SN 8333 to 12119, Z-30/20N (PN 1000046)

SN 8333 to 12119, Z-30/20N (PN 1000046)
Operator's Manual
Fourth Edition • Third Printing
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
Copyright © 1995 by Genie Industries
Contact us:
Fourth Edition:
Internet: http://www.genielift.com
e-mail: [email protected]
Third Printing, February 2010
"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.
Printed on recycled paper
Printed in U.S.A.
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
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.
Part No. 1000046
Z-30/20N
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Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
Electrocution Hazards
Tip-over Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity
500 lbs
227 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.
Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations and the following chart.
Voltage
Phase to Phase
Minimum Safe
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 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 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.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
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Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
Do not drive over 0.7 mph / 1 km/h with the primary
boom raised or extended or the secondary boom
raised.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
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 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.
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.
Counterweight uphill
35%
19°
Counterweight downhill
20%
11°
Side slope
25%
14°
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.
Maximum slope rating, stowed position
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
Do not alter or disable machine components that in
any way affect safety and 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.
Part No. 1000046
Do not replace items critical to machine stability
with items of different weight or specification.
Z-30/20N
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Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
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 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 place ladders or scaffolds in the platform or
against any part of this machine.
Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform floor at
all times.
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.
4
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.
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
Do not lower the boom unless the area below is
clear of personnel and obstructions.
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.
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.
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.
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
Component Damage Hazard
Decal Legend
Do not use the machine as a ground for welding.
Genie product decals use symbols, color coding
and signal words to identify the following:
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.
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.
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.
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.
6
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
SAFETY RULES
Battery Safety
Component Damage Hazards
Burn Hazards
Do not use any battery charger greater than 48V to
charge the batteries.
Batteries contain acid. Always wear protective
clothing and eyewear when working with 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 spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
The battery pack must remain in an upright
position.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Do not expose the batteries or the charger to water
or rain.
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.
Explosion Hazards
Keep sparks, flames
and lighted tobacco
away from batteries.
Batteries emit an
explosive gas.
Lifting Hazard
The battery pack cover
must remain off during
the entire charging
cycle.
Use a forklift to remove or install the battery packs.
Do not contact the battery terminals or the cable
clamps with tools that may cause sparks.
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
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)
11 Proportional control handle for drive function and
thumb rocker for steer function
12 Platform overload indicator light (if equipped)
13 Not used
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 Platfom rotate switch
10 Machine not level indicator light (if equipped)
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Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
CONTROLS
Ground Control Panel
1 Secondary boom up/down switch
8 Hour meter
2 Turntable rotate switch
9 Red Emergency Stop button
3 Platform rotate switch
10 10A breaker for electrical circuits
4 Platform level switch
11 Platform overload indicator light (if equipped)
5 Primary boom extend/retract switch
12 Jib boom rotate switch (option)
6 Auxiliary power switch
13 Jib boom up/down switch
7 Key switch for platform/off/ground selection
14 Primary boom up/down switch
15 Function enable switch
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
Legend
1 Non-steer tire
9 Platform controls
2 Battery box
10 Platform
3 Steer tire
11 Lanyard anchorage point
4 Power to charger (between steer tires)
12 Sliding mid-rail
5 Ground controls
13 Manual storage container
6 Secondary boom
14 Foot switch
7 Primary boom
8 Jib boom
10
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
Pre-operation Inspection
Fundamentals
It is the responsibility of the operator to perform a
pre-operation inspection and routine maintenance.
Do Not Operate Unless:
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 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.
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.
If damage or any unauthorized 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 in the responsibilities
manual.
Part No. 1000046
Z-30/20N
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Operator's Manual
Fourth Edition • Third Printing
PRE-OPERATION INSPECTION
Pre-operation Inspection
Check entire machine for:
R Be sure that the operator's, safety and
responsibilities manuals are complete, legible
and in the storage container located on the
platform.
R Cracks in welds or structural components
R Dents or damage to machine
R Be sure that all decals are legible and in place.
See Decals section.
R Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
R Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
R Be sure that both battery packs are in place,
latched and properly connected.
R 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, improperly installed or missing parts and
unauthorized modifications:
R After you complete your inspection, be sure that
all compartment covers are in place and
latched.
