Par ts Manual

Operator's Manual Supplement

Special Supplement
Serial Number Range

to Genie Industries
Operator's Manual

For Authorized and Trained

Set Lighting Technicians
and Studio Grips

WARNING
This manual is solely for use by set lighting technicians
and studio grips who have completed training offered
by qualified trainers in aerial work platform operation
combined with use of set lighting, camera equipment and
light diffusion frames. Users of this manual must be trained Original Instructions
as Genie aerial work platform operators. Failure to receive Part No. 97636
training and to use the information contained in this
First Edition
supplement and in the operator’s manual may result in
Eighth Printing
death or serious injury.
Operator's Manual Supplement First Edition • Eighth Printing

Special Supplement
to Genie Industries
Operator's Manual
For Authorized and Trained Set Lighting
Technicians and Studio Grips

Important
This is a supplemental manual and modifications
permitted herein are exceptions to normal operation.
Instructions for normal operation are contained in the
Operator's Manual for each machine.

Genie Industries reserves the right to modify this

supplement without notice, or to revoke the
modification approval if the supplement is used in a
manner that creates a safety concern.

Copyright © 1999 by Genie Industries

Contents First Edition, Eighth Printing, February 2022

"Genie" is a registered trademark

Page of Genie Industries in the U.S.A. and many
other countries.
Limited Purpose of this Manual .................................. 3
Proof of Training & Records Retention ....................... 3 These machines comply with
ANSI A92.5
Safety Rules .............................................................. 4 CAN B354.4
Wind Speed Chart ...................................................... 6 CE - Machinery Directive 2006/42/EC

Platform Capacity Reduction Chart ............................ 9 Printed on recycled paper

Material Lifting Applications ...................................... 12 Printed in U.S.A.

2 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

Important Information

Limited Purpose of This

Manual
This Supplemental Manual was prepared by Genie
Industries at the express request of unions
representing Set Lighting Technicians and Studio
Warning Grips. These operators requested Genie's written
permission to use the Approved Models listed
Failure to comply with the following below in certain ways that deviate from Genie's
standard manuals for that equipment. This
requirements may result in death or Supplemental Manual contains Genie's written
serious injury. permission and the requirements that must be
followed by specifically trained operators to enable
them to use the Approved Models in the manner
• Any operator using Genie equipment in the set forth in this Supplemental Manual.
manner set forth in this Supplemental Manual
must be a Set Lighting Technician or Studio
Grip AND must have completed a specific Proof of Training and Records
training course that complies with the
requirements of this Supplemental Manual. If Retention
you are not a Set Lighting Technician or Studio
Qualified trainers shall provide proof of training to
Grip who has received specific training, do not
all successful trainees. The document evidencing
deviate from the requirements of the standard
training shall include the following information:
Genie Operator's Manual for use of Genie
equipment. 1 The name of the person (operator) being trained
• Strict compliance with this Supplemental or retrained.
Manual, as well as Genie's standard Operator's 2 The name of the organization providing training
Manual and Manual of Responsibilities, along or retraining.
with completion of specialized training, is
essential to safe operation of the Approved 3 The name of the trainer(s).
Models as set forth in this supplement. 4 Clear identification that the training covered the
applications contained in this Supplemental
Manual.
Approved Models
5 The date of training.
S®-40 S®-85 XC™ Z®-45/25J
Records of training shall be retained by the trainers
S®-45 S®-100 Z®-34/22 IC for at least four years and shall include all the
information listed above.
S®-60 S®-105 Z®-45 XC™

