Genie Z-22IC User's Manual
Contents
1. Do not spray ether into engines equipped with glow plugs 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 A TEREX COMPANY 6 Z 34 221C 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 areato 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 lighted2. 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 PartNo 1000048 Fourth Edition First Printing Operator s Manual Do not drive over 0 6 mph 1 km h with the primary boom raised or extended or the secondary boom raised 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 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 Part No 1000048 Z 34 221C SAFETY RULES Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of th
3. First Printing with Maintenance Information Part No 1000048 perator s Manual Fourth Edition E 2 34 22 IC Power Operator s Manual Fourth 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 Hule8 scettr d etate eeu sese pu nee nenas 1 Seite RTT 8 Legend 10 Pre operation Inspection eeeeseseeessseses 11 Maintenance sseessesseseeneennnee nennen nnne nnns 13 FUNCION TESIS i seid qutisose Duetccrt tenute nre ampia dS ote 16 Workplace Inspection seessssessssss 21 Operating Instructions eeeseeeeeee eee 22 Biel mw 28 Transport and Lifting Instructions 32 wle elzi eg meM 35 Copyright 1996 by Genie Industries Contact us First Edition Second Printing November 1996 ww Edition Sixth Printi 2002 Internet http www genielift com Second Edition Sixth Printing September 200 e mail techpub 2genieind com Third Edition First Printing June 2003 Fourth Edition First Printing October 2005
4. Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating counterweight uphill gradeability 2WD 3796 20 4WD 45 24 Maximum slope rating counterweight downhill 2WD 20 11 4WD 40 22 Maximum side slope rating 25 14 Note Slope rating is subject to ground conditions and adequate traction The term gradeability applies to the counterweight uphill configuration only Be sure the boom is below horizontal and the platform is between the non steer wheels Move the drive speed select switch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure OPERATING INSTRUCTIONS Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example lt rise Piece of wood 144 inches 3 6 m Run 144 inches 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 396 grade 0 3 m 3 6 m 0 0
5. 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 amp s Printed on recycled paper Printed in U S A A TEREX COMPANY Z 34 22 1C PartNo 1000048 Fourth 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 M 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine A TEREX COMPANY PartNo 1000048 Z 34 221C 1 Operator s Manual Fourth Edition First Printing SAFETY RULES Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to ele
6. First Printing Operator s Manual Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always performa 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 5 Only use the machine as it was intended 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 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 b
7. Note Machine functions will not operate while the operation for maximum drive speed generator is running and the foot switch is not pressed down When the foot switch is pressed down the generator will turn off and the machine functions will operate A TEREX COMPANY 26 Z 34 221C Part No 1000048 Fourth Edition First Printing Operator s Manual Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off Machine Not Level Indicator Light if equipped A Light on indicates the machine is not level The tilt alarm will be sounding when this light is on Move the machine Saf toa firm level surface Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions After Each Use 1 Selecta safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable so that the boom is between the non steer wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use 5 Chock the wheels A TEREX COMPANY Part No 1000048 Z 34 22 IC OPERATINGINSTRUCTIONS 2 Operat
8. Patch Label Tire Pressure Label Lower Mid rail Quantity 1 1 NINI N gt PartNo 1000048 Fourth Edition First Printing Operator s Manual DECALS 28160 28158 Serial 44981 82472 roun or 28159 Plate Ground Controls Side _ Ee 28174 or 28235 5084 40434 82487 82548 82544 82609 72095 82620 a Jn 44779 82611 82620 82487 82609 i E sre 52968 NB J j TII 37053 37055 m 82601 E 37056 Chassis E Platform 44981 37056 82602 37055 lt n 7 or 82604 37054 62947 or e i 62948 40434 82472 Shading indicates decal is hidden from view i e under covers 28171 82544 OE 28174 82609 82609 Engine 82548 62930 82472 or 28235 82620 82473 82620 Side A TEREX COMPANY PartNo 1000048 Z 34 22 IC 31 Operator s Manual Fourth Edition First Printing Transport and Lifting Instructions Observe and Obey M The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps are s
9. hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Besure the boom is in the stowed position 2 Visually inspect the site gauge located on the side of the hydraulic tank O Result The hydraulic oil level should be within the FULL and ADD marks on the hydraulic tank 3 Add oil if necessary Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent Check the Engine Coolant Level Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems 1 Check the fluid level in the coolant recovery tank Result The fluid level should be in the NORMAL range 2 Add fluid if necessary A TEREX GOI NY Part No 1000048 Z 34 22 C 13 Operator s Manual Fourth Edition First Printing MAINTENANCE Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine of
10. is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge and add air as needed Tire pressure MAINTENANCE Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Industrial tire 100 psi 6 89 bar Rough terrain tire 45 psi 3 1 bar High flotation tire 44 psi 3 0 bar Genie A TEREX COMPANY PartNo 1000048 Z 34 22 C 15 Operator s Manual Fourth Edition First Printing Fr unction Tests Do Not Operate Unless M You learn and practice the principles of safe 16 machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know andunderstand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine m
11. the on position but do not start the engine 21 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side O Result The engine should not start 22 Do not press down the foot switch and start the engine 23 Do not press down the foot switch Test each machine function Result The machine functions should not operate A TEREX COMPANY Z 34 221C Test Machine Functions 24 Press down the foot switch 25 Activate each machine function control handle or toggle switch O Result All boom and platform functions should operate through a full cycle Note Control the speed of boom functions by adjusting the boom function speed controller Drive and steer functions are not affected by the boom function speed controller Testthe Steering 26 Press down the foot switch 2 Depress the thumb rocker switch on top of the drive control handle in the direction identified by the blue triangle on the control panel Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 28 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis PartNo 1000048 Fourth Edition First Printing Operator s Manual Test Drive and Braking 29 Press down the foot switch 3
12. 0 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The travel alarm should sound The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 31 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The travel alarm should sound The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Part No 1000048 FUNCTION TESTS Test the Drive Enable System 32 Press down the foot switch 33 Retract the primary boom to the stowed position 34 Rotate the turntable until the boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 35 Move the drive control handle off center Result The drive function should not operate 36 Move and hold the drive enable toggle switch up or down and slowly move the drive control handle off center Result The drive function should operate Note When the drive enable system is in use the machi
13. 83 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting section A TEREX GOI NY Part No 1000048 Z 34 22 C 25 Operator s Manual Fourth Edition First Printing OPERATING INSTRUCTIONS Drive Enable Engine Idle Select rpm Select the engine idle rpm using the symbols on the control panel Light on indicates that the boom has moved just past either non steer wheel and the drive function has been interrupted y To drive hold the drive enable switch to either side uu Ad and slowly move the drive control handle off center Be aware that the machine may move in the Rabbit and foot switch symbol foot switch opposite direction that the drive and steer controls activated high idle are moved M Turtle symbol low idle Always use the color coded direction arrows on the platform controls and the drive chassis to identify Rabbit symbol high idle the direction the machine will travel Generator if equipped Drive Speed Select To start the generator move the generator toggle switch to the on position CR uA Plug a power tool into the power to platform GFCI outlet Machine on incline symbol Low range operation me To turn off the generator move the generator toggle for inclines switch to the off position Machine on level surface symbol High range i
14. D L Tires and wheels Fourth Edition First Printing L Engine and related components L Limit switches Ll Nuts bolts and other fasteners Li Platform entry mid rail gate L Beacon and alarms if equipped Check entire machine for UL Cracks in welds or structural components Li Dents or damage to machine L Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Li After you complete your inspection be sure that all compartment covers are in place and latched A TEREX COMPANY Z 34 22 IC PartNo 1000048 Fourth Edition First Printing Operator s Manual Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator MI Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Maintenance Check the Hydraulic Oil Level Maintaining the
