Terex Genie Z62D-150 Operator's Manual
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Terex Genie Z62D-150 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 Z62D-150
AUS
Australia
with
Maintenance
Information
Original Instructions
First Edition
Fourth Printing
Part No. 1257654GT

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Summary of Contents for Terex Genie Z62D-150

  • Page 1 Operator's Manual Serial Number Range -62/40 ® from Z6215A-101 to Z6216A-1086 from Z6216N-1087 to Z6216N-2999 Australia from Z62H-3000 from Z62D-150 with Maintenance Information Original Instructions First Edition Fourth Printing Part No. 1257654GT...

  • Page 2: Table Of Contents

    Maintenance ............64 Specifications ............68 Copyright © 2014 Terex Corporation First Edition: Fourth Printing, December 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 AS 1418.10 ®...

  • Page 3: Introduction

    First Edition • Fourth 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 safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Fourth 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 First Edition • Fourth 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 number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual First Edition • Fourth 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

    First Edition • Fourth 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 First Edition • Fourth Printing Symbol and Hazard Pictorials Definitions Tie-down point Lifting point Platform tie-down Lifting and 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 First Edition • Fourth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Read the operator’s Read the service Access by trained manual manual and authorized 1 Lower primary. 1 Retract primary.

  • Page 10: General Safety

    Operator's Manual First Edition • Fourth Printing General Safety General Safety ® -62/40 Part No. 1257654GT...
  • Page 11 First Edition • Fourth Printing Operator's Manual General Safety ® Part No. 1257654GT -62/40...
  • Page 12 Operator's Manual First Edition • Fourth Printing General Safety ® -62/40 Part No. 1257654GT...

  • Page 13: Personal Safety

    First Edition • Fourth 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 First Edition • Fourth 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 15 First Edition • Fourth 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 First Edition • Fourth Printing Work Area Safety Do not alter or disable machine components that Use extreme care and in 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 First Edition • Fourth 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 machine.
  • Page 18 Operator's Manual First Edition • Fourth 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 First Edition • Fourth 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 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 20 Operator's Manual First Edition • Fourth 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 explosive substances.
  • Page 21 First Edition • Fourth 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, clothing and eye wear when...
  • Page 22 Operator's Manual First Edition • Fourth 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 23 First Edition • Fourth 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 First Edition • Fourth 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

    First Edition • Fourth Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 26 Operator's Manual First Edition • Fourth Printing Controls Ground Control Panel Gasoline/LPG models: Check engine light Diesel models: Oil pressure light Function enable button Light on and engine stopped: Tag the machine Press and hold the function enable button to and remove from service.
  • Page 27 First Edition • Fourth Printing Operator's Manual Controls 11 Gasoline/LPG models: Fuel select switch 15 Engine start switch Move the fuel select switch to the gasoline Move the engine start switch to either side to position to select gasoline. Move the fuel start the engine.
  • Page 28 Operator's Manual First Edition • Fourth Printing Controls Platform Control Panel 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 13 Red Emergency Stop button...
  • Page 29 First Edition • Fourth 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 First Edition • Fourth Printing Controls Platform Control Panel Machine not level indicator light The machine not level indicator light will come Horn button on when the tilt alarm sounds. Press this button and the horn will sound. Auxiliary power switch Release the button and the horn will stop.
  • Page 31 First Edition • Fourth 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 32 Operator's Manual First Edition • Fourth 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 33: Inspections

    First Edition • Fourth 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 34 Operator's Manual First Edition • Fourth Printing Inspections Pre-operation Inspection ❑ Wear pads ❑ Tires and wheels ❑ Be sure that the operator’s manual is ❑ Engine and related components complete, legible and in the storage container located in the platform. ❑...
  • Page 35 First Edition • Fourth 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 Do Not Operate Unless: malfunctions are discovered, the machine must be tagged and removed from service.
  • Page 36 Operator's Manual First Edition • Fourth Printing Inspections At the Ground Controls Test the Tilt Sensor 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 37 First Edition • Fourth Printing Operator's Manual Inspections At the Platform Controls Test Machine Functions 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 38 Operator's Manual First Edition • Fourth Printing Inspections Models with 4 wheel steer 34 Slowly move the control handle in the direction indicated by the yellow triangle on the control Test the Steering panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 39 First Edition • Fourth Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 38 Press down the foot switch and lower the 42 Press down the foot switch. boom to the stowed position. 43 Raise the primary boom approximately 61 cm. 39 Rotate the turntable until the primary boom 44 Slowly move the drive control handle to the full moves past one of the non-steer or circle-end...
  • Page 40 Operator's Manual First Edition • Fourth Printing Inspections Test Drive Tilt Cutout 60 Return to level ground and stow the boom. 52 Press down the foot switch. 61 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 53 With the boom fully stowed, drive the machine greater than 4.5°.
  • Page 41 First Edition • Fourth Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) 68 Return to level ground and extend the primary boom approximately 1.6 ft / 0.5 m. 76 Start the engine from the platform controls. 69 Drive the machine onto a slope where the 77 Drive the right steer tire up onto a 15 cm block chassis roll angle is greater than 2.5°.
  • Page 42 Operator's Manual First Edition • Fourth Printing Inspections Test the Contact Alarm (if equipped) 89 Operate each machine function. 85 Do not activate the foot switch and press on Result: All machine functions should not the contact alarm cable to release the actuator operate.
  • Page 43 First Edition • Fourth Printing Operator's Manual Inspections Test the Lift/Drive Select Function Test Aircraft Protection Package (if equipped) 92 Press down the foot switch. Note: Two people may be required to perform this 93 Move the drive control handle off center and test.
  • Page 44 Operator's Manual First Edition • Fourth Printing 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 45 First Edition • Fourth Printing Operator's Manual Inspections Inspection for Decals with Words Part No.Decal Description 97579 Danger – Tip-over Welder (option) Use the pictures on the next page to verify that all 97602 Warning – Explosion Hazard decals are legible and in place. 97815 Label –...
  • Page 46 Operator's Manual First Edition • Fourth Printing Inspections *28160 *82366 114236 1258471 1257660 31060 31060 72086 ***72875 52607 219486 *114425 825579 114390 *28160 1253845 *1253629 31788 97865 218559 114397 219487 *826345 1263543 *133278 114258 *28158 31060 *28159 1258616 ***1258955 ***46137 27207 27206 27204...
  • Page 47 First Edition • Fourth Printing Operator's Manual Inspections Inspection for Decals with Words Part No. Decal Description 1273574 Platform Control Panel, models with Continued from previous page. LCD screen Use the pictures on the next page to verify that all 1273578 Platform Control Panel decals are legible and in place.
  • Page 48 Operator's Manual First Edition • Fourth Printing Inspections *28160 *82366 114236 1258471 1257660 31060 31060 72086 ***72875 52607 219486 *114425 825579 114390 *28160 1253845 *1253629 31788 97865 114397 219487 218559 *826345 1263543 *133278 114258 *28158 31060 *28159 1258616 ***1258955 ***46137 27207 27206 27204...

