Genie Z-30, Z-20, Z-30HD, Z-20HD, Z-30/20HD Operator's Manual

before serial number 2214

Contents

Page

Safety Rules .............................................................. 3

Pre-operational & Safety Inspection ........................... 4

Operating Instructions................................................ 6

Transport .................................................................. 12

Maintenance & Routine Service ................................ 12

Specifications ........................................................... 14

SAFETY RULES & OPERATING INSTRUCTIONS

Read and understand these Safety Rules and Operating Instructions before operating the Genie
Boom Z-30/20HD or the Genie Boom Z-30/20. Do not permit anyone to use the machine who
does not understand the material in this document. K eep these instructions in the water-tight
plastic tube on the machine at all times for operator reference.

If there is anything you do not understand, or if you have questions regarding the operation of
this machine, call Genie Industries in the U.S .A., [phone] or [phone].

2

Do not use machine or position
platform within 10 feet of
power lines

Do not raise platform unless
machine is level

Do not stand on or
place loads on guard
rail

SAFETY RULES

• Before using the Genie Boom Z-30/20HD or the Genie Boom Z-30/20, thoroughly inspect machine for

damage such as cracked welds, hydraulic leaks, damaged control cables, loose wires and
connections or tire damage. Do not use damaged equipment. (Contact Genie Industries for
instructions.) Do not change operating or safety system.

• Do not raise platform unless machine is level.

• Always survey work area for surface hazards such as holes, drop-offs, bumps and debris before

elevating platform. Do not drive while elevated except on firm, level surfaces with less than 1° slope.

• Do not allow speed of machine down any slope to exceed 3 mph / 4.8 km/h (walking speed).

• Always look up and around for overhead obstructions and electrical conductors. Do not operate

machine or position platform within 10 ft / 3 m of power lines. THIS MACHINE IS NOT
ELECTRICALLY INSULATED.

• Always lower mid-rail bar across entrance after mounting platform.

• Always use OSHA required safety belts and lanyards when occupying platform.

• Do not recharge batteries near sparks or open flame; batteries that are being charged emit highly

explosive hydrogen gas.

• Do not sit, stand or climb on guard rail or mid-rail.

• Do not attach overhanging loads or increase platform size.

WARNING: F AILURE T O UNDERST AND AND FOLLO W ALL

SAFETY RULES AND OPERATING INSTRUCTIONS MIGHT

RESULT IN SERIOUS INJURY OR DEATH.

3

PRE-OPERATIONAL & SAFETY INSPECTION

• Open module covers. (Photos 1, 2, 3, & 4)

• Visually inspect machine for any damage or missing parts.

• Check that platform is secured, with all fasteners in place.

• Check hydraulic oil level with platform fully lowered and boom completely retracted. Oil should be

within 1 inch / 2.5 cm of tank top. (Photo 5) IMPORTANT: If hydraulic oil is required, use only Shell
Tellus No. 46 or equivalent.

• Check battery fluid level. CAUTION: To ensure proper battery care, add battery fluid only after

charging.

• Check battery terminals for tightness of connectors and cleanliness. (Photo 6)

• Check battery charger to verify that output meter indicates charging current. (Photo 7)

• Check tires daily. Maintain 45 psi (310 kPa) air pressure. Make sure all lug nuts are securely

tightened. Torque lug nuts to 65 -75 ft-lbs / 289 - 334 Nm. (Photo 8)

• After preceding checks have been completed, operate machine from the ground through all functions

to check that machine and controls are in safe working condition. (Photo 9)

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3-Open module cover

1-Open module cover

4-Open module cover 5-Check hydraulic oil

2-Open module cover

6-Check battery terminals 7-Check battery charger 8-Check tires and wheels

9-Operate machine from
ground

5

OPERATING INSTRUCTIONS

UNDERST AND FUNCTIONS OF ALL CONTR OLS BEFORE OPERA TING MA CHINE

TURNING ON MACHINE

• Select POWER ON mode on control console. (Photo 10)

ACTIVATING EMERGENCY STOP

• To de-activate lift and drive controls at the platform and set machine parking brake, close
EMERGENCY STOP red toggle switch cover. (Photo 11)

DRIVING DOWN A RAMP

• Before driving down a ramp, make sure that platform is fully retracted and lowered. (Photo 12)

• Select DRIVE mode on control console. (Photo 13)

• Press down on foot switch. (Photo 14)

• Release service brake and allow machine to coast by moving accelerator lever slightly off center.
(Photo 15)

• After coasting a few feet, apply service brake and bring machine to a FULL STOP by returning
accelerator lever to the neutral position and releasing foot switch.