15. Emergency Stop button to the on position 48 Press down the foot switch 49 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserve battery power test each function through a partial cycle O Result All boom and steer functions should operate Drive function should not operate with auxiliary power Test the Lift Drive Select Function if equipped 50 Press down the foot switch 51 Move the drive control handle off center and activate a boom function toggle switch Result No boom functions should operate The machine will move in the direction indicated on the control panel PartNo 1000048 Fourth Edition First Printing Operator s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris Do Not Operate Unless sloped surfaces M You learn and practice the principles of safe unstable or slippery surfaces Mad operation contained in this operator s overhead obstructions and high voltage manual conductors 1 Avoid hazardous situations hazardous locations 2 Always perform a pre operation inadequate surface support to withstand all load Inspection forces imposed by the machine 3 Always perform function tests prior to use aid ana weaiercondiions 4 Inspect the workplace the presence of unauthorized personnel HO
16. Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Brasil Phone 55 11 41 665 755 Fax 55 1141 665 754 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
17. W and understand the workplace other possible unsafe conditions inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine A TEREX COMPANY PartNo 1000048 Z 34 22 IC 21 Operator s Manual Fourth Edition First Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Alwaysperform 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 A TEREX COMPANY Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel s
18. alarm if equipped should sound while the boom is lowering FUNCTION TESTS Test the Tilt Sensor 9 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform control 10 Open the ground control side turntable cover and locate the tilt sensor 11 Press down one side of the tilt Sensor O Result The alarm located in the platform should sound Test Auxiliary Controls 12 Turn the key switch to ground control and shut the engine off 13 Pull out the red Emergency Stop button to the on position 14 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch Note To conserve battery power test each function through a partial cycle O Result All boom functions should operate Part No 1000048 Z 34 22 IC 17 Operator s Manual Fourth Edition First Printing FUNCTION TESTS At the Platform Controls Test the Emergency Stop 15 Turn the key switch to platform control and restart the engine 16 Push in the platform red Emergency Stop button to the off position O Result The engine should turn off and all functions should not operate 17 Pull out the red Emergency Stop button and restart the engine Testthe Horn 18 Push the horn button O Result The horn should sound Test the Foot Switch 19 Push in the platform red Emergency Stop button to the off position 20 Pull out the red Emergency Stop button to
19. ctrical current c lt NW Ly E NW ih 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 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 REX COMI 2 Z 34 221C Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity 500 Ibs Maximum platform capacity 227 kg Maximum occupants 2 The weight of options and accessories such as pipe cradles panel cradles and welders will reduce 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
20. e entire machine for loose or unsecured items Securing the Chassis Use the tie points on the drive chassis for anchoring down to the transport surface Use chains or straps of ample load capacity Use a minimum of 4 chains Adjust the rigging to prevent damage to the chains Truck bed TRANSPORT AND LIFTING INSTRUCTIONS Securing the Platform Make sure the jib and platform are in the stowed position Place a block under the edge of the platform beneath the platform entry Secure the platform with a nylon strap placed over the platform mount near the platform rotator see below Do not use excessive downward force when securing the boom section CRE CT N ZF d Ta IND p r A Truck bed A TEREX COMPANY PartNo 1000048 Z 34 22 IC 33 Operator s Manual Fourth Edition First Printing TRANSPORT ANDLIFTING INSTRUCTIONS Observe and Obey M Only qualified riggers should rig and lift the machine M Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the machine weight X Axis 34 Z 34 221C Lifting Instructions Fully lower and retract the boom Fully lower the jib Remove all loose items on the machine Determine the c