R Electrical components, wiring and electrical
cables
R Hydraulic power unit, reservoir, hoses,
fittings, cylinders and manifolds
R Drive and turntable motors and drive hubs
R Boom wear pads
R Tires and wheels
R Limit switches
R Nuts, bolts and other fasteners
R Platform entry mid-rail/gate
R Beacon and alarms (if equipped)
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Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
Maintenance
Check the Hydraulic Oil Level
Observe and Obey:
Only routine maintenance items specified in this
manual shall be performed by the operator.
Scheduled maintenance inspections shall be
completed by qualified service technicians,
according to the manufacturer's specifications
and the requirements specified in the
responsibilities manual.
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,
then 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.
Hydraulic oil specifications
Maintenance Symbols Legend
Hydraulic oil type
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.
Chevron Rykon
Premium MV equivalent
Indicates that tools will be required to
perform this procedure.
Indicates that new parts will be
required to perform this procedure.
Part No. 1000046
Z-30/20N
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Operator's Manual
Fourth Edition • Third Printing
MAINTENANCE
Check the Batteries
Scheduled Maintenance
Proper battery condition is essential to good
machine performance and operational safety.
Improper fluid levels or damaged cables and
connections can result in component damage and
hazardous conditions.
Electrocution hazard. Contact with
hot or live circuits could result in
death or serious injury. Remove all
rings, watches and other jewelry.
Maintenance performed quarterly, 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
inspection before they are put back into service.
Bodily injury hazard. Batteries
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 Put on protective clothing and eyewear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Remove the battery vent caps.
4 Check the battery acid level. If needed,
replenish with distilled water to the bottom of the
battery fill tube. Do not overfill.
5 Install the vent caps.
14
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
Function Tests
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.
Do Not Operate Unless:
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.
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
perform a pre-operation inspection and function
tests again before putting the machine into service.
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.
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 Push in the red Emergency Stop button to the
off position.
Result: All ground and platform control functions
should not operate.
5 Pull out the red Emergency Stop button to
the on position.
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
FUNCTION TESTS
Test the Boom Functions
Test Auxiliary Controls
6 Do not hold the function enable
switch to either side. Attempt
to activate each boom and
platform function toggle switch.
11 Turn the key switch to ground control.
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.
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.
Result: The alarm, located in the
platform, should sound.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions should operate.
Result: All boom and platform functions should
operate through a full cycle. The descent alarm
(if equipped) should sound while the boom is
lowering.
10 Press down one side of the tilt
sensor.
12 Simultaneously hold the
auxiliary power switch on and
activate each boom function
toggle switch.
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.
16
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
FUNCTION TESTS
Test Machine Functions
Test Drive and Braking
18 Press down the foot switch.
23 Press down the foot switch.
19 Activate each machine function toggle switch.
24 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: 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.
Test the Steering
20 Press down the foot switch.
21 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.
22 Depress the thumb rocker switch in the direction
identified by the yellow triangle on the control
panel.
Result: The brake release 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.
25 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 brake release 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.
Note: The brakes must be able to hold the machine
on any slope it is able to climb.
Result: The steer wheels should turn in the
direction that the yellow triangles point on the
drive chassis.
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
FUNCTION TESTS
Test Limited Drive Speed
Test the Drive Enable System
26 Press down the foot switch.
35 Press down the foot switch and retract the
primary boom to the stowed position.
27 Raise the primary boom 1 foot / 30 cm.
28 Slowly move the drive control handle to the full
drive position.
36 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.
Result: The maximum achievable drive speed
with the primary boom raised should not exceed
1 foot / 30 cm per second.
29 Lower the boom to the stowed position.
30 Raise the secondary boom 1 foot / 30 cm.
37 Move the drive control handle off center.
31 Slowly move the drive control handle to the full
drive position.
Result: The drive function should not operate.
38 Hold the drive enable toggle switch up or down
and slowly move the drive control handle off
center.
Result: The maximum achievable drive speed
with the secondary boom raised should not
exceed 1 foot / 30 cm per second.
Result: The drive function should operate.
32 Lower the boom to the stowed position.
33 Extend the primary boom 1 foot / 30 cm.
34 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, immediately tag and
remove the machine from service.
18
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 controls and the
drive chassis to identify the
direction of travel.
Z-30/20N
Blue
Yellow
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
FUNCTION TESTS
Test Auxiliary Controls
39 Press down the foot switch.
40 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, steer and drive functions
should operate.