S®-65 S®-120 Z®-60/34

S®-60HC S®-125 Z®-60/37 FE

S®-80 SX™-125 XC™ Z®-60/37 DC

S®-85 Z®-45/25 Z®-80/60

Part No. 97636 3

Operator's Manual Supplement First Edition • Eighth Printing

Safety Rules
For the Attachment of Set • The aerial lift must be operated only on a firm,
level surface.
Lighting, Camera Equipment
• Operators must be trained and be able to
and Light Diffusion Frames demonstrate proficiency in the operation of the
specific model of Genie aerial lift being
operated.
• Genie booms are not insulated. Precautions
shall be taken to protect the operator and people
on the ground from electrocution hazards. The
attachment of power supply cables to the boom
shall not restrict the movement of the aerial lift
or endanger the operator or people on the
Danger ground.
Failure to comply with the following • Attachment of power supply cables to the boom
shall be accomplished in a manner that does
requirements will result in death or not cause a tip-over hazard due to a side or
serious injury. vertical force that could result in the machine
becoming unstable.
Modification of the Approved Models • Power supply cables must be attached to the
for use by attachment of lights, light end of each boom section in a manner that
mounting hardware, camera mounting ensures the cable cannot be damaged from
tensioning, pinching or crushing when the boom
hardware and light diffusion frames is operated.
(LDFs) to the platform guard rail is
authorized by Genie Industries only if • LDFs hung from the platform guard rail must not
be rigidly attached in any manner that could
the following rules and requirements cause or impose a side or vertical load from
are strictly followed: wind or contact with adjacent objects greater
than the rated side load posted at the entrance
• Operators must have completed training for the to the platform.
attachment of lighting or camera equipment and
LDFs to the platform guard rail. Training must • Attachment of LDFs and rope to the platform
include, but not be limited to, information shall be accomplished in a manner that does
regarding the effect on platform capacity and not cause a tip-over hazard due to a side or
stability resulting from the attachment of vertical force that could result in the machine
equipment to the platform guard rail or to the becoming unstable.
boom of the aerial lift, and hazards associated • Do not alter the guard rail system by drilling,
with this application. welding, crushing, damaging or making any
• All operating instructions and warnings other modifications that compromise the
contained in the Operator’s Manual, Safety strength of the guard rail when attaching movie
Manual and Manual of Responsibilities, and on production equipment.
decals found on the particular Genie aerial lift,
must be followed.

4 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

SAFETY RULES

• The entrance to the platform, the platform

controls, including the foot switch and the
emergency stop button, the lanyard anchorage
points, the platform decals and instruction
container must remain accessible when movie
production equipment is attached to the
platform.
• Operators must not gain access to or exit the
platform by means of walking or climbing on the
boom or lift structure or by attaching a rope or a
hanging ladder from the platform or its
supporting structure. Access to and exit from
the platform shall be accomplished at ground
level only.
• Loading restrictions greater than rated capacity
are provided in this manual and are restricted to
material lifting only.
• Do not exceed rated capacity of the machine
when there are personnel in the platform.
The combined weight of platform attachments,
power supply cables, mounting hardware,
platform occupant(s), tools and equipment must
in all cases remain less than the maximum
rated platform capacity for both personnel lifting
and material only lifting applications. Use the
platform capacity reduction chart found in this
supplement to determine allowable platform
load.
• The number and size of attachments must be
limited by consideration of the maximum
allowable wind speed and the surface area of
platform attachments. Use the wind speed chart
found in this supplement to determine maximum
allowable wind speed.
• Information regarding the attachment of LDFs
and lighting and camera equipment shall be
supplied only to trained union members.
Operators must be familiar with these
supplemental instructions and warnings before
they are allowed to operate any Genie boom
that is approved for this application.

Part No. 97636 5

Operator's Manual Supplement First Edition • Eighth Printing

Wind Speed Chart

For Light Diffusion Frames and
Large Surface Area Platform
Attachments on Genie Booms

Approved Models
S®-40 S®-85 SX™-125 XC™

S®-45 S®-85 XC™ Z®-45/25

S®-60 S®-100 Z®-45/25J
S®-65 S®-105 Z®-34/22 IC

S®-60HC S®-120 Z®-60/34

S®-80 S®-125 Z®-60/37 FE
Z®-80/60

Tip Over Hazard

Using a boom in wind speeds greater than
recommended or exceeding the recommended
surface area of the platform by attaching movie
production equipment will result in the boom
becoming unstable and will result in death or
serious injury.

When movie production equipment, such as light

diffusion frames or set lighting, is attached to a
boom platform, operation in windy conditions is
limited by the frame size (or total surface area of
the equipment) and wind speed as follows:

Maximum
Frame Wind
Size (Area) Speed

4’ x 4’ (16 sq. ft.) 25 mph

6’ x 6’ ( 36 sq. ft.) 25 mph

8' x 8' (64 sq. ft.) 25 mph

12' x 12' (144 sq. ft) 18 mph

20' x 20' (400 sq. ft) 11 mph

6 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

WIND SPEED CHART

For Light Diffusion Frames and

Large Surface Area Platform
Attachments on Genie Booms

Approved Models
Z®-45 XC™

Tip Over Hazard

Using a boom in wind speeds greater than
recommended or exceeding the recommended
surface area of the platform by attaching movie
production equipment will result in the boom
becoming unstable and will result in death or
serious injury.

