TMZ-34/19 to SN T3499-796, (PN 97781)
Contents
1. Part No Description Quantity Part No Description Quantity 27564 Danger Electrocution Hazard 2 48726 Notice Battery Charger Operating Instructions 1 28157 Label Dexron 1 48727 Danger Battery Charger Safety 1 28161 Warning Crushing Hazard 4 f 48730 Platform Control Panel 1 28164 Notice Hazardous Materials 1 48733 Danger Tip over batteries 1 28171 Label No Smoking 1 48734 Notice Battery Connection Diagram 1 28174 Label Power to Platform 230V 2 49918 Notice Material Lifting Operation 1 28175 Caution Compartment Access 1 ae 52004 Label Interlock Display Lights 2 28176 Notice Missing Manuals 1 52008 Danger General Safety Ground 1 28235 Label Power to Platform 115V 2 52475 Label Transport Tie down 4 28236 Warning Failure To Read 1 nE 7 52495 Notice Manual Lowering Instructions 1 31060 Danger Do Not Alter Limit Switch 1 52496 Notice Manual Rotation Instructions 1 35579 Notice Max Cap Hook 500 Ibs 227 kg 1 52557 Label Parking Brake Mechanical 1 37051 Notice Side Force 150 lbs 667N ANSI amp CSA 1 62066 Cosmetic Genie TMZ 34 19 2 37052 Notice Max Cap 500 Ibs 227 kg 1 62707 Warning Towing Hazard 2 37145 Label Manual Lowering 4 62722 Notice Max Cap Hook 440 Ibs 200 kg 1 40434 Label Lanyard Anchorage 2 72897 Notice Tire Specification ANSI amp CSA 2 44248 Notice Max Cap 440 Ibs 200kg 1 72899 Notice Transport Instructions 1 436582. Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are properly inflated and in good condition and lug nuts are properly tightened SAFETY RULES Do not use batteries that weigh less than the original equipment Four batteries are used as counterweight and are critical to machine stability Each battery must weigh 75 pounds 34 kg 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 Collision Hazards Be aware of boom position when rotating the turntable The machine must be on a level surface or secured before releasing the parking brake Use the parking brake to control the speed of the machine when pushing a machine that is not attached to a tow vehicle Check the work area for overhead obstructions or other possible hazards Do not lower the boom unless the area below is clear of personnel and obstructions Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating the machine Component Damag
3. Genie Operator s Manual poss with Maintenance Information Part No 97781 TMZ 34 19 This manual replaces part number 72894 Operator s Manual 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 ccs vas sae cecenceki eas lebeebadhde cba cagessacdepdcnuibetadedeeeiees 1 CONTOS oreca E 8 Pre operation Inspection eessseeeessrrreeseeernnenerenns 12 Maintenance ccccecee cece eeeeeeeeeeeeseeeanaaeeaeeaeeeeeeees 14 FUNCHON TeStS siccicncisicetsneiceacesecashedtiaceseearngescaetoeuns 16 Workplace Inspection cc cceeeceeeeeceeeeeeteeeeeeneeeees 21 Operating Instructions 0 c cc eeeeeeeeeeeeeeeeeeeetteeeeeees 22 DOCS ruuka E a E A 28 SPOCIPICALI OMS s ronen arai NS 30 Reporting Safety Defects cccesceeeeeeeeeeneeees 31 Contact us Internet http www genielift com e mail techpub genieind com Third Edition First Printing SSS ae Notice This operator s manual is for TMZ 34 19 machines before serial number T3400 2 It replaces operator s manual part number 72894 Copyright 1998 by Genie Industries
4. A S v a r m gt BATTERY CHARGE EO O O O O F 1 Primary boom up down buttons 6 Outrigger interlock display lights four 2 Hornbutton 7 Key switch for ground off platform selection 3 Jib boom up down buttons 8 Battery charge indicator 4 Stop indicator light indicates that either red 9 Function enable speed select buttons a Stop button is pushed in to the off 10 Powerindicator light 5 Red Emergency Stop button 11 Turntable rotate buttons 12 Secondary boom up down buttons 10 Genie TMZ 34 19 Part No 97781 Third Edition First Printing Operator s Manual CONTROLS an r STOP Ground Control Panel 1 Function enable button for Primary boom down Secondary boom down Jib boom down Turntable rotate right 2 Function enable button for Primary boom up Secondary boom up Jib boom up Turntable rotate left Z fN O l 0 HE Ox OF OS f N OR Og Red Emergency Stop button Jib boom up down button Horn button Key switch for ground off platform selection Primary boom up down button Secondary boom up down button o ON OOUR O Turntable rotate button Part No 97781 Genie TMZ 34 19 11 Operator s Manual Third Edition First 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 perfo
5. Part No 97781 Genie TMZ 34 19 25 Operator s Manual Third Edition First Printing OPERATINGINSTRUCTIONS Material Lifting Configuration Observe and Obey M Maintain safe distances between operator machine and fixed objects M Be aware of the direction the boom will travel when using the platform controls Material Lifting Configuration Set up 1 2 Turn the key switch to the off position Remove the two wing nuts that secure the material lifting hook to the base Remove the material lifting hook and replace the wing nuts on the mounting studs Disconnect the running lights and the platform controls from the platform Remove the platform controls Open the clamp on the back of the platform controls and slide the controls up and off Open the controls side turntable cover Disconnect the electrical cord on the bottom right side of the ground control box Connect the platform control cord disconnected in step 3 to the ground control box Close the turntable cover Support the platform Remove the 1 2 inch toggle pin that secures the platform to the jib boom Lift the platform up and remove it from the machine To install the material lifting hook insert the bottom rail into the platform mounting bracket and rotate up into position Insert the 1 2 inch toggle pin 10 Operate the material lifting hook from the ground with the platform controls The key switch should be turned to the pl
6. TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Pre operation Inspection 11 Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform 1 Be sure that all decals are legible and in place See Decals section Add oil if needed See Maintenance section L Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section l Check for proper tire pressure and lug nut torque Add air to tires if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications 1 Electrical components wiring and electrical cables m Hydraulic power unit reservoir hoses fittings cylinders and manifolds Boom components and wear pads Tires and wheels Trailer lights and reflectors Parking brake components Outriggers leveling jacks and foot pads Limit switch alarms and horn Nuts bolts and other fasteners Platform entry mid rail gate Uooovuouououoe oo O Surge brake components if equipped 1 Check for hydraulic oil leaks and proper oil level PRE OPERATION INSPECTION Axle components Safety chains if required Mechanical brake components if equipped m m m Beacon and alarms if equipped Check entire machine for L Cracks in welds or structur
7. a hill 4 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Personnel Lifting Configuration Tip over Hazards Do not use the platform as a crane Do not place loads outside the platform perimeter Do not place or attach overhanging loads to any part of the platform Do not push off or pull toward any object outside of the platform iow Ap EN Maximum allowable manual force CE 90 Ibs 400 N Maximum allowable side force ANSI amp CSA 150 Ibs 667 N 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 Fall Hazards Occupants must wear a safety belt or harness and comply with applicable governmental regulations Attach lanyard to anchor provided in platform SAFETY RULES Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times 4 Do not climb down from the platform when raised sn a Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Collision Hazard Be aware of crushing hazards when grasping the platform guard rail Material Lifting Configuration Collision Hazards Do not raise the load unless the material lifti
8. machine into service Genie TMZ 34 19 Part No 97781 Third Edition First Printing Operator s Manual Setup 1 Select a test area that is firm level and free of obstructions 2 Be sure the boom hold down latches are unlatched 3 Position the machine directly below the desired work area 4 Set the parking brake Disconnect the trailer lights chains and surge brake safety cable from the vehicle 6 Open the latch on the ball coupler 7 Pull the jack release handle and rotate the tongue jack to the lifting position 8 Raise the tongue by turning the jack handle 9 Open all boom hold down latches 10 Insert the key and turn to ground control 11 Pull out the red Emergency Stop buttons at the ground and platform controls Result The power light if equipped should come on 12 Select an outrigger Maintain a firm grasp on the outrigger Pull the outrigger release handle and lower the outrigger Be sure the outrigger lock pin is locked 13 Repeat the procedure for each of the remaining outriggers 14 Adjust the outriggers to level the machine and raise the wheels slightly off the ground 15 If equipped Check the interlock display lights at the ground controls and on the turntable Confirm that all four display lights are on If any interlock display light is flashing adjust the corresponding outrigger until the light remains on 16 If equipped Check the bubble level to make sure the machine i
9. will not provide protection from contact with or proximity to electrical current N O amp Maintain safe distances from electrical power lines 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 operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity Maximum platform capacity ANSI amp CE models 500 Ibs 227 kg Maximum platform capacity CSA models 440 lbs 200 kg Maximum platform capacity with Optional Platform Rotate 440 Ibs 200 kg Maximum occupants 2 Do not raise the boom unless the machine is level Do not set the machine up on a surface where it cannot be leveled using only the leveling jacks yo Ae Do not raise the boom unless all four outriggers are lowered and locked the footpads a
10. First Edition First Printing March 2001 Third Edition First Printing May 2005 Genie and TMZ are registered trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 2 1990 Printed on recycled paper Printed in U S A Genie TMZ 34 19 PartNo 97781 Third Edition First 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 M 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 Part No 97781 Genie TMZ 34 19 1 Operator s Manual Third Edition First Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and
