Terex Z-30/20N, Z-30/20N RJ Operator's Manual

Operator's Manual Fifth Edition • Second Printing

Z-30/20N • Z-30/20N RJ Part No. 133546

Copyright © 1995 by Genie Industries

First Edition: Fourth Printing, August 1996

Second Edition: Fourth Printing, July 2000

Third Edition: Third Printing, November 2009

Fourth Edition: Second Printing, November 2009

Fifth Edition: Second Printing, August 2011

"Genie" and "Z" are registered trademarks of
Genie Industries in the USA and many other
countries.

These machines comply with
ANSI A92.5
CSA B354.4

Complies with EC Directive 2006/42/EC

See EC Declaration of Conformity

Printed on recycled paper

Printed in U.S.A.

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

Safety Rules .............................................................. 1

Controls ..................................................................... 8

Legend ..................................................................... 10

Pre-operation Inspection........................................... 11

Maintenance ............................................................. 13

Function Tests .......................................................... 15

Workplace Inspection ............................................... 20

Operating Instructions .............................................. 21

Decals ...................................................................... 26

Transport and Lifting Instructions.............................. 30

Specifications ........................................................... 33

Contact us:

Internet: http://www.genielift.com
e-mail: [e-mail]

Operator's Manual

Fifth Edition • Second Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 1

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:

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.

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 properly trained to safely operate the

machine.

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2 Z-30/20N • Z-30/20N RJ Part No. 133546

SAFETY RULES

Electrocution Hazards

This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.

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, equipment and materials shall not
exceed the maximum platform capacity.

Maximum platform capacity 500 lbs 227 kg

Maximum platform capacity

Machine equipped with
Aircraft Protection Package 440 lbs 200 kg

Maximum occupants 2

The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
factored into the total platform load. See the decals
on the options.

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.

Operator's Manual

Fifth Edition • Second Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 3

If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.

If the tilt alarm sounds when the platform is raised:
Use extreme caution. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.

If the tilt alarm sounds with the
platform uphill:

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.

Do not alter or disable the limit switches.

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 may
exceed 28 mph / 12.5 m/s. If wind speeds exceed
28 mph / 12.5 m/s when the boom is raised, lower
the boom and do not continue to operate the
machine.

3

3

Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.

Use extreme care and slow speeds while driving
the machine in the 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.

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, stowed position

Counterweight uphill 35% 19°

Counterweight downhill 20% 11°

Side slope 25% 14°

Note: Slope rating is subject to ground conditions
and adequate traction.

Do not push off or pull toward any object outside
of the platform.

Maximum allowable
side force - ANSI &
CSA

150 lbs / 667 N

Maximum allowable
manual force - CE

90 lbs / 400 N

SAFETY RULES

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4 Z-30/20N • Z-30/20N RJ Part No. 133546

SAFETY RULES

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 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.

Lower the platform entry mid-rail or close the entry
gate before operating.

Do not alter or disable machine components that in
any way affect safety and stability.

Do not replace items critical to machine stability
with items of different weight or specification.

Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. 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.

Do not place or attach 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 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 battery box including batteries must weigh a
minimum of 530 pounds / 240.4 kg.

Operator's Manual

Fifth Edition • Second Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 5

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.

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 while operating a
machine.

Collision Hazards

Be aware of limited sight
distance and blind spots
when driving or operating.

Be aware of boom position when rotating the
turntable.

Check the work area for overhead obstructions or
other possible hazards.

Be aware of crushing hazards when grasping the
platform guard rail.

Operators must comply with employer, job site and
governmental rules regarding the 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.

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6 Z-30/20N • Z-30/20N RJ Part No. 133546

Decal Legend

Genie product decals use symbols, color coding
and signal words to identify the following:

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.

Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.

Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Yellow without safety alert
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.

SAFETY RULES

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.

Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
advised when performing a pre-operation
inspection. All compartments must remain closed
and secured during operation.

Operator's Manual

Fifth Edition • Second Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 7

SAFETY RULES

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 an upright
position.

Do not expose the batteries or the charger to water
or rain.

Explosion Hazards

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.

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,
cables and wires. Replace
damaged items before
operating.

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.

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8 Z-30/20N • Z-30/20N RJ Part No. 133546

Controls

Platform Control Panel

1 Drive enable switch

2 Drive enable indicator light

3 Auxiliary power switch

4 Platform level switch

5 Horn button

6 Primary boom extend/retract switch

7 Red Emergency Stop button

8 Jib boom rotate switch (option)

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 equipped)

14 Boom function speed controller

15 Jib boom up/down switch

16 Secondary boom up/down switch

17 Primary boom up/down switch

18 Turntable rotate switch

19 Platform rotate switch

20 Not used

To drive, hold drive enable
switch up or down and
slowly move drive control
handle. Machine may drive
in opposite direction that
the drive and steer controls
are moved.

Use color-coded direction
arrows on this panel and
drive chassis to identify the
direction machine will travel.

Light on indicates that boom
has moved past a non-steer
tire and drive function is
turned off.

DRIVE
ENABLE
OPERATION

STOP

F

E

1
2

CREEP

19

18

17

16

13

15

14

20

20

20

20

20

12

11

10

9

8

7

6

5

4

3

2

1

Operator's Manual

Fifth Edition • Second Printing

Part No. 133546 Z-30/20N • Z-30/20N RJ 9

CONTROLS

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 electrical circuits

11 Platform overload indicator light (if equipped)

12 Jib boom rotate switch (option)

13 Jib boom up/down switch

14 Primary boom up/down switch

15 Function enable switch

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10 Z-30/20N • Z-30/20N RJ Part No. 133546

Legend

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 point

12 Sliding mid-rail

13 Manual storage container

14 Foot switch