Genie TMZ-34, TMZ-19 User Manual

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Operator’sManual

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FourthEdition FirstPrinting PartNo.97866

Thismanualreplaces partnumber72895

Operator's Manual Fourth Edition • First 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 Industries.

Contents

Page

Safety ........................................................................ 1

Controls ..................................................................... 8

Pre-operation Inspection ........................................... 14

Maintenance ............................................................. 16

Function Tests.......................................................... 19

Workplace Inspection................................................ 24

Operating Instructions............................................... 25

Decals ...................................................................... 32

Specifications ........................................................... 34

Reporting Safety Defects .......................................... 3 5

Notice

This operator's manual is for TMZ-34/19 machines after serial number T3499-796. It replaces operator's manual part number 72895.

Internet: http://www.genielift.com e-mail: techpub@genieind.com

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 Part No. 97866

Fourth 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:

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.

Part No. 97866 Genie TMZ-34/19 1

Operator's Manual Fourth 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

Tip-over Hazards

Occupants, equipment and materials shall not exceed the maximum platform capacity.

Maximum platform capacity ANSI & CE models 500 lbs 227 kg

Maximum platform capacity CSA models 440 lbs 200 kg

Maximum platform capacity with Optional Platform Rotate 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.

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.

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 adjust or stow the outriggers when the boom is raised.

Do not operate the machine near drop-offs, holes, bumps, debris, unstable or slippery surfaces or other possible hazardous conditions.

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Operator's Manual

SAFETY RULES

Do not move the machine when the boom is raised. 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.

When the tilt alarm sounds, immediately lower the boom and adjust the outriggers to level the machine. When the alarm sounds, boom up functions will not operate.

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.

Be sure all tires are properly inflated and in good condition and lug nuts are properly tightened.

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.

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.

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 modify or alter an aerial work platform. 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 load.

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.

Part No. 97866 Genie TMZ-34/19 3

Operator's Manual Fourth Edition • First Printing

SAFETY RULES

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 Damage 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.

Lifting Hazards

Use proper lifting techniques to move, load or unload the machine.

Use proper lifting techniques when installing or removing the platform.

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 place and legible. Be sure the operator’s, safety and responsibilities

manuals are complete, legible and in the storage container located on the platform.

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Operator's Manual

SAFETY RULES

Towing Hazards

Read, understand and obey all of your tow vehicle manufacturer’s recommendations, warnings and instructions before towing this machine.

Do not tow the machine unless the boom hold-down latches are securely locked in place.

Do not overload your tow vehicle. Check the manufacturer's Gross Vehicle Weight Rating (GVWR). To obtain the gross vehicle weight, add the tongue weight of the trailer to the vehicle weight (including vehicle, passengers and cargo).

Do not load cargo on the machine. The TMZ-34 is not designed to carry any extra cargo.

Be sure the hitch is securely attached to the tow vehicle.

Be sure the safety chains (if required) are securely attached to the tow vehicle.

Be sure that all driving 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.

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.

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.

Part No. 97866 Genie TMZ-34/19 5

Operator's Manual Fourth Edition • First Printing

SAFETY RULES

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.

Maximum allowable side force -

90 lbs / 400 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.

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.

Collision Hazard

Be aware of crushing hazards when grasping the platform guard rail.

Material Lifting Configuration

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.

Lower the platform entry mid-rail or close the entry gate before operating.

6 Genie TMZ-34/19 Part No. 97866

Collision Hazards

Do not raise the load unless the material lifting hook is properly secured to the machine.

Do not raise unless the load is properly balanced and secured to the 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.

Fourth Edition • First Printing

Operator's Manual

SAFETY RULES

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 75 pounds / 34 kg.

Lifting Hazard

Use the appropriate number of people and proper lifting techniques when lifting batteries.

Part No. 97866 Genie TMZ-34/19 7

Operator's Manual Fourth Edition • First Printing

Controls

Note: Refer to the control panel pictures on the

following pages to determine which panels are on your machine.

