Genie Z34N, Z-22, Z-22N User Manual

Before serial number Z34N-2101 and Z34-1735:

Incorrect operation can result from use of this manual on machines that have not been updated according to Genie Campaign Bulletin 070001. Death or Serious Injury can result.

This manual only applies to machines that have been updated according to Genie Campaign Bulletin 070001. Contact Genie Industries for information on this bulletin.

After serial number Z34N-2100 and Z-34-1734:

Genie Campaign Bulletin 070001 does not apply to these machines.

Operator’s Manual

with Maintenance Information

Second Edition

Ninth Printing

Part No. 43654

Operator's Manual Second Edition • Ninth 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........................................... 10

Maintenance............................................................. 12

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

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

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

Transport & Lifting Instructions ................................. 25

Decals ......................................................................28

Specifications ...........................................................30

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

First Edition: Third Printing, July 1996 Second Edition: Ninth Printing, June 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 92.5-1992.

Printed on recycled paper

Printed in U.S.A.

Genie Z-34/22 & Genie Z-34/22N Part No. 43654

Second Edition • Ninth 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. 43654 Genie Z-34/22 & Genie Z-34/22N 1

Operator's Manual Second Edition • Ninth 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 and equipment 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.

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.

2 Genie Z-34/22 & Genie Z-34/22N Part No. 43654

Second Edition • Ninth Printing

Operator's Manual

SAFETY RULES

Do not alter or disable the limit switches. Do not drive over 0.6 mph / 1 km/h with the primary

boom raised or extended or the secondary boom raised.

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 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 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,

Counterweight uphill 20% (11°) Counterweight downhill 20% (11°) Side slope 20% (11°)

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

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

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.

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 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 the load.

Part No. 43654 Genie Z-34/22 & Genie Z-34/22N 3

Operator's Manual Second Edition • Ninth Printing

SAFETY RULES

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 use the machine on a moving or mobile surface or vehicle.

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

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 88 lbs / 40 kg. Each battery box including batteries must weigh a minimum of 452 lbs / 205 kg.

Do not use the machine as a crane.

Fall Hazards

Occupants must wear a safety belt or harness and comply with applicable governmental regulations. Attach 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.

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.

4 Genie Z-34/22 & Genie Z-34/22N Part No. 43654

Second Edition • Ninth Printing

Operator's Manual

SAFETY RULES

Collision Hazards

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

Be aware of boom position when rotating the turntable.

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

Do not drive the machine with the brakes released. If the travel alarm sounds when not driving, the brakes are released.

Check work area for overhead obstructions or other possible hazards.

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.

Use extreme care and slow speeds while driving the machine in the stowed position on any slope.

Do not drive on a slope with boom raised. Do not allow the machine speed on any slope to

exceed 3 mph / 4.8 km/h (walking pace).

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

It is recommended that operators wear an approved hard hat when operating the machine.

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

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.

Stop the machine by returning the drive control handle to the center position or releasing the foot switch.

When stopped on a slope, the machine may initially move slightly downhill when the drive control handle is moved to drive up the slope. Be sure the area behind the machine is clear.

Do not drive on a slope with the wheels turned. Be sure the wheels are aligned up and down the slope.

Always use a winch to load and unload a machine from a transport vehicle.

Part No. 43654 Genie Z-34/22 & Genie Z-34/22N 5

Operator's Manual Second Edition • Ninth Printing

SAFETY RULES

Component Damage Hazard

Do not use the machine as a ground for welding.

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

Genie Z-34/22 & Genie Z-34/22N 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.

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.

6 Genie Z-34/22 & Genie Z-34/22N Part No. 43654

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Operator's Manual

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.

The battery pack must remain in upright position. Do not expose the batteries or the charger to water

or rain.

Explosion Hazards

Component Damage Hazards

Do not use any battery charger greater than 48V to charge the batteries.

Both battery packs must be charged together. Disconnect the battery pack plug before removing

the battery pack.

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

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

The battery pack cover must remain off during the entire charging cycle.

Do not contact the battery terminals or the cable clamps with tools that may cause sparks.

Part No. 43654 Genie Z-34/22 & Genie Z-34/22N 7

Lifting Hazard

Use a forklift to remove or install the battery packs.

Operator's Manual Second Edition • Ninth Printing

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 and/or low voltage

interrupt (option)

8 Genie Z-34/22 & Genie Z-34/22N Part No. 43654

1 0 Proportional control handle for drive function and

thumb rocker for steer function 1 1 Boom function speed controller 1 2 Jib boom up/down switch 1 3 Low battery indicator light 1 4 Secondary boom up/down switch 1 5 Primary boom up/down switch 1 6 Turntable rotate switch 1 7 Platform rotate switch

Second Edition • Ninth Printing

Operator's Manual

CONTROLS

Ground Control Panel

1 Turntable rotate switch 2 Platform rotate switch 3 Platform level switch 4 Primary boom extend/retract switch 5 Auxiliary power switch 6 Hour meter 7 Key switch for platform/off/ground selection

Part No. 43654 Genie Z-34/22 & Genie Z-34/22N 9

8 Red Emergency Stop button 9 10A breaker for electrical circuits 10 Remote brake release 1 1 Not used 1 2 Jib boom up/down switch 1 3 Primary boom up/down switch 1 4 Function enable switch 1 5 Secondary boom up/down switch

+ 25 hidden pages