Terex Genie Z-62/40 Operator's Manual
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Terex Genie Z-62/40 Operator's Manual

Terex Genie Z-62/40 Operator's Manual

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Operator's Manual
Z
-62/40
®
Z
-62/40 TRAX
®
Serial Number Range
from Z62M-1501
™
CE
with
Maintenance
Information
Original Instructions
Second Edition
First Printing
Part No. 1304187GT

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Summary of Contents for Terex Genie Z-62/40

  • Page 1 Operator's Manual Serial Number Range -62/40 ® from Z62M-1501 -62/40 TRAX ® ™ with Maintenance Information Original Instructions Second Edition First Printing Part No. 1304187GT...

  • Page 2: Table Of Contents

    The Netherlands Copyright © 2014 Terex Corporation Second Edition: First Printing, June 2020 Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "TraX" is a trademark of Terex South Dakota, Inc.

  • Page 3: Introduction

    Second 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 personnel, safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Second Edition • First Printing Introduction Platform controls symbology and related Ground controls symbology and related machine movement: machine movement: Platform level swtich Platform level, jib boom up/down, primary boom extend/retract, primary boom up/down, and secondary boom Platform rotate switch retract/lower.
  • Page 5 Second Edition • First Printing Operator's Manual 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 importance number and serial number of your machine, along to Genie.
  • Page 6 Operator's Manual Second Edition • First Printing 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 7: Symbol And Hazard Pictorials Definitions

    Second Edition • First Printing Operator's Manual 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 8 Operator's Manual Second Edition • First Printing Symbol and Hazard Pictorials Definitions Tie-down point Lifting point Platform tie-down Lifting & tie down Lanyard anchorage instructions instructions points Corrosive acid. Color coded direction Runaway hazard Collision hazard Overhead obstruction arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for...
  • Page 9 Second Edition • First Printing Operator's Manual Symbol and Hazard Pictorials Definitions Recovery procedure if tilt alarm sounds while elevated. Read the operator’s Read the service Access by trained Platform uphill: Platform downhill: manual manual and authorized 1 Lower primary. 1 Retract primary.

  • Page 10: General Safety

    Operator's Manual Second Edition • First Printing General Safety General Safety ® ® ™ -62/40 • Z -62/40 TRAX Part No. 1304187GT...
  • Page 11 Second Edition • First Printing Operator's Manual General Safety *114249 (Z-62) 114252 114249 *133263 (Z-62 Trax) 82487 *114249 (Z-62) 114249 1263542 *133263 (Z-62 Trax) 114251 133067 114251 1286362 1256425 1286362 A 1256425 1256425 A *1304217 DEUTZ TD2.2 1256425 A ® ®...
  • Page 12 Operator's Manual Second Edition • First Printing General Safety ® ® ™ -62/40 • Z -62/40 TRAX Part No. 1304187GT...

  • Page 13: Personal Safety

    Second Edition • First Printing Operator's Manual 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 14: Work Area Safety

    Operator's Manual Second Edition • First Printing Work Area Safety Work Area Safety Pictures in this manual may show a boom with tires Keep away from the and wheels instead of tracks. All safety information machine if it contacts and operating instructions still apply to the Z-62/40 energized power lines.
  • Page 15 Second Edition • First Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds boom unless the machine with the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 16 Operator's Manual Second Edition • First Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 17 Second Edition • First Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this machine. the maximum uphill, downhill or side slope rating of the machine.
  • Page 18 Operator's Manual Second Edition • First Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the Be aware of the boom position and tailswing when...
  • Page 19 Second Edition • First Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Do not operate the machine with a hydraulic oil or and steer functions. air leak.
  • Page 20 Operator's Manual Second Edition • First Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 21 Second Edition • First Printing Operator's Manual Work Area Safety Panel Cradle Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand, and obey all warnings and instructions provided with the panel cradles. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.
  • Page 22 Operator's Manual Second Edition • First Printing Work Area Safety Welder Safety Tow Package Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the welding power unit. instructions provided with the tow package. Do not connect weld leads or cables unless the When vehicle is in free-wheel configuration, there welding power unit is turned off at the platform...
  • Page 23 Second Edition • First Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location–firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable so that the boom is between the non-steer wheels.