Platform Control Panel

1 Red Emergency Stop button 2 Jib boom up button 3 Jib boom down button 4 Horn button 5 Low battery indicator light 6 Function enable/speed select buttons 7 Turntable rotate right button

8 Genie TMZ-34/19 Part No. 97866

8 Turntable rotate left button 9 Secondary boom down button 1 0 Secondary boom up button 1 1 Primary boom down button 1 2 Primary boom up button

Fourth Edition • First Printing

Operator's Manual

CONTROLS

STOP

1 2

Platform 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

3 Red Emergency Stop button 4 Horn button 5 Battery charge indicator 6 Primary boom up/down button 7 Jib boom up/down button 8 Secondary boom up/down button 9 Turntable rotate button 1 0 Boom function speed controller

Part No. 97866 Genie TMZ-34/19 9

Operator's Manual Fourth Edition • First Printing

CONTROLS

Ground Control Panel (manual outriggers)

1 Red Emergency Stop button 2 Jib boom up button 3 Jib boom down button 4 Horn button 5 Battery charge indicator 6 Key switch for ground/off/platform selection 7 Outrigger interlock display lights (four)

10 Genie TMZ-34/19 Part No. 97866

8 Function enable/speed select buttons 9 Turntable rotate right button 1 0 Turntable rotate left button 1 1 Secondary boom down button 1 2 Secondary boom up button 1 3 Primary boom down button 1 4 Primary boom up button

Fourth Edition • First Printing

Operator's Manual

CONTROLS

Ground Control Panel (hydraulic outriggers)

Part No. 97866 Genie TMZ-34/19 11

1 0 Automatic leveling button 11 Extend outrigger(s) enable button 1 2 Function enable/speed select buttons 1 3 Turntable rotate right button 1 4 Turntable rotate left button 1 5 Secondary boom down button 1 6 Secondary boom up button 1 7 Primary boom down button 1 8 Primary boom up button

Operator's Manual Fourth Edition • First Printing

CONTROLS

STOP

Ground Control Panel (manual outriggers)

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 down Turntable rotate left

3 Red Emergency Stop button 4 Primary boom up/down button 5 Horn button 6 Key switch for ground/off/platform selection 7 Jib boom up/down button 8 Secondary boom up/down button 9 Turntable rotate button

12 Genie TMZ-34/19 Part No. 97866

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Operator's Manual

CONTROLS

STOP

Ground Control Panel (hydraulic outriggers)

1 Function enable button for:

Primary boom down Secondary boom down Jib boom down Turntable rotate right Outrigger lower

2 Function enable button for:

Primary boom up Secondary boom up Jib boom up Turntable rotate left Outrigger raise

3 Red Emergency Stop button 4 Outrigger raise/lower button

(individual outrigger) 5 Outrigger auto level button 6 Horn button 7 Primary boom up/down button 8 Key switch for ground/off/platform selection 9 Jib boom up/down button 10 Secondary boom up/down button 11 Turntable rotate button

Part No. 97866 Genie TMZ-34/19 13

Operator's Manual Fourth Edition • First Printing

Pre-operation Inspection

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.

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 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.

14 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Pre-operation Inspection

Operator's Manual

PRE-OPERATION INSPECTION

o Be sure that the operator's, safety and

responsibilities manuals are complete, legible and in the storage container located on the platform.

o Be sure that all decals are legible and in place.

See Decals section.

o Check for hydraulic oil leaks and proper oil level.

Add oil if needed. See Maintenance section.

o Check for battery fluid leaks and proper fluid

level. Add distilled water if needed. See Maintenance section.

o 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:

o Electrical components, wiring and electrical

cables

o Hydraulic power unit, reservoir, hoses,

fittings, cylinders and manifolds

o Boom components and wear pads o Tires and wheels

o Axle components o Beacon and alarms (if equipped)

Check entire machine for:

o Cracks in welds or structural components o Dents or damage to machine

o Be sure that all structural and other critical

components are present and all associated

fasteners and pins are in place and properly

tightened. o 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. o Be sure that the batteries are in place and

properly connected. o Models equipped with surge brake systems:

Check the hydraulic oil level in the surge brake.

