Genie Z-45J Operator's Manual

Operator's Manual

Serial Number Range

Z®-45J

from Z4525F-62000

ANSI/CSA North America South America Asia

DC Power Bi-Energy Power

with Maintenance Information

Original Instructions Fifth Edition First Printing Part No. 1297032GT

Operator's Manual Fifth Edition • First Printing

Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Front Matter

Contents

Introduction ............................................................1

Symbol and Hazard Pictorials Definitions ..............7

General Safety .................................................... 10

Personal Safety ................................................... 18

Work Area Safety ................................................ 19

Legend ................................................................ 28

Controls ............................................................... 29

Inspections .......................................................... 36

Operating Instructions ......................................... 54

Transport and Lifting Instructions ....................... 63

Maintenance ....................................................... 66

Specifications ...................................................... 69

Dakota, Inc. in the U.S.A. and many other countries. These machines comply with

ANSI/SAIA A92.20 CAN/CSA B354.6

Fifth Edition • First Printing Operator's Manual

Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 1

Introduction

About this manual

Genie appreciates your choice of our machine for your application. Our number one priority is user safety, which is best achieved by our joint efforts. This book is an operation and daily maintenance manual for the user or operator of a Genie 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, contact Genie.

Product Identification

The machine serial number is located on the serial label.

Serial number stamped on chassis

Serial label

(located under cover)

Intended Use and Familiarization Guide

The intended use of this machine is to lift personnel, including tools, and materials to an

aerial work site. Before operating the machine, it’s the operator’s responsibility to read and

understand this familiarization guide.

 Each person must be trained to operate a

Mobile Elevating Work Platform (MEWP).

 Familiarization with the MEWP must be given

to each person who is authorized, competent and trained.

 Only trained and authorized personnel should

be permitted to operate the machine.

 The operator is responsible to read,

understand, and obey the manufacturer’s

instructions and safety rules provided in the Operator’s Manual.

 The Operator’s Manual is located in the

manual storage container, at the platform.

 For specific product applications, see

Contacting The Manufacturer.

Operator's Manual Fifth Edition • First Printing

Introduction

2 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Platform controls symbology and related machine movement:

Platform level Platform rotate

Jib boom up/down

Primary boom up/down Turntable rotate Primary boom extend/retract

Secondary boom up/down

Drive forward/reverse

Steer right/left

Fifth Edition • First Printing Operator's Manual

Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 3

Ground controls symbology and related machine movement:

Platform level Platform rotate

Jib boom up/down

Primary boom up/down Turntable rotate Primary boom extend/retract

Secondary boom up/down

Sequential functions and movement:

 Drive and steer.

Interlocked functions:

 Elevated drive speed.  Elevated drive in an off-level condition.  Drive enable when the boom is rotated past the

non-steer wheels.

 All platform and ground controls.

Limitations of use:

 The intended use of this machine is to lift

personnel, including tools, and materials to an aerial work site.

 Do not elevate the platform unless the machine

is on firm level ground.

Stability enhancing means:

 Foam filled tires

Restricted operating envelope:

 500 lbs/227 kg platform capacity.

Operator's Manual Fifth Edition • First Printing

Introduction

4 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Genie. Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners.

The information contained in the bulletins is tied to specific machines using the machine model and serial number.

Distribution of bulletins is based on the most current owner on record along with their associated dealer, so it is important to register your machine and keep your contact information up to date.

To ensure safety of personnel and the reliable continued operation of your machine, be sure to comply with the action indicated in a respective bulletin.

To view any open bulletins for your machine, visit us on the web at www.genielift.com.

Contacting the Manufacturer

At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At minimum, Genie should be contacted for:

Accident reporting Questions regarding product applications and

safety Standards and regulatory compliance information Current owner updates, such as changes in

machine ownership or changes in your contact information. See Transfer of Ownership, below.

Transfer of Machine Ownership

Taking a few minutes to update owner information will ensure that you receive important safety, maintenance and operating information that applies to your machine.

Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800.

Fifth Edition • First Printing Operator's Manual

Introduction

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 5

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.

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-based cleaners because they may damage the safety sign material.

Operator's Manual Fifth Edition • First Printing

Introduction

6 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Hazard Classification

Decals on this machine use symbols, color coding, and signal words to identify the following:

Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a property damage message.

