Operator`s Manual
Contents
1. 28178 Chassis al eC 28285 27207 KJ i S 7 44981 28178 _ T s 28176 30080 27206 L 28165 27205 S Platform 28236 or 52967 or 44986 or 97548 or 97571 28181 mmes or 114169 L 97602 40434 m a 9 27564 ZZZzzz ZZZ KY E 28161 Engine 31059 316 o H or Side 52965 44981 28161 114244 114166 114244 Genie A TEREX COMPANY Part No 1000209 Z 60 34 31 Operators Manual DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in Sixth Edition Second Printing a as place Part No Decal Description Quantity Part No Decal Description Quantity 27204 Arrow Blue 1 82472 Warning Crushing Hazard 4 27205 Arrow Yellow 1 82473 Caution Compartment Access 1 27206 Triangle Blue 2 82487 Label Read the Manual 2 27207 Triangle Yellow 2 82545 Danger Maximum Capacity 227 kg 1 28158 Label Unleaded 1 82548 Warning Platform Rotate 2 28159 Label Diesel 1 82589 Label Tire Press2. 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 Part No 1000209 Sixth Edition Second Printing Operator s Manual Test the Machine Functions 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 S FUNCTION TESTS Test Auxiliary Controls 13 Turn the key switch to grou
3. 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Genie Z 60 34 Fundamentals It is the responsibility of the operator to perform a Pre operation Inspection and 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 If damage or any unauthorized 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 Part No 1000209 Sixth Edition Second Printing Operator s Manual Pre operation Inspection L J
4. Genie i a Operator s Manual eine l l econd Printing with Maintenance Information Part No 1000209 Z 60 34 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 sese eee eee 1 Ieai 8 LOGON PA E E 11 Pre operation Inspection se eee eee eee eee 12 Malintenanee eneee a aE ri a et 14 FUNCTION TESS scienee arini 18 Workplace Inspection sese ee eee eee 23 Operating Instructions sss eee eee eee 24 Decals isian ia aE 30 Transport and Lifting Instructions sse sees ee eee 34 Specifications ae zesxvgoovet zez vgvooosg aza niia 37 Copyright 1993 by Genie Industries Contact us First Edition First Printing February 1993 Second Edition Third Printing September 1996 Internet http www genielift com Third Edition Sixth Printing November 2001 E mail techpub genieind com 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
5. 16 ply Gradeability stowed 2WD 4WD 27 45 Ground clearance 16 in 40 1 cm Fuel tank capacity 33 gallons 125 liters Weight See Serial Label Machine weights vary with option configurations 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 Floor loading information Controls 12V DC proportional 5 Tire load maximum 9 931 lbs 4504 kg Platform dimensions 6 foot 30 x 72 in width x length 76cmx1 8m Tire contact pressure 65 psi 4 57 kg cm2 448 kPa Platform dimensions 8 foot 36 x 96 in width x length 91 erm x 2 4 m Occupied pressure 254 psf 1240 kg m 12 16 kPa Platform leveling self leveling Note Floor loading information is approximate and Platform rotation 180 does not incorporate different option configurations It hould b ly with fety f AC outlet in platform OR should be used only with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie Part No 1000209 Z 60 34 37 Operator s Manual Sixth Edition Second Printing SPECIFICATIONS Z 60 34 Range of Motio
6. Be sure that the operators safety and responsibilities manuals are complete legible and in the storage container located in the platform 1 Be sure that all decals are legible and in place See Decals section L Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section L Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section L Check for engine coolant leaks and proper level of coolant Add coolant if needed See Maintenance section L Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section L J Check for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications 1 Electrical components wiring and electrical cables 1 Hydraulic hoses fittings cylinders and manifolds 1 Fuel and hydraulic tanks _ Drive and turntable motors and drive hubs L Boom wear pads _ Tires and wheels 1 Engine and related components PRE OPERATION INSPECTION _ Limit switches and horn J Alarms and beacons if equipped J Nuts bolts and other fasteners J Platform entry mid rail or gate Check entire machine for J Crack in welds or structural components J Dents or damage to machine Excessive rust corrosion or oxidation LJ Be sure that all
7. 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 500 Ibs 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 on the options Do not raise or extend the boom unless the machine is on a firm level surface va 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 so
8. move drive control handle A Machine may drive in opposite direction A that drive and steer controls are moved O Use color coded direction arrows on this panel and drive hasas to identify the direction machine will travel X O O 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 Part No 1000209 Genie Z 60 34 CONTROLS STOP 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 Operators Manual Sixth Edition Second Printing CONTROLS SR RO 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 B 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 Volt
