Terex Genie Z-40N Operator's Manual
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Terex Genie Z-40N Operator's Manual

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Operator's Manual
Z
-40N
®
Z
-40N RJ
®
Serial Number Range
from Z40NF-6900
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
Original Instructions
Third Edition
First Printing
Part No. 1315875GT

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  • Page 1 Operator's Manual Serial Number Range -40N ® ANSI/CSA from Z40NF-6900 North America -40N RJ ® South America Asia with Maintenance Information Original Instructions Third Edition First Printing Part No. 1315875GT...

  • Page 2: Table Of Contents

    Maintenance ............54 Specifications ............56 Copyright © 2006 Terex Corporation Third Edition: First Printing, September 2022 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/SAIA A92.20 CAN/CSA B354.6...

  • Page 3: Introduction

    Third Edition • First Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • First Printing Introduction Platform controls symbology and related Turntable rotate machine movement: Platform level Primary boom extend/retract Platform rotate Secondary boom up/down Jib boom up/down Drive forward/reverse Jib boom rotate Primary boom up/down Steer right/left -40N •...
  • Page 5 Third Edition • First Printing Operator's Manual Introduction Ground controls symbology and related Sequential functions and movement: machine movement: Drive and steer. • Platform level Interlocked functions: Elevated drive speed. • Elevated drive in an off-level condition. • Platform rotate Drive enable when the boom is rotated past the •...
  • Page 6 Operator's Manual Third Edition • First Printing Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 7 Third Edition • First Printing Operator's Manual 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-based cleaners because they may damage the safety sign material.

  • Page 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Third Edition • First Printing Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine.
  • Page 9 Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wheel load Wind speed Maximum capacity Manual force Support the platform or boom during maintenance Tie-down point Lifting point Platform tie-down Lifting and tie down Lanyard anchorage instructions instructions points Corrosive acid.
  • Page 10 Operator's Manual Third Edition • First Printing Symbol and Hazard Pictorials Definitions Electrocution hazard Avoid contact Disconnect battery Voltage rating for Pressure rating for air power to platform line to platform Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Read the operator’s Access by trained...

  • Page 11: General Safety

    Third Edition • First Printing Operator's Manual General Safety Gener al Safety Part No. 1315875GT -40N • Z -40N RJ ® ®...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety -40N • Z -40N RJ Part No. 1315875GT ® ®...
  • Page 13 Third Edition • First Printing Operator's Manual General Safety Part No. 1315875GT -40N • Z -40N RJ ® ®...
  • Page 14 Operator's Manual Third Edition • First Printing General Safety -40N • Z -40N RJ Part No. 1315875GT ® ®...
  • Page 15 Third Edition • First Printing Operator's Manual General Safety Part No. 1315875GT -40N • Z -40N RJ ® ®...
  • Page 16 Operator's Manual Third Edition • First Printing General Safety -40N • Z -40N RJ Part No. 1315875GT ® ®...

  • Page 17: Personal Safety

    Third Edition • First Printing Operator's Manual Personal Safety Pers onal 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.

  • Page 18: Work Area Safety

    Operator's Manual Third Edition • First Printing Work Area Safety Electrocution Hazards Work Ar ea Safety Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the proximity to electrical current.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds when the platform is raised, boom unless the machine use extreme caution. The Machine Not Level indicator light will come on and the drive function is on a firm, level surface.
  • Page 20 Operator's Manual Third Edition • First Printing Work Area Safety Do not raise the boom Do not modify or alter a mobile elevating work when wind speeds may platform without prior written permission from the exceed 28 mph/12.5 m/s. manufacturer. Mounting attachments for holding If wind speeds exceed tools or other materials onto the platform, 28 mph/12.5 m/s when the...
  • Page 21 Third Edition • First Printing Operator's Manual Work Area Safety Fall Hazards Do not use batteries that weigh less than the original equipment. Batteries are used as Occupants must wear a counterweight and are critical to machine stability. safety belt or harness in Each battery must weigh a minimum of accordance with 105 lbs / 47.6 kg.
  • Page 22 Operator's Manual Third Edition • First Printing Work Area Safety Collision Hazards Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive and steer functions. Be aware of limited sight distance and blind spots Do not lower the boom when driving or operating.
  • Page 23 Third Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Do not operate the machine with a hydraulic oil or Do not use a damaged or malfunctioning machine. air leak. An air leak or hydraulic leak can penetrate Conduct a thorough pre-operation inspection of and/or burn skin.
  • Page 24 Operator's Manual Third Edition • First Printing Work Area Safety Battery Safety Component Damage Hazard Do not use any battery charger greater than 48V Burn Hazards to charge the batteries. Batteries contain acid. Always wear protective Both battery packs must be charged together. clothing and eye wear when working with batteries.

