from SN 951 to 6289, Z-30/20N (PN 43651)
Contents
1. 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 Instructions section Part No 43651 Genie Z 30 20N 23 Operator s Manual Second Edition Ninth Printing OPERATINGINSTRUCTIONS Driving Up Down Slopes Drive Brake Control Theory Brakes release progressively as the drive control handle is moved out of neutral in either direction Brakes apply progressively as the drive control handle is moved toward the neutral position If the machine is on a slope the progressive release application of the brakes combined with torque from the drive motors allows you to control the speed of the machine For this reason in some circumstances it is more effective to drive down a sloped surface by moving the drive control handle in the uphill direction This is called plug braking Apply these principles for driving on a slope by following the instructions below Driving up a slope Be sure the platform is fully lowered and the platform is between the drive wheels Be sure the wheels are aligned up and down the slope 1 Press down the foot switch 2 Move the drive control handle firmly When stopped on a slope the machine may initially move slightly downhill when the drive control handle is moved to drive up the slope Be sure the area behind the machine is clear Driving down a slope Be sure2. cables and wires Replace damaged items before operating w Avoid electrical shock from contact with battery terminals Remove all rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 105 pounds 47 6 kg Each battery box including batteries must weigh a minimum of 530 pounds 240 4 kg Lifting Hazard Use a forklift to remove or install the battery packs Part No 43651 Genie Z 30 20N 7 Operator s Manual Second Edition Ninth Printing Controls oO W E J a so OO EES NE DRIVE ENABLE OPERATION 4g Light on indicates that boom has moved past a non steer tire and drive function is To drive hold drive enable switch up or down ant slowly move drive control andle Machine may drive in opposite direction that the drive and steer controls are move Use color coded direction arrows on this panel and drive chassis to identify the direction machine will travel FR Vs amp Gal as CREEP 4 2 ae 6 00 Platform Control Panel ON OU R ND Drive enable switch Drive enable indicator light Auxiliary power switch Platform level switch Horn button Boom extend retract switch Red Emergency Stop button Jib rotate sw
3. immediately tag and remove the machine from service FUNCTION TESTS Test the Drive Enable System 44 Move the lift drive select switch to the lift position if equipped 45 Press down the foot switch and retract the primary boom to the stowed position 46 Rotate the turntable until the boom moves past one of the non steer wheels Result The drive enable indicator light should come on and remain on while the boom is anywhere in the range shown 47 Move the drive control handle off center Result The drive function should not operate 48 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 systertris 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 controls and the drive chassis t to identify the direction of d travel Yellow Part No 43651 Genie Z 30 20N 17 Operator s Manual Second Edition Ninth Printing FUNCTION TESTS Test Auxiliary Controls 49 Move the lift drive select switch to the appropriate position if equipped 50 Press down the foot switch 51 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 Resul
4. Push in the red Emergency Stop button to the off position Result All ground and platform control functions should notoperate 5 Pull out the red Emergency Stop button to the on position 14 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Test the Boom Functions 6 Donothold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not 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 The descent alarm if equipped should sound while the boom is lowering Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch Test the Tilt Sensor 8 Pull out the platform red Emergency Stop button to the on position Turn the key switch to platform control 9 Open the ground control side turntable cover and locate the tilt sensor next to the function manifold 10 Press down one side of the tilt sensor Result The alarm located in the platform should sound FUNCTION TESTS Test Auxiliary Controls 11 Turn the key switch to ground control 12 Simultaneously hold the auxiliary power switch on and activa
5. acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill 26 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Transport 8 Lifting Instructions Observe and Obey MI The transport vehicle must be parked on a level surface M The transport vehicle must be secured to prevent rolling while the machine is being loaded MI Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See serial plate MI The machine must be on a level surface or secured before releasing the brakes M Always use a winch to load and unload a machine from a transport vehicle Free wheel Configuration for Winching 1 Chock the wheels to prevent the machine from rolling Release the non steer wheel brakes by turning over the torque hub disconnect caps see below Machines with remote brake switch Plug the switch into the adaptor at the ground control box Apply the remote brake release switch while winching the machine Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions After the machine is loaded 1 Chock the wheels to prevent the machine from rolling Apply the non steer wheel brakes by turning over the torque hub disconnect caps see below Towing the Genie Z 30 20N is not recom
