Genie Z-40/23N User manual

Operator's Manual
Z-40/23N•Z-40/23NRJ PartNo.1258834
Second Edition • Second Printing
Copyright © 2006 by Terex Corporation
Second Edition: Second Printing, January 2015
"Genie" is a registered trademark of
Terex South Dakota, Inc. in the U.S.A. and
many other countries. "Z" is a trademark of
Terex South Dakota, Inc.
This machine complies with EN 60204-1 in
regards to ambient air temperature limitations
and maximum operating altitude.
Printed on recycled paper
Printed in U.S.A.
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.
Contents
Page
Introduction ................................................................ 1
Symboland Hazard Pictorials .................................... 3
GeneralSafety........................................................... 5
PersonalSafety ......................................................... 7
Work Area Safety....................................................... 8
Legend ...................................................................... 14
Controls .................................................................... 15
Inspections ............................................................... 21
OperatingInstructions............................................... 30
TransportandLifting Instructions .............................. 36
Maintenance ............................................................. 39
Specifications ........................................................... 41
Contact us:
Internet:www.genielift.com
e-mail:[email protected]

PartNo.1258834 Z-40/23N•Z-40/23NRJ 1
Operator's Manual
Second Edition • Second Printing
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'sinstructionsand safety rules—
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's Manual Second Edition • Second Printing
2 Z-40/23N•Z-40/23NRJ PartNo.1258834
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
deathorseriousinjury.
Indicatesa hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicatesa hazardous situation
which, if not avoided, could result
inminor ormoderateinjury.
Indicatesa hazardous situation
which, if not avoided, could result
inpropertydamage.
Red
Orange
Yellow
Blue

PartNo.1258834 Z-40/23N•Z-40/23NRJ 3
Operator's Manual
Second Edition • Second Printing
CrushHazard FireHazardElectrocution
Hazard
FallHazard CrushHazard
MaximumManual
Force MaximumWind Speed
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.
Platformuphill:
1 Lowerprimary
2 Lowersecondary
3 Retractprimary
Voltageratingfor
powertoplatform Pressureratingfor air line to platform
Platform
tie-down
instructions
Chassis
tie-down
instructions
NoSmoking
ExplosionHazard BurnHazard
NoOpenFlames
Platformdownhill:
1 Retract primary
2 Lowersecondary
3 Lowerprimary
3
3
Recovery procedure if tilt alarm sounds
whileelevated.

Operator's Manual Second Edition • Second Printing
4 Z-40/23N•Z-40/23NRJ PartNo.1258834
Lanyard
anchoragepoint Wheel loadGroundedAC 3-wireoutletonly Replacedamaged wiresandcords Batteries used as counterweight
Symbol and Hazard Pictorials Definitions

PartNo.1258834 Z-40/23N•Z-40/23NRJ 5
Operator's Manual
Second Edition • Second Printing
General Safety
Safety signs and locations
82548
114252
82487
82487
82472
82544
82481
82548
114252 82544
82472
114248
114252
82487
82601
82601
82604
82604
114345
82481
114345
114248

Operator's Manual Second Edition • Second Printing
6 Z-40/23N•Z-40/23NRJ PartNo.1258834
Safety signs and locations
General Safety
82473
114247
114334
114345
82548
82544
82481
114252
82544
82481
114345
82473
82548
114334
114247
114252

PartNo.1258834 Z-40/23N•Z-40/23NRJ 7
Operator's Manual
Second Edition • Second Printing
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's Manual Second Edition • Second Printing
8 Z-40/23N•Z-40/23NRJ PartNo.1258834
Work Area Safety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Maintainrequiredclearancesfromelectricalpower
linesandapparatusinaccordancewith applicable
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.Personnelonthegroundor
in the platform must not touch or operate the
machine until energized power lines are shut off.
Donotoperatethemachineduringlightningor
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 227 kg
Maximum occupants 2
The weight of options and accessories, such as
pipecradles,panel cradlesandwelders,will reduce
the rated platform capacity and must be factored
into the total platform load. See the decals with the
options and accessories.
If using accessories, read, understand and obey
the decals and instructions with the accessory.
Do not alter or disable the limit switches.
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.