21. e machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position 2WD Counterweight uphill 37 20 Counterweight downhill 20 11 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Counterweight downhill 40 22 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Do not push off or pull toward any object outside of the platform Maximum allowable a side force ANSI amp Z D CSA 150 Ibs 667 N SN xI lt Maximum allowable manual force CE 90 Ibs 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 Operator s Manual Fourth Edition First Printing SAFETY RULES Do not place or attach overhanging loads to any part of this machine AY 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 toeboard
22. efore 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 1000048 Z 34 22 IC 11 Operator s Manual E PRE OPERATION INSPECTION Pre operation Inspection L Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Be sure that all decals are legible and in place See Decals section Check for engine oil leaks and proper fluid level Add oil if needed See Maintenance section Check for engine coolant leaks and proper fluid level Add coolant if needed See Maintenance section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications LI Electrical components wiring and electrical cables L1 Hydraulic power unit reservoir hoses fittings cylinders and manifolds Generator belts and related components Fuel and hydraulic tanks Drive and turntable motors and torque hubs Boom wear pads LD LD D
23. enter of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the chassis Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis 35 9 in 91 3 cm Y Axis 33 3 in 84 7 cm S Caf PartNo 1000048 Fourth Edition First Printing Operator s Manual Z 34 22 2WD Industrial Height working maximum Height plattorm maximum Height stowed maximum Horizontal reach maximum Width Length stowed Maximum load capacity Maximum wind speed Wheelbase Turning radius outside Turning radius inside Ground clearance Turntable rotation degrees Turntable tailswing Platform leveling Platform rotation degrees Controls Platform dimensions length x width Power source Fuel capacity AC outlet in platform Specifications Weight See Serial Plate Machine weights vary with option configurations 40 ft 6 in 12 5 m Airborne noise emissions 80 dB 34 ft 6 in 10 5 m Maximum sound level at normal operating workstations 6 ft 7 in a UVeWelgnteo 22 f13 in Em Drive speeds maximum Boom stowed 4 0 mph 6 4 km h 9 8 in 1 7m 40 ft 6 8 sec12 2 m 6 8 sec 18 ft 6 in 96M Boom 0 7 mph 1 0 km h 500 Ib 227 kg raised or extended 40 ft 40 sec 12 2 m 40 sec 28 mph 12 5 m s Maximum slope rating stowed position 2WD 6ft2in 19m Counterweight uphill 37 20 13 ft1in am C
24. f 1 Checkthe oil level dipstick Add oil as needed Kubota Engine DF 752 E2 Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Se 10W 30 1 Puton protective clothing and eye wear ADOLE ENJING Messe 2 Be sure that the battery cable connections are Oil type 10W 30 tight and free of corrosion Perkins Engine 404C 11 3 Be sure that the battery hold down bracket is tight Oil type 15W 40 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Genie A TEREX COMPANY 14 Z 34 221C Part No 1000048 Fourth Edition First Printing Operator s Manual Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option Bodily injury hazard An over AWARNING inflated tire can explode and may cause death or serious injury Tip over hazard Do not use AWARNING temporary flat tire repair products To safeguard maximum stability achieve optimum machine handling and minimize tire wear it
25. h ground and platform red Emergency Stop buttons to the on position Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel Machines equipped with Platform Level Control To Drive Press down the foot switch Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward center otop Return the drive control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the booms are raised or extended Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch To Steer 1 Press down the foot switch 2 Turn the steer wheels with the thumb rocker switch located on top of the drive control handle Use the color coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn 24 Z 34 221C A TEREX COMPANY PartNo 1000048 Fourth Edition First Printing Operator s Manual
26. hould be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine 22 Z 34 221C Part No 1000048 Fourth Edition First Printing Operator s Manual Starting the Engine 1 Atthe ground controls turn the key switch to the desired position 2 Besure both ground and platform control red Emergency Stop buttons are pulled out to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds If the engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again All models In extreme cold conditions 20 F 6 C and below warm the engine for 5 minutes to prevent hydraulic system damage Gasoline LPG models In extreme cold conditions 20 F 6 C and below the machine should be started on gasoline then switched to LPG Emergency Stop Push in the red Emergency Stop button