11. Notice Power to Battery Charger 230V 1 72900 Notice Operating Instructions Ground 1 44980 Notice Power to Battery Charger 115V 1 72908 Notice Tire specification CE 2 44986 Notice Side Force 90 Ibs 400N CE 1 97777 Platform Control Panel 1 46276 Ground Control Panel 1 97778 Ground Control Panel 1 48719 Danger General Safety Platform 1 97846 Notice Operating Instructions Platform 1 48721 Notice Operating Instructions Platform 1 97847 Notice Operating Instructions Ground 1 48723 Label Parking Brake Surge 1 28 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual OOOO DECALS 28161 37145 48730 or Ground 62066 52004 97777 Controls Side S l 37145 TEE 37145 28161 e M 72900 72899 k ly or 97847 52008 SS 49918 27564 46276 SN 2 or 97778 48733 i ae 48734 _ pariak Pavel 48723 or _ Py 28161 52557 i AO l Safety Tape 35579 62722 48719 ia 28236 Safety Tape y fue epa i or 97846 37052 72897 or 72908 or 44248 62707 a 52475 ae or 62066 a ey Safety Tape 28174 or 28235 lt 40434 27564 gt Safety Tape 52004 28175 37145 MUNS 28161 28171 Jam 28157 Power 31060 rages Unit S
12. ake sure the machine is level Operator s Manual SSS eS OPERATINGINSTRUCTIONS Operation from Ground 1 Turn the key switch to ground control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Be sure the batteries are connected before operating the machine To Position Platform 1 Press and hold a function enable button 2 Press the appropriate boom function button according to markings on the control panel Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Besure that the batteries are connected before operating the machine To Position Platform 1 Press and hold a function enable button 2 Press the appropriate boom function button according to markings on the control panel Manual Rotation 1 Open the power unit side turntable cover 2 Turn the override knob on the manifold in the counterclockwise direction Push the turntable in the desired direction 4 Turn the override knob on the manifold in the clockwise direction to operate the machine Part No 97781 Genie TMZ 34 19 23 Operator s Manual Third Edition First Printing OPERATINGINSTRUCTIONS Manual Lowering 1 Open the power unit side turntable cover 2 Loosen the jam nut and tighten the gold solenoid valve override knob clockwise The individual boom manual lowering valves will not
13. al components Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Be sure that the machine is properly configured for use Personnel lifting configuration Be sure the platform is properly installed Material lifting configuration Be sure the material lifting hook is properly installed Be sure that the batteries are in place and properly connected Models equipped with surge brake systems Check the hydraulic oil level in the surge brake Check for leaks After you complete your inspection be sure that all compartment covers are in place and latched Part No 97781 Genie TMZ 34 19 13 Operator s Manual Third Edition First Printing Maintenance Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator M 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 Indic
14. ates that new parts will be required to perform this procedure Check the Tires and Wheels Bodily injury hazard An over AWARNING inflated tire can explode and may cause death or serious injury Collision hazard An excessively AWARNING worn tire can cause poor handling and continued use could result in tire failure Tip over hazard Do not use AWARNING temporary flat tire repair products Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result ina machine tip over Component damage may also result if problems are not discovered and repaired in a timely fasion 1 Check the tire surface and sidewalls for cuts cracks punctures and uneven or excessive tread wear Result Replace the tire if uneven or excessive tread wear is found Always replace the tires with specifications equal to original equipment manufacturer 2 Check each wheel for damage bends and cracks Result Replace the wheel if any damage is found 3 Check each tire with an air pressure gauge and add air as needed 14 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual 4 Check the torque of each lug nut Tires and wheels Tire size ANSI amp CSA ST195 75D14 Lug nut torque 80 ft lbs 108 Nm Tire pressure cold 65 psi 4 5 bar Tire size CE ST195 65R14 Lug nut torque 80 ft lbs 108 Nm Tire p
15. atform control position 11 Reverse the above process to install the platform and return the machine to a personnel lifting configuration 26 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Battery and Charger Instructions Observe and Obey M Do not an use external charger or booster battery M Charge the battery in a well ventilated area M Use proper AC input voltage for charging as indicated on charger M Use only a Genie authorized battery and charger To Charge Battery 1 Be sure the batteries are connected before charging the batteries 2 Open the turntable covers The covers should remain open for the entire charging cycle 3 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle 4 Replace the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 Turn the battery charger on 7 The charger will indicate when the battery is fully charged 8 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill OPERATINGINSTRUCTIONS Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte un