PartNo.1258834 Z-40/23N•Z-40/23NRJ 9
Operator's Manual
Second Edition • Second Printing
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
surfacebeforeraising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. The Machine Not Level
indicator light will come on and the drive function in
one or both directions will not operate. 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
whilelowering.
If the tilt alarm sounds with the
platformuphill:
1 Lowertheprimaryboom.
2 Lowerthesecondaryboom.
3 Retractthe primaryboom.
If the tilt alarm sounds with the
platformdownhill:
1 Retracttheprimary
boom.
2 Lowerthesecondary
boom.
3 Lowertheprimary
boom.
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
withtheboomraisedorextended.
Do not push off or pull
towardanyobject
outside 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 modify or alter an aerial work platform
withoutprior writtenpermissionfromthe
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.
Work Area Safety
3
3

Operator's Manual Second Edition • Second Printing
10 Z-40/23N•Z-40/23NRJ PartNo.1258834
Work Area Safety
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.
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
Platform downhill 30% (17°)
Platform uphill 20% (11°)
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.
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)in theplatform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all tires are in good condition and lug nuts
areproperlytightened.
Do not use the platform controls to free a platform
thatiscaught, snagged orotherwiseprevented
from normal motion by an adjacent structure. All
personnelmustberemovedfrom the platform
before attempting to free the platform using the
groundcontrols.
Do not use batteries that weigh less than the
originalequipment.Batteries areusedas
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.

PartNo.1258834 Z-40/23N•Z-40/23NRJ 11
Operator's Manual
Second Edition • Second Printing
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Checktheworkarea for overhead obstructionsor
otherpossiblehazards.
Beaware ofcrushinghazardswhengraspingthe
platformguardrail.
Observeandusethecolor-codeddirectionarrows
on the platform controls and drive chassis for drive
and steer functions.
Do not lower the boom unless the area below is
clearofpersonnel andobstructions.
Limit travel speed according to the condition of the
ground surface, congestion, slope, location of
personnel, and any other factors which may cause
collision.
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.
Collision Hazards
Be aware of limited sight
distance and blind spots
whendrivingoroperating.
Beaware of the boom position and tailswing when
rotatingtheturntable.
Work Area Safety

Operator's Manual Second Edition • Second Printing
12 Z-40/23N•Z-40/23NRJ PartNo.1258834
Work Area Safety
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
outand/orprecautionshave been taken to prevent
any potential collision.
Nostuntdriving or horseplay while operatinga
machine.
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.
Impropercontactwith components underanycover
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.
Explosion and Fire Hazards
Chargethebattery onlyinanopen, well-ventilated
area away from sparks, flames and lighted tobacco.
Donotoperatethemachineinhazardous locations
orlocations wherepotentiallyflammableor
explosive gases or particles may be present. 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.
Damaged Machine Hazards
Donotuseadamagedor malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each work
shift. Immediately tag and remove from service a
damagedormalfunctioningmachine.
Besureallmaintenancehasbeenperformed as
specifiedinthis manual and the appropriateGenie
servicemanual.
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
containerlocatedontheplatform.
Component Damage Hazard
Do not use the machine as a ground for welding.

PartNo.1258834 Z-40/23N•Z-40/23NRJ 13
Operator's Manual
Second Edition • Second Printing
Battery Safety
Burn Hazards
Batteries contain acid. Always wear protective
clothingand eyewearwhen workingwithbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
The battery pack must remain in the upright
position.
Do not expose the batteries or the charger to water
orrain.
Explosion Hazards
Keep sparks, flames and
lightedtobaccoawayfrom
batteries. Batteries emit
an explosive gas.
The battery pack cover
must remain off during the
entirechargingcycle.
Do not contact the battery
terminals or the cable
clamps with tools that
may cause sparks.
Component Damage Hazards
Do not use any battery charger greater than 48V to
chargethebatteries.
Both battery packs must be charged together.
Disconnectthe battery pack plug before removing
the battery pack.
Electrocution Hazards
Connect the battery charger to a
grounded,AC3-wireelectrical
outlet only.
Inspect daily for damaged cord,
cablesandwires.Replace
damageditemsbefore
operating.
Avoid electrical shock from contact with battery
terminals. Remove all rings, watches and other
jewelry.
Tip-over Hazard
Do not use batteries that weigh less than the
originalequipment.Batteries areusedas
counterweight and are critical to machine stability.
Each battery must weigh a minimum od
105 lbs / 47.6 kg. Each battery box including
batteries must weigh a minimum of
530 lbs / 240.4 kg.
Lifting Hazard
Use a forklift to remove or install the battery packs.
Work Area Safety

Operator's Manual Second Edition • Second Printing
14 Z-40/23N•Z-40/23NRJ PartNo.1258834
1 Foot switch
2 Manualstoragecontainer
3 Slidingmid-rail
4 Lanyardanchoragepoint
5 Platform
6 Platformcontrols
7 Jibboom
8 Primaryboom
9 Secondaryboom
10 Groundcontrols
11 Powertocharger(betweentires)
12 Steertire
13 Battery box
14 Non-steertire
Legend
4
3
2
1
14
12
13
11
6
9
7
8
5
10

