Terex Genie Z-62 Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-62/40
from Z6215A-101
to Z6216N-
2999
from Z6216D-
101
to Z6216D-149
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
from Z6216M-101
To Z6216M-
399
from Z62D-150
from Z62H-
3000
from Z62M-400
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1268555GT
Rev B1
June 2022

Service and Repair Manual June 2022
Introduction
ii Z®-62/40 Part No. 1268555GT
Intro ductio n Intro ductio n
Importan t Inf or matio n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268555GT Rev B1, June 2022
First Edition, Second Printing
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.

June 2022 Service and Repair Manual
Introduction
Part No. 1268555GT Z®-62/40 iii
RevisionHistory
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 11/2017 Specifications Machine Specifications
A3 2/2020 Specifications Hydraulic Component Specifications
B 5/2020 All Sections Add Deutz TD 2.2 L3 Engine
Fault Codes Control System Fault Codes
B1 6/2022 Repair 5-1
Reference Examples:
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual June 2022
Introduction
iv Z®-62/40 Part No. 1268555GT
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label (located under cover)
From September 1,
2016
1 Model
2 Facility code
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label (located under cover)

June 2022 Service and Repair Manual
Safety Rules
Part No. 1268555GT Z®-62/40 v
Sec ti on 1 Safety Rul es
Gene ralS af ety Rul es
Danger
Failure to obey the instructions and safety
rules in this manual and the appropriate
Operator's Manual on your machine will result
in death or serious injury.
Many of the hazards identified in the
operator's manual are also safety hazards
when maintenance and repair procedures are
performed.
Do not modify or alter a MEWP without prior
written permission from the manufacturer.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety
rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual June 2022
Safety Rules
vi Z®-62/40 Part No. 1268555GT
Personal Safety
Any person working on or around a machine
must be aware of all known safety hazards.
Personal safety and the continued safe
operation of the machine should be your top
priority.
Read each procedure thoroughly. This
manual and the decals on the
machine, use signal words to identify
the following:
Safety alert sym
bol—used to
alert personnel to potential
personal injury hazards. Obey
all safety messages that follow
this symbol to avoid possible
injury or death.
Indicates a imminently
hazardous situation which, if
not avoided, will result in death
or serious injur
y.
Indicates a potentially
hazardous situation which, if
not avoided, could result in
death or serious injury.
Indicates a potentially
hazardous situation which, if
not avoided, may cause minor
or moderate injury.
Indicates a
potentially
hazardous situation which, if
not avoided, may result in
property damage.
Be sure to wear protective eye wear
and other protective clothing if the
situation warrants it.
Be aware of potential crushing
hazards such as moving parts,
free
swinging or unsecured components
when lifting or placing loads. Always
wear approved steel
-toed shoes.
Workplace Safety
Any person working on or around a machine
must be aware of all known safety hazards.
Personal safety and the continued safe
operation of the machine should be your top
priority.
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have
an approved fire extinguisher within
easy reach.
Be sur
e that all tools and working
areas are properly maintained and
ready for use. Keep work surfaces
clean and free of debris that could get
into machine components and cause
damage.
Be sure any forklift, overhead crane or
other lifting or supporting device
is
fully capable of supporting and
stabilizing the weight to be lifted. Use
only chains or straps that are in good
condition and of ample capacity.
Be sure that fasteners intended for
one time use (i.e., cotter pins and self-
locking nuts) are not reuse
d. These
components may fail if they are used
a second time.
Be sure to properly dispose of old oil
or other fluids. Use an approved
container. Please be environmentally
safe.
Be sure that your workshop or work
area is properly ventilated and
well lit.

June 2022
Table of Contents
Part No. 1268555GT Z®-62/40 vii
Introduction Introduction ......................................................................................................ii
Important Information ......................................................................................... ii
Find a Manual for this Model............................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend....................................................................................... iv
Section 1 Safety Rules......................................................................................................v
General Safety Rules .........................................................................................v
Section 2 Specifications...................................................................................................1
Machine Specifications .......................................................................................1
Performance Specifications ................................................................................2
Hydraulic Oil Specifications ................................................................................2
Hydraulic Component Specifications...................................................................5
Manifold Component Specifications ....................................................................6
Ford MSG-425 EFI Engine Specifications ...........................................................7
Deutz D2011 L03i Engine Specifications.............................................................8
Deutz TD2011 L04i Engine Specifications ..........................................................9
Deutz TD 2.2 L3 Engine Specifications.............................................................10
Deutz D 2.9 L4 Engine Specifications ...............................................................11
Perkins 404D-22 Engine Specifications ............................................................12
Perkins 404F-22 Engine Specifications.............................................................13
Machine Torque Specifications .........................................................................14
TRAX Torque Specifications.............................................................................14
Hydraulic Hose and Fitting Torque Specifications .............................................15
Torque Procedure ............................................................................................16
SAE and Metric Fasteners Torque Charts.........................................................18