Fifth Edition • First Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 7

Symbol and Hazard Pictorials Definitions

Fire hazard

Explosion hazard

Do not use ether or other high energy starting aids on machines equipped with glow plugs.

No smoking. No flame. Stop engine. Fire extinguisher

No smoking

Explosion hazard

Electrocution hazard

Maintain required clearance

Tip-over hazard

Tire specifications

Operator's Manual Fifth Edition • First Printing

Symbol and Hazard Pictorials Definitions

8 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Wheel load

Wind speed

Maximum capacity

Manual force

Support the platform or boom during maintenance

Tie-down point

Lifting point

Platform tie-down instructions

Lifting & tie down instructions

Lanyard anchorage points

Corrosive acid.

Color coded direction arrows

Runaway hazard

Collision hazard

Overhead obstruction

Fifth Edition • First Printing Operator's Manual

Symbol and Hazard Pictorials Definitions

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 9

Electrocution hazard

Avoid contact

Disconnect battery

Voltage rating for power to platform

Pressure rating for air line to platform

Recovery procedure if tilt alarm sounds while elevated.

Platform uphill:

1 Lower primary. 2 Lower secondary. 3 Retract primary.

Platform downhill:

1 Retract primary. 2 Lower secondary. 3 Lower primary.

Read the operator’s

manual

Access by trained and authorized personnel only

Read the service manual

Emergency lowering

Crush hazard

Operator's Manual Fifth Edition • First Printing

General Safety

10 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

General Safety

Fifth Edition • First Printing Operator's Manual

General Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 11

Operator's Manual Fifth Edition • First Printing

General Safety

12 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Fifth Edition • First Printing Operator's Manual

General Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 13

* These decals are model, option or configuration specific.

Operator's Manual Fifth Edition • First Printing

General Safety

14 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Fifth Edition • First Printing Operator's Manual

General Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 15

Operator's Manual Fifth Edition • First Printing

General Safety

16 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Fifth Edition • First Printing Operator's Manual

General Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 17

* These decals are model, option or configuration specific.

Operator's Manual Fifth Edition • First Printing

Personal Safety

18 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Personal Safety

Personal Fall Protection

Personal fall protection equipment (PFPE) is required when operating this machine.

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

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

All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE

manufacturer’s instructions.

Fifth Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 19

Work Area Safety

Electrocution Hazards

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

Obey all local and governmental regulations regarding required clearance from electrical power lines. At a minimum, the required clearance contained in the chart below must be followed.

Line Voltage

Required Clearance

0 to 50KV

10 ft

3.05 m

50 to 200KV

15 ft

4.60 m

200 to 350KV

20 ft

6.10 m

350 to 500KV

25 ft

7.62 m

500 to 750KV

35 ft

10.67 m

750 to 1000KV

45 ft

13.72 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 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.

Tip-over Hazards

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

Maximum platform capacity

500 lbs

227 kg

Maximum platform capacity

Machine equipped with Aircraft Protection Package

440 lbs

200 kg

Maximum occupants

The weight of options and accessories, such as pipe cradles, panel cradles and welders, will reduce the rated platform capacity and must be subtracted from the platform capacity. See the decals with the options and accessories.

If using accessories, read, understand and obey the decals, instructions and manuals with the accessory.

Do not alter or disable the limit switches.

Operator's Manual Fifth Edition • First Printing

Work Area Safety

20 Z®-45J DC • Z®-45J Bi-Energy Part No. 1297032GT

Do not use air-filled tires. These machines are equipped with foam-filled tires. Wheel weight and proper counterweight configuration are critical to stability.

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 surface before raising the platform.

If the tilt alarm sounds when the platform is raised, use extreme caution. The Machine Not Level indicator light will come on and the drive function in one or both directions will not operate. 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 platform uphill:

1 Lower the primary

boom.

2 Lower the

secondary boom.

3 Retract the primary

boom.

If the tilt alarm sounds with the platform downhill:

1 Retract the primary

boom.

2 Lower the

secondary boom.

3 Lower the primary

boom.

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.

Fifth Edition • First Printing Operator's Manual

Work Area Safety

Part No. 1297032GT Z®-45J DC • Z®-45J Bi-Energy 21

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.

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 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 – 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 a mobile elevating 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 place or attach fixed or 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.

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

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.

+ 51 hidden pages