Terex Genie Z6215A-101 Operator's Manual
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Terex Genie Z6215A-101 Operator's Manual

Terex Genie Z6215A-101 Operator's Manual

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Operator's Manual
Z-62/40
Serial Number Range
from Z6215A-101 to Z6216A-1086
from Z6216N-1087 to Z6216N-2999
from Z62H-3000
from Z6216M-101 to Z6216M-399
from Z62M-400
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 1257653

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Summary of Contents for Terex Genie Z6215A-101

  • Page 1 Operator's Manual Serial Number Range Z-62/40 from Z6215A-101 to Z6216A-1086 from Z6216N-1087 to Z6216N-2999 from Z62H-3000 from Z6216M-101 to Z6216M-399 from Z62M-400 with Maintenance Information Original Instructions First Edition Second Printing Part No. 1257653...

  • Page 2: Table Of Contents

    Specifications ............59 Copyright © 2014 Terex Corporation First Edition: Second Printing, March 2016 Genie and "Z" are registered trademarks of Terex South Dakota,Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity Z-62/40 Part No.

  • Page 3: Introduction

    First Edition • Second Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools, and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Second Printing Introduction 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: Danger Accident reporting...
  • Page 5 First Edition • Second Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding, Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual First Edition • Second 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 7 First Edition • Second Printing Operator's Manual 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 Runaway Hazard Collision hazard Collision hazard Direction Arrows Electrocution hazard Avoid contact Disconnect battery Voltage rating for...

  • Page 8: General Safety

    Operator's Manual First Edition • Second Printing General Safety General Safety Z-62/40 Part No. 1257653...
  • Page 9 First Edition • Second Printing Operator's Manual General Safety Part No. 1257653 Z-62/40...
  • Page 10 Operator's Manual First Edition • Second Printing General Safety Z-62/40 Part No. 1257653...

  • Page 11: Personal Safety

    First Edition • Second 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 12: Work Area Safety

    Operator's Manual First Edition • Second Printing 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 13 First Edition • Second 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 14 Operator's Manual First Edition • Second 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 15 First Edition • Second 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 the maximum uphill, downhill or side slope rating of machine.
  • Page 16 Operator's Manual First Edition • Second 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 17 First Edition • Second Printing Operator's Manual Work Area Safety Observe and use the color-coded direction arrows Bodily Injury Hazard on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 18 Operator's Manual First Edition • Second Printing Work Area Safety Explosion and Fire Hazards Damaged Machine Hazards Do not start the engine if you smell or detect liquid Do not use a damaged or malfunctioning machine. petroleum gas (LPG), gasoline, diesel fuel or other Conduct a thorough pre-operation inspection of the explosive substances.
  • Page 19 First Edition • Second Printing Operator's Manual Work Area Safety Battery Safety Panel Cradle Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the panel cradles. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective combined weight of the cradles, panels, occupants, clothing and eye wear when...
  • Page 20 Operator's Manual First Edition • Second Printing Work Area Safety Pipe Cradle Safety Welder Safety Read, understand, and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 21 First Edition • Second 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 22: Legend

    Operator's Manual First Edition • Second Printing Legend Legend Ground controls Foot switch Primary boom Manual storage container Jib boom Sliding mid-rail 10 Platform controls Lanyard anchorage points 11 Platform Models with 2 wheel steer: Non-steer tire Models with 4 wheel steer: Circle-end tire 12 Secondary boom Models with 2 wheel steer: Steer tire Models with 4 wheel steer: Square-end tire...

  • Page 23: Controls

    First Edition • Second Printing Operator's Manual Controls Controls Ground Control Panel Gasoline/LPG models: Check 11 Gasoline/LPG models: Fuel Function enable button engine light select switch Secondary boom up/down Diesel models: Oil pressure 12 Platform level switch switch light 13 Engine idle (rpm) select Primary boom up/down Platform overload indicator switch...
  • Page 24 Operator's Manual First Edition • Second Printing Controls Platform overload indicator light Ground Control Panel Light flashing indicates the platform is Function enable button overloaded. The engine will stop and no Press and hold the function enable button to functions will operate. Remove weight until the enable the functions on the ground control light goes off and then restart the engine.
  • Page 25 First Edition • Second Printing Operator's Manual Controls 13 Engine idle (rpm) select switch Move the engine idle select switch to the turtle position for low idle. Move the engine idle select switch to the rabbit position 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.
  • Page 26 Operator's Manual First Edition • Second Printing Controls Platform Control Panel Platform control box heater (if equipped) Horn button 10 Generator switch (if equipped) Platform level switch 11 Aircraft protection override switch (if equipped) Platform rotate switch 12 Steer mode select switch (if equipped) Jib boom up/down switch 13 Red Emergency Stop button Platform overload indicator light...
  • Page 27 First Edition • Second Printing Operator's Manual Controls 20 Gasoline/LPG models: Fuel select switch 15 Drive enable indicator light 21 Proportional control handle for secondary boom 16 Drive enable switch 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 28 Operator's Manual First Edition • Second Printing Controls Machine not level indicator light Platform Control Panel The machine not level indicator light will come Horn button on when the tilt alarm sounds. Press this button and the horn will sound. Emergency power switch with cover Release the button and the horn will stop.
  • Page 29 First Edition • Second Printing Operator's Manual Controls 13 Red Emergency Stop button 15 Drive enable indicator light Push in the red Emergency Stop button to the Light on indicates that the boom has moved off position to stop all functions and turn the just past either non-steer wheel and drive engine off.
  • Page 30 Operator's Manual First Edition • Second Printing 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 31: Inspections

