Genie TMZ-50/30 User manual

Operator’s Manual
with Maintenance Information
Second Edition
Second Printing
Part No. 114255
This manual replaces
part number 72896
Before Driving
On The Road
Before Towing · Boom hold-down latch is securely locked in place
·
·
·
· Fasten safety restraints
· Properly adjust mirrors
· 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
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 and working
· Tires are properly inflated
Distributed By:
Towing Checklist
(Use at each stop)
Genie North America
Genie Australia Pty Ltd.
Genie China
Genie Malaysia
Genie Japan
Genie Korea
Genie Brasil
Genie Holland
Phone
Toll Free
Fax
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
425.881.1800
USA and Canada
800.536.1800
425.883.3475
61 7 3375 1660
61 7 3375 1002
86 21 53852570
86 21 53852569
65 98 480 775
65 67 533 544
81 3 3453 6082
81 3 3453 6083
82 25 587 267
82 25 583 910
55 11 41 665 755
55 11 41 665 754
31 183 581 102
31 183 581 566
Genie Scandinavia
Genie France
Genie Iberica
Genie Germany
Genie U.K.
Genie Mexico City
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
Phone +
Fax +
46 31 575100
46 31 579020
33 (0)2 37 26 09 99
33 (0)2 37 26 09 98
34 93 579 5042
34 93 579 5059
49 (0)4202 88520
49 (0)4202 8852-20
44 (0)1476 584333
44 (0)1476 584334
52 55 5666 5242
52 55 5666 3241
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Operator's Manual Second Edition • Second Printing
GenieTMZ-50/30 PartNo.114255
Copyright © 1999 by Genie Industries
First Edition: ThirdPrinting, November2001
Second Edition: Second Printing, April 2007
"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.
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.................................................................... 10
Pre-operation Inspection .......................................... 15
Maintenance............................................................. 17
Function Tests ......................................................... 20
Work Place Inspection ............................................. 25
Operating Instructions.............................................. 26
Decals ...................................................................... 34
Specifications........................................................... 36
Reporting Safety Defects......................................... 37
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]
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Operator's Manual
Second Edition • Second Printing
Part No. 114255 Genie TMZ-50/30 1
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:
Manufacturer's instructions and safety
rules—safety and operator's manuals
and machine decals
employer's safety rules and worksite
regulations
applicable governmental regulations
You are properly trained to safely operate the
machine.
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2 Genie TMZ-50/30 Part No. 114255
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 and equipment shall not exceed the
maximum platform capacity.
Maximum platform capacity
ANSI & CE models 500 lbs 227 kg
CSA models 440 lbs 200 kg
Maximum platform capacity with
Optional Platform Rotate
ANSI & CE models 440 lbs 200 kg
CSA models not available
Maximum occupants 2
Do not raise or extend 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. Do not use chocks, blocks or shims
of any kind to level the machine.
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 3
Do not raise or extend the boom unless all four
outriggers are lowered and locked, the footpads
are in firm contact with the ground and the
machine is level.
Do not adjust or stow the outriggers when the
boom is raised or extended.
Do not operate the machine near drop-offs, holes,
bumps, debris, unstable or slippery surfaces or
other possible hazardous conditions.
Do not move the machine when the boom is
raised or extended.
Do not depend on the tilt alarm as a level
indicator. The tilt alarm sounds in the platform only
when the machine is on a severe slope.
If the tilt alarm sounds, 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 switch(es).
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.
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 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.
Models with batteries: Do not use batteries that
weigh less than the original equipment. 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.
SAFETY RULES
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Operator's Manual Second Edition • Second Printing
4 Genie TMZ-50/30 Part No. 114255
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: Always operate the machine
in a well-ventilated area to avoid carbon monoxide
poisoning.
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.
It is recommended that operators wear an
approved hard hat when operating the machine.
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.
SAFETY RULES
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.
Do not use any battery or charger greater than
12V to jump-start the engine.
Lifting Hazards
Use proper lifting techniques to move the
machine.
Use proper lifting techniques when installing or
removing the platform.
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 5
SAFETY RULES
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not refuel the machine 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.
