Genie Z Series Maintenance Manual

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Maintenance Manual - Booms

Booms

Refer to the inside cover for a list of models

included in this manual.

This manual includes detailed

procedures for each

maintenance inspection.

For Repair procedures, Fault

Codes, Electrical and Hydraulic

Schematics, refer to the

appropriate Service and Repair

Manual for your machine.

Part No. 1268489GT

Rev F1

April 2018

Table of Contents

Chapters

Table of Contents

Summary of Contents for Genie Z Series

Page 1 Maintenance Manual - Booms Booms ® This manual includes detailed procedures for each maintenance inspection. Booms ® For Repair procedures, Fault Codes, Electrical and Hydraulic Schematics, refer to the appropriate Service and Repair Manual for your machine. Part No. 1268489GT Refer to the inside cover for a list of models included in this manual.
Page 2 1268489 Rev F, December 2017 Group B/Type 3 as defined by ISO 16368 First Edition, Sixth Printing Genie, "S" and "Z" are registered trademarks of Terex South Machine Design Life Dakota, Inc. in the U.S.A. and many other countries. "TraX" and "XC" are trademarks of Terex South Dakota, Inc.
Page 3 April 2018 Maintenance Manual Introduction Models included in this manual Z-34/22 DC from Z3414-9686 to Z3416F-11999 Z34F-12000 Use the following chart to identify the specific serial Z-34/22 N from Z34N14-10984 to Z34N16F-13999 from Z34N15D-102 to Z34N16D-279 number for models included in this manual. from Z34NF-14000 from Z34ND-280 Models...
Page 4 Maintenance Manual April 2018 Introduction Identifying the Correct Procedure for your Model Unless otherwise noted, each procedure will apply to all models. Procedures that only apply to specific models or options will include the information in the procedure title. Examples of procedures that apply to specific models: •...
Page 5 April 2018 Maintenance Manual Introduction Revision History Revision Date Section Procedure / Description 9/2015 Initial Release 10/2015 Quarterly Q-27 Test the Primary Angle Sensor 11/2015 Specifications Hydraulic and Drive Hub Capacities 11/2015 Introduction Updated Z-80/60 serial number for models included 12/2015 Quarterly Q-17 Inspect the Calibration Decal...
Page 6 Maintenance Manual April 2018 Introduction Revision History (continued) Revision Date Section Procedure / Description 3/2017 All Sections Add SX-125 XC and Z-45 XC 3/2017 Programmed Remove 10 year cable inspection 6/2017 All Sections Add S80/85 XC, SX-105 XC Specifications Add Deutz D436 L3i CN3 Engine Deutz TD2011 Engine Specifications 4/2018 Specifications...
Page 7 April 2018 Maintenance Manual Safety Rules Section 1 Safety R ules 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.
Page 8 Maintenance Manual April 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 9: Table Of Contents
April 2018 Table of Contents Section 3 Maintenance Procedures .................. 30 Introduction ......................30 Maintenance Schedule ..................32 Pre-Delivery Preparation Report ................33 Scheduled Maintenance Inspection Report – Quarterly or Frequent ....34 Scheduled Maintenance Inspection Report - Annual........... 35 Programmed Maintenance Inspection Report - Booms ........
Page 10 April 2018 Table of Contents Q-21 Test the Drive Brakes .................. 62 Q-22 Test the Drive Speed – Stowed Position ............. 63 Q-23 Test the Drive Speed - Raised or Extended Position ........63 Q-24 Test the Drive Speed – Raised and Extended, ALC1000 Models ....64 Q-25 Test the Turntable Level Sensor - Z-135/70, ZX-135/70, SX-105 XC, SX-125 XC, SX-135 XC, SX-150 and SX-180 ......
Page 11 April 2018 Table of Contents Annual Maintenance Procedures ..............101 A-1 Grease the Turntable Rotation Bearing and Rotate Gear ......101 A-2 Check the Turntable Rotation Bearing Bolts ..........102 A-3 Inspect for Turntable Bearing Wear ............103 A-4 Check the Extendable Axle - S-100, S-105, S-120 and S-125 ....104 A-5 Perform Maintenance- Jib Rotate Bearing ..........
Page 12 April 2018 Table of Contents Programmed Maintenance Procedures ............128 P0-1 Check the Track Tension and Fastener Torque, TRAX Models - S-60, S-65 and Z-62 Models ..............128 P0-2 Check the Track Tension and Fastener Torque, TRAX Models - S-40 and S-45 Models ................129 P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125 ....
Page 13 April 2018 Maintenance Manual Performance Specifications Section 2 Performanc e Specific ati ons Function Speeds - S-100, S-105 and S-100HD Models Note: Function speeds are maximum from platform controls with maximum rated load in platform. Primary boom up/down, 80 - 88 seconds (retracted) Primary boom up/down, 100 - 100 seconds...
Page 14 Maintenance Manual April 2018 Performance Specifications Function Speeds - S-120, S-125 and S-120HD Models Note: Function speeds are maximum from platform controls with maximum rated load in platform. Primary boom up/down, 80 - 88 seconds (retracted) Primary boom up/down, 100 - 100 seconds extended to >4 ft / >1.2 m (time from fully stowed to the fully raised position)
Page 15 April 2018 Maintenance Manual Performance Specifications Function Speeds - All Other Models Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function S-40, S-45 S-60, S-65, S-60HC, S-80, S-85, S-80X S-80, S-85 S-80XC, S-85XC (includes TRAX S-60X, S-60 XC (ANSI/CSA models) (AS/CE models)
Page 16 Maintenance Manual April 2018 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function Z-34 IC Z-40N, Z-40N Z-45/25, Z-45/25J Z-45/25, Z-45/25J Z-45 XC (DC, BE models) (IC models) Primary boom up 15 - 21 seconds 26 - 30 seconds 32 - 40 seconds 24 - 28 seconds...
Page 17 April 2018 Maintenance Manual Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function Z-135 ZX-135 Primary boom up/down 88 - 105 seconds 110 - 125 seconds Primary boom extend/retract 38 - 42 seconds 35 - 48 seconds Secondary boom up/down 80 - 95 seconds...
Page 18 Maintenance Manual April 2018 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function SX-105 XC SX-125 XC SX-135 XC Primary boom 80 - 88 seconds / 83° 80 - 88 seconds / 83° 88 - 94 seconds / 75°...
Page 19 April 2018 Maintenance Manual Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function SX-150 SX-180 Primary boom 80 - 88 seconds / 82° 80 - 88 seconds / 82° up/down, (stowed) Primary boom up/down 100 - 110 seconds / 82°...
Page 20 Maintenance Manual April 2018 Performance Specifications Drive Speeds Function S-40, S-45 S-60, S-65, S-80, S-85, S-80X S-80XC, S-85XC S-100, S-105, (includes TRAX S-60HC, S-60X, S-120, S-125, models) S-60XC S-100HD, S-120HD, (includes TRAX SX-105 XC, models) SX-125 XC 2WD models, 5.2 - 5.9 seconds 6.1 - 7.8 seconds 7.9 - 8.5 seconds Stowed position...
