Genie Z-45/25 Manuale utente

Third Edition

Second Printing

Part No. 110015

Operator’s Manual

with Maintenance Information

Bi-Energy PowerIC Power

Operator's Manual Third Edition · Second Printing

Z-45/25•Z-45/25J PartNo.110015

First Edition: Seventh Printing, May 2002

Second Edition: Second Printing, August 2004

Third Edition: Second Printing, October 2005

"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.

Important

Read,understandand obey thesesafetyrules 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 Rules .............................................................. 1

Legend ....................................................................... 8

Controls ..................................................................... 9

Pre-operationInspection ........................................... 12

Maintenance ............................................................. 14

Function Tests.......................................................... 18

WorkplaceInspection................................................ 24

OperatingInstructions............................................... 25

Transportand LiftingInstructions .............................. 31

Decals ...................................................................... 34

Specifications ........................................................... 38

Internet:http://www.genielift.com

E-mail:[email protected]

Operator's ManualThird Edition · Second Printing

PartNo.110015 Z-45/25•Z-45/25J 1

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.

Knowandunderstandthesafetyrulesbefore

going on to the next section.

2 Alwaysperformapre-operationinspection.

3 Always perform function tests prior to use.

4 Inspect the workplace.

5 Only use the machine as it was intended.

Youread,understandandobeythe

manufacturer'sinstructions andsafetyrules—

safetyandoperator'smanualsandmachine

decals.

Youread,understandandobeyemployer's

safety rules and worksite regulations.

Youread,understandandobeyallapplicable

governmentalregulations.

Youareproperly trained tosafelyoperate the

machine.

Operator's Manual Third Edition · Second Printing

2 Z-45/25•Z-45/25J PartNo.110015

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

andapparatusinaccordancewithapplicable

governmentalregulationsandthefollowingchart.

Voltage Minimum Safe

Phase to Phase Approach Distance

Feet Meters

0to300V AvoidContact

300Vto50KV 10 3.1

50KVto200KV 15 4.6

200KVto350KV 20 6.1

350KVto500KV 25 7.6

500KVto750KV 35 10.7

750KVto1000KV 45 13.7

Allow for platform movement, electrical line sway or

sag and beware of strong or gusty winds.

Keep away from the machine if it contacts

energizedpowerlines. Personnelonthegroundor

in the platform must not touch or operate the

machine until energized power lines are shut off.

Do not use the machine as a ground for welding.

Donotoperate themachineduring lightningor

storms.

Tip-over Hazards

Occupants,equipmentandmaterials shall not

exceed the maximum platform capacity.

Maximum platform capacity 500 lbs 227 kg

Maximum occupants 2

The weight of options and accessories, such as

pipecradles, panelcradles andwelders,willreduce

the rated platform capacity and must be factored

into the total platform load. See the decals on the

options.

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.

Donotrotatetheboom while lowering. Move the

machine to a firm, level surface before raising the

platform.

Operator's ManualThird Edition · Second Printing

PartNo.110015 Z-45/25•Z-45/25J 3

SAFETY RULES

Do not use the platform controls to free a platform

thatis caught,snaggedor otherwiseprevented

from normal motion by an adjacent structure. All

personnelmustbe removedfromthe platform

before attempting to free the platform using the

groundcontrols.

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.

Use extreme care and slow speeds while driving

the machine in stowed position across uneven

terrain,debris,unstable or slippery surfacesand

nearholesanddrop-offs.

Do not alter or disable the limit switches.

Donotdrive the machine onornear uneven terrain,

unstablesurfacesorotherhazardousconditions

withtheboom raisedorextended.

Do not drive the machine on a slope that exceeds

the maximum uphill, downhill or side slope rating of

the machine. Slope rating applies only to machines

in the stowed position.

Maximum slope rating, stowed position, 2WD

Counterweight uphill 30% (17°)

Counterweight downhill 25% (14°)

Side slope 25% (14°)

Maximum slope rating, stowed position, 4WD

Counterweight uphill 45% (24°)

Counterweight downhill 25% (14°)

Side slope 25% (14°)

Note: Slope rating is subject to ground conditions

andadequatetraction.

Do not push off or pull toward any object outside

of the platform.

Maximum allowable

side force - ANSI and CSA

150 lbs / 667 N

Maximum allowable

manual force - CE and

Australia

90 lbs / 400 N

Do not alter or disable machine components that in

any way affect safety and stability.

Operator's Manual Third Edition · Second Printing

4 Z-45/25•Z-45/25J PartNo.110015

SAFETY RULES

Do not replace items critical to machine stability

with items of different weight or specification.

Do not modify or alter an aerial work platform

withoutprior writtenpermission fromthe

manufacturer.Mountingattachmentsforholding

toolsorothermaterials 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 overhanging loads to any

part of this machine.