27. itch 2 Platform rotate switch 3 Primary boom up down switch 4 Platform level switch 5 Primary boom extend retract switch 6 1OAbreakerfor engine electrical circuits i 10A breaker for control electrical circuits 8 Auxiliary power switch Part No 1000048 9 Q9 0 Q2 69 v LZ 0 M QRZ J O nbs O c m of 10 11 12 13 14 15 16 A 9 8 OO STOP a EE DN DN O O C ees N Gasoline LPG models Water temperature gauge Diesel models Oil temperature gauge Travelalarm Oil pressure gauge Key switch for platform off ground selection Voltage gauge Red Emergency Stop button Not used Hour meter A TEREX COMPANY Z 34 221C i 00009 9 F O 17 18 19 20 21 22 23 CONTROLS amp 9 GG G9 G Gasoline LPG models Choke switch Diesel models Glow plug switch option Engine start switch Function enable switch Gasoline LPG models Fuel select switch Platform overload indicator light if equipped Jib boom up down switch Primary boom extend retract switch Operator s Manual Fourth Edition First Printing Legend 1 Noncsteertire 8 Platform 2 Steertire 9 Lanyardanchorage point 3 Groundcontrols 10 Sliding mid rail 4 Secondary boom 11 Manual storage container 5 Primary boom 12 Foot switch 6 Jibboom 7 Platform controls A TEREX COMPANY 10 Z 34 221C Part No 1000048 Fourth Edition
28. ne may drive in the opposite direction that the drive and steer control handle is moved Use the color coded direction arrows on the Blue platform controls and the drive chassis to identify 4 the direction of travel Yellow Z 34 22 C 19 Operator s Manual Fourth Edition First Printing FUNCTION TESTS Test Limited Drive Speed 3 Press down the foot switch 38 Raise the primary boom 1 foot 30 cm 39 Slowly move the drive control handle to the full drive position O Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 40 Lower the boom to the stowed position 41 Raise the secondary boom 1 foot 30 cm 42 Slowly move the drive control handle to the full drive position O Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 foot 30 cm per second 43 Lower the boom to the stowed position 44 Extend the primary boom 1 foot 30 cm 45 Slowly move the drive control handle to the full drive position O Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot 30 cm per second If the drive speed with the primary boom raised or extended or the secondary boom raised exceeds 1 foot 30 cm per second immediately tag and remove the machine from service 20 A TEREX COMPANY Z 34 221C Test Auxiliary Controls 46 Shut off the engine 47 Pull out the red
29. on is turned off To drive hold drive enable switch up or down an slowly move drive control handle Machine may drive in opposite direction that the drive and steer controls are move Use color coded direction nel a drive chassis to identify the direction machine will travel CREEP 4 Platform Control Panel 1 2 3 4 5 6 Drive enable switch Drive enable indicator light Auxiliary power switch Platform level switch Horn button Primary boom extend retract switch Red Emergency Stop button 8 Notused 9 Battery charge indicator option 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 amp foot switch foot switch activated high idle Turtle low idle Rabbit high idle A TEREX COMPANY Z 34 221C 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 PartNo 1000048 Fourth Edition First Printing Operator s Manual Ground Control Panel 1 Turntable rotate sw
30. or s Manual Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No 2 564 28158 28159 28160 28161 28164 28165 28171 28174 28175 28176 28177 28181 28235 28236 31060 33952 3 052 3 053 3 054 3 055 3 056 28 Decal Description Quan Danger Electrocution Hazard Label Unleaded Label Diesel Label LPG Danger Crushing Hazard Notice Hazardous Materials Notice Foot Switch Label No Smoking Label Power to Platform 230V Caution Compartment Access Notice Missing Manuals Warning Platform Rotate Warning No Step or Ride Label Power to Platform 115V Warning Failure To Read Danger Tip over Hazard Interlock Danger Tilt Alarm Notice Maximum Load 500 lbs 227 kg Arrow Blue Arrow Yellow Triangle Blue Triangle Yellow tity Part No 2 40434 1 41971 1 44779 1 44981 3 44986 1 52968 1 62930 2 62947 2 62948 1 72094 1 72095 2 82292 1 82366 2 82609 1 82901 4 97602 1 97890 1 97893 1 107760 1 2 2 Genie Z 34 22 IC Fourth Edition First Printing Decal Description Quantity Label Lanyard Anchorage 2 Notice Tire Pressure 4 Notice Generator option 1 Label Air Line to Platform 2 Notice Max Manual Force 90 lbs 400 N Cosmetic Genie Boom Cosmetic Genie Z 34 22 Cosmetic IC P
