Terex Z40NF-6200 Operator's Manual
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Terex Z40NF-6200 Operator's Manual

Terex Z40NF-6200 Operator's Manual

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Operator's Manual
Z
-40N
®
Z
-40N RJ
®
Serial Number Range
from Z40NF-6200
AUS
Australia
with
Maintenance
Information
Third Edition
First Printing
Part No. 1307433GT

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Summary of Contents for Terex Z40NF-6200

  • Page 1 Operator's Manual Serial Number Range -40N ® from Z40NF-6200 Australia -40N RJ ® with Maintenance Information Third Edition First Printing Part No. 1307433GT...

  • Page 2: Table Of Contents

    Maintenance ............50 Specifications ............52 Copyright © 2006 Terex Corporation Third Edition: First Printing, September 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 AS 1418.10 ®...

  • Page 3: Introduction

    Third Edition • First Printing Operator's Manual Introduction Introduction 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 Turntable rotate Platform controls symbology and related 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 ®...
  • Page 5 Third Edition • First Printing Operator's Manual Introduction Sequential functions and movement: Ground controls symbology and related machine movement:  Drive and steer. Platform level Interlocked functions:  Elevated drive speed.  Elevated drive in an off-level condition. Platform rotate ...
  • 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 Hazard Pictorials Definitions Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine. machines equipped with glow plugs.
  • Page 9 Third Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Support the platform Wheel load Wind speed Maximum capacity Manual force or boom during maintenance Tie-down point Lifting point Platform tie-down Lifting & 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 General Safety ® ® Part No. 1307433GT -40N • Z -40N RJ...
  • Page 12 Operator's Manual Third Edition • First Printing General Safety ® ® -40N • Z -40N RJ Part No. 1307433GT...
  • Page 13 Third Edition • First Printing Operator's Manual General Safety ® ® Part No. 1307433GT -40N • Z -40N RJ...

  • Page 14: Personal Safety

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

  • Page 15: Work Area Safety

    Third Edition • First Printing Operator's Manual Work Area Safety Work Area Safety Electrocution Hazards 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 ground proximity to electrical current.
  • Page 16 Operator's Manual Third Edition • First Printing 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 is on a firm, level surface. indicator light will come on and the drive function in one or both directions will not operate.
  • Page 17 Third Edition • First Printing Operator's Manual Work Area Safety Do not operate the machine in strong or gusty Do not modify or alter a mobile elevating work winds. Do not increase the surface area of the platform without prior written permission from the platform or the load.
  • Page 18 Operator's Manual Third Edition • First Printing 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 105 lbs / accordance with 47.6 kg.
  • Page 19 Third Edition • First Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Collision Hazards 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 20 Operator's Manual Third Edition • First Printing 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 the and/or burn skin.
  • Page 21 Third Edition • First Printing Operator's Manual Work Area Safety Battery Safety Component Damage Hazard Do not use any battery charger greater than 48V to Burn Hazards 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 22: Legend

    Operator's Manual Third Edition • First Printing 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 ®...

  • Page 23: Controls

    Third Edition • First Printing Operator's Manual 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 24 Operator's Manual Third Edition • First Printing Ground Control Panel Turntable rotate switch Used for optional equipment Auxiliary power switch Move the turntable rotate switch to the right and the Use auxiliary power if the primary power turntable will rotate to the source fails.
  • Page 25 Third Edition • First Printing Operator's Manual Ground Control Panel 14 Secondary boom up/down switch 12 Hour meter Move the switch up and The hour meter displays the number of hours the secondary boom will the machine has operated. raise. Move the switch 13 Z-40/23N RJ: Jib rotate switch down and the secondary boom will lower.

  • Page 26: Platform Control Panel

    Operator's Manual Third Edition • First Printing Platform Control Panel Platform Control Panel Platform Control Panel Platform level switch Horn button Press this button and the horn will sound. Move the platform level Release the button and the horn will stop. switch up and the level of the platform will raise.
  • Page 27 Third Edition • First Printing Operator's Manual Platform Control Panel Platform rotate switch 11 Red Emergency Stop button Move the platform rotate Push in the red Emergency Stop button to the switch to the right and the off position to stop all functions. Pull out the platform will rotate to the red Emergency Stop button to the on position right.
  • Page 28 Operator's Manual Third Edition • First Printing Platform Control Panel 18 Dual axis proportional control handle for 15 LCD display primary boom up/down and turntable rotate Display screen for system fault information and left/right functions battery charge level. Move the control handle up 16 Drive enable switch and the primary boom will raise.

