Terex Genie Z-51/30J Operator's Manual
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Terex Genie Z-51/30J Operator's Manual

Terex Genie Z-51/30J Operator's Manual

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Operator's Manual
Z
-51/30J
®
Serial Number Range
from Z5130M-3501
CE
with
Maintenance
Information
Original Instructions
Eighth Edition
First Printing
Part No. 1305352GT

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Summary of Contents for Terex Genie Z-51/30J

  • Page 1 Operator's Manual Serial Number Range -51/30J ® from Z5130M-3501 with Maintenance Information Original Instructions Eighth Edition First Printing Part No. 1305352GT...

  • Page 2: Table Of Contents

    Specifications ............68 Copyright © 2012 Terex Corporation Eighth Edition: First Printing, June 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity ®...

  • Page 3: Introduction

    Eighth 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 personnel, safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Eighth Edition • First Printing Introduction Platform controls symbology and related Secondary boom up/down machine movement: Platform level Drive forward/reverse Platform rotate Jib boom up/down Steer right/left Primary boom up/down Turntable rotate Primary boom extend/retract ® -51/30J Part No. 1305352GT...
  • Page 5 Eighth Edition • First Printing Operator's Manual Introduction Ground controls symbology and related Sequential functions and movement: machine movement: • Drive and steer. Platform level Interlocked functions: • Elevated drive speed. • Elevated drive in an off-level condition. Platform rotate •...
  • Page 6 Operator's Manual Eighth Edition • First Printing 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 importance number and serial number of your machine, along to Genie.
  • Page 7 Eighth Edition • First Printing Operator's Manual 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 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Eighth Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Keep away from Read the operator’s Crush hazard Overhead obstruction Collision hazard moving parts manual Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard...
  • Page 9 Eighth Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Manual force No smoking. Explosion hazard Burn hazard Explosion hazard No flame. Stop engine. Wheel load Tire specifications No smoking Explosion hazard Fire hazard Platform tie-down Lifting & tie down Lanyard anchorage Tie-down point Lifting point...
  • Page 10 Operator's Manual Eighth Edition • First Printing Symbol and Hazard Pictorials Definitions Maximum capacity Runaway hazard Color coded Pressure rating for air Voltage rating for direction arrows line to platform power to platform Recovery procedure if tilt alarm sounds while elevated.

  • Page 11: General Safety

    Eighth Edition • First Printing Operator's Manual General Safety General Safety ® Part No. 1305352GT -51/30J...
  • Page 12 Operator's Manual Eighth Edition • First Printing General Safety ® -51/30J Part No. 1305352GT...
  • Page 13 Eighth Edition • First Printing Operator's Manual General Safety ® Part No. 1305352GT -51/30J...

  • Page 14: Personal Safety

    Operator's Manual Eighth 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

    Eighth Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground or proximity to electrical current.
  • Page 16 Operator's Manual Eighth Edition • First Printing Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 17 Eighth Edition • First Printing Operator's Manual Work Area Safety Do not replace factory-installed tires with tires of Use extreme care and different specification or ply rating. slow speeds while driving the machine in the stowed Do not use air-filled tires. These machines are position across uneven equipped with foam-filled tires.
  • Page 18 Operator's Manual Eighth Edition • First Printing Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this machine. the maximum uphill, downhill or side slope rating of the machine.
  • Page 19 Eighth Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 20 Operator's Manual Eighth Edition • First Printing Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 21 Eighth Edition • First Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 22 Operator's Manual Eighth Edition • First Printing Work Area Safety Contact Alarm Safety Panel Cradle Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the contact alarm. instructions provided with the panel cradles. Do not exceed the rated platform capacity.
  • Page 23 Eighth Edition • First Printing Operator's Manual Work Area Safety Pipe Cradle Safety Lockout After Each Use Read, understand, and obey all warnings and Select a safe parking location–firm level instructions provided with the pipe cradles. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 24: Legend

    Operator's Manual Eighth Edition • First Printing Legend Legend Foot switch Platform controls Manual storage container Primary boom Sliding mid-rail Secondary boom Lanyard anchorage points 10 Ground controls Jib boom 11 Steer tire Platform 12 LPG tank (if equipped) 13 Non-steer tire ®...