Page 21 April 2018 Maintenance Manual Performance Specifications Function Z-34 IC Z-40N, Z-40N RJ Z-45/25, Z-45/25J Z-45/25 IC, Z-45/25J (DC and BE models) IC, Z-51, Z-45 XC 2WD models, 8.5 - 10.5 seconds 8 - 10 seconds 6 - 6.8 seconds (ANSI / CSA) Stowed position 40 ft / 12.2 m 40 ft / 12.2 m...
Page 22 Maintenance Manual April 2018 Torque Specifications Tires and Wheels Torque values are listed as lubricated unless otherwise noted. Lug nuts must be coated with a mineral based lubricant when removed and replaced on the machine. Model Lug nut Tire pressure Tire pressure high Tire pressure torque...
Page 23 April 2018 Maintenance Manual Torque Specifications TraX™ Torque Specifications Sprocket to hub adapter fasteners 3/4 -10 nuts, GR 8, dry 317 ft-lbs 430 Nm 3/4 -10 nuts, GR 8, lubricated 281 ft-lbs 381 Nm 1/2-13 FHS screws, dry 80 ft-lbs 108 Nm 1/2 -13 screws, lubricated 60 ft-lbs...
Page 24 Maintenance Manual April 2018 Engine Specifications Engine Operator and Ford DSG-423 Maintenance Manuals Genie part number 119488GT Diagnostic Manual Deutz D2011L03i and TD2011L04i Genie part number 119494GT Genie part number 139320GT Ford MSG-425 Deutz D 2.9 L4 and TD 2.9 L4...
Page 25 April 2018 Maintenance Manual Engine Specifications Deutz Engine Models D 2.9 L4 Low idle (standby) 1000 rpm D2011 L03i • D436 L3i CN3 1000 Hz Low idle 1500 rpm Low idle (with function enable) 1500 rpm 313 Hz 1500 Hz High idle 2500 rpm High idle...
Page 26 Maintenance Manual April 2018 Engine Specifications Perkins Engine Models 404D-22T Low idle (standby) 1000 rpm 403D-11 500 Hz Low idle 1500 rpm Low idle (with function enable) 1500 rpm 150 Hz 750 Hz High idle 2800 rpm High idle 2500 rpm 280 Hz 1250 Hz Oil capacity (including filter)
Page 27 April 2018 Maintenance Manual Engine Specifications 804D-33 1104D-44T Low idle (with generator) 1400 rpm Low idle 1300 rpm 284.7 Hz 314.2 Hz Low idle (without generator) 1650 rpm High idle 2450 rpm 335.5 Hz (SX-135 XC, SX-150 and SX-180) 592 Hz High idle 2300 rpm High idle (all other models)
Page 28 Maintenance Manual April 2018 Engine Specifications Ford Engine Models Kubota Engine Models DSG-423 D1105-E3B Low idle 1600 rpm Low idle 1250 rpm 53.3 Hz 208.3 Hz High idle 2500 rpm High idle 3000 rpm 83.3 Hz 500 Hz Oil capacity (including filter) 4 quarts Oil capacity (including filter) 5.4 quarts...
Page 29 April 2018 Maintenance Manual Engine Specifications GM Engine Models WG-972 Low idle 1600 rpm .998L 266.7 Hz Low idle 1100 rpm High idle 3000 rpm 36.6 Hz 500 Hz High idle 3000 rpm Oil capacity (including filter) 3 quarts 100 Hz 2.8 liters Oil capacity (including filter) 3.2 quarts...
Page 30 Maintenance Manual April 2018 Engine Specifications Continental Engine Models Cummins Engine Models TME27 B3.3T Low idle 1600 rpm Low idle 1300 rpm 53.3 Hz 229.7 Hz High idle 2500 rpm High idle 2350 rpm 83.3 Hz 415 Hz Oil capacity (including filter) 7 quarts Oil capacity (including filter) 9 quarts...
Page 31 April 2018 Maintenance Manual Hydraulic Specifications Hydraulic Relief Valve Pressure Function Manifold Relief Valve Pressure / Bar Model System Primary Secondary Secondary Primary Secondary Turntable Proportional Platform relief boom boom boom up boom boom rotate relief level down down extend extend S-40 2600 psi...
Page 32 Maintenance Manual April 2018 Hydraulic Specifications Model System Primary Secondary Secondary Primary Secondary Turntable Proportional Platform relief boom boom boom up boom boom rotate relief level down down extend extend Z-45/25, Z-45/25J 3200 psi 2100 psi 221 bar 145 bar (DC and BE models) Z-45/25 IC, Z-45/25J 3200 psi...
Page 33 April 2018 Maintenance Manual Hydraulic Specifications Traction and Steer/Axle Manifolds, and Oscillate Relief Valve Pressure / Bar Model Hot oil relief Oscillate relief Axle extend 280 psi 950 psi S-40, S-45 19.3 bar 66 bar (includes TRAX models) S-60, S-65, S-60HC, S-60X, S-60XC 280 psi 800 psi 19.3 bar...
Page 34 Maintenance Manual April 2018 Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Model Turntable Hydraulic tank Hydraulic system Drive hub Drive hub (including tank) rotation drive S-40, S-45 20 fl oz 20 fl oz...
Page 35 April 2018 Maintenance Manual Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities, continued Model Turntable Hydraulic tank Hydraulic system Drive hub Drive hub rotation drive (including tank) Z-45/25, Z-45/25J EW1 type 25.5 fl oz 8 gallons 11 gallons 17 fl oz 750 cc 30 liters 41 liters...
Page 36 Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
Page 37 April 2018 Maintenance Manual Hydraulic Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
Page 38 Maintenance Manual April 2018 Hydraulic Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C cSt @ 0°F / -18°C...
Page 39 Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...
Page 40 Note: The O-ring in Parker Seal Lok™ fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.
Page 41 April 2018 Maintenance Manual Hydraulic Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 42: Maintenance Procedures
 Repair any machine damage or malfunction before operating the machine.  Use only Genie approved replacement parts.  Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.
Page 43 April 2018 Maintenance Manual Maintenance Procedures About This Section Maintenance Symbols Legend Note: The following symbols have been used in this This section contains detailed procedures for each manual to help communicate the intent of the scheduled maintenance inspection. instructions. When one or more of the symbols Each procedure includes a description, safety appear at the beginning of a maintenance warnings and step-by-step instructions.
Page 44: Maintenance Schedule
Maintenance Manual April 2018 Maintenance Procedures Maintenance Schedule Programmed Example (under 1000 HRS): The maintenance procedures have been divided into subsections that include: Commissioning, Quarterly, Annually and Programmed maintenance intervals. The maintenance inspection report has been divided into general areas of the machine that include: Drive Chassis, Booms and Platform, Functions and Controls, Engine and Turntable.
Page 45: Pre-Delivery Preparation Report
April 2018 Maintenance Manual Pre-Delivery Preparation Report Fundamentals Instructions It is the responsibility of the owner or dealer to Use the operator’s manual on your machine. perform the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.
Page 46: Scheduled Maintenance Inspection Report - Quarterly Or Frequent
Scheduled - Quarterly April 2018 Maintenance Inspection Report - Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Inspection Type Legend Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection.
Page 47: Scheduled Maintenance Inspection Report - Annual
Scheduled - Annual April 2018 Maintenance Inspection Report - booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Inspection Type Legend Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection. Select the appropriate procedures for the type of A = annual inspections R = repaired...