Test the Lift/Drive Select Function
(if equipped)
41 Press down the foot switch.
42 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.
Part No. 1000046
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Operator's Manual
Fourth Edition • Third Printing
Workplace Inspection
Workplace Inspection
Be aware of and avoid the following hazardous
situations:
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator's
manual.
·
drop-offs or holes
·
bumps, floor obstructions or debris
·
sloped surfaces
·
unstable or slippery surfaces
·
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
1 Avoid hazardous situations.
2 Always perform a pre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the 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 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.
20
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Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
Operating Instructions
Fundamentals
The Operating Instructions section provides
instructions for each aspect of machine operation.
It is the operator's responsibility to follow all the
safety rules and instructions in the operator's,
safety and responsibilities manuals.
Do Not Operate Unless:
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.
Part No. 1000046
Using the machine for anything other than lifting
personnel, along with their tools and materials, to
an aerial worksite 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 a pre-operation
inspection, function tests, and a work place
inspection before using the machine.
Z-30/20N
21
Operator's Manual
Fourth Edition • Third Printing
OPERATING INSTRUCTIONS
Emergency Stop
To Position Platform
Push in the red Emergency Stop button to the off
position at the ground or platform controls to stop
all machine functions.
1 Hold the function enable switch to
either side.
2 Move the appropriate toggle switch according to
markings on the control panel.
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.
Drive and steer functions are not available from the
ground controls.
Operation from Platform
Auxiliary Controls
1 Turn the key switch to platform control.
Use auxiliary power if the primary power source
fails.
2 Pull out both ground and platform red
Emergency Stop buttons to the on position.
1 Turn the key switch to ground or platform
control.
3 Be sure that both battery packs are connected
before operating the machine.
To Position Platform
2 Pull out the red Emergency Stop button to the
on position.
3 Press down the foot switch when operating the
auxiliary controls from the platform.
4 Simultaneously hold the
auxiliary power switch on and
activate the desired function.
The boom, steer and drive functions will operate
with auxiliary power.
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.
22
1 Set the boom function speed controller to the
desired speed.
Note: Drive and steer functions are not affected by
the boom function speed controller.
2 Press down the foot switch.
3 Move the appropriate toggle switch according to
the markings on the control panel.
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 triangles on the
platform controls and the drive chassis to identify
the direction the wheels will turn.
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
OPERATING INSTRUCTIONS
To Drive
To determine the slope grade:
1 Press down the foot switch.
Measure the slope with a digital inclinometer OR
use the following procedure.
2 Increase speed: Slowly move the drive control
handle off center.
You will need:
Decrease speed: Slowly move the drive control
handle toward center.
carpenter’s level
Stop: Return the drive control handle to center
or release the foot switch.
tape measure
Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.
Machine travel speed is restricted when the booms
are raised or extended.
Battery condition will affect machine performance.
Driving on a slope
straight piece of wood, at least 3 feet / 1 m long
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.
While holding the piece of wood level, measure the
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.
Determine the uphill, downhill and side slope
ratings for the machine and determine the slope
grade.
Example:
Maximum slope rating, counterweight
uphill (gradeability): 35% (19°)
Maximum slope rating, counterweight
downhill: 20% (11°)
Maximum side slope rating: 25% (14°)
Piece of wood = 144 inches (3.6 m)
Run = 144 inches (3.6 m)
Note: Slope rating is subject to ground conditions
and adequate 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 wheels.
Part No. 1000046
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.
Z-30/20N
23
Operator's Manual
Fourth Edition • Third Printing
OPERATING INSTRUCTIONS
Drive Enable
Platform Overload Indicator
Light (if equipped)
Light on indicates that the boom has
moved past either non-steer wheel
and the drive function has been
interrupted.
Light flashing indicates the
platform is overloaded and no
functions will operate.
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 Voltage Interrupt
(if equipped)
Machines equipped with Low Voltage Interrupt will
lose primary and secondary boom up functions
from the platform when batteries are low.
Machine Not Level Indicator
Light (if equipped)
Remove weight from the platform
until the light goes off.
Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s 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.
Light on indicates the machine is not
level. The tilt alarm will be sounding
when this light is on. Move the
machine to a firm level surface.
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.
5 Chock the wheels.
6 Charge the batteries.
24
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
OPERATING INSTRUCTIONS
Dry Battery Filling and
Charging Instructions
1 Remove the battery vent caps and permanently
remove the plastic seal from the battery vent
openings.