  • Page 25: Controls

    Eighth Edition • First Printing Operator's Manual 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 26 Operator's Manual Eighth Edition • First Printing Controls Ground Control Panel Engine idle (rpm) select switch Move the engine idle select switch to the turtle Gasoline/LPG models:Check engine light position for foot switch activated low idle. Diesel models:Oil pressure light Move the engine idle select switch to the rabbit Light on and engine stopped: Tag the machine position for foot switch activated high idle.
  • Page 27 Eighth Edition • First Printing Operator's Manual Controls 18 Function enable button 14 Platform rotate switch Press and hold the function enable button to Move the platform rotate switch to the right and enable the functions on the ground control the platform will rotate to the right.
  • Page 28 Operator's Manual Eighth Edition • First Printing Controls Platform Control Panel With Hour Meter ® -51/30J Part No. 1305352GT...
  • Page 29 Eighth Edition • First Printing Operator's Manual Controls ® Part No. 1305352GT -51/30J...
  • Page 30 Operator's Manual Eighth Edition • First Printing Controls Platform overload indicator light Platform Control Panel with Hour Meter Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 31 Eighth Edition • First Printing Operator's Manual Controls 10 Generator switch (if equipped) 13 Dual axis proportional control handle for drive and steer functions. Move the generator switch up to activate the generator. Move the switch down to turn off the Proportional control handle for drive function generator.
  • Page 32 Operator's Manual Eighth Edition • First Printing Controls 14 Drive enable indicator light 17 Engine idle (rpm) select switch Light on indicates that the boom has moved Move the engine idle select switch to the turtle just past either non-steer wheel and drive position for foot switch activated low idle.
  • Page 33 Eighth Edition • First Printing Operator's Manual Controls 21 Primary boom extend/retract switch Move the primary boom extend/retract switch up and the primary boom will retract. Move the boom extend/retract switch down and the primary boom will extend. 22 Dual axis proportional control handle for primary boom up/down and turntable rotate left/right functions Move the control handle up...
  • Page 34 Operator's Manual Eighth Edition • First Printing Controls Platform Control Panel With LCD Display ® -51/30J Part No. 1305352GT...
  • Page 35 Eighth Edition • First Printing Operator's Manual Controls ® Part No. 1305352GT -51/30J...
  • Page 36 Operator's Manual Eighth Edition • First Printing Controls Platform overload indicator light Platform Control Panel with Hour Meter Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 37 Eighth Edition • First Printing Operator's Manual Controls 10 Generator switch (if equipped) 13 Dual axis proportional control handle for drive and steer functions. Move the generator switch up to activate the generator. Move the switch down to turn off the Proportional control handle for drive function generator.
  • Page 38 Operator's Manual Eighth Edition • First Printing Controls 14 Drive enable indicator light 20 Proportional control handle for secondary boom up/down function Light on indicates that the boom has moved just past either non-steer wheel and drive Move the control handle function has been interrupted.

  • Page 39: Inspections

    Eighth Edition • First Printing Operator's Manual 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 40 Operator's Manual Eighth Edition • First Printing Inspections Pre-operation Inspection  Limit switches and horn  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Contact alarm responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 41 Eighth Edition • First Printing Operator's Manual 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 42 Operator's Manual Eighth Edition • First Printing 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 43 Eighth Edition • First Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 19 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 15 Turn the key switch to platform control and 20 Pull out the red Emergency Stop button to the restart the engine.
  • Page 44 Operator's Manual Eighth Edition • First Printing Inspections Test the Steering Test the Drive Enable System 26 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 27 Press the thumb rocker switch on top of the drive control handle in the direction indicated 33 Rotate the turntable until the primary boom by the blue triangle on the control panel OR...
  • Page 45 Eighth Edition • First Printing Operator's Manual Inspections Test Limited Drive Speed Test the Oscillating Axle (if equipped) 36 Press down the foot switch. 46 Start the engine from the platform controls. 37 Raise the primary boom approximately 61 cm. 47 Drive the right steer tire up onto a 15 cm block or curb.
  • Page 46 Operator's Manual Eighth Edition • First Printing Inspections Test the Contact Alarm (if equipped) 56 Operate each machine function. 52 Do not activate the foot switch and press on Result: All machine functions should not the contact alarm cable to release the actuator operate.
  • Page 47 Eighth Edition • First Printing Operator's Manual Inspections Test Aircraft Protection Package (if equipped) Note: Two people may be required to perform this test. 59 Extend the primary boom approximately 30 cm. 60 Move the yellow bumper at the bottom of the platform 10 cm in any direction.
  • Page 48 Operator's Manual Eighth Edition • First Printing Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 49 Eighth Edition • First Printing Operator's Manual Inspections Decal Inspection Part No. Decal Description 161162 Danger, Warning — Tip-over Hazard, Use the pictures on the next page to verify that all CE, Aircraft Protection decals are legible and in place. 214932 Ground Control Panel Below is a numerical list with quantities and...
  • Page 50 Operator's Manual Eighth Edition • First Printing Inspections ® -51/30J Part No. 1305352GT...