Page 48: Programmed Maintenance Inspection Report - Booms
Programmed April 2018 Maintenance Inspection report - Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Programmed maintenance will be completed based on machine Legend Make copies of this report to use for each hours.
Page 49: Commissioning Procedures
April 2018 Maintenance Manual Commissioning Procedures Perform Engine Maintenance - 50 Perform 50 Hour Service Hours The 50 hour maintenance procedure is a one time sequence of procedures to be performed after the The 50 hour maintenance procedure is a one time first 50 hours of usage.
Page 50: Perform 150 Hour Service
Maintenance Manual April 2018 Commissioning Procedures Perform 150 Hour Service The 150 hour maintenance procedure is a one time sequence of procedures to be performed after the first 150 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.
Page 51: Quarterly Maintenance Procedures
An important way to ensure your machine has no open bulletins is to frequently Select "Customer Login" to login or select check the serial number of your Genie machine "Request New Access" to create a new against our bulletin database. Using the links below account.
Page 52: Battery Inspection
Put on protective clothing and eye wear. Remove the battery vent caps and check the specific gravity of each battery cell with a Genie specifications require that this procedure be hydrometer. Note the results. performed quarterly. Check the ambient air temperature and adjust...
Page 53 April 2018 Maintenance Manual Quarterly Maintenance Procedures 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10° F / 5.5° C above 80° F / 26.7° C. •...
Page 54: Inspect The Electrical Wiring
Inspect the Electrical Wiring • Cables on the primary, secondary and jib booms • Jib boom/platform rotate manifold Genie specifications require that this procedure be • Inside of the platform control box performed quarterly. • All wire harness connectors to platform...
Page 55: Inspect The Electrical Contactor - Dc / Bi-Energy Models
Inspect the Electrical Contactor - Open the turntable cover and remove the fuse DC / Bi-Energy Models box cover. Genie specifications require that this procedure be performed quarterly. Maintaining the electrical contactor in good condition is essential to safe machine performance.
Page 56: Check The Exhaust System
Quarterly Maintenance Procedures Check the Exhaust System Inspect the Tires, Wheels and Lug Nut Torque Genie specifications require that this procedure be performed quarterly. Maintaining the exhaust system is essential to good engine performance and service life. Genie specifications require that this procedure be Operating the engine with a damaged or leaking performed quarterly.
Page 57: Check The Generator Belts And Pulleys, Bi-Energy Models
Check the Generator Belts, specification using a straightedge. Pulleys and voltage - Bi-Energy Models Genie specifications require that this procedure be performed quarterly. Maintaining the generator belts and the pulleys is essential to good generator performance and service life. The generator will not operate properly with loose or defective belts and continued use may cause component damage.
Page 58: Check The Oscillate Directional Valve Linkage (If Equipped)
Refer to Repair Procedure in the appropriate Valve Linkage (if equipped) Service and Repair Manual for your machine, How to Adjust the Generator Belts. Genie specifications require that this procedure be performed quarterly. Note: Perform this test only on models equipped with an oscillating axle.
Page 59: Visual Inspection Of The Hydraulic Oil
• Color: oil should be a clear, light-honey colored • Appearance, oil should be clear and not Genie specifications require that this procedure be cloudy or visibly distorts the view through performed quarterly. the sight glass or container •...
Page 60: Inspect The Hydraulic Filters
Models without Filter Condition Indicator: Inspect the Hydraulic Filters Note: Models without a filter condition indicator cannot be inspected. At the required maintenance Genie specifications require that this procedure be interval, replace the filters. performed quarterly. Hydraulic Tank Cap (if equipped):...
Page 61: Check And Adjust The Engine Rpm
Gauges re-programming the ECM. If RPM or service is Start the engine from the ground controls. required, please contact Genie Product Support. Press the Home button on the display. Press GM Models: .998L • 3.0L button 2 under the engine idle icon and select low idle.
Page 62 Maintenance Manual April 2018 Quarterly Maintenance Procedures Models with ALC-1000 operating system: Kubota WG-972: Note: Use the following chart to identify the Low rpm idle adjustment: description of each LCD screen control button used Loosen the core clamp screw so the cable in this procedure.
Page 63 April 2018 Maintenance Manual Quarterly Maintenance Procedures Tighten the lock nut. All other engine models: Low rpm idle adjustment: Loosen the lock nut on the low idle adjustment screw. Turn the adjustment screw clockwise to increase low rpm or counterclockwise to decrease low rpm.
Page 64 Maintenance Manual April 2018 Quarterly Maintenance Procedures Kubota Z482-E Deutz TD2011L04i 1 low idle adjustment screw (not shown) 2 high idle adjustment nut 3 high idle solenoid 1 high idle solenoid 4 fuel shut off solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Deutz D2011L03i...
Page 65 April 2018 Maintenance Manual Quarterly Maintenance Procedures Perkins 403D-11 Perkins 404D-22 1 high idle solenoid 1 high idle solenoid 2 high idle adjustment nut 2 high idle adjustment nut 3 lock nut 3 low idle adjustment screw 4 low idle adjustment screw Perkins 804D-33 1 high idle solenoid 2 high idle adjustment nut...
Page 66: Test The Ground Control Override
Quarterly Maintenance Procedures Perkins 1104D-44T Q-12 Test the Ground Control Override Genie specifications require that this procedure be performed quarterly. A properly functioning ground control override is essential to safe machine operation. The ground control override function is intended to allow...
Page 67: Test The Alarm Package (If Equipped)
Activate the boom down function, hold for a equipped) moment and then release it. Result: The descent alarm should sound when Genie specifications require that this procedure be the down function is activated. performed quarterly. Complete this step for each boom that applies: The alarm package includes: Primary, Secondary and Jib Booms.
Page 68: Test The Emergency Power System
Test the Emergency Power Test the Engine Idle Select System Operation - Engine Models (excludes ALC-600 and ALC-1000 Genie specifications require that this procedure be Models) performed quarterly. A properly operating engine idle select function is essential to good engine performance and safe machine operation.