Check for leaks. o After you complete your inspection, be sure

that all compartment covers are in place and

latched.

o Trailer lights and reflectors o Parking brake components o Outriggers, leveling jacks and foot pads o Limit switch, alarms and horn o Nuts, bolts and other fasteners o Platform entry mid-rail/gate o Surge brake components (if equipped) o Safety chains (if required) o Mechanical brake components (if equipped)

Part No. 97866 Genie TMZ-34/19 15

Operator's Manual Fourth Edition • First Printing

Maintenance

Check the Hydraulic Oil Level

Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic

Observe and Obey:

Only routine maintenance items specified in this

manual shall be performed by the operator.

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.

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.

1 Be sure the boom is in the stowed position and

the hydraulic outriggers (if equipped) are

retracted. 2 Visually inspect the oil level in the hydraulic

power unit reservoir.

Result: The hydraulic oil level should be visible

in the gauge.

Hydraulic oil specifications

Hydraulic oil type Dexron equivalent

Indicates that new parts will be required to perform this procedure.

16 Genie TMZ-34/19 Part No. 97866

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Operator's Manual

MAINTENANCE

Check the Tires and Wheels

Bodily injury hazard. An overinflated tire can explode and may cause death or serious injury.

Collision hazard. An excessively worn tire can cause poor handling and continued use could result in tire failure.

Tip-over hazard. Do not use 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 in a 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.

4 Check the torque of each lug nut.

Tires and wheels - ANSI & CSA

Tire size ST195/75D14 Lug nut torque 80 ft-lbs 108 Nm Tire pressure (cold) 65 psi 4.5 bar

Tires and wheels - CE

Tire size 195/65R15 91T Lug nut torque 80 ft-lbs 108 Nm Tire pressure (cold) 44 psi 3.0 bar

Result: Replace the tire if uneven or excessive

tread wear is found.

Always replace the tire 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.

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Operator's Manual Fourth Edition • First Printing

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.

This procedure does not need to be performed on machines with sealed or maintenance-free batteries.

Bodily injury hazard. Batteries contain acid. Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda

and water. 1 Put on 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.

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.

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.

18 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

Function Tests

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.

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.

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.

A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be tagged and removed from service. Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

After repairs are completed, the operator must perform a pre-operation inspection and function tests again before putting the machine into service.

Set up

1 Position the machine directly below the desired

work area. 2 Set the parking brake. 3 Disconnect the trailer lights, chains and surge

brake safety cable from the vehicle. 4 Open the latch on the ball coupler. 5 Pull the jack release handle and rotate the

tongue jack to the lifting position. 6 Raise the tongue by turning the jack handle. 7 Open all boom hold-down latches. 8 Release the jib hold-down straps (if equipped).

Part No. 97866 Genie TMZ-34/19 19

Operator's Manual Fourth Edition • First Printing

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 22. Follow the step-by-step instructions below the pictures to test all machine functions.

Ground Control Panels

Platform Control Panel

At the Ground Controls

1 Insert the key and turn to ground control. 2 Pull out the red Emergency Stop buttons at the

ground and platform controls.

Machines with LED diagnostic readout: LED

should read ----.

Note: Machines with LED diagnostic readout perform a self-check when the power is turned on. The self-check takes about 5 seconds. Do not touch the buttons of the ground control panel until the self-check is done.

3 Models with manual outriggers: 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. Repeat the procedure for each of the remaining outriggers.

Models with hydraulic outriggers: Push and

hold the auto-level button. Push and hold the

extend outrigger button. The outriggers will lower

and adjust to level the machine and raise the

wheels slightly off the ground. Level the

machine using only the outriggers. 4 Check the interlock display lights at the ground

controls and on the turntable. Confirm that all

four lights are on. Note: If any interlock display light is flashing, the

machine is not level. Adjust the leveling jacks or use the individual outrigger buttons to level the machine.

