Genie TZ-50 User Manual

Operator’s Manual

with Maintenance Information

Second Edition

Seventh Printing

First Printing

Part No. 43645

Part No. 114164

Operator's Manual Second 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 ........................................... 11

Maintenance ............................................................. 13

Function Tests.......................................................... 16

Workplace Inspection................................................ 20

Operating Instructions............................................... 21

Transport and Lifting Instructions .............................. 29

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

Specifications ........................................................... 35

Reporting Safety Defects .......................................... 3 7

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

Industries in the USA and many other countries. These machines comply with

ANSI/SIA 92.2-2001. Printed on recycled paper Printed in U.S.A.

Genie TZ-50 Part No. 82900

Second 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. 114164 Genie TZ-50 1

Operator's Manual Second Edition • First Printing

SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage Minimum Safe Phase to Phase Approach Distance

Feet Meters

0 to 300V Avoid Contact 300V to 50KV 10 3.05 50KV to 200KV 15 4.60 200KV to 350KV 20 6.10 350KV to 500KV 25 7.62 500KV to 750KV 35 10.67 750KV to 1000KV 45 13.72

Tip-over Hazards

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

Maximum capacity

ANSI and CSA models 500 lbs 227 kg CE and Australia models 440 lbs 200 kg

Maximum occupants 2

Do not raise the boom unless the machine is level.

Do not set the machine up on a surface where it cannot be leveled using only the outriggers.

Do not raise the boom unless all four outriggers are lowered, the footpads are in firm contact with the ground and the machine is level.

Do not set the machine up unless it is on a firm surface. Avoid drop-offs, holes, unstable or slippery surfaces and other possible hazardous conditions.

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

Do not move the machine when the boom is raised.

Do not adjust or stow the outriggers when the boom is raised.

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.

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Operator's Manual

SAFETY RULES

Do not depend on the tilt alarm as a level indicator. The tilt alarm sounds only when the machine is on a severe slope.

When the tilt alarm sounds, immediately lower the boom and adjust the outriggers to level the machine.

Do not alter or disable the limit switches. Do not raise the boom when wind speeds may

exceed 28 mph / 12.5 m/s. If wind speeds exceed 28 mph / 12.5 m/s when the boom is raised, lower the boom and do not continue to operate the machine.

Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.

Do not place ladders or scaffolds in the platform or against any part of this machine.

Do not use the machine on a moving or mobile surface or vehicle.

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

Do not use the platform as a crane. Do not place loads outside the platform perimeter. Do not place or attach overhanging loads to any

part of the platform.

Do not push off or pull toward any object outside of the platform.

Maximum allowable manual force, CE and Australia 400 N

Do not alter or disable machine components that in any way affect safety and stability.

Do not replace items critical to machine stability with items of different weight or specification.

Do not modify or alter an aerial work platform without prior written permission from the manufacturer. Mounting attachments for holding tools or other materials onto the platform, toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load.

Do not transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.

Do not push the machine or other objects with the boom.

Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.

Do not use batteries that weigh less than the original equipment. Four batteries are used as counterweight and are critical to machine stability. Each battery must weigh 65 pounds / 29.5 kg.

Do not contact adjacent structures with the boom. Do not tie the boom or platform to adjacent

structures.

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Operator's Manual Second Edition • First Printing

SAFETY RULES

Fall Hazards

Occupants must wear a safety belt or harness and comply with applicable governmental regulations. Attach the lanyard to the anchor provided in the platform.

Do not sit, stand or climb on the platform guard rails. Maintain a firm footing on the platform floor at all times.

Do not climb down from the platform when raised. Keep the platform floor clear of debris. Lower the platform entry mid-rail or close the entry

gate before operating.

Collision Hazards

The machine must be on a level surface or secured before releasing the parking brake.

Check the work area for overhead obstructions or other possible hazards.

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

Be aware of the boom position when rotating the turntable.

Operators must comply with employer, job site and governmental rules regarding use of personal protective equipment.

Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision.

No stunt driving or horseplay while operating the machine.

Do not attempt to manually move a machine unless it is on a firm, level surface. Use the parking brake to control the speed of the machine when pushing a machine that is not attached to a tow vehicle.

Explosion and Fire Hazards

Models with engines: Do not start the engine if you smell or detect liquid petroleum gas (LPG), gasoline, diesel fuel or other explosive substances.

Models with engines: Do not refuel the machine with the engine running.

Refuel the machine and charge the battery only in an open, well-ventilated area away from sparks, flames and lighted tobacco.

Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present.

Component Damage Hazards

Do not use the machine as a ground for welding.

Do not lower the boom unless the area below is clear of personnel and obstructions.

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Second Edition • First 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 in place and legible. Be sure the operator’s, safety and responsibilities

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

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil or air leak. An air leak or hydraulic leak can penetrate and/or burn skin.

Models with engines: When the engine is running, operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.

Towing Hazards

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

Make sure your tow vehicle is properly maintained and capable of towing this machine.

Be sure the hitch is properly and securely attached to your tow vehicle.

