Operator's Manual

Serial Number Range

Z®-62/40 from Z62M-1501

CE

Z®-62/40 TRAX™

with
Maintenance
Information

Original Instructions
Second Edition
Second Printing
Part No. 1304187GT
Operator's Manual Second Edition • Second Printing

Front Matter

Manufacturer:
Contents
Terex Global GmbH
Introduction ........................................................... 1
Bleicheplatz 2
Schaffhausen, 8200 Symbol and Hazard Pictorials Definitions ............. 5
Switzerland General Safety ...................................................... 8
Personal Safety................................................... 11
EU Authorized representative:
Work Area Safety ................................................ 12
Genie Industries B.V. Legend ................................................................ 22
Boekerman 5
4751 XK OUD GASTEL Controls ............................................................... 23
The Netherlands Inspections .......................................................... 36
Operating Instructions ......................................... 50
UK Authorized representative:
Towing Instructions ............................................. 68
Genie UK Limited Transport and Lifting Instructions ....................... 69
The Maltings
Maintenance ....................................................... 72
Wharf Road
Grantham Specifications ...................................................... 76
NG31 6BH
UK

Copyright © 2014 Terex Corporation

Second Edition: Second Printing, December 2022
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.
Complies with EC Directive 2006/42/EC
See EC Declaration of Conformity
Supply of Machinery (Safety) Regulations 2008

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Introduction
Introduction

About this manual Intended Use and Familiarization

Genie appreciates your choice of our machine for Guide
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. personnel, including tools, and materials to an
This book is an operation and daily maintenance aerial work site. Before operating the machine, it’s
manual for the user or operator of a Genie the operator’s responsibility to read and
machine. understand this familiarization guide.
This manual should be considered a permanent
 Each person must be trained to operate a
part of your machine and should remain with the
Mobile Elevating Work Platform (MEWP).
machine at all times. If you have any questions,
contact Genie.  Familiarization with the MEWP must be given
to each person who is authorized, competent
and trained.
Product Identification
 Only trained and authorized personnel should
The machine serial number is located on the serial be permitted to operate the machine.
label.
 The operator is responsible to read,
Sequence number understand, and obey the manufacturer’s
Serial label stamped on chassis instructions and safety rules provided in the
(located under cover) (ground control side) Operator’s Manual.
 The Operator’s Manual is located in the
manual storage container, at the platform.
 For specific product applications, see
Contacting The Manufacturer.

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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.

Turntable rotate and

Jib boom up/down platform rotate

Sequential functions and movement:

Primary boom up/down
• Drive and steer.
Interlocked functions:
• Elevated drive speed.

Turntable rotate • Elevated drive in an off-level condition.

• Drive enable when the boom is rotated past
the non-steer wheels.
• All platform and ground controls.
Primary boom extend/retract Limitations of use:
switch
• The intended use of this machine is to lift
personnel, including tools, and materials to an
aerial work site.
Secondary boom up/down
• Do not elevate the platform unless the machine
is on firm level ground.
Stability enhancing means:
Drive forward/reverse • Foam filled tires (if equipped).

Steer right/left

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Introduction

Bulletin Distribution and Contacting the Manufacturer

Compliance At times it may be necessary to contact Genie.
Safety of product users is of paramount When you do, be ready to supply the model
importance to Genie. Various bulletins are used by number and serial number of your machine, along
Genie to communicate important safety and with your name and contact information. At
product information to dealers and machine minimum, Genie should be contacted for:
owners. Accident reporting
The information contained in the bulletins is tied to Questions regarding product applications and
specific machines using the machine model and safety
serial number.
Standards and regulatory compliance information
Distribution of bulletins is based on the most
current owner on record along with their Current owner updates, such as changes in
associated dealer, so it is important to register machine ownership or changes in your contact
your machine and keep your contact information information. See Transfer of Ownership, below.
up to date.
To ensure safety of personnel and the reliable Transfer of Machine Ownership
continued operation of your machine, be sure to
comply with the action indicated in a respective Taking a few minutes to update owner information
bulletin. will ensure that you receive important safety,
maintenance and operating information that
To view any open bulletins for your machine, visit applies to your machine.
us on the web at www.genielift.com.
Please register your machine by visiting us on the
web at www.genielift.com or by calling us toll free
at 1-800-536-1800.

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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.

Danger
Hazard Classification
Failure to obey the instructions and
Decals on this machine use symbols, color coding,
safety rules in this manual will result and signal words to identify the following:
in death or serious injury.
Safety alert symbol—used to alert
you to potential personal injury
Do Not Operate Unless: hazards. Obey all safety
messages that follow this symbol
 You learn and practice the principles of safe to avoid possible injury or death.
machine operation contained in this operator’s
manual. Indicates a hazardous situation
which, if not avoided, will result in
1 Avoid hazardous situations. death or serious injury.
Know and understand the safety rules
before going on to the next section. Indicates a hazardous situation
which, if not avoided, could result
2 Always perform a pre-operation inspection. in death or serious injury.
3 Always perform function tests prior to use.
Indicates a hazardous situation
4 Inspect the workplace. which, if not avoided, could result
in minor or moderate injury.
5 Only use the machine as it was intended.
 You read, understand and obey the Indicates a property damage
manufacturer’s instructions and safety rules— message.
safety and operator’s manuals and machine
decals.
 You read, understand and obey employer’s
safety rules and worksite regulations.
 You read, understand and obey all applicable
governmental regulations.
 You are properly trained to safely operate the
machine.

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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.

Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required

clearance

Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Tire specifications

Wheel load Wind speed Maximum capacity Manual force Weight of welder
reduces capacity

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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 Pressure rating for air
power to platform line to platform

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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
1 Lower primary. 1 Retract primary. manual manual and authorized
2 Lower secondary. 2 Lower secondary. personnel only
3 Retract primary. 3 Lower primary.

Auxiliary lowering Crush hazard Support the platform Replace tracks with Wheel load
or boom during same tracks.
maintenance

Platform overloaded

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General Safety
General Safety

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General Safety

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General Safety

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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.
All PFPE must comply with applicable
governmental regulations, and must be inspected
and used in accordance with the PFPE
manufacturer’s instructions.

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Work Area Safety

Work Area 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.
the Z-62/40 TRAX, even if the picture does not Personnel on the ground
show the tracks. or in the platform must not
touch or operate the
machine until energized
Electrocution Hazards power lines are shut off.
This machine is not electrically insulated and will
not provide protection from contact with or
Do not operate the machine during lightning or
proximity to electrical current.
storms.
Obey all local and Do not use the machine as a ground for welding.
governmental regulations
regarding required
clearance from electrical Tip-over Hazards
power lines. At a minimum,
the required clearance Occupants, equipment and materials shall not
contained in the chart exceed the maximum platform capacity or the
below must be followed. maximum platform capacity of the platform
extension.

Maximum platform capacity 500 lbs 227 kg

Maximum occupants 2
Line Voltage Required Clearance
0 to 50KV 10 ft 3.05 m The weight of options and accessories, such as
50 to 200KV 15 ft 4.60 m pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
200 to 350KV 20 ft 6.10 m subtracted from the platform capacity. See the
350 to 500KV 25 ft 7.62 m decals with the options and accessories.
500 to 750KV 35 ft 10.67 m
If using accessories, read, understand and obey
750 to 1000KV 45 ft 13.72 m the decals, instructions and manuals with the
accessory.
Allow for platform movement, electrical line sway
or sag, and beware of strong or gusty winds.

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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.
1 Lower the primary
boom.
2 Lower the
secondary boom.
3 Retract the primary
boom.
If the tilt alarm sounds
with the platform
downhill:
1 Retract the primary
boom.
2 Lower the
secondary boom.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the 3 Lower the primary
machine is on a severe slope. boom.

If the tilt alarm sounds while the boom is lowered:

Do not extend, rotate or raise the boom above
horizontal. Move the machine to a firm, level Do not raise the boom
surface before raising the platform. when wind speeds may
exceed 28 mph/12.5 m/s.
If the tilt alarm sounds when the platform is raised, If wind speeds exceed
use extreme caution. Identify the condition of the 28 mph/12.5 m/s when the
boom on the slope as shown in the tilt alarm boom is raised, lower the
procedure. Follow the steps to lower the boom boom and do not continue
before moving to a firm, level surface. Do not to operate the machine.
rotate the boom while lowering.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed
to the wind will decrease machine stability.

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Work Area Safety

Use extreme care and Do not alter or disable machine components that
slow speeds while driving in any way affect safety and stability.
the machine in the stowed Do not replace items critical to machine stability
position across uneven with items of different weight or specification.
terrain, debris, unstable or
slippery surfaces and near Do not replace tracks with tires.
holes and drop-offs.
Do not use the platform controls to free a platform
that is caught, snagged, or otherwise prevented
from normal motion by an adjacent structure. All
Do not drive the machine on or near uneven
personnel must be removed from the platform
terrain, unstable surfaces or other hazardous
before attempting to free the platform using the
conditions with the boom raised or extended.
ground controls.
Do not use the machine as a crane.
Do not modify or alter a mobile elevating work
Do not push the machine or other objects with the platform without prior written permission from the
boom. manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
Do not contact adjacent structures with the boom. toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
Do not tie the boom or platform to adjacent platform or the load.
structures.
Do not place loads outside the platform perimeter.

Do not push off or pull

toward any object outside
of the platform.

Maximum allowable
manual force:
90 lbs / 400 N

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Work Area Safety

Do not place or attach Operation on Slopes Hazards

fixed or overhanging loads
to any part of this Do not drive the machine on a slope that exceeds
machine. the maximum uphill, downhill or side slope rating
of the machine. Slope rating applies only to
machines in the stowed position.

Maximum slope rating, stowed position, 2WD

Platform downhill 30% (17°)
Do not place ladders or Platform uphill 10% (6°)
scaffolds in the platform or Side slope 25% (14°)
against any part of this
Maximum slope rating, stowed position, 4WD
machine.
Platform downhill 45% (24°)
Platform uphill 30% (17°)
Side slope 25% (14°)

Note: Slope rating is subject to ground conditions

Do not transport tools and materials unless they with one person in the platform and adequate
are evenly distributed and can be safely handled traction. Additional platform weight may reduce
by person(s) in the platform. slope rating. See Driving on a Slope in the
Operating Instructions section.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all track lug nuts are properly tightened.