Test Emergency Stop

5 Push in the ground red Emergency Stop button

to the off position.

Result: The power will shut off and all ground

and platform control functions should not

operate. 6 Pull out the red Emergency Stop button to

the on position.

Test Outrigger Interlock

7 Unscrew one leveling jack or use the leveling

buttons to raise one outrigger until the

corresponding interlock display light turns off.

Result: Boom functions should not operate.

8 Return the leveling jack to the previous setting

or use the leveling buttons to lower the

outrigger. 9 Repeat the procedure for each outrigger.

Adjust the outriggers to level the machine and

raise the wheels slightly off the ground. Level the machine using only the leveling jacks.

20 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

FUNCTION TESTS

Test the Boom Functions

1 0 Do not hold a function enable/speed select

button. Attempt to activate each boom function button.

Result: All boom functions should not operate.

1 1 Press and hold a function enable/speed select

button. Activate each boom function button.

Result: All boom functions should operate

through a full cycle.

Test the Tilt Sensor

1 2 Raise the jib boom approximately 6 in / 15 cm.

Raise the primary boom approximately 6 in / 15 cm off the boom rest. Raise the secondary boom approximately 6 in / 15 cm off the boom rest.

1 3 Locate the tilt sensor on

the chassis near the ground controls.

1 4 Press down 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.

1 5 Test all ground and platform control functions.

Result: 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, the jib boom down and the turntable rotate functions should operate normally.

At the Platform Controls

1 8 Pull out the red Emergency Stop buttons at the

ground and platform controls.

Test Emergency Stop

1 9 Push in the platform red Emergency Stop button

to the off position.

Result: The power will shut off and all platform

control functions should not operate.

Test the Horn

2 0 Pull out the red Emergency Stop button to the

on position. 2 1 Push the horn button.

Result: The horn should sound.

Test Machine Functions

2 2 Do not hold a function enable/speed select

button. Attempt to activate each boom function

button.

Result: All boom functions should not operate.

2 3 Press and hold a function enable/speed select

button. 2 4 Activate each boom function button.

Result: All boom functions should operate

through a full cycle.

1 6 Remove the tilt sensor test tool. 1 7 Turn the key switch to platform control.

Part No. 97866 Genie TMZ-34/19 21

Operator's Manual Fourth Edition • First Printing

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 20. Follow the step-by-step instructions below the pictures to test all machine functions

STOP

1 2

STOP

Platform Control Panel

Ground Control Panels

STOP

At the Ground Controls

1 Insert the key and turn to ground control. 2 Pull out the red Emergency Stop buttons at the

ground and platform controls.

3 Models with manual outriggers: Select an

Adjust the outriggers to level the machine and

raise the wheels slightly off the ground. Level the machine using only the outriggers. Use the bubble level to make sure the machine is level.

Models with hydraulic outriggers: Push and

hold the yellow function enable button. Push and hold the auto level button or the individual outrigger buttons to lower the outriggers and level the machine. Level the machine using only the outriggers. Use the bubble level to make sure the machine is level.

Test Emergency Stop

4 Push in the ground red Emergency Stop button

to the off position.

Result: All ground and platform control functions

should not operate. 5 Pull out the red Emergency Stop button to

the on position.

Test Outrigger Interlock

6 Unscrew one leveling jack or use the leveling

buttons to raise one outrigger off the ground.

Result: All boom functions should not operate.

7 Return the leveling jack to the previous setting

or use the leveling buttons to lower the

outrigger. 8 Repeat the procedure for each outrigger.

Test the Boom Functions

9 Do not push a function enable button. Attempt to

activate each boom function button.

Result: All boom functions should not operate.

1 0 Push and hold the blue function enable button.

Activate each boom function button.

Result: Primary boom up, primary boom extend,

secondary boom up and turntable rotate right

should all function. 1 1 Push and hold the yellow function enable button.

Activate each boom function button.

Result: Primary boom down, primary boom

retract, secondary boom down and turntable

rotate left should all function.

