Terex Genie Z-30N Operator'S Manual Download

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Operator's Manual

Serial Number Range

-30/20N

from Z30NF-22000

ANSI/CSA
North

America

South

America

Asia

-30/20N RJ

from Z30ND-1400

with
Maintenance
Information

Original Instructions
Seventh Edition
First Printing
Part No. 1297932GT

Summary of Contents for Genie Z-30N

Page 1: ...l Serial Number Range Z 30 20N from Z30NF 22000 ANSI CSA North America South America Asia Z 30 20N RJ from Z30ND 1400 with Maintenance Information Original Instructions Seventh Edition First Printing Part No 1297932GT ...

Page 2: ... Safety 12 Work Area Safety 13 Legend 21 Controls 22 Inspections 24 Operating Instructions 39 Transport and Lifting Instructions 47 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: ...chassis Serial label located under cover Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a Mobile Elevating Work Platform MEWP Familiarization with t...

Page 4: ...ary boom extend retract primary boom up down and secondary boom retract lower Turntable rotate and platform rotate Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition Drive enable when the boom is rotated past the non steer wheels All platform and ground controls Limitations of use The intended use of this machine is...

Page 5: ...ation of your machine be sure to comply with the action indicated in a respective bulletin Contacting the Manufacturer At times it may be necessary to contact Genie When you do be ready to supply the model number and serial number of your machine along with your name and contact information At minimum Genie should be contacted for Accident reporting Questions regarding product applications and saf...

Page 6: ...on 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals You read understand and obey employer s safety rules and worksite regulations You read understand and obey all applicable governmental regulations You are prop...

Page 7: ...otential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Indic...

Page 8: ...s equipped with glow plugs No smoking No flame Stop engine Crush hazard No smoking Explosion hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Grounded AC 3 wire only Replace damaged wires and cords Replace tires with tires of same specification Wheel load Wind speed Maximum capacity Side force Batteries used as counterweights Tie down point Lifting point Plat...

Page 9: ... Electrocution hazard Avoid contact Disconnect battery Voltage rating for power to platform Pressure rating for air line to platform Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower primary 2 Lower secondary 3 Retract primary Platform downhill 1 Retract primary 2 Lower secondary 3 Lower primary Read the operator s manual Read the service manual Access by trained and a...

Page 10: ...ING Scheduled maintenance inspections must be completed as specified in the appropriate service manual Use this decal to record the date of the annual inspection the initials of the inspector and the machine owner Use the maintenance inspection report in the service manual for required recordkeeping Keep records on all inspections for four years Maintenance inspections must be completed by a perso...

Page 11: ...ety Part No 1297932GT Z 30 20N Z 30 20N RJ 9 These decals are model option or configuration specific These decals are installed on both sides of chassis 31787 31508 31788 1298847 31060 1263543 114390 218559 219487 28236 31060 218550 114397 1298837 72875 1299791 ...

Page 12: ...Operator s Manual Seventh Edition First Printing General Safety 10 Z 30 20N Z 30 20N RJ Part No 1297932GT 133067 1286362 114252 82487 133067 114252 1263542 1263542 ...

Page 13: ...art No 1297932GT Z 30 20N Z 30 20N RJ 11 These decals are model option or configuration specific These decals are installed on both sides of chassis 114334 114249 1263542 133067 219958 219956 82487 114252 114248 82487 114252 1299439 82487 82481 219954 1299436 1299792 ...

Page 14: ...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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manuf...

Page 15: ... 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 Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity Maximum ...

Page 16: ...es Do not drive over 0 7 mph 1 km h with the primary boom raised or extended or the secondary boom raised 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 raise the boom when wind speeds ...

Page 17: ...the weight in the platform and the surface area of the platform or the load Do not place or attach fixed or overhanging loads to any part of this machine Do not place ladders or scaffolds in the platform or against any part of this 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...

Page 18: ...e in the Operating Instructions section 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 Do not climb down from the platform when raised Keep the platform floor clear of debris...

Page 19: ...e and governmental rules regarding use of personal protective equipment 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 fa...

Page 20: ...tilated 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 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 fr...

Page 21: ...le clamps with tools that may cause sparks Component Damage Hazard Do not use any battery charger greater than 48V to charge the batteries Both battery packs must be charged together Disconnect the battery pack plug before removing the battery pack Electrocution Burn Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cords cables and wires ...

Page 22: ...educe the rated platform capacity and must be subtracted from the total platform load The contact alarm assembly weighs 10 lbs 4 5 kg Be sure the contact alarm is securely installed Lockout 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...

Page 23: ...d 1 Non steer tire 2 Battery box 3 Steer tire 4 Power to charger between steer tires 5 Ground controls 6 Secondary boom 7 Primary boom 8 Jib boom 9 Platform controls 10 Platform 11 Lanyard anchorage points 12 Sliding mid rail 13 Manual storage container 14 Foot switch 3 4 6 7 8 9 10 11 5 2 1 12 13 11 14 ...

