Genie Z-60/34 User manual

Operator’s Manual
Z-60 34
Seventh Edition
First Printing
Part No. 133083
Serial Number Range
after 00000
with
Maintenance
Information
CE

Operator's Manual
Z-60/34 Part No.133083
Seventh 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
Introduction ................................................................ 1
Symbol and Hazard Pictorial Definitions..................... 3
GeneralSafety ........................................................... 5
Personal Safety ......................................................... 8
Work Area Safety....................................................... 9
Legend ...................................................................... 17
Controls .................................................................... 18
Inspections ............................................................... 25
OperatingInstructions ............................................... 36
Transport and Lifting Instructions .............................. 46
Maintenance ............................................................. 49
Specifications ........................................................... 53
Contact us:
Internet:www.genielift.com
E-mail:[email protected]
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
Fifth Edition: Second Printing, August 2004
Sixth Edition: Second Printing, June 2006
Seventh Edition: First Printing, December 2007
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
Printed on recycled paper
Printed in U.S.A.

Operator's ManualSeventh Edition · First Printing
Part No.133083 Z-60/34 1
Introduction
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
1 Avoid hazardous situations.
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.
You read, understand and obey the
manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.
You read, understand and obey employer's
safety rules and worksite regulations.
You read, understand and obey all applicable
governmental regulations.
You are properly trained to safely operate the
machine.
Owners, Users and Operators:
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmental rules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use good safe work practices in a
commonsense way.
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, running the machine.
If there is anything in this manual that is not clear
or which you believe should be added, please
contact us.
Internet: www.genielift.com
E-mail: [email protected]

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2 Z-60/34 Part No.133083
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to
an aerial work site.
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal
words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a hazardous situation
which, if not avoided, could result
in property damage.
Red
Orange
Yellow
Blue

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Part No.133083 Z-60/34 3
Symbol and Hazard Pictorials Definitions
CrushHazard Explosion Hazard Fire Hazard ExplosionHazard Electrocution
Hazard
FallHazard Crush Hazard Tip-overHazard Tip-over Hazard Tip-overHazard
Tip-overHazard Tip-over Hazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface.
Keep away from
moving parts.
Keep away from
path of moving
platform.
No smoking.
No flame.
Stopengine.
Do not use ether
or other high
energystarting
aids on machines
equippedwith
glow plugs.
Read service
manual
Ratedplatform
capacity
Platform uphill:
1 Lower primary
2 Lower secondary
3 Retract primary
Platformdownhill:
1 Retract primary
2 Lower secondary
3 Lower primary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.
Onlytrained
maintenance
personnelshould
access
compartments

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4 Z-60/34 Part No.133083
Symbol and Hazard Pictorials Definitions
Lanyard
attachment point
Wheelload Voltage rating for
power to platform
Pressure rating for
air line to platform
Avoid contact. Tie-down
instructions
Tie-down
instructions
Fireextinguisher
Weight of welder
reduces capacity
Windspeed
Turntable lock can
shear.
Keep away from
moving parts.
Collisionhazard Keep away from
moving parts.
Tirepressure

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Part No.133083 Z-60/34 5
General Safety
Safety signs and locations

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General Safety
Safety signs and locations

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Part No.133083 Z-60/34 7
General Safety
Safety signs and locations

Operator's Manual Seventh Edition · First Printing
8 Z-60/34 Part No.133083
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

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Part No.133083 Z-60/34 9
Work Area Safety
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
accordancewith
applicable
governmental
regulations and the
followingchart.
Line Voltage Required Clearance
0 to 50KV 3.0 m
50 to 200KV 4.6 m
200 to 350KV 6.1 m
350 to 500KV 7.6 m
500 to 750KV 10.6 m
750 to 1000KV 13.7 m
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.
Do not operate the machine during lightning or
storms.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
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
with the options.
If using accessories, read, understand and obey
the decals and instructions with the accessory.

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10 Z-60/34 Part No.133083
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
while the boom is
lowered: 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. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with the platform uphill:
1 Lower the primary boom.
2 Lower the secondary boom.
3 Retract the primary boom.
If the tilt alarm sounds with the
platformdownhill:
1 Retract the primary
boom.
2 Lowerthesecondary
boom.
3 Lowertheprimary
boom.
Do not raise the boom
when wind speeds may
exceed 12.5 m/s. If
wind speeds exceed
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
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.
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.
Work Area Safety
3
3

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Part No.133083 Z-60/34 11
Work Area Safety
Do not place or attach
overhangingloadsto
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.
Be sure all tires are in good condition, air-filled tires
are properly inflated and lug nuts are properly
tightened.
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 push off or pull
toward any object
outside
of the platform.
Maximum allowable
manual force
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 replace factory-installed tires with tires of
different specification or ply rating.
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, toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.