Page 69 April 2018 Maintenance Manual Quarterly Maintenance Procedures All other models: Push and release the rpm select button until low rpm is selected (turtle symbol). Pull out the red Emergency Stop button to the Result: The engine should return to low idle. on position at both the ground and platform controls.
Page 70: Test The Fuel Select Operation - Gasoline/Lpg Models
Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and Genie specifications require that this procedure be operate smoothly in low and high idle. performed quarterly. Note: The engine may hesitate momentarily and...
Page 71: Inspect The Calibration Decal - Alc1000 Models
Quarterly Maintenance Procedures Q-17 Inspect the Calibration Decal - ALC-1000 Models Genie specifications require that this procedure be performed quarterly. Maintaining the safety decal in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine.
Page 72: Test The Recovery Mode System - Alc-1000 Models
Quarterly Maintenance Procedures Q-18 Test the Recovery System - ALC-1000 Models Genie specifications require that this procedure be performed quarterly. A properly functioning recovery system is essential to safe machine operation. The Recovery mode allows the platform to be lowered in the event the...
Page 73: Test The Platform Self-Leveling
Note: The bypass/recovery key switch is located on the front panel in the lower right corner on Z-80 before serial number Z8013-3911 and Z-135 Genie specifications require that this procedure be before serial number Z13512-1712. performed quarterly. Turn and hold the bypass/recovery key switch ALC-1000 Models: to the recovery position.
Page 74: Confirm The Proper Brake Configuration
Q-20 Q-21 Confirm the Proper Brake Test the Drive Brakes Configuration Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. Proper brake action is essential to safe machine operation. The drive brake function should operate...
Page 75: Test The Drive Speed - Stowed Position
Test the Drive Speed – Stowed Test the Drive Speed – Raised or Position Extended Position Genie specifications require that this procedure be Genie specifications require that this procedure be performed quarterly. performed quarterly. Proper drive function is essential to safe machine Proper drive function is essential to safe machine operation.
Page 76: Test The Drive Speed - Raised And Extended, Alc1000 Models
4 feet / 1.2 m. Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use Genie specifications require that this procedure be when crossing the start and finish lines. performed quarterly.
Page 77 April 2018 Maintenance Manual Quarterly Maintenance Procedures SX-150 and SX-180 Z-80/60, Z-135/70 and ZX-135/70 Note: This procedure will require 2 people to Create start and finish lines by marking two perform. lines on the ground 40 feet / 12.2 m apart. Press down the foot switch and raise the Create start and finish lines by marking two primary boom greater than 10 degrees and the...
Page 78: Test The Turntable Level Sensor
Note: A digital level will be required to perform this procedure. Note: A kit is available through Genie Product Y axis (ZX-135/70 shown) Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
Page 79 April 2018 Maintenance Manual Quarterly Maintenance Procedures Note: Perform this procedure with the booms in the Turn the key switch to ground control and pull fully stowed position and the axles fully extended. out the red Emergency Stop button to the on position at both ground and platform controls.
Page 80: Test The Secondary Boom Angle Sensor - Z-135/70 And Zx-135/70
(ZX-135/70 shown) Note: A digital level will be required to perform this procedure. Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
Page 81: Test The Turntable Level Sensor
April 2018 Maintenance Manual Quarterly Maintenance Procedures Press the plus and minus buttons at the Lower the secondary boom to 65°. same time on the LCD screen to enter the Result: The reading at the display and digital MACHINE STATUS screen. Press the enter level is within ±...
Page 82: Test The Primary Boom Angle Sensor - Z-135/70 And Zx-135/70
Note: A digital level will be required to perform this Secondary Boom Angle Sensor. procedure. Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
Page 83 April 2018 Maintenance Manual Quarterly Maintenance Procedures Note: Use the following chart to identify the Raise the primary boom while watching the description of each LCD screen control button used display screen. in this procedure. Continue to raise the primary boom until it stops at approximately 58°.
Page 84 Maintenance Manual April 2018 Quarterly Maintenance Procedures Lower the primary boom to -50°. 10 Raise the primary boom to 10°. Result: The reading at the display and digital Result: The reading at the display and digital level is within ± 2° of each other and of -50°. level is within ±...
Page 85: Test The Primary Boom Angle Sensor
Result: The reading at the display and digital level is greater than ± 2° of each other and of Note: A kit is available through Genie Product 74°. The primary boom angle sensor must be Support (Genie part number 58351). This kit calibrated.
Page 86 Maintenance Manual April 2018 Quarterly Maintenance Procedures Lower the primary boom to 57°. Lower the primary boom to 23°. Result: The reading at the display and digital Result: The reading at the display and digital level is within ± 2° of each other and of 57°. level is within ±...
Page 87 April 2018 Maintenance Manual Quarterly Maintenance Procedures SX-135 XC Lower the primary boom to 59°. Turn the key switch to ground control and pull Result: The reading at the display and digital out the red Emergency Stop button to the on level is within ±...
Page 88 Maintenance Manual April 2018 Quarterly Maintenance Procedures SX-150 and SX-180 Lower the primary boom to 25°. Turn the key switch to ground control and pull Result: The reading at the display and digital out the red Emergency Stop button to the on level is within ±...
Page 89 April 2018 Maintenance Manual Quarterly Maintenance Procedures Lower the primary boom to 66°. Lower the primary boom to 32°. Result: The reading at the display and digital Result: The reading at the display and digital level is within ± 2° of each other and of 66°. level is within ±...
Page 90: Test The Safety Envelope Limit Switches
XC, SX-150 and SX-180 Models end cover to a suitable lifting device. Genie specifications require that this procedure be Remove the lower cover retaining fasteners performed quarterly. and remove the lower cover from turntable.
Page 91 April 2018 Maintenance Manual Quarterly Maintenance Procedures Connect the leads from a multimeter with 13 Locate and disconnect the Deutsch connector continuity checking capability to pins 1 and 2 to LSS1RS. at the Deutsch connector of the limit switch Result: The alarm should sound. cable.
