Genie S-80HF Maintenance Manual
  1. Manuals
  2. Brands
  3. Genie Manuals
  4. Boom Lifts
  5. S-80HF
  6. Maintenance manual

Genie S-80HF Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Maintenance Manual - Booms
S
Booms
®
Z
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 G
October 2018

Advertisement

Table of Contents
loading

Related Manuals for Genie S-80HF

Summary of Contents for Genie S-80HF

  • 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 G, October 2018 Group B/Type 3 as defined by ISO 16368 First Edition, Seventh 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: Introduction

    S-80, S-85, from S80/85/80X15-12264 to16H-13999 from Z4525XCM-101 S-80XC, from S80/85/80X15D-101 to 16D-339 S-85XC. from S80/85/80XH-14000 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199 S-80HF, from S80/85/80XD-340 from Z4525N-57200 S-85HF from S80/85XCH-101 Z-51/30J from Z513014B-1201 to Z5130M-2000 S-100, S-105 from S10015D-1001 to S10016D-1549...

  • Page 4: Identifying The Correct Procedure For Your Model

    Maintenance Manual October 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: Revision History

    October 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 4/2018 Specifications Deutz TD2011 Engine Specifications 10/2018 All Sections Add S60XC, S-65XC, S-80HF, S-85HF Models Add Perkins 404F-E22T, 404F-E22TA Engine Reference Examples: Section – Specifications Electronic Version Click on any content or procedure in the Table of Contents to view Section –...

  • Page 7: Safety Rules

    October 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 October 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

    October 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Models included in this manual ................iii Identifying the Correct Procedure for your Model ..........iv Find additional Manuals for your Model ..............iv Revision History...................... v Section 1 Safety Rules ......................
  • Page 10 October 2018 Table of Contents Hydraulic Specifications ................... 21 Hydraulic Relief Valves ..................21 Hydraulic and Drive Hub Fluid Capacities ............24 Hydraulic Oil Specifications ................. 26 Hydraulic Hose and Fitting Torque Specifications ..........29 Torque Procedure ....................30 Section 3 Maintenance Procedures ..................
  • Page 11 October 2018 Table of Contents Quarterly Maintenance Procedures ..............41 Q-1 Check for Open Bulletins and Owner Registration ........41 Q-2 Battery inspection ..................42 Q-3 Inspect the Electrical Wiring ................44 Q-4 Inspect the Electrical Contactor - DC / Bi-Energy Models ......45 Q-5 Check the Exhaust System ................
  • Page 12 October 2018 Table of Contents 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 ......68 Q-26 Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70 ..70 Q-27 Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70 ....72 Q-28 Test the Primary Boom Angle Sensor - SX-105 XC, SX-125 XC, SX-135 XC, SX-150 and SX-180 ......
  • Page 13 A-16 Test the Dual Capacity and Platform Overload System - Z-45 XC Models ..................127 A-17 Test the Dual Capacity and Platform Overload System - S-60 XC from S60ZXH-45001 and S60XCM-101, S-65 XC, S-80HF, S-85 HF, S-80 XC, S-85 XC ..................128 Part No. 1268489GT ®...
  • Page 14 October 2018 Table of Contents Programmed Maintenance Procedures ............130 P0-1 Check the Track Tension and Fastener Torque, TRAX Models - S-60, S-65 and Z-62 Models ..............130 P0-2 Check the Track Tension and Fastener Torque, TRAX Models - S-40 and S-45 Models ................131 P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125 ....

  • Page 15: Performance Specifications

    October 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. Function speeds are shown in seconds. Primary boom up/down, 80 - 88 (retracted)

  • Page 16: Function Speeds - S-120, S-125 And S-120Hd

    Maintenance Manual October 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. Function speeds are shown in seconds. Primary boom up/down, 80 - 88 (retracted) Primary boom up/down, 100 - 100...