6. approved hard hat when operating the machine Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions SAFETY RULES 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 factors which may cause collision Use extreme care and slow speeds while driving the machine in the stowed position on any slope Do not drive on a slope with boom raised Do not allow the machine speed on any slope to exceed 3 mph 4 8 km h walking pace Stop the machine by returning the drive control handle to the center position or release the foot switch When stopped on a slope the machine may initially move slightly downhill when the drive control handle is moved to drive up the slope Be sure the area behind the machine is clear Do not drive on a slope with the wheels turned Be sure the wheels are aligned up and down the slope Always use a winch to load and unload a machine from a transport vehicle Part No 43651 Genie Z 30 20N Operator s Manual Second Edition Ninth Printing SAFETY RULES Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay whil
7. interrupted To drive hold the drive enable switch up or down and slowly move the drive control handle off center Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Low Battery Indicator Light Flashing light indicates battery power is low and the batteries need to be charged There is adequate power left to lower the boom and move it to a location where the batteries can be charged Light on indicates the batteries are fully discharged Stop using the boom and charge the batteries immediately Note Machines equipped with Low Voltage Interrupt Option will lose primary and secondary boom lift functions when batteries are fully discharged OPERATING INSTRUCTIONS After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the boom to the stowed position 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 5 Chock the wheels 6 Charge the batteries Part No 43651 Genie Z 30 20N 25 Operator s Manual Second Edition Ninth Printing OPERATING INSTRUCTIONS Battery and Charger Instructions Observe and Obey MI Do not use an externa
8. the tilt alarm sounds when the platform is raised use extreme caution to retract the boom and lower the platform Do not rotate the boom while lowering Move the machine to a firm level surface before raising the platform Do not alter or disable the limit switches 2 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Do not drive over 0 6 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 attempiing to free the platform using the ground controls Do not operate the machine in strong or gusty winds Do not increase the surface area ofthe platform or the load Increasing the area exposed to the wind will decrease machine stability Use extreme care and slow speeds while driving CEJ NR EE the machine in stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended SAFETY RULES Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies to machines in the stowed position Maximum slope rating sto
9. 33 Notice Operating Instructions Platform 1 30 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual DECALS 38110 28164 43653 43663 28161 50 Ground 28171 35538 060 8 28181 Controls 43652 or Side 72080 38111 z 38112 NI 28177 32700 a 31060 He 65171 Me gt 38188 Se 38187 RE ms 52968 72833 LL 1 e 37054 62929 37056 37055 35583 or 31060 43036 or L 72081 Chassis y Q 38186 33952 O I 38185 114333 s z RA 40434 Pi gt 114880 e NEGE Es 28176 1 A 37055 37056 37051 or s 44986 Platform a Pe 28236 Or 43658 44981 31508 40434 38185 28165 38186 37052 z 31060 62928 or 72167 28177 28161 tle 28157 a or 82336 Power 28171 Unit 27564 Side Shading indicates decal is hidden from view i e under covers 35542 Lik 28235 or 28161 44981 28174 35542 62929 72833 28372 Part No 43651 Genie Z 30 20N 31 Operator s Manual Second Edition Ninth Printing Specifications Height working max
10. 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie J apan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 455 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
11. Before serial number Z30N 3448 Incorrect operation can result from use of this manual on machines that have not been updated according to Genie Campaign Bulletin 070001 Death or Serious Injury can result This manual only applies to machines that have been updated according to Genie Campaign Bulletin 070001 Contact Genie Industries for information on this bulletin After serial number Z30N 3447 Genie Campaign Bulletin 070001 does not apply to these machines Mm GNIQ G Ni Operator s Manual Second Edition Ninth Printing with Maintenance Information Part No 43651 2 30 20N Operator s Manual Second Edition Ninth Printing Eg Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions call Genie Industries Contents Page ai EE OE baza WAZA apa 1 Sepie AR RE AE AAAA 8 Pre operation Inspection ssena 10 METER dac RE NE 12 Funcion EE OE EE OE 14 Workplace Inspection ee ee ee 19 Operating Instructions ee ek ee AA ee 20 Transport amp Lifting Instructions 2 1 1111121211 25 BE ae ees E a o cates N 28 Specifications staid ies eee a 30 Contact us Copyri