9. structural and other critical components are present and all associated fasteners and pins are in place and properly tightened LJ After you complete your inspection be sure that all compartment covers are in place and latched Genie Part No 1000209 A TEREX COMPANY Z 60 34 13 Operators Manual Sixth Edition Second Printing Maintenance Observe and Obey KI Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual 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 Indicates that a cold engine is required before performing this 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 Add oil as needed Perk
10. 4 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 5 chains Adjust the rigging to prevent damage to the chains Truck bed TRANSPORT AND LIFTING INSTRUCTIONS Securing the Platform Make sure the jib and platform are in the stowed position Place a wooden block under the platform rotator Do not allow the block to contact the platform cylinder Secure the platform with a nylon strap placed through the lower platform support Do not use excessive downward force when securing the boom section Genie Part No 1000209 A TEREX COMPANY Z 60 34 35 Operator s Manual Sixth Edition Second Printing TRANSPORT AND LIFTING INSTRUCTIONS Lifting Instructions Fully lower and retract the boom Move the jib perpendicular with the ground Remove all loose items on the machine Use the turntable rotation lock to secure the turntable Observe and Obey Determine the center of gravity of your machine M Only qualified riggers should rig and lift the using the picture on this page machine Attach the riggi
11. a 28175 Gaons mpana Access 1 97548 Notice Deutz Engine Specifications 1 28176 Notice Wissing Manuais 1 97571 pes Ford Engine Specifications FOUL yaring P atori Ole 2 97602 Warning Explosion Hazard 1 GT Poll 2 97815 Label Lower Mid rail 1 28181 ___Waming No Step or Ride 1 97875 Label Weld Cable to Platform option 2 28235 Label Power to Platform 115V 2 97887 Notice Maximum Side Force 28236 Warning Failure To Read 1 150 Ibs 667 N ANSI and CSA 1 30080 Notice Max Capacity 500 Ibs 227kg 1 97890 Danger General Safety 2 31059 Warning Collision Hazard 2 114166 Label Transport Diagram 2 31060 Danger Tip over Hazard Interlock 2 114169 Notice Ford Engine Specifications 32728 Label Generator option 1 E l 114244 Label Wheel Load 4 33952 Danger Tilt Alarm 1000210 Notice Operating Instructions 2 Genie 30 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual DECALS 1000210 97890 28160 28161 31059 Serial 98174 or 28235 Ground Controls Side 40434 SU 28171 25994 82366 28158 or 28159 114244 27564 S U e YR a S A L E 114166 82316 or 82229 ae 52968 82238 27204 aS ey 32728 L l f T 1000210 27207 T T 97815
12. age gauge option 11 Red Emergency Stop button 10 16 17 18 19 20 21 22 23 Genie SIS Gasoline LPG models Check engine light Hour meter Secondary boom up down switch Deutz Diesel models Glow plug switch option Function enable switch Engine start switch 15A breaker for engine electrical circuits 20A breaker for oil cooler and options 15A breaker for control electrical circuits Jib boom up down switch Platform level switch Platform rotate switch A TEREX COMPANY Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual 1 2 3 4 5 6 7 8 9 Legend Foot switch Manual storage container Sliding mid rail Lanyard anchorage point Non steer tire Steer tire Ground controls Primary boom Jib boom 10 Platform controls 11 Platform 12 Secondary boom Genie A TEREX COMPANY Part No 1000209 Z 60 34 11 Operators Manual Sixth Edition Second Printing Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section
13. ch to either side and slowly move the drive control handle off center Result The drive function should operate Note When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved q1 Yellow Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction of travel Test the Oscillate Axle oscillating axle equipped models 40 Start the engine from the platform controls 41 Drive the right steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground 42 Drive the left steer tire up onto a 6 inch 15cm block or curb Result The three remaining tires should stay in firm contact with the ground 43 Drive both steer tires up onto a 6 inch 15 cm block or curb Result The non steer tires should stay in firm contact with the ground Genie Part No 1000209 A TEREX COMPANY Z 60 34 21 Operators Manual Sixth Edition Second Printing FUNCTION TESTS Test Limited Drive Speed 44 Press down the foot switch 45 Raise the primary boom approximately 2 feet 61 cm 46 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 47 Lower the primary boom to the stowed pos
14. 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 Genie A TEREX COMPANY 6 Z 60 34 Part No 1000209 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 ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING 2 ge used to indicate the prese