When movie production equipment, such as light

diffusion frames or set lighting, is attached to a
boom platform, operation in windy conditions is
limited by the frame size (or total surface area of
the equipment) and wind speed as follows:

Maximum
Frame Wind
Size (Area) Speed

4’ x 4’ (16 sq. ft.) 25 mph

6’ x 6’ ( 36 sq. ft.) 25 mph

8' x 8' (64 sq. ft.) 18 mph

12' x 12' (144 sq. ft) 18 mph

20' x 20' (400 sq. ft) 11 mph

Part No. 97636 7

Operator's Manual Supplement First Edition • Eighth Printing

WIND SPEED CHART

For Light Diffusion Frames and

Large Surface Area Platform
Attachments on Genie Booms

Approved Models
Z®-60/37 DC

Tip Over Hazard

Using a boom in wind speeds greater than
recommended or exceeding the recommended
surface area of the platform by attaching movie
production equipment will result in the boom
becoming unstable and will result in death or
serious injury.

When movie production equipment, such as light

diffusion frames or set lighting, is attached to a
boom platform, operation in windy conditions is
limited by the frame size (or total surface area of
the equipment) and wind speed as follows:

Maximum
Frame Wind
Size (Area) Speed

4’ x 4’ (16 sq. ft.) 25 mph

6’ x 6’ ( 36 sq. ft.) 25 mph

8' x 8' (64 sq. ft.) 25mph

12' x 12' (144 sq. ft) 11 mph

20' x 20' (400 sq. ft) 5 mph

8 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

Platform Capacity Reduction Chart

For Determining the Reduction Reduce platform capacity according to the
following:
In Platform Capacity Due To
Attachment Of Movie Production • Attachment of power supply cables to the
boom reduces the platform capacity. Subtract
Equipment To Genie Boom the total suspended weight of cables and
Platforms with Operator(s) in the rigging from the rated platform capacity.
Platform • Subtract the load applied to the platform by
the attachment of additional movie production
equipment (as shown in Illustration 1) by using
Approved Models the procedure and chart on the following
S®-40 S®-85 XC™ Z®-45/25J pages.
S-40, S-60, S-60HC, S-80, S-100, Z-34/22 IC,
S®-45 S®-100 Z®-34/22 IC
Z-45/25, Z-45/25J, Z-60/34 and Z-80/60:
S®-60 S®-105 Z®-45 XC™ • With operator(s) in the platform, no additional
S®-65 S®-120 Z®-60/34 load above rated platform capacity is allowed.
• When used as a material lift only, the payload
S®-60HC S®-125 Z®-60/37 FE
(with adjustment per Platform Capacity
S®-80 SX™-125 XC™ Z®-60/37 DC Reduction Chart) must not exceed the load
shown in the attached load rating range-of-
S®-85 Z®-45/25 Z®-80/60 motion charts.
S-45, S-65, S-85, S-85 XC, S-105, S-120, S-125,
Tip Over Hazard SX-125 XC, Z-45 XC, Z-60/37 DC and Z-60/37 FE:
Exceeding the recommended load restrictions
of the platform by attaching movie production • No additional load above rated platform
equipment will result in the boom becoming capacity is allowed. Personnel and payload
unstable and will result in death or serious (with adjustment per Platform Capacity
injury. Always calculate the reduction of the Reduction Chart) must not exceed the load
platform capacity caused by attachment of more shown in the appropriate Operator's
production equipment. Manual and Decals for your machine.

Theory:
Platform maximum capacity is based on an evenly
distributed load. When movie production equipment,
such as light diffusion frames, set lighting and
camera mounts, are attached to the front of the
platform (entry side), the platform capacity is
reduced by more than the weight of the equipment.
The farther the equipment is mounted from the
center of the platform, the greater the reduction in
platform capacity.
Definition:
Center of Gravity (C.G.): The balance point of an
object. The point at which the entire weight of an
object is concentrated so that if the object is
suspended from that point, it will be balanced.

