Genie Z-45/25 Einrichtungshandbuch

Second Edition

Second Printing

Part No. 82596

Operator’s Manual

with Maintenance Information

Bi-Energy Power

GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596

Operator's Manual Second Edition · Second Printing

First Edition: Fifth Printing, April 2002

Second Edition: Second Printing, August 2004

"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,understandandobeythesesafetyrulesand

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-operationInspection ........................................... 11

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

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

WorkplaceInspection................................................ 21

OperatingInstructions............................................... 22

Transportand LiftingInstructions .............................. 27

Decals ...................................................................... 30

Specifications ........................................................... 34

Internet:http://www.genielift.com

E-mail:[email protected]

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 1

Operator's ManualSecond Edition • Second Printing

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 and safetyrules—

safetyandoperator'smanualsandmachine

decals.

Youread,understandandobeyemployer's

safety rules and worksite regulations.

Youread,understandandobeyallapplicable

governmentalregulations.

Youareproperlytrainedtosafelyoperate the

machine.

2 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596

Operator's Manual Second Edition • Second 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 ApproachDistance

Feet Meters

0 to 300V Avoid Contact

300V to 50KV 10 3.1

50KV to 200KV 15 4.6

200KV to 350KV 20 6.1

350KV to 500KV 25 7.6

500KV to 750KV 35 10.7

750KV to 1000KV 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

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 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 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.

Donot rotate the boom whilelowering. Move the

machine to a firm, level surface before raising the

platform.

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.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 3

Operator's ManualSecond Edition • Second Printing

SAFETY RULES

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 the stowed position across uneven

terrain,debris,unstableor slippery surfaces and

nearholesanddrop-offs.

Donotdrivethe machine on or near uneven terrain,

unstablesurfacesor otherhazardousconditions

withthe 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

side 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

withoutprior writtenpermission fromthe

manufacturer.Mountingattachmentsforholding

toolsor 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 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.

Do not transport tools and materials unless they are

evenly distributed and can be safely handled by

person(s)intheplatform.

Be sure all tires are in good condition, air-filled tires

areproperlyinflated andlug nutsareproperly

tightened.

Do not use batteries that weigh less than the

originalequipment. Batteriesareused as

counterweight and are critical to machine stability.

Each battery must weigh 105 pounds / 47.6 kg.

Each battery box including batteries must weigh a

minimum of 530 pounds / 240.4 kg.

4 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596

Operator's Manual Second Edition • Second Printing

SAFETY RULES

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.

Collision Hazards

Be aware of limited sight

distance and blind spots

whendrivingoroperating.

Beawareofboompositionwhenrotatingturntable.

Operators must comply with employer, job site and

governmentalrulesregardingtheuseofpersonal

protectiveequipment.

Checkthe work area for overheadobstructionsor

otherpossiblehazards.

Beawareofcrushinghazards whengrasping the

platformguardrail.

Observeandusecolor-codeddirectionarrowson

the platform controls and drive chassis for drive

and steer functions.

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.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 5

Operator's ManualSecond Edition • Second Printing

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.

Nostunt driving or horseplaywhileoperatinga

machine.

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.

Whenthe engine isrunning,operate the machinein

awell-ventilatedareatoavoidcarbonmonoxide

poisoning.

Impropercontact with componentsunderany cover

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.

Component Damage Hazards

Do not use any battery or charger greater than 12V

tojump-starttheengine.

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, diesel fuel or other

explosive substances.

Donot refuel the machine with the engine running.

Refuel the machine and charge the battery only in

anopen, well-ventilatedareaaway from sparks,

flames and lighted tobacco.

Donot operate the machine in hazardous locations

orlocationswherepotentiallyflammableor

explosive gases or particles may be present.

Donot spray etherintoengines equipped with glow

plugs.

Damaged Machine Hazards

Donot use a damaged or malfunctioning machine.

Conductathoroughpre-operationinspectionofthe

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-45/25

Bi-Energy&Z-45/25JBi-Energy Service Manual.

Be sure all decals are in place and legible.

Be sure the operator’s, safety and responsibilities

manualsarecomplete, legible and in the storage

containerlocated on the platform.

SAFETY RULES

6 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596

Operator's Manual Second Edition • Second Printing

SAFETY RULES

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.

The battery pack must remain in an upright

position.

Do not expose the batteries or the charger to water

orrain.

Explosion Hazards

Keep sparks, flames

andlightedtobacco

awayfrom batteries.

Batteries emit an

explosive gas.

The battery pack cover

mustremain off during

theentirecharging

cycle.

Do not contact the battery terminals or the cable

clamps with tools that may cause sparks.

Component Damage Hazards

Do not use any battery charger greater than 48V to

chargethebatteries.

Both battery packs must be charged together.

Disconnectthe battery pack plug before removing

the battery pack.

Electrocution Hazards

Connect the battery charger to a

grounded,AC3-wireelectrical

outlet only.

Inspect daily for damaged cord,

cablesandwires. Replace

damageditemsbefore

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

originalequipment. Batteriesareused as

counterweight and are critical to machine stability.

Each battery must weigh 105 pounds / 47.6 kg.

Each battery box including batteries must weigh a

minimum of 530 pounds / 240.4 kg.

Lifting Hazard

Use a forklift to remove or install the battery packs.

PartNo.82596 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy 7

Operator's ManualSecond Edition • Second Printing

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.

SAFETY RULES

8 GenieZ-45/25Bi-Energy&GenieZ-45/25JBi-Energy PartNo.82596

Operator's Manual Second Edition • Second Printing

6 Platform rotate switch

7 Platform level switch

8 Optionalequipment

9 Glowplug switch

10 Engine start switch

PlatformControlPanel

1 Hornbutton

2 Auxiliarypower switch

3 Driveenableindicatorlight

4 Driveenableswitch

5 Z-45/25JBi-Energy models: Jib boom

up/down switch

Controls

56 7

18198

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