Terex Genie Z-30/20N Operator's Manual
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Terex Genie Z-30/20N Operator's Manual

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Operator's Manual
Z
-30/20N
®
Z
-30/20N RJ
®
Serial Number Range
from Z30NF-22000
from Z30ND-1400
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Seventh Edition
First Printing
Part No. 1297932GT

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  • Page 1 Operator's Manual Serial Number Range -30/20N ® from Z30NF-22000 ANSI/CSA North America -30/20N RJ ® from Z30ND-1400 South America Asia with Maintenance Information Original Instructions Seventh Edition First Printing Part No. 1297932GT...

  • Page 2: Table Of Contents

    Maintenance ............51 Specifications ............53 Copyright © 1995 Terex Corporation Seventh Edition: First Printing, February 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI A92.20 CSA B354.6...

  • Page 3: Introduction

    Seventh Edition • First Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Seventh Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom Platform rotate switch up/down, and secondary boom retract/lower.
  • Page 5 Seventh Edition • First Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual Seventh Edition • First Printing Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.
  • Page 7 Seventh Edition • First Printing Operator's Manual Introduction Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Seventh Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 9 Seventh Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Corrosive acid. Color coded direction Runaway hazard Collision hazard Collision hazard arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated.

  • Page 10: General Safety

    Operator's Manual Seventh Edition • First Printing General Safety General Safety 31060 31060 WARNING Annual Inspection Record Failure to complete required inspections could result in death or serious injury. Scheduled maintenance Use the maintenance inspections must be inspection report in the completed as specified in service manual for required the appropriate service...
  • Page 11 Seventh Edition • First Printing Operator's Manual General Safety 31788 31508 **31060 31787 **1298847 1263543 *218550 114390 *1299791 218559 114397 219487 1298837 28236 31060 72875 These decals are model, option or configuration specific. These decals are installed on both sides of chassis. ®...
  • Page 12 Operator's Manual Seventh Edition • First Printing General Safety 114252 114252 133067 82487 1263542 1286362 1263542 133067 ® ® -30/20N • Z -30/20N RJ Part No. 1297932GT...
  • Page 13 Seventh Edition • First Printing Operator's Manual General Safety 114334 1299439 82481 82487 114252 1263542 **114249 *219954 133067 *1299792 219958 114248 219956 1299436 82487 114252 82487 These decals are model, option or configuration specific. These decals are installed on both sides of chassis. ®...

  • Page 14: Personal Safety

    Operator's Manual Seventh Edition • First Printing Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 15: Work Area Safety

    Seventh Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Tip-over Hazards Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity. not provide protection from contact with or proximity to electrical current.
  • Page 16 Operator's Manual Seventh Edition • First Printing Work Area Safety Do not use the platform controls to free a platform If the tilt alarm sounds while the boom is lowered: that is caught, snagged, or otherwise prevented Do not extend, rotate or raise the boom above from normal motion by an adjacent structure.
  • Page 17 Seventh Edition • First Printing Operator's Manual Work Area Safety Do not drive the machine on a slope that exceeds Do not place ladders or the maximum uphill, downhill or side slope rating of scaffolds in the platform or the machine. Slope rating applies only to machines against any part of this in the stowed position.
  • Page 18 Operator's Manual Seventh Edition • First Printing Work Area Safety Operation on Slopes Hazards Do not sit, stand, or climb on the platform guard Do not drive the machine on a slope that exceeds rails. Maintain a firm the maximum uphill, downhill or side slope rating of footing on the platform the machine.
  • Page 19 Seventh Edition • First Printing Operator's Manual Work Area Safety Collision Hazards Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Be aware of limited sight and steer functions. distance and blind spots when driving or operating.
  • Page 20 Operator's Manual Seventh Edition • First Printing Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of the and/or burn skin.
  • Page 21 Seventh Edition • First Printing Operator's Manual Work Area Safety Battery Safety Component Damage Hazard Burn Hazards Do not use any battery charger greater than 48V to charge the batteries. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Both battery packs must be charged together.
  • Page 22 Operator's Manual Seventh Edition • First Printing Work Area Safety Contact Alarm Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the contact alarm. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 23: Legend

    Seventh Edition • First Printing Operator's Manual Legend Legend Non-steer tire Jib boom Battery box Platform controls Steer tire 10 Platform Power to charger (between steer tires) 11 Lanyard anchorage points Ground controls 12 Sliding mid-rail Secondary boom 13 Manual storage container Primary boom 14 Foot switch ®...