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12 Z-60/34 Part No.133083
Fall Hazards
Occupants must wear a
safety belt or harness
in accordance with
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.
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 enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
the maximum uphill, downhill or side slope rating of
the machine. Slope rating applies only to machines
in the stowed position.
Maximum slope rating, stowed position, 2WD
Platform downhill 25% (14°)
Platform uphill 20% (11°)
Side slope 25% (14°)
Maximum slope rating, stowed position, 4WD
Platform downhill 40% (22°)
Platform uphill 30% (17°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions Section.
Work Area Safety

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Collision Hazards
Be aware of limited
sight distance and blind
spots when driving or
operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overheadobstructions
or other possible
hazards.
Be aware of crushing
hazardswhen grasping
the platform guard rail.
Operators must comply
with employer, job site
andgovernmental rules
regarding the use of
personalprotective
equipment.
Observe and use the
color-codeddirection
arrows on the platform
controls and drive
chassis for drive and
steer functions.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or
horseplaywhile
operating a machine.
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.
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.
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.
Work Area Safety

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14 Z-60/34 Part No.133083
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.
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 Genie
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 Hazards
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.
Work Area Safety
Battery Safety
Burn Hazards
Batteries contain acid.
Always wear protective
clothing and eye wear
whenworkingwith
batteries.
Avoid spilling or
contacting battery acid.
Neutralize battery acid
spills with baking soda
andwater.
Explosion Hazard
Keep sparks, flames
and lighted tobacco
away from batteries.
Batteries emit
explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.

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Pipe Cradle Safety
Read, understand and obey all warnings and
instructions provided with the pipe cradles.
Do not exceed the rated platform capacity. The
pipe cradle assembly and the weight in the pipe
cradles will reduce rated platform capacity and
must be factored into total platform load.
The pipe cradle assembly weighs 9.5 kg.
The maximum capacity of the pipe cradle assembly
is 91 kg.
The weight of the pipe cradle assembly and the
load in the pipe cradles may limit the maximum
number of occupants in platform.
Center the load within the perimeter of the platform.
Secure the load to the platform.
Do not obstruct the entrance or the exit of the
platform.
Do not obstruct the ability to operate the platform
controls or the red Emergency Stop button.
Do not operate unless you are adequately
instructed and are aware of all of the hazards
associated with movement of the platform with an
overhangingload.
Do not cause a horizontal force or side load to the
machine by raising or lowering a fixed or
overhangingload.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.
Panel Cradle Safety
Read, understand and obey all warnings and
instructions provided with the panel cradles.
Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, occupants,
tools and any other equipment must not exceed
rated capacity.
The panel cradle assembly weighs 13.6 kg.
The maximum capacity of the panel cradles is
113 kg.
The weight of the panel cradles and the load in the
panel cradles may limit the maximum number of
occupants in platform to one person.
Secure the cradles to the platform. Secure the
panel(s) to the platform railing using the straps
provided.
Do not operate unless you are adequately
instructed and are aware of all hazards associated
with lifting panels.
Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhangingload.
Maximum vertical height of panels: 1.2 m
Maximum panel area: 3 m2
Work Area Safety

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16 Z-60/34 Part No.133083
Work Area Safety
Lockout After Each Use
1 Select a 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.
Welder Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected and the welder is properly grounded.
The weight of the welder will reduce the rated
platform capacity and must be factored into the
total platform load. The welder power supply weighs
34 kg.
Do not operate the welder unless a fire extinguisher
is immediately available for instant use, per OSHA
regulation1926.352(d).
Weld Line to Platform Safety
Read, understand and obey all warnings and
instructions provided with the welding power unit.
Do not connect weld leads or cables unless the
welding power unit is turned off at the platform
controls.
Do not operate unless the weld cables are properly
connected.
Connect the positive lead to the twist-lock
connector at the turntable and platform.
Clamp the negative lead to the ground post at the
turntable and platform.

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Part No.133083 Z-60/34 17
Legend
1 Foot switch
2 Manual storage container
3 Sliding mid rail
4 Lanyard anchorage point
5 Non- steer tire
6 Steer tire
7 Ground controls
8 Primary boom
9 Jib boom
10 Platform controls
11 Platform
12 Secondary boom

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18 Z-60/34 Part No.133083
Controls
Platform Control 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
- Turtle symbol: low idle
- Rabbit symbol: high idle
10 Gasoline/LPG models: Gasoline/LPG
select switch
11 Red Emergency Stop button
1 2 3 4 56
17
1820 19