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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
platform. Be aware of the boom position and tailswing when
rotating the turntable.
Do not sit, stand, or climb
on the platform guard rails. Check the work area for
Maintain a firm footing on overhead obstructions or
the platform floor at all other possible hazards.
times.

Do not climb down from the

platform when raised. Be aware of crushing
hazards when grasping the
platform guard rail.

Keep the platform floor clear of debris.

Operators must comply with employer, job site,
Lower the platform entry mid-rail or close the entry and governmental rules regarding use of personal
gate before operating. protective equipment.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Hazards related with the specific product
application of exiting at height have been
considered in the design of the machine, for
further information contact Genie (see section
Contacting the Manufacturer).

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Work Area Safety

Observe and use the color-coded direction arrows Bodily Injury Hazard
on the platform controls and drive chassis for drive
and steer functions. Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
Stay clear of all Trax rotating or moving parts such and/or burn skin.
as sprockets and rollers.
Always operate the machine in a well-ventilated
Do not lower the boom area to avoid carbon monoxide poisoning.
unless the area below is
Do not allow any object to come near moving
clear of personnel and
parts. The object could be thrown out of the Trax
obstructions.
undercarriage.
Improper contact with components under any
cover will cause serious injury. Only trained
maintenance personnel should access
compartments. Access by the operator is only
Limit travel speed advised when performing a pre-operation
according to the condition inspection. All compartments must remain closed
of the ground surface, and secured during operation.
congestion, slope, location
of personnel, and any
other factors which may
Explosion and Fire Hazards
cause collision. Do not start the engine if you smell or detect liquid
petroleum gas (LPG), gasoline, diesel fuel or other
explosive substances.
Do not operate a boom in the path of any crane Do not refuel the machine with the engine running.
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent Refuel the machine and charge the battery only in
any potential collision. an open, well-ventilated area away from sparks,
flames and lighted tobacco.
No stunt driving or horseplay while operating a
machine. Do not operate the machine or charge the battery
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engines equipped with
glow plugs.

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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 machine and test all functions before each Batteries contain acid.
work shift. Immediately tag and remove from Always wear protective
service a damaged or malfunctioning machine. clothing and eye wear when
working with batteries.
Be sure all maintenance has been performed as
specified in this manual and the appropriate Genie Avoid spilling or contacting
service manual. battery acid. Neutralize
battery acid spills with
Be sure all decals are in place and legible. baking soda and water.
Be sure the operator's manual is complete, legible,
and in the storage container located on the Explosion Hazards
machine.
Keep sparks, flames, and
lighted tobacco away from
Component Damage Hazards batteries. Batteries emit
Do not use any battery or charger greater than explosive gas.
12V to jump-start the engine.
Do not use the machine as a ground for welding.
Do not operate the machine in locations where
extremely high magnetic fields may be present.

Electrocution Hazard
Avoid contact with electrical terminals.

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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. The Do not exceed the rated platform capacity. The
combined weight of the cradles, panels, pipe cradle assembly and the weight in the pipe
occupants, tools and any other equipment must cradles will reduce rated platform capacity and
not exceed rated capacity. must be factored into total platform load.
The panel cradle assembly weighs 30 lbs/13.6 kg. The pipe cradle assembly weighs 21 lbs/9.5 kg.
The maximum capacity of the panel cradles is The maximum capacity of the pipe cradle
250 lbs/113 kg. assembly is 200 lbs/91 kg.
The weight of the panel cradles and the load in the The weight of the pipe cradle assembly and the
panel cradles may limit the maximum number of load in the pipe cradles may limit the maximum
occupants in platform to one person. number of occupants in platform.
Secure the cradles to the platform. Secure the Center the load within the perimeter of the
panel (s) to the platform railing using the straps platform.
provided.
Secure the load to the platform.
Do not operate unless you are adequately
instructed and are aware of all hazards associated Do not obstruct the entrance or the exit of the
with lifting panels. platform.

Do not cause a horizontal force or side load to Do not obstruct the ability to operate the platform
machine by raising or lowering a fixed or controls or the red Emergency Stop button.
overhanging load. Do not operate unless you are adequately
Maximum vertical height of panels: 4 ft/1.2 m. instructed and are aware of all of the hazards
associated with movement of the platform with an
Maximum wind speed: 15 mph/6.7 m/sec. overhanging load.
Maximum panel area: 32 sq ft/3 m2. Do not cause a horizontal force or side load to
machine by raising or lowering a fixed or
overhanging load.
Electrocution Hazard: Keep pipes away from all
energized electrical conductors.

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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 are no brakes and machine may move, resulting in
controls. death, serious injury or property damage.
Do not operate unless the weld cables are Do not exceed maximum towing speed, or
properly connected and the welder is properly maximum towing time.
grounded.
Maximum tow speed 8 mph/13 km/h
The weight of the welder will reduce the rated
Maximum towing time at
platform capacity and must be factored into the 30 minutes
8 mph/13 km/h
total platform load. The welder power supply
weighs 75 lbs/34 kg. Maximum towing time at
60 minutes
6 mph/10 km/h
Do not operate the welder unless a fire
extinguisher is immediately available for instant
use.

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Work Area Safety

Lockout After Each Use

1 Select a safe parking location—firm level
surface, clear of obstruction and traffic.
2 Retract and lower the boom to the stowed
position.
3 Rotate the turntable so that the boom is
between the non-steer wheels.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized
use.

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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.

1 Foot switch 7 Ground controls

2 Manual storage container 8 Primary boom
3 Sliding mid-rail 9 Jib boom
4 Lanyard anchorage points 10 Platform controls
5 Non-steer tire 11 Platform
6 Steer tire 12 Secondary boom

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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.
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. When the ground control station is selected, the platform controls are
inoperable, including the E-stop switch.

Ground Control Panel With LCD Display

Ground Control Panel With Hour Meter

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Controls

Ground Control Panel 6 Gasoline/LPG models: Check engine light

Diesel models: Oil pressure light
1 Function enable button
Light on and engine stopped: Tag the machine
Press and hold the function enable button to
and remove from service.
enable the functions on the ground control
Light on and engine still running: Contact
panel to operate.
service personnel within 24 hours.
2 Secondary boom up/down switch
7 Platform overload indicator light
Move the secondary boom up/down switch up
Light flashing indicates the platform is
and the secondary boom will raise. Move
overloaded. The engine will stop and no
secondary boom up/down switch down and
functions will operate. Remove weight until the
the secondary boom will lower.
light goes off and then restart the engine.
3 Primary boom up/down switch
8 Key switch for ground selection/off/platform
Move the primary boom up/down switch up
Turn the key switch to the ground position and
and the boom will raise. Move the primary
the ground controls will operate. Turn the key
boom up/down switch down and the boom will
switch to the off position and the machine will
lower.
be off. Turn the key switch to the platform
4 Primary boom extend/retract switch position and the platform controls will operate.
Move the primary boom extend/retract switch 9 Red Emergency Stop button
to the right and the primary boom will extend.
Push in the red Emergency Stop button to the
Move the boom extend/retract switch to the left
off position to stop all functions and turn the
and the primary boom will retract.
engine off. Pull out the red Emergency Stop
5 LCD readout screen button to the on position to operate the
machine.
Screen displays hour meter, voltage, oil
pressure and coolant temperature. Screen 10 Jib boom up/down switch
also displays fault codes and other service
Move the jib boom switch up and the jib boom
information.
will raise. Move the jib boom switch down and
or the jib boom will lower.
Hour meter
The hour meter displays the number of hours
the machine has operated.

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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.
select switch to the LPG position to select
16 Platform rotate switch
LPG.
Move the platform rotate switch to the right
12 Platform level switch
and the platform will rotate to the right. Move
Move the platform level switch up and the level the platform rotate switch to the left and the
of the platform will raise. Move the platform platform will rotate to the left.
level switch down and the level of the platform
17 Auxiliary power switch
will lower.
Use auxiliary power if the primary power
13 Engine idle (rpm) select switch
source (engine) fails.
Move the engine idle select switch to the turtle Simultaneously hold the auxiliary power switch
position for low idle. to either side and activate the desired function.
Move the engine idle select switch to the rabbit
18 Turntable rotate switch
position for high idle.
Move the turntable rotate switch to the right
14 Diesel models: Glow plug switch (if equipped)
and the turntable will rotate to the right. Move
Move the glow plug switch to either side and the turntable rotate switch to the left and the
hold for 3 to 5 seconds. turntable will rotate to the left.
19 Regeneration Enable switch (models with LCD
screen)
Move the Regeneration Enable switch to the
right to enable all the machine functions. Move
the Regeneration Enable switch to the left to
disable all the machine functions.

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Controls

Platform Control Panel With Hour Meter

1 Horn button 9 Platform control box heater (if equipped)
2 Platform level switch 10 Generator switch (if equipped)
3 Platform rotate switch 11 Aircraft protection override switch (if equipped)
4 Jib boom up/down switch 12 Steer mode select switch (if equipped)
5 Platform overload indicator light 13 Red Emergency Stop button
6 Machine not level indicator light 14 Dual axis proportional control handle for drive
7 Auxiliary power switch with cover and steer functions.
8 Drive speed select switch OR
Proportional control handle for drive function and
thumb rocker for steer function

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Controls

15 Drive enable indicator light 20 Gasoline/LPG models: Fuel select switch

16 Drive enable switch 21 Proportional control handle for secondary boom
17 Diesel models:Glow plug switch up/down function
18 Engine idle (rpm) select switch 22 Primary boom extend/retract switch
Turtle: foot switch activated low idle 23 Dual axis proportional control handle for primary
Rabbit: foot switch activated high idle boom up/down and turntable rotate left/right
functions
19 Engine start switch

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Controls

Platform Control Panel, Models 6 Machine not level indicator light

With Hour Meter The machine not level indicator light will come
1 Horn button on when the tilt alarm sounds.

