Terex Z-30/20N User manual

Operator's Manual
Serial Number Range
Z
®
-
30/20N from Z30NF
-
22000 ANSI/CSA
North America
South America
Asia
Z
®
-
30/20N RJ from Z30ND
-
1400
with
Maintenance
Information
Original Instructions
Seventh Edition
First Printing
Part No. 1297932GT

Operator's Manual Seventh Edition • First Printing
Z
®-30/20N • Z®-30/20N RJ Part No. 1297932GT
Front Matter
Contents
Introduction ........................................................... 1
Symbol and Hazard Pictorials Definitions............. 6
General Safety ...................................................... 8
Personal Safety................................................... 12
Work Area Safety................................................ 13
Legend ................................................................ 21
Controls............................................................... 22
Inspections.......................................................... 24
Operating Instructions......................................... 39
Transport and Lifting Instructions ....................... 47
Maintenance ....................................................... 51
Specifications...................................................... 53
Copyright © 1995 Terex Corporation
Seventh Edition: First Printing, February 2020
Genie and "Z" are registered trademarks of Terex South Dakota,
Inc. in the U.S.A. and many other countries.
These machines comply with
ANSI A92.20
CSA B354.6

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 1
Introducti on
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
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,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial number stamped
on chassis
Serial label
(located under cover)
Intended Use and Familiarization
Guide
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site. Before operating the machine, it’s
the operator’s responsibility to read and
understand this familiarization guide.
Each person must be trained to operate a
Mobile Elevating Work Platform (MEWP).
Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Only trained and authorized personnel should
be permitted to operate the machine.
The operator is responsible to read,
understand, and obey the manufacturer’s
instructions and safety rules provided in the
Operator’s Manual.
The Operator’s Manual is located in the
manual storage container, at the platform.
For specific product applications, see
Contacting The Manufacturer.

Operator's Manual Seventh Edition • First Printing
Introduction
2 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
Platform controls symbology and related
machine movement:
Platform level swtich
Platform rotate switch
Jib boom up/down
Primary boom up/down
Turntable rotate
Primary boom extend/retract
switch
Secondary boom up/down
Drive forward/reverse
Steer right/left
Ground controls symbology and related
machine movement:
Platform level, jib
boom up/down,
primary boom
extend/retract,
primary boom
up/down, and
secondary boom
retract/lower.
Turntable rotate and
platform rotate
Sequential functions and movement:
Drive and steer.
Interlocked functions:
Elevated drive speed.
Elevated drive in an off-level condition.
Drive enable when the boom is rotated past the
non-steer wheels.
All platform and ground controls.
Limitations of use:
The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
Do not elevate the platform unless the machine
is on firm level ground.
Stability enhancing means:
Foam filled tires.
Restricted operating envelope:
500 lbs/227 kg platform capacity.

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 3
Bulletin Distribution and
Compliance
Safety of product users is of paramount
importance to Genie. Various bulletins are used by
Genie to communicate important safety and
product information to dealers and machine
owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their
associated dealer, so it is important to register your
machine and keep your contact information up to
date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

Operator's Manual Seventh Edition • First Printing
Introduction
4 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
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.
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-based cleaners because they may damage
the safety sign material.

Seventh Edition • First Printing Operator's Manual
Introduction
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 5
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
DANGER
WARNING
CAUTION
NOTICE

Operator's Manual Seventh Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
Symbol and Hazard Pic torials Definiti ons
Fire hazard Explosion hazard Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking.
No flame.
Stop engine.
Crush hazard No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Grounded AC
3-wire only
Replace damaged
wires and cords
Replace tires with
tires of same
specification.
Wheel load Wind speed Maximum capacity Side force Batteries used as
counterweights
Tie-down point Lifting point Platform tie-down
instructions
Lifting & tie down
instructions
Lanyard anchorage
points

Seventh Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 7
Corrosive acid. Color coded direction
arrows
Runaway hazard Collision hazard Collision hazard
Electrocution hazard Avoid contact Disconnect battery Voltage rating for
power to platform
Pressure rating for air
line to platform
Recovery procedure if tilt alarm sounds while
elevated.
Platform uphill:
1Lower primary.
2Lower secondary.
3Retract primary.
Platform downhill:
1Retract primary.
2Lower secondary.
3Lower primary.
Read the operator’s
manual
Read the service
manual
Access by trained and
authorized personnel
only

Operator's Manual Seventh Edition • First Printing
General Safety
8 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
General Safety
1280819
Annual Inspection Record
Failure to complete required inspections
could result in death or serious injury.
Model Serial number
Date of
Inspection
Inspected
by
Machine
Owner
52865 B
WARNING
Scheduled maintenance
inspections must be
completed as specified in
the appropriate service
manual.
Use this decal to record
the date of the annual
inspection, the initials of
the inspector and the
machine owner.
Use the maintenance
inspection report in the
service manual for required
recordkeeping. Keep
records on all inspections
for four years.
Maintenance inspections
must be completed by a
person trained and qualified
on the maintenance of this
machine.
114390
1267121
31060
52865
31060
114390
1263543
1263543