15. comply with ANSI SIA 92 5 1992 g Printed on recycled paper Printed in U S A enie A TEREX COMPANY 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 M 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals M You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine Genie A TEREX COMPANY Part No 1000209 Z 60 34 1 Operators 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 N i NY a is i Maintain safe distances from electrical power lines and
16. e while the generator is running and the foot switch is not pressed down When the foot switch is pressed down the generator will turn off and the machine functions will operate Genie A TEREX COMPANY 28 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Check Engine Light if equipped T Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Machine Not Level Indicator Light if equipped A Light on indicates the machine is not level The tilt alarm will be sounding when this light is on Move the machine to a firm level surface a Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off OPERATING INSTRUCTIONS Fall Protection Personal fall protection equipment PFPE is required when operating this machine All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions 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 p
17. es then switched to LPG Warm engines can be started on LPG Emergency Stop Push in either the ground or platform red Emergency Stop button to the off position to stop all functions and turn the engine off Repair any function that operates when the red Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform red Emergency Stop button Genie Part No 1000209 A TEREX COMPANY Z 60 34 25 Operators Manual Sixth Edition Second Printing OPERATING INSTRUCTIONS Auxiliary Controls Use auxiliary power only if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when operating the auxiliary controls from the platform The drive function will not operate with auxiliary power 4 Simultaneously hold the auxiliary power switch on and activate the desired function Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Start the engine To Position Platform 1 Hold the function enable switch to either side 2 Move the appropriate toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls Operation from Platform 1 Turn the key switch to platform control 2 Pull ou
18. esel 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 rh N 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 pr
19. ess 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 26 Do not press down the foot switch and restart the engine Result The engine should start 27 Do not press down the foot switch Test each machine function Result The machine functions should not operate Test the Machine Functions 28 Press down the foot switch 29 Activate each machine function control handle or toggle switch Result All boom platform functions should operate through a full cycle 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 Steering 30 Press down the foot switch 31 Press the thumb rocker switch on top of the drive control handle in the direction indicated by the blue triangle on the control panel OR slowly move the control handle in the direction indicated by the blue triangle Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 32 Press the thumb rocker switch on top of the drive control handle in the direction indicated by the yellow triangle on the control panel OR slowly move the control handle in the direction indicated by the yellow triangle Result The steer wheels should turn
20. event any potential collision Genie Part No 1000209 A TEREX COMPANY Z 60 34 Operators 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
21. 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 Check the Tire Pressure This procedure does not need to be performed on machines equipped with the foam filled tire option AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING 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 pressure 65 psi 4 5 bar High flotation tire pressure 65 psi 4 5 bar Genie A TEREX COMPANY 16 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual IMS MAINTENANCE Scheduled Maintenance Maintenance performed quarterly 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 Genie A TEREX COMPANY Part No 1000209 Z 60 34 17 Operators Manual Sixth Edition Second Printi
22. ility 2WD 25 14 4WD 40 22 GEL g mS Note Slope rating is subject to ground conditions and adequate traction The term gradeability applies to the counterweight uphill configuration only Maximum slope rating counterweight downhill 2WD 20 11 4WD 30 17 Maximum side slope rating 25 14 Be sure the boom is below horizontal and the platform is between the non steer wheels Move the drive speed select switch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Part No 1000209 Genie Z 60 34 27 OPERATING INSTRUCTIONS Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example lt run rise bA Piece of wood 144 inches 3 6 m Run 144 inches 3 6 m Rise 12 inches 0 3 m 12 in 144 in 0 083 x 100 8 3 grade 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rati
23. imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Operators Manual Sixth Edition Second Printing Operating Instructions Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 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 Genie 24 Z 60 34 Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial worksite is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Part N
24. in the direction that the yellow triangles point on the drive chassis Genie A TEREX COMPANY 20 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Test Drive and Braking 33 Press down the foot switch 34 Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 35 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Drive Enable System 36 Press down the foot switch and lower the boom to the stowed position 37 Rotate the turntable until the primary boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 38 Move the drive control handle off center Result The drive function should not operate FUNCTION TESTS 39 Move and hold the drive enable toggle swit
25. ins 404 22 Engine Oil type 15W 40 Oil type cold conditions 5W 40 Ford Engine EPA Compliant Oil type 10W 40 Oil type cold conditions 5W 30 Deutz F3L 2011F Engine Tier Il Oil type 15W 40 Oil type cold conditions 5W 30 Genie A TEREX COMPANY 14 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s 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 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 MAINTENANCE 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 ACAUTION engine part
26. ition 48 Extend the primary boom approximately 2 feet 61 cm 49 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot 30 cm per second 50 Retract the primary boom to the stowed position 51 Raise the secondary boom approximately 2 feet 61 cm 52 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 foot 30 cm per second 53 Lower the secondary boom to the stowed position Note If the drive speed with the primary boom raised or extended or the secondary boom raised exceeds 1 foot 30 cm per second immediately tag and remove the machine from service Test Auxiliary Controls 54 Shut the engine off 55 Pull out the red Emergency Stop button to the on position 56 Press down the foot switch 57 Simultaneously hold the auxiliary power switch on and activate each function control handle or toggle switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Drive functions should not operate with auxiliary power Test the Lift Drive Select Function if equipped 58 Press down the foot switch 59 Move the drive control handle off center and activate a boom function toggle switch Result No boom func
27. n 70 ft 21 4m 60 ft 18 3m 50 ft 15 3m 40 ft 12 2m 30 ft 9 2m 20 ft 6 1m 10 ft 3 1m 0 ft 10ft 20ft 30 ft 40 ft Om 3 1m 6 1m 9 2m 12 2m Genie A TEREX COMPANY 38 Z 60 34 Part No 1000209 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 5511 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
28. nce of a potentially A hazardous situation which if not avoided could result in death or serious injury gt Yellow with safety alert symbol ACAUTION used to indicate the presence of a 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 CAUTION Green used to indicate operation or maintenance information Genie Part No 1000209 A TEREX COMPANY Z 60 34 7 Operators Manual Sixth Edition Second Printing Controls Platform Control Panel 1 2 3 4 5 6 7 Horn button Platform level switch Platform rotate switch Jib boom up down switch Auxiliary power switch Drive speed select switch Glow plug switch option D 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 Genie A TEREX COMPANY Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual DRIVE ENABLE OPERATION Light on indicates that boom has moved past a non steer tire and A drive function is Q turned off To drive hold drive enable switch to side and slowly
29. nd Controls Side U 82671 82646 82238 32728 11T 97815 LA 82487 le 28174 ee e or 28235 44981 52965 82605 Part No 1000209 82671 Genie A TEREX COMPANY Hh 82545 82602 Platform or 82604 A J 82473 EO L T 82472 114244 82589 114166 114244 82589 Z 60 34 33 Operators Manual Sixth Edition Second Printing Transport and Lifting Instructions Observe and Obey M Genie Industries provides this securement information as a recommendation Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations other localized regulations and their company policy MI Genie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing loading and securing construction and lifting equipment for international shipment M Only qualified aerial lift operators should move the machine on or off the truck M The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded M Be
