Genie Z-60 User Manual

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

Contact us:

Internet: http://www.genielift.com
E-mail: [e-mail]

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
"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

Operator's ManualSixth Edition · Second 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 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.

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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

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.

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 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 ManualSixth Edition · Second Printing

SAFETY RULES

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.

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.

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 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.

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.

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.

4 Z-60/34 Part No. 1000209

Lower the platform entry mid-rail or close the entry
gate before operating.

Operator's ManualSixth Edition · Second 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.

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.

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.

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

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

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.

Genie Z-60/34

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.

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.

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.

6 Z-60/34 Part No. 1000209

Operator's ManualSixth Edition · Second Printing

SAFETY RULES

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.

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

1 2 3 4

5

6

19

Platform Control Panel

1 Horn button
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 Z-60/34 Part No. 1000209

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

1820

17

Operator's ManualSixth Edition · Second Printing

CONTROLS

7

8910 11

16

15

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

13

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

12

14

16 Drive enable switch

Part No. 1000209 Z-60/34 9

Operator's Manual Sixth Edition · Second Printing

CONTROLS

Ground Control Panel

1 Turntable rotate switch
2 Primary boom up/down switch
3 Primary boom extend/retract switch
4 Platform overload indicator light (if equipped)
5 Gasoline/LPG models: Fuel select switch
6 Auxiliary power switch
7 Gasoline/LPG models: Water temperature

gauge (option)

Deutz Diesel models: Oil temperature gauge
8 Key switch for platform/off/ground selection
9 Oil pressure gauge (option)
10 Voltage gauge (option)
11 Red Emergency Stop button

10 Z-60/34 Part No. 1000209

12 Gasoline/LPG models: Check engine light
13 Hour meter
14 Secondary boom up/down switch
15 Deutz Diesel models: Glow plug switch

(option)
16 Function enable switch
17 Engine start switch
18 15A breaker for engine electrical circuits
19 20A breaker for oil cooler and options
20 15A breaker for control electrical circuits
21 Jib boom up/down switch
22 Platform level switch
23 Platform rotate switch

Operator's ManualSixth Edition · Second Printing

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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