannot
retract.
run
rise
Piece of wood = 3.6 m
Run = 144 inches 3.6 m
Rise = 12 inches 0.3 m
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.
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Operator's Manual
Operating Instructions
Operating Envelope Indicator
Lights
Engine Idle Select (rpm)
Select the engine idle (rpm) setting. Move the
switch or push the 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
The operating envelope indicator lights will come on
to notify the operator that a function has been
interrupted and/or an action is required by the
operator.
Lower/Retract Secondary Boom
indicator light flashing: Lower/
retract the secondary boom until
the indicator light is off.
Lower Primary Boom indicator
light flashing: Lower the primary
boom until the indicator light is
off.
Check Engine Light
Light on and engine stopped: Tag
the machine and remove from
service.
Light on and engine still running:
Contact service personnel within 24
hours.
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.
Out of Operational Envelope
Recovery
If all functions stop operating, you may have
exceeded the operational envelope. A trained
operator on the ground will need to lower the
platform from the ground controls. Please see the
Service Bypass / Recovery Key Switch section in
the service manual.
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Operating Instructions
Generator (if equipped)
After Each Use
To operate the generator, press the generator
button or move the generator switch. The indicator
light will come on and the engine will continue to
run.
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
Plug power tools into the power to platform GFCI
outlet.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is between
the circle-end wheels.
To turn off the generator, push the generator button
or move the switch. The indicator light will turn off.
Aircraft Protection Package
(if equipped)
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chock the wheels.
If the platform bumpers come in contact with
aircraft components, the machine will shut down
and no functions will operate.
Move the function override toggle switch to either
side to operate the machine.
Platform Overload Indicator
Light
Light flashing indicates the
platform is overloaded and no
functions will operate.
Remove weight from the platform
until the light goes off.
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Operating Instructions
Observe and Obey:
Pipe Cradle Instructions
The pipe cradle assembly consists of 2 pipe
cradles positioned at either side of the platform and
mounted to the guardrails with U-bolts.
Pipe cradles must be installed on the inside of
the platform.
Pipe cradles must not obstruct the platform
controls or the platform entrance.
The bottom of the pipe cradle tube must rest on
the platform floor.
Be sure the platform is level before installing a
pipe cradle.
Pipe Cradle Installation
1 Install a pipe cradle on each side of the
platform. Refer to the illustration on the left.
Make sure the bottom of the pipe cradle tube
rests on the platform floor.
2 Install two U-bolts from the outside of the
platform rails through each pipe cradle mount.
3 Secure each U-bolt with 2 washers and 2 nuts.
a strap
b U-bolts
c pipe cradle mount
d upper platform
railing
e pipe cradle
weldment
f
g flat washers
h
Part No. 114475
middle platform
railing
3/8-inch
nylock nuts
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Operating Instructions
Pipe Cradle Operation
1 Be sure the pipe cradle assembly and
installation instructions have been followed
properly and that the pipe cradles are secured to
the platform railings.
2 Place the load so that it rests in both pipe
cradles. The length of the load should be
parallel with the length of the platform.
3 Center the load in the pipe cradles.
4 Secure the load to each pipe cradle. Pass the
nylon strap over the load. Depress the buckle
and slide the strap through. Tighten the strap.
5 Gently push and pull on the load to make sure
the pipe cradles and load are secure.
6 Keep the load secured when the machine is
moving.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles will
reduce the rated platform capacity of the
machine and must be factored into the total
platform load.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles may
limit the maximum number of occupants in the
platform.
Maximum Pipe Cradle Capacity
All models
Pipe Cradle Assembly Weight
46
90.7 kg
9.5 kg
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Operator's Manual
Operating Instructions
Panel Cradle Assembly
Installation of Padding
1 Apply the warning decal to the front of each
panel cradle (if needed).
1 Install the 2 pieces of padding on the platform
rails. Position the padding to protect the panels
from contact with the platform rails.
2 Install rubber bumper 1 in the panel cradle base.
See the illustration.
3 Secure the bumper with 2 high profile lock nuts
and 2 washers.
Installation of Strap
1 Open the clamp and install it around a vertical
platform rail tube.
Panel Cradle Installation
2 Insert a bolt with a washer through one side of
the clamp.
1 Insert the hook piece through the slots in the
panel cradle base.
3 Install the strap assembly end plate onto the
bolt.
2 Hook the panel cradle to the bottom platform
tube in the desired location.
4 Insert the bolt through the other side of the
clamp.
3 Install rubber bumper 2 through the panel cradle
base and the hook piece. See the illustration.
5 Secure with a washer and a nut. Do not overtighten. The strap assembly end plate should be
able to slide on the platform rail.
4 Secure with 2 low profile lock nuts.
5 If the panel cradle is installed at a platform floor
support tube, insert the U-bolt through the floor,
around the tube and into the panel cradle base.
6 Secure the U-bolt with 2 nuts and 2 washers.
Proceed to step 9.
7 If the panel cradle is not installed at a platform
floor support tube, use the aluminum tube
provided.
8 Place the tube between the panel cradle and the
platform floor. Insert the U-bolt through the floor,
around the tube and into the panel cradle base.
9 Repeat above for the second set of parts.
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Operating Instructions
Panel Cradle Operation
rubber
bumper 2
1 Secure both panel cradles to the platform.
2 Place the load so that it rests in both panel
cradles.