    First Edition • Second 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 32 Operator's Manual First Edition • Second Printing Inspections  Wear pads Pre-operation Inspection  Tires and wheels  Be sure that the operator’s, safety, and  Engine and related components responsibilities manuals are complete, legible  Limit switches and horn and in the storage container located in the platform.
  • Page 33 First Edition • Second 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 34 Operator's Manual First Edition • Second 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 obstruction. platform red Emergency Turn the key switch to ground control.
  • Page 35 First Edition • Second 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 36 Operator's Manual First Edition • Second Printing Inspections 33 Slowly move the drive control handle in the Models with 4 wheel steer direction indicated by the blue triangle on the control panel OR press the thumb rocker Test the Steering switch in the direction indicated by the blue 29 Move the steer mode select switch and choose triangle.
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 39 Press down the foot switch and lower the 43 Press down the foot switch. boom to the stowed position. 44 Raise the primary boom approximately 61 cm. 40 Rotate the turntable until the primary boom 45 Slowly move the drive control handle to the full moves past one of the non-steer or circle-end...
  • Page 38 Operator's Manual First Edition • Second Printing Inspections Test the Oscillating Axle (if equipped) Test the Lift/Drive Select Function 54 Start the engine from the platform controls. 62 Press down the foot switch. 55 Drive the right steer tire up onto a 15 cm block 63 Move the drive control handle off center and or curb.
  • Page 39 First Edition • Second 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 40 Operator's Manual First Edition • Second Printing Inspections Decal Inspection Part No.Decal Description 82551 Label – Tire Pressure Use the pictures on the next page to verify that all 82552 Label – Tire Pressure, decals are legible and in place. High Flotation Tires Below is a numerical list with quantities and 97815...
  • Page 41 First Edition • Second Printing Operator's Manual Inspections 1263542 114252 114252 82481 133205 125581 28158 or 28159 72086 1253845 133067 82487 28160 1257660 114251 1257658 114252 114249 114249 1257658 52475 72086 82551 52475 1273578 or 82552 82551 1257659 or 82552 114248 52475 219956...

  • Page 42: Operating Instructions

    Operator's Manual First Edition • Second 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 First Edition • Second Printing Operator's Manual Operating Instructions All models Starting the Engine If the engine fails to start after 15 seconds of At the ground controls, turn the key switch to cranking, determine the cause and repair any the desired position.
  • Page 44 Operator's Manual First Edition • Second 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 45 First Edition • Second Printing Operator's Manual Operating Instructions To Steer Operation from Platform Press down the foot switch. Turn the key switch to platform control. If equipped with 4 wheel steer: Select the steer Pull out both ground and platform red mode by moving the steer mode switch.
  • Page 46 Operator's Manual First Edition • Second 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 47 First Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) When the foot switch is not pressed, the engine Light on indicates that the boom will idle at the lowest rpm. has moved just past either non-steer or circle-end wheel and ...
  • Page 48 Operator's Manual First Edition • Second Printing Operating Instructions Machine Not Level Indicator Light Check Engine Light If the tilt alarm sounds when the Light on and engine stopped: Tag platform is raised, the Machine Not the machine and remove from Level indicator light will come on service.
  • Page 49 First Edition • Second Printing Operator's Manual Operating Instructions Platform Overload Indicator Light Light flashing indicates the platform is overloaded and no functions will operate. Remove weight from the platform until the light goes off. After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic.
  • Page 50 Operator's Manual First Edition • Second Printing 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 the platform.
  • Page 51 First Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rails. Position the padding to protect the panels rubber bumper 2 from contact with the platform rails. Installation of Strap rubber Open the clamp and install it around a vertical bumper 1...

  • Page 53: Towing Instructions

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

  • Page 54: Transport And Lifting Instructions

    Operator's Manual First Edition • Second 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 55 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Use a minimum of 6 chains. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 56 Operator's Manual First Edition • Second 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 57: Maintenance

    First Edition • Second 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 58 Operator's Manual First Edition • Second Printing Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Ford and Perkins Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 59 First Edition • Second Printing Operator's Manual Maintenance Check the Batteries Check the Tire Pressure Proper battery condition is essential to good Tip-over hazard. An over-inflated tire can machine performance and operational safety. explode which may compromise machine Improper fluid levels or damaged cables and stability and cause the machine to tip over.
  • Page 60 Operator's Manual First Edition • Second Printing Maintenance 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.

  • Page 61: Specifications

    First Edition • Second Printing Operator's Manual Specifications Specifications Model Z-62/40 Maximum slope rating, stowed position, 2WD Height, working maximum 20.7 m Counterweight uphill 17° Height, platform maximum 18.87 m Counterweight downhill 6° Height, stowed maximum 2.9 m Side slope 14°...
  • Page 62 Operator's Manual First Edition • Second Printing Specifications Z-62/40 Range of Motion Chart Z-62/40 Part No. 1257653 Operator's Manual First Edition • Second Printing Z-62/40 Part No. 1257653...

This manual is also suitable for:

Genie z-62/40Genie z6216a-1086Genie z6216n-1087Genie z6216n-2999Genie z62h-3000Genie z6216m-101 ... Show all

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