Page 92 Maintenance Manual April 2018 Quarterly Maintenance Procedures Z-135/70, ZX-135/70, SX-105 XC, SX-125 XC, Connect the leads from a multimeter with SX-135 XC, SX-150 and SX-180 Models continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch Turntable Rotate Safety Limit Switch, LST1S cable.
Page 93 April 2018 Maintenance Manual Quarterly Maintenance Procedures Z-135/70, ZX-135/70, SX-105 XC, SX-125 XC, 10 Choose an axle extend safety limit switch to SX-135 XC, SX-150 and SX-180 Models test. 11 Locate and disconnect the Deutsch connector Axle Extended Safety Limit Switches, LSFA1ES to the axle extend limit switch.
Page 94: Test The Primary Boom Angle Sensor - Z-80/60
Raise the primary boom. The display will begin Sensor - Z-80/60 showing a boom angle of 40°. Continue raising the primary boom until the Genie specifications require that this procedure be display shows 65°. performed quarterly. Result: The primary boom stops.
Page 95: Test The Safety Envelope And Circuits - Z-80/60
Circuits - Z-80/60 secondary boom. The connection will be marked with yellow zip ties on the wire Genie specifications require that this procedure be assembly. Disconnect the connectors. performed quarterly. Locate the Deutsch connectors from the...
Page 96 Maintenance Manual April 2018 Quarterly Maintenance Procedures 12 Remove the key from the main key switch, 21 Locate the Deutsch connectors from the insert it into the bypass/recovery key switch, secondary boom #2 angle operational limit turn the key to Bypass mode and raise the switch (LSS2AO) on the inside of the turntable secondary boom above 60°...
Page 97: Check The Safety Envelope Limit Switches And Angle Sensor - S-60X, S-60Xc And S-80X
Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls. Note: The following step can be done using a measuring tape or a digital protractor (Genie part number 58377). Part No. 1268489GT ®...
Page 98 0°. Place the protractor on top of the primary boom. The protractor should display 58° ± 2°. Result: The primary boom angle is not within specifications. Consult Genie Product Support. 1 restricted maximum platform capacity 2 unrestricted maximum platform capacity Raise the primary boom until it is fully elevated.
Page 99: Test The Safety Envelope And Circuits
S-125, S-100HD and S-120HD Result: Primary boom down should return to normal operation. Genie specifications require that this procedure be performed quarterly. Lower the primary boom 5 feet / 1.5 m and activate primary boom extend. Testing the machine safety envelope is critical to Result: Primary boom extend will stop and the safe machine operation.
Page 100 Maintenance Manual April 2018 Quarterly Maintenance Procedures 65° Angle Safety Switch, LSB9AS: Disconnect the 68° proximity switch LSB14AO and install a wire jumper between pin 3 and 14 Raise the boom to the maximum angle. pin 4 of the Deutsch connector. 15 Fully extend the boom.
Page 101 April 2018 Maintenance Manual Quarterly Maintenance Procedures 21 With the key switch off, press and hold the 31 Measure the angle of the boom. enter button and turn the key switch to the on Result: the angle of the boom should be position.
Page 102 Maintenance Manual April 2018 Quarterly Maintenance Procedures 76 feet / 23.2 m Length Safety Switch, LSB4ES: Cable Break Safety Switch, LSB6S: 40 Disconnect the 75 feet / 22.9 m safety switch 49 Start the engine and activate the function LSB3EO. enable/high RPM button and retract the boom until the boom is extended to less than 2 feet / 41 Start the engine and activate the function...
Page 103 April 2018 Maintenance Manual Quarterly Maintenance Procedures 54 Allow the switch to return to its neutral 60 Place a metal washer over the target area of position, then rotate the head of the switch 45° the axle extend proximity switch LSAX1EO counter clockwise and activate the function and place a metal washer over the target area enable/high RPM button and attempt to...
Page 104 Maintenance Manual April 2018 Quarterly Maintenance Procedures 62 Activate the function enable/high RPM button 66 Activate the function enable/high RPM button and attempt to raise the boom. and attempt to raise the boom. Result: The boom should not raise to more Result: The boom should not raise to more than 11°.
Page 105: Test The Aircraft Protection System (If Equipped)
Move the yellow bumper at the bottom of the System (if equipped) platform 4 inches/10 cm in any direction. Genie specifications require that this procedure be performed quarterly. Testing the machine aircraft protection system is critical to safe machine operation. If the boom is...
Page 106 Maintenance Manual April 2018 Quarterly Maintenance Procedures Articulated (Z) Booms: Activate and hold the aircraft protection override switch. 17 Raise the secondary boom approximately 3 ft / Activate each function control handle or toggle 1 m. switch. 18 Move the yellow bumper at the bottom of the Result: All boom, drive and steer functions platform 4 inches/10 cm in any direction.
Page 107: Test The Operator Protection Alarm (If Equipped)
Inspect and Adjust the Boom Alarm (if equipped) Extend/Retract Cables - All Models Genie specifications require that this procedure be performed quarterly. Testing the operator protection alarm (OPA) is important for proper operation. Genie specifications require that this procedure be...
Page 108: Test The Recovery Mode System - Alc-600 Models
Quarterly Maintenance Procedures Q-37 Test the Recovery System - ALC-600 Models Genie specifications require that this procedure be performed quarterly. A properly functioning recovery system is essential to safe machine operation. The Recovery mode allows the platform to be lowered in the event the...
Page 109: Test The Turntable Level Sensor - S-80 Xc And S-85 Xc
Note: A digital level will be required to perform this procedure. Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
Page 110 Maintenance Manual April 2018 Quarterly Maintenance Procedures Note: Perform this procedure on a firm, level Turn the key switch to ground control and pull surface with the machine in the stowed position. out the red Emergency Stop button to the on position at both ground and platform controls.
Page 111: Test The Primary Boom Angle Sensor - S-80 Xc, S-85 Xc
Note: A digital level will be required to perform this procedure. Note: A kit is available through Genie Product Support (Genie part number 58351). This kit includes a digital level with a magnetic base and cable harnesses.
Page 112 Maintenance Manual April 2018 Quarterly Maintenance Procedures Note: Use the following chart to identify the Raise the primary boom to the fully elevated description of each LCD screen control button used position while watching the display screen. in this procedure. Result: The reading at the display and digital level is within ±...
Page 113: Annual Maintenance Procedures
Locate the 2 grease fittings on top of the worm drive housing. Bearing and Rotate Gear Genie specifications require that this procedure be performed annually. Perform this procedure more often if dusty conditions exist and when operating the machine in high temperature environments.