  • Page 17: Function Speeds - All Other Models

    S-80, S-85 S-80XC, S-80, S-85, (all models) S-60HC, S-60X, S60XCH-45001 S-80X (AS/CE models) S-85XC, S-60XC to 45000 (ANSI/CSA S-80HF, (all models) models) S-85HF S60XCM-101, S-65XC Primary boom up 50 - 60 60 - 70 65 - 75 57 - 65...
  • Page 18 Maintenance Manual October 2018 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function Z-30N, Z-30N RJ Z-34 BE Z-34N, Z-34 Z-33 (DC models) Primary boom up 14 - 22 14 - 22 16 - 22...

  • Page 19: Primary Boom Extend

    October 2018 Maintenance Manual Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. 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...

  • Page 20: Turntable Rotate

    Maintenance Manual October 2018 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function Z-135 ZX-135 Primary boom up/down 88 - 105 110 - 125 Primary boom extend/retract 38 - 42 35 - 48 Secondary boom up/down...

  • Page 21: Platform Rotate

    October 2018 Maintenance Manual Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function SX-105 XC SX-125 XC SX-135 XC Primary boom 80 - 88 / 83° 80 - 88 / 83°...
  • Page 22 Maintenance Manual October 2018 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function SX-150 SX-180 Primary boom 80 - 88 / 82° 80 - 88 / 82° up/down, (stowed) Primary boom up/down 100 - 110 / 82°...

  • Page 23: Drive Speeds

    Note: Drive speeds are shown in seconds. Function S-40, S-45 S-60, S-65, S-60XC from S-80, S-85, S-80X S-80XC, S-85XC, (all models) S-60HC, S-60X, S60XCH-45001 S-80HF, S-85HF S-60XC to 45000 and S60XCM-101, (all models) S-65XC 2WD models, 5.2 - 5.9 6.1 - 7.8 7.9 - 8.5...
  • Page 24 Maintenance Manual October 2018 Performance Specifications Note: Drive speeds are shown in seconds. Function S-100, S-105, SX-135 XC, Z-30N, Z30N RJ Z-33 Z-34N, Z34DC, S-120, S-125, SX-150, SX-180 Z-34BE S-100HD, S-120HD, SX-105 XC, SX-125 XC 2WD models, 6 - 8 8.5 - 10.5 6 - 8 Stowed position...

  • Page 25: Ansi/Csa

    October 2018 Maintenance Manual Performance Specifications Note: Drive speeds are shown in seconds. 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 (ANSI / CSA) 8 - 10 6 - 6.8 Stowed position...

  • Page 26: Torque Specifications

    S60XCM-101, S-65XC S-80, S-85, S-80X 320 ft-lbs 70 psi / 4,8 bar 434 Nm 320 ft-lbs 100 psi / 6,9 bar S-80XC, S-85XC, S-80HF, S-85HF 434 Nm S-100, S-100HD, S-105, S-120, 320 ft-lbs S-120HD, S-125 434 Nm 320 ft-lbs SX-105 XC, SX-125 XC, SX-135 XC,...

  • Page 27: Trax Torque Specifications

    October 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 28: Engine Specifications

    Maintenance Manual October 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 29: Deutz Engine Models

    October 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 30: Perkins Engine Models

    Maintenance Manual October 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 31 October 2018 Maintenance Manual Engine Specifications 404F-E22T 854F-E34T Low idle (standby) 1000 Low idle (standby) 1000 rpm 500 Hz (SX-105 XC, SX-125 XC, SX-135 XC, 500 Hz SX-150, SX-180, Z-135, ZX-135) Low idle (with function enable) 1500 rpm (S-100/105/120/125/100HD/120HD) 750 Hz Low idle (with function enable) 1500 rpm High idle...

  • Page 32: Ford Engine Models

    Maintenance Manual October 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 33: Gm Engine Models

    October 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 34: Continental Engine Models

    Maintenance Manual October 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 35: Hydraulic Specifications

    October 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 36 Maintenance Manual October 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-30N, Z-30N RJ 3000 psi 1600 1600 psi 1800 1100 psi 207 bar 110 bar 76 bar...
  • Page 37 41,4 bar S60XCM-101, S-65XC (all models) 280 psi 950 psi S-80, S-85, S-80X, S-80XC, S-85XC, 19,3 bar 66 bar S-80HF, S-85HF S-100, S-100HD, S-105, S-120, 280 psi 1800 psi 19,3 bar 124 bar S-120HD, S-125 240 psi 2400 psi SX-105 XC, SX-125 XC, SX-135 XC...