  • Page 24: Controls

    Operator's Manual Seventh Edition • First Printing Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 25 Seventh Edition • First Printing Operator's Manual Controls Platform Control Panel Drive enable switch 11 Proportional control handle for drive function and thumb rocker for steer function Drive enable indicator light 12 Platform overload indicator light (if equipped) Auxiliary power switch 13 Function Override - Aircraft Protection Package Platform level switch (if (if equipped)

  • Page 26: Inspections

    Operator's Manual Seventh Edition • First Printing Inspections Inspections Pre-operation Inspection 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. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 27 Seventh Edition • First Printing Operator's Manual Inspections Pre-operation Inspection Check entire machine for:  Cracks in welds or structural components  Be sure that the operator’s, safety and  Dents or damage to machine responsibilities manuals are complete, legible and in the storage container located in the Check entire machine for: platform.
  • Page 28 Operator's Manual Seventh Edition • First Printing Inspections Function Test 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 Do Not Operate Unless: tagged and removed from service.
  • Page 29 Seventh Edition • First Printing Operator's Manual Inspections Test the Tilt Sensor At the Ground Controls Turn the key switch to Select a test area that is firm, level and free of platform control. Pull out the hazards. platform red Emergency Turn the key switch to ground control.
  • Page 30 Operator's Manual Seventh Edition • First Printing Inspections Note: Control the speed of boom functions by At the Platform Controls adjusting the boom function speed controller. Drive 14 Turn the key switch to platform control. and steer functions are not affected by the boom function speed controller.
  • Page 31 Seventh Edition • First Printing Operator's Manual Inspections 27 Slowly move the control handle in the direction 31 Hold the drive enable toggle switch up or down indicated by the yellow arrow on the control and slowly move the drive control handle off panel until the machine begins to move, then center.
  • Page 32 Operator's Manual Seventh Edition • First Printing Inspections 38 Lower the secondary boom to the stowed 46 Lower the primary boom to the stowed position. position. 39 Extend the primary boom approximately 1 ft / Result: The machine should drive. 30 cm.
  • Page 33 Seventh Edition • First Printing Operator's Manual Inspections 54 Lower the secondary boom to the stowed 62 Return to level ground and stow the boom. position or drive in the opposite direction. 63 With the boom fully stowed, drive the machine Result: The machine should drive.
  • Page 34 Operator's Manual Seventh Edition • First Printing Inspections Test Aircraft Protection Package Test the Contact Alarm (if equipped) (if equipped) 72 Do not activate the foot switch and press on the contact alarm cable to release the actuator Note: Two people may be required to perform this from the switch socket.
  • Page 35 Seventh Edition • First Printing Operator's Manual Inspections 77 Insert the actuator into the switch socket. Test Auxiliary Power Result: The lights and horn will turn off. 79 Pull out the red Emergency Stop button to the on position. 78 Operate each machine function. 80 Press down the foot switch.
  • Page 36 Operator's Manual Seventh Edition • First Printing Inspections Workplace Inspection 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.
  • Page 37 Seventh Edition • First Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 82592 Ground Control Panel Determine whether the decals on your machine 97815 Label – Lower Mid-rail have words or symbols. Use the appropriate inspection to verify that all decals are legible and in 114117 Notice –...
  • Page 38 Operator's Manual Seventh Edition • First Printing Inspections 31060 1263546 114390 *82366 38149 1294398 31508 *133286 *44980 72086 37053 *72875 37056 52475 31060 37055 31788 72086 31787 **1298847 31785 114117 52475 37056 *1278982 **139586 72086 **72833 *1278542 52475 31788 37054 *48732 72081 1263543...
  • Page 39 Seventh Edition • First Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 114249 Label – Tip-over Hazard, Tires** 114252 Label – Tip-over Hazard, Limit Determine whether the decals on your machine Switches have words or symbols. Use the appropriate 114334 Label –...
  • Page 40 Operator's Manual Seventh Edition • First Printing Inspections 114252 133067 1263542 *82366 38149 1294398 114334 *133286 *44980 72086 37053 52475 *82487 37056 72086 114252 82481 52475 1299439 82487 *1278982 37056 **114249 1263542 72086 **139586 *1278542 52475 37055 37054 82481 **1297941 72081 *48732 133067...