30. nd 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 At the Platform Controls Test Emergency Stop 16 Turn the key switch to platform control and restart the engine 17 Push in the platform 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 or 3 seconds 18 Pull out the red Emergency Stop button and restart the engine Genie Part No 1000209 A TEREX COMPANY Z 60 34 19 Operators Manual Sixth Edition Second Printing FUNCTION TESTS Test the Hydraulic Oil Return Filter 19 Move the engine idle select switch to high idle rabbit symbol 20 Locate and check the hydraulic filter Result The indicator should be in the green area 21 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol Test the Horn 22 Push the horn button Result The horn should sound Test the Foot Switch 23 Push in the platform red Emergency Stop button to the off position 24 Pull out the red Emergency Stop button to the on position but do not start the engine 25 Pr
31. ng Function Tests Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Genie Z 60 34 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 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
32. ng then the machine must be winched or transported up or down the slope See Transport and Lifting section Operators Manual Sixth Edition Second Printing OPERATING INSTRUCTIONS Drive Enable Light on indicates that the primary boom has moved just past either non steer wheel and the drive function has been d interrupted To drive hold the drive enable switch to either side and slowly move the drive control handle off center Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded Be T direction arrows on the platform controls and drive chassis to q identify the direction the machine will travel olor Drive Speed Select Yellow Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Engine Idle Select rpm Select engine idle rpm using the symbols on the control panel When the foot switch is not pressed the engine will idle at its lowest rpm gt Turtle symbol foot switch activated low idle Rabbit symbol foot switch activated high idle Generator if equipped To start the generator move the generator toggle switch to the on position Plug a power tool into the power to platform GFCI outlet To turn off the generator move the generator toggle switch to the off position Note Machine functions will not operat
33. ng only to the designated lifting Be sure the crane capacity loading surfaces points on the machine There are four lifting points and straps or lines are sufficient to withstand on the chassis the machine weight See the serial plate for the machine weight Adjust the rigging to prevent damage to the machine and to keep the machine level Chassis Lifting Points 2 Lifting Points 2 Genie A TEREX COMPANY 36 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Specifications Height working maximum 66 ft 20 1 m Height platform maximum 60 ft 18 3 m Height stowed maximum 8 ft 10 in 2 7m Horizontal reach maximum 34 ft 10 4m Width 8 ft 1in 2 5m Length stowed 26 ft 9 in 8 2m Maximum load capacity 500 Ibs 227 kg Maximum wind speed 28 mph 12 5 m s Wheelbase 8 ft 3 in 2 5m Turning radius outside 40 ft 1 in 12 2 m Turning radius inside 19 ft 9 in 6 1m Turntable rotation degrees continuous Turntable tailswing 0 Drive speed stowed 4 0 mph 6 4 km h 40 ft 6 8 sec12 2 m 6 8 sec Drive speed raised or extended 0 6 mph 1 0 km h 40 ft 40 sec 12 2 m 40 sec Airborne noise emissions 105 dB Maximum sound level at normal operating workstations A weighted Hydraulic pressure maximum 2400 psi 166 bar boom functions System voltage 12V Tires 15 x 19 5
34. o 1000209 Sixth Edition Second Printing Operator s Manual Starting the Engine 1 At the ground controls turn the key switch to the desired position 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position Gasoline LPG models 3 Choose fuel by moving the fuel select switch to the desired position 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds Diesel models 3 Move the glow plug switch if equipped to either side and hold for 3 to 5 seconds 4 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds OPERATING INSTRUCTIONS All models If engine fails to start after 15 seconds of cranking determine the cause and repair any malfunction Wait 60 seconds before trying to start again In cold conditions 20 F 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage In extreme cold conditions 0 F 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 0 F 18 C may require the use of a booster battery Gasoline LPG models In cold conditions 20 F 6 C and below the machine should be started on gasoline and warmed for 2 minut
35. osition and remove the key to secure from unauthorized use 5 Chock the wheels Genie Part No 1000209 A TEREX COMPANY Z 60 34 29 Operators Manual Sixth Edition Second Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Decal Description Quantity Part No Decal Description Quantity 25994 Caution Component Damage 1 40434 Label Lanyard Anchorage 3 27204 Arrow Blue 1 44981 Label Air Line to Platform option 2 27205 Arrow Yellow 1 44986 Notice Maximum Manual Force 27206 Tangs Blue lt 90 Ibs 400 N CE and Australia 1 27207 Trlangl Vellow gt 52965 Cosmetic Genie Z 60 34 1 27564 Danger Electrocution Hazard 2 pees Ga 1 28158 Label Unleaded jy Sa RE 28159 Label Diesel 1 52968 Cosmetic Genie Boom 1 28160 babel Liquid Petrolaum Gas opin 1 82229 Notice Tire Specifications High Flotation 4 28161 Warning Crtshing Hazard 3 82238 Platform Control Panel 1 28164 Notice Hazardous Materials 1 A TE S 28165 Notice lt Foot Switch 1 82366 Label Chevron Rykon 1 28171 Label No Smoking 1 82644 Notice Perkins Engine Specifications 1 28174 Lapel Power to Platform 230V a ee Se