Battery and Charger Instructions
2 Fill each cell with battery acid (electrolyte) until
the level is sufficient to cover the plates.
Observe and Obey:
Do not use an external charger or booster
battery.
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.
Charge the battery in a well-ventilated area.
3 Install the battery vent caps.
Use proper AC input voltage for charging as
indicated on the charger.
4 Charge the battery.
Use only Genie authorized battery and charger.
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.
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 The charger will indicate when the battery is fully
charged.
7 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.
Part No. 1000046
Z-30/20N
25
Operator's Manual
Fourth Edition • Third Printing
Decals
Inspection for Decals with Words
Determine whether the decals on your machine
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.
Part No.
Decal Description
27564
Danger - Electrocution Hazard
28161
Part No.
Decal Description
2
37055
Triangle - Blue
2
Warning - Crushing Hazard
3
37056
Triangle - Yellow
2
28164
Notice - Hazardous Materials
1
40434
Label - Lanyard Anchorage
2
28165
Notice - Foot Switch
1
43653
Notice - Operating Instructions, Ground
1
28171
Label - No Smoking
2
43658
Label - Power to Charger, 230V
1
28174
Label - Power to Platform, 230V
2
44980
Label - Power to Charger, 115V
1
28175
Caution - Compartment Access
1
44981
Label - Air Line to Platform
2
28176
Notice - Missing Manuals
1
44986
Notice - Max Side Force, 90 lbs / 400 N
1
28177
Warning - Platform Rotate
2
52968
Cosmetic - Genie Boom
1
28181
Warning - No Step or Ride
1
62928
Cosmetic - Genie Z-30/20N
1
28235
Label - Power to Platform, 115V
2
62929
Cosmetic - Genie Z-30/20N
2
28236
Warning - Failure To Read . . .
1
65171
Label - Circuit Breaker & Status Light
1
28372
Caution - Component Damage
2
72081
Platform Control Panel
1
31060
Danger - Tip-over Hazard, Interlock
4
72167
Cosmetic - Genie Z-30/20N RJ
1
31508
Notice - Power to Charger
1
72833
Label - Open
2
31785
Notice - Battery Charger Instructions
2
82366
Label - Chevron Rykon
1
31786
Notice - Battery Connection Diagram
2
82592
Ground Control Panel
1
31787
Danger - Tip-over, Batteries
2
97890
Danger - General Safety
2
31788
Danger - Battery/Charger Safety
2
97893
Notice - Max Side Force, 150 lbs / 667 N
1
33952
Danger - Tilt-Alarm
1
97894
Notice - Operating Instructions, Platform
1
35542
Notice - Lug Nuts
4
139586
Label - Wheel Load
4
37052
Notice - Maximum Load, 500 lbs / 227 kg 1
37053
Arrow - Blue
1
37054
Arrow - Yellow
1
26
Quantity
Z-30/20N
Quantity
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
DECALS
Serial
Plate
28161
28181
28177
40434
31060
28171
28164
43653
82592
97890
31060
65171
72833
35542
28372
139586
62929
139586
35542
Ground
Controls
Side
38188
38187
52968
37054
37056
37055
31060
72081
33952
28235
or 28174
97894
97890
28176
28236
97893
or 44986
44981
28165
37052
Chassis
Platform
38186
38185
38187
38188
28175
37055
37056
37053
44980
or 43658
31508
38185
38186
31060
40434
62928
or 72167
28161
82366
28171
28177
28161
27564
35542
28372
139586
Power
Unit
Side
Shading indicates decal is
hidden from view, i.e., under
covers.
Part No. 1000046
72833
28235 35542
44981 or 28174
139586 62929
Z-30/20N
27
Operator's Manual
Fourth Edition • Third Printing
DECALS
Inspection for Decals with
Symbols
Determine whether the decals on your machine
have words or symbols. Use the appropriate
inspection to verify that all decals are legible and in
place.
Part No.
Decal Description
28174
Label - Power to Platform, 230V
28235
Part No.
