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Genie Z-60, Z-34 manual

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Table of contents for the manual

  • Page 1

    Sixth Edition Second Printing Part No. 1000209 Operator’ s Manual with Maintenance Information[...]

  • Page 2

    Operator's Manual Sixth Edition · Second Printing Z-60/34 Par t N o . 1000209 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[...]

  • Page 3

    Operator's Manual Sixth Edition · Second Printing P ar t No . 1000209 Z-60/34 1 Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injur y . Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid [...]

  • Page 4

    Operator's Manual Sixth Edition · Second Printing 2 Z-60/34 Part No . 1000209 SAFETY RULES Electrocution Hazar ds 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 gover[...]

  • Page 5

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 3 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. Slo[...]

  • Page 6

    Operator's Manual Sixth Edition · Second Printing 4 Z-60/34 Part No . 1000209 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 an[...]

  • Page 7

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 5 Explosion and Fire Hazard s 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,[...]

  • Page 8

    Operator's Manual Sixth Edition · Second Printing 6 Z-60/34 Part No . 1000209 Damaged Machine Hazar ds 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 al[...]

  • Page 9

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 7 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 possib[...]

  • Page 10

    Operator's Manual Sixth Edition · Second Printing 8 Z-60/34 Part No . 1000209 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 Engine start switch 9 Engine idle (rpm) control switch - Turtle symbol:[...]

  • Page 11

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 9 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 equippe[...]

  • Page 12

    Operator's Manual Sixth Edition · Second Printing 10 Z-60/34 Par t No . 1000209 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 temp[...]

  • Page 13

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 11 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[...]

  • Page 14

    Operator's Manual Sixth Edition · Second Printing 12 Z-60/34 Par t No . 1000209 Pre-operation Inspection Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operati[...]

  • Page 15

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 13 PRE-OPERATION INSPECTION Pre-operation Inspection R Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform. R Be sure that all decals are legible and in place. See Decals sectio[...]

  • Page 16

    Operator's Manual Sixth Edition · Second Printing 14 Z-60/34 Par t No . 1000209 Maintenance Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator. Scheduled maintenance inspections shall be completed by qualified service technicians, according to the manufacturer's specifications and[...]

  • Page 17

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 15 MAINTENANCE Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic oil levels can damage hydraulic components. Daily checks allow the inspector to identify changes in oil level that mig[...]

  • Page 18

    Operator's Manual Sixth Edition · Second Printing 16 Z-60/34 Par t No . 1000209 Chec k the Tire Pressure This procedure does not need to be performed on machines equipped with the foam-filled tire option. Bodily injury hazard. An over- inflated tire can explode and could cause death or serious injury. Tip-over hazard. Do not use temporary fla[...]

  • Page 19

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 17 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. Mac[...]

  • Page 20

    Operator's Manual Sixth Edition · Second Printing 18 Z-60/34 Par t No . 1000209 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 Op[...]

  • Page 21

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 19 Test Auxiliary Controls 13 Turn the key switch to ground control and shut the engine off. 14 Pull out the red Emergency Stop button to the on position. 15 Simultaneously hold the auxiliary power switch on and activate each boom function toggle switch. Note: To con[...]

  • Page 22

    Operator's Manual Sixth Edition · Second Printing 20 Z-60/34 Par t No . 1000209 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 switc[...]

  • Page 23

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 21 FUNCTION TESTS 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: [...]

  • Page 24

    Operator's Manual Sixth Edition · Second Printing 22 Z-60/34 Par t No . 1000209 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 rais[...]

  • Page 25

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 23 W orkplace Inspection W orkplace 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 conduct[...]

  • Page 26

    Operator's Manual Sixth Edition · Second Printing 24 Z-60/34 Par t No . 1000209 Operating Instructions Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior[...]

  • Page 27

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 25 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 t[...]

  • Page 28

    Operator's Manual Sixth Edition · Second Printing 26 Z-60/34 Par t No . 1000209 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 indic[...]

  • Page 29

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 27 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 (gradeability): 2WD: 25% (14°) 4WD: 40% (22°) Maximum slope rating, counterweight downhill: 2WD: 20[...]

  • Page 30

    Operator's Manual Sixth Edition · Second Printing 28 Z-60/34 Par t No . 1000209 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 interrupted. To drive, hold the drive enable switch to either side and slowly move the drive control handle off [...]

  • Page 31

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 29 Chec k Engine Light (if equipped) 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) Light on indicates the machine is [...]

  • Page 32

    Operator's Manual Sixth Edition · Second Printing 30 Z-60/34 Par t No . 1000209 Decals Part No. Decal Description Quantity 25994 Caution - Component Damage 1 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 27206 Triangle - Blue 2 27207 Triangle - Yellow 2 27564 Danger - El ectrocution Hazard 2 28158 Label - Unleaded 1 28159 Label - Diesel 1 28160[...]

  • Page 33

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 31 DECALS Engine Side Ground Controls Side Chassis Platform[...]

  • Page 34

    Operator's Manual Sixth Edition · Second Printing 32 Z-60/34 Par t No . 1000209 DECALS Part No. Decal Description Quantity 27204 Arrow - Blue 1 27205 Arrow - Yellow 1 27206 Triangle - Blue 2 27207 Triangle - Yellow 2 28158 Label - Unleaded 1 28159 Label - Diesel 1 28160 Label - Liquid Petroleum Gas (option) 1 28171 Label - No Smoking 1 28174 [...]

  • Page 35

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 33 DECALS Engine Side Ground Controls Side Chassis Platform[...]

  • Page 36

    Operator's Manual Sixth Edition · Second Printing 34 Z-60/34 Par t No . 1000209 Free-wheel Configuration fo r 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. 4WD models: Release the wheel brakes by turning over all four drive hub disco[...]

  • Page 37

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 35 TRANSPORT AND LIFTING INSTRUCTIONS Securing to T ruck or T railer fo r T ransit 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 mach[...]

  • Page 38

    Operator's Manual Sixth Edition · Second Printing 36 Z-60/34 Par t No . 1000209 TRANSPORT AND LIFTING INSTRUCTIONS Observe and Obey: Only qualified riggers should rig and lift the machine. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight. See the serial plate for the machine weigh[...]

  • Page 39

    Operator's Manual Sixth Edition · Second Printing P ar t No. 1000209 Z-60/34 37 Specifications Height, working maximum 66 ft 20.1 m Height, platform maximum 60 ft 18.3 m Height, stowed maximum 8 ft 10 in 2.7 m Horizontal reach maximum 34 ft 10.4 m Width 8 ft 1 in 2.5 m Length, stowed 26 ft 9 in 8.2 m Maximum load capacity 500 lbs 227 kg Maxim[...]

  • Page 40

    Operator's Manual Sixth Edition · Second Printing 38 Z-60/34 Par t No . 1000209 SPECIFICATIONS Z-60/34 Range of Motion 0 ft 10 ft 20 ft 30 ft 40 ft 0m 3.1m 6.1m 9.2m 12.2m 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 0m[...]

  • Page 41

    Distributed By: California Proposition 65 W ARNING W ARNING 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 + 6[...]