June 2022
Table of Contents
viii Z®-62/40 Part No. 1268555GT
Section 3 Repair Procedures ......................................................................................... 19
Introduction...................................................................................................... 19
Platform Controls........................................................................................... 21
1-1 ALC-500 Circuit Board ............................................................................... 21
1-2 Joysticks.................................................................................................... 22
How to Adjust the Joystick Threshold Setting .............................................. 22
How to Adjust the Joystick Max-out Setting ................................................. 23
How to Adjust the Joystick Ramp Rate Setting ............................................ 24
Platform Components.................................................................................... 26
2-1 Platform Leveling Slave Cylinder ................................................................ 26
2-2 Platform Rotator......................................................................................... 28
2-3 Platform Overload System.......................................................................... 30
Jib Boom Components.................................................................................. 32
3-1 Jib Boom.................................................................................................... 32
3-2 Jib Boom Lift Cylinder ................................................................................ 33
Primary Boom Components .......................................................................... 34
4-1 Cable Track ............................................................................................... 34
How to Remove the Cable Track................................................................. 34
How to Repair the Cable Track.................................................................... 35
4-2 Primary Boom ............................................................................................ 35
How to Disassemble the Primary Boom....................................................... 36
4-3 Primary Boom Lift Cylinder......................................................................... 37
4-4 Primary Boom Extension Cylinder .............................................................. 38
4-5 Platform Leveling Master Cylinder.............................................................. 39
Secondary Boom Components ..................................................................... 40
5-1 Secondary Boom Lift Cylinder .................................................................... 41

June 2022
Table of Contents
Part No. 1268555GT Z®-62/40 ix
Engines...........................................................................................................43
6-1 RPM adjustment - Deutz Models.................................................................43
6-2 RPM adjustment - Perkins Models ..............................................................43
6-3 Flex Plate ...................................................................................................43
How to Install the Flex Plate ........................................................................44
How to install the Pump and Bell Housing Assembly....................................46
6-4 Ford MSG-425 Engine Fault Codes ............................................................47
6-5 Engine Fault Codes - Deutz TD 2.2 L3 Models ...........................................48
6-6 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models ............48
6-7 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 .................................49
Hydraulic Pumps ............................................................................................50
7-1 Function Pump ...........................................................................................50
7-2 Drive Pump ................................................................................................51
Manifolds ........................................................................................................54
8-1 Function Manifold Components ..................................................................54
8-2 Valve Adjustments - Function Manifold .......................................................60
How to Adjust the System Relief Valve ........................................................60
How to Adjust the Platform Level Up Relief Valve ........................................60
How to Adjust the Platform Level Down Relief Valve....................................61
8-3 Jib Boom / Platform Rotate Manifold Components ......................................62
8-4 Brake / Two Speed Manifold Components ..................................................63
8-5 Brake / Two Speed / Steer Mode Manifold Components .............................64
8-6 Steer Select Manifold Components.............................................................65
8-7 Turntable Rotation Manifold Components ...................................................66
8-8 Oscillate Directional Valve Manifold Components .......................................67
8-9 How to Set Up the Oscillate Directional Valve .............................................68
8-10 Valve Adjustment - Oscillate Relief Valve..................................................69
8-11 Drive Oil Diverter Manifold Components (welder option) ...........................70
8-12 Traction Manifold Components, 2WD........................................................72
8-13 Traction Manifold Components, 4WD........................................................74
8-14 Valve Adjustments, Traction Manifold .......................................................76
8-15 Hydraulic Generator Manifold Components, 3kW......................................77
8-16 Valve Coils ...............................................................................................78
How to Test a Coil Diode .............................................................................79

June 2022
Table of Contents
x Z®-62/40 Part No. 1268555GT
Turntable Rotation Components................................................................... 80
9-1 Turntable Rotation Assembly ..................................................................... 80
Axle Components........................................................................................... 82
10-1 Oscillating Axle Cylinders......................................................................... 82
Track Components......................................................................................... 83
11-1 Track Assembly ....................................................................................... 83
Generators...................................................................................................... 87
12-1 Hydraulic Generator ................................................................................. 87
Section 4 Fault Codes .................................................................................................... 88
Introduction...................................................................................................... 88
Control System Fault Codes.......................................................................... 89
How to Retrieve Control System Fault Codes.............................................. 89
Control System Fault Codes........................................................................ 90
Fault Code Display - Deutz and Perkins Models........................................... 93
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 93
How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3 Models ........ 94
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 95
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 96
Soft Key Functions and Icons - Deutz TD 2.2 L3 Models ............................. 97
Main Menu Structure - Deutz D 2.9 L4 Models ............................................ 98
Main Menu Structure - Deutz TD 2.2 L3 Models .......................................... 99
Main Menu Structure - Perkins 404F-22 Models ........................................ 100
Deutz TD 2.2 L3 Engine Fault Codes........................................................... 101
Deutz D 2.9 L4 Engine Fault Codes............................................................. 111
Perkins 404F-E22T Engine Fault Codes...................................................... 122
Ford MSG-425 Engine Fault Codes ............................................................. 124
How to Retrieve Ford MSG-425 Engine Fault Codes ................................. 124