Page 114: Check The Turntable Rotation Bearing Bolts
Raise the boom and remove the safety chock OR lifting device. Lower the boom to the stowed position. Genie specifications require that this procedure be Using a star pattern, confirm that each lower performed annually. bearing mounting bolt is torqued in sequence to specification.
Page 115: Inspect For Turntable Bearing Wear
Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing. Genie specifications require that this procedure be performed annually. Periodic inspection of turntable bearing wear is essential to safe machine operation, good machine performance and service life.
Page 116: Check The Extendable Axle - S-100, S-105, S-120 And S-125
Result: The measurement is more than specification. The bearing is worn and needs to be replaced. Models Measurement Genie specifications require that this procedure be S-40 (all), S-60 (all), Z-60 DC/FE, Z-62/40 0.063 inch performed annually. 1.6 mm 0.055 inch...
Page 117: Perform Maintenance- Jib Rotate Bearing
April 2018 Maintenance Manual Annual Maintenance Procedures While rotating the jib, pump grease into the worm gear grease fitting until fresh grease is Perform Maintenance – visible at one sealing lip or bearing cap. Jib Rotate Bearing - SX-150 and SX-180 Jib rotate bearing specifications require that these procedures be performed annually.
Page 118: Test The Bypass/Recovery Key Switch - Alc1000 Models
Result: The measurement is less than 0.063 inch / 1.6 mm. The bearing is good. Models Result: The measurement is more than 0.063 Genie specifications require that this procedure be inch / 1.6 mm. The bearing is worn and needs performed annually. to be replaced.
Page 119 April 2018 Maintenance Manual Annual Maintenance Procedures When the Bypass/Recovery key switch is turned Note: Perform this procedure on a firm, level and held to the recovery position, the emergency surface with the machine in the stowed position. power unit turns on and starts a sequence to lower the platform.
Page 120: Grease The Platform Overload Mechanism (If Equipped)
13 Turn the main key switch to the off position. Genie specifications require that this procedure be 14 Remove the key from the main key switch and performed annually. insert the key into the bypass/recovery key Perform this procedure more often if dusty switch.
Page 121: Test The Platform Overload System
Emergency Stop button to the on position at both the ground and platform controls. Level the platform. Genie specifications require that this procedure be performed annually OR when the machine fails to Determine the maximum platform capacity.
Page 122 Maintenance Manual April 2018 Annual Maintenance Procedures Carefully move the test weights to each Using emergency power, test all machine remaining location on the platform. Refer to functions from the ground controls. Illustration 1. Result: All ground control functions should Engine Models: Result: The platform operate normally.
Page 123: Test The Platform Overload System - Alc1000 Models
Result: The platform overload indicator light should be off at platform controls and there should be no error message displayed at the Genie specifications require that this procedure be ground control LCD screen. The alarm should performed annually OR when the machine fails to not sound and the engine should continue to lift the maximum rated load.
Page 124: Test The Platform Load Sense System - S-60 Hc
PLATFORM OVERLOAD displayed at the ground control LCD screen. The alarm is sounding and the engine should Genie specifications require that this procedure be not start and run. performed annually OR when the machine fails to Note: There may be a 2 second delay before the lift the maximum rated load.
Page 125: Inspect The Boom Extend/Retract Cables - S-60 And S-80 Models
Result: The amber restricted range of motion LED at the platform controls should come on and the engine should continue to run. Genie specifications require that this procedure be performed annually. Using a suitable lifting device, place an additional appropriate test weight equal to Manufacturers specifications require that this 227.2 to 231.3 kg on to the center of the...
Page 126 Maintenance Manual April 2018 Annual Maintenance Procedures Note: A flashlight and inspection mirror may be S-60, S-65, S-60X, S-60XC, S-60 TRAX, necessary to thoroughly inspect the above items, S-65 TRAX, S-80, S-85, S-80X, S-80XC, or an endoscope inspection camera.. S-85XC: Remove the boom end cover from the pivot end of the boom and set aside.
Page 127: Inspect The Boom Extend/Retract Cables - S-100, S-105, S-120, S-125, Sx-105 Xc And Sx-125 Xc
1/2 inch / 13 mm before the number 3 boom tube begins to retract. Note: If the number 2 boom tube moves more than Genie specifications require that this procedure be 1/2 inch / 13 mm before the number 3 boom tube performed annually.
Page 128 Maintenance Manual April 2018 Annual Maintenance Procedures Note: Perform this procedure with the boom in the Visually inspect the cables and components stowed position. through the inspection holes for the following: • Frayed or broken wire strands Note: Perform this procedure with the engine off. •...
Page 129: Inspect The Boom Extend And Retract Cables
Extend the boom approximately 2 feet / 0.6 m. Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 Genie specifications require that this procedure be boom tubes. performed annually. Result: The number 2 boom tube should not...
Page 130 Maintenance Manual April 2018 Annual Maintenance Procedures SX-135 XC models: Measure the distance between boom tubes #2 and #3 using points (6) and (7) in the Note: Properly adjusted extend/retract cables will illustration. The gap should be maintain a relationship of the gap between boom 1 in / 2.6 cm to 1.5 in /3.9 cm greater than tubes #2 and #3.
Page 131 April 2018 Maintenance Manual Annual Maintenance Procedures SX-150 and SX-180 models: Note: Properly adjusted extend/retract cables will maintain a relationship of the gap between boom tubes #2 and #3 and boom tubes #3 and #4. Start the engine from the ground controls. Fully raise the boom then extend the boom approximately 15 ft / 4.6 m.
Page 132 Maintenance Manual April 2018 Annual Maintenance Procedures All models: Measure the distance between boom tubes #2 and #3 using points (9) and (10) in the Note: This procedure will require the use of an illustration. The gap should be aerial work platform. 1 in / 2.6 cm to 1.5 in /3.9 cm greater than dimension "A"...
Page 133: Check The Drive Hub Oil Level And Fastener Torque
Fastener Torque and remove as many sprocket retaining fasteners as possible from the hub adapter. Genie specifications require that this procedure be performed annually. Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage.