  • Page 24: Legend

    Operator's Manual Second Edition • First Printing Legend Legend Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety information and operating instructions still apply to the Z-62/40 TRAX, even if the picture does not show the tracks. Foot switch Ground controls Manual storage container...

  • Page 25: Controls

    Second Edition • First Printing Operator's Manual Controls Controls The Z-62/40 machine will have one of these two styles of ground control panels. It will have either an LCD screen, shown in the top view, or an hour meter, shown in the bottom view. The descriptions in this section and the instructions in the Function Test and Operating Instructions apply to both panels, unless specifically noted.
  • Page 26 Operator's Manual Second Edition • First Printing Controls LCD readout screen Ground Control Panel Screen displays hour meter, voltage, oil Function enable button pressure and coolant temperature. Screen also Press and hold the function enable button to displays fault codes and other service enable the functions on the ground control information.
  • Page 27 Second Edition • First Printing Operator's Manual Controls Red Emergency Stop button 15 Engine start switch Push in the red Emergency Stop button to the Move the engine start switch to either side to off position to stop all functions and turn the start the engine.
  • Page 28 Operator's Manual Second Edition • First Printing Controls Platform Control Panel With Hour Meter Horn button Platform control box heater (if equipped) Platform level switch 10 Generator switch (if equipped) Platform rotate switch 11 Aircraft protection override switch (if equipped) Jib boom up/down switch 12 Steer mode select switch (if equipped) Platform overload indicator light...
  • Page 29 Second Edition • First Printing Operator's Manual Controls 15 Drive enable indicator light 20 Gasoline/LPG models: Fuel select switch 16 Drive enable switch 21 Proportional control handle for secondary boom up/down function 17 Diesel models:Glow plug switch 22 Primary boom extend/retract switch 18 Engine idle (rpm) select switch 23 Dual axis proportional control handle for primary Turtle: foot switch activated low idle...
  • Page 30 Operator's Manual Second Edition • First Printing Controls Platform overload indicator light Platform Control Panel, Models With Hour Meter Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 31 Second Edition • First Printing Operator's Manual Controls 10 Generator switch (if equipped) 14 Dual axis proportional control handle for drive and steer functions. Move the generator switch up to activate the generator. Move the switch down to turn off the Proportional control handle for drive function generator.
  • Page 32 Operator's Manual Second Edition • First Printing Controls 18 Engine idle (rpm) select switch 15 Drive enable indicator light Move the engine idle select switch to the turtle Light on indicates that the boom has moved position for foot switch activated low idle. just past either non-steer wheel and drive Move the engine idle select switch to the rabbit function has been interrupted.
  • Page 33 Second Edition • First Printing Operator's Manual Controls 21 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary boom will raise. Move the control handle down and the secondary boom will lower. 22 Primary boom extend/retract switch Move the primary boom extend/retract switch up and the primary boom will...
  • Page 34 Operator's Manual Second Edition • First Printing Controls Platform Control Panel With LCD Display Horn button Platform control box heater (if equipped) Platform level switch 10 Generator switch (if equipped) Platform rotate switch 11 Aircraft protection override switch (if equipped) Jib boom up/down switch 12 Red Emergency Stop button Platform overload indicator light...
  • Page 35 Second Edition • First Printing Operator's Manual Controls 14 Drive enable indicator light 19 Models with LCD screen: Engine shut down indicator light 15 Drive enable switch 20 Proportional control handle for secondary boom 16 Glow plug indicator light up/down function 17 Engine idle (rpm) select switch 21 Primary boom extend/retract switch Turtle: foot switch activated low idle...
  • Page 36 Operator's Manual Second Edition • First Printing Controls Platform overload indicator light Platform Control Panel, Models With LCD Screen Light flashing indicates the platform is overloaded. The engine will stop and no Horn button functions will operate. Remove weight until the light goes off and then restart the engine.
  • Page 37 Second Edition • First Printing Operator's Manual Controls 11 Aircraft protection override switch (if equipped) 14 Drive enable indicator light Move and hold the aircraft protection override Light on indicates that the boom has moved switch to operate the machine when the just past either non-steer wheel and drive platform bumper is against an object.
  • Page 38 Operator's Manual Second Edition • First Printing Controls 20 Proportional control handle for secondary boom up/down function Move the control handle up and the secondary boom will raise. Move the control handle down and the secondary boom will lower. 21 Primary boom extend/retract switch Move the primary boom extend/retract switch up and the primary boom will...