Press this button and the horn will sound. 7 Auxiliary power switch with cover
Release the button and the horn will stop. Use auxiliary power if the primary power
2 Platform level switch source fails.
Simultaneously hold the auxiliary power switch
Move the platform level on and activate the desired function.
switch up and the level of the
platform will raise. Move the 8 Drive speed select switch
platform level switch down Machine on incline symbol: Low range
and the level of the platform operation for inclines.
will lower. Machine on level surface symbol: High range
3 Platform rotate switch operation for maximum drive speed.
9 Platform control box heater (if equipped)
Move the platform rotate
switch to the right and the Move the heater switch up to turn on the
platform will rotate to the platform control box heater. Move the heater
right. Move the platform switch down to turn off the platform control box
rotate switch to the left heater.
and the platform will rotate 10 Generator switch (if equipped)
to the left.
Move the generator switch up to activate the
4 Jib boom up/down switch generator. Move the switch down to turn off
the generator.
Move the jib boom switch
up and the jib boom will 11 Aircraft protection override switch (if equipped)
raise. Move the jib boom Move and hold the aircraft protection override
switch down and the jib switch to operate the machine when the
boom will lower. platform bumper is against an object.
5 Platform overload indicator light 12 Steer mode select switch (if equipped)
Light flashing indicates the platform is Move the steer mode select switch to the left
overloaded. The engine will stop and no to select square-end steer. Move the steer
functions will operate. Remove weight until the mode select switch to the right to select
light goes off and then restart the engine. coordinated steer.

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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. Pull out the red Emergency Stop function has been interrupted.
button to the on position to operate the
16 Drive enable switch
machine.
To drive when the drive enable light is on, hold
14 Dual axis proportional control handle for drive
the drive enable switch to either side and
and steer functions.
slowly move the drive control handle off
OR
center. Be aware that the machine may move
Proportional control handle for drive function
in the opposite direction that the drive and
and thumb rocker for steer function.
steer controls are moved.
Move the control handle in the direction
17 Diesel models: Glow plug switch
indicated by the blue arrow on the control
panel and the machine will drive forward. Move the glow plug switch to either side and
Move the control handle in the direction hold for 3 to 5 seconds.
indicated by the yellow arrow and the machine
18 Engine idle (rpm) select switch
will drive backwards. Move the control handle
in the direction indicated by the blue triangle Move the engine idle select switch to the turtle
and the machine will steer to the left. Move the position for foot switch activated low idle.
control handle in the direction indicated by the Move the engine idle select switch to the rabbit
yellow triangle and the machine will steer to position for foot switch activated high idle.
the right.
OR 19 Engine start switch
Move the control handle in the direction Move the engine start switch to either side to
indicated by the blue arrow on the control start the engine.
panel and the machine will drive forward.
Move the control handle in the direction 20 Gasoline/LPG models: Fuel select switch
indicated by the yellow arrow and the machine Move the fuel select switch to the gasoline
will drive backwards. Press the left side of the position to select gasoline. Move the fuel
thumb rocker and the machine will steer to the select switch to the LPG position to select
left. Press the right side of the thumb rocker LPG.
and the machine will steer to the right.

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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
retract. Move the boom
extend/retract switch down
and the primary boom will
extend.

23 Dual axis proportional control handle for

primary boom up/down and turntable rotate
left/right functions

Move the control handle up

and the primary boom will
raise. Move the control
handle down and the
primary boom will lower.

Move the control handle to

the right and the turntable
will rotate to the right. Move
the control handle to the left
and the turntable will rotate
to the left.

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Controls

Platform Control Panel With LCD Display

1 Horn button 9 Platform control box heater (if equipped)
2 Platform level switch 10 Generator switch (if equipped)
3 Platform rotate switch 11 Aircraft protection override switch (if equipped)
4 Jib boom up/down switch 12 Red Emergency Stop button
5 Platform overload indicator light 13 Dual axis proportional control handle for boom
6 Machine not level indicator light up/down and turntable rotate left/right functions
7 Auxiliary power switch with cover OR Proportional control handle for drive function
and thumb rocker for steer function
8 Drive speed select switch

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Controls

14 Drive enable indicator light 19 Models with LCD screen: Engine shut down
15 Drive enable switch indicator light
16 Glow plug indicator light 20 Proportional control handle for secondary boom
17 Engine idle (rpm) select switch up/down function
Turtle: foot switch activated low idle 21 Primary boom extend/retract switch
Rabbit: foot switch activated high idle 22 Dual axis proportional control handle for boom
up/down and turntable rotate left/right functions
18 Engine start switch

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Controls

Platform Control Panel, Models 5 Platform overload indicator light

With LCD Screen Light flashing indicates the platform is
overloaded. The engine will stop and no
1 Horn button functions will operate. Remove weight until the
Press this button and the horn will sound. light goes off and then restart the engine.
Release the button and the horn will stop. 6 Machine not level indicator light
2 Platform level switch Light on indicates the tilt sensor activation
settings have been exceeded. See the
Move the platform level
instructions in the Operating Instructions
switch up and the level of the
section.
platform will raise. Move the
platform level switch down 7 Auxiliary power switch
and the level of the platform
Use auxiliary power if the primary power
will lower.
source (engine) fails.
3 Platform rotate switch Simultaneously hold the auxiliary power switch
to either side and activate the desired function.
Move the platform rotate
8 Drive speed select switch
switch to the right and the
platform will rotate to the Machine on incline symbol: Low range
right. Move the platform operation for inclines.
rotate switch to the left Machine on level surface symbol: High range
and the platform will rotate operation for maximum drive speed.
to the left.
9 Platform control box heater (if equipped)
4 Jib boom up/down switch Move the heater switch up to turn on the
platform control box heater. Move the heater
Move the jib boom switch
switch down to turn off the platform control box
up and the jib boom will
heater.
raise. Move the jib boom
switch down and the jib 10 Generator switch (if equipped)
boom will lower.
Move the generator switch up to activate the
generator. Move the switch down to turn off
the generator.

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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. function has been interrupted.
12 Red Emergency Stop button 15 Drive enable switch
Push in the red Emergency Stop button to the To drive when the drive enable light is on, hold
off position to stop all functions and turn the the drive enable switch to either side and
engine off. Pull out the red Emergency Stop slowly move the drive control handle off
button to the on position to operate the center. Be aware that the machine may move
machine. in the opposite direction that the drive and
steer controls are moved.
13 Dual axis proportional control handle for drive
and steer functions. 16 Glow plug indicator light
OR
The light comes on when the temperature is
Proportional control handle for drive function
low.
and thumb rocker for steer function.
17 Engine idle (rpm) select switch
Move the control handle in the direction
indicated by the blue arrow on the control Move the engine idle select switch to the turtle
panel and the machine will drive forward. position for foot switch activated low idle.
Move the control handle in the direction Move the engine idle select switch to the rabbit
indicated by the yellow arrow and the machine position for foot switch activated high idle.
will drive backwards. Move the control handle
18 Engine start switch
in the direction indicated by the blue triangle
and the machine will steer to the left. Move the Move the engine start switch to either side to
control handle in the direction indicated by the start the engine.
yellow triangle and the machine will steer to
the right. 19 Models with LCD screen: Engine shut-down
OR indicator light
Move the control handle in the direction Light on indicates that the engine has shut
indicated by the blue arrow on the control down. Contact service personnel.
panel and the machine will drive forward.
Move the control handle in the direction
indicated by the yellow arrow and the machine
will drive backwards. Press the left side of the
thumb rocker and the machine will steer to the
left. Press the right side of the thumb rocker
and the machine will steer to the right.

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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
retract. Move the boom
extend/retract switch down
and the primary boom will
extend.

22 Dual axis proportional control handle for

primary boom up/down and turntable rotate
left/right functions

Move the control handle up

and the primary boom will
raise. Move the control
handle down and the
primary boom will lower.

Move the control handle to

the right and the turntable
will rotate to the right. Move
the control handle to the left
and the turntable will rotate
to the left.

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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
 You learn and practice the principles of safe operator performs the function tests.
machine operation contained in this operator’s
manual. The pre-operation inspection also serves to
determine if routine maintenance procedures are
1 Avoid hazardous situations.
required. Only routine maintenance items specified
2 Always perform a pre-operation in this manual may be performed by the operator.
inspection.
Refer to the list on the next page and check each
Know and understand the pre-operation of the items.
inspection before going on to the next
section. If damage or any unauthorized variation from
factory delivered condition is discovered, the
3 Always perform function tests prior to use. machine must be tagged and removed from
4 Inspect the workplace. service.
5 Only use the machine as it was intended. Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer’s specifications. After repairs are
completed, the operator must perform a pre-
operation inspection again before going on to the
function tests.
Scheduled maintenance inspections shall be
performed by qualified service technicians,
according to the manufacturer’s specifications.

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Inspections

Pre-operation Inspection ❑ Engine and related components

❑ Limit switches and horn
❑ Be sure that the operator’s manual is
complete, legible and in the storage container ❑ Contact alarm (if equipped)
located in the platform.
❑ Alarms and beacons (if equipped)
❑ Be sure that all decals are legible and in place.
❑ Nuts, bolts and other fasteners
See Inspections section.
❑ Platform entry mid-rail or gate
❑ Check for hydraulic oil leaks and proper oil
level. Add oil if needed. See Maintenance ❑ Lanyard anchorage points
section.
❑ Platform load cell
❑ Check for battery fluid leaks and proper fluid
❑ Generator (if equipped)
level. Add distilled water if needed. See
Maintenance section. ❑ Tires and wheels
❑ Check for engine oil leaks and proper oil level. Check entire machine for:
Add oil if needed. See Maintenance section.
❑ Cracks in welds or structural components
❑ Check for engine coolant leaks and proper
level of coolant. Add coolant if needed. See ❑ Dents or damage to machine
Maintenance section. ❑ Excessive rust, corrosion or oxidation
❑ Check rubber tracks for signs of wear, cracks ❑ Verify that all structural and other critical
and cuts. components are present and all associated
Check the following components or areas for fasteners and pins are in place and properly
damage, improperly installed, or missing parts and tightened.
unauthorized modifications: ❑ After you complete your inspection, be sure
that all compartment covers are in place and
❑ Electrical components, wiring, and
latched.
electrical cables
Pictures in this manual may show a boom with
❑ Hydraulic hoses, fittings, cylinders, and
tires and wheels instead of tracks. All safety
manifolds
information and operating instructions still apply to
❑ Fuel and hydraulic tanks the Z-62/40 TRAX, even if the picture does not
show the tracks.
❑ Drive and turntable motors and drive hubs
❑ Wear pads
❑ Tracks, sprocket, idler, bogey,
undercarriage/frame, tensioner

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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. Repairs to the
 You learn and practice the principles of safe machine may only be made by a qualified service
machine operation contained in this operator’s technician, according to the manufacturer’s
manual. specifications.
1 Avoid hazardous situations. After repairs are completed, the operator must
2 Always perform a pre-operation inspection. perform a pre-operation inspection and function
tests again before putting the machine into
3 Always perform function tests prior to service.
use.
Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.