  • Page 25: Legend

    Third Edition • First Printing Operator's Manual Legend Legend Foot switch Primary boom Manual storage container Secondary boom Sliding mid-rail 10 Ground controls Lanyard anchorage points 11 Power to charger (between steer tires) Platform 12 Steer tire Platform controls 13 Battery box Jib boom 14 Non-steer tire Part No.

  • Page 26: Controls

    Operator's Manual Third Edition • First Printing Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 27 Third Edition • First Printing Operator's Manual Controls Ground Control Panel Primary boom extend/retract switch Platform rotate switch Move the switch to the left and the boom will extend. Move the platform rotate Move the switch to the switch to the right and right and the boom will the platform will rotate to retract.
  • Page 28 Operator's Manual Third Edition • First Printing Controls 11 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red Emergency Stop button to the on position to operate the machine. 12 Hour meter The hour meter displays the number of hours the machine has operated.
  • Page 29 Third Edition • First Printing Operator's Manual Controls STOP Platform Control Panel Part No. 1315875GT -40N • Z -40N RJ ® ®...
  • Page 30 Operator's Manual Third Edition • First Printing Controls Platform Control Panel Function speed control switch Move the switch to the Horn button left to decrease the Press this button and the horn will sound. function speeds for Release the button and the horn will stop. primary boom extend/retract, Platform level switch...
  • Page 31 Third Edition • First Printing Operator's Manual Controls Auxiliary power switch 14 LCD readout screen Use auxiliary power if the primary power source (engine) fails. Simultaneously hold the auxiliary power switch to either side and activate the desired function. 10 Red Emergency Stop button Push in the red Emergency Stop button to the see operator's manual off position to stop all functions and turn the...

  • Page 32: Inspections

    Operator's Manual Third Edition • First Printing Inspections Ins pections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 33 Third Edition • First Printing Operator's Manual Inspections Pre-operation Inspection Check entire machine for:  Cracks in welds or structural components  Be sure that the operator’s, safety, and  Dents or damage to machine responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 34 Operator's Manual Third Edition • First Printing Inspections Function Test 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 35 Third Edition • First Printing Operator's Manual Inspections At the Ground Controls Test the Tilt Sensor Select a test area that is firm, level and free of Turn the key switch to hazards. platform control. Pull out the platform red Emergency Turn the key switch to ground control.
  • Page 36 Operator's Manual Third Edition • First Printing Inspections At the Platform Controls Test Machine Functions and Descent Alarm 14 Turn the key switch to platform control. 21 Press down the foot switch. 15 Pull out the platform red Emergency Stop 22 Activate each machine function control handle button to the on position.
  • Page 37 Third Edition • First Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 26 Press down the foot switch. 29 Press down the foot switch and lower the boom to the stowed position. 27 Slowly move the drive control handle in the direction indicated by the blue arrow on the 30 Rotate the turntable until the primary boom control panel until the machine begins to...
  • Page 38 Operator's Manual Third Edition • First Printing Inspections Test Limited Drive Speed Test Drive Tilt Cutout 33 Press down the foot switch. 43 Press down the foot switch. 34 Raise the primary boom approximately 44 With the boom fully stowed, drive the machine 3 ft/91 cm.
  • Page 39 Third Edition • First Printing Operator's Manual Inspections 51 Return to level ground and stow the boom. 58 Lower the primary boom to the stowed position or drive in the opposite direction. 52 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is Result: The machine should drive.
  • Page 40 Operator's Manual Third Edition • First Printing Inspections Test Auxiliary Power Test the Contact Alarm (if equipped) 74 Pull out the red Emergency Stop button to the 67 Do not activate the foot switch and press on on position. the contact alarm cable to release the actuator from the switch socket.
  • Page 41 Third Edition • First Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces You learn and practice the principles of safe ...
  • Page 42 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Words Part No. Decal Description 114180 Label - Wheel Load Use the pictures on the next page to verify that all 114343 Label – Emergency Lowering decals are legible and in place. 114350 Label - AC Inverter Power (option)* Part No.
  • Page 43 Third Edition • First Printing Operator's Manual Inspections 1299757 1299757 114180 114180 72833 72086** 28372 52475** 31060 27207 27206 27206 27207 31788 27204 31788 27205 31787 31787 31785 31508 31785 114117 133286 114117 52865 72086** 1299757 1299756 1299757 52475** 114180 1299756 72833 114180...
  • Page 44 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 114345 Label – Tip-over Hazard, Batteries 114350 Label - AC Inverter Power (option)* Use the pictures on the next page to verify that all 133067 Label –...
  • Page 45 Third Edition • First Printing Operator's Manual Inspections 114252 72086** 27207 27206 52475** 27207 27206 27205 114180 114180 27204 114249 114249 82481 82481 114334 114345 114345 133286 114249 114249 114180 1299756 52475** 114180 72086** 1299756 114252 114248 1256899 1262343 1316086 133067 1317063 219958...

