Genie Z-62/40 TRAX User manual

Operator's Manual
Z®-62/40 TRAX™
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
First Edition
Second Printing
Part No. 1272873GT

Operator's Manual First Edition • Second Printing
Z®-62/40 TRAX™Part No. 1272873GT
FrontMatter
Contents
Introduction ............................................................1
Symbol and Hazard Pictorials Definitions..............4
General Safety.......................................................6
Personal Safety................................................... 12
Work Area Safety................................................ 13
Legend................................................................ 22
Controls............................................................... 23
Inspections.......................................................... 31
Operating Instructions......................................... 44
Transport and Lifting Instructions ....................... 54
Maintenance ....................................................... 57
Specifications...................................................... 60
Copyright © 2016 Terex Corporation
First Edition: Second Printing, August 2018
Genie and "Z" are registered trademarks of
Terex South Dakota, Inc. in the U.S.A. and
many other countries.
These machines comply with
ANSI/SIA A92.5
CAN B.354.4

First Edition • Second Printing Operator's Manual
Introduction
Part No. 1272873GT Z®-62/40 TRAX™1
Intr oduct io n
About this manual
Genie appreciates your choice of our machine for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
This book is an operation and daily maintenance
manual for the user or operator of a Genie
machine.
This manual should be considered a permanent
part of your machine and should remain with the
machine at all times. If you have any questions,
contact Genie.
Product Identification
The machine serial number is located on the serial
label.
Serial label
(located under cover)
Sequence number
stamped on chassis
(ground control side)
Intended Use
This machine is intended to be used only to lift
personnel, along with their tools, and materials to
an aerial work site.
Bulletin Distribution and
Compliance
Safety of product users is of paramount importance
to Genie. Various bulletins are used by Genie to
communicate important safety and product
information to dealers and machine owners.
The information contained in the bulletins is tied to
specific machines using the machine model and
serial number.
Distribution of bulletins is based on the most
current owner on record along with their associated
dealer, so it is important to register your machine
and keep your contact information up to date.
To ensure safety of personnel and the reliable
continued operation of your machine, be sure to
comply with the action indicated in a respective
bulletin.

Operator's Manual First Edition • Second Printing
Introduction
2 Z®-62/40 TRAX™Part No. 1272873GT
Contacting the Manufacturer
At times it may be necessary to contact Genie.
When you do, be ready to supply the model
number and serial number of your machine, along
with your name and contact information. At
minimum, Genie should be contacted for:
Accident reporting
Questions regarding product applications and
safety
Standards and regulatory compliance information
Current owner updates, such as changes in
machine ownership or changes in your contact
information. See Transfer of Ownership, below.
Transfer of Machine Ownership
Taking a few minutes to update owner information
will ensure that you receive important safety,
maintenance and operating information that
applies to your machine.
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.
Danger
Failure to obey the instructions and
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machine operation contained in this operator’s
manual.
1 Avoid hazardous situations.
Know and understand the safety rules
before going on to the next section.
2 Always perform a pre-operation inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
You read, understand and obey the
manufacturer’s instructions and safety
rules—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.

First Edition • Second Printing Operator's Manual
Introduction
Part No. 1272873GT Z®-62/40 TRAX™3
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.
Hazard Classification
Decals on this machine use symbols, color coding,
and signal words to identify the following:
Safety alert symbol
—used to ale
rt
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a hazardous
situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.

Operator's Manual First Edition • Second Printing
Symbol and Hazard Pictorials Definitions
4 Z®-62/40 TRAX™Part No. 1272873GT
Symb ol an d H az ard Pi ct orial s D efi niti on s
Fire hazard Explosion hazard Explosion hazard Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs.
No smoking.
No flame.
Stop engine.
Fire extinguisher No smoking Explosion hazard Electrocution hazard Maintain required
clearance
Tip-over hazard Tip-over hazard Tip-over hazard Tip-over hazard Replace tracks with
same tracks.
Tracks load Wind speed Maximum capacity Side force Weight of welder
reduces capacity
Tie-down point Lifting point Platform tie-down
instructions Lifting & tie down instructions Lanyard anchorage points