36. ous 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 i force ANSI and CSA EN 150 Ibs 667 N a ii Maximum allowable manual force CE and 2 Australia 90 Ibs 400 N N E Genie Part No 1000209 A TEREX COMPANY Z 60 34 3 Operators 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 no
37. s 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 radiator are under pressure and extremely hot Use caution when removing cap and adding fluids Genie Part No 1000209 A TEREX COMPANY Z 60 34 15 Operators Manual Sixth Edition Second Printing MAINTENANCE 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 sealed or maintenance free batteries Electrocution hazard Contact with AWARNING hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton 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
38. sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial plate for the machine weight See the Decals section for the serial plate location MI Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation M Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section MI If the slope of the transport vehicle bed exceeds the uphill or downhill maximum slope rating the machine must be loaded and unloaded using a winch as described See the Specifications section for the slope ratings Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling 2WD models Release the non steer wheel brakes by turning over the drive hub disconnect caps Disengage 4WD models Release the wheel brakes by turning over all four drive hub disconnect caps Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstruction Reverse the procedures described to re engage the brakes Note The pump free wheel valve should always remain closed Note Towing the Genie Z 60 34 is not recommended If the machine must be towed do not exceed 2 mph 3 2km h Genie A TEREX COMPANY 3
39. t both the ground and platform red Emergency Stop buttons to the on position 3 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slowly move the appropriate function control handle or toggle switch according to the markings on the control panel To Steer 1 Press down the foot switch 2 Slowly move the control handle in the direction indicated by the blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction triangles on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward the center Stop Return the drive control handle to the center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the booms are raised or extended Genie A TEREX COMPANY 26 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating counterweight uphill gradeab
40. t place or attach overhanging loads to any part of the machine d L 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 Genie A TEREX COMPANY 4 Z 60 34 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 H AN ASA 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 Part No 1000209 Sixth Edition Second Printing Operator s Manual Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline di
41. tions should operate The machine will move in the direction indicated on the control panel 60 Repair any malfunctions before operating the machine Genie A TEREX COMPANY 22 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The Workplace Inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Part No 1000209 Genie Z 60 34 23 Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations drop offs or holes bumps floor obstructions or debris sloped surfaces unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces
42. unds 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 Genie A TEREX COMPANY 2 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual 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 Ne YW 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 hazard
43. ure 4 28160 Label Liquid Petroleum Gas option 1 82671 Label Weld Cable to Platform option 2 28171 Label No Smoking 1 82602 Danger Maximum Side Force 28174 Label Power to Platform 230V 2 Berane 28235 Label Power to Platform 115V 2 Benth meee vee 1 32728 Label Generator option 1 82605 Warning Collision Hazard 2 40434 Label Lanyard Anchorage 3 82606 Warning Shear Point 2 44981 Label Air Line to Platform option 2 82646 Label Drive Enable Patch 1 52965 Cosmetic Genie Z 60 34 1 82673 Ground Control Panel 1 52966 Cosmetic 4 x 2 1 82924 Caution Component Damage 1 52967 Cosmetic 4x 4 1 97815 Label Lower Mid rail 1 52968 Cosmetic Genie Boom 1 114166 Label Transport Diagram 2 82238 Platform Control Panel 1 114244 Label Wheel Load 4 82544 Danger Electrocution Hazard 2 82548 Warning Platform Rotate 2 Genie 32 Z 60 34 Part No 1000209 Sixth Edition Second Printing Operator s Manual 28171 82924 28158 or 28159 82487 28 Serial 160 28174 or 28235 82472 82605 114166 82589 52968 27204 27206 g e JL Chassis 27207 meo 82606 27207 82606 aia 27206 br 97205 rT x 52966 i or 52967 6 ENI S Engine Side DECALS Grou
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