16. ation or maintenance information Part No 97781 Genie TMZ 34 19 7 Operator s Manual Third Edition First Printing Controls Note Refer to the control panel pictures on the following pages to determine which panels are on your machine Z No Platform Control Panel 1 Secondary boom up down buttons 6 Stop indicator light indicates that either red Emergency Stop button is pushed in to the off 2 Primary boom up down buttons position 3 Hornbutton 7 Function enable speed select buttons 4 Jibboom up down buttons 8 Powerindicator light 5 Red Emergency Stop button 9 Turntable rotate buttons 8 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual CONTROLS Platform Control Panel 1 Function enable button for Primary boom down Secondary boom down Jib boom down Turntable rotate right Function enable button for Primary boom up Secondary boom up Jib boom up Turntable rotate left Red Emergency Stop button Horn button Battery charge indicator Primary boom up down button Jib boom up down button Secondary boom up down button o ON OO RA Turntable rotate button 10 Boom function speed controller Part No 97781 Genie TMZ 34 19 9 Operator s Manual Third Edition First Printing CONTROLS Ground Control Panel ao So So Z
17. e Hazards Do not use the machine as a ground for welding Do not fully lower the booms unless the booms are aligned with the tongue The booms must be lowered onto the boom rests Part No 97781 Genie TMZ 34 19 3 Operator s Manual Third Edition First Printing SAFETY RULES Lifting Hazards Use proper lifting techniques to move load or unload the machine Use proper lifting techniques when installing or removing the platform Bodily Injury Hazards Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Explosion and Fire Hazards Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present 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
18. eel in a straight ahead position sufficient to maintain the lane of travel If the combination travels off the paved roadway hold the steering wheel firmly Let off the gas pedal Do not apply your brakes Do not turn sharply Slow down below 25 mph 40 km h Then gradually turn the steering wheel to get back on the roadway Proceed with caution when entering traffic Set all tires to the proper pressure Find the recommended cold pressures on the tire sidewall owner s manual or on the trailer decal Do not put more pressure in the tire than is on the tire sidewall Tire pressures go up during driving Do not let off this extra pressure OPERATING INSTRUCTIONS When passing other vehicles be sure to leave enough room for the extra length of the trailer You will need to go much farther beyond the passed vehicle before you can return to your lane When turning with a trailer avoid jerky or sudden movements Inspect all connections at each stop Use the checklist provided on the back cover of this manual After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Rotate the turntable so that the platform is opposite the tongue of the machine Lower the boom to the stowed position 4 Secure the boom with the hold down latches 5 Turn the key switch to the off position and remove the key to secure from unauthorized use 6 Chock the wheels 7 Charge the batteries
19. function until the gold valve on the power unit is open solenoid valve override knob jam nut 3 Locate the manual lowering valve at the base of the primary boom cylinder and push the override knob until the primary boom is fully lowered 4 Locate the manual lowering valve at the base of the secondary boom cylinder and push the override knob until the secondary boom is fully lowered 5 Locate the manual lowering valve at the base of the jib boom cylinder and push the override knob until the jib boom is fully lowered 6 Loosen the override valve and tighten the jam nut to operate the machine Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions Moving Machine Without a Tow Vehicle Do not attempt to manually move a machine unless itis on a firm level surface Use the parking brake to control the speed of the machine while moving it Backing Up with Trailer if equipped with surge brake Surge brake systems are optional equipment on the Genie TMZ If your machine is equipped with a surge brake the system must be released before backing up Consult the surge brake system manual for specific instructions on each surge brake Be sure that the machine is returned to towing or operating configuration when finished T
20. i 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 Part No 97781 Genie TMZ 34 19 15 Operator s Manual Third Edition First Printing Function Tests Do Not Operate Unless K 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 and understand 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
21. ide mally ape 72897 or 62707 72908 52475 Safety 281740r 43658 or 52475 52495 52496 Tape 28235 44980 Part No 97781 Genie TMZ 34 19 29 Operator s Manual Third Edition First Printing Specifications Height working maximum 40 ft 12 2m Height platform maximum 34 ft 10 4m Height stowed maximum 6 ft 51 2 in 1 97m Horizontal reach maximum 16 ft 9 in from centerline of machine 5 1m Outrigger footprint 10 ft x 11 ft w x 1 3 05 x 3 35 m Maximum platform capacity 500 Ibs ANSI amp CE models 227 kg Maximum load capacity CSA models 440 Ibs amp models with Optional Platform Rotate 200 kg Width 59 in 150 cm Length stowed 19 ft 8 in 6m Turntable rotation 358 degrees Power source 4 Group L16 6V 250AH Batteries Platform dimensions length x width 48 in x 30 in 122 cm x 76cm Platform leveling self leveling AC outlet in platform standard Tire size ST195 75D14 ANSI amp CSA Load Range D Tire size CE ST195 65R14 Ground clearance 71 2 in 19 cm Hydraulic tank capacity 1 5 gallons 5 7 liters Weight 2 750 Ibs 1247 kg Maximum towing speed 60 mph 96 5 km h Maximum tongue weight 160 lbs 73 kg Airborne noise emissions 70 dB Maximum sound level at normal operating workstations A weighted Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligat
22. ion 30 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Reporting Safety Defects Genie Industries PO Box 97030 Redmond WA 98073 9730 Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to Genie Industries If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual problems between you your dealer or Genie Industries To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington DC area or write to NHTSA U S Department of Transportation 400 7th Street SW NSA 11 Washington DC 20590 You can also obtain information about motor vehicle safety from the Hotline Part No 97781 Genie TMZ 34 19 31 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Towing Checklist Use at each stop Before Towing Boom hold down latch is securely locked in place Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected a
23. l out the red Emergency Stop button to the on position 33 Press the horn button Result The horn should sound Test Machine Functions 34 Do not press a function enable button Attempt to activate each boom function Result All boom functions should not operate 35 Press and hold the blue function enable button Activate each boom function Result Primary boom up secondary boom up jib boom up and turntable rotate right should all function 36 Press and hold the yellow function enable button Activate each boom function Result Primary boom down secondary boom down jib boom down and turntable rotate left should all function 20 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations 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 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 mo
24. nd working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Holland Phone 31 10 2207911 Fax 31 10 220 6642 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 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 U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles
25. ng hook is properly secured to the machine Do not raise unless the load is properly balanced and secured to machine Do not stand under or allow personnel under the load or the machine when the load is raised Crushing Hazard Use common sense and planning when operating the machine with the platform controls from the ground Maintain safe distances between the operator the machine and fixed objects Part No 97781 Genie TMZ 34 19 5 Operator s Manual Third Edition First Printing SAFETY RULES Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazards e AN l Keep sparks flames and lighted tobacco away from batteries Batteries emit an explosive gas The covers should be open during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks Component Damage Hazards Do not use any battery charger greater than 24V to charge the batteries Do not expose the batteries or the charger to water or rain Electrocution Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cord cables and wires Replace damaged items before operating Avoid electrical shock from contact with bat
26. ns should operate through a full cycle Test the Tilt Sensor 24 Raise the jib boom approximately 6 inches 15 cm Raise the primary boom approximately 6 inches 15 cm off the boom rest Raise the secondary boom approximately 6 inches 15 cm off the boom rest 25 Locate the tilt sensor on the chassis near the ground controls 26 Press down on one side of the tilt sensor and place the tilt sensor test tool under one of the posts Result The alarm located in the platform should sound after 1 second The interlock display light should flash 27 Test all ground and platform control functions Result The turntable rotate function should not operate The primary boom up the secondary boom up and the jib boom up functions should not operate The primary boom down the secondary boom down and the jib boom down functions should operate normally 28 Remove the tilt sensor test tool 29 Turn the key switch to platform control At the Platform Controls Test Emergency Stop 30 Push in the platform red Emergency Stop button to the off position Result The stop light should be on and all platform control functions should not operate Test the Horn 31 Pull out the red Emergency Stop button to the on position 32 Raise the jib boom the primary boom or the secondary boom 33 Press the horn button Result The horn should sound Note The horn will not sound when the machine is in the fully stowed po