  • Page 29: Inspections

    Third Edition • First Printing Operator's Manual Inspections Inspections 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 30 Operator's Manual Third Edition • First Printing 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 31 Third Edition • First Printing Operator's Manual 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 malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 32 Operator's Manual Third Edition • First Printing 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 33 Third Edition • First Printing Operator's Manual Inspections Test Machine Functions and Descent At the Platform Controls 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 34 Operator's Manual Third Edition • First Printing 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 move,...
  • Page 35 Third Edition • First Printing Operator's Manual 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 3 feet / 44 With the boom fully stowed, drive the machine 91 cm.
  • Page 36 Operator's Manual Third Edition • First Printing Inspections 53 Return to level ground and raise the secondary 61 Retract the primary boom to the stowed boom to an out of stowed position position. (approximately 15° above horizontal). Result: The machine should drive. Result: The machine should stop once the 62 Return to level ground and stow the boom.
  • Page 37 Third Edition • First Printing Operator's Manual Inspections 72 Insert the actuator into the switch socket. Test the Contact Alarm (if equipped) Result: The lights and horn will turn off. 67 Do not activate the foot switch and press on the contact alarm cable to release the actuator 73 Operate each machine function.
  • Page 38 Operator's Manual Third Edition • First Printing Inspections 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. 4 Inspect the workplace.
  • Page 39 Third Edition • First Printing Operator's Manual Inspections Workplace Inspection Workplace Inspection Checklist Fundamentals Be aware of and avoid the following hazardous situations: The workplace inspection helps the operator determine if the workplace is suitable for safe  drop-offs or holes machine operation.
  • Page 40 Operator's Manual Third Edition • First Printing Inspections Inspection for Decals with Words Part No. Decal Description 114132 Ground Control Panel Use the pictures on the next page to verify that all 114133 Platform Control Panel decals are legible and in place. 114180 Label - Wheel Load Part No.
  • Page 41 Third Edition • First Printing Operator's Manual Inspections ® ® Part No. 1307433GT -40N • Z -40N RJ...

  • Page 42: Operating Instructions

    Operator's Manual Third Edition • First Printing Operating Instructions Operating Instructions 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 43 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 44 Operator's Manual Third Edition • First Printing Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
  • Page 45 Third Edition • First Printing Operator's Manual Operating Instructions Drive Enable Machine Not Level Indicator Light Light on indicates that the boom Light on indicates the machine is has moved just past either not level. The tilt alarm will be non-steer wheel and the drive sounding when this light is on and function has been interrupted.
  • Page 46 Operator's Manual Third Edition • First Printing Operating Instructions Lay the piece of wood on the slope. Driving on a slope Determine the uphill, downhill and side slope At the downhill end, lay the level on the top edge of ratings for the machine and determine the slope the piece of wood and lift the end until the piece of grade.
  • Page 47 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 48 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 49: Transport And Lifting Instructions

    Third Edition • First Printing Operator's Manual Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 50 Operator's Manual Third Edition • First Printing Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for 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 51 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 52: Maintenance

    Operator's Manual Third Edition • First Printing Maintenance Maintenance 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 hydraulic ...
  • Page 53 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 54: Specifications

    Operator's Manual Third Edition • First Printing Specifications Specifications Model Platform dimensions, 4 foot 46 in x 30 in Z-40N RJ (length x width) 1.2 m x 76 cm Height, working maximum 46 ft 5 in 14.2 m Platform leveling self-leveling Height, platform maximum 40 ft 5 in...
  • Page 55 Third Edition • First Printing Operator's Manual Specifications Platform dimensions, 4 foot 46 in x 30 in Model Z-40N (length x width) 1.2 m 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 56 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 57 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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Genie z-40n rjGenie z-40n

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