Terex Genie Z-51/30J Manuals

Maintenance Manual - Booms S® Booms This manual includes detailed procedures for each maintenance inspection. Z® Booms For Repair procedures, Fault Codes, Electrical and Hydraulic Schematics, refer to the appropriate Service and Repair Manual for your machine. Refer to the inside cover for a list of models included in this manual. Part No. 1268489GT Rev J May 2020 Maintenance Manual May 2020 Introduction ii S® Booms • Z® Booms Part No. 1268489GT Intro ductio n Intro ductio n Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance be performed at an authorized Genie dealer service center. Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: Internet: www.genielift.com E-mail: [email protected] Copyright © 2015 by Terex Corporation 1268489GT Rev J, May 2020 First Edition, Ninth Printing Genie, "S" and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "TraX" and "XC" are trademarks of Terex South Dakota, Inc. May 2020 Maintenance Manual Introduction Part No. 1268489GT S® Booms • Z® Booms iii Models included in this manual Use the following chart to identify the specific serial number for models included in this manual. Models Serial number S-40, S-45, S- 40HF, S-45HF, S-40XC, S-45XC from S4015-20505 to S4016H-23499 from S4515-20505 to S4516H-23499 from S40H-23500 from S45H-23500 from S40XCH-101 from S45XCH-101 S-60, S-65, S- 60HF, S-65HF, S-60J, S-60X, S-60XC, S- 65XC from S6013-26296 to S6016-31260 from S6016N-31261 to S6016N-35000 from S6016H-35001 to S6016H-36399 from S6014D-101 to S6016D-639 from S6016M-101 to S6016M-399 from S60X13-26296 to S60X16H-36399 from S60XC13-26296 to S60XC16H-36399 from S60HC13-26296 to S60HC15A- 29544 from S60TX13-26296 to S60TX16H- 36399 from S60TX14D-101 to S60TX16D-639 from S65TX13-26296 to S65TX16H-36399 from S65TX14D-101 to S65TX16D-639 from S60H/S60X/S60TX/S65TXH-36400 from S60XCH-36400 to S60XCH-45000 from S60XCH/S65XCH-45001 from S60/S60TX/S60XD-640 from S60JH-101 from S60M-400 from S65XCM-101 from S65TXM-101 S-80, S-85, S- 80X, S-80XC, S-85XC. S- 80HF, S-85HF from S80/85/80X15-12264 to16H-13999 from S80/85/80X15D-101 to 16D-339 from S80/85/80XH-14000 from S80/85/80XD-340 from S80/85XCH-101 S-100, S-105 from S10015D-1001 to S10016D-1549 from S10515D-983 to S10516D-1549 from S100D-1550 from S105D-1550 S-120, S-125 from S12015D-1012 to S12016D-1549 from S12515D-984 to S12516D-1549 from S120D-1550 from S125D-1550 S-100HD, S-120HD from S100HD14D-200 to S100HD16D-229 from S120HD14D-201 to S120HD16D-229 from S100/S120HDD-230 SX-105 XC from SX105D-101 SX-125 XC from SX125D-101 SX-135 XC from SX135H-101 SX-150 from SX15015-100 to SX15016H-499 from SX150H-500 SX-180 from SX18014-101 to SX18016H-599 from SX180H-600

Maintenance Manual - Booms S® Booms This manual includes detailed procedures for each maintenance inspection. Z® Booms For Repair procedures, Fault Codes, Electrical and Hydraulic Schematics, refer to the appropriate Service and Repair Manual for your machine. Refer to the inside cover for a list of models included in this manual. Part No. 1268489GT Rev J1 March 2022 Maintenance Manual March 2022 Introduction ii S® Booms • Z® Booms Part No. 1268489GT Intro ductio n Intro ductio n Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance be performed at an authorized Genie dealer service center. Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: Internet: www.genielift.com E-mail: [email protected] Copyright © 2015 by Terex Corporation 1268489GT Rev J, May 2020 First Edition, Ninth Printing Genie, "S" and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "TraX" and "XC" are trademarks of Terex South Dakota, Inc. March 2022 Maintenance Manual Introduction Part No. 1268489GT S® Booms • Z® Booms iii Models included in this manual Use the following chart to identify the specific serial number for models included in this manual. Models Serial number S-40, S-45, S- 40HF, S-45HF, S-40XC, S-45XC from S4015-20505 to S4016H-23499 from S4515-20505 to S4516H-23499 from S40H-23500 from S45H-23500 from S40XCH-101 from S45XCH-101 S-60, S-65, S- 60HF, S-65HF, S-60J, S-60X, S-60XC, S- 65XC from S6013-26296 to S6016-31260 from S6016N-31261 to S6016N-35000 from S6016H-35001 to S6016H-36399 from S6014D-101 to S6016D-639 from S6016M-101 to S6016M-399 from S60X13-26296 to S60X16H-36399 from S60XC13-26296 to S60XC16H-36399 from S60HC13-26296 to S60HC15A- 29544 from S60TX13-26296 to S60TX16H- 36399 from S60TX14D-101 to S60TX16D-639 from S65TX13-26296 to S65TX16H-36399 from S65TX14D-101 to S65TX16D-639 from S60H/S60X/S60TX/S65TXH-36400 from S60XCH-36400 to S60XCH-45000 from S60XCH/S65XCH-45001 from S60/S60TX/S60XD-640 from S60JH-101 from S60M-400 from S65XCM-101 from S65TXM-101 S-80, S-85, S- 80X, S-80XC, S-85XC, S- 80HF, S-85HF, S-80J from S80/85/80X15-12264 to16H-13999 from S80/85/80X15D-101 to 16D-339 from S80/85/80XH-14000 from S80/85/80XD-340 from S80/85XCH-101 from S80JH-101 S-100, S-105 from S10015D-1001 to S10016D-1549 from S10515D-983 to S10516D-1549 from S100D-1550 from S105D-1550 S-120, S-125 from S12015D-1012 to S12016D-1549 from S12515D-984 to S12516D-1549 from S120D-1550 from S125D-1550 S-100HD, S-120HD from S100HD14D-200 to S100HD16D-229 from S120HD14D-201 to S120HD16D-229 from S100/S120HDD-230 SX-105 XC from SX105D-101 SX-125 XC from SX125D-101 SX-135 XC from SX135H-101 SX-150 from SX15015-100 to SX15016H-499 from SX150H-500 SX-180 from SX18014-101 to SX18016H-599 from SX180H-600