27. om up and turntable rotate left should all function 24 Press and hold the yellow function enable button Activate each boom function Result Primary boom down secondary boom down jib boom down and turntable rotate right should all function Test the Tilt Sensor 25 Raise the jib boom approximately 6 inches 15 cm Raise the primary boom approximately 6 inches 15 cm off the boom rest Raise the secondary boom approximately 6 inches 15 cm off the boom rest 26 Locate the tilt sensor on the chassis near the ground controls 27 Press down on one side of the tilt sensor and place the tilt sensor test tool under one of the posts Result The alarm located in the platform should sound after 1 second 28 Test all ground and platform control functions Result The turntable rotate function should not operate The primary boom up the secondary boom up and the jib boom up functions should not operate The primary boom down the secondary boom down and the jib boom down functions should operate normally 29 Remove the tilt sensor test tool 30 Turn the key switch to platform control Part No 97781 Genie TMZ 34 19 19 Operator s Manual Third Edition First Printing Oooo l FUNCTION TESTS At the Platform Controls Test Emergency Stop 31 Push in the platform red Emergency Stop button to the off position Result All platform control functions should not operate Test the Horn 32 Pul
28. ous 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 work place inspection before using the machine 22 Genie TMZ 34 19 Part No 97781 Third Edition First Printing Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions Repair any function that operates when either red Emergency Stop button is pushed in Set up 1 Position the machine directly below the desired work area 2 Set the parking brake Disconnect the trailer lights chains and surge brake safety cable from the vehicle 4 Open the latch on the ball coupler Pull the jack release handle and rotate the tongue jack to the lifting position Raise the tongue by turning the jack handle 7 Open all boom hold down latches 8 Lower the outriggers and adjust to level the machine and raise the wheels slightly off the ground 9 If equipped Be sure that all four interlock display lights are on at the ground control panel and on the turntable 10 If equipped Check the bubble level to m
29. place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Towing Hazards Read understand and obey all of your tow vehicle manufacturer s recommendations warnings and instructions before towing this trailer Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Do not overload your tow vehicle Check the Gross Vehicle Weight Rating GVWR on the label inside driver door To obtain GVWR add the tongue weight of the trailer to the vehicle weight including vehicle passengers and cargo Do not load cargo on the trailer The trailer is not designed to carry any extra cargo Do not transport the machine unless the boom has been secured with hold down latches Models equipped with surge brake system Do not attempt to back up the trailer unless the surge brake system is released See the surge brake system manual Be sure the hitch is securely attached to the tow vehicle and the hitch ball is securely attached to the hitch Be sure the safety chains if required are securely attached to the tow vehicle Be sure that all lights are operational Be sure all hitch components lights and mirrors and methods of attaching the trailer to the tow vehicle conform to local state and Federal regulations Be sure the tires are properly inflated Be sure to chock the wheels of the trailer when parking on
30. ransport 1 Set the parking brake Secure the boom with the hold down latches Raise the tongue by turning the jack handle gt O N Position the ball of the transport vehicle directly under the ball coupler Open the latch on the ball coupler Lower the tongue by turning the jack handle Close the latch on the ball coupler oN O A Attach the chains if required and the brake safety cable to the vehicle 9 Pullthe jack release handle and rotate the tongue jack to the stowed position 10 Connect and test the trailer lights 11 Release the parking brake 24 Genie TMZ 34 19 Part No 97781 Third Edition First Printing Operator s Manual Towing Information Use the checklist provided on the back cover of this manual before towing and while on the road Driving a vehicle trailer combination is different from driving a vehicle alone Anticipate stops Brake early Increase the distance between your vehicle and the vehicle in front of you to twice the normal following distance when towing a trailer Allow more following distance in adverse weather Slow down for downgrades and shift your transmission into a lower gear Slow down for curves adverse weather hazardous road conditions and expressway exits Your vehicle trailer combination may experience momentary disturbances If a disturbance happens do not brake speed up or turn the steering wheel Let off the gas pedal and keep the steering wh
31. re in firm contact with the ground and the machine is level Do not set the machine up unless it is on a firm surface Avoid drop offs holes unstable or slippery surfaces and other possible hazardous conditions Do not adjust or stow the outriggers when the boom is raised Do not move the machine when the boom is raised Do not depend on the tilt alarm as a level indicator 2 Genie TMZ 34 19 Part No 97781 Third Edition First Printing Operator s Manual The tilt alarm sounds in the platform only when the machine is on a severe slope When the alarm sounds boom up functions will not operate When the tilt alarm sounds immediately lower the boom and adjust the outriggers to level the machine Do not alter or disable the limit switches Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load