31. ounterweight downhill 2096 11 5ft9in iim Side slope 2596 14 6 in im Note Slope rating is subject to ground conditions and adequate traction ida Floor Loading Information i Tire load maximum 4800 Ibs 2177 kg Seu cevelng Tire contact pressure per tire 100 psi 7 03 kg cm 180 689 kPa 12V DC proportional Occupied floor pressure 228 psf 10 93 kPa 1115 kg m2 Kubota G LPG 24 5 hp 56 in x 30 in 1 4 m x 76 cm Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors OR Kubota Diesel 26 hp 9 3 gallons Hydraulic pressure maximum 3200 psi boom functions System voltage Tires size Industrial High flotation PartNo 1000048 35 2 liters standard 220 7 bar 12V 9 14 5 31x 15 5 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie Z 34 22 C 35 Operator s Manual Fourth Edition First Printing SPECIFICATIONS Z 34 22 2WD and 4WD RT Height working maximum Height platform maximum Height stowed maximum Horizontal reach maximum Width Length stowed Maximum load capacity Maximum wind speed Wheelbase Turning radius outside Turning radius inside Ground clearance Turntable rotation degrees Turntable tailswing Platform leveling Platform rotation degrees Controls Platform dimensions length x width Powe
32. ower 4 x 2 Cosmetic IC Power 4 x 4 Ground Control Panel Platform Control Panel Notice Kubota DF 750 Engine Specs Label Chevron Rykon Label Wheel Load Notice Perkins Diesel Engine Specs Warning Explosion Hazard Danger Safety Rules Notice Max Side Force 150 lbs 667 N Notice Kubota Diesel Tier II Engine Specs 1000044 Notice Operating Instructions 1 PartNo 1000048 Fourth Edition First Printing Operator s Manual DECALS 97890 31060 82366 28158 28181 Serial 44981 28161 Ground or 28159 Plate Controls Side zi 28174 D or 28235 ind EN 40434 28171 o 28177 28164 USS ES l 72095 e i 44769 1000044 mu 41971 33952 82609 44779 ae 1000044 41971 ecce 82609 o o 32700 52968 1 Ac g 37055 cum MN 28176 f CF 37052 37056 a _ 31060 44981 Platform 37056 pei 97893 37055 4 n or 44986 37054 s 62947 or x _ 62948 40434 31060 28161 97602 31060 Shading indicates 2 564 decal is hidden from view i e 82292 under covers or 82901 or 107760 82609 Engine 28177 62930 28161 or28235 28171 41971 28175 41971 Side A TEREX COMPANY Pa
33. ption configurations It should be used only with adequate safety factors PartNo 1000048 Fourth Edition First Printing Operator s Manual SPECIFICATIONS Range of Motion S 10 6 m L 30 ft Ll l Lj 9 1m r H 25 ft e 7 6m 72 20 ft 6 1 m 15 ft 4 6 m 10 ft 3m 5 ft l o N SG 1 52 m 0 ft 0 Om O ft 5ft 1oft 15ft 20ft 25ft Om 15m 3m 46m 61m 7 6m oo Oee Part No 1000048 Z 34 22 IC 37 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 449 0 4202 8852 20 Genie U K Phone 44 0 1476 584333 Fax 444 0 1476 584334 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie
34. r source Fuel capacity AC outlet in platform 40 ft 10 in 34 ft 10 in 6 ft 9 in 22 ft 3 in 6 ft 1 in 18 ft 7 in 500 Ib 28 mph 6ft2in 13 ft 6 in 5 ft 11 in 6 5 in 12 6m 10 6m 2m 6 8m 1 8m o m 227 kg 12 5 m s 1 9m 4 1 m 1 8m 16 5 cm 355 0 self leveling 180 12V DC proportional 56 in x 30 in 1 4 m x 76 cm Kubota G LPG 24 5 hp OR Kubota Diesel 26 hp 9 3 gallons Hydraulic pressure maximum 3200 psi boom functions System voltage Tires size Rough terrain High flotation 36 35 2 liters standard 220 7 bar 12V 10 16 5NHS 31 x 15 5 A TEREX COMI Z 34 221C Weight See Serial Plate Machine weights vary with option configurations Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Drive speeds maximum Boom stowed 3 5 mph 5 6 km h 40 ft 7 8 sec 12 2 7 8 sec Boom raised or extended 0 7 mph 1 0 km h 2WD amp 4WD models 40 ft 40 sec Maximum slope rating stowed position 4WD 12 2 m 40 sec Counterweight uphill 45 24 Counterweight downhill 40 22 Side slope 25 14 Note Slope rating is subject to ground conditions and adequate traction Floor Loading Information Tire load maximum 4800 lbs 2177 kg Tire contact pressure per tire 45 psi 3 16 kg cm 310 kPa Occupied floor pressure 226 psf 10 82 kPa 1102 kg m2 Note Floor loading information is approximate and does not incorporate different o
35. rt No 1000048 Z 34 22 IC 29 Operator s Manual DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No 28158 28159 28160 28171 28174 28235 3 053 3 054 3 055 3 056 40434 44779 44981 52968 62930 62947 62948 30 Decal Description Label Unleaded Label Diesel Label LPG Label No Smoking Label Power to Platform 230V Label Power to Platform 115V Arrow Blue Arrow Yellow Triangle Blue Triangle Yellow Label Lanyard Anchorage Label Generator option Label Air Line to Platform Cosmetic Genie Boom Cosmetic Genie Z 34 22 Cosmetic IC Power 4 x 2 Cosmetic IC Power 4 x 4 Quantity 1 1 A TEREX COMPANY Part No 72094 72095 82472 82473 82487 82544 82548 82601 82602 82604 82609 8261 1 82620 97815 Z 34 221C Fourth Edition First Printing EEG n n Decal Description Ground Control Panel Platform Control Panel Warning Crushing Hazard Caution Compartment Access Label Operating Instructions Danger Electrocution Hazard Warning Platform Rotate Danger Maximum Load 227 kg Danger Max Manual Force 667 N Danger Max Manual Force 400 N Label Wheel Load Label Drive Enable