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 legible and in place.
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 machine.
Do not tow the machine unless the mast is
lowered to the horizontal position and the mast
hold-down latch is 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 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.
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Operator's Manual Second Edition • Second Printing
6 Genie TMZ-50/30 Part No. 114255
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 Hazard
Be aware of crushing hazards when grasping the
platform guard rail.
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.
SAFETY RULES
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 7
SAFETY RULES
Material Lifting Configuration
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.
Optional Drive System
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.
Collision Hazards
Do not drive the machine unless the parking brake
on the tongue is set.
Do not drive the machine from the ground. The
platform must be fully lowered and the operator
must be in the platform.
Be aware of limited sight distance and blind spots
when driving or operating.
Observe and use the color-coded direction arrows
on the platform controls 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.
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Operator's Manual Second Edition • Second Printing
8 Genie TMZ-50/30 Part No. 114255
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
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
Models with batteries: Do not use batteries that
weigh less than the original equipment. 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.
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 9
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
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Operator's Manual Second Edition • Second Printing
10 Genie TMZ-50/30 Part No. 114255
Platform Control Panel
1 Red Emergency Stop button
2 Primary boom retract button
3 Primary boom extend button
4 Jib boom up button
5 Jib boom down button
6 Platform level up button
7 Platform level down button
8 Engine power indicator light
9 Battery power indicator light
10 Low battery indicator light
11 Function enable/speed select
buttons
12 Turntable rotate right button
13 Engine start button
14 Horn button
15 Turntable rotate left button
16 Secondary boom down
button
17 Secondary boom up button
18 Primary boom down button
19 Primary boom up button
Gasoline models with LED
diagnostic readout: Choke
function is activated by pushing
engine start button and slow
function speed select button
Note: Refer to the control panel pictures on the
following pages to determine which panels are on
your machine.
Controls
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 11
1 Boom function enable button
2 Horn button
3 Red Emergency Stop button
4 Power select toggle switch
5 Engine start button
6 Choke button
7 Battery charge indicator
8 Boom function speed controller
9 Turntable rotate left/right toggle switch
10 Secondary boom up/down toggle
11 Platform level up/down toggle
12 Primary boom up/down toggle
13 Primary boom extend/retract toggle
14 Jib boom up/down toggle
Gasoline models: Choke function is
activated by pushing engine start
button.
Platform Control Panel
CONTROLS
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Operator's Manual Second Edition • Second Printing
12 Genie TMZ-50/30 Part No. 114255
Ground Control Panel
1 Red Emergency Stop button
2 Primary boom retract button
3 Primary boom extend button
4 Jib boom up button
5 Jib boom down button
6 Platform level up button
7 Platform level down button
8 Engine power indicator light
9 Battery power indicator light
10 Battery charge level indicator
lights
19 Engine start button
20 Horn button
21 Turntable rotate left button
22 Secondry boom down button
23 Secondary boom up button
24 Primary boom down button
25 Primary boom up button
Gasoline models with LED
diagnostic readout: Choke
function is activated by pushing
engine start button and slow
function speed select button
11 Key switch for ground/off/
platform selection
12 Outrigger status indicator
lights
13 Outrigger button
14 Retract outrigger(s) enable
button
15 Automatic leveling button
16 Extend outrigger(s) enable
button
17 Function enable/speed select
buttons
18 Turntable rotate right button
CONTROLS
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Part No. 114255 Genie TMZ-50/30 13
CONTROLS
Ground Control Panel
1 Boom function enable button
2 Outrigger(s) retract enable
button.
3 Outrigger(s) extend enable
button
4 Red Emergency Stop button
5 Power select toggle switch
6 Engine start button
7 Outrigger button
8 Choke button
9 Key switch for ground/off/
platform selection
10 Horn button
11 Turntable rotate left/right
toggle
12 Platform level up/down
toggle
13 Jib boom up/down toggle
14 Secondary boom up/down
toggle
15 Primary boom up/down
toggle
16 Primary boom extend /
retract toggle
17 Automatic leveling button
Gasoline models: Choke
function is activated by pushing
engine start button.