  • Page 41: Operating Instructions

    Seventh Edition • First Printing Operator's Manual Operating Instructions Operating Instructions 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.
  • Page 42 Operator's Manual Seventh Edition • First Printing Operating Instructions To Position Platform Emergency Stop Hold the function enable switch Push in the red Emergency Stop button to the off to either side. position at the ground controls or the platform controls to stop all functions.
  • Page 43 Seventh Edition • First Printing Operator's Manual Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the control grade.
  • Page 44 Operator's Manual Seventh Edition • First Printing Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the boom use the following procedure. has moved just past either non-steer wheel and the drive You will need: function has been interrupted.
  • Page 45 Seventh Edition • First Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Tilt Sensor Activation Settings If the tilt alarm sounds when the Model Chassis Angle Chassis Angle (side to side) (front to back) platform is raised, use extreme caution.
  • Page 46 Operator's Manual Seventh Edition • First Printing Operating Instructions Platform Overload Indicator Light Contact Alarm (if equipped) The contact alarm is designed to alert ground Light flashing indicates the personnel when an operator makes contact with platform is overloaded and no the platform control panel, interrupting boom functions will operate.
  • Page 47 Seventh Edition • First Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.
  • Page 48 Operator's Manual Seventh Edition • First Printing Operating Instructions Standard Batteries Remove the battery vent caps and check the battery acid level. If necessary, add only enough distilled water to cover the plates. Do not overfill prior to the charge cycle. Replace the battery vent caps.

  • Page 49: Transport And Lifting Instructions

    Seventh Edition • First Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 50 Adjust the rigging to prevent damage to the chains. rolling. Apply the non-steer wheel brakes by turning over the drive hub disconnect caps. Towing the Genie Z-30/20N is not recommended. If the machine must be towed, do not exceed 2 mph / 3.2 km/h. ®...
  • Page 51 Seventh Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Platform Make sure the jib and platform are in the stowed position. Place a block under the edge of the platform beneath the platform entry. Secure the platform with a nylon strap placed over the platform mount near the platform rotator (see below).
  • Page 52 Operator's Manual Seventh Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 53: Maintenance

    Seventh Edition • First Printing Operator's Manual Maintenance 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 Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic ...
  • Page 54 Operator's Manual Seventh Edition • First Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 55: Specifications

    Seventh Edition • First Printing Operator's Manual Specifications Specifications Z-30/20N without rotating jib Ground clearance 3.5 in 8.9 cm Height, working maximum 36 ft 11 m Weight (Machine weights vary with option configurations. See Height, platform maximum 30 ft 9.1 m serial label for specific machine weight.) Height, stowed maximum 6 ft 7 in...
  • Page 56 Operator's Manual Seventh Edition • First Printing Specifications Ground clearance 3.50 in 8.9 cm Z-30/20N with rotating jib Weight Height, working maximum 35 ft 2 in 10.7 m (Machine weights vary with option configurations. See Height, platform maximum 29 ft 2 in 8.89 m serial label for specific machine weight.) Height, stowed maximum...
  • Page 57 Seventh Edition • First Printing Operator's Manual Specifications Range of Motion Chart, Z-30/20N & Z-30/20N RJ +75° -67° Max Height Max Reach 30 ft 9.1 m 0 ft 25 ft 7.6 m 5 ft 1.5 m 20 ft 6.1 m 10 ft 15 ft 4.6 m 15 ft 4.6 m...
  • Page 58 Operator's Manual Seventh Edition • First Printing Specifications Range of Motion Chart, Rotating Jib, Z-30/20N RJ Max Rotate Max Reach 5 ft 1.5 m 0 ft 0 ft 5 ft 1.5 m 5 ft 1.5 m 10 ft 15 ft 4.6 m ®...

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