3 Center the load on the platform.
rubber
bumper 1
U-bolt
mounting
slots
4 Secure the load to the platform using the strap.
Tighten the strap.
decal
panel
cradle
base
hook
piece
padding
clamp
hook
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Operator's Manual
Transport and Lifting Instructions
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.
Observe and Obey:
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.
Genie customers needing to containerize any lift
or Genie product should source a qualified
freight forwarder with expertise in preparing,
loading and securing construction and lifting
equipment for international shipment.
Only qualified aerial lift operators should move
the machine on or off the truck.
The transport vehicle must be parked on a level
surface.
The transport vehicle must be secured to
prevent rolling while the machine is being
loaded.
Be sure the vehicle capacity, loading surfaces
and chains or straps are sufficient to withstand
the machine weight. See the serial label for the
machine weight.
Part No. 114475
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.
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Transport and Lifting Instructions
Securing the Platform
Securing to Truck or Trailer for
Transit
Always use the turntable rotation lock pin each time
the machine is transported.
Turn the key switch to the off position and remove
the key before transporting.
Place a block under the platform rotator. Do not
allow the block to contact the platform cylinder.
Secure the platform with a nylon strap placed
through the lower platform support. Do not use
excessive downward force when securing the boom
section.
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
Secondary boom width:
66 cm
Jib boom width:
41 cm
12.97 m
3.07 m
1.31 m
3.3 m
5.84 m
4.25 m
7.65 m
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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.
Only qualified riggers should rig and lift the
machine.
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial label for the
machine weight.
Adjust the rigging to prevent damage to the
machine and to keep the machine level.
1.5 m
1.4 m
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Maintenance
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.
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Note: Check the oil level with the engine off.
1 Check the engine oil dipstick. Add oil as
needed.
Perkins 1104C-44 and 804D-33T Engine
Use only Genie approved replacement parts.
Oil type
15W-40
Oil type - cold conditions, 1104C
10W-30
Oil type - cold conditions, 804D
5W-40
Deutz BF4L2011 and TD2011L04i Engine
Oil type
Maintenance Symbols Legend
15W-40
Oil type - cold conditions
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.
5W-30
Cummins B4.5C80 and B3.3C80 Engine
Oil type
15W-40
Oil type - cold conditions
10W-30
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.
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Operator's Manual
Maintenance
Check the Hydraulic Oil Level
Check the Batteries
Maintaining the hydraulic oil at the proper level is
essential 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.
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 hot or live
circuits may result in death or serious injury.
Remove all rings, watches and other jewelry.
1 Be sure that the engine is off and the boom is in
the stowed position.
Bodily injury hazard. Batteries contain acid.
Avoid spilling or contacting battery acid.
Neutralize battery acid spills with baking soda
and water.
2 Visually inspect the sight gauge located on the
side of the hydraulic oil tank.
Result: The hydraulic oil level should be
between the two marks on the decal next to the
sight gauge. Add oil as needed.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
Maximum oil level
3 Be sure that the battery hold-down bar is in
place and secure.
4 Remove the battery vent caps.
Minimum oil level
5 Check the battery acid level. If needed,
replenish with distilled water to the bottom of the
battery fill tube. Do not overfill.
Hydraulic oil specifications
Hydraulic oil type
Part No. 114475
6 Install the vent caps.
Chevron Rykon®
Premium MV equivalent
Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate corrosion on
the battery terminals and cables.
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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 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.
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Operator's Manual
Specifications
Z-135/70
Platform leveling
self-leveling
160°
Height, working maximum
42.9 m
Platform rotation
Height, platform maximum
41.1 m
AC outlet in platform
Height, stowed maximum
3.1 m
Horizontal reach, maximum
Hydraulic pressure, maximum
(boom functions)
203 bar
218 bar
21.3 m
Width, axles retracted
2.5 m
Hydraulic pressure, maximum
(auxiliary power unit)
Width, axles extended
3.9 m
System voltage
Length, stowed
12.9 m
Tire size
Maximum load capacity
272 kg
Fuel tank capacity
Maximum wind speed
12.5 m/s
Wheelbase, axles extended
4.1 m
Wheelbase, axles retracted
4.7 m
Ground clearance
51 cm
2.3 m
5.6 m
Turning radius, axles retracted
inside
outside
5.5 m
7.8 m
360° continuous
Turntable tailswing,
secondary boom lowered
4.3 m
Turntable tailswing,
secondary boom raised
78 cm
Drive speed, stowed
4.8 km/h
12.2 m/9.1 sec
1.1 km/h
12.2 m/40 sec
Drive speed,
raised and extended
0.6 km/h
12.2 m/68 sec
151 liters
Airborne noise emissions
113 dB
Maximum sound level at normal operating workstations
(A-weighted)
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.
Floor loading information
Tire contact pressure
Occupied floor pressure
11,336 kg
9.14 kg/cm2
896 kPa
996 kg/m2
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.
12V DC proportional
Platform dimensions, 1.8 m
(length x width)
1.8 m x 76 cm
Platform dimensions, 2.4 m
(length x width)
2.4 m x 91 cm
Part No. 114475
18-22.5, 18 ply FF
Weight
See Serial Label
(Machine weights vary with option configurations)
Tire load, maximum
Drive speed,
raised or extended
Controls
12V
Vibration value does not exceed 2.5 m/s2
Turning radius, axles extended
inside
outside
Turntable rotation
standard
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
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Specifications
Z-135/70 Range of Motion
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Part No. 114475