Genie Z-51/30J Setup guide

First Edition
Second Printing
Part No. 97900
Operator’s Manual
with Maintenance Information
Bi-Energy PowerIC Power

Operator's Manual First Edition · Second Printing
Z-51/30J PartNo.97900
Copyright © 2005 by Genie Industries
First Edition: Second Printing, March 2006
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
Printed on recycled paper
Printed in U.S.A.
Important
Read,understandandobeythesesafetyrulesand
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 ........................................................................ 1
Controls ..................................................................... 7
Legend ...................................................................... 10
Pre-operationInspection ........................................... 11
Maintenance ............................................................. 13
Function Tests.......................................................... 15
WorkplaceInspection................................................ 21
OperatingInstructions ............................................... 22
Decals ...................................................................... 28
Transportand LiftingInstructions .............................. 30
Specifications ........................................................... 33
Contact us:
Internet:http://www.genielift.com
E-mail:[email protected]

Operator's ManualFirst Edition • Second Printing
PartNo.97900 Z-51/30J 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.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandand obeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobey allapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.

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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
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Phase to Phase Approach Distance
Meters
0 to 300V Avoid Contact
300V to 50KV 3.1
50KV to 200KV 4.6
200KV to 350KV 6.1
350KV to 500KV 7.6
500KV to 750KV 10.7
750KV to 1000KV 13.7
Allow for platform movement, electrical line sway or
sag and beware of strong or gusty winds.
Keep away from the machine if it contacts
energizedpowerlines. Personnel onthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not use the machine as a ground for welding.
Donotoperate themachineduringlightningor
storms.
Tip-over Hazards
Occupants,equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipecradles, panelcradlesand welders, willreduce
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.
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.
Donot rotate the boom while lowering.Move the
machine to a firm, level surface before raising the
platform.

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PartNo.97900 Z-51/30J 3
SAFETY RULES
Do not use the platform controls to free a platform
thatis caught, snaggedorotherwise prevented
from normal motion by an adjacent structure. All
personnelmust be removed from the platform
before attempting to free the platform using the
groundcontrols.
Do not raise the boom when wind speeds may
exceed 12.5 m/s. If wind speeds exceed 12.5 m/s
when the boom is raised, lower the boom and do
notcontinue to operate the machine.
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,unstableor slippery surfaces and
nearholesanddrop-offs.
Do not alter or disable the limit switches.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesor otherhazardousconditions
withthe 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 only to machines
in the stowed position.
Maximum slope rating, stowed position
Counterweight uphill 45% 24°
Counterweight downhill 25% 14°
Side slope 25% 14°
Note: Slope rating is subject to ground conditions
andadequatetraction.
Do not push off or pull
towardany object outside
of the platform.
Maximum allowable
manual force
400 N
Do not alter or disable
machinecomponentsthat
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
withoutprior writtenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor 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.

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SAFETY RULES
Do not place or attach overhanging loads to any
part of this machine.
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
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
areproperlytightened.
Do not use air-filled tires. These machines are
equippedwith foam-filled tires. Wheel weight is
critical to stability.
Do not replace factory-installed tires with tires of
different specification or ply rating.
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 in
accordancewith
governmentalregulations.
Attach the lanyard to the
anchorprovidedinthe
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
gatebeforeoperating.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position whenrotating the
turntable.

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PartNo.97900 Z-51/30J 5
Checkthe work area for overheadobstructionsor
otherpossiblehazards.
Beawareofcrushinghazardswhengrasping the
platformguardrail.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Observeandusethecolor-codeddirectionarrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom unless the area below is
clearof personnel andobstructions.
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
outand/or precautions have been taken toprevent
any potential collision.
Nostunt driving or horseplay whileoperatinga
machine.
Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel
fuel or other explosive substances.
Donot refuel the machine with the engine running.
Refuel the machine and charge the battery only in
anopen, well-ventilatedareaaway from sparks,
flames and lighted tobacco.
Donot operate the machine in hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Donot spray etherintoengines equipped with glow
plugs.
Damaged Machine Hazards
Donot use a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besure all maintenance has been performed as
specified in this manual and the appropriate service
manual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocated on the platform.
SAFETY RULES

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SAFETY RULES
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Alwaysoperatethemachineinawell-ventilated
areatoavoidcarbonmonoxidepoisoning.
Impropercontact with componentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworkingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazard
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Electrocution Hazard
Avoid contact with electrical terminals.
Component Damage Hazards
Do not use any battery or charger greater than 12V
tojump-starttheengine.
Do not use the machine as a ground for welding.
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
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—usedtoindicateoperation
ormaintenanceinformation.

