Genie Z-60/34 User manual

Fourth Edition
First Printing
Part No. 82315
Operator’s Manual
with Maintenance Information

GenieZ-60/34 PartNo.82315
Operator's Manual Fourth Edition · First Printing
Copyright © 1993 by Genie Industries
First Edition: First Printing, February 1993
Second Edition: Third Printing, September 1996
Third Edition: Sixth Printing, November 2001
Fourth Edition: First Printing, July 2002
"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, 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 is
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
Pre-operationInspection ........................................... 11
Maintenance ............................................................. 13
Function Tests .......................................................... 17
WorkplaceInspection ................................................ 23
OperatingInstructions ............................................... 24
Decals ...................................................................... 28
TransportInstructions ............................................... 30
Specifications ........................................................... 32
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]

PartNo.82315 GenieZ-60/34 1
Operator's ManualFourth Edition · First 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 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey:
Manufacturer's instructions and safety
rules—safetyand operator's manuals
and machine decals
employer's safety rules and worksite
regulations
applicablegovernmentalregulations
You are properly trained to safely operate the
machine.

2 GenieZ-60/34 Part No.82315
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 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 Approach Distance
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 and equipment 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.
Do not rotate the boom while lowering. Move the
machine to a firm, level surface before raising the
platform.

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Operator's ManualFourth Edition · First Printing
SAFETY RULES
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 & Australia
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.
Mounting attachments for holding tools or other
materials onto the platform, toeboards or guard rail
system can increase the weight in the platform and
the surface area of the platform or the load.
Do not place or attach overhanging loads to any
part of the machine.
Do not place ladders or scaffolds in the platform or
against any part of the machine.
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
groundcontrols.
Do not alter or disable the limit switches.
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, 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.

4 GenieZ-60/34 Part No.82315
Operator's Manual Fourth Edition · First Printing
SAFETY RULES
Do not use the machine on a moving or mobile
surface or vehicle.
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.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchor provided in the
platform.
It is recommended that operators wear an approved
hard hat when operating the machine.
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.
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.

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Operator's ManualFourth Edition · First Printing
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.
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom unless the area below is
clear of personnel and obstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
No stunt driving or horseplay while operating a
machine.
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.
SAFETY RULES

6 GenieZ-60/34 Part No.82315
Operator's Manual Fourth Edition · First Printing
SAFETY RULES
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
damagedor malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the
Genie Z-60/34
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.
Component Damage Hazard
Do not use the machine as a ground for welding.
Be sure the hydraulic shutoff valves (located by the
hydraulic tank) are open before starting the engine.
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
area to avoid carbon monoxide poisoning.
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 lighted tobacco away
from the battery. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Component Damage Hazard
Do not use any battery or charger greater than 12V
to jump-start the engine or charge the battery.

PartNo.82315 GenieZ-60/34 7
Operator's ManualFourth Edition ·First Printing
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
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.
Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
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—usedtoindicate operation
ormaintenanceinformation.
SAFETY RULES

8 GenieZ-60/34 Part No.82315
Operator's Manual Fourth Edition ·First Printing
PlatformControl Panel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 Jib boom up/down switch
5 Auxiliary power switch
6 Drive speed select switch
7 Glow plug switch (option)
8 Engine start switch
9 Engine idle (rpm) control switch
- Rabbit and foot switch symbol:
foot switch activated high idle
- Turtle symbol: low idle
- Rabbit symbol: high idle
10 Gasoline/LPGmodels:Gasoline/LPG
select switch
Deutz Diesel models: Glow plug switch (option)
11 Red Emergency Stop button
1 2 3 4 56
16
1719 18
Controls

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Operator's ManualFourth Edition ·First Printing
CONTROLS
12 Proportional control handle for drive function and
thumb rocker for steer function
OR dual axis proportional control handle for
drive and steer functions
13 Optionalequipment
14 Drive enable indicator light
15 Drive enable switch
16 Proportional control handle for secondary boom
up/downfunction
17 Primary boom extend/retract switch
18 not used
19 Dual axis proportional control handle for primary
boom up/down and turntable rotate left/right
functions
89 10 11
12
15 13
13
14
7

10 GenieZ-60/34 PartNo. 82315
Operator's Manual Fourth Edition ·First Printing
Ground Control Panel
1 Platform rotate switch
2 Turntable rotate switch
3 Primary boom up/down switch
4 Primary boom extend/retract switch
5 Secondary boom up/down switch
6 Key switch for platform/off/ground selection
7 Auxiliary power switch
8 Gasoline/LPGmodels:Water temperature
gauge(option)
Deutz Diesel models: Oil temperature gauge
9 Oilpressure gauge (option)
10 Voltagegauge(option)
11 Red Emergency Stop button
12 Hourmeter
13 Gasoline/LPG models: Check engine light
Deutz Diesel models: Glow plug switch
(option)
14 Function enable switch
15 Engine start switch
16 15A breaker for engine electrical circuits
17 Gasoline/LPG select switch
18 15A breaker for control electrical circuits
19 Jib boom up/down switch
20 Platform level switch
11
12
15171920 1618
7
6
8 9 10
1
2
3
5
4
14
13
CONTROLS

PartNo.82315 Genie Z-60/34 11
Operator's ManualFourth Edition ·First Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
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-operationInspectionand 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 and locations for modifications,
damage or loose or missing parts.
A damaged or modified machine must never be
used. If damage or any 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 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.

