Genie Z-34/22 User manual

Operator's Manual Fourth Edition • Third Printing
Z-34/22 IC Part No.1000048
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 Rules .............................................................. 1
Controls ..................................................................... 8
Legend ..................................................................... 10
Pre-operationInspection........................................... 11
Maintenance............................................................. 13
Function Tests.......................................................... 16
Workplace Inspection ............................................... 21
Operating Instructions .............................................. 22
Decals ...................................................................... 28
Transport and Lifting Instructions.............................. 32
Specifications ........................................................... 35
Contact us:
Internet:http://www.genielift.com
e-mail:[email protected]
Copyright © 1996 by Genie Industries
Fourth Edition: Third Printing, February 2010
"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.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
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.
Youareproperlytrainedto safely operate the
machine.

Operator's Manual Fourth Edition • Third Printing
2 Z-34/22IC PartNo.1000048
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
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
energizedpowerlines.Personnelonthegroundor
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 occupants 2
The weight of options and accessories, such as
pipecradles, panelcradlesand welders,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.
Donot 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.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 3
CE and Australia Markets: 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 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.
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.
Maximumsloperating,stowedposition,2WD
Counterweightuphill 37% 20°
Counterweightdownhill 20% 11°
Sideslope 25% 14°
Maximumsloperating,stowedposition,4WD
Counterweightuphill 45% 24°
Counterweightdownhill 40% 22°
Sideslope 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.
Maximumallowable
side force - ANSI &
CSA
150 lbs / 667 N
Maximumallowable
manual force - CE
90 lbs / 400 N
Do not alter or disable machine components that
in any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
SAFETY RULES

Operator's Manual Fourth Edition • Third Printing
4 Z-34/22IC PartNo.1000048
SAFETY RULES
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
complywithapplicable
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 gate before operating.
Do not place or attach overhanging loads to any
part of this machine.
Do not place ladders or scaffolds in the platform
or against any part of this machine.
Do not 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
withoutprior writtenpermission fromthe
manufacturer.Mountingattachmentsforholding
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
platformor the load.
Be sure all tires are in good condition, air-filled
tiresare properly inflated and lugnutsare properly
tightened.
Do not use the machine as a crane.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 5
CollisionHazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position when rotating the
turntable.
Checkthe work area foroverheadobstructions or
otherpossiblehazards.
Be aware of crushing hazards when grasping the
platformguardrail.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
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.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
outand/or precautions have beentakentoprevent
any potential collision.
Nostunt driving or horseplaywhileoperating a
machine.
Component Damage Hazard
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
SAFETY RULES

Operator's Manual Fourth Edition • Third Printing
6 Z-34/22IC PartNo.1000048
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
anopen, well-ventilatedareaaway fromsparks,
flames and lighted tobacco.
Donotoperate the machine in hazardouslocations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Donot spray etherintoengines equipped withglow
plugs.
Damaged Machine Hazards
Donotuse a damaged ormalfunctioningmachine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureall maintenance has been performedas
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
manualsarecomplete,legibleandinthestorage
containerlocatedon the platform.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Alwaysoperatethemachine in a well-ventilated
areatoavoidcarbonmonoxidepoisoning.
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.
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 Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 7
SAFETY RULES
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 Fourth Edition • Third Printing
8 Z-34/22IC PartNo.1000048
Controls
PlatformControlPanel
1 Driveenableswitch
2 Driveenableindicatorlight
3 Auxiliary power switch
4 Platform level switch
5 Hornbutton
6 Primaryboomextend/retract
switch
7 RedEmergencyStop button
8 Notused
9 Batterychargeindicator
(option)
16 Engine start switch
17 Gasoline/LPGmodels:
Gasoline/LPG select switch
18 Boomfunction speed
controller
19 Jibboomup/downswitch
20 Secondaryboomup/down
switch
21 Primaryboomup/downswitch
22 Turntablerotateswitch
23 Platform rotate switch
10 Machine not level indicator
light(ifequipped)
11 Proportionalcontrolhandlefor
drivefunction and thumb
rocker for steer function
12 Platformoverloadindicator
light(ifequipped)
13 Drive speed select switch
14 Gasoline/LPGmodels:Choke
switch
Dieselmodels: Glowplug
switch(option)
15 Engineidle(rpm) select
switch
· Rabbit & foot switch: foot
switch activated high idle
· Turtle:lowidle
· Rabbit:highidle