22 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

FUNCTION TESTS

Test the Tilt Sensor

1 2 Raise the jib boom approximately 6 in / 15 cm.

Raise the primary boom approximately 6 in / 15 cm off the boom rest. Raise the secondary boom approximately 6 in / 15 cm off the boom rest.

1 3 Locate the tilt sensor on

the chassis near the ground controls.

1 4 Press down 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.

1 5 Test all ground and platform control functions.

Result: 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, the jib boom down and the turntable rotate functions should operate

normally. 1 6 Remove the tilt sensor test tool. 1 7 Turn the key switch to platform control.

At the Platform Controls

1 8 Pull out the platform red Emergency Stop button

to the on position.

Test Emergency Stop

1 9 Push in the platform red Emergency Stop button

to the off position.

Result: All ground and platform control functions

should not operate.

Test the Horn

2 0 Pull out the red Emergency Stop button to

the on position.

2 1 Push the horn button.

Result: The horn should sound.

Test Boom Functions and Function Enable

2 2 Do not push a function enable button. Attempt to

activate each boom function button.

Result: All boom functions should not operate.

2 3 Push and hold the blue function enable button.

Activate each boom function button.

Result: Primary boom up, secondary boom up,

jib boom up and turntable rotate right should all function.

2 4 Push and hold the yellow function enable button.

Activate each boom function button.

Result: Primary boom down, secondary boom

down, jib boom down and turntable rotate left should all function.

Part No. 97866 Genie TMZ-34/19 23

Operator's Manual Fourth Edition • First Printing

Workplace Inspection

Be aware of and avoid the following hazardous situations:

· drop-offs or holes

· bumps, floor obstructions or debris

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. Know and understand the work place

inspection before going on to the next

section.

· 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

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.

24 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

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.

Operator's Manual

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.

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.

Part No. 97866 Genie TMZ-34/19 25

Operator's Manual Fourth Edition • First Printing

OPERATING INSTRUCTIONS

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. 3 Disconnect the trailer lights, chains and surge

brake safety cable from the vehicle. 4 Open the latch on the ball coupler. 5 Pull the jack release handle and rotate the

tongue jack to the lifting position. 6 Raise the tongue by turning the jack handle. 7 Open all boom hold-down latches. 8 Release the jib hold-down straps (if equipped). 9 Lower the outriggers and adjust to level the

machine and raise the wheels slightly off the

ground. 10 If equipped: Be sure that all four interlock

display lights are on at the ground control panel

and on the turntable. 11 If equipped: Check the bubble level to make

sure the machine is level.

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 Be sure that the batteries are connected before

operating 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.

3 If equipped: Rotate

the platform by turning the hand crank in either a clockwise or counterclockwise direction.

26 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

OPERATING INSTRUCTIONS

Manual Lowering

1 Open the power unit side turntable cover and

locate the manual override valve. 2 Push and turn the brass

knob clockwise to open

the valve. The

individual boom manual

lowering valves will not

function until this valve

is open. 3 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. 4 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. 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 To operate the machine,

push and turn

counterclockwise to

close the override valve.

Manual Turntable Rotation

1 Open the power unit side turntable cover.

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.

Transport

1 Set the parking brake. 2 Secure the boom with the hold-down latches. 3 Attach the jib hold-down straps and latch

properly (if equipped). 4 Raise the tongue by turning the jack handle. 5 Position the ball of the transport vehicle directly

under the ball coupler. 6 Open the latch on the ball coupler. 7 Lower the tongue by turning the jack handle. 8 Close the latch on the ball coupler. 9 Attach the safety chains (if required) and the

brake safety cable to the vehicle. 1 0 Pull the jack release handle and rotate the

tongue jack to the stowed position. 1 1 Connect and test the trailer lights. 1 2 Release the parking brake.

2 Turn the override knob on

the manifold in the counterclockwise direction.

3 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. 97866 Genie TMZ-34/19 27

Operator's Manual Fourth Edition • First Printing

OPERATING INSTRUCTIONS

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 wheel 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.

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.