Operator's ManualFirst Edition • Second Printing
PartNo.97900 Z-51/30J 7
Controls
GroundControlPanel
1 Platform level switch
2 Platform rotate switch
3 Jibboom up/down switch
4 Turntablerotateswitch
5 Primaryboomup/downswitch
6 Primaryboom extend/retract switch
7 Notused
8 Platformoverloadindicatorlight(ifequipped)
9 Auxiliarypower switch
10 Oilpressure light
11 Key switch for platform/off/ground selection
12 RedEmergencyStop button
13 Hourmeter
14 Watertemperaturelight
15 Glowplugswitch
16 Functionenableswitch
17 Engine start switch
18 15A breaker for engine electrical circuits
19 Secondaryboomup/downswitch
20 15A breaker for control electrical circuits

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1 3
6 Drive speed select switch
7 Glowplug switch
8 Engine start switch
9 Engine idle (rpm) select switch
10 Notused
11 RedEmergencyStop button
PlatformControlPanel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 Jibboom up/down switch
5 Auxiliarypower switch
2
CONTROLS
4 5 6
171820 19

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PartNo.97900 Z-51/30J 9
CONTROLS
12 Dualaxisproportionalcontrolhandlefordrive
and steer functions
ORProportionalcontrolhandlefordrivefunction
and thumb rocker for steer function
13 Platformoverloadindicatorlight(ifequipped)
14 MachineNot Level indicatorlight (if equipped)
15 Driveenableindicatorlight
16 Driveenableswitch
117 8 9 10
1216 15
17 Proportionalcontrolhandleforsecondaryboom
up/downfunction
18 Primaryboom extend/retract switch
19 Usedforoptionalequipment
20 Dualaxisproportionalcontrolhandleforprimary
boom up/down and turntable rotate
left/rightfunctions
13
14

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Legend
1 Foot switch
2 Manualstoragecontainer
3 Slidingmid-rail
4 Lanyardanchoragepoint
5 Jibboom
6 Platform
7 Platformcontrols
8 Primaryboom
9 Secondaryboom
10 Groundcontrols
11 Steertire
12 Non-steertire

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PartNo.97900 Z-51/30J 11
Pre-operation Inspection
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.
Knowandunderstandthepre-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-operationinspectionandroutinemaintenance.
Thepre-operationinspection 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.
Thepre-operationinspectionalsoservesto
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.
Ifdamage oranyunauthorized variationfrom
factory delivered condition is discovered, the
machinemust 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.

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PRE-OPERATIONINSPECTION
Pre-operation Inspection
• Be sure that the operator’s, safety and
responsibilitiesmanualsarecomplete,legible
and in the storage container located in the
platform.
• Be sure that all decals are legible and in place.
See Decals section.
• Check for engine oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
• Check for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
• Check for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
Checkthe following components or areas for
damage,improperly installed or missingpartsand
unauthorizedmodifications:
• Electricalcomponents,wiring and
electrical cables
• Hydraulic hoses, fittings, cylinders and
manifolds
• Fuel and hydraulic tanks
• Driveand turntable motorsand drive hubs
• Boomwearpads
• Tiresandwheels
• Engineandrelatedcomponents
• Limit switches and horn
• Alarmsandbeacons(ifequipped)
• Nuts, bolts and other fasteners
• Platformentrymid-railor gate
Checkentire machine for:
• Cracks in welds or structural components
• Dentsor damage tomachine
• Excessive rust, corrosion or oxidation
• Be sure that all structural and other critical
components are present and all associated
fasteners and pins are in place and properly
tightened.
• After you complete your inspection, be sure that
all compartment covers are in place and
latched.

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PartNo.97900 Z-51/30J 13
Maintenance
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
responsibilitiesmanual.
MaintenanceSymbolsLegend
Thefollowing 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
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.
Indicates that a cold engine is required
beforeperformingthisprocedure.
Check the Engine Oil Level
Maintaining the proper engine oil level is essential
to good engine performance and service life.
Operating the machine with an improper oil level
can damage engine components.
Check the oil level with the
engine off.
1 Check the oil dipstick. Add oil as needed.
Deutz F3L 2011F Engine (Tier II)
Oil type 15W-40
Oil type - cold conditions 5W-30

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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,
then visually inspect the sight gauge located on
the side of the hydraulic oil tank.
Result: The hydraulic oil level should be within
the top 5 cm of the sight gauge.
2 Add oil as needed.
Hydraulic oil specifications
Hydraulic oil type Chevron Rykon
Premium MV equivalent
MAINTENANCE
Check the Battery
Proper battery condition is essential to good engine
performanceandoperationalsafety.Improperfluid
levels or damaged cables and connections can
resultinenginecomponentdamageandhazardous
conditions.
Electrocutionhazard. Contactwith
hot or live circuits may result in
death or serious injury. Remove all
rings, watches and other jewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contacting battery acid. Neutralize
battery acid spills with baking soda
and water.
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedand qualifiedto perform maintenanceon this
machineaccording 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.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections are
tight and free of corrosion.
3 Be sure that the battery hold-down bracket is
secure.
4 Remove the battery vent caps.
5 Check the battery acid level. If needed,
replenish with distilled water to the bottom of
the battery fill tube. Do not overfill.
6 Install the vent caps.
Adding terminal protectors and a
corrosion preventative sealant will
help eliminate corrosion on the
battery terminals and cables.

Operator's ManualFirst Edition • Second Printing
PartNo.97900 Z-51/30J 15
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.
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.
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.
Knowandunderstandthefunctiontests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

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FUNCTIONTESTS
Test the Tilt Sensor
9 Turn the key switch to
platform control. Pull out
theplatformredEmergency
Stop button to the on
position.
10 Opentheengineside
turntable cover and locate
the tilt sensor to the right of
the hydraulic pump.
11 Press down one side of the tilt sensor.
Result: The alarm, located in the platform,
shouldsound.
TestAuxiliaryControls
12 Turn the key switch to ground control and shut
the engine off.
13 Pull out the red Emergency Stop button to the
onposition.
14 Simultaneouslyholdthe
auxiliarypower switch on and
activate each boom function
toggle switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom functions should operate.
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.
4 Startthe engine. See Operating Instructions
section.
TestEmergencyStop
5 Push in the red Emergency Stop button to the
off position.
Result: The engine will shut off after 2 to 3
seconds.
6 Pull out the red Emergency Stop button to
the on position and restart the engine.
TesttheMachineFunctions
7 Donot hold the function enable
switch to either side. Attempt to
activate each boom and platform
function toggle switch.
Result: All boom and platform functions should
notoperate.
8 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
(ifequipped)should sound while the boom is
lowering.

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PartNo.97900 Z-51/30J 17
FUNCTIONTESTS
TestMachineFunctions
24 Press down the foot switch.
25 Activate each machine function control handle
or toggle switch.
Result: All boom/platform functions should
operate through a full cycle.
TesttheSteering
26 Press down the foot switch.
27 Press the thumb rocker switch on top of the
drive control handle in the direction indicated by
the blue triangle on the control panel OR slowly
move the drive/steer control handle in the
directionindicated by the blue triangle.
Result: The steer wheels should turn in the
direction that the blue triangles point on the
drive chassis.
28 Press the thumb rocker switch on top of the
drive control handle in the direction indicated by
the yellow triangle on the control panel OR
slowly move the drive/steer control handle in the
directionindicatedbytheyellowtriangle.
Result: The steer wheels should turn in the
direction that the yellow triangles point on the
drive chassis.
At the Platform Controls
TestEmergencyStop
15 Turn the key switch to platform control and
restart the engine.
16 Push in the platform red Emergency Stop
button to the off position.
Result: The engine will shut off after 2 or 3
seconds.
17 Pull out the red Emergency Stop button and
restart the engine.
Test the Horn
18 Push the horn button.
Result: The horn should sound.
Test the Foot Switch
19 Push in the platform red Emergency Stop button
to the off position.
20 Pull out the red Emergency Stop button to
the on position but do not start the engine.
21 Press down the foot switch and attempt to start
the engine by moving the start toggle switch to
either side.
Result: The engine should not start.
22 Do not press down the foot switch and restart
theengine.
Result: The engine should start.
23 Do not press down the foot switch and test each
machinefunction.
Result: The machine functions should not
operate.

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TestDriveandBraking
29 Press down the foot switch.
30 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 machine should move in the
direction that the blue arrow points on the drive
chassis, then come to an abrupt stop.
31 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 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.
Testthe Drive EnableSystem
32 Press down the foot switch and lower the boom
to the stowed position.
33 Rotatetheturntableuntil the primary boom
moves past one of the non-steer wheels.
Result:Thedrive enable
indicatorlight should come
onand remain on while the
boom is anywhere in the
rangeshown.
34 Move the drive control handle off center.
Result: The drive function should not operate.
35 Move and hold the drive enable toggle switch to
either side and slowly move the drive control
handleoff center.
Result:Thedrivefunctionshouldoperate.
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.
Usethecolor-codeddirection
arrowsontheplatform
controls and the drive
chassis to identify the
direction of travel.
FUNCTIONTESTS
Blue
Yellow