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 9
CONTROLS
GroundControlPanel
1 Turntablerotateswitch
2 Platform rotate switch
3 Primaryboomup/down
switch
4 Platform level switch
5 Primaryboomextend/
retract switch
6 10Abreakerforengine
electrical circuits
7 10Abreakerforcontrol
electrical circuits
8 Auxiliarypower switch
9 Gasoline/LPGmodels:
Watertemperaturegauge
Diesel models: Oil
temperaturegauge
10 Travelalarm
11 Oilpressuregauge
12 Key switch for platform/off/
groundselection
13 Voltagegauge
14 RedEmergencyStop
button
15 Notused
16 Hourmeter
17 Gasoline/LPGmodels:
Chokeswitch
Dieselmodels: Glowplug
switch(option)
18 Engine start switch
19 Functionenableswitch
20 Gasoline/LPGmodels:Fuel
select switch
21 Platformoverloadindicator
light(ifequipped)
22 Jibboomup/downswitch
23 Primaryboomextend/
retract switch

Operator's Manual Fourth Edition • Third Printing
10 Z-34/22IC PartNo.1000048
Legend
1 Non-steertire
2 Steertire
3 Groundcontrols
4 Secondaryboom
5 Primaryboom
6 Jibboom
7 Platformcontrols
8 Platform
9 Lanyardanchoragepoint
10 Slidingmid-rail
11 Manualstoragecontainer
12 Foot switch

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 11
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operation
inspection.
Knowandunderstandthepre-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-operationinspectionandroutinemaintenance.
Thepre-operationinspectionisavisualinspection
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.
Thepre-operationinspectionalsoservesto
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.
Ifdamage oranyunauthorized variationfrom
factory delivered condition is discovered, the
machinemust be tagged andremovedfrom
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 before 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.

Operator's Manual Fourth Edition • Third Printing
12 Z-34/22IC PartNo.1000048
PRE-OPERATIONINSPECTION
Pre-operation Inspection
RBe sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
RBe sure that all decals are legible and in place.
See Decals section.
RCheck for engine oil leaks and proper fluid
level. Add oil if needed. See Maintenance
section.
RCheck for engine coolant leaks and proper fluid
level. Add coolant if needed. See Maintenance
section.
RCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
RCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenance section.
RCheck for proper tire pressure. Add air if
needed.SeeMaintenancesection.
Checkthefollowing components or areas for
damage,improperly installed ormissingparts and
unauthorizedmodifications:
RElectricalcomponents,wiringandelectrical
cables
RHydraulicpowerunit,reservoir,hoses,
fittings, cylinders and manifolds
RGenerator,beltsandrelatedcomponents
RFuel and hydraulic tanks
RDriveandturntablemotorsandtorquehubs
RBoomwearpads
RTiresandwheels
REngineandrelatedcomponents
RLimit switches
RNuts, bolts and other fasteners
RPlatformentrymid-rail/gate
RBeaconandalarms(ifequipped)
Checkentiremachine for:
RCracks in welds or structural components
RDentsor damagetomachine
RBe sure that all structural and other critical
componentsare present andallassociated
fastenersandpins are in place and properly
tightened.
RAfter you complete your inspection, be sure that
all compartment covers are in place and
latched.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 13
Maintenance
Observe and Obey:
Only routine maintenance items specified in
this manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
Check the Hydraulic Oil Level
Maintaining the 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 Be sure the boom is in the stowed position.
2 Visually inspect the site gauge located on the
side of the hydraulic tank.
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
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.
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.