  • Page 38: Hydraulic And Drive Hub Fluid Capacities

    30.5 fl oz 43 fl oz 40 gallons 50 gallons 680 cc 902 cc 1262 cc 151 liters 189 liters S-80XC, S-85XC, S-80HF, S-85HF 30.5 fl oz 43 fl oz 40 gallons 64 gallons 902 cc 1262 cc 151 liters 242 liters...
  • Page 39 October 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 750 cc 30 liters 41 liters (DC and BE models)

  • Page 40: Hydraulic Oil Specifications

    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 41 October 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 42 Maintenance Manual October 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 43: Hydraulic Hose And Fitting Torque Specifications

    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 44: Torque Procedure

    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 45 October 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 46: 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 47 October 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 48: Maintenance Schedule

    Maintenance Manual October 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 49: Pre-Delivery Preparation Report

    October 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 50: Scheduled Maintenance Inspection Report - Quarterly Or Frequent

    Test the Recovery System - ALC600 models Q-37 Test the Turntable Level Sensor - S-60XC from Q-38 S60XCH-45001 and S60XCM-101, S-65XC, S-80XC, S-85XC, S-80HF, S-85HF Test the Primary Boom Angle Sensor - S-60XC from Q-39 S60XCH-45001 and S60XCM-101, S-65XC, S-80XC, S-85XC, S-80HF, S-85HF ®...

  • Page 51: Scheduled Maintenance Inspection Report - Annual

    Test Dual Capacity / Overload - Z-45XC A-16 Test Dual Capacity / Overload - S-60XC from A-17 S60XCH-45001 and S60XCM-101, S-65XC, S-80XC, S-85XC, S-80HF, S-85HF Inspect Boom Cables - All S-60, S-80 Models A-11 Inspect Boom Cables - S-100 to S-125, S-100HD, A-12...

  • Page 52: Programmed Maintenance Inspection Report - Booms

    Programmed October 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 53: Commissioning Procedures

    October 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 54: Perform 150 Hour Service

    Maintenance Manual October 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 55: Quarterly Maintenance Procedures

    Select "Customer Login" to login or select your machine has no open bulletins is to frequently "Request New Access" to create a new check the serial number of your Genie machine account. against our bulletin database. Using the links below you can view any open bulletins for your machine(s) At the homepage, select "Unit Configuration"...

  • Page 56: 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 57 October 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 58: 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 59: 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 60: 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 61: 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 62: 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 63: 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 64: 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 65: 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 66 Maintenance Manual October 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 67 October 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 68 Maintenance Manual October 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 69 October 2018 Maintenance Manual Quarterly Maintenance Procedures Perkins 403D-11 Perkins 404D-22 1 high idle solenoid 2 high idle adjustment nut 1 high idle solenoid 3 lock nut 2 high idle adjustment nut 4 low idle adjustment screw 3 low idle adjustment screw Perkins 804D-33 1 high idle solenoid 2 high idle adjustment nut...

  • Page 70: 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 71: 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 72: 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 73 October 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 74: 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 75: 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 76: 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 77: 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 78: 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 79: 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 80: 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 81 October 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 82: Test The Turntable Level Sensor

    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 83 October 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 84: 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 85 October 2018 Maintenance Manual Quarterly Maintenance Procedures Lower the secondary boom to 65°. Press the plus and minus buttons at the 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 86: Test The Primary Boom Angle Sensor - Z-135/70 And Zx-135/70

    Secondary Boom Angle Sensor. 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 87 October 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 88 Maintenance Manual October 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 89: Test The Primary Boom Angle Sensor

    Result: The reading at the display and digital procedure. 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 90 Maintenance Manual October 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 91 October 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 92 Maintenance Manual October 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 93 October 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 94: Test The Safety Envelope Limit Switches - Z-135/70, Zx-135/70, Sx-105

    XC, SX-150 and SX-180 Models Remove the lower cover retaining fasteners and remove the lower cover from turntable. Genie specifications require that this procedure be performed quarterly. Crushing hazard. The turntable riser lower cover could become...
  • Page 95 October 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 96 Maintenance Manual October 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 97 October 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 98: Test The Primary Boom Angle Sensor - Z-80/60