12. ch to the lift position if equipped 30 Press down the foot switch 31 Raise the primary boom 1 foot 30 cm 32 Move the lift drive select switch to the drive position if equipped 33 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 1 foot 30 cm per second 16 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual 34 Move the lift drive select switch to the lift position if equipped 35 Lower the boom to the stowed position 36 Raise the secondary boom 1 foot 30 cm 37 Move the lift drive select switch to the drive position if equipped 38 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the secondary boom raised should not exceed 1 foot 30 cm per second 39 Move the lift drive select switch to the lift position if equipped 40 Lower the boom to the stowed position 41 Extend the primary boom 1 foot 30 cm 42 Move the lift drive select switch to the drive position if equipped 43 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom extended should not exceed 1 foot 30 cm per second If the drive speed with the primary boom raised or extended or the secondary boom raised exceeds 1 foot 30 cm per second
13. e Drive and steer functions are not affected by the boom function speed controller 3 Press down the foot switch 4 Move the appropriate toggle switch according to the markings on the control panel Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch To Steer 1 Press down the foot switch 2 Turn the steer wheels with the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slowly move the drive control handle off center Decrease speed Slowly move the drive control handle toward center Stop Return the drive control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel The travel alarm will sound when the drive controller is moved off center Note When the turntable is rotated so the boom is past the non steer tires the machine may move in the opposite direction that the drive and steer controls are moved Machine travel speed is restricted when the booms are raised or extended Battery condition will affect the ability of the machine to climb a slope 22 Gen
14. e operating a machine Component Damage Hazard Do not use the machine as a ground for welding 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 from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the Genie Z 30 20N Service Manual Be sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Decal Legend Genie product decals use symbols color coding and signal words to identify the following messages that follow this symbol to avoid possible injury or death Red used to indicate the ADANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING __ presence of a potentially hazardous situation which if not avoided could result in death or serious injury Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety Yellow with safety alert symbol ACAUTION used to indicate the p
15. ectrically insulated and will not provide protection from contact with or proximity to electrical current I O R Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Voltage Minimum Safe Phase to Phase Approach Distance Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 500KV to 750KV 35 10 67 750KV to 1000KV 45 13 72 Allow for platform movement electrical line sway or sag and beware of strong or gusty 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 and equipment shall not exceed the maximum platform capacity 500 Ibs Maximum platform capacity 227 kg Maximum occupants 2 Do not raise or extend the boom unless the machine is on a firm level surface Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope If the tilt alarm sounds Do not extend rotate or raise the boom above horizontal Move the machine to a firm level surface before raising the platform If
16. elect switch to the drive position if equipped 22 Press down the foot switch 23 Depress the thumb rocker switch on top of the drive control handle in the direction identified by the blue triangle on the control panel Result The steer wheels should turn in the direction that the blue triangles point on the drive chassis 24 Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The steer wheels should turn in the direction that the yellow triangles point on the drive chassis Test Drive and Braking 25 Move the lift drive select switch to the drive position if equipped 26 Press down the foot switch 27 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 The travel alarm should sound The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop 28 Slowly move the drive control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The travel alarm should sound The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Test Limited Drive Speed 29 Move the lift drive select swit
