Terex Z62M-2230 Owner's Manual

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Operator's Manual

-62/40

-62/40 TRAX

Front Matter

Serial Number Range

from Z62M-2230

™

with

Maintenance

Information

Original Instructions

Fourth Edition

Second Printing

Part No. 1324020GT

Table of Contents

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Summary of Contents for Terex Z62M-2230

Page 1 Operator's Manual Serial Number Range -62/40 ® from Z62M-2230 -62/40 TRAX ® ™ with Maintenance Information Original Instructions Fourth Edition Second Printing Part No. 1324020GT Front Matter...
Page 2: Table Of Contents
NG31 6BH Copyright © 2014 Terex Corporation Fourth Edition: Second Printing, March 2025 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: About This Manual
Fourth Edition • Second Printing Operator's Manual Introduction Intr oducti on 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 Fourth Edition • Second 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: Bulletin Distribution And Compliance
Fourth Edition • Second 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: Hazard Classification
Operator's Manual Fourth Edition • Second 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
Fourth Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Fire hazard Explosion hazard Explosion hazard Do not use ether or No smoking. other high energy No flame. starting aids on Stop engine.
Page 8 Operator's Manual Fourth Edition • Second 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 Fourth Edition • Second 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 Fourth Edition • Second Printing General Safety Gener al Safety -62/40 • Z -62/40 TRAX Part No. 1324020GT ® ® ™...
Page 11 Fourth Edition • Second Printing Operator's Manual General Safety -62/40 • Z -62/40 TRAX Part No. 1324020GT ® ® ™...
Page 12 Operator's Manual Fourth Edition • Second Printing General Safety -62/40 • Z -62/40 TRAX Part No. 1324020GT ® ® ™...
Page 13: Personal Safety
Fourth Edition • Second Printing Operator's Manual Personal Safety Pers onal 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.
Page 14: Work Area Safety
Operator's Manual Fourth Edition • Second Printing Work Area Safety Work Ar ea Safety Pictures in this manual may show a boom with Keep away from the tires and wheels instead of tracks. All safety machine if it contacts information and operating instructions still apply to energized power lines.
Page 15 Fourth 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 16 Operator's Manual Fourth Edition • Second 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 Fourth 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 machine.
Page 18: Fall Hazards
Operator's Manual Fourth 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 19: Explosion And Fire Hazards
Fourth Edition • Second 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: Battery Safety
Operator's Manual Fourth Edition • Second 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 Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
Page 21 Fourth Edition • Second 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 Fourth Edition • Second 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 Fourth 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 24: Legend
Operator's Manual Fourth Edition • Second 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
Fourth Edition • Second 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: Ground Control Panel
Operator's Manual Fourth Edition • Second 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 Fourth Edition • Second 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 Fourth Edition • Second 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 Fourth Edition • Second 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 Fourth Edition • Second Printing Controls Platform Control Panel, Models Machine not level indicator light With Hour Meter The machine not level indicator light will come on when the tilt alarm sounds. Horn button Auxiliary power switch with cover Press this button and the horn will sound.
Page 31 Fourth 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 32 Operator's Manual Fourth 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 33 Fourth Edition • Second Printing Operator's Manual 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 34 Operator's Manual Fourth Edition • Second Printing 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 35 Fourth Edition • Second Printing Operator's Manual Controls Platform Control Panel, Models Platform overload indicator light 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 36 Operator's Manual Fourth Edition • Second Printing 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 37 Fourth Edition • Second Printing Operator's Manual 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 38: Inspections
Operator's Manual Fourth Edition • Second Printing Inspections Ins pections 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 39: Pre-Operation Inspection
Fourth Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection  Engine and related components  Limit switches and horn  Be sure that the operator’s manual is  Contact alarm (if equipped) complete, legible and in the storage container located in the platform.
Page 40 Operator's Manual Fourth Edition • Second Printing 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 41 Fourth Edition • Second Printing Operator's Manual 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 42 Operator's Manual Fourth Edition • Second Printing 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 43 Fourth Edition • Second Printing Operator's Manual 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 triangle.
Page 44: Test The Drive Enable System
Operator's Manual Fourth Edition • Second Printing Inspections Test Drive and Braking Test the Drive Enable System 35 Press down the foot switch. 38 Press down the foot switch and lower the boom to the stowed position. 36 Slowly move the drive control handle in the direction indicated by the blue arrow on the 39 Rotate the turntable until the primary boom control panel until the machine begins to...
Page 45 Fourth Edition • Second Printing Operator's Manual Inspections Test Limited Drive Speed Test Drive Tilt Cutout 42 Press down the foot switch. 52 Press down the foot switch. 43 Raise the primary boom approximately 2 ft / 53 With the boom fully stowed, drive the machine 61 cm.
Page 46 Operator's Manual Fourth Edition • Second Printing Inspections 60 Return to level ground and stow the boom. 68 Return to level ground and extend the primary boom approximately 1.6 ft / 0.5 m. 61 With the boom fully stowed, drive the machine onto a slope where the chassis pitch angle is 69 Drive the machine onto a slope where the greater than 2.5°.
Page 47 Fourth Edition • Second Printing Operator's Manual Inspections Test the Oscillating Axle (if equipped) Test the Contact Alarm (if equipped) 76 Drive the right steer tire up onto a 6 in/15 cm 84 Do not activate the foot switch and press on block or curb.
