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Operator's Manual

First Edition • First Printing

Maintenance

58 Z-62/40

Part No. 1257653

Scheduled Maintenance

Maintenance performed quarterly, annually and
every two years must be completed by a person
trained and qualified to perform maintenance on
this machine according to the procedures found in
the service manual for this machine.

Machines that have been out of service for more
than three months must receive the quarterly
inspection before they are put back into service.

Summary of Contents for Z-40

Page 1: ...Operator s Manual Serial Number Range Z 62 40 from Z6215A 101 CE with Maintenance Information Original Instructions First Edition First Printing Part No 1257653...

Page 2: ...Legend 20 Controls 21 Inspections 29 Operating Instructions 40 Towing Instructions 51 Transport and Lifting Instructions 52 Maintenance 55 Specifications 59 Copyright 2014 Terex Corporation First Edit...

Page 3: ...tamped on chassis ground control side 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 Comp...

Page 4: ...o 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 Danger Failure to obey the instructions and safety rules in this...

Page 5: ...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 safety messages that follow this symbol to avoid...

Page 6: ...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...

Page 7: ...Coded Direction Arrows Runaway Hazard Collision hazard Collision hazard Electrocution hazard Avoid contact Disconnect battery Voltage rating for power to platform Pressure rating for air line to plat...

Page 8: ...Operator s Manual First Edition First Printing General Safety 6 Z 62 40 Part No 1257653 General Safety...

Page 9: ...First Edition First Printing Operator s Manual General Safety Part No 1257653 Z 62 40 7...

Page 10: ...Operator s Manual First Edition First Printing General Safety 8 Z 62 40 Part No 1257653...

Page 11: ...cupants 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 govern...

Page 12: ...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 l...

Page 13: ...ne 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 wh...

Page 14: ...ine 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 replace factory installed tires wit...

Page 15: ...e all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum up...

Page 16: ...loor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at gr...

Page 17: ...e unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine Bodily Injury Haza...

Page 18: ...equipped with glow plugs Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shif...

Page 19: ...ot exceed the rated platform capacity The combined weight of the cradles panels occupants tools and any other equipment must not exceed rated capacity The panel cradle assembly weighs 13 6 kg The maxi...

Page 20: ...te the platform controls or the red Emergency Stop button Do not operate unless you are adequately instructed and are aware of all of the hazards associated with movement of the platform with an overh...

Page 21: ...or property damage Do not exceed maximum towing speed or maximum towing time Maximum tow speed 12 87 km h Maximum towing time at 13 km h 30 minutes Maximum towing time at 10 km h 60 minutes Lockout Af...

Page 22: ...end 20 Z 62 40 Part No 1257653 Legend 1 Foot switch 2 Manual storage container 3 Sliding mid rail 4 Lanyard anchorage points 5 Non steer tire 6 Steer tire 7 Ground controls 8 Primary boom 9 Jib boom 1...

Page 23: ...LPG models Check engine light Diesel models Oil pressure light 7 Platform overload indicator light 8 Key switch for ground selection off platform 9 Red Emergency Stop button 10 Jib boom up down switc...

Page 24: ...ated 6 Gasoline LPG models Check engine light Diesel models Oil pressure light Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service per...

Page 25: ...for high idle 14 Diesel models Glow plug switch if equipped Move the glow plug switch to either side and hold for 3 to 5 seconds 15 Engine start switch Move the engine start switch to either side to s...

Page 26: ...6 Machine not level indicator light 7 Emergency power switch with cover 8 Drive speed select switch 9 Platform control box heater if equipped 10 Generator switch if equipped 11 Aircraft protection ove...

Page 27: ...ch Turtle foot switch activated low idle Rabbit foot switch activated high idle 18 Engine start switch 19 Gasoline LPG models Fuel select switch 20 Proportional control handle for secondary boom up do...

Page 28: ...ght Light flashing indicates the platform is overloaded The engine will stop and no functions will operate Remove weight until the light goes off and then restart the engine 6 Machine not level indica...

Page 29: ...y the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will drive backwards Press the left side...

Page 30: ...ry boom extend retract switch up and the primary boom will retract Move the boom extend retract switch down and the primary boom will extend 22 Dual axis proportional control handle for primary boom u...

Page 31: ...is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance proc...

Page 32: ...d tires for proper tire pressure Add air if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Elect...

Page 33: ...the machine as it was intended 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...

Page 34: ...rt the engine Test Machine Functions 7 Do not push and hold the function enable button Attempt to activate each boom and platform function toggle switch Result No boom and platform functions should op...

Page 35: ...and restart the engine Result The engine should start 20 Do not press down the foot switch and test each machine function Result No functions should operate Test Machine Functions 21 Press down the fo...

Page 36: ...ssis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test the Drive Enable System 29 Press down the foot switch and lower the boom to the...

Page 37: ...m approximately 61 cm 42 Slowly move the drive control handle to the full drive position 43 Result The maximum achievable drive speed with the secondary boom raised should not exceed 30 cm s 44 Lower...

Page 38: ...epair any malfunctions before operating the machine Test Aircraft Protection Package if equipped Note Two people may be required to perform this test 51 Extend the primary boom approximately 30 cm 52...

Page 39: ...or determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and...

Page 40: ...Read the Manual 2 82487 Label Read the Manual panel cradle 2 Part No Decal Description Qty 82487 Label Read the Manual pipe cradle 2 82551 Label Tire Pressure 4 82552 Label Tire Pressure High Flotati...

Page 41: ...First Edition First Printing Operator s Manual Inspections Part No 1257653 Z 62 40 39...

Page 42: ...operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with t...

Page 43: ...onds 2 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds All models If the engine fails to start aft...

Page 44: ...on position 3 Press down the foot switch when using the controls from the platform 4 Break the security tie and lift the emergency power switch cover Note If the security tie is broken or missing cons...

Page 45: ...s on the control panel To Steer 1 Press down the foot switch 2 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on t...

Page 46: ...o machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 1...

Page 47: ...Speed Select Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Engine Idle Select rpm When the foot switch is not...

Page 48: ...e 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...

Page 49: ...ndicates the platform is overloaded and no functions will operate Remove weight from the platform until the light goes off After Each Use 1 Select a safe parking location firm level surface clear of o...

Page 50: ...e and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on th...

Page 51: ...cradles may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 90 7 kg Pipe Cradle Assembly Weight 9 5 kg Panel Cradle Assembly 1 Apply the warning decal to...

Page 52: ...ne side of the clamp 3 Install the strap assembly end plate onto the bolt 4 Insert the bolt through the other side of the clamp 5 Secure with a washer and a nut Do not over tighten The strap assembly...

Page 53: ...ase the front drive torque hubs by turning over the drive disconnect caps 5 Turn the steering bypass valve counterclockwise to hydraulically release the steering Do not exceed recommended maximum towi...

Page 54: ...fficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight See the inspections section for the serial label location Be sure...

Page 55: ...and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Chassis Use chains of ample load capacity Use a minimum of 6 chains Adjust the rigging to pr...

Page 56: ...ces and straps or lines are sufficient to withstand the machine weight See the serial label for the machine weight Lifting Instructions Fully lower and retract the boom Fully lower the jib Remove all...

Page 57: ...t of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure In...

Page 58: ...op 5 cm of the sight gauge 3 Add oil as needed Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Check the Engine Coolant Level Ford and Perkins Models Mainta...

Page 59: ...ld down brackets are in place and secure Note Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Check the Tire Press...

Page 60: ...ly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Mach...

Page 61: ...e 75 7 liters Maximum slope rating stowed position 2WD Counterweight uphill 30 17 Counterweight downhill 10 6 Side slope 25 14 Maximum slope rating stowed position 4WD Counterweight uphill 45 24 Count...

Page 62: ...Operator s Manual First Edition First Printing Specifications 60 Z 62 40 Part No 1257653 Z 62 40 Range of Motion Chart Z 62 40 Part No 1257653 Operator s Manual First Edition First Printing...

Page 63: ...Distributed By www genielift com...

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