• Repeat above three steps until machine is at the bottom of ramp.

• WARNING: The steeper the ramp, the less distance machine should be allowed to coast. NEVER
allow speed of machine down any ramp to exceed 3 mph / 4.8 km/h (walking speed). BEFORE
speed becomes excessive, apply service brake and bring machine to a FULL STOP by returning
accelerator lever to the neutral position and releasing foot switch.

TRAVELING WITH PLATFORM DOWN - LEVEL SURFACE

• Maximum travel speed is attainable only when platform is down.

• Always check to be sure route is clear of persons and obstructions.

• Select DRIVE mode on control console. (Photo 13)

• Press down on foot switch. (Photo 14)

• To change speed, move accelerator lever slowly forward or backward. (Photo 15)

• To slow down, move accelerator lever to the opposite direction that the machine is traveling.

• To stop, apply service brake by returning accelerator lever to the neutral position and releasing foot
switch.

STEERING

• Always check to be sure area around wheels is clear of persons and obstructions.

• Select DRIVE mode on control console. (Photo 13)

• Operate steering toggle switch left or right as required. (Photo 16)

• NOTE: Steering is not self-centering-to return wheels to straight ahead position use toggle switch.

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10-POWER ON mode 11-EMERGENCY STOP 12-Boom retracted and lowered

13-DRIVE mode 14-Foot switch

16-Steering switch

15-Accelerator lever

7

OPERATION INSTRUCTIONS (continued)

LEVELING PLATFORM (Z-30/20)

• Before raising or lowering platform, always disengage platform locking pin so that platform will self­level. To disengage locking pin, pull knob and turn 90° in either direction. (Photo 17)

• When desired working position is reached, engage platform locking pin by turning knob until pin locks
in place.

• Always drive machine with platform in the locked position.

PLATFORM ROTATION (Z-30/20HD)

• Platform may be rotated to desired working position by turning the manual hand crank in either a
clockwise or counter-clockwise direction. (Photo 18)

RAISING BOOM RISER

• Check for overhead obstructions.

• Select LIFT mode on control console. (Photo 19)

• Operate BOOM RISER UP toggle switch on control console. (Photo 20)

• BOOM RISER operates independently of BOOM UP or BOOM EXTEND.

RAISING BOOM

• Select LIFT mode on control console. (Photo 19)

• Operate BOOM UP toggle switch on control console. (Photo 21)

• NOTE: BOOM UP operates independently of BOOM RISER or BOOM EXTEND.

EXTENDING BOOM

• Select LIFT mode on control console. (Photo 19)

• Operate BOOM EXTEND toggle switch on control console. (Photo 22)

• BOOM EXTEND operates independently of BOOM RISER or BOOM UP.

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17-Platform locking pin

20-BOOM RISER UP

18-Platform rotation

19-LIFT mode

22-BOOM EXTEND21-BOOM UP

9

OPERATION INSTRUCTIONS (continued)

ROTATING TURRET

• Check for obstructions around turret turntable and platform.

• Select LIFT mode on control console. (Photo 19)

• Operate TURRET ROTATION toggle switch on control console. (Photo 23) Turret will rotate in either
direction.

TRAVELING WITH PLATFORM UP - LEVEL SURFACE

• With platform up, machine travel speed is restricted.

• Always check to be sure route is clear of persons and obstructions.

• Select DRIVE mode on control console. (Photo 13)

• Press down on foot switch. (Photo 14)

• To change speed, move accelerator lever slowly forward or backward. (Photo 15)

• To slow down, move accelerator lever to the opposite direction that the machine is traveling.

• To stop, apply service brake by returning accelerator lever to the neutral position and releasing foot
switch.

RETRACTING BOOM

• Select LIFT mode on control console. (Photo 19)

• Operate BOOM RETRACT toggle switch on control console. (Photo 24)

• BOOM RETRACT operates independently of BOOM RISER or BOOM DOWN.