17. en operating the auxiliary controls from the platform 4 Press down the foot switch when operating the auxiliary controls from the platform 5 Simultaneously hold the auxiliary power switch on and activate the desired function The boom steer and drive functions will operate with auxiliary power OPERATING INSTRUCTIONS Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Be sure both battery packs are connected before operating the machine To Position Platform 1 Hold the function enable switch to either side 2 Move the appropriate toggle switch according to markings on the control panel Drive and steer functions are not available from the ground controls Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised past the drive speed limit switch Part No 43651 Genie Z 30 20N 21 Operator s Manual Second Edition Ninth Printing OPERATING INSTRUCTIONS Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Be sure that both battery packs are connected before operating the machine To Position Platform 1 Move the lift drive select switch to the lift position if equipped 2 Set the boom function speed controller to the desired speed Not
18. ght 1995 by Genie Industries First Edition Fourth Printing August 1996 Internet http www genielift com s Second Edition Ninth Printing June 2007 e mail techpub genieind com s Genie and Z are registered trademarks of Genie Industries in the USA and many other countries These machines comply with ANSI SIA 92 5 1992 4 Printed on recycled paper Printed in U S A Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey Manufacturer s instructions and safety rules safety and operator s manuals and machine decals employer s safety rules and worksite regulations applicable governmental regulations M You are properly trained to safely operate the machine Part No 43651 Genie Z 30 20N 1 Operator s Manual Second Edition Ninth Printing SAFETY RULES Electrocution Hazards This machine is not el
19. ie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual 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 20 11 Maximum slope rating counterweight downhill 20 11 Maximum side slope rating 20 11 kk Note Slope rating is subject to ground conditions and adeduate traction The term gradeability applies to the counterweight uphill configuration only Be sure the boom is below horizontal and the platform is between the non steer tires To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level OPERATING INSTRUCTIONS While holding the piece of wood level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example run gt rise Piece of wood 144 inches 3 6 m Run 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
20. imum 36 ft 11m Maximum slope rating stowed position Models without rotating jib Counterweight uphill 20 11 Height working maximum 35 ft 2 in 10 7 m Models with rotating jib Counterweight downhill 20 119 Height platform maximum 30 ft 9 1 m Side slope 20 11 Models without rotating jib Note Slope rating is subject to ground conditions and Height platform maximum 29 ft 2 in 8 8 m adequate traction Models with rotating jib Ground clearance 31 2 in 8 9 cm Height stowed maximum 6 ft 7 in 2m Hydraulic tank capacity 4 gallons 15 liters Horizontal reach maximum 21 ft 6 4m Weight See Serial Plate Width 3 ft 11 in 1 2m Machine weights vary with option configurations Length stowed 16 ft 9 in 5 1m Airborne noise emissions 70 dB Models without rotating jib Maximum sound level at normal operating workstations A weighted Length stowed 17 ft 6 in 5 3 m E Models with rotating jib Drive speeds Maximum load capacity 500 Ib 227 kg Drive speed stowed 0 3 3 mph 0 5 3 km h 46 inch 117 cm platform 40 ft 8 2 sec 12 2 m 8 2 sec Wheelbase 5 ft 2 in 1 6 m Drive speed 0 0 6 mph 0 1 0 km h booms raised 40 ft 40 sec 12 2 m 40 sec Turning radius outside 9 ft 10 in 3 0m or extended Turning radius inside 5 ft 5 in 1 7M Continuous improvement of our products is a Turntable rotation 359 Genie policy Product specifications are subject to change without notice or obligation Turntable tailswing 0 Power source 8 Gro
21. itch option Battery charge indicator and or low voltage interrupt option 63 69 9 10 Notused 11 Proportional control handle for drive function and thumb rocker for steer function 12 Boom function speed controller 13 Jib boom up down switch 14 Lowbattery indicator light 15 Secondary boom up down switch 16 Primary boom up down switch 17 Turntable rotate switch 18 Platform rotate switch Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual CONTROLS O 6 0009 9 Q STOP BY 2 OE REMOTE BRAKE RELEASE du EE 15 Ground Control Panel 1 Turntable rotate switch 8 Red Emergency Stop button 2 Platform rotate switch 9 10A breaker for electrical circuits 3 Platform level switch 10 Remote brake release 4 Boom extend retract switch 11 Jib rotate switch option 5 Auxiliary power switch 12 Jib boom up down switch 6 Hour meter 13 Secondary boom up down switch 7 Key switch for platform off ground selection 14 Function enable switch 15 Primary boom up down switch Part No 43651 Genie Z 30 20N 9 Operator s Manual Second Edition Ninth Printing Pre operation Inspection Do Not Operate Unless M 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
22. l charger or booster battery M Charge the battery in a well ventilated area MI Use proper AC input voltage for charging as indicated on the charger MI Use only a Genie authorized battery and charger To Charge Battery 1 Be sure the batteries are connected before charging the batteries 2 Open the battery compartment The compartment should remain open for the entire charging cycle 3 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 4 Replace the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 Turn the battery charger on 7 The charger will indicate when the battery is fully charged 8 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 Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 5 Check the battery