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Inspections

At the Ground Controls Test the Tilt Sensor

1 Select a test area that is firm, level and free of 9 Turn the key switch to
hazards. platform control. Pull out the
platform red Emergency
2 Turn the key switch to ground control.
Stop button to the on
3 Pull out the red Emergency Stop button to the position.
on position.
10 Open the control panel side
Result: The beacon (if equipped) should flash. turntable cover and locate
the tilt sensor next to the
4 Start the engine. See Operating Instructions function manifold.
section.
11 Press down one side of the tilt sensor.
Test Emergency Stop
Result: The alarm, located in the platform,
5 Push in the red Emergency Stop button to the should sound.
off position.
Result: The engine will shut off after 2 to Test Auxiliary Controls
3 seconds. 12 Turn the key switch to ground control and shut
6 Pull out the red Emergency Stop button to the the engine off.
on position and restart the engine. 13 Pull out the red Emergency Stop button to the
on position.
Test Machine Functions
14 Simultaneously hold the auxiliary
7 Do not push and hold the power switch on and activate each
function enable button. Attempt boom function toggle switch.
to activate each boom and
platform function toggle switch. Note: To conserve battery power, test each
function through a partial cycle.
Result: No boom and platform functions
should operate. Result: All boom functions should operate.

8 Press and hold the function enable button and

activate each boom and platform function
toggle switch.
Result: All boom and platform functions should
operate through a full cycle. The descent
alarm should sound while the boom is
lowering.

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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.
restart the engine.
Result: All boom and platform functions should
16 Push in the platform red Emergency Stop operate through a full cycle.
button to the off position.
Result: The engine will shut off after 2 to Models with 2 wheel steer
3 seconds.
Test the Steering
17 Pull out the red Emergency Stop button and
restart the engine. 26 Press down the foot switch.
27 Press the thumb rocker switch on top of the
Test the Horn drive control handle in the direction indicated
18 Press the horn button. by the blue triangle on the control panel OR
slowly move the control handle in the direction
Result: The horn should sound. indicated by the blue triangle.

Test the Foot Switch Result: The steer wheels, or steer tracks
should turn in the direction that the blue
19 Push in the platform red Emergency Stop triangles point on the drive chassis.
button to the off position.
28 Press the thumb rocker switch in the direction
20 Pull out the red Emergency Stop button to the indicated by the yellow triangle on the control
on position and do not start the engine. panel OR slowly move the control handle in
the direction indicated by the yellow triangle.
21 Press down the foot switch and attempt to
start the engine by moving the start toggle Result: The steer wheels, or steer tracks
switch to either side. should turn in the direction that the yellow
triangles point on the drive chassis.
Result: The engine should not start.
22 Do not press down the foot switch and restart
the engine.
Result: The engine should start.
23 Do not press down the foot switch and test
each machine function.
Result: No functions should operate.

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Inspections
Models with 4 wheel steer 33 Slowly move the drive control handle in the
direction indicated by the blue triangle on the
Test the Steering control panel OR press the thumb rocker
switch in the direction indicated by the blue
29 Move the steer mode select switch and triangle.
choose square-end (blue arrow) steer.
Result: The square-end wheels should turn in
30 Slowly move the drive control handle in the the direction that the blue triangles point on
direction indicated by the blue triangle on the the drive chassis. The circle-end wheels
control panel OR press the thumb rocker should turn in the direction that the yellow
switch in the direction indicated by the blue triangles point on the drive chassis.
triangle.
34 Slowly move the control handle in the direction
Result: The square-end wheels should turn in indicated by the yellow triangle on the control
the direction that the blue triangles point on panel OR press the thumb rocker switch in the
the drive chassis. direction indicated by the yellow triangle.
31 Slowly move the control handle in the direction Result: The square-end wheels should turn in
indicated by the yellow triangle on the control the direction that the yellow triangles point on
panel OR press the thumb rocker switch in the the drive chassis. The circle-end wheels
direction indicated by the yellow triangle. should turn in the direction that the blue
Result: The square-end wheels should turn in triangles point on the drive chassis.
the direction that the yellow triangles point on
the drive chassis.
32 Move the steer mode select switch and
choose coordinated steer.

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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 moves past one of the non-steer wheels.
move, then return the handle to the center
position. Result: The drive enable
indicator light should
Result: The machine should move in the come on and remain on
direction that the blue arrow points on the while the boom is
drive chassis, then come to an abrupt stop. anywhere in the range
37 Slowly move the control handle in the direction shown.
indicated by the yellow arrow on the control
40 Move the drive control handle off center.
panel until the machine begins to move, then
return the handle to the center position. Result: The drive function should not operate.
Result: The machine should move in the 41 Move and hold the drive enable toggle switch
direction that the yellow arrow points on the to either side and slowly move the drive
drive chassis, then come to an abrupt stop. control handle off center.
Note: The brakes must be able to hold the Result: The drive function should operate.
machine on any slope it is able to climb.
Note: When the drive enable system is in use, the
machine may drive in the opposite direction that
the drive and steer control handle is moved.

Use the color-coded direction

arrows on the platform controls
and the drive chassis to identify
the direction of travel.

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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. onto a slope where the chassis pitch angle is
44 Slowly move the drive control handle to the full greater than 4.5°.
drive position. Result: The machine should continue to drive.
Result: The maximum achievable drive speed 54 Return to level ground and raise the primary
with the primary boom raised should not boom to an out of stowed position
exceed 1 ft / 30 cm per second. (approximately 10° above horizontal).
45 Lower the primary boom to the stowed 55 Drive the machine onto a slope where the
position. chassis pitch angle is greater than 4.5°.
46 Extend the primary boom approximately Result: The machine should stop once the
2 feet/61 cm. machine reaches 4.5° of chassis tilt and the
47 Slowly move the drive control handle to the full alarm should sound at the platform controls.
drive position. 56 Lower the primary boom to the stowed
Result: The maximum achievable drive speed position.
with the primary boom extended should not Result: The alarm should turn off and the
exceed 1 ft/30 cm per second. machine should drive.
48 Retract the primary boom to the stowed 57 Return to level ground and extend the primary
position. boom approximately 1.6 ft / 0.5 m.
49 Raise the secondary boom approximately 58 Drive the machine onto a slope where the
2 feet/61 cm. chassis pitch angle is greater than 4.5°.
50 Slowly move the drive control handle to the full Result: The machine should stop once the
drive position. machine reaches 4.5° of chassis tilt and the
Result: The maximum achievable drive speed alarm should sound at the platform controls.
with the secondary boom raised should not 59 Retract the primary boom to the stowed
exceed 1 ft / 30 cm per second. position.
51 Lower the secondary boom to the stowed Result: The alarm should turn off and the
position. machine should drive.
If the drive speed with the primary or secondary
boom raised or the primary boom extended
exceeds 1 ft/30 cm per second, immediately tag
and remove the machine from service.

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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 4.5°. chassis roll angle is greater than 2.5°.
Result: The machine should continue to drive. Result: The machine should stop once the
machine reaches 2.5° of chassis tilt and the
62 Return to level ground and raise the
alarm should sound at the platform controls.
secondary boom to an out of stowed position
(approximately 15° above horizontal). 70 Retract the primary boom to the stowed
position.
Result: The machine should stop once the
machine reaches 4.5° of chassis tilt and the Result: The alarm should turn off and the
alarm should sound at the platform controls. machine should drive.
63 Lower the secondary boom to the stowed 71 Return to level ground and stow the boom.
position or drive in the opposite direction.
72 With the boom fully stowed, drive the machine
Result: The alarm should turn off and the onto a slope where the chassis roll angle is
machine should drive. greater than 2.5°.
64 With the boom fully stowed, drive the machine Result: The machine should continue to drive.
onto a slope where the chassis pitch angle is
73 Return to level ground and raise the
greater than 4.5°.
secondary boom to an out of stowed position
Result: The machine should continue to drive. (approximately 15° above horizontal).
65 Return to level ground and raise the primary 74 Drive the machine onto a slope where the
boom to an out of stowed position chassis roll angle is greater than 2.5°.
(approximately 10° above horizontal).
Result: The machine should stop once the
66 Drive the machine onto a slope where the machine reaches 2.5° of chassis tilt and the
chassis roll angle is greater than 2.5°. alarm should sound at the platform controls.
Result: The machine should stop once the 75 Lower the primary boom to the stowed
machine reaches 2.5° of chassis tilt and the position.
alarm should sound at the platform controls.
Result: The alarm should turn off and the
67 Lower the primary boom to the stowed position machine should drive.
or drive in the opposite direction.
Result: The alarm should turn off and the
machine should drive.

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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. the contact alarm cable to release the actuator
from the switch socket.
Result: The three remaining tires should stay
in firm contact with the ground. Result: The contact alarm lights will not flash
and the machine horn will not sound.
77 Drive the left steer tire up onto a 6 in/15 cm
block or curb. 85 Activate the foot switch by pressing the foot
switch down.
Result: The three remaining tires should stay
in firm contact with the ground. Result: The contact alarm lights will flash and
the machine horn will sound.
78 Drive both steer tires up onto a 6 in/15 cm
block or curb. 86 Insert the actuator into the switch socket.
Result: The non-steer tires should stay in firm Result: The lights and horn will turn off.
contact with the ground.
87 Activate the foot switch by pressing the foot
switch down and press on the contact alarm
Test Auxiliary Controls cable to release the actuator from the switch
79 Push in the red Emergency Stop button to the socket.
off position to shut off the engine. Result: The contact alarm lights will flash and
80 Pull out the red Emergency Stop button to the the machine horn will sound.
on position.
81 Press down the foot switch.
82 Simultaneously move and hold the auxiliary
power switch and activate each function
control handle, toggle switch or thumb rocker
switch.
Note: To conserve battery power, test each
function through a partial cycle.
Result: All boom and steer functions should
operate. Drive functions should not operate
with auxiliary power.
83 Restart the engine.

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Inspections

88 Operate each machine function. Test the Lift/Drive Select Function (if
equipped)
Result: All machine functions should not
operate. 91 Press down the foot switch.
89 Insert the actuator into the switch socket. 92 Move the drive control handle off center and
activate a boom function toggle switch.
Result: The lights and horn will turn off.
Result: No boom functions should operate.
90 Operate each machine function. The machine will move in the direction
Result: All machine functions should operate. indicated on the control panel.
Repair any malfunctions before operating the
machine.