Moving Machine Without a Tow Vehicle

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 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.

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.

28 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

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.

3 Use the black arrows to properly align the

turntable. 4 Lower the boom to the stowed position. 5 Secure the boom with the hold-down latches. 6 Turn the key switch to the off position and

remove the key to secure from unauthorized

use. 7 Chock the wheels.

Operator's Manual

OPERATING INSTRUCTIONS

8 Charge the batteries.

Part No. 97866 Genie TMZ-34/19 29

Operator's Manual Fourth Edition • First Printing

OPERATING INSTRUCTIONS

Material Lifting Configuration Set up

1 Turn the key switch to the off position. 2 Remove the pin that secures the material lifting

hook to the base. Remove the material lifting

Material Lifting Configuration Observe and Obey:

Maintain safe distances between the operator,

the machine and fixed objects.

Be aware of the direction the boom will travel

when using the platform controls.

hook and replace the pin.

3 Disconnect the running lights and the platform

controls from the platform.

4 Remove the platform controls. Open the clamp

on the back of the platform controls and slide

the controls up and off. 5 Open the controls side turntable cover. 6 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. 7 Support the platform. Remove the toggle pin that

secures the platform to the jib boom. 8 Lift the platform up and remove it from the

machine. 9 To install the material lifting hook, insert the

bottom rail into the platform mounting bracket

and rotate up into position. Insert the toggle pin. 1 0 Operate the material lifting hook from the ground

with the platform controls. The key switch

should be turned to the platform control position. 1 1 Reverse the above process to install the

platform and return the machine to a personnel

lifting configuration.

30 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

OPERATING INSTRUCTIONS

Dry Battery Filling and Charging Instructions

1 Remove the battery vent caps and permanently

remove the plastic seal from the battery vent

openings.

Battery and Charger Instructions Observe and Obey:

Do not use external charger or booster battery. Charge battery in a well-ventilated area. Use proper AC input voltage for charging as

indicated on charger.

Use only Genie authorized battery and charger.

T o 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.

2 Fill each cell with battery acid (electrolyte) until

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 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 voltage range points to the triangle printed on the lip of the module.

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.

Part No. 97866 Genie TMZ-34/19 31

Operator's Manual Fourth 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.

Part No. Description Quantity

27564 Danger - Electrocution Hazard 2 28157 Label - Dexron 1 28161 Warning - Crushing Hazard

28161 Warning - Crushing Hazard

28164 Notice - Hazardous Materials 1 28171 Label - No Smoking 1 28174 Label - Power to Platform, 230V 2 28175 Caution - Compartment Access 1 28176 Notice - Missing Manuals 1 28235 Label - Power to Platform, 115V 2 28236 Warning - Failure To Read . . . 1 31060 Danger - Do not alter limit switch 1 35579 Notice - Max Cap, Hook, 500 lbs / 227 kg 1 37052 Notice - Max Cap, 500 lbs / 227 kg 1 37145 Label - Manual Lowering 4 40434 Label - Lanyard Anchorage 2 43658 Notice - Power to Battery Charger, 230V 1 44248 Notice - Max Cap, 440 lbs / 200kg 1 44980 Notice - Power to Battery Charger, 115V 1 44981 Label - Air Line to Platform 2 44986 Notice - Side Force, 90 lbs/400N (CE) 1 48719 Danger - General Safety, Platform 1 48723 Label - Parking Brake (Surge) 1 48726 Notice - Battery Charger Operating Instr. 1 48727 Danger - Battery/Charger Safety 1 48733 Danger - Tip-over (batteries) 1 48734 Battery Connection Diagram 1 49918 Notice - Material Lifting Operation 1

(Models with manual outriggers) 4

(Models with hydraulic outriggers) 12

Part No. Description Quantity

52004 Label - Interlock Display Lights 2 52008 Danger - General Safety, Ground 1 52475 Label - Transport Tie-down 4 52496 Notice - Manual Rotation Instructions 1 52557 Label - Parking Brake (Mechanical) 1 62066 Cosmetic, Genie TMZ-34/19 2 62707 Warning - Towing Hazard 2 62719 Label - Arrow 2 62722 Notice - Max Cap, Hook, 440 lbs / 200 kg 1 65056 Label - Water Line to Platform 2 65066 Ground Control Panel Patch