PartNo.1258834 Z-40/23N•Z-40/23NRJ 15
Operator's Manual
Second Edition • Second Printing
Controls
GroundControlPanel
1 Platform rotate switch
2 Platform level switch
3 Turntablerotateswitch
4 Jibboomup/downswitch
5 Primaryboomextend/retract switch
6 Primaryboomup/downswitch
7 Usedforoptionalequipment
8 Auxiliarypowerswitch
9 Platformoverloadindicatorlight
10 Key switch for platform/off/ground selection
11 RedEmergencyStopbutton
12 Hourmeter
13 Z-40/23N RJ: Jib rotate switch
14 Secondaryboomup/downswitch
15 Functionenableswitch
16 15Acircuitbreaker(48V)
17 15Acircuitbreaker(24V)
STOP
00009.9
2
1
3
4
5
6
7
8
910
13
14
15
16
17
12
11

Operator's Manual Second Edition • Second Printing
16 Z-40/23N•Z-40/23NRJ PartNo.1258834
Controls
GroundControlPanel
1 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.
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 platform will lower.
3 Turntablerotateswitch
Move the switch to the right
and the turntable will move to
the right. Move the switch to
the left and the turntable will
move to the left.
4 Jibboomup/downswitch
Move the switch up and the jib
boom will raise. Move the
switch down and the jib boom
willlower.
5 Primaryboomextend/retract switch
Move the switch to the left
and the boom will extend.
Move the switch to the right
and the boom will retract.
6 Primaryboomup/downswitch
Move the switch up and the
primary boom will raise. Move
the switch down and the
primaryboomwilllower.
7 Usedforoptionalequipment
8 Auxiliary power switch with cover
Useauxiliarypoweriftheprimarypower source
fails.
Simultaneouslyholdtheauxiliarypowerswitch
on and activate the desired function.
9 Platformoverloadindicatorlight
Light flashing indicates the platform is
overloadedandnofunctionswilloperate.
Remove weight from the platform until the light
goes off.
10 Key switch for platform/off/ground selection
Turn the key switch to the platform position and
the platform controls will operate. Turn the key
switch to the off position and the machine will
be off. Turn the key switch to the ground
positionand thegroundcontrolswill operate.
11 RedEmergencyStopbutton
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
operatethemachine.

PartNo.1258834 Z-40/23N•Z-40/23NRJ 17
Operator's Manual
Second Edition • Second Printing
12 Hourmeter
The hour meter displays the number of hours the
machinehasoperated.
13 Z-40/23N RJ: Jib rotate switch
Move the jib rotate switch to
the right and the jib will move
to the right. Move the jib rotate
switch to the left and the jib will
move to the left.
14 Secondaryboomup/downswitch
Move the switch up and
thesecondaryboomwill
raise. Move the switch
downandthesecondary
boomwilllower.
15 Functionenableswitch
Move the function enable switch to either side to
enablethefunctions on thegroundcontrolpanel
tooperate.
16 15Acircuitbreaker(48V)
17 15Acircuitbreaker(24V)
Controls

Operator's Manual Second Edition • Second Printing
18 Z-40/23N•Z-40/23NRJ PartNo.1258834
11 RedEmergencyStopbutton
12 Proportionalcontrolhandlefordrivefunctionand
thumb rocker for steer function
13 Boomfunctionspeedcontroller
14 Driveenableindicatorlight
15 LCDdisplay
16 Driveenableswitch
17 Thumb rocker switch for primary boom extend /
retractfunction
18 Dualaxisproportionalcontrolhandleforprimary
boomup/downandturntablerotateleft/right
functions
PlatformControlPanel
1 Hornbutton
2 Usedforoptionalequipment
3 Secondaryboomup/downswitch
4 Platform level switch
5 Jibboomup/downswitch
6 Platform rotate switch
7 Z-40/23N RJ: Jib rotate switch
8 Auxiliarypowerswitch
9 Platformoverloadindicatorlight
10 Machine not level indicator light
Controls
To drive, hold drive enable
switch to either side and
slowly move drive control
handle. Machine may drive
in opposite direction that
the drive and steer controls
are moved.
To drive, hold drive enable
switch to either side and
slowly move drive control
handle. Machine may drive
in opposite direction that
the drive and steer controls
are moved.
Use color-coded direction
arrows on this panel and
drive chassis to identify the
direction machine will travel.
Use color-coded direction
arrows on this panel and
drive chassis to identify the
direction machine will travel.
Light on indicates that boom
has moved past a non-steer
tire and drive function is
turned off.
Light on indicates that boom
has moved past a non-steer
tire and drive function is
turned off.
DRIVE ENABLE OPERATION
STOP
111
2
17
18 16 14 13 12
15
3529
2
46810
7