First Edition • Second Printing Operator's Manual
Symbol and Hazard Pictorials Definitions
Part No. 1272873GT Z®-62/40 TRAX™5
Corrosive acid. Color coded
direction arrows Runaway hazard Collision hazard Collision hazard
Electrocution hazard Avoid contact Disconnect battery Voltage rating for
power to platform Pressure rating for air line to platform
Recovery procedure if tilt alarm sounds while
elevated.
Platform uphill:
1 Lower primary.
2 Lower secondary.
3 Retract primary.
Platform downhill:
1 Retract primary.
2 Lower secondary.
3 Lower primary.
Read the operator’s
manual Read the service manual Access by trained and authorized
personnel only
Emergency lowering Support the platform
or boom during
maintenance

Operator's Manual First Edition • Second Printing
General Safety
6 Z®-62/40 TRAX™Part No. 1272873GT
Gener al Safety

First Edition • Second Printing Operator's Manual
General Safety
Part No. 1272873GT Z®-62/40 TRAX™7

Operator's Manual First Edition • Second Printing
General Safety
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First Edition • Second Printing Operator's Manual
General Safety
Part No. 1272873GT Z®-62/40 TRAX™9

Operator's Manual First Edition • Second Printing
General Safety
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First Edition • Second Printing Operator's Manual
General Safety
Part No. 1272873GT Z®-62/40 TRAX™11

Operator's Manual First Edition • Second Printing
Personal Safety
12 Z®-62/40 TRAX™Part No. 1272873GT
Pers onal Safet y
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.

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1272873GT Z®-62/40 TRAX™13
Work Ar ea Safety
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.
Electrocution Hazards
This machine is not electrically insulated and will
not provide protection from contact with or
proximity to electrical current.
Obey all local and
governmental regulations
regarding required
clearance from electrical
power lines. At a minimum,
the required clearance
contained in the chart below
must be followed.
Line Voltage
Required Clearance
0
to 50KV 10 f
t
3.05
m
5
0 to 200KV 15 f
t
4.60
m
20
0 to 350KV 20 f
t
6.10
m
35
0 to 500KV 25 f
t
7.62
m
50
0 to 750KV 35 f
t
10.67
m
75
0 to 1000KV 45 f
t
13.72
m
Allow for platform movement, electrical line sway or
sag, and beware of strong or gusty winds.
Keep
away from the
machine if it contacts
energized power lines.
Personnel on the ground
or in the platform must not
touch or operate the
machine until energized
power lines are shut off.
Do not operate the machine during lightning or
storms.
Do not use the machine as a ground for welding.
Tip-over Hazards
Occupants, equipment and materials shall not
exceed the maximum platform capacity or the
maximum platform capacity of the platform
extension.
Maximum platform capacity
500 l
bs
227 k
g
Maximum occupants
2
The weight of options and accessories, such as
pipe cradles, panel cradles and welders, will
reduce the rated platform capacity and must be
subtracted from the platform capacity. See the
decals with the options and accessories.
If using accessories, read, understand and obey
the decals, instructions and manuals with the
accessory.

Operator's Manual First Edition • Second Printing
Work Area Safety
14 Z®-62/40 TRAX™Part No. 1272873GT
Do not raise or extend the
boom unless the machine
is on a firm, level surface.
Do not depend on the tilt alarm as a level indicator.
The tilt alarm sounds in the platform only when the
machine is on a severe slope.
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
surface before raising the platform.
If the tilt alarm sounds when the platform is raised,
use extreme caution. Identify the condition of the
boom on the slope as shown in the tilt alarm
procedure. Follow the steps to lower the boom
before moving to a firm, level surface. Do not rotate
the boom while lowering.
If the tilt alarm sounds with
the platform uphill:
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.
3
Lower the primary
boom.
Do
not raise the boom
when wind speeds may
exceed 28
mph/12.5 m/s.
If wind speeds exceed
28
mph/12.5
m/s when the
boom is raised, lower the
boom and do not continue
to operate the machine.
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.