  • Page 46: Operating Instructions

    Operator's Manual Third Edition • First Printing Operating Instructions Operati ng Instr ucti ons 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.
  • Page 47 Third Edition • First Printing Operator's Manual Operating Instructions Emergency Stop Operation from Ground Push in the red Emergency Stop button to the off Turn the key switch to ground control. position at the ground controls or the platform Pull out the red Emergency Stop button to the controls to stop all functions.
  • Page 48 Operator's Manual Third Edition • First Printing Operating Instructions Operation from Platform Drive Enable LCD symbol on indicates that Turn the key switch to platform control. the boom has moved just past Pull out both ground and platform red either non-steer wheel and the Emergency Stop buttons to the on position.
  • Page 49 Third Edition • First Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings Machine Not Level LCD Symbol LCD Symbol on indicates the Model Chassis Angle Chassis Angle machine is not level. The tilt alarm (side to side) (front to back) will be sounding when the LCD Z-40N 4.5°...
  • Page 50 Operator's Manual Third Edition • First Printing Operating Instructions Driving on a slope To determine the slope grade: Measure the slope with a digital inclinometer OR Determine the uphill, downhill and side slope use the following procedure. ratings for the machine and determine the slope grade.
  • Page 51 Third Edition • First Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) The contact alarm is designed to alert ground personnel when an operator makes contact with the platform control panel, interrupting boom movement, sounding an alarm and flashing warning lights.
  • Page 52 Operator's Manual Third Edition • First Printing Operating Instructions Standard Batteries 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. Replace the battery vent caps.

  • Page 53: Transport And Lifting Instructions

    Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 54 Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Platform Transit Make sure the jib and platform are in the stowed position. Always use the turntable rotation lock pin each Place a block under the edge of the platform time the machine is transported.
  • Page 55 Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Remove all loose items on the machine. Use the turntable rotation lock to secure the turntable. Determine the center of gravity of your machine Observe and Obey: using the table and the picture on this page.

  • Page 56: Maintenance

    Operator's Manual Third Edition • First Printing Maintenance Maintenanc e 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 Observe and Obey: checks allow the inspector to identify changes in oil level that might indicate the presence of Only routine maintenance items specified in...
  • Page 57 Third Edition • First Printing Operator's Manual Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 58: Specifications

    Operator's Manual Third Edition • First Printing Specifications Specific ati ons Model Platform dimensions, 4 foot 46 in x 30 in Z-40N RJ (length x width) 117 cm x 76 cm Height, working maximum 46 ft 5 in 14.2 m Platform leveling self-leveling Height, platform maximum...
  • Page 59 Third Edition • First Printing Operator's Manual Specifications Platform dimensions, 4 foot 46 in x 30 in Model Z-40N (length x width) 117 cm x 76 cm Height, working maximum 46 ft 5 in 14.2 m Platform dimensions, 5 foot 56 in x 30 in Height, platform maximum 40 ft 5 in...
  • Page 60 Operator's Manual Third Edition • First Printing Specifications Z-40N RJ Range of motion chart Max Height Max Reach 50 ft 15.2 m -5 ft -1.5 m 40 ft 12.1 m 0 ft 30 ft 9.1 m 5 ft 1.5 m 20 ft 6.1 m 10 ft...
  • Page 61 Third Edition • First Printing Operator's Manual Specifications Z-40N Range of motion chart Max Height Max Reach 50 ft 15.2 m -5 ft -1.5 m 40 ft 12.1 m 0 ft 30 ft 9.1 m 5 ft 1.5 m 20 ft 6.1 m 10 ft 3.0 m...

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