Operator's Manual Fourth Edition • Third Printing
14 Z-34/22IC PartNo.1000048
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 off.
1 Check the oil level dipstick. Add oil as needed.
Kubota Engine DF-752-E2
Oil type 10W-30
Kubota Engine D-905 B-22
Oil type 10W-30
Perkins Engine 404C-11
Oil type 15W-40
Check the Batteries
Proper battery condition is essential to good engine
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultinenginecomponentdamageandhazardous
conditions.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking
soda and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down bracket is
tight.
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.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 15
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedand qualifiedtoperformmaintenanceon this
machineaccordingto 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.
Check the Tire Pressure
Thisproceduredoesnotneed
to be performed on machines
equipped with the foam-filled
tire option.
Bodily injury hazard. An over-
inflated tire can explode and may
cause death or serious injury.
Tip-over hazard. Do not use
temporary flat tire repair products.
To safeguard maximum stability, achieve
optimum machine handling and minimize tire
wear, it 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
Industrial tire 100 psi 6.89 bar
Rough terrain tire 45 psi 3.1 bar
High flotation tire 44 psi 3.0 bar
MAINTENANCE

Operator's Manual Fourth Edition • Third Printing
16 Z-34/22IC PartNo.1000048
Function Tests
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
2 Alwaysperformapre-operation
inspection.
3 Alwaysperformfunctiontestspriorto
use.
Knowandunderstandthefunctiontests
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.
Theoperator must followthestep-by-step
instructions to test all machine functions.
A malfunctioning machine must 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,accordingtothemanufacturer's
specifications.
Afterrepairsare completed, the operatormust
performapre-operationinspectionandfunction
tests again before putting the machine into service.

Operator's Manual
Fourth Edition • Third Printing
PartNo.1000048 Z-34/22IC 17
FUNCTIONTESTS
1 Select a test area that is firm, level and free of
obstruction.
At the Ground Controls
2 Turn the key switch to ground control.
3 Pull out the red Emergency Stop button to the
onposition.
Result:Thebeacon (if equipped) shouldflash.
4 Startthe engine. See Operating Instructions
section.
TesttheEmergencyStop
5 Push in the red Emergency Stop button to the
off position.
Result: The engine should turn off and all
functionsshould notoperate.
6 Pull out the red Emergency Stop button to
the on position and restart the engine.
TesttheMachineFunctions
7 Donot hold the function enable
switch to either side. Attempt to
activate each boom and platform
function toggle switch.
Result: All boom and platform functions should
notoperate.
8 Hold the function enable switch to either side
and activate each boom and platform function
toggle switch.
Result: All boom and platform functions should
operate through a full cycle. The descent alarm
(ifequipped)should sound while the boom is
lowering.
Test the Tilt Sensor
9 Pull out the platform red Emergency Stop button
to the on position. Turn the key switch to
platformcontrol.
10 Openthe groundcontrol sideturntable coverand
locate the tilt sensor.
11 Press down one side of the tilt
sensor.
Result: The alarm, located in
theplatform,should sound.
TestAuxiliaryControls
12 Turn the key switch to ground control and shut
the engine off.
13 Pull out the red Emergency Stop button to the
onposition.
14 Simultaneouslyholdthe
auxiliarypower switch on and
activate each boom function
toggle switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions should operate.

Operator's Manual Fourth Edition • Third Printing
18 Z-34/22IC PartNo.1000048
FUNCTIONTESTS
At the Platform Controls
TesttheEmergencyStop
15 Turn the key switch to platform control and
restarttheengine.
16 Push in the platform red Emergency Stop button
to the off position.
Result: The engine should turn off and all
functionsshould notoperate.
17 Pull out the red Emergency Stop button and
restarttheengine.
TesttheHorn
18 Push the horn button.
Result:The hornshouldsound.
Testthe FootSwitch
19 Push in the platform red Emergency Stop button
to the off position.
20 Pull out the red Emergency Stop button to 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.
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
machinefunction.
Result: The machine functions should not
operate.
TestMachineFunctions
24 Press down the foot switch.
25 Activate each machine function control handle
or toggle switch.
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
boomfunctionspeedcontroller.
TesttheSteering
26 Press down the foot switch.
27 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.