  • Page 49: Operating Instructions

    First Edition • Fourth Printing Operator's Manual 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 manual.
  • Page 50 Operator's Manual First Edition • Fourth Printing Operating Instructions Starting the Engine All models 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 51 First Edition • Fourth Printing Operator's Manual 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 52 Operator's Manual First Edition • Fourth Printing Operating Instructions Operation from Platform To Steer 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 53 First Edition • Fourth Printing Operator's Manual 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 54 Operator's Manual First Edition • Fourth Printing 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 the •...
  • Page 55 First Edition • Fourth Printing Operator's Manual Operating Instructions Machine Not Level Indicator Light Tilt Sensor Activation Settings Model Chassis Angle Chassis Angle (front If the tilt alarm sounds when the (side to side) to back) platform is raised, the Machine Not Level indicator light will come on 4.5°...
  • Page 56 Operator's Manual First Edition • Fourth Printing Operating Instructions Aircraft Protection Package (if equipped) Platform Overload Indicator Light If the platform bumper comes Light flashing indicates the into contact with an object, the platform is overloaded and no machine will shut down and no functions will operate.
  • Page 57 First Edition • Fourth 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 the platform.
  • Page 58 Operator's Manual First Edition • Fourth Printing Operating Instructions Pipe Cradle Operation Panel Cradle Be sure the pipe cradle assembly and Genie has produced 2 different styles of Panel installation instructions have been followed Cradles, they are referred to as, Bolt-in and Weld- properly and that the pipe cradles are secured in.
  • Page 59 First Edition • Fourth Printing Operator's Manual Operating Instructions Repeat above for the second set of parts. foam pad x 2 hook panel cradle x 2 clamp Panel Cradle Assembly - Weld-In Weld-in Panel Cradle comes pre-assembled. rubber bumper 1 Panel Cradle Installation - Weld-In rubber bumper 2 Note: Perform this procedure on a firm, level...
  • Page 60 Operator's Manual First Edition • Fourth Printing Operating Instructions Place the Panel Cradle Tray over the toe Installation of Padding board and push it down until the tray is flush Install the 2 pieces of padding on the platform across the top of the toe board with the slots rails.
  • Page 61 First Edition • Fourth Printing Operator's Manual Operating Instructions After Each Use Machine Storage Select a safe parking location—firm level Properly preparing and stowing the machine for surface, clear of obstruction and traffic. extended storage will make it easier to put the machine back into service.

  • Page 62: Towing Instructions

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

  • Page 63: Transport And Lifting Instructions

    First Edition • Fourth Printing Operator's Manual 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 64 Operator's Manual First Edition • Fourth Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Chassis Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 65 First Edition • Fourth Printing Operator's Manual 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 66: Maintenance

    Operator's Manual First Edition • Fourth Printing 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 67 First Edition • Fourth Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled 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 68 Operator's Manual First Edition • Fourth Printing 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 69 First Edition • Fourth Printing Operator's Manual 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 70: Specifications

    Operator's Manual First Edition • Fourth Printing 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 71 First Edition • Fourth Printing Operator's Manual Specifications Z-62/40 Range of Motion Chart Z®-62/40 Part No. 1257654GT Operator's Manual First Edition • Fourth Printing ® Part No. 1257654GT -62/40...

This manual is also suitable for:

Genie z6215a-101Genie z6216a-1086Genie z6216n-1087Genie z6216n-2999Genie z62h-3000Genie z-62/40 ... Show all

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