Page 24: ...on is selected the platform controls are inoperable including the E stop switch Ground Control Panel 1 Secondary boom up down switch 2 Turntable rotate switch 3 Platform rotate switch 4 Platform level switch 5 Primary boom extend retract switch 6 Auxiliary power switch 7 Key switch for platform off ground selection 8 Hour meter 9 Red Emergency Stop button 10 10A breaker for control electrical circ...

Page 25: ...e switch if equipped 9 Battery charge indicator and or low voltage interrupt option 10 Machine not level indicator light if equipped 11 Proportional control handle for drive function and thumb rocker for steer function 12 Platform overload indicator light if equipped 13 Function Override Aircraft Protection Package if if equipped 14 Boom function speed controller 15 Jib boom up down switch 16 Seco...

Page 26: ...spection 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 un...

Page 27: ...ng and electrical cables Hydraulic power unit reservoir hoses fittings cylinders and manifolds Drive and turntable motors and drive hubs Wear pads Tires and wheels Limit switches and horn Contact alarm if equipped Beacons and alarms if equipped Nuts bolts and other fasteners Platform entry mid rail or gate Platform load cell Lanyard anchorage points Check entire machine for Cracks in welds or stru...

Page 28: ...Only use the machine as it was intended 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 tagged and removed from service Repairs to the machin...

Page 29: ...atform functions should operate 7 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 Test the Tilt Sensor 8 Turn the key switch to platform control Pull out the platform red Emergency Stop button to the on position 9 Open the control panel side turntable cover and locat...

Page 30: ...eed controller Drive and steer functions are not affected by the boom function speed controller Test the Steering 22 Press down the foot switch 23 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 i...

Page 31: ...e off center Result The drive function should not operate 31 Hold the drive enable toggle switch up or down 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 Use the color coded direction arrows on the platform contr...

Page 32: ...ere the chassis pitch angle is greater than 2 5 Result The machine should stop once the machine reaches 2 5 of chassis tilt and the alarm should sound at the platform controls 46 Lower the primary boom to the stowed position Result The machine should drive 47 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 48 Drive the machine onto a slope where the chassis pitch angl...

Page 33: ... 59 Return to level ground and extend the primary boom approximately 1 6 ft 0 5 m 60 Drive the machine onto a slope where the chassis roll angle is greater than 4 5 Result The machine should stop once the machine reaches 4 5 of chassis tilt and the alarm should sound at the platform controls 61 Retract the primary boom to the stowed position Result The machine should drive 62 Return to level groun...

Page 34: ...er functions should operate Test the Contact Alarm if equipped 72 Do not activate the foot switch and press on the contact alarm cable to release the actuator from the switch socket Result The contact alarm lights will not flash and the machine horn will not sound 73 Activate the foot switch by pressing the foot switch down Result The contact alarm lights will flash and the machine horn will sound...

Page 35: ...ator 2 contact alarm cable 3 flashing alarm 4 switch socket Test Auxiliary Power 79 Pull out the red Emergency Stop button to the on position 80 Press down the foot switch 81 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...

Page 36: ...he 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 Workplace Inspection Checklist Be aware of and avoid the following hazardous si...

Page 37: ...el 1 72086 Label Lifting Point 4 72833 Label Open 2 72867 Label Work Lights option 1 72875 Warning Pipe Cradle option 1 82366 Label Chevron Rando 2 Part No Decal Description Qty 82592 Ground Control Panel 1 97815 Label Lower Mid rail 1 114117 Notice Battery Connection Diagram 2 114343 Label Emergency Lowering 1 114390 Danger Electrocution Hazard 3 114397 Danger Tilt Alarm 1 133286 Label Power to C...

Page 38: ...785 37056 37054 1263543 72086 133286 44980 31508 31060 28164 114343 1263543 52865 114390 1298858 1280819 82592 48731 1272242 1267121 28174 28235 44981 1281174 114397 218550 1299791 114390 218559 28174 28235 28236 1298837 97815 219487 31060 44981 T112773 1281174 72081 72875 1278982 1278542 46468 32728 72867 65171 72086 52475 72086 52475 72086 52475 52947 1292512 1292513 1292514 1292515 1291624 2272...

Page 39: ...tatus Light 1 82611 Label Drive Enable Patch 1 97815 Label Lower Mid rail 1 114248 Label Tip over Hazard Tilt Alarm 1 Part No Decal Description Qty 114249 Label Tip over Hazard Tires 4 114252 Label Tip over Hazard Limit Switches 5 114334 Label Electrocution Hazard Plug 1 114343 Label Emergency Lowering 1 133067 Label Electrocution Hazard 3 133286 Label Power to Charger 1 139586 Label Wheel Load 1 ...