23. m 1 28171 Label No Smoking 2 38111 Warning Brakes Release 1 28174 Power to Platform 230V 2 38112 Caution Collision Hazard 1 28175 Caution Compartment Access 1 40434 Label Lanyard Anchorage 2 28176 Notice Missing Manuals 1 43036 Platform Control Panel 1 28177 Warning Platform Rotate 2 43652 Ground Control Panel 1 28181 Warning No Step or Ride 1 43653 Notice Operating Instructions Ground 1 28235 Power to Platform 115V 2 43658 Power to Charger 230V 1 28236 Warning Failure To Read 1 43663 Notice Function Enable 1 28372 Caution Component Damage 2 44980 Power to Charger 115V 1 31060 Danger Tip over Hazard Interlock 4 44981 Airline to Platform 2 31508 Notice Power to Charger 1 44986 Notice Max Manual Force 90 Ibs 400 N 1 31785 Notice Battery Charger Instructions 2 52968 Cosmetic Genie Boom 1 31786 Notice Battery Connection Diagram 2 62928 Cosmetic Genie Z 30 20N 1 31787 Danger Tip over Batteries 2 62929 Cosmetic Genie Z 30 20N 2 31788 Danger Battery Charger Safety 2 65171 Label Circuit Breaker amp Status Light 1 32700 Danger Safety Rules 1 72080 Ground Control Panel 1 33952 Danger Tilt Alarm 1 72081 Platform Control Panel 1 35542 Notice Lug Nuts 4 72167 Cosmetic Genie Z 30 20N RJ 1 35583 Platform Control Panel 1 72833 Label Open 2 37051 Notice Max Side Force 150 lbs 667 N 1 82336 Label Chevron Rykon 1 37052 Notice Maximum Load 500 Ibs 227 kg 1 114330 Danger Safety Rules 1 1143
24. machine weight See serial plate TRANSPORT 8 LIFTINGINSTRUCTIONS 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 lifting points on the chassis Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis 31 2 in 79 2 cm Y Axis 34 3 in 87 2 cm X Axis Part No 43651 Genie Z 30 20N 29 Operator s Manual Second Edition Ninth Printing Decals Decal Inspection Use the pictures on the next page to verify that all decals are legible and in place Below is a numerical list with quantities and descriptions PartNo Decal Description Quantity PartNo Decal Description Quantity 27564 Danger Electrocution Hazard 2 37053 Arrow Blue 1 28157 Label Dexron 1 37054 Arrow Yellow 1 28161 Danger Crushing Hazard 3 37055 Triangle Blue 2 28164 Notice Hazardous Materials 1 37056 Triangle Yellow 2 28165 Notice Foot Switch 1 38110 Label Travel Alar
25. mended If the machine must be towed do not exceed 2 mph 3 2 km h Remote brake switch Disengage Position Engage Position PartNo 43651 Genie Z 30 20N 27 Operator s Manual Second Edition Ninth Printing TRANSPORT amp LIFTING INSTRUCTIONS 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 the entire machine for loose or unsecured items Securing the Chassis Use the tie points on the drive chassis for anchoring down to the transport surface Use chains or straps of ample load capacity Use a minimum of 4 chains Adjust the rigging to prevent damage to the chains Truck bed 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 28 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Observe and Obey M Only qualified riggers should rig and lift the machine MI Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the
26. n the responsibilities manual 10 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Pre operation Inspection Ii Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located on the platform HA Be sure that all decals are legible and in place See Decals section Add oil if needed See Maintenance section H Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage modifications and improperly installed or missing parts Ly Electrical components wiring and electrical cables H Hydraulic power unit reservoir hoses fittings cylinders and manifolds Drive and turntable motors and torque hubs Boom wear pads Tires and wheels Limit switches alarms and horn Nuts bolts and other fasteners Platform entry mid rail gate L LL LU LE HO O Beacon and alarms if eguipped H Check for hydraulic oil leaks and proper oil level m m PRE OPERATION INSPECTION Check entire machine for U Cracks in welds or structural components I Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Be sure that both battery packs are in place latched and properly connected After you c
27. omplete your inspection be sure that all compartment covers are in place and latched Part No 43651 Genie Z 30 20N 11 Operator s Manual Second Edition Ninth Printing Maintenance Observe and Obey MI Only routine maintenance items specified in this manual shall be performed by the operator M Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance 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 Ed EZ 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 might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position 2 Visually inspect the reservoir on the hydraulic power unit Result The hydraulic oil level should be within the FULL and ADD marks on the hydraulic reservoir Hyd
28. pection before they are put back into service Part No 43651 Genie Z 30 20N 13 Operator s Manual Second Edition Ninth Printing Function Tests Do Not Operate Unless M 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 to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended 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 machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must preform a pre operation inspection and function tests again before putting the machine into service 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 Test Emergency Stop 4
29. pectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator determine if the work place 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 drop offs or holes bumps floor obstructions or debris overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of unauthorized personnel other possible unsafe conditions Determine the slope of any surface in the path of travel on the job site Part No 43651 Genie Z 30 20N 19 Operator s Manual Second Edition Ninth Printing Operating Instructions Do Not Operate Unless MI 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 to use 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The Operating Instructions section provides instructions for each a
30. pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended 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 The inspection 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 and locations for modifications damage or loose or missing parts A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed i
31. raulic oil specifications Hydraulic oil type Refer to machine decal 12 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can resultin engine component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the batteries 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion Remove the battery vent caps 4 Check the battery acid level If necessary replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps MAINTENANCE Scheduled Maintenance Maintenance performed guarterly 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 Machines that have been out of service for more than three months must receive the quarterly ins
32. resence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert CAUTION symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Green used to indicate operation or maintenance information 6 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eyewear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water The battery pack must remain in upright position Do not expose the batteries or the charger to water orrain Explosion Hazards a NEER N Keep sparks flames and lighted tobacco away from batteries Batteries emit an explosive gas The battery pack cover must remain off during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks SAFETY RULES Component Damage Hazards 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 Hazards Connect the battery charger to a grounded AC 3 wire electrical outlet only Inspect daily for damaged cord
33. ry box including batteries must weigh a minimum of 530 pounds 240 4 kg Do not use the machine as a crane Do not push the machine or other objects with the boom Do not contact adjacent structures with the boom Do not tie the boom or platform to adjacent structures Do not place loads outside the platform perimeter Fall Hazards Occupants must wear a safety belt or harness and comply with applicable governmental regulations Attach lanyard to anchor provided in platform Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times al p Do not climb down from the platform when raised p Keep the platform floor clear of debris Lower the platform entry mid rail or close the entry gate before operating 4 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of boom position when rotating the turntable The machine must be on a level surface or secured before releasing the brakes Do not drive the machine with the brakes released If the travel alarm sounds when not driving the brakes are released Check work area for overhead obstructions or other possible hazards A s w M Be aware of crushing hazards when grasping the platform guard rail It is recommended that operators wear an
34. spect 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 Using the machine for anything other than lifting personnel and tools 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 to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform apre operation inspection function tests and a workplace inspection before using the machine 20 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Emergency Stop Push in the red Emergency Stop button to the off position at the ground or platform controls to stop all machine functions Repair any function that operates when the red Emergency Stop button is pushed in Selecting and operating the ground controls will override the platform red Emergency Stop button Auxiliary Controls Use auxiliary power if the primary power source fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Move the lift drive select switch to the appropriate position if equipped wh