  • Page 39: Inspections

    Second 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 40 Operator's Manual Second Edition • First Printing Inspections Pre-operation Inspection  Engine and related components  Limit switches and horn  Be sure that the operator’s, safety, and  Contact alarm (if equipped) responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 41 Second 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 42 Operator's Manual Second Edition • First Printing Inspections Test the Tilt Sensor At the Ground Controls Turn the key switch to Select a test area that is firm, level and free of platform control. Pull out the hazards. platform red Emergency Turn the key switch to ground control.
  • Page 43 Second Edition • First Printing Operator's Manual Inspections Test Machine Functions At the Platform Controls 24 Press down the foot switch. Test Emergency Stop 25 Activate each machine function control handle 15 Turn the key switch to platform control and or toggle switch.
  • Page 44 Operator's Manual Second Edition • First Printing Inspections Test Drive and Braking Test the Drive Enable System 29 Press down the foot switch. 32 Press down the foot switch and lower the boom to the stowed position. 30 Slowly move the drive control handle in the direction indicated by the blue arrow on the 33 Rotate the turntable until the primary boom control panel until the machine begins to move,...
  • Page 45 Second Edition • First Printing Operator's Manual Inspections Test Limited Drive Speed Test Drive Tilt Cutout 36 Press down the foot switch. 46 Press down the foot switch. 37 Raise the primary boom approximately 2 ft / 47 With the boom fully stowed, drive the machine 61 cm.
  • Page 46 Operator's Manual Second Edition • First Printing Inspections 54 Return to level ground and stow the boom. 62 Return to level ground and extend the primary boom approximately 1.6 ft / 0.5 m. 55 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 63 Drive the machine onto a slope where the greater than 4.5°.
  • Page 47 Second Edition • First Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Contact Alarm (if equipped) 70 Drive the right steer tire up onto a 6 in/15 cm 78 Do not activate the foot switch and press on block or curb.
  • Page 48 Operator's Manual Second Edition • First Printing Inspections Test the Lift/Drive Select Function (if 82 Operate each machine function. equipped) Result: All machine functions should not 85 Press down the foot switch. operate. 86 Move the drive control handle off center and 83 Insert the actuator into the switch socket.
  • Page 49 Second 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  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 50 Operator's Manual Second Edition • First Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 1257659 Label — Transport/Lifting 1257660 Label — Manual Lowering, Z-62 Use the pictures on the next page to verify that all 1257661 Label — Slope Rating, Z-62 decals are legible and in place.
  • Page 51 Second Edition • First Printing Operator's Manual Inspections ® ® ™ Part No. 1304187GT -62/40 • Z -62/40 TRAX...