Part No. 97636 9

Operator's Manual Supplement First Edition • Eighth Printing

PLATFORM CAPACITY REDUCTION CHART

How to use this chart 3 From these numbers, determine the total load of
your equipment on the platform.
Note: The numbers in the shaded area on the chart
Personnel lifting applications: Subtract this
are to be used for material lifting applications only.
number from the maximum platform capacity of
No personnel shall be in the platform if the rated
the machine, as defined in the appropriate
platform capacity is exceeded.
machine operator's manual and decals, to
Follow these steps for each piece of equipment determine the remaining platform capacity.
attached to the platform. Material lifting applications: Subtract this
1 Locate the weight of your equipment in the first number from the maximum platform capacities
column on the chart. Always round up to the called out on the range-of-motion charts on the
next number. following pages.

2 Measure the distance from the back toeboard to S®-45, S®-65, S®-85, S®-85 XC™, S®-105,
the center of gravity of the equipment (distance S®-120, SX-125 XC™, Z®-45 XC™, Z®-60/37 DC
A or distance B). This is the load center. and Z®-60/37 FE: Refer to the appropriate
Refer to Illustration 1. Operator's Manual and decals on your machine
for maximum platform capacity. These models
are not approved for material lifting applications
where rated platform capacity is exceeded.
Example: Lighting equipment and the mounting
bracket used to attach it to the guard rail weigh 167
pounds. Their center of gravity (balance point) is
located at 35 inches from the back toeboard.
Because the load is concentrated at the front guard
rail, its effect on capacity is greater than a
distributed load. The chart tells us that the
reduction in capacity is 241 lbs. On a platform with
a 500 lb capacity, the remaining capacity is 259 lbs
(500-241=259).

Illustration 1

10 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

PLATFORM CAPACITY REDUCTION CHART

Weight of
Equipment Load Center (inches)
(lbs) (Distance from back toeboard to center of gravity of load)

30 36 48 60 72 84 96 108 120 132 144 156

50 67 69 81 94 106 119 131 144 156 169 181 194

75 100 103 122 141 159 178 197 216 234 253 272 291
100 133 138 163 188 213 238 263 288 313 338 363 388
125 167 172 203 234 266 297 328 359 391 422 453 484
150 200 206 244 281 319 356 394 431 469 506 544 581
175 233 241 284 328 372 416 459 503 547 591 634 678
200 267 275 325 375 425 475 525 575 625 675 725 775
225 300 309 366 422 478 534 591 647 703 759 816 872
250 333 344 406 469 531 594 656 719 781 844 906 969
275 367 378 447 516 584 653 722 791 859 928 997
300 400 413 488 563 638 713 788 863 938
325 433 447 528 609 691 772 853 934
350 467 481 569 656 744 831 919
375 500 516 609 703 797 891 984
400 533 550 650 750 850 950
425 567 584 691 797 903
450 600 619 731 844 956
475 633 653 772 891
500 667 688 813 938
525 700 722 853 984
550 733 756 894 = Material Lifting
575 767 791 934 Applications Only
600 800 825 975
625 833 859
650 867 894
675 900 928
700 933 963
725 967 997

Part No. 97636 11

Operator's Manual Supplement First Edition • Eighth Printing

Material Lifting Applications Only

Multiple Platform Load Rating • The Range-of-Motion charts on the following
pages are for use by trained Set Lighting
Range of Motion Charts Technicians and Studio Grips only.
For Booms Used in Material Lifting • Do not exceed the maximum load rating for each
Applications Only. No Operators Shall model shown on the following Range-of-Motion
charts.
be in the Platform.
• The machine must be set on firm, level ground.
• Elevating a boom in windy conditions must be
Tip Over Hazard restricted to the instructions found in this
The following Range-of-Motion charts apply to supplement and in the operator's manual for the
material lifting applications only. No personnel machine being used. Refer to the Wind Speed
shall be in the platform when the boom is used Chart on page 6.
in applications where the rated platform
• Platform loading must be restricted to the
capacity is exceeded. Allowing personnel in the
instructions found in this supplement and in the
boom will result in the boom becoming
operator's manual for the machine being used.
unstable and will result in death or serious
injury. • Do not use machines in tandem for lifting
trusses.
Approved Models To determine boom extension:
S®-40 Z®-45/25 When the boom is lowered, measure for allowable
extension from the lower outside edge of the
S®-60 Z®-45/25J platform to the center line of the turntable bearing.
S®-60HC Z®-34/22 IC
S®-80 Z®-60/34
S®-100 Z®-80/60

boom extension

12 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only

No personnel shall be in the platform while the rated platform capacity is exceeded
65 ft

