Terex Genie Z-40N User manual

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

Operator's Manual Third Edition • First Printing
Z®-40N • Z®-40N RJ Part No. 1315875GT
FrontMatter
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............6
General Safety .......................................................9
Personal Safety................................................... 15
Work Area Safety................................................ 16
Legend ................................................................ 23
Controls............................................................... 24
Inspections.......................................................... 30
Operating Instructions......................................... 44
Transport and Lifting Instructions ....................... 51
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

Third Edition • First Printing Operator's Manual
Introduction
Part No. 1315875GT Z®-40N • Z®-40N RJ 1
Intr od ucti o n
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 Third Edition • First Printing
Introduction
2 Z®-40N • Z®-40N RJ Part No. 1315875GT
Platform controls symbology and related
machine movement:
Platform level
Platform rotate
Jib boom up/down
Jib boom rotate
Primary boom up/down
Turntable rotate
Primary boom extend/retract
Secondary boom up/down
Drive
forward/reverse
Steer right/left

Third Edition • First Printing Operator's Manual
Introduction
Part No. 1315875GT Z®-40N • Z®-40N RJ 3
Ground controls symbology and related
machine movement:
Platform level
Platform rotate
Jib boom up/down
Jib boom rotate
Primary boom up/down
Turntable rotate
Primary boom
extend/retract
Secondary boom up/down
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:
•Solid tires

Operator's Manual Third Edition • First Printing
Introduction
4 Z®-40N • Z®-40N RJ Part No. 1315875GT
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.
To view any open bulletins for your machine, visit
us on the web at www.genielift.com.
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.

Third Edition • First Printing Operator's Manual
Introduction
Part No. 1315875GT Z®-40N • Z®-40N RJ 5
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.
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 safe
ty
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.

Operator's Manual Third Edition • First Printing
Symbol and Hazard Pictorials Definitions
6 Z®-40N • Z®-40N RJ Part No. 1315875GT
Symb ol and H az ard Pict or i als De fi nit i on s
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.
Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Tire specifications

Third Edition • First Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1315875GT Z®-40N • Z®-40N RJ 7
Wheel load Wind speed Maximum capacity Manual force Support the platform
or boom during
maintenance
Tie-down point Lifting point Platform tie-down
instructions
Lifting and tie down
instructions
Lanyard anchorage
points
Corrosive acid. Color coded direction
arrows
Runaway hazard Collision hazard Overhead obstruction

Operator's Manual Third Edition • First Printing
Symbol and Hazard Pictorials Definitions
8 Z®-40N • Z®-40N RJ Part No. 1315875GT
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:
1 Lower primary.
2 Lower secondary.
3 Retract primary.
Platform downhill:
1 Retract primary.
2 Lower secondary.
3 Lower primary.
Read the operator’s
manual
Access by trained
and authorized
personnel only
Read the service
manual
Auxiliary lowering Crush hazard

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1315875GT Z®-40N • Z®-40N RJ 9
Gener al Saf et y

Operator's Manual Third Edition • First Printing
General Safety
10 Z®-40N • Z®-40N RJ Part No. 1315875GT

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1315875GT Z®-40N • Z®-40N RJ 11

Operator's Manual Third Edition • First Printing
General Safety
12 Z®-40N • Z®-40N RJ Part No. 1315875GT

Third Edition • First Printing Operator's Manual
General Safety
Part No. 1315875GT Z®-40N • Z®-40N RJ 13

Operator's Manual Third Edition • First Printing
General Safety
14 Z®-40N • Z®-40N RJ Part No. 1315875GT

Third Edition • First Printing Operator's Manual
Personal Safety
Part No. 1315875GT Z®-40N • Z®-40N RJ 15
Pers on al Safe ty
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.

Operator's Manual Third Edition • First Printing
Work Area Safety
16 Z®-40N • Z®-40N RJ Part No. 1315875GT
Work Ar ea Saf ety
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from
electrical
power lines. At a
minimum, the required
clearance contained in
the chart below must be
followed.
Line Voltage
Required Clearance
0
to 50KV 10 f
t
3.05
m
5
0 to 200KV 15 f
t
4.60
m
20
0 to 350KV 20 f
t
6.10
m
35
0 to 500KV 25 f
t
7.62
m
50
0 to 750KV 35 f
t
10.67
m
75
0 to 1000KV 45 f
t
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 l
bs
227 k
g
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.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.
Do not alter or disable the limit switches.
Do not use air-filled tires. These machines are
equipped with solid tires. Wheel weight is critical to
stability.

Third Edition • First Printing Operator's Manual
Work Area Safety
Part No. 1315875GT Z®-40N • Z®-40N RJ 17
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.
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. 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 while lowering.
If the tilt alarm sounds
with the platform uphill:
1
Lower the primary
boom.
2
Lower the
secondary boom.
3
Retract the primary
boom.
If the tilt
alarm sounds
with the platform
downhill:
1
Retract the primary
boom.
2
Lower the
secondary boom.
3
Lower the primary
boom.

Operator's Manual Third Edition • First Printing
Work Area Safety
18 Z®-40N • Z®-40N RJ Part No. 1315875GT
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.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
manual force
–
9
0 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 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.