Test Aircraft Protection Package

(if equipped)
Note: Two people may be required to perform this
test.
93 Extend the primary boom approximately
1 ft/30 cm.
94 Move the yellow bumper at the bottom of the
1 actuator platform 4 inches/10 cm in any direction.
2 contact alarm cable 95 Activate each function control handle or toggle
3 flashing alarm switch.
4 switch socket Result: No boom and steer functions should
operate.

96 Move and hold the aircraft

protection override switch.

97 Activate each function control handle or toggle

switch.
Result: All boom and steer functions should
operate.

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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
 You learn and practice the principles of safe
machine operation contained in this operator’s ❑ overhead obstructions and high voltage
manual. conductors
1 Avoid hazardous situations. ❑ hazardous locations
2 Always perform a pre-operation inspection. ❑ inadequate surface support to withstand all
load forces imposed by the machine
3 Always perform function tests prior to use.
❑ wind and weather conditions
4 Inspect the workplace.
❑ the presence of unauthorized personnel
Know and understand the workplace
inspection before going on to the next ❑ other possible unsafe conditions
section.
5 Only use the machine as it was intended.

Workplace Inspection
Fundamentals
The workplace inspection helps the operator
determine if the workplace is suitable for safe
machine operation. It should be performed by the
operator prior to moving the machine to the
workplace.
It is the operator’s responsibility to read and
remember the workplace hazards, then watch for
and avoid them while moving, setting up, and
operating the machine.

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Inspections

Inspection for Decals with Part No. Decal Description Qty

Symbols 1256425 Label – Danger, Electrocution Hazard 3
1257658 Label – Wheel Load, Z-62 4
Use the pictures on the next page to verify that all
decals are legible and in place. 1257659 Label – Transport/Lifting 2
1257660 Label – Manual Lowering, Z-62 1
Below is a numerical list with quantities and 1257661 Label – Slope Rating, Z-62 1
descriptions.
1263542 Label – Compartment Access 2
Part No. Decal Description Qty 1272242 Label – Machine Registration/Owner 1
Transfer
27204 Arrow – Blue 1
1272876 Label – Track Load, Z-62/40 TRAX 4
27205 Arrow – Yellow 1
1273574 Platform Control Panel, models with 1
27206 Triangle – Blue 2
LCD screen
27207 Triangle – Yellow 2
1273578 Platform Control Panel 1
28158 Label – Unleaded 1
1278542 Label – Contact Alarm Weight 1
28159 Label – Diesel 1
1278982 Label – Actuator Switch Socket 1
28160 Label – Liquid Petroleum Gas 1
1281175 Label – Lanyard Anchorage Point, Fall 8
28174 Label – Power to Platform, 230V 3 Restrained
28235 Label – Power to Platform, 115V 3 1286362 Label – Crush Hazard, Service 1
44981 Label – Air Line to Platform (option) 2 1298991 Warning – Panel Cradle (option) 2
52475 Label – Transport Tie Down 6 1301030 Label – Diesel, Stage V 1
65278 Caution – No Step 3 1301075 Label – Center the Raw Air Hose 1
65278 Caution – No Step (option) 3 (Stage V)
72086 Label – Lifting Point 6 1304217 Label – Explosion Hazard 1
82240 Label – 105 dB 1 Shading indicates decal is hidden from view, i.e.
82481 Label – Battery/Charger Safety 1 under covers
82487 Label – Read the Manual 3 * These decals are model, option or configuration
specific.
82487 Label – Read the Manual (pipe cradle) 2
** These decals are installed on both sides of chassis.
82487 Label – Read the Manual (panel cradle) 2
*** These decals are installed on both sides of chassis
97815 Label – Lower Mid-rail 2 and are model, option, or configuration specific.
114236 Label – CB Symbol 2
114248 Label – Tip-over Hazard, Tilt Alarm 1
114249 Label – Tip-over Hazard, Tires 4
114251 Label – Explosion Hazard 2
114252 Label – Tip-over Hazard, Limit Switches 5
133067 Label – Electrocution Hazard 3
133205 Label – Electrocution/Burn Hazard 1
133263 Label – Tracks Specifications 4
215526 Label – Belt Routing (MSG-425) 1
219954 Label – Tip-over Hazard 1
219956 Label – Platform Overload 1
219958 Label – Tip-over, Crush Hazard 1
1253845 Ground Control Panel 1

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Inspections

1253845 **114236 *28160 114252 ***82487

114252
72086 ***82487

133067
82487
114251 *1298991
1257660
82481
*28160 114248 219956 219958
133205
*28158
1263542
*28159
219954
114252 *1301030
1257661
27207 27206
27204
27206 114252 *44981
**72086 27207
**52475 27205 *28174
133067
65278 *28235
***114249
***133263 **72086
**52475 82487
***1257658
**52475 ***1257658 ***114249 *82487
***1272876
***1272876 ***133263
**1257659
1281175
*65278
*1273574 *1256425
*1273578

97815 *1256425

1281175
82240 1272242 72086

215526

1286362 *1256425
1278982 *44981
*28174 *28174
*28235 *28235
1304217
1278542
1301075 114251 1263542 133067

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Operating Instructions
Operating Instructions

Pictures in this manual may show a boom with Fundamentals

tires and wheels instead of tracks. All safety
information and operating instructions still apply to The Operating Instructions section provides
the Z-62/40 TRAX, even if the picture does not instructions for each aspect of machine operation.
show the tracks. It is the operator’s responsibility to follow all the
safety rules and instructions in the operator’s
manual.
Using the machine for anything other than lifting
personnel, along with their tools and materials, to
an aerial work site is unsafe and dangerous.
Only trained and authorized personnel should be
permitted to operate a machine. If more than one
operator is expected to use a machine at different
Do Not Operate Unless: times in the same work shift, they must all be
 You learn and practice the principles of safe qualified operators and are all expected to follow
machine operation contained in this operator’s all safety rules and instructions in the operator’s
manual. manual. That means every new operator should
perform a pre-operation inspection, function tests,
1 Avoid hazardous situations. and a workplace inspection before using the
2 Always perform a pre-operation inspection. machine.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was
intended.

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Operating Instructions

Starting the Engine Models with automatic glow plugs:

5 The LCD screen will display the glow
Gasoline/LPG models plug symbol when the automatic glow
plugs are on.
1 At the ground controls, turn the key switch to
the desired position. 6 When the automatic glow plug symbol turns
2 Be sure both ground and platform control red off, move the engine start toggle switch to
Emergency Stop buttons are pulled out to the either side. If the engine fails to start or dies,
on position. the restart delay will disable the start switch for
3 seconds.
3 Choose fuel by moving the fuel select switch
to the desired position.
All models
4 Move the engine start toggle switch to either
If the engine fails to start after 15 seconds of
side. If the engine fails to start or dies, the
cranking, determine the cause and repair any
restart delay will disable the start switch for
malfunction. Wait 60 seconds before trying to start
3 seconds.
again.
Diesel models In cold conditions, 20°F/-6°C and below, warm the
engine for 5 minutes before operating to prevent
1 At the ground controls, turn the key switch to hydraulic system damage.
the desired position.
In extreme cold conditions, 0°F/-18°C and below,
2 Be sure both ground and platform control red machines should be equipped with optional cold
Emergency Stop buttons are pulled out to the start kits. Attempting to start the engine when
on position. temperatures are below 0°F/-18°C may require the
use of a booster battery.
Models with glow plug toggle switch:
3 Move the glow plug switch to either side and Gasoline/LPG models: In cold conditions, 20°F/-
hold for 3 to 5 seconds. 6°C and below, the machine should be started on
gasoline and warmed for 2 minutes, then switched
4 Move the engine start toggle switch to either
to LPG. Warm engines can be started on LPG.
side. If the engine fails to start or dies, the
restart delay will disable the start switch for
3 seconds.

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Operating Instructions

Emergency Stop Operation from Ground

Push in the red Emergency Stop button to the off 1 Turn the key switch to ground control.
position at the ground controls or the platform
2 Pull out the red Emergency Stop button to the
controls to stop all machine functions and turn the
on position.
engine off.
3 Gasoline/LPG models: Choose fuel by moving
Repair any function that operates when either red the fuel select switch to the desired position.
Emergency Stop button is pushed in.
4 Start the engine.
Selecting and operating the ground controls will
override the platform red Emergency Stop button. To Position Platform
1 Press and hold a function enable
Auxiliary Power button.
Use auxiliary power if the primary power source
(engine) fails.
1 Turn the key switch to ground or platform 2 Move the appropriate toggle switch according
control. to the markings on the control panel.
2 Pull out the red Emergency Stop button to the Drive and steer functions are not available from
on position. the ground controls.
3 Press down the foot switch when using the
Platform Overload Indicator Light
controls from the platform.
Light flashing indicates the platform is overloaded.
4 Simultaneously hold the auxiliary The engine will stop and no functions will operate.
power switch on and activate the
desired function. Remove weight from the platform until the light
goes off and then restart the engine.
The drive function will not operate with auxiliary
power. Note: An alarm will sound at the platform when an
overload condition occurs and will stop sounding
when weight is removed from the platform.

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Operating Instructions

Operation from Platform To Drive

1 Turn the key switch to platform control. 1 Press down the foot switch.

2 Pull out both ground and platform red 2 Increase speed: Slowly move the control
Emergency Stop buttons to the on position. handle off center.

3 Gasoline/LPG models: Choose fuel by moving Decrease speed: Slowly move the control
the fuel select switch to the desired position. handle toward center.

4 Start the engine. Do not press down the foot Stop: Return the control handle to center or
switch when starting the engine. release the function enable switch.
Use the color-coded direction arrows on the
To Position Platform platform controls and the drive chassis to identify
1 Press down the foot switch. the direction the machine will travel.

2 Slowly move the appropriate function control Machine travel speed is restricted when the boom
handle or toggle switch or press the is raised.
appropriate button according to the markings
on the control panel. Platform Overload Indicator Light
Light flashing indicates the platform is overloaded.
To Steer The engine will stop and no functions will operate.
1 Press down the foot switch.
Remove weight from the platform until the light
2 Slowly move the drive control handle in the goes off and then restart the engine.
direction indicated by blue or yellow triangles
OR press the thumb rocker switch located on Note: An alarm will sound at the platform when an
top of the drive control handle. overload condition occurs and will stop sounding
when weight is removed from the platform.
Use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the wheels or tracks will turn.