Do not transport tools and materials unless they are

evenly distributed and can be safely handled by

person(s)intheplatform.

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, air-filled tires

areproperlyinflatedandlugnutsareproperly

tightened.

Do not replace factory-installed tires with tires of

different specification or ply rating.

Z-45/25andZ-45/25JNarrowBaseModels:

Do not use air-filled tires. These machines are

equippedwithfoam-filledtires.Wheelweightand

propercounterweightconfigurationarecriticalto

stability.

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 in

accordancewith

governmentalregulations.

Attach the lanyard to the

anchorprovidedinthe

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

gatebeforeoperating.

Operator's ManualThird Edition · Second Printing

PartNo.110015 Z-45/25•Z-45/25J 5

Collision Hazards

Be aware of limited sight

distance and blind spots

whendrivingoroperating.

Beawareoftheboom position when rotating the

turntable.

Checkthe work areafor overheadobstructionsor

otherpossiblehazards.

Beawareofcrushinghazards whengraspingthe

platformguardrail.

Do not lower the boom unless the area below is

clearof personnelandobstructions.

Limit travel speed according to the condition of the

ground surface, congestion, slope, location of

personnel, and any other factors which may cause

collision.

SAFETY RULES

Operators must comply with employer, job site and

governmentalrulesregardingtheuseofpersonal

protectiveequipment.

Observeandusethecolor-codeddirectionarrows

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

outand/or precautions havebeen taken toprevent

any potential collision.

Nostunt driving orhorseplay whileoperatinga

machine.

Component Damage Hazards

Do not use any battery or charger greater than 12V

tojump-startthe engine.

Do not use the machine as a ground for welding.

Explosion and Fire Hazards

Do not start the engine if you smell or detect liquid

petroleumgas(LPG), gasoline,dieselfuel orother

explosive substances.

Donotrefuel themachinewith theenginerunning.

Refuel the machine and charge the battery only in

anopen, well-ventilatedarea awayfromsparks,

flames and lighted tobacco.

Donotoperate themachinein hazardous locations

orlocationswherepotentiallyflammableor

explosive gases or particles may be present.

Donot sprayetherinto enginesequipped withglow

plugs.

Operator's Manual Third Edition · Second Printing

6 Z-45/25•Z-45/25J PartNo.110015

Damaged Machine Hazards

Donotuse adamagedor malfunctioningmachine.

Conductathoroughpre-operationinspectionofthe

machine and test all functions before each work

shift. Immediately tag and remove from service a

damagedormalfunctioningmachine.

Besureall maintenancehasbeen performed as

specified in this manual and the

Genie Z-45/25 &

GenieZ-45/25JServiceManual.

Be sure all decals are in place and legible.

Be sure the operator’s, safety and responsibilities

manualsarecomplete, legible and inthestorage

containerlocatedon theplatform.

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil or

air leak. An air leak or hydraulic leak can penetrate

and/orburnskin.

Alwaysoperatethe machine inawell-ventilated

areatoavoidcarbonmonoxidepoisoning.

Impropercontact withcomponentsunder anycover

will cause serious injury. Only trained maintenance

personnel should access compartments. Access

by the operator is only advised when performing a

pre-operationinspection.Allcompartmentsmust

remainclosedandsecuredduringoperation.

Battery Safety

Burn Hazards

Batteries contain acid. Always wear protective

clothingandeyewearwhenworkingwithbatteries.

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.

Operator's ManualThird Edition · Second Printing

PartNo.110015 Z-45/25•Z-45/25J 7

Decal Legend

Genie product decals use symbols, color coding

and signal words to identify the following:

Safety alert symbol—used to alert

personneltopotentialpersonal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Red—usedtoindicatethe

presence of an imminently

hazardous situation which, if not

avoided, will result in death or

seriousinjury.

Orange—usedtoindicatethe

presence of a potentially

hazardous situation which, if not

avoided, could result in death or

seriousinjury.

Yellow with safety alert symbol—

used to indicate the presence of a

potentiallyhazardoussituation

which, if not avoided, may cause

minorormoderateinjury.

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—usedtoindicateoperation

ormaintenanceinformation.

Operator's Manual Third Edition · Second Printing

8 Z-45/25•Z-45/25J PartNo.110015

Legend

1 Foot switch

2 Manualstoragecontainer

3 Slidingmid-rail

4 Lanyardanchoragepoint

5 Jibboom(Z-45/25J)

6 Platform

7 Platformcontrols

8 Primaryboom

9 Secondaryboom

10 Groundcontrols

11 Steertire

12 LPGtank(ifequipped)

13 Non-steertire

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