Page 134 Maintenance Manual April 2018 Annual Maintenance Procedures Attach a lifting strap from an overhead crane 10 Remove the plug located at 90 degrees and (2000 lbs / 1000 kg) to the center-point of the check the oil level. track assembly, above the sprocket. Result: The oil level should be even with the bottom of the plug hole.
Page 135: Test The Dual Capacity And Platform Overload System
Result: The oil level should be even with the SX-135 XC Models bottom of the side hole. Genie specifications require that this procedure be performed annually OR when the machine fails to lift the maximum rated load. Testing the platform overload system regularly is essential to safe machine operation.
Page 136 Maintenance Manual April 2018 Annual Maintenance Procedures Using a suitable lifting device, remove all test Start the engine and extend the jib. weights from the platform. Result: The jib should fully extend and retract. Result: The platform overload indicator light is Add an additional 100 lbs / 45kg to the off at platform controls, there is no error platform.
Page 137: Z-45 Xc Models
Result: The restricted range of motion indicator light is on at the ground controls. Genie specifications require that this procedure be Result: The unrestricted range of motion performed annually OR when the machine fails to indicator light is on. Calibrate the overload lift the maximum rated load.
Page 138 Note: There may be an 2 second delay before the overload indicator lights and alarm turn off. Genie specifications require that this procedure be Start the engine and test all machine functions performed annually OR when the machine fails to from the ground controls.
Page 139 April 2018 Maintenance Manual Annual Maintenance Procedures Using a suitable lifting device, place a test Using a suitable lifting device, remove all test weight of 600 lbs / 272kg in the center of the weights from the platform. platform. Secure the weight to the platform. Result: The platform overload indicator light is Note: The test weight may be within -0% / +5%.
Page 140: Programmed Maintenance Procedures
Maintenance Manual April 2018 Programmed Maintenance Procedures P0-1 Visually inspect the section of track under the bogey wheels. Check the Track Tension and Result: There should be less than 1 inch / 2.5 Fastener Torque, TRAX Models - cm of gap between the bogey wheels and the S-60, S-65 and Z-62 Models inside surface of the track.
Page 141: P0-2 Check The Track Tension And Fastener Torque, Trax Models
April 2018 Maintenance Manual Programmed Maintenance Procedures P0-2 Locate the grease zerk fitting on the other side of the track tension cylinder. Check the Track Tension and Pump grease into the grease zerk fitting of the Fastener Torque, TRAX Models - tension cylinder until grease, free from air, S-40 and S-45 Models comes out of the grease plug.
Page 142 Maintenance Manual April 2018 Programmed Maintenance Procedures Visually inspect the section of track under the Loosen the tensioner jam nut and idler axle bogey wheels. bolts on both sides of the tensioner wheel and tighten the tensioner nut until there is between Result: There should be less than 1 inch / 2.5 0.75 - 1 inch / 1.9 - 2.5 cm of gap between the cm of gap between the bogey wheels and the...
Page 143: P0-3 Grease The Extendable Axles - S-100, S-105, S-120 And S-125
Cycle the extending axles in and out. Note: Genie recommends that the extending axles be cycled in and out at least once a week. Part No. 1268489GT ®...
Page 144: P0-4 Continental Engine Maintenance - Under 1000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P0-4 Continental Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 145: P0-5 Cummins Engine Maintenance - Under 1000 Hours
April 2018 Maintenance Manual Programmed Maintenance Procedures P0-5 Cummins Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 146: P0-6 Deutz Engine Maintenance - Under 1000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P0-6 Deutz Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 147: P0-7 Ford Engine Maintenance - Under 1000 Hours
April 2018 Maintenance Manual Programmed Maintenance Procedures P0-7 Ford Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 148: P0-8 Kubota Engine Maintenance - Under 1000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P0-8 Kubota Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 149: P0-9 Perkins Engine Maintenance - Under 1000 Hours
April 2018 Maintenance Manual Programmed Maintenance Procedures P0-9 Perkins Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 150: P0-10 Gm .998L Engine Maintenance - Under 1000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P0-10 GM .998L Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 151: P0-11 Gm 3.0L Engine Maintenance - Under 1000 Hours
April 2018 Maintenance Manual Programmed Maintenance Procedures P0-11 GM 3.0L Engine Maintenance – Under 1000 Hours Additional engine maintenance is required. Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply. Required maintenance procedures and additional engine information are available in the manufacturer's manuals.
Page 152: P1-1 Perform Engine Maintenance - 1000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P1-1 Deutz Models Perform Engine Maintenance – All Models: 1000 Hours • Fuel system primary filter (water separator) element – replace • Fuel system secondary filter – replace Engine specifications require that this procedure be •...
Page 153: P1-2 Replace The Drive Hub Oil
April 2018 Maintenance Manual Programmed Maintenance Procedures P1-2 Perkins Models Replace the Drive Hub Oil All Models: • Alternator and fan belts - replace • Engine valve lash – inspect/adjust Drive hub specifications require that this procedure • Engine crankcase breather - replace be performed after the first 50 hours of operation.
Page 154 Maintenance Manual April 2018 Programmed Maintenance Procedures Models with TRAX: Drive the machine until one of the two plugs is at the highest point. Select the drive hub to be serviced. Loosen and remove as many sprocket retaining fasteners as possible from the hub adapter. Drive the machine in either direction just enough to access the remaining fasteners.
Page 155 April 2018 Maintenance Manual Programmed Maintenance Procedures Locate the hub disconnect pin in the center of 16 Raise the machine, remove the jack stands the drive hub. Manually depress the pin and lower the machine. rotate the drive hub until one of the two plugs 17 Drive the machine in either direction just until is at the lowest point.
Page 156: P2-1 Perform Engine Maintenance - 2000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P2-1 Remove the drive hub mounting bolts from the drive hub assembly. Carefully remove the Perform Engine Maintenance – turntable rotate drive hub assembly from the 2000 Hours machine. Note: If equipped with two turntable rotation drive hub assemblies, do not remove them both at the same time.
