Genie Z-34, Z-22 User Manual

Operator’s Manual

with Maintenance Information

IC Power

Third Edition

First Printing

Part No. 82594

Operator's Manual Third 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 ..................................................................... 7

Pre-operation Inspection ............................................ 9

Maintenance ............................................................. 11

Function Tests .......................................................... 14

Workplace Inspection ................................................ 19

Operating Instructions ............................................... 20

Decals ...................................................................... 24

Transport and Lifting Instructions .............................. 28

Specifications ........................................................... 31

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

First Edition: Second Printing, November 1996

Second Edition:Sixth Printing, September 2002

Third Edition: First Printing, June 2003

"Genie" and "Z" are registered trademarks of Genie Industries in the U.S.A. and many other countries.

These machines comply with ANSI/SIA 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Genie Z-34/22 IC Part No. 82594

Third 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.

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Operator's Manual Third 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

Allow for platform movement, electrical line sway or sag and beware of strong or gusty winds.

Tip-over Hazards

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

Maximum platform capacity 500 lbs 227 kg Maximum occupants 2

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: Do not extend, rotate or raise the boom above horizontal. Move the machine to a firm, level surface before raising the platform. If the tilt alarm sounds when the platform is raised, use extreme caution to retract the boom and lower the platform. Do not rotate the boom while lowering. Move the machine to a firm, level surface before raising the platform.

Do not alter or disable the limit switches.

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.

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Third Edition • First Printing

Operator's Manual

SAFETY RULES

Do not drive over 0.6 mph / 1 km/h with the primary boom raised or extended or the secondary boom raised.

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 stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the boom raised or extended.

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

Maximum allowable side force - ANSI & CSA 150 lbs / 667 N

Maximum allowable manual force - CE

90 lbs / 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 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 transport tools and materials unless they are evenly distributed and can be safely handled by person(s) in the platform.

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

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.

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Operator's Manual Third Edition • First Printing

SAFETY RULES

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

Do not use the machine as a crane.

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.

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.

Collision Hazards

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

Be aware of the boom position when rotating the turntable.

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

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

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

Observe and use color-coded direction arrows on the platform controls and drive chassis for drive and steer functions.

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.

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Third Edition • First Printing

Operator's Manual

SAFETY RULES

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

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

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 a machine.

Component Damage Hazard

Do not use any battery or charger greater than 12V to jump-start the engine.

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.

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.

Do not use the machine as a ground for welding.

Part No. 82594 Genie Z-34/22 IC 5

Operator's Manual Third Edition • First Printing

SAFETY RULES

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.

Always operate the machine in a well-ventilated area to avoid carbon monoxide poisoning.

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.

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 Hazard

Keep sparks, flames and lighted tobacco away from batteries. Batteries emit explosive gas.

Electrocution Hazard

Avoid contact with electrical terminals.

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.

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Third Edition • First Printing

Operator's Manual

Controls

Platform Control Panel

1 Drive enable switch 2 Drive enable indicator light 3 Auxiliary power switch 4 Platform level switch 5 Horn button 6 Primary boom extend/retract

switch 7 Red Emergency Stop button 8 Not used 9 Battery charge indicator

(option)

Part No. 82594 Genie Z-34/22 IC 7

10 Machine not level indicator

light (if equipped)

11 Proportional control handle for

drive function and thumb rocker for steer function

12 Platform overload indicator

light (if equipped) 13 Drive speed select switch 14 Gasoline/LPG models: Choke

switch

Diesel models:

Glow plug switch (option) 15 Engine idle (rpm) select

switch

· Rabbit & foot switch: foot switch activated high idle

· Turtle: low idle

· Rabbit: high idle

16 Engine start switch 17 Gasoline/LPG models:

Gasoline/LPG select switch

18 Boom function speed

controller 19 Jib boom up/down switch 20 Secondary boom up/down

switch 21 Primary boom up/down switch 22 Turntable rotate switch 23 Platform rotate switch

Operator's Manual Third Edition • First Printing

CONTROLS

Ground Control Panel

1 Turntable rotate switch 2 Platform rotate switch 3 Primary boom up/down

switch 4 Platform level switch 5 Primary boom extend/

retract switch 6 10A breaker for engine

electrical circuits 7 10A breaker for control

electrical circuits 8 Auxiliary power switch

8 Genie Z-34/22 IC Part No. 82594

9 Gasoline/LPG models:

Water temperature gauge Diesel models: Oil

temperature gauge 10 Travel alarm 11 Oil pressure gauge 12 Key switch for platform/off/

ground selection 13 Voltage gauge 14 Red Emergency Stop

button 15 Not used 16 Hour meter

17 Gasoline/LPG models:

Choke switch Diesel models: Glow plug

switch (option) 18 Engine start switch 19 Function enable switch 20 Gasoline/LPG models: Fuel

select switch 21 Platform overload indicator

light (if equipped) 22 Jib boom up/down switch 23 Primary boom extend/

retract switch

Third 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.

Operator's Manual

Pre-operation Inspection

Fundamentals

It is the responsibility of the operator to perform a pre-operation nspection 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.

5 Only use the machine as it was intended.

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. 82594 Genie Z-34/22 IC 9

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