Operator's Manual Z-45/25 AUS Australia Z-45/25J Z-51/30J IC Power with Maintenance Information Seventh Edition First Printing Part No. 219414 Operator's Manual Seventh Edition • First Printing Z-45/25 • Z-45/25J • Z-51/30J Part No. 219414 Front Matter Contents Introduction ........................................................... 1 Symbol and Hazard Pictorials Definitions ............. 5 General Safety ...................................................... 7 Personal Safety ................................................... 10 Work Area Safety ................................................ 11 Legend ................................................................ 18 Controls ............................................................... 19 Inspections .......................................................... 27 Operating Instructions ......................................... 38 Transport and Lifting Instructions ....................... 44 Maintenance ....................................................... 47 Specifications ...................................................... 51 Copyright © 2012 Terex Corporation Seventh Edition: First Printing, June 2013 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS 1418.14 Seventh Edition • First Printing Operator's Manual Introduction Part No. 219414 Z-45/25 • Z-45/25J • Z-51/30J 1 Introduction 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. Intended Use This machine is intended to be used only to lift personnel, along with their tools and materials to an aerial work site. 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. Sequence number stamped on chassis Serial label (located under cover)

Operator's Manual Serial Number Range Z®-51/30J from Z5130M-3501 CE with Maintenance Information Original Instructions Eighth Edition First Printing Part No. 1305352GT Operator's Manual Eighth Edition • First Printing Z®-51/30J Part No. 1305352GT Front Matter Manufacturer Terex Global GmbH Bleicheplatz 2 Schaffhausen, 8200 Switzerland Authorized representative: Genie Industries B. V. Boekerman 5 4751 XK OUD GASTEL The Netherlands Contents Introduction ........................................................... 1 Symbol and Hazard Pictorials Definitions ............. 6 General Safety ...................................................... 9 Personal Safety ................................................... 12 Work Area Safety ................................................ 13 Legend ................................................................ 22 Controls ............................................................... 23 Inspections .......................................................... 37 Operating Instructions ......................................... 49 Transport and Lifting Instructions ....................... 61 Maintenance ....................................................... 64 Specifications ...................................................... 68 Copyright © 2012 Terex Corporation Eighth Edition: First Printing, June 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Eighth Edition • First Printing Operator's Manual Introduction Part No. 1305352GT Z®-51/30J 1 Introduction 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. 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 Eighth Edition • First Printing Introduction 2 Z®-51/30J Part No. 1305352GT Platform controls symbology and related machine movement: Platform level Platform rotate Jib boom up/down Primary boom up/down Turntable rotate Primary boom extend/retract Secondary boom up/down Drive forward/reverse Steer right/left

Service and Repair Manual Serial Number Range Z®-51/30J from Z513014B-1201 to Z513016M-1999 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics from Z5130M-2000 For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268553GT Rev A2 November 2017 Service and Repair Manual November 2017 Introduction ii Z®-51/31J Part No. 1268553GT Intr oducti on Intr oducti on Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any procedure. This manual provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: Internet: www.genielift.com E-mail: [email protected] Find a Manual for this Model Go to http://www.genielift.com Use the links to locate Service Manuals, Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals. Copyright © 2015 by Terex Corporation 1268553 Rev A, September 2015 First Edition, First Printing Genie and “Z” are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. November 2017 Service and Repair Manual Introduction Part No. 1268553GT Z®-51/31J iii Revision History Revision Date Section Procedure / Page / Description A 9/2015 Initial Release A1 9/2016 Introduction Serial Number Legend A2 11/2017 Specifications Machine Specifications Reference Examples: Electronic Version Click on any content or procedure in the Table of Contents to view the update. Section – Repair Procedure, 4-2 Section – Fault Codes, All charts Section – Schematics, Legends and schematics Service and Repair Manual November 2017 Introduction iv Z®-51/31J Part No. 1268553GT Serial Number Legend To August 31, 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number (stamped on chassis) 6 Serial label (located under cover) From September 1, 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number (stamped on chassis) 5 Serial label (located under cover)