    Raise the primary boom. The display will begin showing a boom angle of 40°. Sensor - Z-80/60 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 99: 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 100 Maintenance Manual October 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 101: Check The Safety Envelope Limit Switches And Angle Sensor - S-60X, S-80X, And S-60Xc To S60Xc-45000

    Emergency Stop button to the Start the engine from the ground controls. 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 102 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 103: 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 Lower the primary boom 5 feet / 1.5 m and performed quarterly. activate primary boom extend. Testing the machine safety envelope is critical to Result: Primary boom extend will stop and the safe machine operation.
  • Page 104 Maintenance Manual October 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 105 October 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 106 Maintenance Manual October 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 107 October 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 108 Maintenance Manual October 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 109: 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 110 Maintenance Manual October 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 111: 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 112: 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 113: S60Xcm-101, S-65 Xc, S-80 Hf, S-85 Hf, 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 X axis (roll) includes a digital level with a magnetic base and cable harnesses.
  • Page 114 Maintenance Manual October 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 115: Test The Primary Boom Angle Sensor - S-60 Xc From S60Xch-45001 And S60Xcm-101, S-65 Xc, S-80 Hf, S-85 Hf, S-80 Xc, S-85 Xc

    Sensor. Note: A digital level will be required to perform this procedure. Note: A kit is available through Genie Product negative degree uphill slope Support (Genie part number 58351). This kit includes a digital level with a magnetic base and Tip-over hazard.
  • Page 116 Maintenance Manual October 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 117: 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 118: 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 119: 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 120: Check The Extendable Axle - S-100, S-105, S-120 And S-125

    Result: The measurement is more than S-120HD and S-125 specification. The bearing is worn and needs to be replaced. Models Measurement Genie specifications require that this procedure be S-40/45 (all), S-60/65 (all), Z-60 DC/FE, 0.063 inch performed annually. Z-62/40 1.6 mm Z-30/20N, Z-34/22 (all), Z-40/23, Z-45/25 (all), 0.055 inch...

  • Page 121: Perform Maintenance- Jib Rotate Bearing

    October 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 122: 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 123 October 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 Open the ground controls side turntable side the platform.

  • Page 124: 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 switch.

  • Page 125: Test The Platform Overload System - All Models

    Level the platform. Determine the maximum platform capacity. Refer to the machine serial plate. Genie specifications require that this procedure be Using a suitable lifting device, place a test performed annually OR when the machine fails to weight equal to that of the available capacity in lift the maximum rated load.
  • Page 126 Maintenance Manual October 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 127: 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 128: 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 129: Inspect The Boom Extend/Retract Cables - S-60/65 And S-80/85 Models

    LED at the platform controls should come on and the engine should continue to run. Using a suitable lifting device, place an Genie specifications require that this procedure be additional appropriate test weight equal to performed annually. 227.2 to 231.3 kg on to the center of the Manufacturers specifications require that this platform floor.
  • Page 130 Maintenance Manual October 2018 Annual Maintenance Procedures S-60, S-65, S-60X, S-60 XC, S-65 XC, S-60 • S-60 HC: String potentiometer cable break TRAX, S-65 TRAX, S-80, S-85, S-80X, S-80 limit switch arm is securely attached to end of cable HF, S-85 HF, S-80 XC, S-85 XC: Remove the boom end cover from the pivot end of the Note: A flashlight and inspection mirror may be boom and set aside.

  • Page 131: Inspect The Boom Extend/Retract Cables

    Component damage hazard. The Genie specifications require that this procedure be cable from the string potentiometer performed annually. can become damaged if it is kinked or pinched.
  • Page 132 Maintenance Manual October 2018 Annual Maintenance Procedures Remove the boom end cover from the pivot Remove the retaining fasteners from the end of the boom. access covers located on the side of the boom at the platform end of the machine. Remove the covers.