  • Page 51: Operating Instructions

    Eighth 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 52 Operator's Manual Eighth Edition • First Printing Operating Instructions All models Starting the Engine If the engine fails to start after 15 seconds of At the ground controls, turn the key switch to cranking, determine the cause and repair any the desired position.
  • Page 53 Eighth Edition • First Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all machine functions and turn the on position.
  • Page 54 Operator's Manual Eighth Edition • First Printing Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 55 Eighth Edition • First Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 56 Operator's Manual Eighth Edition • First Printing Operating Instructions Drive Enable Engine Idle Select (rpm) When the foot switch is not pressed, the engine will Light on indicates that the boom idle at the lowest rpm. has moved just past either non-steer wheel and the drive •...
  • Page 57 Eighth Edition • First Printing Operator's Manual Operating Instructions Standstill Regeneration Under emergencies, the DPF standstill regeneration can be interrupted in three ways: When the LCD screen displays the message "Regen Warning Lvl 1" (level 1 or higher), the DPF ...
  • Page 58 Operator's Manual Eighth Edition • First Printing Operating Instructions Using the control buttons 2 and 3 below the Using the control buttons 2 and 3 below the LCD screen, select "Diagnostics" from the LCD screen, select "Initiate Regen". Press the Main Menu.
  • Page 59 Eighth Edition • First Printing Operator's Manual Operating Instructions 12 If the engine is not already running, the LCD 10 The LCD screen will display the message " screen displays the message "Start Engine". Warning: Machine must be in a nonflammable environment".
  • Page 60 Operator's Manual Eighth Edition • First Printing Operating Instructions Generator (if equipped) 15 The regeneration process auto-advances and once it is completed the LCD screen displays To start the generator, move the message "Regen Successful". the generator toggle switch to the on position.
  • Page 61 Eighth Edition • First Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Check Engine Light If the tilt alarm sounds when the Light on and engine stopped: Tag platform is raised, the Machine Not the machine and remove from Level indicator light will come on service.
  • Page 62 Operator's Manual Eighth Edition • First Printing Operating Instructions Control Box Heater (if equipped) After Each Use Select a safe parking location–firm level Move the control box heater switch up surface, clear of obstruction and traffic. to activate the heater. Retract and lower the boom to the stowed position.

  • Page 63: Transport And Lifting Instructions

    See the serial label for the the brakes. machine weight. See the inspections section Note: Towing the Genie Z-51/30J is not for the serial label location. recommended. If the machine must be towed, do not exceed 3.2 km/h.
  • Page 64 Operator's Manual Eighth Edition • First Printing Transport and Lifting Instructions Securing the Platform – Z-51/30J Securing to Truck or Trailer for Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 65 Eighth Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 66: Maintenance

    Operator's Manual Eighth Edition • First Printing Maintenance Maintenance 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 Observe and Obey: can damage engine components.
  • Page 67 Eighth Edition • First Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 68 Operator's Manual Eighth Edition • First Printing Maintenance Check the Engine Coolant Level – Check the Batteries Ford and Perkins Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 69 Eighth Edition • First Printing Operator's Manual Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Tip-over hazard. An over-inflated tire can this machine according to the procedures found in explode which may compromise machine the service manual for this machine.

  • Page 70: Specifications

    Operator's Manual Eighth Edition • First Printing Specifications Specifications Z-51/30J Airborne noise emissions Sound pressure level at ground 86 dBA Height, working maximum 17.42 m workstation Height, platform maximum 15.59 m Sound pressure level at platform 79 dBA Height, stowed maximum 2.13 m workstation Horizontal reach, maximum...
  • Page 71 Eighth Edition • First Printing Operator's Manual Specifications Z-51/30J Range of Motion Chart ® Part No. 1305352GT -51/30J...
  • Page 72 Operator's Manual Eighth Edition • First Printing Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

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