12 GenieZ-60/34 PartNo. 82315
Operator's Manual Fourth Edition ·First Printing
PRE-OPERATIONINSPECTION
Pre-operation Inspection
oBe sure that the operator’s, safety and
responsibilities manuals are complete, legible
and in the storage container located in the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
oCheck for engine coolant leaks and proper level
of coolant. Add coolant if needed. See
Maintenancesection.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
oCheck for proper tire pressure. Add air if needed.
See Maintenance section.
Check the following components or areas for
damage, modifications and improperly installed or
missing parts:
oElectrical components, wiring and
electrical cables
oHydraulic hoses, fittings, cylinders and
manifolds
oFuel and hydraulic tanks
oDrive and turntable motors and drive hubs
oBoom wear pads
oTires and wheels
oEngine and related components
oLimit switches and horn
oAlarms and beacons (if equipped)
oNuts, bolts and other fasteners
oPlatform entry mid-rail or gate
Check entire machine for:
oCrack in welds or structural components
oDents or damage to machine
oBe sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
oAfter you complete your inspection, be sure that
all compartment covers are in place and
latched.

PartNo.82315 Genie Z-60/34 13
Operator's ManualFourth Edition ·First Printing
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
responsibilitiesmanual.
MaintenanceSymbolsLegend
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
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.
Indicates that a cold engine is required
beforeperformingthis procedure.
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 dipstick.
Fordmodels:
Result: The oil level should be between the ADD
and SAFE marks. Add oil as needed.
Deutzmodels:
Result: The oil level should be within the two
marks on the dipstick. Add oil as needed.
Ford LRG-425 EFI Engine
Oil viscosity requirements
below 60°F / 15.5°C 5W-30
-10°to 90°F / -23°to 32°C 5W-30
above -10°F / -23°C 5W-30
above 25°F / -4°C 10W-30
Use oils meeting API classification SH or SG grade.
Units ship with 10-40 CC/SG.

14 GenieZ-60/34 PartNo. 82315
Operator's Manual Fourth Edition ·First Printing
MAINTENANCE
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 that the boom is in the stowed position
2 Visually inspect the sight gauge located on the
side of the hydraulic oil tank. Add oil as needed.
Result: The hydraulic oil level should be within
the top 2 inches / 5 cm of the sight gauge.
Hydraulic oil specifications
Hydraulic oil type Chevron Rykon®
Premium MV equivalent
Deutz F4L 1011F Engine
Oil viscosity requirements
below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
above -4°F / -34°C 15W-40
Engine oil should have properties of API classification
CC/SE or CC/SF grades.
Units ship with 10-40 CC/SG.

PartNo.82315 Genie Z-60/34 15
Operator's ManualFourth Edition ·First Printing
Check the Engine Coolant Level
- Gasoline/LPG Models
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.
Burn hazard. Beware of hot engine
parts and coolant. Contact with hot
engine parts and/or coolant may
cause severe burns.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed.
Result: The fluid level should be at the
FULL mark.
Bodily injury hazard. Fluids in the
radiatorare under pressure and
extremely hot. Use caution when
removing cap and adding fluids.
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.
This procedure does not need to
be performed on machines with
sealedormaintenance-free
batteries.
Electrocution hazard. Contact with
hot or live circuits may result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
andwater.
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 bar is in
place.
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.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.
MAINTENANCE

16 GenieZ-60/34 PartNo. 82315
Operator's Manual Fourth Edition ·First Printing
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-
inflated tire can explode and could
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. Add
air as needed.
Tire specifications Tire Size Pressire
Rough Terrain 15-19.5 NHS 65 psi
4.5 bar
Hi-floation 41/18LL x 22.5 65 psi
4.5 bar
MAINTENANCE
Scheduled Maintenance
Maintenanceperformedquarterly, 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.

PartNo.82315 Genie Z-60/34 17
Operator's ManualFourth Edition ·First Printing
Function Tests
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 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, 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.
SymbolLegend
Indicates that a specific result is expected after
performing a series of steps.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
2 Alwaysperforma pre-operation
inspection.
3 Alwaysperformfunction testspriorto
use.
Knowandunderstandthefunctiontests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

18 GenieZ-60/34 PartNo. 82315
Operator's Manual Fourth Edition ·First Printing
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 on position.
Result: The beacon (if equipped) should flash.
4 Start the engine. See Operating Instructions
section.
Test Emergency Stop
5 Push in the red Emergency Stop button to the
off position.
Result: The engine should turn off and all
functions should not operate.
Deutz Diesel models: The engine will shut off
after 2 to 3 seconds.
6 Pull out the red Emergency Stop button to
the on position and restart the engine.
TesttheMachineFunctions
7 Do not 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
not operate.
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
(if equipped) should sound while the boom is
lowering.
Machines equipped with Platform Level Control
Disable Function: The platform level toggle switch
will not operate when the primary boom is raised
or extended or the secondary boom is raised past
the drive speed limit switches.
Test the Tilt Sensor
9 Pull out the platform red Emergency Stop button
to the on position.
10 Turn the key switch to platform
control.
11 Open the control panel side
turntable cover and locate the tilt
sensor next to the control box.
12 Press down one side of the tilt
sensor.
Result: The alarm, located in the
platform, should sound.
TestAuxiliaryControls
13 Turn the key switch to ground control and shut
the engine off.
14 Pull out the red Emergency Stop button to the
on position.
15 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.
Result: All boom functions should operate.
FUNCTIONTESTS