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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.
grade.
You will need:
Maximum slope rating,
• carpenter’s level
platform downhill
(gradeability): • straight piece of wood, at least 3 feet/1 m long
2WD: 30% (17°)
• tape measure
4WD: 45% (24°)
Lay the piece of wood on the slope.
Maximum slope rating,
platform uphill: At the downhill end, lay the level on the top edge
2WD: 10% (6°) of the piece of wood and lift the end until the piece
4WD: 30% (17°) of wood is level.

Maximum side slope rating: While holding the piece of wood level, measure
25% (14°) the vertical distance from the bottom of the piece
of wood to the ground.

Note: Slope rating is subject to ground conditions Divide the tape measure distance (rise) by the
with one person in the platform and adequate length of the piece of wood (run) and multiply by
traction. Additional platform weight may reduce 100.
slope rating. The term gradeability applies to the Example:
counterweight uphill configuration only.
Be sure the boom is below horizontal and the
platform is between the non-steer wheels.
Move the drive speed select switch to machine on
incline symbol.

Piece of wood = 144 inches (3.6 m)

Run = 144 inches (3.6 m)
Rise = 12 inches (0.3 m)
12 in ÷ 144 in = 0.083 x 100 = 8.3% grade
0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade
If the slope exceeds the maximum slope or side
slope rating, then the machine must be winched or
transported up or down the slope. See Transport
and Lifting section.

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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. and the drive function in one or
both directions will not operate.
Identify the condition of the boom
on the slope as shown below.
Follow the steps to lower the boom
To drive, hold the drive enable switch to either side before moving to a firm, level
and slowly move the drive control handle off surface. Do not rotate the boom
center. while lowering.

Be aware that the machine may move in the If the tilt alarm sounds
opposite direction that the drive and steer controls with the platform uphill:
are moved.
1 Lower the primary
Always use the color-coded direction arrows on boom.
the platform controls and the drive chassis to
2 Lower the
identify the direction the machine will travel.
secondary boom.
Drive Speed Select 3 Retract the primary
boom.
If the tilt alarm sounds
with the platform
downhill:
• Machine on incline symbol: Low range
operation for inclines 1 Retract the primary
boom.
• Machine on level surface symbol: High range
operation for maximum drive speed. 2 Lower the
secondary boom.
3 Lower the primary
boom.

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Operating Instructions
Tilt Sensor Activation Settings Engine Idle Select (rpm)
Model Chassis Angle Chassis Angle (front When the foot switch is not pressed, the engine
(side to side) to back) will idle at the lowest rpm.
Z-62/40 4.5° 4.5°
• Turtle symbol: Foot
Z-62/40 TraX 4.5° 4.5° switch activated low idle
When the Machine On Incline • Rabbit symbol: Foot
indicator light is on and the tilt switch activated high idle
alarm sounds, the following
functions are affected; drive If foot switch activated low idle or high idle do not
functions are disabled. work, contact service personnel within 24 hours.

To restore drive functions, Foot switch activated idle settings are disabled by
follow the steps to lower the certain fault codes.
boom in the Machine Not
Level Indicator Light Generator (if equipped)
procedure.
To start the generator, move
When the machine is stowed, the generator toggle switch to
on a slope, and the tilt alarm the on position.
sounds, the following
Plug a power tool into the
functions are affected; lift
power to platform GFCI outlet.
functions are disabled.
Return the machine to level To turn off the generator, move the generator
ground to restore lift toggle switch to the off position.
functions. Note: Machine functions will not operate while the
generator is running and the foot switch is not
pressed down. When the foot switch is pressed
down, the generator will turn off and the machine
functions will operate.

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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.
Light on and engine still running:
Contact service personnel within Remove weight from the
24 hours. platform until the light goes off
and then restart the engine.

Control Box Heater (if equipped) When the machine is stowed, on a slope, and the
tilt alarm sounds, the following functions are
Move the control box heater switch up affected; lift functions are disabled.
to activate the heater.
Aircraft Protection Package (if equipped)
If the platform bumper comes
Engine Shut-down indicator light (if into contact with an object, the
machine will shut down and no
equipped)
functions will operate.
Light on: Tag and remove the machine
1 Start the engine.
from service.
2 Press down the foot switch.
3 Move and hold the aircraft
protection override switch.
4 Move the appropriate
function control handle or
toggle switch to move the
machine away from aircraft
components.

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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 temperature. The screen also
warning lights. displays fault codes and other
When the contact alarm cable is tripped, the lift service information.
and drive functions are disabled at the platform.
The audio and visual warnings will activate alerting
others that assistance may be needed. These
notifications will continue until the system is reset.
1 The contact alarm cable is tripped, releasing
the actuator from the switch socket.
2 Insert the actuator into the switch socket to
turn off flashing lights and audio alarm.

1 actuator
2 contact alarm cable
3 flashing alarm
4 switch socket

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Operating Instructions
Standstill Regeneration Under emergencies, the DPF standstill
When the LCD screen displays the message regeneration can be interrupted in three ways:
"Regen Warning Lvl 1" (level 1 or higher), the DPF  The engine is turned off by the key switch.
(Diesel Particulate Filter) requires a Standstill
Regeneration.  The ESC button is pressed.
 The ESTOP stop button is pushed.
If this occurs, the standstill regeneration may
need to be restarted.
The DPF standstill regeneration cannot begin
until the engine has been run for at least two
minutes and the coolant temperature has
reached 35°C.
To start the regeneration, proceed as follows.
1 Close the engine side cover.
2 Select a safe parking location—firm and level,
clear of obstructions and traffic, clear of
Note: At the end of the regeneration procedure, flammable material and clear of explosive
make sure to move the Regeneration Enable gasses.
switch to the right, otherwise the machine
functions are locked. 3 At the ground control panel, turn the key
switch to the ground position.
During the DPF standstill generation process,
all boom functions are disabled. 4 At the ground Control Panel, move the
Regeneration Enable switch to the left to
Keep clear of the engine exhaust and muffler. disable all the machine functions.

Don't leave the machine unattended. 5 Press the control button 4 below the LCD
screen twice.
The DPF standstill regeneration cannot be
activated if not requested by the engine, or in
the presence of some engine faults.
If the standstill regeneration request is
ignored, the soot in the DPF can reach
extreme levels. The filter will be permanently
damaged and will have to be replaced by a
qualified service technician.
If this occurs, the following message will be
displayed "Not possible, service needed".

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Operating Instructions
6 Using the control buttons 2 and 3 below the 8 Using the control buttons 2 and 3 below the
LCD screen, select "Diagnostics" from the LCD screen, select "Initiate Regen". Press the
Main Menu. Press the control button 4 to control button 4 to confirm the selection.
confirm the selection.

7 Using the control buttons 2 and 3 below the 9 The LCD screen will display the message
LCD screen, select "Regen Menu". Press the "Initiate Regen". Press the control button 4 to
control button 4 to confirm the selection. confirm.

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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". Press the control button 4 to
confirm.

13 Start the engine. The engine will go into a pre-

warm cycle.
11 The LCD screen will display the message 14 The LCD screen will display the message
"Notice: All functions will lock. Regen takes "Standstill Regen Active Minutes remaining:
approx 1 hour". Press the control button 4 to 35".
confirm.

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Operating Instructions

15 The regeneration process auto-advances and Pipe Cradle Instructions

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.

16 At the ground Control Panel, move the

Regeneration Enable switch to the right to
enable all the machine functions.

1 strap
2 U-bolts
3 pipe cradle mount
4 upper platform railing
5 pipe cradle weldment
6 middle platform railing
7 flat washers
8 nylock nuts

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Operating Instructions
Observe and Obey: Pipe Cradle Operation
 Pipe cradles must be installed on the inside of 1 Be sure the pipe cradle assembly and
the platform. installation instructions have been followed
properly and that the pipe cradles are secured
 Pipe cradles must not obstruct the platform to the platform railings.
controls or the platform entrance.
2 Place the load so that it rests in both pipe
 The bottom of the pipe cradle tube must rest cradles. The length of the load should be
on the platform floor. parallel with the length of the platform.
 Be sure the platform is level before installing a 3 Center the load in the pipe cradles.
pipe cradle.
4 Secure the load to each pipe cradle. Pass the
Pipe Cradle Installation nylon strap over the load. Depress the buckle
and slide the strap through. Tighten the strap.
1 Install a pipe cradle on each side of the
platform. Refer to the illustration on the left. 5 Gently push and pull on the load to make sure
Make sure the bottom of the pipe cradle tube the pipe cradles and load are secure.
rests on the platform floor. 6 Keep the load secured when the machine is
2 Install two U-bolts from the outside of the moving.
platform rails through each pipe cradle mount. Tip-over hazard. The weight of the pipe cradle
3 Secure each U-bolt with 2 washers and 2 nuts. assembly and the load in the pipe cradles will
reduce the rated platform capacity of the
machine and must be factored into the total
platform load.
Tip-over hazard. The weight of the pipe cradle
assembly and the load in the pipe cradles may
limit the maximum number of occupants in the
platform.

Maximum Pipe Cradle Capacity

All models 200 lbs
90.7 kg
Pipe Cradle Assembly Weight 21 lbs
9.5 kg

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Operating Instructions
Panel Cradle 9 Repeat above for the second set of parts.
Genie has produced 2 different styles of Panel 1 2 3 4
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

1 Apply the warning decal to the front of each
panel cradle (if needed).
2 Install rubber bumper 1 in the panel cradle
base. See the illustration.
3 Secure the bumper with 2 high profile lock
nuts and 2 washers.

Panel Cradle Installation - Bolt In

1 Insert the hook piece through the slots in the
panel cradle base.
2 Hook the panel cradle to the bottom platform
tube in the desired location.
3 Install rubber bumper 2 through the panel
cradle base and the hook piece. See the
illustration.
4 Secure with 2 low profile lock nuts.
5 If the panel cradle is installed at a platform 7 6 5
floor support tube, insert the U-bolt through the
floor, around the tube and into the panel cradle 1 rubber bumper 1
base. 2 rubber bumper 2
6 Secure the U-bolt with 2 nuts and 2 washers. 3 U-Bolt
Proceed to step 9. 4 aluminum tube
7 If the panel cradle is not installed at a platform 5 panel cradle base
floor support tube, use the aluminum tube 6 hook piece
provided.
7 warning decal
8 Place the tube between the panel cradle and
the platform floor. Insert the U-bolt through the
floor, around the tube and into the panel cradle
base.