35. t All boom steer and drive functions should operate Test the Lift Drive Select Function CE models Machines with lift drive select switch 52 Move the lift drive select switch to the lift position 53 Press down the foot switch 54 Move the drive control handle off center Result No drive functions should operate 55 Activate each boom function toggle switch Result All boom functions should operate 56 Move the lift drive select switch to the drive position 57 Press down the foot switch 58 Activate each boom function toggle switch Result No boom functions should operate 59 Move the drive control handle off center Result The drive functions should operate Machines without lift drive select switch 60 Press down the foot switch 61 Move the drive control handle off center and activate a boom function toggle switch Result No boom functions should operate The machine will move in the direction indicated on the control panel 18 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations Do Not Operate Unless MI 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 to use 4 Ins
36. te each boom function toggle switch Note To conserve battery power test each function through a partial cycle Result All boom functions should operate 13 Turn the key switch to platform control At the Platform Controls Test Emergency Stop 14 Push in the platform red Emergency Stop button to the off position Result All platform control functions should not operate Test the Horn 15 Pull out the red Emergency Stop button to the on position 16 Push the horn button Result The horn should sound Test the Foot Switch 17 Do not press down the foot switch Activate each machine function Result The machine functions should not operate Part No 43651 Genie Z 30 20N 15 Operator s Manual Second Edition Ninth Printing FUNCTION TESTS Test Machine Functions 18 Move the lift drive select switch to the lift position if equipped 19 Press down the foot switch 20 Activate each machine function toggle switch Result All boom platform functions should operate through a full cycle Note Control the speed of boom functions by adjusting the boom function speed controller Drive and steer functions are not affected by the boom function speed controller Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the primary boom is raised past the drive speed limit switch Test the Steering 21 Move the lift drive s
37. the platform is fully lowered and the platform is between the drive wheels Be sure the wheels are aligned up and down the slope 1 Position the steer wheels on the downhill side of the slope 2 Press down the foot switch 3 On steeper slopes it may be more effective to move the drive control handle in the uphill direction plug braking in order to drive downhill For this reason no matter what slope you are on always begin the process of driving downhill by slowly moving the drive control handle in the uphill direction Use small movements of the drive control handle to control the machine speed If the machine moves uphill instead of downhill the slope is too small to use plug braking Move the drive control handle back to the neutral position to apply the brakes and proceed as follows 4 Slowly move the drive control handle downhill Use small movements of the drive control handle to control the machine speed To stop the machine completely return the drive control handle to the center neutral position The machine can also be stopped by removing your foot from the foot switch or pushing in the red Emergency Stop button If machine speed exceeds 3 mph 4 8 km h walking pace immediately stop the machine 24 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual Drive Enable Light on indicates that the boom has moved past either non steer wheel and the drive function has been
38. up L16 6V 350AH Batteries Controls 24V DC proportional Platform dimensions 46 in x 30 in length x width 1 17 m x 76 cm Platform leveling self leveling Platform rotation 180 Jib rotation optional 200 AC outlet in platform standard Hydraulic pressure maximum 2800 psi boom functions 193 bar 22 x 7 x 178 4 in 56 x 18 x 45 cm Tire size solid rubber 32 Genie Z 30 20N Part No 43651 Second Edition Ninth Printing Operator s Manual 10 FI 3 05m 91m SF 25 ft w 1 52 m 7 6 m 20 ft aoe 75 OF 6 1 m om T 15 ft ih D E SF S 1 52 m 10ft 3m g DA TR 5 ft D 10 FI 3 05 m toem A OFT SFL TOET 18 FT 20 FT om 1 52 m 3 05 m 4 57 m 610m Oft 5 ft 10 ft 15 ft 20 ft Om 152m 3m 46m 61m Part No 43651 Genie Z 30 20N 33 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 617 3375 1002 Genie Scandinavia Phone 46 31575100 Fax 446 31579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93
39. wed position Counterweight uphill 20 11 Counterweight downhill 20 11 Side slope 20 11 Note Slope rating is subject to ground conditions and adequate traction A sd N SJ Do not alter or disable machine components that in any way affect safety and stability Do not push off or pull toward any object outside of the platform Maximum allowable side force ANSI amp CSA 150 Ibs 667 N Maximum allowable side force CE 90 Ibs 400 N Do not replace items critical to machine stability with items of different weight or specification Do not modify or alter an aerial work platform Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Part No 43651 Genie Z 30 20N 3 Operator s Manual Second Edition Ninth Printing SAFETY RULES Do not place or attach overhanging loads to any part of this machine AS Do not place ladders or scaffolds in the platform or against any part of this machine Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition and lug nuts are properly tightened Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 105 pounds 47 6 kg Each batte
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