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Operator's Manual Second Edition • Second Printing
14 Genie TMZ-50/30 Part No. 114255
Drive Control Panel (option)
CONTROLS
1 Extend outrigger(s) enable button
2 Machine level indicator light
3 Automatic leveling button
4 Red Emergency Stop button
5 Drive and steer controller
6 Horn button
7 Drive function enable button
8 Retract outrigger(s) enable button
1 Outrigger(s) extend enable button.
2 Automatic leveling button
3 Red Emergency Stop button
4 Proportional control handle for drive and steer
functions
5 Outrigger(s) retract enable button
6 Horn button
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Operator's Manual
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Part No. 114255 Genie TMZ-50/30 15
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 and locations for modifications,
damage or loose or missing parts.
A damaged or modified machine must never be
used. If damage or any 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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Operator's Manual Second Edition • Second Printing
16 Genie TMZ-50/30 Part No. 114255
Pre-operation Inspection
RBe sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
RBe sure that all decals are legible and in place.
See Decals section.
RCheck for hydraulic oil leaks and proper oil
level. Add oil if needed. See Maintenance
section.
RModels with engines: Check for engine oil leaks
and proper fluid level. Add oil if needed. See
Maintenance section.
RCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
RCheck 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, modifications and improperly installed or
missing parts:
RElectrical components, wiring and electrical
cables
RHydraulic pump(s), reservoir, hoses,
fittings, cylinders and manifolds
RFuel tank (if equipped)
REngine and related components
(if equipped)
RBoom components and wear pads
RTires and wheels
RTrailer lights and reflectors
PRE-OPERATION INSPECTION
RParking brake components
ROutriggers and foot pads
RAlarms and horn
RNuts, bolts and other fasteners
RPlatform entry mid-rail/gate
RSurge brake components (if equipped)
RSafety chains (if required)
RMechanical brake components (if equipped)
RBeacon and alarms (if equipped)
Check entire machine for:
RCracks in welds or structural components
RDents or damage to machine
RExcessive rust, corrosion or oxidation
RBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
RBe 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.
RBe sure that the batteries are in place and
properly connected.
RModels equipped with hydraulic surge brake
systems: Check the hydraulic oil level in the
surge brake. Check for leaks.
RAfter you complete your inspection, be sure
that all compartment covers are in place and
latched.
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Part No. 114255 Genie TMZ-50/30 17
Maintenance
Observe and Obey:
Only routine maintenance items specified in
this manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
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 the boom is in the stowed position and
the outriggers are retracted.
2 Visually inspect the oil level in the hydraulic
tank.
Result: The hydraulic oil level should be
3 inches / 7.6 cm from the top of tank.
Hydraulic oil specifications
Hydraulic oil type Dexron equivalent
Maintenance Symbols Legend
The following symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginning of a maintenance
procedure, it conveys the
meaning below.
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be
required to perform this procedure.
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18 Genie TMZ-50/30 Part No. 114255
MAINTENANCE
Check the Engine Oil Level -
Engine Models
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
1 Check the oil level dipstick.
Result: The oil level should be at the FULL mark
on the dipstick. Add oil as needed.
Honda GX340K1 Engine
Oil viscosity requirements
Temperature below 60°F / 15.5°C 5W-30
-10°F to 90° / -23°C to 32°C 10W-30
Temperature above -10°F / -23°C 10W-40 to 10W-50
Temperature above 20°F / -6.6°C 20W-40 or 20W-50
Use oils meeting API classification SG (labeled SG/CC
or SG/CD) as they offer improved wear protection.
Units ship with 10W-40 SG/CC
Hatz 1B30 Engine
Oil viscosity requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90° / -23°C to 32°C 10W-40
Temperature above -4°F / 34°C 15W-40
Engine oil should have properties of API classification
CD, CE, CF or CG grades.
Units ship with 10W-40 SG/CC
Check the Batteries
Proper battery condition is essential to good
engine performance and safe operation. Improper
fluid levels or damaged cables and connections
can result in engine 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 straps are in
place and 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.
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