LOWERING PLATFORM

• Check for obstructions below platform.

• Select LIFT mode on control console. (Photo 19)

• Operate BOOM DOWN toggle switch to descend. (Photo 25)

• Operate BOOM RISER DOWN toggle switch to descend. (Photo 26)

EMERGENCY/GROUND LEVEL CONTROLS

• IF PLATFORM FAILS TO RETRACT OR DESCEND, NEVER CLIMB DOWN BOOM ASSEMBLY.
Ask a person on the ground to actuate proper emergency controls to retract, rotate and lower
platform. These controls are located at front of turntable. (Photo 27)

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13-DRIVE mode

19-LIFT mode

14-Foot switch 15-Accelerator lever

23-TURRET ROTATION 24-BOOM RETRACT

25-BOOM DOWN

26-BOOM RISER DOWN 27-Emergency controls

11

TRANSPORT

LIFTING

• Weight of Genie Boom Z-30/20HD
20 is approximately 5,500 lbs / 2495 kg.

• Use fork truck pockets provided on either side of machine under counterbalance weights. (Photo 28)

SECURING TO TRUCK OR TRAILER FOR ROAD TRANSIT

• Before transporting machine, insert pin in transportation lock hole. (Photo 29)

• Use chains or straps of ample load capacity.

• Always chock wheels on truck or trailer bed. (Photo 30)

• Use tie points on chassis for anchoring down to truck or trailer bed. (Photo 31)

is approximately 9,000 lbs / 4082 kg. Weight of Genie Boom Z-30/

MAINTENANCE & ROUTINE SERVICE

BATTERY MAINTENANCE

• Check the battery fluid level daily, especially if machine is being used in a warm, dry climate.
(Photo 32)

• Charge batteries at the end of each work shift, or sooner, if the batteries have been discharged.

TO CHARGE BATTERIES

• Leave battery pack cover open during all charging. Dangerous gases are present during charging.
Keep in well ventilated area. (Photo 4)

• Connect charge A.C. cord to a properly grounded 115 volt, 60 HZ power supply which has adequate
circuit breaker or fuse protection. (Photo 33)

• Charge rate will vary from 20 to 29 amps depending on the state of discharge of the batteries. Charge
rate will taper gradually to a finish rate of 5 to 10 amps when all cells are good.

• Charger turns off automatically when batteries are fully charged.

• Replace defective cords or wires immediately.

• Keep all charger ventilation openings free from obstructions.

• Keep battery tops free of moist, greasy film.

CAUTION

• This charger is for use on battery systems of the type and capacity specified on the charger name
plate (36 volt). Use otherwise will damage charger and/or batteries.

• Do not expose charger to rain.

• For best battery life, follow detailed instructions in battery manufacturer’s owners manual.

• DANGER: Never perform service on machine while platform or boom linkage is elevated.

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4-Open module cover

309-Chock wheels

28-Fork truck pockets

29-Insert transport locking pin

31-Tie down 32-Check battery fluid

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• For complete list of required Maintenance Service consult the “Genie Boom Operating and Maintenance Manual. ”

33-Connect charge cord

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13

Z-30/20HD Specifications

AC outlet in platform standard
Height, working maximum 38 ft 11.58 m
Height, platform maximum 31 ft 9.45 m
Height, stowed 6 ft 7 in 2 m
Horizontal reach, maximum 20 ft 6.1 m
Width 5 ft 11 in 1.8 m
Length, stowed 16 ft 6 in 5.03 m
Maximum load capacity 500 lb 227 kg

46 inch (117 cm) platform
Wheelbase 6 ft 1.83 m
Turning radius (outside) 14 ft 4.26 m
Turning radius (inside) 7 ft 2.13 m
Turntable rotation (degrees) 360°
Turntable tailswing 0
Power source 8 6V 220AH Batteries

Drive speeds

Drive speed, stowed 0 - 4 mph 0 - 6.5 km/h
Drive speed, raised 0 - 0.6 mph 0 - 1 km/h

Hydraulic pressure (maximum) 2000 psi

(boom functions) 138 bar

Tire size 11LT-15

Gradeability 20% (11°)

Ground clearance 51/2 in 14 cm

Hydraulic tank capacity 2.5 gallons 9.5 liters

Weight 8500 lbs 3855 kg

Continuous improvement of our products is a Genie

policy. Product specifications are subject to change

without notice or obligation.