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 9
* These decals are model, option or configuration specific.
** These decals are installed on both sides of chassis.
31787
31508 31788
**1298847
**31060
1263543
114390
218559
219487
28236 31060
*218550
114397
1298837
72875
*1299791

Operator's Manual Seventh Edition • First Printing
General Safety
10 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
1330671286362
114252
82487
133067
114252
1263542
1263542

Seventh Edition • First Printing Operator's Manual
General Safety
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 11
* These decals are model, option or configuration specific.
** These decals are installed on both sides of chassis.
114334
**114249
1263542
133067
219958
219956
82487 114252
114248
82487
114252
1299439
82487
82481
*219954
1299436
*1299792

Operator's Manual Seventh Edition • First Printing
Personal Safety
12 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
Personal Safety
Personal Fall Protection
Personal fall protection equipment (PFPE) is
required when operating this machine.
Occupants must wear a safety belt or harness in
accordance with governmental regulations. Attach
the lanyard to the anchor provided in the platform.
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 13
WorkArea 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
and apparatus in accordance with applicable
governmental regulations and the following chart.
Voltage
Phase to Phase
Minimum Safe
Approach Distance
0 to 300V Avoid Contact
300V to 50KV 10 ft 3.05 m
50KV to 200KV 15 ft 4.60 m
200KV to 350KV 20 ft 6.10 m
350KV to 500KV 25 ft 7.62 m
500KV to 750KV 35 ft 10.67 m
750KV to 1000KV 45 ft 13.72 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
energized power lines. Personnel on the ground or
in the platform must not touch or operate the
machine until energized power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity.
Maximum platform capacity 500 lbs 227 kg
Machine equipped with Aircraft
Protection Package
440 lbs 200 kg
Maximum occupants 2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
14 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
If the tilt alarm sounds while the boom is lowered:
Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the
boom on the slope as shown below. Follow the
steps to lower the boom before moving to a firm,
level surface. Do not rotate the boom while
lowering.
If the tilt alarm sounds with
the platform uphill:
1Lower the primary
boom.
2Lower the secondary
boom.
3Retract the primary
boom.
If the tilt alarm sounds with
the platform downhill:
1Retract the primary
boom.
2Lower the secondary
boom.
3Lower the primary
boom.
Do not alter or disable the limit switches.
Do not drive over 0.7 mph/1 km/h with the primary
boom raised or extended or the secondary boom
raised.
Do not use the platform controls to free a platform
that is caught, snagged, or otherwise prevented
from normal motion by an adjacent structure. All
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not raise the boom when wind speeds may
exceed 28 mph/12.5 m/s. If wind speeds exceed
28 mph/12.5 m/s when the boom is raised, lower
the boom and do not continue to operate the
machine.
Do not operate the
machine in strong or gusty
winds. Do not increase the
surface area of the
platform or the load.
Increasing the area
exposed to the wind will
decrease machine
stability.
Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery surfaces and near
holes and drop-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 15
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.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable side
force - 90 lbs/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 modify or alter a mobile elevating 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
fixed or overhanging loads
to any part of this
machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled
by person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure the tires are in good condition and the lug
nuts 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 a minimum of 105 lbs /
47.6 kg. Each battery box including batteries must
weigh a minimum of 530 lbs / 240.4 kg.
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.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
16 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
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 side slope rating, stowed position
Platform downhill 35% (19°)
Platform uphill 20% (11°)
Side slope 25% (14°)
Note: Slope rating is subject to ground conditions
with one person in the platform and adequate
traction. Additional platform weight may reduce
slope rating. See Driving on a Slope in the
Operating Instructions section.
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand, or climb
on the platform guard
rails. Maintain a firm
footing on the platform
floor at all times.
Do not climb down from
the platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Hazards related with the specific product
application of exiting at height have been
considered in the design of the machine, for further
information contact Genie (see section Contacting
the Manufacturer).

Seventh Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1297932GT Z®-30/20N • Z®-30/20N RJ 17
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site,
and governmental rules regarding 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.
Do not lower the boom
unless the area below is
clear of personnel and
obstructions.
Limit travel speed
according to the condition
of the ground surface,
congestion, slope,
location of personnel, and
any other factors which
may cause collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.

Operator's Manual Seventh Edition • First Printing
Work Area Safety
18 Z®-30/20N • Z®-30/20N RJ Part No. 1297932GT
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.
Explosion and Fire Hazards
Charge the battery only in an open, well-ventilated
area away from sparks, flames and lighted
tobacco.
Do not operate the machine in hazardous locations
or locations where potentially flammable or
explosive gases or particles may be present.
Damaged Machine Hazards
Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the
machine and test all functions before each work
shift. Immediately tag and remove from service a
damaged or malfunctioning machine.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie
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 machine.
Component Damage Hazards
Do not use the machine as a ground for welding.