Genie TMZ-50, TMZ-17, TMZ-30, TMZ-10 User Manual

Operator’s Manual
with Maintenance Information
Second Edition
First Edition
Seventh Printing
Third Printing
Part No. 43645
Part No. 72896
Operator's Manual First Edition • Third 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 ..................................................................... 9
Pre-operation Inspection ........................................... 12
Maintenance ............................................................. 14
Function Tests .......................................................... 17
Work Place Inspection .............................................. 20
Operating Instructions ............................................... 21
Decals ...................................................................... 28
Specifications ........................................................... 30
Reporting Safety Defects .......................................... 31
Contact us:
Internet: http://www.genielift.com e-mail: techpub@genieind.com
Copyright © 1999 by Genie Industries
First Edition: Third Printing, November 2001
"Genie" and "TMZ" are registered trademarks of Genie Industries in the USA and many other countries.
These machines comply with ANSI/SIA 92.2-1990.
Printed on recycled paper
Printed in U.S.A.
Genie TMZ-50/30 & Genie TMZ-17/10 Part No. 72896
First Edition • Third 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: 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.
Part No. 72896 Genie TMZ-50/30 & Genie TMZ-17/10 1
Operator's Manual First Edition • Third 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 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
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
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
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72
of any kind to level the machine.
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.
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 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 operate the machine during lightning or storms.
Do not use the machine as a ground for welding.
2 Genie TMZ-50/30 & Genie TMZ-17/10 Part No. 72896
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Operator's Manual
SAFETY RULES
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.
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.
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.
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.
Part No. 72896 Genie TMZ-50/30 & Genie TMZ-17/10 3
Operator's Manual First Edition • Third 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.
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.
Lifting Hazards
Use proper lifting techniques to move the machine.
Use proper lifting techniques when installing or removing the platform.
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.
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.
4 Genie TMZ-50/30 & Genie TMZ-17/10 Part No. 72896
First Edition • Third Printing
Operator's Manual
SAFETY RULES
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift. Immediately tag and remove from service a damaged or malfunctioning machine.
Be sure all maintenance has been performed as specified in this manual and the appropriate service manual.
Be sure all decals are 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 TML 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.
Part No. 72896 Genie TMZ-50/30 & Genie TMZ-17/10 5
Operator's Manual First Edition • Third 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.
Fall Hazards
Occupants shall 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 hazard when grasping the platform guard rail.
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.
6 Genie TMZ-50/30 & Genie TMZ-17/10 Part No. 72896
First Edition • Third Printing
Operator's Manual
SAFETY RULES
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 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.
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. 72896 Genie TMZ-50/30 & Genie TMZ-17/10 7
Operator's Manual First Edition • Third Printing
SAFETY RULES
Battery Safety Burn Hazards
Batteries contain acid. Always wear protective clothing and eyewear when working with batteries.
Avoid spilling or contacting battery acid. Neutralize battery acid spills with baking soda and water.
Explosion Hazards
Keep sparks, flames and lighted tobacco away from batteries. Batteries emit an explosive gas.
The covers should be open during the entire charging cycle.
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
Do not contact the battery terminals or the cable clamps with tools that may cause sparks.
8 Genie TMZ-50/30 & Genie TMZ-17/10 Part No. 72896
Use the appropriate number of people and proper lifting techniques when lifting batteries.
First Edition • Third Printing
Operator's Manual
Controls
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
Part No. 72896 Genie TMZ-50/30 & Genie TMZ-17/10 9
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 Secondry 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
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