Decal Description
2
82481
Danger - Battery Safety
2
Label - Power to Platform, 115V
2
82487
Label - Operating Instructions
2
37053
Arrow - Blue
1
82544
Danger - Electrocution Hazard
2
37054
Arrow - Yellow
1
82548
Warning - Platform Rotate
2
37055
Triangle - Blue
2
82592
Ground Control Panel
1
37056
Triangle - Yellow
2
82601
Danger - Maximum Capacity, 227 kg
1
40434
Label - Lanyard Anchorage
2
82602
Danger - Maximum Side Force, 667 N
1
43658
Label - Power to Charger, 230V
1
82604
Danger - Maximum Manual Force, 400 N
1
44980
Label - Power to Charger, 115V
1
82610
Label - Circuit Breaker & Status Light
1
44981
Label - Air Line to Platform
2
82611
Label - Drive Enable Patch
1
52968
Cosmetic - Genie Boom
1
97815
Label - Lower Mid-rail
1
62928
Cosmetic - Genie Z-30/20N
1
139586
Label - Wheel Load
4
62929
Cosmetic - Genie Z-30/20N
2
72081
Platform Control Panel
1
72167
Cosmetic - Genie Z-30/20N RJ
1
82472
Warning - Crushing Hazard
3
28
Quantity
Z-30/20N
Quantity
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
DECALS
Serial
Plate
82472
28235 or
28174
Ground
Controls
Side
40434
82592
82487
82544
82548
82610
139586
52968
37054
37056
37055
62929
72081
82611
Chassis
82487
97815
82602
or 82604
44981
82601
82481
82481
37055
37056
37053
44980
or 43658
Platform
40434
62928
or 72167
82548
82472
82472
82544
Power
Unit
Side
28235 or
44981 28174 139586 62929 139586
Part No. 1000046
Z-30/20N
29
Operator's Manual
Fourth Edition • Third Printing
Transport and Lifting Instructions
Free-wheel Configuration for
Winching
1 Chock the wheels to prevent the machine from
rolling.
Disengage
Observe and Obey:
Common sense and planning must be applied to
control the movement of the machine when
lifting it with a crane or forklift.
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.
2 Release the nonsteer wheel brakes
by turning over the
drive hub
disconnect caps.
Position
Engage
Position
3 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:
Be sure the vehicle capacity, loading surfaces
and chains or straps are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.
1 Chock the wheels to prevent 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.
The machine must be on a level surface or
secured before releasing the brakes.
Do not drive the machine on a slope that
exceeds the slope or side slope rating. See
Driving on a Slope in the Operating Instructions
section.
If the slope of the transport vehicle bed exceeds
the uphill or downhill maximum slope rating, the
machine must be loaded and unloaded using a
winch as described.
30
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
TRANSPORT AND LIFTING INSTRUCTIONS
Securing the Platform
Securing to Truck or Trailer for
Transit
Make sure the jib and platform are in the stowed
position.
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.
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.
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.
Part No. 1000046
Z-30/20N
31
Operator's Manual
Fourth Edition • Third Printing
TRANSPORT AND LIFTING INSTRUCTIONS
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.
Observe and Obey:
Attach the rigging only to the designated lifting
points on the machine. There are four lifting points
on the chassis.
Only qualified riggers should rig and lift the
machine.
Be sure the crane capacity, loading surfaces
and straps or lines are sufficient to withstand
the machine weight. See the serial plate for the
machine weight.
32
Adjust the rigging to prevent damage to the
machine and to keep the machine level.
X Axis
31.19 in
79.2 cm
Y Axis
34.34 in
87.2 cm
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
Specifications
Z-30/20N without rotating jib
31/2 in
Ground clearance
8.9 cm
Weight
See Serial Plate
(Machine weights vary with option configurations)
Height, working maximum
36 ft
11 m
Height, platform maximum
30 ft
9.1 m
6 ft 7 in
2m
Horizontal reach maximum
21 ft 5 in
6.5 m
Airborne noise emissions
70 dB
Maximum sound level at normal operating workstations
(A-weighted)
Width
3 ft 11 in
1.2 m
Drive speeds
Length, stowed
16 ft 9 in
5.1 m
Drive speed, stowed
Maximum load capacity
500 lbs
227 kg
Maximum wind speed
28 mph
12.5 m/s
Wheelbase
5 ft 3 in
1.6 m
Turning radius (outside)
10 ft 7 in
3.2 m
Turning radius (inside)
5 ft 5 in
1.7 m
Height, stowed maximum
Turntable rotation
359°
Turntable tailswing
Power source
Controls
Platform dimensions,
(length x width)
0°
8 Group-L16,
6V 350AH Batteries
24V DC proportional
46 in x 30 in
1.8 m x 76 cm
Platform leveling
self-leveling
Platform rotation
180°
AC outlet in platform
standard
Hydraulic pressure, maximum
(boom functions)
2800 psi
193 bar
System voltage
Tire size (solid rubber)
48V
Drive speed,
booms raised
or extended
3.0 mph
40 ft/9 sec
4.8 km/h
12.2 m/9 sec
0.7 mph
40 ft/40 sec
1.0 km/h
12.2 m/40 sec
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.