Page 40: ...1297941 72086 82487 1299439 37056 37054 1263542 52475 114334 114252 82487 114343 1263542 133067 1298858 82592 1272242 1286362 28174 28235 44981 133067 82366 38149 114248 219954 1299792 133067 219958 28174 28235 82487 97815 219956 114252 44981 1281174 72081 1278982 1278542 46468 32728 72867 82610 72086 52475 82611 1281174 1299436 1294398 82487 72086 52475 133286 44980 72086 52475 114252 1263542 ...

Page 41: ...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 work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected t...

Page 42: ...n the key switch to ground control 3 Pull out the red Emergency Stop button to the on position 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 Note Drive and steer functions are not available from the ground controls Operation from Platform 1 Be sure both battery packs are connected before ope...

Page 43: ... travel speed is restricted when the booms are raised or extended Battery condition will affect machine performance Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating platform downhill gradeability 35 19 Maximum slope rating platform uphill 20 11 Maximum side slope rating 25 14 Note Slope rating is subject to g...

Page 44: ...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 rating then the machine must be winched or transported up or down the slope See Transport and Lifting section Drive Enable Light on indicates that the boom has moved just past either non steer wheel and the drive function has been...

Page 45: ... 1 Lower the primary boom 2 Lower the secondary boom 3 Retract the primary boom If the tilt alarm sounds with the platform downhill 1 Retract the primary boom 2 Lower the secondary boom 3 Lower the primary boom Tilt Sensor Activation Settings Model Chassis Angle side to side Chassis Angle front to back Z 30N 4 5 2 5 Z 30N RJ 4 5 2 5 When the Machine On Incline indicator light is on and the tilt al...

Page 46: ...handle or toggle switch to move the machine away from aircraft components Contact Alarm if equipped The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel interrupting boom movement sounding an alarm and flashing warning lights When the contact alarm cable is tripped the lift and drive functions are disabled at the platform The audio ...

Page 47: ...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 position and remove the key to secure from unauthorized use ...

Page 48: ...h distilled water to cover the plates Do not overfill prior to the charge cycle 2 Replace the battery vent caps 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Ch...

Page 49: ...ed mobile elevating work platform operators should move the machine on or off the truck The transport vehicle must be parked on a level surface The transport vehicle must be secured to prevent rolling while the machine is being loaded Be 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 S...

Page 50: ...the machine from rolling 2 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 Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Turn the key switch to the off position and remove the key before transporting Inspect th...

Page 51: ...9 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 Do not use excessive downward force when securing the boom section ...

Page 52: ...s or lines are sufficient to withstand the machine weight See the serial label for the machine weight 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 Attach the rigging only to the designated lifting points on the machine There are four liftin...

Page 53: ...tenance 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 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 ...

Page 54: ...ter Perform this test after fully charging the battery 1 Put on protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion Standard Batteries 3 Remove the battery vent caps 4 Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps Scheduled...

Page 55: ...is subjected does not exceed 0 5 m s2 Ambient operating temperature 20 F to 120 F 29 C to 49 C Ground clearance 3 5 in 8 9 cm Weight Machine weights vary with option configurations See serial label for specific machine weight Drive speeds Drive speed stowed 3 0 mph 40 ft 9 sec 4 8 km h 12 2 m 9 sec Drive speed raised or extended 0 7 mph 40 ft 40 sec 1 0 km h 12 2 m 40 sec Maximum slope rating stow...

Page 56: ...body is subjected does not exceed 0 5 m s2 Ambient operating temperature 20 F to 120 F 29 C to 49 C Ground clearance 3 50 in 8 9 cm Weight Machine weights vary with option configurations See serial label for specific machine weight Drive speeds Drive speed stowed 3 0 mph 40 ft 9 sec 4 8 km h 12 2 m 9 sec Drive speed raised or extended 0 7 mph 40 ft 40 sec 1 0 km h 12 2 m 40 sec Maximum slope ratin...

Page 57: ...N Z 30 20N RJ 55 Range of Motion Chart Z 30 20N Z 30 20N RJ Max Height Max Reach 1 30 ft 9 1 m 8 0 ft 0 m 2 25 ft 7 6 m 9 5 ft 1 5 m 3 20 ft 6 1 m 10 10 ft 3 m 4 15 ft 4 6 m 11 15 ft 4 6 m 5 10 ft 3 m 12 20 ft 6 1 m 6 5 ft 1 5 m 14 25 ft 7 6 m 7 0 ft 0 m 10 9 8 7 6 5 4 3 75 67 2 1 11 12 13 ...

Page 58: ... 20N RJ Part No 1297932GT Range of Motion Chart Rotating Jib Z 30 20N RJ Max Rotate Max Reach 1 5 ft 1 5 m 4 0 ft 0 m 2 0 ft 0 m 5 5 ft 1 5 m 3 5 ft 1 5 m 6 10 ft 3 m 7 15 ft 4 6 m Z 30 20N Z 30 20N RJ Part No 1297932GT Operator s Manual Seventh Edition First Printing 6 5 3 1 4 2 7 ...

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Terex Genie Z-30N, Operator'S Manual

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