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Operating Instructions
1 2 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.

1 foam pad x 2
2 hook
3 panel cradle x 2
4 clamp

1 foam pad x 2
Panel Cradle Assembly - Weld-In
2 decal x 2
1 Weld-in Panel Cradle comes pre-assembled. 3 panel cradle tray
Panel Cradle Installation - Weld-In 4 clamp
3 Use the provided fasteners to secure the tray
Note: Perform this procedure on a firm, level to the platform. Tighten the fasteners.
surface with the boom in the stowed position.
Note: Kit decals should already be installed onto
the tray.
1 Adjust the platform so that the toe board at the
front of the platform is at a comfortable
working height.

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Operating Instructions

Panel Cradle Operation

Installation of Padding
Note: The bolt-in style has 2 cradles and the Weld-
Install the 2 pieces of padding on the platform in has 1.
rails. Position the padding to protect the panels
from contact with the platform rails. Operating Instructions:
1 Secure the panel cradle and strap assembly to
Installation of Strap the platform.
1 Open the clamp and install it around a vertical 2 Center the load on the platform.
platform rail tube.
3 Secure the load to the platform using the
2 Insert a bolt with a washer through one side of strap.
the clamp.
4 Tighten the strap.
3 Install the strap assembly end plate onto the
bolt.
4 Insert the bolt through the other side of the
clamp.
Secure with a washer and a nut. Do not over-
tighten.
Note: The strap assembly must be secured
between the clamp.
Note: The strap assembly should be able to slide
freely up and down the platform rail.

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Operating Instructions
After Each Use Machine Storage
1 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.
2 Retract and lower the boom to the stowed
position. 1 See After Each Use section for basic machine
stowing instructions.
3 Rotate the turntable so that the boom is
between the non-steer wheels. 2 Store the machine in a dry and well-ventilated
location. Be sure machine is clean and dry.
4 Turn the key switch to the off position and
remove the key to secure from unauthorized 3 Perform a complete Pre-Operation Inspection.
use.
Models with Engines: fill the fuel tank.
4 Refer to the Scheduled Maintenance section in
the appropriate Service Manual, and complete
each lubrication procedure.
5 Remove and store the battery.
6 Models with Engines: Refer to the OEM
engine manual for additional extended storage
procedures. As needed, start and run the
engine for 10 minutes.

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Towing Instructions
Towing Instructions

Using the Tow Package After Towing:

1 Immediately after towing, chock the wheels,
Before Towing:
detach the tow bar and reverse the drive hub
1 Position the machine on a level surface. disconnect caps.
Chock the wheels to prevent the machine from
2 Secure the tow bar back onto the machine.
rolling.
3 Test steer, drive and brake functions on a level
2 Attach the tow bar securely to the machine.
surface prior to returning the machine to
Attach the tow bar securely to the towing
operation. See Function Tests.
vehicle.
3 Release the drive torque hubs by turning over
the drive hub disconnect caps.
4 4WD models: Release the front drive torque
hubs by turning over the drive disconnect
caps.
5 Turn the steering bypass valve
counterclockwise to hydraulically release the
steering.
Do not exceed recommended
maximum towing speed or
maximum towing times.

Maximum tow speed 8 mph/13 km/h

Maximum towing time at 30 minutes
8 mph/13 km/h
Maximum towing time at 60 minutes
6 mph/10 km/h

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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. See Driving on a Slope in the Operating
Observe and Obey: Instructions section.

 Genie provides this securement information as  If the slope of the transport vehicle bed
a recommendation. Drivers are solely exceeds the uphill or downhill maximum slope
responsible for making sure machines are rating, the machine must be loaded and
properly secured and the correct trailer is unloaded using a winch as described in the
selected. brake release operation. See the
Specifications section for the slope ratings.
 Genie customers needing to containerize any
lift or Genie product should source a qualified
freight forwarder with expertise in preparing, Free-wheel Configuration for
loading and securing construction and lifting Winching
equipment for international shipment.
Chock the wheels to prevent the machine from
 Only qualified mobile elevating work platform rolling.
operators should move the machine on or off
the truck. Release the non-steer
 The transport vehicle must be parked on a wheel brakes by
level surface. turning over the drive
hub disconnect caps.
 The transport vehicle must be secured to
prevent rolling while the machine is being Be sure the winch line
loaded. is properly secured to
the drive chassis tie
 Be sure the vehicle capacity, loading surfaces points and the path is
and chains or straps are sufficient to withstand clear of all
the machine weight. Genie lifts are very heavy obstructions.
relative to their size. See the serial label for
the machine weight. See the inspections Reverse the procedures described to re-engage
section for the serial label location. the brakes.

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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.
Adjust the rigging to prevent damage to the
chains.
For diagram, refer to the Lifting Instructions.

Securing the Platform

Make sure the jib and platform are in the stowed
position.
Secure the platform with a nylon strap placed
through the lower platform support. Do not use
excessive downward force when securing the
boom section.
1 Turntable rotation lock pin
Turn the key switch to the off position and remove
the key before transporting.
Inspect the entire machine for loose or unsecured
items.

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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.
 Only qualified riggers should rig the machine.
 Only certified crane operators should lift the Adjust the rigging to prevent damage to the
machine and only in accordance with the machine and to keep the machine level.
applicable crane regulations.
Center of gravity X Axis Y Axis
 Be sure the crane capacity, loading surfaces 3.6 ft 4.5 ft
and straps or lines are sufficient to withstand Z-62/40
1.09 m 1.37 m
the machine weight. See the serial label for
the machine weight.

1 = X Axis
2 = Y Axis

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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.
 Only routine maintenance items specified in Note: Check the oil level with the engine off.
this manual shall be performed by the
operator. 1 Check the oil level dipstick. Add oil as needed.
 Scheduled maintenance inspections shall be Perkins 404D-22 Engine
performed by qualified service technicians,
Oil type 15W-40
according to the manufacturer’s specifications.
Oil type - cold conditions 5W-40
 Dispose of material in accordance with
governmental regulations. Perkins 404F-22T Engine
Oil type 15W-40
 Use only Genie approved replacement parts.
Oil type - cold conditions 5W-40
Maintenance Symbols Legend Ford MSG-425 EFI Engine

The following symbols have been used in this Oil type 5W-20
manual to help communicate the intent of the Deutz D2011 L03i Engine
instructions. When one or more of the symbols
Oil type 15W-40
appear at the beginning of a maintenance
procedure, it conveys the meaning below. Oil type - cold conditions 5W-40
Deutz D2.9 L4 Engine
Indicates that tools will be required to
Oil type 15W-40
perform this procedure.
Oil type - cold conditions 5W-40
Deutz TD 2.2 L3 Engine
Indicates that new parts will be required to
perform this procedure. Oil type 15W-40
Oil type - cold conditions 5W-40
Deutz D436 Engine
Indicates that a cold engine is required Oil type 15W-40
before performing this procedure. Oil type - cold conditions 5W-40

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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. Improper hydraulic
quality fuel will give the following result: long oil levels can damage hydraulic components. Daily
engine life and acceptable exhaust emissions checks allow the inspector to identify changes in
levels. oil level that might indicate the presence of
hydraulic system problems.
Minimum diesel fuel requirements for each engine
are listed below. 1 Be sure that the boom is in the stowed
position.
Perkins 404D-22 Engine
2 Visually inspect the sight gauge located on the
Fuel Type Low Sulfur Diesel (LSD) side of the hydraulic oil tank.
Perkins 404F-22T Engine
Result: The hydraulic oil level should be within
Fuel Type Ultra Low Sulfur Diesel (ULSD) the top 5 cm of the sight gauge.
Deutz D2011 L03i Engine 3 Add oil as needed. Do not overfill.
Fuel Type Low Sulfur Diesel (LSD)
Hydraulic oil specifications
Deutz D2.9 L4 Engine
Hydraulic oil type Chevron Rando HD equivalent
Fuel Type Ultra Low Sulfur Diesel (ULSD)
Deutz TD 2.2 L3 Engine
Fuel Type Ultra Low Sulfur Diesel (ULSD)
Deutz D436 Engine
Fuel Type Low Sulfur Diesel (LSD)

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Maintenance

Check the Engine Coolant Level – Check the Batteries

Liquid Cooled Models

Proper battery condition is essential to good

Maintaining the engine coolant at the proper level machine performance and operational safety.
is essential to engine service life. Improper coolant Improper fluid levels or damaged cables and
level will affect the engine’s cooling capability and connections can result in component damage and
damage engine components. Daily checks will hazardous conditions.
allow the inspector to identify changes in coolant Electrocution hazard. Contact with hot or live
level that might indicate cooling system problems. circuits may result in death or serious injury.
Burn hazard. Beware of hot engine parts and Remove all rings, watches and other jewelry.
coolant. Contact with hot engine parts and/or Bodily injury hazard. Batteries contain acid.
coolant may cause severe burns. Avoid spilling or contacting battery acid.
Burn hazard. Do not remove the radiator cap if Neutralize battery acid spills with baking soda
the engine has been running. Contact with and water.
pressurized coolant may cause severe burns. 1 Put on protective clothing and eye wear.
Allow engine to cool before removing the
radiator cap. 2 Be sure that the battery cable connections are
tight and free of corrosion.
1 Check the fluid level in the coolant recovery
tank. Add fluid as needed. 3 Be sure that the battery hold-down brackets
are in place and secure.
Result: The fluid level should be at the FULL
mark on the tank or visible in the sight gauge. Note: Adding terminal protectors and a corrosion
preventative sealant will help eliminate the
corrosion on the battery terminals and cables.

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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
stability and cause the machine to tip over. manuals for this machine.
Tip-over hazard. The use of temporary flat tire Machines that have been out of service for more
repair products may lead to tire failure which than three months must receive the quarterly
could compromise machine stability and cause inspection before they are put back into service.
the machine to tip over.
Bodily injury hazard. An over-inflated tire can
explode and may cause death or serious
injury.
Note: This procedure does not need to be
performed on machines equipped with foam-filled
tires.
1 Check each tire with an air pressure gauge.
Add air as needed.