36. 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 Part No 1000048 SAFETY RULES Do not lower the boom unless the area below is clear of personnel and obstructions tm aer art De wu P at N lt gt 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 Do not use the machine as a ground for welding Z 34 22 C 5 Operator s Manual Fourth Edition First Printing SAFETY RULES 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 Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present
37. s or guard rail system can increase the weight in the platform and the surface area of the platform or the load Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Do not use the machine as a crane A TEREX COMI 4 Z 34 22 C 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 A yn 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 PartNo 1000048 Fourth Edition First Printing Operator s Manual 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
38. to the off position at the ground or platform controls to stop all machine functions and turn the engine off Repair any function that operates when the red Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform red Emergency Stop button OPERATING INSTRUCTIONS Auxiliary Controls Use auxiliary power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platform The drive function will not operate with auxiliary power 4 Simultaneously hold the auxiliary power switch on and activate the desired function Operation from Ground 1 Turn the key switch to ground control 2 Pullout the red Emergency Stop button to the on position 3 Gasoline LPG models Choose fuel by moving the fuel select switch to the desired position 4 Startthe engine To Position Platform 1 Hold the function enable switch to either side 2 Move the appropriate toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls A TEREX COMPANY PartNo 1000048 Z 34 22 IC 23 Operator s Manual Fourth Edition First Printing OPERATING INSTRUCTIONS Operation from Platform Turn the key switch to platform control Pull out bot
39. tobacco away from batteries Batteries emit explosive gas Electrocution Hazard Avoid contact with electrical terminals Part No 1000048 Fourth Edition First Printing Operator s Manual ERE MM M SAFETY RULES 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 ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a A potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green usedto indicate operation or maintenance information A TEREX COMPANY PartNo 1000048 Z 34 221C 7 Operator s Manual Fourth Edition First Printing Controls OPERATION g Light on indicates that boom has moved past a non steer tire and drive functi
40. ufficient to withstand the machine weight See the serial plate for the machine weight VI The machine must be on a level surface or secured before releasing the brakes V Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section V If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described A TEREX COMPANY 32 Z 34 221C Free wheel Configuration for Winching 1 Chockthe wheels to prevent the machine from rolling 2 Release the non steer wheel brakes by turning over the torque hub disconnect caps see below 3 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions After the machine is loaded 1 Chock the wheels to prevent the machine from rolling 2 Apply the non steer wheel brakes by turning over the torque hub disconnect caps see below Towing a Genie Z 34 22 is not recommended If the machine must be towed do not exceed 2 mph 3 2 km h Disengage Position Engage Position PartNo 1000048 Fourth Edition First Printing Operator s Manual Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Turn the key switch to the off position and remove the key before transporting Inspect th
41. ust never be used If malfunctions are discovered the machine must be tagged and removed from service 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 and function tests again before putting the machine into service A TEREX COMPANY Z 34 221C Part No 1000048 Fourth Edition First Printing Operator s Manual 1 Selecta test area that is firm level and free of obstruction At the Ground Controls 2 Turn the key switch to ground control 3 Pullout the red Emergency Stop button to the on position O Result The beacon if equipped should flash 4 Startthe engine See Operating Instructions section Test the Emergency Stop 5 Pushin the red Emergency Stop button to the off position O Result The engine should turn off and all functions should not operate 6 Pull out the red Emergency Stop button to the on position and restart the engine Test the Machine Functions 7 Donot hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch O Result All boom and platform functions should not operate 8 Hold the function enable switch to either side and activate each boom and platform function toggle switch O Result All boom and platform functions should operate through a full cycle The descent
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