Do not overload your tow vehicle. Observe the manufacturer’s Gross Vehicle Weight Rating (GVWR).

Be sure all lights, mirrors and hitch components conform to federal and local regulations.

Be sure that all driving lights are operational. Be sure the tires are properly inflated. Do not tow the machine unless the boom is

lowered into the chassis cradle and the hold-down latch is securely locked in place.

Do not load cargo on the machine. The TZ is not designed to carry any extra cargo.

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.

Part No. 114164 Genie TZ-50 5

Be sure the safety chains (if required) are securely attached to the tow vehicle. Cross the chains under the hitch. This will create a cradle to catch the tongue of the trailer if it becomes disconnected from the tow vehicle.

Do not tow the machine on public roads unless it meets all governmental regulations for towing.

Do not exceed 60 mph / 97 km/h. Obey all local and national towing speed laws.

Be sure to chock the wheels of the trailer when parking on a hill.

Operator's Manual Second Edition • First Printing

SAFETY RULES

Optional Drive System Safety Tip-over Hazards

Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Do not drive the machine on a slope that exceeds the maximum uphill, downhill or side slope rating of the machine. Slope rating applies to machines in the stowed position.

Maximum slope rating, stowed position

Toungue/hitch uphill 20 % (11°) Toungue/hitch downhill 20 % (11°) Side slope 20 % (11°)

Note: Slope rating is subject to ground conditions and adequate traction.

Collision Hazards

Do not drive the machine unless the parking brake is released on the tongue.

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.

Do not drive the machine unless the platform is fully lowered.

Be aware of limited sight distance and blind spots when driving or operating.

Observe and use the color-coded direction arrows on the drive control box for drive and steer functions.

Limit travel speed according to the condition of the ground surface, congestion, slope, location of personnel, and any other factors which may cause collision.

Use common sense and planning when operating the drive system from the ground. Remove the drive control box from its mounting and step away from the machine before driving. Maintain safe distances between the operator, the machine and fixed objects.

6 Genie TZ-50 Part No. 114164

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.

Second 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.

Component Damage Hazards

Do not use any battery charger greater than 24V to charge the batteries.

Do not expose the batteries or the charger to water or rain.

Electrocution Hazards

Connect the battery charger to a grounded, AC 3-wire electrical outlet only.

Inspect daily for damaged cord, cables and wires. Replace damaged items before operating.

Avoid electrical shock from contact with battery terminals. Remove all rings, watches and other jewelry.

Tip-over Hazard

Do not use batteries that weigh less than the original equipment. Four batteries are used as counterweight and are critical to machine stability. Each battery must weigh 65 pounds / 29.5 kg.

Lifting Hazard

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.

Part No. 114164 Genie TZ-50 7

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

Operator's Manual Second Edition • First Printing

Controls

STOP

Ground Control Panel

1 Outrigger raise/lower

button and indicator light

(individual outrigger) 2 Outrigger auto level button 3 Platform level button 4 Function enable button for:

Platform down

Primary boom down

Primary boom retract

Secondary boom down

Jib boom down

Turntable rotate right

Platform rotate right

Outrigger lower

8 Genie TZ-50 Part No. 114164

5 Function enable button for:

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

6 15 amp breaker for controls

circuits 7 Red Emergency Stop button 8 15 amp breaker for engine controls

(if equipped) 9 Key switch for platform/off/ground

selection

10 Engine start button

(if equipped)

11 Platform overload indicator

light (if equipped)

12 Engine choke button

(if equipped)

13 Primary boom extend/retract

button

14 Primary boom up/down

button 15 Jib boom up/down button 16 Secondary boom up/down

button 17 Platform rotate button

(if equipped) 18 Turntable rotate button

Second Edition • First Printing

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Operator's Manual

CONTROLS

STOP

Platform Control Panel

1 Function enable button for:

Platform down Primary boom down Primary boom retract Secondary boom down Jib boom down Turntable rotate right Platform rotate right (if equipped)

2 Function enable button for:

Platform up Primary boom up Primary boom extend Secondary boom up Jib boom up Turntable rotate left Platform rotate left (if equipped)

3 Red Emergency Stop button 4 Platform rotate button

(if equipped) 5 Platform level button 6 Primary boom extend/retract 7 Jib boom up/down button 8 Boom function speed

controller 9 Platform overload indicator

light (if equipped)

10 Engine start button

(if equipped)

11 Engine choke button

(if equipped) 12 Battery charge indicator 13 Secondary boom up/down

button 14 Primary boom up/down

button 15 Turntable rotate button

Part No. 114164 Genie TZ-50 9

Operator's Manual Second Edition • First Printing

CONTROLS

STOP

Drive Control Panel (Option)

1 Outrigger auto level button

(ANSI models)

2 Function enable button for

outrigger lower (ANSI models)

3 Function enable button for

outrigger raise (ANSI models)

10 Genie TZ-50 Part No. 114164

4 Red Emergency Stop button 5 Proportional control handle for

drive and steer functions

Second 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.

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.

Operator's Manual

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. 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.

Part No. 114164 Genie TZ-50 11

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