65067 Platform Control Panel Patch

65068 Ground Control Panel Patch

65303 Notice - Manual Lowering Instructions 1 65305 Notice - Operating Instructions, Platform 1 65307 Caution - Forklift Pockets 2 65309 Notice - Side Force, 90 lbs / 400 N 1 72899 Decal - Warning, Transport Instructions 1 72897 Notice - Tire Specifications, ANSI & CSA 2 72901 Notice - Operating Instructions, Ground 1 72908 Notice - Tire Specifications, CE 2 72971 Label, Transport to Canada 2 76095 Ground Control Panel 1 76096 Ground Control Panel (Auto-leveling) 1 76097 Platform Control Panel 1 82228 Label - Fault Codes 1 82232 Label - LED Readout 1 97777 Platform Control Panel 1

97778 Ground Control Panel 1 97814 Ground Control Panel (Auto-leveling) 1

97846 Notice - Operating Instructions, Platform 1 97847 Notice - Operating Instructions, Ground 1

(Non-English panels only) 1

32 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

Operator's Manual

DECALS

65307

Ground Controls Side

37145 28161 72899

52008 27564 48733 48734 48723 or

52557 35579 or 62722

48727 Safety Tape

48726 52475 72897 or 72908

62707 52475

62066

27564 52004

52496

28175 28164 28171

44981 or 65056

31060

28157

Safety

Tape

62066

52475

82228

62707

82232

65303

52004

72901or

97847

72897 or 72908

3714528161

37145

52475

76097 or 97777

Safety

Tape

65067

28174 or 28235

Note: Optional hydraulic outriggers have two each of decal 28161.

72971 49918

65066

or 65068

76095 or 76096 or 97778 or 97814

Serial Label

62719 62719

28161

Safety Tape

48719 28236 28176 65305

or 97846

37052

or 44248

44986

or 65309

40434

72971

Safety Tape

44981

or 65056

28174 or 28235

40434

Safety Tape

37145

28161

65307

Power Unit Side

43658 or 44980

Part No. 97866 Genie TMZ-34/19 33

Operator's Manual Fourth Edition • First Printing

Specifications

Height, working maximum 40 ft

12.2 m

Height, platform maximum 34 ft

10.4 m

Height, stowed maximum 6 ft 51/2 in

1.97 m

Horizontal reach maximum 19 ft 9 in from centerline of machine 6.0 m

Outrigger footprint 10 ft x 11 ft (w x l) 3.05 x 3.35 m

Maximum load capacity 500 lbs ANSI & CE models 227 kg

Maximum load capacity - CSA models 440 lbs & models with Optional Platform Rotate 200 kg

Width 591/2 in

151 cm

Length, stowed 19 ft 8 in

5.9 m

Length, stowed 20 ft 8 in (with mechanical or combination hitch) 6.2 m

Turntable rotation 358 degrees

Ground clearance 71/2 in

19 cm

Hydraulic tank capacity 2.0 gallons

7.6 liters

Weight See Serial Label (Machine weights vary with option configurations)

Maximum towing speed 60 mph

97 km/h

Maximum tongue weight 165 lbs ANSI & CSA 75 kg

Maximum tongue weight 220 lbs CE 100 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 obligation.

Power source 4 Group-GC2,

6V 225AH Batteries

Platform dimensions, 48 in x 30 in (length x width) 122 cm x 76 cm

Platform leveling self-leveling AC outlet in platform standard Tire size ST195/75D14

ANSI & CSA models Load Range D Tire size 195/65R15 91T

CE models

34 Genie TMZ-34/19 Part No. 97866

Fourth Edition • First Printing

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.

Operator's Manual

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. 97866 Genie TMZ-34/19 35

Genie TMZ-34, TMZ-19 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual