Terex Genie Z-51/30 J User manual

Operator’s Manual
Second Edition
First Printing
Part No. 114392
Serial Number Range
after 00000
with
Maintenance
Information
Australia
IC Power
Z-51 30 J

Operator's Manual
Z-51/30J PartNo.114392
Second Edition • First Printing
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
Introduction ................................................................ 1
Symboland Hazard Pictorials Definitions................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 8
Work Area Safety....................................................... 9
Legend ...................................................................... 15
Controls .................................................................... 16
Inspections ............................................................... 23
OperatingInstructions............................................... 34
TransportandLiftingInstructions .............................. 40
Maintenance ............................................................. 43
Specifications ........................................................... 46
Contact us:
Internet:www.genielift.com
E-mail:[email protected]
Copyright © 1998 by Genie Industries
First Edition: Second Printing, March 2006
Second Edition: First Printing, March 2007
"Genie" and "Z" are registered trademarks of
Genie Industries in the U.S.A. and many other
countries.
These machines comply with
ANSI/SIA 92.5
Printed on recycled paper
Printed in U.S.A.

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 1
Introduction
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
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
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,understandandobeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
Owners, Users and Operators:
Genieappreciates your choice of our machinefor
yourapplication.Ournumberonepriorityis user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the equipment users and
operators:
1 Comply with employer, job site and
governmentalrules.
2 Read, understand and follow the instructions
in this and other manuals supplied with this
machine.
3 Use goodsafe work practices ina
commonsenseway.
4 Onlyhavetrained/certifiedoperators,directed
byinformedandknowledgeablesupervision,
runningthemachine.
If there is anything in this manual that is not clear
orwhichyoubelieveshould be added, please
contact us.
Internet:www.genielift.com
E-mail:[email protected]

Operator'sManual Second Edition · First Printing
2 Z-51/30J PartNo.114392
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools and materials to an
aerial work site.
Introduction
Safety Sign Maintenance
Replace any missing or damaged safety signs.
Keep operator safety in mind at all times. Use mild
soap and water to clean safety signs. Do not use
solvent-basedcleanersbecausetheymaydamage
the safety sign material.
Hazard Classification
Genie uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
youtopotentialpersonalinjury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicatesa hazardous situation
which, if not avoided, will result in
deathorserious injury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor ormoderate injury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 3
CrushHazard ExplosionHazard FireHazard ExplosionHazard Electrocution
Hazard
FallHazard CrushHazard Tip-overHazard
Symbol and Hazard Pictorials Definitions
Tip-overHazard Electrocution
Hazard
Maintainrequired
clearance.
Readthe
operator’s
manual.
Keep off this
surface. Keepawayfrom movingparts. Keepawayfrom path of moving
platform.
Onlytrained
maintenance
personnelshould
access
compartments.
Nosmoking.
Noflame.
Stopengine. Platformuphill:
1 Lowerprimary
2 Lowersecondary
3 Retractprimary
Platformdownhill:
1 Retract primary
2 Lowersecondary
3 Lowerprimary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.

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4 Z-51/30J PartNo.114392
Lanyard
attachmentpoint
Symbol and Hazard Pictorials Definitions
Wheelload Voltageratingfor
powertoplatform Pressureratingfor air line to platform Replacetires with
same tire.
Tie-down
instructions Tie-down instructions

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PartNo.114392 Z-51/30J 5
General Safety
Safety
signs and
locations

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6 Z-51/30J PartNo.114392
General Safety
Safety signs and locations

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 7
General Safety
Safety signs and locations

Operator'sManual Second Edition · First Printing
8 Z-51/30J PartNo.114392
Personal Safety
Fall Protection
Personal fall protection equipment (PFPE) is
requiredwhenoperatingthismachine.
Occupants must wear a safety belt or harness in
accordancewithgovernmentalregulations.Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
All PFPE must comply with applicable
governmentalregulations,andmustbeinspected
and used in accordance with the PFPE
manufacturer’sinstructions.

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 9
Work Area Safety
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.
LineVoltage Required Clearance
0 to 50KV 3.0 m
50 to 200KV 4.6 m
200 to 350KV 6.1 m
350 to 500KV 7.6 m
500 to 750KV 10.6 m
750 to 1000KV 13.7 m
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. Personnelontheground or
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.
Donotoperatethemachineduring lightningor
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 with the
options.
If using accessories, read, understand and obey
the decals and instructions with the accessory.

Operator'sManual Second Edition · First Printing
10 Z-51/30J PartNo.114392
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 while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surfacebefore raising theplatform.
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,
levelsurface.Do not rotate the boomwhilelowering.
If the tilt alarm sounds with the
platformuphill:
1 Lowertheprimaryboom.
2 Lowerthesecondaryboom.
3 Retractthe primaryboom.
If the tilt alarm sounds with
theplatformdownhill:
1 Retractthe primaryboom.
2 Lowerthesecondary
boom.
3 Lowertheprimaryboom.
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.
Donotdrivethe machine on or near uneven terrain,
unstablesurfacesorotherhazardousconditions
withthe boom raised or extended.
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.
Work Area Safety
3
3

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 11
Work Area Safety
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)intheplatform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition, air-filled tires
areproperlyinflated andlugnutsareproperly
tightened.
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 push off or pull
towardany objectoutside
of the platform.
Maximum allowable
manual force
400 N
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 replace factory-installed tires with tires of
different specification or ply rating.
Do not use air-filled tires. These machines are
equippedwithfoam-filledtires.Wheelweightand
propercounterweightconfigurationarecriticalto
stability.
Do not modify or alter an aerial work platform
withoutpriorwrittenpermission 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.

Operator'sManual Second Edition · First Printing
12 Z-51/30J PartNo.114392
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.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Operation on Slopes Hazards
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, 4WD
Platform downhill 45% (24°)
Platform uphill 25% (14°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
and adequate traction. See Driving on a Slope in
the Operating Instructions section.
Work Area Safety

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 13
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position and tailswing when
rotatingtheturntable.
Checkthe work area foroverheadobstructionsor
otherpossiblehazards.
Beawareof crushinghazards whengraspingthe
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 operate a boom in the path of any crane
unless the controls of the crane have been locked
outand/or precautions have been takentoprevent
any potential collision.
Nostunt driving or horseplaywhileoperating a
machine.
Do not lower the boom unless the area below is
clearof personnelandobstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
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.
Work Area Safety

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14 Z-51/30J PartNo.114392
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworking withbatteries.
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.
Lockout After Each Use
1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is between
thenon-steerwheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.
5 Chockthewheels.
Work Area Safety
Explosion and Fire Hazards
Do not start the engine if you smell or detect liquid
petroleumgas (LPG), gasoline, diesel fuel or other
explosive substances.
Donot refuel the machine with the enginerunning.
Refuel the machine and charge the battery only in
anopen, well-ventilatedareaaway fromsparks,
flames and lighted tobacco.
Donot operate the machine in hazardous locations
orlocationswherepotentiallyflammableor
explosive gases or particles may be present.
Donot spray etherintoengines equipped withglow
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
specifiedin this manual andtheappropriate Genie
servicemanual.
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.
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.

Operator'sManualSecond Edition · First Printing
PartNo.114392 Z-51/30J 15
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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16 Z-51/30J PartNo.114392
Controls
1 3
6 Drive speed select switch
7 Diesel models: Glow plug switch
8 Engine start switch
9 Engine idle (rpm) select switch
10 Gasoline/LPGmodels:Gasoline/LPG
select switch
PlatformControlPanel
1 Hornbutton
2 Platform level switch
3 Platform rotate switch
4 Jibboom up/down switch
5 Auxiliarypower switch
2 4 5 6
171820 19

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PartNo.114392 Z-51/30J 17
Controls
11 RedEmergencyStop button
12 Dualaxisproportionalcontrol handlefordrive
and steer functions
ORProportionalcontrolhandlefordrivefunction
and thumb rocker for steer function
13 Platformoverloadindicatorlight(ifequipped)
14 Machinenotlevelindicatorlight(ifequipped)
15 Driveenableindicatorlight
117 8 9 10
1216 15 13
14
16 Driveenableswitch
17 Proportionalcontrolhandleforsecondaryboom
up/downfunction
18 Primaryboom extend/retract switch
19 usedforoptionalequipment
20 Dualaxisproportionalcontrolhandleforprimary
boomup/downandturntablerotate
left/right functions

Operator'sManual Second Edition · First Printing
18 Z-51/30J PartNo.114392
PlatformControlPanel
1 Hornbutton
Push the horn button and the horn will sound.
Release the horn button and the horn will stop.
2 Platform level switch
Move the platform level
switch up and the level of
the platform will raise. Move
the platform level switch
down and the level of the
platformwilllower.
3 Platform rotate switch
Movethe platform rotate
switch to the right and the
platform will rotate to the
right. Move the platform
rotate switch to the left and
the platform will rotate to the left.
4 Jibboom up/down switch
Move the jib boom switch up
and the jib boom will raise.
Move the jib boom switch down
and the jib boom will lower.
5 Auxiliarypower switch
Useauxiliary power if the primary power source
(engine)fails.
Simultaneouslyholdtheauxiliarypowerswitch
to either side and activate the desired function.
6 Drive speed select switch
Machineoninclinesymbol:Lowrangeoperation
for inclines.
Machine on level surface symbol: High range
operationformaximumdrive speed.
7 Glowplug switch
Move the glow plug switch to either side and
hold for 3 to 5 seconds.
8 Engine start switch
Move the engine start switch to either side to
start the engine.
9 Engine idle (rpm) select switch
Move the engine idle select switch to the turtle
position for foot switch activated low idle.
Move the engine idle select switch to the rabbit
position for foot switch activated high idle.
10 Gasoline/LPG models: Fuel select switch
Move the fuel select switch to the gasoline
position to select gasoline. Move the fuel select
switch to the LPG position to select LPG.
11 RedEmergencyStop button
Push in red Emergency Stop button to the off
position to stop all functions and turn the engine
off. Pull out the red Emergency Stop button to
the on position to operate the machine.
Controls