Genie Z-60 User Manual

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Operator’s Manual

with Maintenance Information

Sixth Edition

Second Printing

Part No. 1000209

Operator's Manual	Sixth Edition · Second 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 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
Legend ......................................................................	11
Pre-operation Inspection ...........................................	12
Maintenance .............................................................	14
Function Tests ..........................................................	18
Workplace Inspection ................................................	23
Operating Instructions ...............................................	24
Decals ......................................................................	30
Transport and Lifting Instructions ..............................	34
Specifications ...........................................................	37

Internet: http://www.genielift.com

E-mail: techpub@genieind.com

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

"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.



Z-60/34	Part No.1000209

Sixth Edition · Second 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:

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.



Part No. 1000209	Z-60/34	1

Operator's Manual	Sixth Edition · Second Printing

SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current.

Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart.

Voltage		Minimum Safe
Phase to Phase	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 operate the machine during lightning or storms.

Do not use the machine as a ground for welding unless the machine is equipped with the weld line to platform option and it is properly connected.

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 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.

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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Do not use the platform controls to free a platform that is caught, snagged or otherwise prevented from normal motion by an adjacent structure. All personnel must be removed from the platform before attempting to free the platform using the ground controls.

Do not alter or disable the limit switches.

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 the stowed position across uneven terrain, debris, unstable or slippery surfaces and near holes and drop-offs.

SAFETY RULES

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.

Maximum slope rating, stowed position, 2WD

Counterweight uphill	25% (14°)

Counterweight downhill	20% (11°)

Side slope	25% (14°)

Maximum slope rating, stowed position, 4WD

Counterweight uphill	40% (22°)

Counterweight downhill	30% (17°)

Side slope	25% (14°)

Note: Slope rating is subject to ground conditions and adequate traction.

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 push off or pull toward any object outside of the platform.

Maximum allowable side force - ANSI and CSA

150 lbs / 667 N

Maximum allowable manual force - CE and Australia

90 lbs / 400 N



Part No. 1000209	Z-60/34	3

Operator's Manual	Sixth Edition · Second Printing

SAFETY RULES

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.

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 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 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 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.



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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.

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.

Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

SAFETY RULES

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.



Part No. 1000209	Z-60/34	5

Operator's Manual	Sixth Edition · Second 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 damaged or 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 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 unless the machine is equipped with the weld line to platform option and is properly connected.

Bodily Injury Hazards

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.

Weld Line to Platform Safety (if equipped)

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 leads to the twist-lock connectors at the turntable and platform.



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Sixth Edition · Second Printing	Operator's Manual

Battery Safety

Burn Hazards

Batteries contain acid. Always wear protective clothing and eye wear 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.

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 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—used to indicate operation or maintenance information.



Part No. 1000209	Z-60/34	7

Operator's Manual	Sixth Edition · Second Printing

Controls

Platform Control Panel

1Horn button

2Platform level switch

3Platform rotate switch

4Jib boom up/down switch

5Auxiliary power switch

6Drive speed select switch

7Glow plug switch (option)

8Engine start switch

9Engine idle (rpm) control switch

-Turtle symbol: low idle

-Rabbit symbol: high idle

10Gasoline/LPG models: Gasoline/LPG select switch

11Red Emergency Stop button



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Sixth Edition · Second Printing	Operator's Manual

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 Platform overload indicator light (if equipped)

14 Machine not level indicator light (if equipped)

15 Drive enable indicator light

16 Drive enable switch

17 Proportional control handle for secondary boom up/down function

18 Primary boom extend/retract switch

19 Optional equipment

20 Dual axis proportional control handle for primary boom up/down and turntable rotate left/ right functions



Part No. 1000209	Z-60/34	9

Operator's Manual	Sixth Edition · Second Printing

CONTROLS



















Ground Control Panel
1	Turntable rotate switch	12	Gasoline/LPG models: Check engine light
2	Primary boom up/down switch	13	Hour meter
3	Primary boom extend/retract switch	14	Secondary boom up/down switch
4	Platform overload indicator light (if equipped)	15	Deutz Diesel models: Glow plug switch
5	Gasoline/LPG models: Fuel select switch		(option)
6	Auxiliary power switch	16	Function enable switch
7	Gasoline/LPG models: Water temperature	17	Engine start switch
	gauge (option)	18	15A breaker for engine electrical circuits
	Deutz Diesel models: Oil temperature gauge	19	20A breaker for oil cooler and options
8	Key switch for platform/off/ground selection	20	15A breaker for control electrical circuits
9	Oil pressure gauge (option)	21	Jib boom up/down switch
10	Voltage gauge (option)	22	Platform level switch
11	Red Emergency Stop button	23	Platform rotate switch

Z-60/34

Part No. 1000209

Sixth Edition · Second Printing	Operator's Manual

Legend

1 Foot switch

2 Manual storage container

3 Sliding mid rail

4 Lanyard anchorage point

5 Nonsteer tire

6 Steer tire

7 Ground controls

8 Primary boom

9 Jib boom

10 Platform controls

11 Platform

12 Secondary boom



Part No. 1000209	Z-60/34	11

+ 28 hidden pages