Controls SCR
Platform dimensions, (length x width)

4 foot 48 in x 30 in 121 cm x 76 cm
Platform leveling self-leveling
Platform rotation 150°

14

Z-30/20 Specifications

AC outlet in platform standard
Height, working maximum 37 ft 11.28 m
Height, platform maximum 30 ft 9.14 m
Height, stowed 6 ft 7 in 2 m
Horizontal reach, maximum 20 ft 6.1 m
Width 5 ft 11 in 1.8 m
Length, stowed 13 ft 6 in 4.11 m
Maximum load capacity 300 lb 136 kg

46 inch (117 cm) platform
Wheelbase 6 ft 1.83 m
Turning radius (outside) 14 ft 4.26 m
Turning radius (inside) 7 ft 2.13 m
Turntable rotation (degrees) 360°
Turntable tailswing 0
Power source 8 6V 220AH Batteries

Drive speeds

Drive speed, stowed 0 - 4 mph 0 - 6.5 km/h
Drive speed, raised 0 - 0.6 mph 0 - 1 km/h

Hydraulic pressure (maximum) 2000 psi

(boom functions) 138 bar

Tire size 7:00 x 15 LT

Gradeability 25% (14°)

Ground clearance 51/2 in 14 cm

Hydraulic tank capacity 2.5 gallons 9.5 liters

Weight 5500 lbs 2495 kg

Continuous improvement of our products is a Genie

policy. Product specifications are subject to change

without notice or obligation.

Controls SCR
Platform dimensions, (length x width)

4 foot 48 in x 30 in 121 cm x 76 cm
Platform leveling gravity

15

W A R R A N T Y

GENIE INDUSTRIES, INC. standard warranty for your Genie Booms covers
repairs or adjustment of manufactured and installed parts and equipment
which prove defective in material or workmanship for a specified period from
the effective date of warranty, but only such defects as results from normal
use. Coverage periods are as follows;

• Structural steel components and bushings........................... 5 years

• Hydraulic componentry....................................................... 3 years

• Electric componentry........................................................... 1 year

• Batteries............................................................................ 90 days

(100% replacement warranty from date unit ships from
manufacturer)

Items specifically not covered under warranty and/or exceptions to
warranty include:

• Tires • Covers • Filters
Repairs required as a result of the following are not covered under
warranty:

• Damage from environment:

· airborne fallout

· chemicals

· salt

· sandblasting

• Damage due to alterations, misuse or accidents:

· fire

· accidents

· abuse

· negligence

• Damage resulting from improper maintenance or failure to follow
established maintenance schedule.

• Damage to the finished appearance from normal deterioration due to
use and exposure.

. job-site hazards
. lightning
. floods
. other acts of God

. objects striking the machine
. misuse of machine
. adjustments to components not
complying to Genie specifications

Seller’s liability shall be limited to the repair or replacement of the defective
material or workmanship at its factory or authorized service center. Buyer
shall be responsible for all freight charges required for the repair.

SELLER MAKES NO OTHER W ARRANTY, EXPRESS OR IMPLIED,
AND SPECIFICALLY MAKES NO WARRANTY AS TO
MERCHANT ABILITY AND FITNESS FOR ANY P ARTICULAR PURPOSE.

Qualification for warranty coverage is conditioned upon completion and filing
of a “Product Warranty Registration” form within 30 days of original invoice,
or from the date the equipment is first put into service, whichever comes
first, and upon prompt notice of the claimed defect. Receipt of the “Product
Warranty Registration” form by Genie Industries establishes the effective
date of warranty. Seller must be given an opportunity to examine any defect
before any alteration is made.

Seller reserves the right to make any changes in design or add any
improvements on its basic product or any accessories thereto at any time
without incurring any obligation to install such improvements on any Genie
Booms or accessory previously purchased.

This warranty supersedes all other warranties, stated or published.
For more information regarding this warranty, please contact the

Genie Customer Service Department toll free at 800-536-1800.
All other manufacturers’ warranties in excess of Genie warranty will be

assigned to purchaser.

Copyright © 1985 by Genie Industries

PRINTED IN U.S.A.