Page 157 April 2018 Maintenance Manual Programmed Maintenance Procedures Deutz Models Kubota Models All Models Z482-E, D1105, WG972 • V-Belts - replace • Radiator coolant (L.L.C.) - replace • Glow plugs - replace • Battery - replace D 2.9 and TD 2.9 Models •...
Page 158: P2-2 Test Or Replace The Hydraulic Oil
If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must be Genie requires that this procedure be performed tested every quarter by an oil distributor until every 2000 hours. the oil fails the test and is replaced.
Page 159: P2-3 Replace The Hydraulic Filters
Replace the Hydraulic Filters housing. Rotate the filter element clockwise to lock it in place. Genie requires that this procedure be performed Install the filter housing cap. every 2000 hours. Use a permanent ink marker to write the date Perform this procedure more often if dusty and number of hours from the hour meter on conditions exist.
Page 160 Maintenance Manual April 2018 Programmed Maintenance Procedures Medium and high pressure filters Case drain filter: Note: The medium pressure filter is for the charge Note: The case drain filter is for the charge pump. pump and the high pressure filter is for all machine Open the engine side turntable cover and functions except the drive circuit and oscillating locate the case drain filter mounted to the...
Page 161: P2-4 Check The Free-Wheel Configuration
Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer / circle-end wheel hub. Genie requires that this procedure be performed every 2000 hours. Proper use of the free-wheel configuration is essential to safe machine operation. The free-wheel configuration is used primarily for towing.
Page 162 Maintenance Manual April 2018 Programmed Maintenance Procedures Lift the wheels or tracks off the ground and 12 Re-engage the drive hubs by turning over the then place jack stands under the drive chassis hub disconnect caps. Rotate each wheel or for support.
Page 163: P2-5 Check The Boom Wear Pads
Top and side wear pads 0.50 inch (platform end of boom) 12.7 mm Bottom wear pads 0.625 inch Genie requires that this procedure be performed (platform end of boom) 15.9 mm every 2000 hours. Top and side wear pads 0.50 inch...
Page 164 15.9 mm Grease Specification Side wear pads - pivot end 0.375 inch Lube a Boom grease 9.5 mm 110147 Genie part number Z-40/23N (RJ) Z-30/20N (RJ), Z-34/22N, Z-34/22DC Primary boom wear pad Minimum Models without rotating jib boom specifications Primary boom wear pad specifications...
Page 165 April 2018 Maintenance Manual Programmed Maintenance Procedures Z-45/25 (J) IC, DC, BE, Z-45 XC, Z-51/30J Z-135/70, ZX-135/70 Note: The minimum shim clearance for the secondary Primary boom wear pad specifications Minimum boom wear pads is 0.070 inch / 1.8 mm and the Top, bottom and side wear pads (platform 0.625 inch maximum allowable shim clearance is 0.25 inch / 6.4...
Page 166: P2-6 Check The Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100Hd And S-120Hd
Check the Turntable Rotation Pads - S-100, S-105, S-120, S-125, Gear Backlash - ALC1000 Models S-100HD and S-120HD Genie requires that this procedure be performed every 2000 hours. Properly adjusted turntable rotation gear backlash is essential for good machine performance and Genie requires that this procedure be performed service life.
Page 167: P2-8 Grease The Steer Axle Wheel Bearings, All 2Wd Models, Except S-60, S-65, Z-60 Dc/Fe And Z-62
0.022 inch / 0.559 mm. The backlash needs to be adjusted. Refer to Repair Procedure in the appropriate Service Genie requires that this procedure be performed and Repair Manual for your machine, How to every 2000 hours.
Page 168 Maintenance Manual April 2018 Programmed Maintenance Procedures Remove the dust cap from the hub. Remove 15 Place the large inner bearing into the rear of the cotter pin from the castle nut. the hub. Tighten the castle nut to specification, to seat 16 Install a new bearing grease seal into the hub the bearings.
Page 169: P2-9 Grease The Steer Axle Wheel Bearings, 2Wd Models - S-60, S-65, Z-60 Dc/Fe And Z-62
Result: If there is side to side or up and down grease the wheel bearings. movement, continue to step 10 and replace Genie requires that this procedure be performed the wheel bearings with new ones. every 2000 hours. Note: When replacing a wheel bearing, both the...
Page 170: P3-1 Perform Engine Maintenance - 3000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P3-1 Remove the shims. Perform Engine Maintenance – Gently pry the outer ring out of the hub. 3000 Hours Pull the hub off of the spindle. The outer bearing should fall loose from the hub. 10 Place the hub on a flat surface and gently pry the inner oil seal out of the hub.
Page 171: P4-1 Perform Engine Maintenance - 4000 Hours
April 2018 Maintenance Manual Programmed Maintenance Procedures P4-1 Perkins Models Perform Engine Maintenance – 403D-11, 403F-11, 404D-22, 404F-22, 4000 Hours 404F-22T, 804D, 1104D-44T • Water pump - inspect • Fuel Injector - test/change Engine specifications require that this procedure be •...
Page 172: P5-1 Perform Engine Maintenance - 5000 Hours
Maintenance Manual April 2018 Programmed Maintenance Procedures P5-1 P6-1 Perform Engine Maintenance – Perform Engine Maintenance – 5000 Hours 6000 Hours Engine specifications require that this procedure be Engine specifications require that this procedure be performed every 6,000 hours. performed every 6,000 hours. Required maintenance procedures and additional Required maintenance procedures and additional engine information are available in the...
Page 173: P12-1 Perform Engine Maintenance - 12000 Hours
Remove and Inspect the Boom 12000 Hours Extend/Retract Cables Engine specifications require that this procedure be Genie specifications require that this procedure be performed every 12000 hours. performed after 12 years. Required maintenance procedures and additional Manufacturers specifications require that this...
Page 174 Maintenance Manual April 2018 Programmed Maintenance Procedures Remove the boom extend and retract cables. Inspect the cables for the following: Refer to the appropriate Service and Repair • Frayed or broken wire strands Manual for repair procedure, How to Replace the Boom Extend/Retract Cables.
Page 175 April 2018 Maintenance Manual Programmed Maintenance Procedures SX-150 and SX-180 Inspect the cable diameter. Measure the diameter in multiple locations along the cable. Extend - Boom 3 .625 inches .594 inches 15.875 mm 15 mm Note: Calipers will be required to perform this Retract - Boom 3 .625 inches .594 inches...
Page 176: Cable Replacement Criteria
Maintenance Manual April 2018 Programmed Maintenance Procedures Cabl e R epl ac ement Criteria Cable Replacement Criteria Note: The cables must be replaced if any condition shown below is observed other than normal wear. Note The cables must be replaced as a set. normal wear abrasion broken wires...
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