Genie Z-45/25 User manual

Operator’s Manual
Z-45 25
Fourth Edition
First Printing
Part No. 114339
Serial Number Range
after 00000
with
Maintenance
Information
IC Power
Z-45 25J
ANSI/CSA
North America
South America
Asia
AUS
Australia
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Operator's Manual
Z-45/25•Z-45/25J PartNo.114339
Fourth Edition • First Printing
Important
Read,understandandobeythesesafetyrulesand
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
Introduction ................................................................ 1
SymbolandHazard Pictorial Definitions..................... 3
GeneralSafety........................................................... 5
PersonalSafety ........................................................ 11
Work Area Safety...................................................... 12
Legend ...................................................................... 19
Controls .................................................................... 20
Inspections ............................................................... 27
OperatingInstructions............................................... 40
Transportand LiftingInstructions .............................. 46
Maintenance ............................................................. 49
Specifications ........................................................... 53
Contact us:
Internet:www.genielift.com
E-mail:[email protected]
Copyright © 1998 by Genie Industries
First Edition: Seventh Printing, May 2002
Second Edition: Second Printing, August 2004
Third Edition: Second Printing, October 2005
Fourth Edition: First Printing, March 2007
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
These machines comply with
ANSI/SIA 92.5
CAN B.354.4
Printed on recycled paper
Printed in U.S.A.
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 1
Introduction
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]
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Operator'sManual Fourth Edition · First Printing
2 Z-45/25•Z-45/25J PartNo.114339
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-basedcleanersbecausetheymay damage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor ormoderateinjury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 3
CrushHazard BurnHazard FireHazard ExplosionHazard Electrocution
Hazard
FallHazard CrushHazard Tip-overHazard
Symbol and Hazard Pictorials Definitions
Tip-overHazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface. Keepawayfrom movingparts. Keepawayfrom path of moving
platform.
Onlytrained
maintenance
personnelshould
access
compartments.
Nosmoking.
Noflame.
Stopengine.
Do not use ether
orotherhigh
energystarting
aids on machines
equippedwith
glowplugs.
Platformuphill:
1 Lowerprimary
2 Lowersecondary
3 Retractprimary
Platformdownhill:
1 Retract primary
2 Lowersecondary
3 Lowerprimary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.
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Operator'sManual Fourth Edition · First Printing
4 Z-45/25•Z-45/25J PartNo.114339
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform Replacetires with
tires of same
specification.
Tie-down
instructions Tie-down instructions
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 5
Safety signs and
locations
General Safety
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Operator'sManual Fourth Edition · First Printing
6 Z-45/25•Z-45/25J PartNo.114339
General Safety
Safety signs and locations
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 7
Safety signs and locations
General Safety
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Operator'sManual Fourth Edition · First Printing
8 Z-45/25•Z-45/25J PartNo.114339
General Safety
Safety signs and locations
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 9
General Safety
Safety signs and locations
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Operator'sManual Fourth Edition · First Printing
10 Z-45/25•Z-45/25J PartNo.114339
General Safety
Safety signs and locations
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 11
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.
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Operator'sManual Fourth Edition · First Printing
12 Z-45/25•Z-45/25J PartNo.114339
Work Area Safety
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
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
LineVoltage Required Clearance
0 to 50KV 10 ft 3.0 m
50 to 200KV 15 ft 4.6 m
200 to 350KV 20 ft 6.1 m
350 to 500KV 25 ft 7.6 m
500 to 750KV 35 ft 10.6 m
750 to 1000KV 45 ft 13.7 m
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines. Personnelonthe groundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not use the machine as a ground for welding.
Donotoperate themachine duringlightningor
storms.
Tip-over Hazards
Occupants,equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Maximum occupants 2
Maximum capacity
Machine equipped with
Aircraft Protection Package 440 lbs 200 kg
The weight of options and accessories, such as
pipecradles, panel cradlesandwelders, willreduce
the rated platform capacity and must be factored
into the total platform load. See the decals with the
options.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 13
Do not raise or extend the boom unless the
machine is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.
If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surfacebefore raising theplatform.
If the tilt alarm sounds when the platform is raised:
Use extreme caution. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the
platformuphill:
1 Lowertheprimaryboom.
2 Lowerthesecondaryboom.
3 Retractthe primaryboom.
If the tilt alarm sounds
withtheplatformdownhill:
1 Retracttheprimary
boom.
2 Lowerthesecondary
boom.
3 Lowertheprimary
boom.
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.
Use extreme care and slow speeds while driving
the machine in the stowed position across uneven
terrain,debris,unstableor slippery surfaces and
nearholesanddrop-offs.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesorotherhazardous conditions
withtheboomraised or extended.
Do not use the machine as a crane.
Work Area Safety
3
3
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14 Z-45/25•Z-45/25J PartNo.114339
Work Area Safety
Z-45/25andZ-45/25JNarrowBaseModels:
Do not use air-filled tires. These machines are
equippedwithfoam-filledtires.Wheelweightand
propercounterweightconfigurationarecriticalto
stability.
Z-45/25andZ-45/25J models equippedwith
AircraftProtectionPackage:
Do not use air-filled tires. These machines are
equippedwithfoam-filledtires.Wheelweightand
propercounterweightconfigurationarecriticalto
stability.
Do not modify or alter an aerial work platform
withoutprior writtenpermissionfrom the
manufacturer.Mountingattachmentsforholding
toolsor other materials onto the platform,toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.
Do not place or attach overhanging loads to any
part of this machine.
Do not place ladders or scaffolds in the platform or
against any part of this machine.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
towardany object outside
of the platform.
Maximum allowable
side force - ANSI & CSA
150 lbs / 667 N
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 replace factory-installed tires with tires of
different specification or ply rating.
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 15
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 30% (17°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 45% (24°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions Section.
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, air-filled tires
areproperlyinflatedandlugnutsareproperly
tightened.
Do not use the platform controls to free a platform
thatis caught, snaggedorotherwiseprevented
from normal motion by an adjacent structure. All
personnelmustbe removed from the platform
before attempting to free the platform using the
groundcontrols.
Work Area Safety
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Operator'sManual Fourth Edition · First Printing
16 Z-45/25•Z-45/25J PartNo.114339
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchorprovidedinthe
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
gatebeforeoperating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position and tailswing when
rotatingtheturntable.
Checkthe work area for overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazardswhengraspingthe
platformguardrail.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Observeandusethecolor-codeddirectionarrows
on the platform controls and drive chassis for drive
and steer functions.
Work Area Safety
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Operator'sManualFourth Edition · First Printing
PartNo.114339 Z-45/25•Z-45/25J 17
Work Area Safety
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
outand/or precautions have been taken toprevent
any potential collision.
Nostunt driving or horseplay whileoperatinga
machine.
Do not lower the boom unless the area below is
clearof personnel andobstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontact with componentsunderanycover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas(LPG), gasoline, diesel fuel or other
explosive substances.
Donotrefuel the machine with the engine running.
Refuel the machine and charge the battery only in
anopen, well-ventilatedareaawayfrom sparks,
flames and lighted tobacco.
Donotoperatethe machine in hazardous locations
orlocationswherepotentially flammableor
explosive gases or particles may be present.
Donot spray etherintoenginesequipped with glow
plugs.
Damaged Machine Hazards
Donotuse a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenance has been performed as
specifiedin this manual and theappropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocatedon the platform.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
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Operator'sManual Fourth Edition · First Printing
18 Z-45/25•Z-45/25J PartNo.114339
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewear whenworkingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is between
thenon-steerwheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chockthewheels.
Work Area Safety
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