Page 48 Operator's Manual Fourth Edition • Second Printing Inspections Test the Lift/Drive Select Function (if 88 Operate each machine function. equipped) Result: All machine functions should not 91 Press down the foot switch. operate. 92 Move the drive control handle off center and 89 Insert the actuator into the switch socket.
Page 49 Fourth 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 Do Not Operate Unless:  sloped surfaces  unstable or slippery surfaces ...
Page 50 Operator's Manual Fourth Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 1253845 Ground Control Panel 1256425 Label – Danger, Electrocution Hazard* Use the pictures on the next page to verify that all 1257658 Label – Wheel Load, Z-62*** decals are legible and in place.
Page 51 Fourth Edition • Second Printing Operator's Manual Inspections 1253845 **114236 *28160 114252 114252 72086 ***82487 133067 114251 82487 *1298991 *82487 1257660 82481 219958 219954 219956 114248 133205 *1256425 1263542 *28158 114252 *28160 *28159 1257661 *1256425 27207 *1301030 27206 65278 27204 *1304217 114252 27206...
Page 52: Operating Instructions
Operator's Manual Fourth Edition • Second Printing Operating Instructions Fundamentals Operati ng Instr ucti ons Pictures in this manual may show a boom with tires and wheels instead of tracks. All safety The Operating Instructions section provides information and operating instructions still apply to instructions for each aspect of machine operation.
Page 53 Fourth Edition • Second Printing Operator's Manual Operating Instructions Starting the Engine Models with automatic glow plugs: 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: Emergency Stop
Operator's Manual Fourth 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 55 Fourth Edition • Second Printing Operator's Manual Operating Instructions Operation from Platform To Drive Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the control Pull out both ground and platform red handle off center. Emergency Stop buttons to the on position.
Page 56 Operator's Manual Fourth 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 57 Fourth Edition • Second 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 non- platform is raised, the Machine Not steer wheel and the drive Level indicator light will come on function has been interrupted.
Page 58: Generator (If Equipped)
Operator's Manual Fourth Edition • Second Printing Operating Instructions Tilt Sensor Activation Settings Engine Idle Select (rpm) When the foot switch is not pressed, the engine Model Chassis Angle Chassis Angle (front will idle at the lowest rpm. (side to side) to back) 4.5°...
Page 59: Check Engine Light
Fourth Edition • Second 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 Fourth Edition • Second 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 coolant movement, sounding an alarm and flashing...
Page 61 Fourth Edition • Second Printing Operator's Manual Operating Instructions Standstill Regeneration (if equipped) Under emergencies, the DPF standstill regeneration can be interrupted in three ways: When the LCD screen displays the message "Regen Warning Lvl 1" (level 1 or higher), the DPF ...
Page 62 Operator's Manual Fourth Edition • Second 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 Fourth Edition • Second Printing Operator's Manual Operating Instructions 12 If the engine is not already running, the LCD 10 The LCD screen will display the message " screen displays the message "Start Engine". Warning: Machine must be in a nonflammable environment".
Page 64 Operator's Manual Fourth Edition • Second Printing Operating Instructions Pipe Cradle Instructions 15 The regeneration process auto-advances and once it is completed the LCD screen displays The pipe cradle assembly consists of 2 pipe the message "Regen Successful". cradles positioned at either side of the platform and mounted to the guardrails with U-bolts.
Page 65 Fourth Edition • Second Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation Be sure the pipe cradle assembly and  Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
Page 66 Operator's Manual Fourth Edition • Second Printing Operating Instructions Panel Cradle Repeat above for the second set of parts. Genie has produced 2 different styles of Panel Cradles, they are referred to as, Bolt-in and Weld- in. This designation refers to the toeboard and how it is attached to the platform, use the appropriate instructions below for your style of Panel Cradle Panel Cradle Assembly - Bolt In...
Page 67 Fourth Edition • Second Printing Operator's Manual Operating Instructions Place the Panel Cradle Tray over the toe board and push it down until the tray is flush across the top of the toe board with the slots on the back of the tray aligned with corresponding slots in the toe board.
Page 68 Operator's Manual Fourth Edition • Second Printing Operating Instructions Panel Cradle Operation Installation of Padding Install the 2 pieces of padding on the platform Note: The bolt-in style has 2 cradles and the Weld- rails. Position the padding to protect the panels in has 1.
Page 69: After Each Use
Fourth Edition • Second 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 70: Towing Instructions
Operator's Manual Fourth Edition • Second Printing Towing Instructions After Towing: Using the Tow Package Towing Ins truc tions 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 71: Observe And Obey
Fourth Edition • Second Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons Be sure the turntable is secured with the  turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
Page 72 Operator's Manual Fourth Edition • Second 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 73 Fourth Edition • Second 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 74: Maintenance
Operator's Manual Fourth Edition • Second Printing Maintenance Maintenanc e 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 75: Diesel Fuel Requirements
Fourth Edition • Second Printing Operator's Manual 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 76: Check The Engine Coolant Level - Liquid Cooled Models
Operator's Manual Fourth Edition • Second Printing 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 77: Check The Tire Pressure
Fourth Edition • Second Printing Operator's Manual Maintenance Check the Tire Pressure Scheduled Maintenance Maintenance performed commissioning, quarterly, annually and every two years must be completed by a person trained and qualified to perform Tip-over hazard. An over-inflated tire can maintenance on this machine according to the explode which may compromise machine procedures found in the service and maintenance...
Page 78: Specifications
Operator's Manual Fourth Edition • Second Printing Specifications Specific ati ons 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 79 Fourth Edition • Second Printing Operator's Manual Specifications Model Z-62/40 TRAX Maximum slope rating, stowed position, 4WD Height, working maximum 68 ft 1 in 20.75 m Counterweight uphill 24° Height, platform maximum 62 ft 1 in 18.92 m Counterweight downhill 17°...
Page 80 Operator's Manual Fourth Edition • Second Printing 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...

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Genie z-62/40 traxGenie z-62/40