  • Page 52: Operating Instructions

    Operator's Manual Second Edition • First Printing Operating Instructions Operating Instructions Pictures in this manual may show a boom with tires Fundamentals and wheels instead of tracks. All safety information The Operating Instructions section provides and operating instructions still apply to the Z-62/40 instructions for each aspect of machine operation.
  • Page 53 Second Edition • First Printing Operator's Manual Operating Instructions Models with automatic glow plugs: Starting the Engine The LCD screen will display the glow Gasoline/LPG models plug symbol when the automatic glow plugs are on. At the ground controls, turn the key switch to the desired position.
  • Page 54 Operator's Manual Second Edition • First Printing 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 machine functions and turn the on position.
  • Page 55 Second Edition • First Printing Operator's Manual Operating Instructions Platform Overload Indicator Light To Steer Light flashing indicates the platform is overloaded. Press down the foot switch. The engine will stop and no functions will operate. Slowly move the drive control handle in the direction indicated by blue or yellow triangles Remove weight from the platform until the light OR press the thumb rocker switch located on...
  • Page 56 Operator's Manual Second Edition • First Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 57 Second Edition • First Printing Operator's Manual Operating Instructions Drive Enable Machine Not Level Indicator Light Light on indicates that the boom If the tilt alarm sounds when the has moved just past either platform is raised, the Machine Not non-steer wheel and the drive Level indicator light will come on function has been interrupted.
  • Page 58 Operator's Manual Second Edition • First Printing Operating Instructions Tilt Sensor Activation Settings Engine Idle Select (rpm) When the foot switch is not pressed, the engine will Model Chassis Angle Chassis Angle idle at the lowest rpm. (side to side) (front to back) Z-62/40 4.5°...
  • Page 59 Second Edition • First Printing Operator's Manual Operating Instructions Check Engine Light Platform Overload Indicator Light Light on and engine stopped: Tag Light flashing indicates the the machine and remove from platform is overloaded. The service. engine will stop and no functions will operate.
  • Page 60 Operator's Manual Second Edition • First Printing Operating Instructions Contact Alarm (if equipped) LCD Screen (if equipped) The contact alarm is designed to alert ground The LCD screen at the ground personnel when an operator makes contact with controls displays hour meter, the platform control panel, interrupting boom voltage, oil pressure and movement, sounding an alarm and flashing...
  • Page 61 Second Edition • First Printing Operator's Manual Operating Instructions Under emergencies, the DPF standstill Standstill Regeneration regeneration can be interrupted in three ways: When the LCD screen displays the message  The engine is turned off by the key switch. "Regen Warning Lvl 1"...
  • Page 62 Operator's Manual Second Edition • First Printing Operating Instructions Using the control buttons 2 and 3 below the Using the control buttons 2 and 3 below the LCD screen, select "Diagnostics" from the LCD screen, select "Initiate Regen". Press the Main Menu.
  • Page 63 Second Edition • First Printing Operator's Manual Operating Instructions 10 The LCD screen will display the message " 12 If the engine is not already running, the LCD Warning: Machine must be in a nonflammable screen displays the message "Start Engine". environment".
  • Page 64 Operator's Manual Second Edition • First Printing Operating Instructions 15 The regeneration process auto-advances and After Each Use once it is completed the LCD screen displays Select a safe parking location–firm level the message "Regen Successful". surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position.
  • Page 65 Second Edition • First Printing Operator's Manual Operating Instructions Pipe Cradle Instructions Observe and Obey:  The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform and the platform.
  • Page 66 Operator's Manual Second Edition • First Printing Operating Instructions Pipe Cradle Operation Be sure the pipe cradle assembly and rubber installation instructions have been followed bumper 2 properly and that the pipe cradles are secured to the platform railings. Place the load so that it rests in both pipe rubber cradles.

  • Page 67: Towing Instructions

    Second Edition • First Printing Operator's Manual Towing Instructions Towing Instructions After Towing: Using the Tow Package Immediately after towing, chock the wheels, Before Towing: detach the tow bar and reverse the drive hub Position the machine on a level surface. Chock disconnect caps.

  • Page 68: Transport And Lifting Instructions

    Operator's Manual Second Edition • First Printing 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 69 Second Edition • First Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each time Use a minimum of 6 chains. the machine is transported.
  • Page 70 Operator's Manual Second Edition • First Printing Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page. Observe and Obey: Attach the rigging only to the designated lifting points on the machine.

  • Page 71: Maintenance

    Second Edition • First Printing Operator's Manual Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 72 Operator's Manual Second Edition • First Printing Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 73 Second Edition • First Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 74 Operator's Manual Second Edition • First Printing Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Tip-over hazard. An over-inflated tire can this machine according to the procedures found in explode which may compromise machine the service and maintenance manuals for this...

  • Page 75: Specifications

    Second Edition • First Printing Operator's Manual Specifications Specifications Model Z-62/40 Maximum slope rating, stowed position, 2WD Height, working maximum 67 ft 11 in 20.7 m Counterweight uphill 17° Height, platform maximum 61 ft 11 in 18.87 m Counterweight downhill 6°...
  • Page 76 Operator's Manual Second Edition • First Printing Specifications Model Z-62/40 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 67 ft 11 in 20.7 m Counterweight uphill 24° Height, platform maximum 61 ft 11 in 18.87 m Counterweight downhill 17°...
  • Page 77 Second Edition • First Printing Operator's Manual Specifications Z-62 Range of Motion Chart Max Height Max Reach 80 ft 24.4 m 0 ft 70 ft 21.4 m 10 ft 3.1 m 60 ft 18.3 m 20 ft 6.1 m 50 ft 16.3 m 30 ft 9.2 m...
  • Page 78 Operator's Manual Second Edition • First Printing Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

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