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1272873GT Z®-62/40 TRAX™15
Use extreme care and
slow speeds while driving
the machine in the stowed
position across uneven
terrain, debris, unstable or
slippery
surfaces and near
holes and drop
-offs.
Do not drive the machine on or near uneven terrain,
unstable surfaces or other hazardous conditions
with the boom raised or extended.
Do not use the machine as a crane.
Do not push the machine or other objects with the
boom.
Do not contact adjacent structures with the boom.
Do not tie the boom or platform to adjacent
structures.
Do not place loads outside the platform perimeter.
Do not push off or pull
toward any object outside
of the platform.
Maximum allowable
s
ide force –ANSI & CSA
150
lbs/667 N
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to machine stability
with items of different weight or specification.
Do not replace tracks with tires.
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
personnel must be removed from the platform
before attempting to free the platform using the
ground controls.
Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform,
toeboards, or guard rail system can increase the
weight in the platform and the surface area of the
platform or the load.

Operator's Manual First Edition • Second Printing
Work Area Safety
16 Z®-62/40 TRAX™Part No. 1272873GT
Do not place or attach
fixed or overhanging loads
to any part of this machine.
Do not place ladders or
scaffolds in the platform or
against any part of this
machine.
Do not transport tools and materials unless they
are evenly distributed and can be safely handled by
person(s) in the platform.
Do not use the machine on a moving or mobile
surface or vehicle.
Be sure all track lug nuts are properly tightened.
Operation on Slopes Hazards
Do not drive the machine on a slope that exceeds
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, 4WD
Platform downhill
45%
(24°)
Platform
uphill
30%
(17°)
Side slope
25%
(14°)
Note: Slope rating is subject to ground conditions
with one person in the platform and adequate
traction. Additional platform weight may reduce
slope rating. See Driving on a Slope in the
Operating Instructions section.

First Edition • Second Printing Operator's Manual
Work Area Safety
Part No. 1272873GT Z®-62/40 TRAX™17
Fall Hazards
Occupants must wear a
safety belt or harness in
accordance with
governmental regulations.
Attach the lanyard to the
anchor provided in the
platform.
Do not sit, stand, or climb
on the platform guard rails.
Maintain a firm
footing on
the platform floor at all
times.
Do not climb down from the
platform when raised.
Keep the platform floor clear of debris.
Lower the platform entry mid-rail or close the entry
gate before operating.
Do not enter or exit the platform unless the
machine is in the stowed position and the platform
is at ground level.
Collision Hazards
Be aware of limited sight
distance and blind spots
when driving or operating.
Be aware of the boom position and tailswing when
rotating the turntable.
Check
the work area for
overhead obstructions or
other possible hazards.
Be aware of crushing
hazards when grasping
the platform guard rail.
Operators must comply with employer, job site, and
governmental rules regarding use of personal
protective equipment.

Operator's Manual First Edition • Second Printing
Work Area Safety
18 Z®-62/40 TRAX™Part No. 1272873GT
Observe and use the color-coded direction arrows
on the platform controls and drive chassis for drive
and steer functions.
Stay clear of all Trax rotating or moving parts such
as sprockets and rollers.
Do not lower the boom
unless the area below is
cl
ear of personnel and
obstructions.
Limit travel speed
according to the
condition of the ground
surface, congestion,
slope, location of
personnel, and any other
factors which may cause
collision.
Do not operate a boom in the path of any crane
unless the controls of the crane have been locked
out and/or precautions have been taken to prevent
any potential collision.
No stunt driving or horseplay while operating a
machine.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.
Always operate the machine in a well-ventilated
area to avoid carbon monoxide poisoning.
Do not allow any object to come near moving parts.
The object could be thrown out of the Trax
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 advised when performing a
pre-operation inspection. All compartments must
remain closed and secured during operation.
Explosion and Fire Hazards
Do not start the engine if you smell or detect diesel
fuel or other explosive substances.
Do not refuel the machine with the engine running.
Refuel the machine and charge the batteries only
in an open, well-ventilated area away from sparks,
flames and lighted tobacco.
Do not operate the machine or charge the batteries
in hazardous locations or locations where
potentially flammable or explosive gases or
particles may be present.
Do not spray ether into engine.