Tire specifications
Models with Aircraft Foam-filled Only
Protection Package
Rough terrain tire 70 psi/4.92 bar
Tire size: 355/55 D625, 14 ply
High flotation tires 60 psi/4.13 bar
Tire size: 41/18LL x 22.5, 14 ply

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Specifications
Specifications

Model Z-62/40 Maximum slope rating, stowed position, 2WD

Height, working maximum 67 ft 11 in 20.7 m Counterweight uphill 30% 17°
Height, platform maximum 61 ft 11 in 18.87 m Counterweight downhill 10% 6°
Height, stowed maximum 9 ft 6 in 2.9 m Side slope 25% 14°
Horizontal reach, maximum 40 ft 9 in 12.42 m Maximum slope rating, stowed position, 4WD
Width 8 ft 2 in 2.49 m Counterweight uphill 45% 24°
Length, stowed 24 ft 10 in 7.57 m Counterweight downhill 30% 17°
Maximum load capacity 500 lbs 227 kg Side slope 25% 14°
Maximum wind speed 28 mph 12.5 m/s Note: Slope rating is subject to ground conditions with
Wheelbase 8 ft 2 in 2.49 m one person in the platform and adequate traction.
Additional platform weight may reduce slope rating.
Ground clearance, center 15 in 41 cm
13 in 33 cm Maximum allowable Refer to "Tilt Sensor
Ground clearance, axle
chassis inclination Activation Settings" section
Turning radius (outside) 18 ft 9 in 5.7 m
Drive speeds
Turning radius (inside) 9 ft 2 in 2.8 m
Drive speed, stowed, 3.0 mph 4.8 km/h
Turntable rotation (degrees) 360° Continuous 2WD 40 ft/9 sec 12.2 m/9.1 sec
Turntable tailswing 0 0 Drive speed, stowed, 3.2 mph 5.1 km/h
Platform dimensions, 1.8 m 72 in x 30 in 183 x 76 cm 4WD 40 ft/8.5 sec 12.2 m/8.5 sec
(length x width) Drive speed, raised or 0.7 mph 1.0 km/h
Platform dimensions, 2.4 m 96 in x 36 in 244 x 91 cm extended 40 ft/40 sec 12.2 m/40 sec
(length x width)
Airborne noise emissions
Platform leveling self-leveling
Sound pressure level at ground workstation <85 dBA
Platform rotation 160°
Sound pressure level at platform workstation <74 dBA
Controls 12V DC proportional
Guaranteed sound power level 105 dBA
AC outlet in platform standard
Total vibration value to which the hand/arm system is
Hydraulic pressure, 3000 psi 206.8 bar subjected does not exceed 2.5 m/s2.
maximum (boom functions)
Highest root mean square value of weighted
System voltage 12V acceleration to which the whole body is subjected does
not exceed 0.5 m/s2.
Tire size 355/55 D625, 14 ply
Weight 21900 lbs 9934 kg Floor loading information
(Machine weights vary with option configurations. See Tire load maximum 12000 lbs 5,443 kg
serial label for specific machine weight.) Tire contact pressure 70 psi 4.9 kg / cm2
Ambient operating temperature -20° F to 120° F 893 kPa
-29° C to 49° C Occupied floor pressure 239 psf 1,165 kg / m2
Low end of temperature range requires the use of 11.4 kPa
special hydraulic and engine oils. Note: Floor loading information is approximate and
Fuel tank capacity, diesel 35 gallons 132.5 liters does not incorporate different option configurations. It
should be used only with adequate safety factors.
Fuel tank capacity, gasoline 20 gallons 75.7 liters
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice or obligation.

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Specifications

Model Z-62/40 TRAX Maximum slope rating, stowed position, 4WD

Height, working maximum 67 ft 11 in 20.7 m Counterweight uphill 45% 24°
Height, platform maximum 61 ft 11 in 18.87 m Counterweight downhill 30% 17°
Height, stowed maximum 9 ft 6 in 2.9 m Side slope 25% 14°
Horizontal reach, maximum 40 ft 9 in 12.42 m Note: Slope rating is subject to ground conditions with
Width 8 ft 5.7 in 2.58 m one person in the platform and adequate traction.
Additional platform weight may reduce slope rating.
Length, stowed 24 ft 10 in 7.57 m
Maximum allowable Refer to "Tilt Sensor
Maximum load capacity 500 lbs 227 kg
chassis inclination Activation Settings" section
Maximum wind speed 28 mph 12.5 m/s
Drive speeds
Wheelbase 8 ft 2 in 2.49 m
Drive speed, stowed, 2.3 mph 3.7 km/h
Ground clearance, center 15 in 41 cm 4WD 40 ft/11.8 sec 12.2 m/11.8 sec
Ground clearance, axle 13 in 33 cm Drive speed, raised or 0.7 mph 1.0 km/h
Turning radius (outside) 21 ft 4 in 6.5 m extended 40 ft/40 sec 12.2 m/40 sec
Turning radius (inside) 11 ft 5 in 3.48 m Airborne noise emissions
Turntable rotation (degrees) 360° Continuous Sound pressure level at ground workstation <85 dBA
Turntable tailswing 0 0 Sound pressure level at platform workstation <74 dBA
Platform dimensions, 1.8 m 72 in x 30 in 183 x 76 cm Guaranteed sound power level 105 dBA
(length x width) Total vibration value to which the hand/arm system is
Platform dimensions, 2.4 m 96 in x 36 in 244 x 91 cm subjected does not exceed 2.5 m/s2.
(length x width) Highest root mean square value of weighted
Platform leveling self-leveling acceleration to which the whole body is subjected does
Platform rotation 160° not exceed 0.5 m/s2.

Controls 12V DC proportional Floor loading information

AC outlet in platform standard Track load maximum 13,125 lbs 5,953 kg
Hydraulic pressure, 3,000 psi 206.8 bar Track contact pressure 11 psi 0.77 kg/cm2
maximum (boom functions) 75.8 kPa
System voltage 12V Occupied floor pressure 247 psf 1,206 kg/m2
11.83 kPa
Weight 27,332 lbs 12,398 kg
Note: Floor loading information is approximate and does
(Machine weights vary with option configurations. See
not incorporate different option configurations. It should
serial label for specific machine weight.)
be used only with adequate safety factors.
Ambient operating temperature -20° F to 120° F
Continuous improvement of our products is a Genie
-29° C to 49° C
policy. Product specifications are subject to change
Low end of temperature range requires the use of without notice or obligation.
special hydraulic and engine oils.
Fuel tank capacity, diesel 35 gallons 132.5 liters

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Specifications
Z-62 Range of Motion Chart Max Height Max Reach

1 80 ft 24.4 m 10 0 ft 0m
2 70 ft 21.4 m 11 10 ft 3.1 m
3 60 ft 18.3 m 12 20 ft 6.1 m
4 50 ft 16.3 m 13 30 ft 9.2 m
5 40 ft 12.2 m 14 40 ft 12.2 m
6 30 ft 9.2 m 15 50 ft 15.3 m
7 20 ft 6.1 m
8 10 ft 3.1 m
9 0 ft 0m

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Specifications

Contents of EC Declaration of Conformity - 1

<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> issued by:
<notified body's name>

<notified body's number>

2. EC Directive EMC: 2014/30/EU, under consideration of harmonized European standard EN 61000-6-
2 and EN 61000-6-4
3. EC Directive 2000/14/EC, Noise Directive, under consideration of Annex V and harmonized standard
EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie Industries B.V
Boekerman 5,
4751 XK Oud Gastel,
The Netherlands

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of EC Declaration of Conformity - 2

<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, Conformity assessment procedure: art.12 (3) (a), with
the application of European Harmonized Standard EN 280:2013+A1:2015.
2. EC Directive EMC: 2014/30/EU, under consideration of harmonized European standard EN 61000-6-
2 and EN 61000-6-4
3. EC Directive 2000/14/EC, Noise Directive, under consideration of Annex V and harmonized standard
EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie Industries B.V
Boekerman 5,
4751 XK Oud Gastel,
The Netherlands

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of UK Declaration of Conformity - 1

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Legislation:
1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI
2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type-
examination certificate <variable field> issued by:
<notified body's name>

<notified body's number>

2. Electromagnetic Compatibility Regulations 2016 (SI 2016/1091) as amended (SI 2017/1206, SI
2019/696) under consideration of designated standard EN 61000-6-2 and EN 61000-6-4
3. Noise Emissions in the Environment by Equipment for use Outdoors Regulations 2001 (SI 2001/1701)
as amended (SI 2001/3958, SI 2005/3525, 2015/98) under consideration of Annex V and designated
standard EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie UK Ltd
The Maltings
Wharf Road
Grantham
NG31 6BH

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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Specifications

Contents of UK Declaration of Conformity - 2

<Manufacturer’s name> hereby declares that the machinery described below complies with the provisions
of the following Legislation:
1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI
2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11. (2) (a) with reference
to designated standard EN 280:2013+A1:2015
2. Electromagnetic Compatibility Regulations 2016 (SI 2016/1091) as amended (SI 2017/1206, SI
2019/696) under consideration of designated standard EN 61000-6-2 and EN 61000-6-4
3. Noise Emissions in the Environment by Equipment for use Outdoors Regulations 2001 (SI 2001/1701)
as amended (SI 2001/3958, SI 2005/3525, 2015/98) under consideration of Annex V and designated
standard EN ISO 3744, internal combustion engine only.
Test Report:
This machine has been tested and passed the following categories prior to entering the market:
1. BRAKES: Brakes working properly in forward and reverse.
2. OVERLOAD: Overload tested at XXX% rated load.
3. FUNCTIONAL: Smooth operation at XXX% rated load.
4. FUNCTIONAL: All safety devices working correctly.
5. FUNCTIONAL: Speeds set within permitted specification.

Model / Type: <machine type> Manufacture Date: <variable field>

Description: <machine classification> Country of Manufacture: <variable field>

Model: <model name> Net Installed Power: <only for IC machines>

Serial Number: <variable field> Guaranteed Sound Power Level: <only for IC machines>

VIN: <where applicable>

Manufacturer: <Manufacturer’s name> Authorized Representative:

Genie UK Ltd
The Maltings
Wharf Road
Grantham
NG31 6BH

Empowered signatory: Place of Issue: <variable field>

Date of Issue: <variable field>

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