Floor Loading Information
Tire load, maximum
7350 lbs
3334 kg
Tire contact pressure (per tire)
103 psi
710 kPa
7.24 kg/cm2
Occupied floor pressure
535 psf
25.62 kPa
2612 kg/m2
Note: Floor loading information is approximate and does
not incorporate different option configurations. It should be
used only with adequate safety factors.
173/4
22 x 7 x
in
56 x 18 x 45 cm
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
Part No. 1000046
Z-30/20N
33
Operator's Manual
Fourth Edition • Third Printing
SPECIFICATIONS
Z-30/20N with rotating jib
31/2 in
Ground clearance
8.9 cm
Weight
See Serial Plate
(Machine weights vary with option configurations)
Height, working maximum
35 ft 2 in
10.7 m
Height, platform maximum
29 ft 2 in
8.8 m
Height, stowed maximum
6 ft 7 in
2m
21 ft
6.4 m
Airborne noise emissions
70 dB
Maximum sound level at normal operating workstations
(A-weighted)
Width
3 ft 11 in
1.2 m
Drive speeds
Length, stowed
17 ft 5 in
5.3 m
Drive speed, stowed
500 lb
227 kg
Maximum wind speed
28 mph
12.5 m/s
Wheelbase
5 ft 3 in
1.6 m
Turning radius (outside)
9 ft 10 in
3.0 m
Turning radius (inside)
5 ft 5 in
1.7 m
Horizontal reach maximum
Maximum load capacity
Turntable rotation
Turntable tailswing
Power source
Controls
Platform dimensions,
(length x width)
359°
0°
8 Group-L16,
6V 350AH Batteries
24V DC proportional
46 in x 30 in
1.8 m x 76 cm
Platform leveling
self-leveling
Platform rotation
180°
Jib rotation
180°
AC outlet in platform
standard
Hydraulic pressure, maximum
(boom functions)
2800 psi
193 bar
System voltage
Tire size (solid rubber)
Drive speed,
booms raised
or extended
3.0 mph
40 ft/9 sec
4.8 km/h
12.2 m/9 sec
0.7 mph
40 ft/40 sec
1.0 km/h
12.2 m/40 sec
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.
Floor Loading Information
Tire load, maximum
7500 lbs
3402 kg
Tire contact pressure (per tire)
103 psi
710 kPa
7.24kg/cm2
Occupied floor pressure
537 psf
25.71 kPa
2622 kg/m2
Note: Floor loading information is approximate and does
not incorporate different option configurations. It should be
used only with adequate safety factors.
48V
22 x 7 x 173/4 in
56 x 18 x 45 cm
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.
34
Z-30/20N
Part No. 1000046
Operator's Manual
Fourth Edition • Third Printing
SPECIFICATIONS
Range of Motion
Range of Motion for Rotating Jib
Part No. 1000046
Z-30/20N
35
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Genie Australia Pty Ltd.
Genie Scandinavia
Phone +46 31 575100
Fax +46 31 579020
Genie France
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Genie Iberica
Phone +34 93 579 5042
Fax +34 93 579 5059
Genie Germany
Phone
Phone
Fax
0800 180 9017
+49 422 149 1818
+49 422 149 1820
Genie U.K.
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Genie Mexico City
Phone +52 55 5666 5242
Fax +52 55 5666 3241
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Genie China
Phone +86 21 53852570
Fax +86 21 53852569
Genie Malaysia
Phone +65 98 480 775
Fax +65 67 533 544
Genie Japan
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Genie Korea
Phone +82 25 587 267
Fax +82 25 583 910
Genie Brasil
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Genie Holland
Phone +31 183 581 102
Fax +31 183 581 566
Distributed By:
Genie North America
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