TZ-50
Operator’s Manual
with Maintenance Information
Second Edition
Seventh Printing
Part No. 43645
Second Edition
First Printing
Part No. 114164
Genie TZ-50 Part No. 82900
Operator's Manual Second Edition • First Printing
Copyright © 2004 by Genie Industries
Second Edition: First Printing, June 2006
"Genie" is a registered trademark of Genie
Industries in the USA and many other countries.
These machines comply with
ANSI/SIA 92.2-2001.
Printed on recycled paper
Printed in U.S.A.
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 ........................................................................ 1
Controls ..................................................................... 8
Pre-operation Inspection ........................................... 11
Maintenance ............................................................. 13
Function Tests.......................................................... 16
Workplace Inspection................................................ 20
Operating Instructions............................................... 21
Transport and Lifting Instructions .............................. 29
Decals ...................................................................... 32
Specifications ........................................................... 35
Reporting Safety Defects .......................................... 3 7
Contact us:
Internet: http://www.genielift.com
e-mail: techpub@genieind.com
Part No. 114164 Genie TZ-50 1
Operator's Manual
Second Edition • First Printing
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:
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.
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 worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
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Operator's Manual Second Edition • First Printing
SAFETY RULES
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.
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 capacity
ANSI and CSA models 500 lbs 227 kg
CE and Australia models 440 lbs 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 outriggers.
Do not raise the boom unless all four outriggers
are lowered, the footpads are 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 move the machine when the boom is
raised.
Do not adjust or stow the outriggers when the
boom is raised.
Part No. 114164 Genie TZ-50 3
Operator's Manual
Second Edition • First Printing
Do not depend on the tilt alarm as a level
indicator. The tilt alarm sounds only when the
machine is on a severe slope.
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 raise the boom when wind speeds may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the boom is raised, lower
the boom and do not continue to operate the
machine.
Do not operate the
machine in strong or
gusty winds. Do not
increase the surface
area of the platform or
the load. Increasing the
area exposed to the
wind will decrease
machine stability.
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.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
SAFETY RULES
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.
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.
Maximum allowable
manual force,
CE and Australia 400 N
Do not push the machine or other objects with the
boom.
Do not use the platform controls to free a platform
that is caught, snagged or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not 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 65 pounds / 29.5 kg.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
4 Genie TZ-50 Part No. 114164
Operator's Manual Second Edition • First Printing
Be aware of the boom position when rotating the
turntable.
Operators must comply with employer, job site and
governmental rules regarding use of personal
protective equipment.
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.
Do not attempt to manually move a machine
unless it is on a firm, level surface. Use the
parking brake to control the speed of the machine
when pushing a machine that is not attached to a
tow vehicle.
Explosion and Fire Hazards
Models with engines: Do not start the engine if you
smell or detect liquid petroleum gas (LPG),
gasoline, diesel fuel or other explosive
substances.
Models with engines: 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.
Component Damage Hazards
Do not use the machine as a ground for welding.
SAFETY RULES
Fall Hazards
Occupants must wear a
safety belt or harness and
comply with applicable
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform floor
at all times.
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.
Collision Hazards
The machine must be on a level surface or
secured before releasing the parking brake.
Check the work area for overhead obstructions or
other possible hazards.
Be aware of crushing hazards when grasping the
platform guard rail.
Do not lower the boom unless the area below is
clear of personnel and obstructions.
Part No. 114164 Genie TZ-50 5
Operator's Manual
Second Edition • First Printing
SAFETY RULES
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of
the machine and test all functions before each
work shift. Immediately tag and remove from
service a damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate
service manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manuals are complete, legible and in the storage
container located on the platform.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Models with engines: When the engine is running,
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.
Towing Hazards
Read, understand and obey all of your tow vehicle
manufacturer’s recommendations, warnings and
instructions before towing this machine.
Make sure your tow vehicle is properly maintained
and capable of towing this machine.
Be sure the hitch is properly and securely
attached to your tow vehicle.
Do not overload your tow vehicle. Observe the
manufacturer’s Gross Vehicle Weight Rating
(GVWR).
Be sure all lights, mirrors and hitch components
conform to federal and local regulations.
Be sure that all driving lights are operational.
Be sure the tires are properly inflated.
Do not tow the machine unless the boom is
lowered into the chassis cradle and the hold-down
latch is securely locked in place.
Do not load cargo on the machine. The TZ is not
designed to carry any extra cargo.
Be sure the safety chains (if required) are securely
attached to the tow vehicle. Cross the chains
under the hitch. This will create a cradle to catch
the tongue of the trailer if it becomes disconnected
from the tow vehicle.
Do not tow the machine on public roads unless it
meets all governmental regulations for towing.
Do not exceed 60 mph / 97 km/h. Obey all local
and national towing speed laws.
Be sure to chock the wheels of the trailer when
parking on a hill.
6 Genie TZ-50 Part No. 114164
Operator's Manual Second Edition • First Printing
Optional Drive System Safety
Tip-over Hazards
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain, debris, unstable or slippery surfaces and
near holes and drop-offs.
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating
of the machine. Slope rating applies to machines
in the stowed position.
Maximum slope rating, stowed position
Toungue/hitch uphill 20 % (11°)
Toungue/hitch downhill 20 % (11°)
Side slope 20 % (11°)
Note: Slope rating is subject to ground conditions
and adequate traction.
Collision Hazards
Do not drive the machine unless the parking brake
is released on the tongue.
Do not drive the machine unless the platform is
fully lowered.
Be aware of limited sight distance and blind spots
when driving or operating.
Observe and use the color-coded direction arrows
on the drive control box for drive and steer
functions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
Use common sense and planning when operating
the drive system from the ground. Remove the
drive control box from its mounting and step away
from the machine before driving. Maintain safe
distances between the operator, the machine and
fixed objects.
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
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.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—used to indicate operation
or maintenance information.
SAFETY RULES
Part No. 114164 Genie TZ-50 7
Operator's Manual
Second Edition • First Printing
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothing and eye wear when working with
batteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion
Hazards
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 battery terminals.
Remove all rings, watches and
other jewelry.
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 65 pounds / 29.5 kg.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
SAFETY RULES
8 Genie TZ-50 Part No. 114164
Operator's Manual Second Edition • First Printing
Ground Control Panel
1 Outrigger raise/lower
button
and indicator light
(individual outrigger)
2 Outrigger auto level button
3 Platform level button
4 Function enable button for:
Platform down
Primary boom down
Primary boom retract
Secondary boom down
Jib boom down
Turntable rotate right
Platform rotate right
Outrigger lower
Controls
5 Function enable button for:
Platform up
Primary boom up
Primary boom extend
Secondary boom up
Jib boom up
Turntable rotate left
Platform rotate left
Outrigger raise
6 15 amp breaker for controls
circuits
7 Red Emergency Stop button
8 15 amp breaker for engine controls
(if equipped)
9 Key switch for platform/off/ground
selection
10 Engine start button
(if equipped)
11 Platform overload indicator
light (if equipped)
12 Engine choke button
(if equipped)
13 Primary boom extend/retract
button
14 Primary boom up/down
button
15 Jib boom up/down button
16 Secondary boom up/down
button
17 Platform rotate button
(if equipped)
18 Turntable rotate button
STOP
1
1
2
3
4
5
6
7
8
10
9
11
12
13
14
15
17
18
16
1
1
Part No. 114164 Genie TZ-50 9
Operator's Manual
Second Edition • First Printing
Platform Control Panel
1 Function enable button for:
Platform down
Primary boom down
Primary boom retract
Secondary boom down
Jib boom down
Turntable rotate right
Platform rotate right
(if equipped)
2 Function enable button for:
Platform up
Primary boom up
Primary boom extend
Secondary boom up
Jib boom up
Turntable rotate left
Platform rotate left (if equipped)
3 Red Emergency Stop button
4 Platform rotate button
(if equipped)
5 Platform level button
6 Primary boom extend/retract
7 Jib boom up/down button
8 Boom function speed
controller
9 Platform overload indicator
light (if equipped)
10 Engine start button
(if equipped)
11 Engine choke button
(if equipped)
12 Battery charge indicator
13 Secondary boom up/down
button
14 Primary boom up/down
button
15 Turntable rotate button
STOP
F
E
1
2
1
2
3
4
6
5
7
9
10
11
12
13
14
15
8
CONTROLS
10 Genie TZ-50 Part No. 114164
Operator's Manual Second Edition • First Printing
Drive Control Panel (Option)
1 Outrigger auto level button
(ANSI models)
2 Function enable button for
outrigger lower (ANSI
models)
3 Function enable button for
outrigger raise (ANSI
models)
4 Red Emergency Stop button
5 Proportional control handle for
drive and steer functions
CONTROLS
STOP
1
2
3
4
5
Part No. 114164 Genie TZ-50 11
Operator's Manual
Second Edition • First Printing
Pre-operation Inspection
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.
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.
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