60 ft

55 ft

50 ft

750 lbs
340 kg
45 ft
1000 lbs
450 kg
40 ft

35 ft

30 ft

25 ft
501 lbs
227 kg

20 ft
750 lbs
340 kg

15 ft

10 ft

5 ft

0 ft
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft

Z®-60/34
Part No. 97636 13
 Operator's Manual Supplement First Edition • Eighth Printing

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

45 ft

40 ft

35 ft
1000 lbs
454 kg
30 ft

750 lbs
340 kg
25 ft

20 ft

501 lbs
227 kg
15 ft
750 lbs
340 kg

10 ft

5 ft

0 ft

-5 ft
-10 ft -5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft

S®-40
14 Part No. 97636
First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

65 ft

60 ft

55 ft

50 ft

45 ft

40 ft

35 ft
750 lbs
1000 lbs 340 kg
450 kg
30 ft

25 ft

501 lbs
227 kg
20 ft
750 lbs
340 kg

15 ft

10 ft

5 ft

0 ft

-5 ft

-10 ft
-10 ft -5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 45 ft 50 ft 55 ft

S®-60 (before serial number 9154)

Part No. 97636 15

Operator's Manual Supplement First Edition • Eighth Printing

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

S®-60 (after serial number 9153)

16 Part No. 97636

First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

S®-60HC
Part No. 97636 17
Operator's Manual Supplement First Edition • Eighth Printing

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

85 ft

80 ft

75 ft

70 ft

65 ft

60 ft

55 ft

50 ft

45 ft
750 Lbs
340 kg 40 ft
1000 lbs
450 kg 35 ft

30 ft

25 ft
501 L
227 k
750 Lbs
340 kg

20 ft
bs
g

15 ft

10 ft

5 ft

0 ft

-5 ft

-10 ft

-15 ft
-10 ft -5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 45 ft 50 ft 55 ft 60 ft 65 ft 70 ft 75 ft

S®-80
18 Part No. 97636
First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded
120 ft

110 ft

100 ft

90 ft

80 ft

70 ft

60 ft

50 ft

40 ft
1000 lbs/
450 kg

30 ft

20 ft

10 ft

0 ft

-10 ft

-20 ft

-20 ft -10 ft 0 ft 10 20 ft 30 ft 40 ft 50 ft 60 ft 70 ft 80 ft 90 ft

S®-100
Part No. 97636 19
Operator's Manual Supplement First Edition • Eighth Printing

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded
90

80

70

60

50

1000 lbs/
40 450 kg

30

20

10

-10

-20

-10 0 10 20 30 40 50 60 70

Z®-80/60
20 Part No. 97636
First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded
50 ft

45 ft

40 ft

75 40 k
0 g
3

lb
s
1000 lbs 35 ft
450 kg

30 ft

25 ft

20 ft
501 lbs
227 kg
750 lbs
340 kg

15 ft

10 ft

5 ft

0 ft

-5 ft
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft

Z®-45/25
Part No. 97636 21
Operator's Manual Supplement First Edition • Eighth Printing

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded
50 ft

45 ft

40 ft

50 27
1 kg
2

lb
s
35 ft
1000 lbs 750 lbs
450 kg 340 kg

30 ft

25 ft

20 ft

15 ft

10 ft

5 ft

0 ft

-5 ft
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft

Z®-45/25J
22 Part No. 97636
First Edition • Eighth Printing Operator's Manual Supplement

MATERIAL LIFTING APPLICATIONS ONLY

Maximum Load Rating Chart for Material Lifting Applications Only
No personnel shall be in the platform while the rated platform capacity is exceeded

40 ft

35 ft

30 ft

875 Lb
397 Kg
25 ft

501 Lb
227 Kg

20 ft

15 ft

10 ft

5 ft

0 ft
-5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft

Z®-34/22 IC
Part No. 97636 23