32. ressure cold 44 psi 3 0 bar Check the Hydraulic Oil Level 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 oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position 2 Visually inspect the sight gauge on the hydraulic power unit reservoir Result The hydraulic oil level should be visible in the gauge Hydraulic Oil Specifications Hydraulic oil type Dexron equivalent MAINTENANCE Check the Batteries Proper battery condition is essential to good performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions 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 Be sure that the battery hold down brackets are secure 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Scheduled Maintenance Maintenance performed quarterly annually sem
33. rm 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 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 12 Genie
34. s level FUNCTION TESTS Note Perform the appropriate function tests for your control system Determine whether the control panels on your machine match the ones below or the ones on page 19 Follow the step by step instructions below the pictures to test all machine functions STOP O POWER Z BATTERY pinge FUNCTION ENABLE Oo t Ground Control Panel eso LU ale J FUNCTION ENABLE J Platform Control Panel At the Ground Controls Test Emergency Stop 17 Push in the red Emergency Stop button to the off position Result The stop light should be on and all ground and platform control functions should not operate 18 Pull out the red Emergency Stop button to the on position Test Outrigger Interlock 19 Unscrew one leveling jack until the corresponding interlock display light turns off Result Boom functions should not operate 20 Return the leveling jack to the previous setting 21 Repeatthe procedure for each outrigger Part No 97781 Genie TMZ 34 19 17 Operator s Manual Third Edition First Printing FUNCTION TESTS Test the Boom Functions 22 Do not press a function enable speed select button Attempt to activate each boom function Result All boom functions should not operate 23 Press and hold a function enable speed select button Activate each boom function button Result All boom functio
35. sition Test Boom Functions 34 Press and hold a function enable speed select button 35 Activate each boom function Result All boom functions should operate through a full cycle 18 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual Note Perform the appropriate function tests for your control system Determine whether the control panels on your machine match the ones below or the ones on page 17 Follow the step by step instructions below the pictures to test all machine functions f a o amp oO OF Ob sine Platform Control Panel Ground Control Panel At the Ground Controls Test Emergency Stop 17 Push in the red Emergency Stop button to the off position Result All ground and platform control functions should not operate 18 Pull out the red Emergency Stop button to the on position Test Outrigger Interlock 19 Unscrew one leveling jack until the outrigger footpad is slightly off the ground Result All boom functions should not operate 20 Return the leveling jack to the previous setting 21 Repeat the procedure for each outrigger FUNCTION TESTS Test the Boom Functions 22 Do not press a function enable button Attempt to activate each boom function Result All boom functions should not operate 23 Press and hold the blue function enable button Activate each boom function Result Primary boom up secondary boom up jib bo
36. tery terminals Remove all rings watches and other jewelry w Tip over Hazard Do not use batteries that weigh less than the original equipment Four batteries are used as counterweight and are critical to machine stability Each battery must weigh 75 pounds 34 kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries 6 Genie TMZ 34 19 PartNo 97781 Third Edition First Printing Operator s Manual O Se SAFETY RULES Decal Legend Genie product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to 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 Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury AWARNING Yellow with safety alert symbol ACAUTION used to indicate the presence of 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 oper
37. til the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Voltage Conversion Some battery chargers are equipped with a multifunction fuse which enables the operator to switch between 110 120 volts and 220 240 volts 1 Locate the fuse drawer module on the front of the a battery charger 2 To change voltage pull the fuse drawer out flip it over so the desired voltage range reads right side up and return the drawer to the slot 3 Check that the triangle next to the desired l voltage range points to l 2 the triangle printed on J the lip of the module 0 Date J Ey Part No 97781 Genie TMZ 34 19 27 Operator s Manual Third Edition First Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions
38. ving 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 drop offs or holes bumps floor obstructions or debris slopes that exceed the machine s leveling capability 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 Part No 97781 Genie TMZ 34 19 21 Operator s Manual Third Edition First 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 apre 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 is unsafe and danger
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