  • Page 133: Inspect The Boom Extend And Retract Cables - Sx-135

    Retract the boom. While retracting the boom, visually inspect the number 2 and number 3 boom tubes. Genie specifications require that this procedure be performed annually. Result: The number 2 boom tube should not move more than 1/2 inch / 13 mm before the Manufacturers specifications require that this number 3 boom tube begins to retract.
  • Page 134 Maintenance Manual October 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 135 October 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 136 Maintenance Manual October 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 137: 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 138 Maintenance Manual October 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 139: 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 140 Maintenance Manual October 2018 Annual Maintenance Procedures Using a suitable lifting device, place a test Add an additional 320 lbs / 145 kg to the weight of 550 lbs / 250 kg in the center of the platform. platform. Secure the weight to the platform. Result: There is an audible alarm.

  • Page 141: 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 142: Xc, S-85 Xc

    Start the engine and test all machine functions from the ground controls. Result: All ground control functions should Genie specifications require that this procedure be operate normally. performed annually OR when the machine fails to lift the maximum rated load.
  • Page 143 October 2018 Maintenance Manual Annual Maintenance Procedures Add additional weight to the platform. Using a suitable lifting device, place a test weight of 550 lbs / 250 kg in the center of the S-80 HF, S-85 HF models: 370 lbs / 168 kg. platform.

  • Page 144: Programmed Maintenance Procedures

    Maintenance Manual October 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, S-60 XC, S-65 XC and inside surface of the track.

  • Page 145: P0-2 Check The Track Tension And Fastener Torque, Trax Models

    October 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 146 Maintenance Manual October 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 147: 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 148: P0-4 Continental Engine Maintenance - Under 1000 Hours

    Maintenance Manual October 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 149: P0-5 Cummins Engine Maintenance - Under 1000 Hours

    October 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 150: P0-6 Deutz Engine Maintenance - Under 1000 Hours

    Maintenance Manual October 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 151: P0-7 Ford Engine Maintenance - Under 1000 Hours

    October 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 152: P0-8 Kubota Engine Maintenance - Under 1000 Hours

    Maintenance Manual October 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 153: P0-9 Perkins Engine Maintenance - Under 1000 Hours

    October 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 154: P0-10 Gm .998L Engine Maintenance - Under 1000 Hours

    Maintenance Manual October 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 155: P0-11 Gm 3.0L Engine Maintenance - Under 1000 Hours

    October 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 156: P1-1 Perform Engine Maintenance - 1000 Hours

    Maintenance Manual October 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 157: P1-2 Replace The Drive Hub Oil

    October 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 158 Maintenance Manual October 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 159 October 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 160: P2-1 Perform Engine Maintenance - 2000 Hours

    Maintenance Manual October 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 161 October 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 162: 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 163: 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 164 Maintenance Manual October 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 165: 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 166 Maintenance Manual October 2018 Programmed Maintenance Procedures Steer or Square-end wheels: 4WD Models 12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each wheel or Chock the non-steer / circle-end wheels or track to check for engagement. Raise the tracks to prevent the machine from rolling.

  • Page 167: 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 168 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 169 October 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 170: 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 171: 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 172 Maintenance Manual October 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 173: 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 174: P3-1 Perform Engine Maintenance - 3000 Hours

    Maintenance Manual October 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 175: P4-1 Perform Engine Maintenance - 4000 Hours

    October 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 176: P5-1 Perform Engine Maintenance - 5000 Hours

    Maintenance Manual October 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 177: 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 178 Maintenance Manual October 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 179 Extend .438 inches .416 inches 11.13 mm 10.5 mm Retract .438 inches .416 inches 11.13 mm 10.5 mm S-80HF, S-85HF, S-80XC and S-85XC Extend .50 inches .475 inches 12.7 mm 12 mm Retract .438 inches .416 inches 11.13 mm 10.5 mm...

  • Page 180: Cable Replacement Criteria

    Maintenance Manual October 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...
  • Page 181 October 2018 Maintenance Manual This page intentionally left blank. ® ® Booms • Z Booms Part No. 1268489GT Maintenanc e M anual October 2018 Maintenanc e Ins pection R eport – Boom s Part No. 1268489GT ® Booms • Z ®...

This manual is also suitable for:

Z seriesS-40S-45S-60S-65S-60xc ... Show all

Table of Contents