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 Group B/Type 3 as defined by ISO 16368 First Edition, Ninth Printing Machine Design Life Genie, "S" and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Unrestricted with proper operation, inspection and "TraX"...
Page 3: Models Included In This Manual
May 2020 Maintenance Manual Introduction SX-105 XC from SX105D-101 Models included in this manual SX-125 XC from SX125D-101 Use the following chart to identify the specific SX-135 XC from SX135H-101 serial number for models included in this manual. from SX15015-100 to SX15016H-499 SX-150 from SX150H-500 Models...
Page 4 Maintenance Manual May 2020 Introduction Z-30/20N, Z- from Z30N14-15222 to Z30N16F-18899 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199 30/20N RJ from Z30N16D-104 to Z30N16D-199 from Z4525N-57200 to Z4525N-58604 from Z30NF-18900 from Z4525F-58605 from Z30ND-200 from Z4525M-6700 Z-33/18 from Z331815M-101 to Z331816M-1299 Z-45 DC, Z-45 from Z45EM-101 from Z3318M-1300...
Page 5: Identifying The Correct Procedure For Your Model
May 2020 Maintenance Manual 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 6: Revision History
Maintenance Manual May 2020 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 7 May 2020 Maintenance Manual Introduction Revision History (continued) Revision Date Section Procedure / Description 2/2020 All Sections Add S40/45HF, S60J, Z45DC/FE, Z45HF models. Add Deutz TD/TCD 2.2 L3 engine Specifications Hydraulic Specifications Annual A-11, A-12, A-13 Programmed P0-6, P1-1 Reference Examples: Section –...
Page 8: Safety Rules
Maintenance Manual May 2020 Safety Rules Secti on 1 Safety Rul es Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 9 May 2020 Maintenance Manual 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 10: Table Of Contents
May 2020 Table of Contents Introduction Introduction ...................... ii Important Information ..................ii Models included in this manual................iii Identifying the Correct Procedure for your Model ..........v Find additional Manuals for your Model .............. v Revision History ....................vi Section 1 Safety Rules ....................
Page 11 May 2020 Table of Contents Section 3 Maintenance Procedures ................34 Introduction ...................... 34 Maintenance Schedule ..................36 Pre-Delivery Preparation Report ............... 37 Scheduled Maintenance Inspection Report - Quarterly or Frequent ....38 Scheduled Maintenance Inspection Report - Annual ......... 39 Programmed Maintenance Inspection Report - Booms ........
Page 12 May 2020 Table of Contents Quarterly Maintenance Procedures............... 43 Q-1 Check for Open Bulletins and Owner Registration ........43 Q-2 Battery inspection ..................44 Q-3 Inspect the Electrical Wiring ..............46 Q-4 Inspect the Electrical Contactors - DC / Bi-Energy Models ......47 Q-5 Check the Exhaust System ................
Page 13 May 2020 Table of Contents Q-17 Inspect the Calibration Decal - ALC1000 Models ........63 Q-18 Test the Recovery Mode System - ALC-1000 Models ....... 64 Q-19 Test the Platform Self-leveling ..............66 Q-20 Confirm the Proper Brake Configuration ........... 66 Q-21 Test the Drive Brakes ................
Page 14 May 2020 Table of Contents Annual Maintenance Procedures ..............105 A-1 Grease the Turntable Rotation Bearing and Rotate Gear ......105 A-2 Check the Turntable Rotation Bearing Bolts ..........106 A-3 Inspect for Turntable Bearing Wear ............108 A-4 Check the Extendable Axle - S-100, S-105, S-120 and S-125 ....109 A-5 Perform Maintenance- Jib Rotate Bearing ..........
Page 15 May 2020 Table of Contents Programmed Maintenance Procedures ............137 P0-1 Check the Track Tension and Fastener Torque, TraX Models - S-60, S-65, S-60 XC, S-65 XC, Z-62 Models ........... 137 P0-2 Check the Track Tension and Fastener Torque, TraX Models - S-40, S-45, S-40 XC, S-45 XC Models ............
Page 16 May 2020 Table of Contents P3-1 Perform Engine Maintenance – 3000 Hours ........... 169 P4-1 Perform Engine Maintenance – 4000 Hours ........... 171 P5-1 Perform Engine Maintenance – 5000 Hours ........... 171 P6-1 Perform Engine Maintenance – 6000 Hours ........... 172 P12-1 Perform Engine Maintenance –...
Page 17: Performance Specifications
May 2020 Maintenance Manual Performance Specifications Secti on 2 Perfor man ce Speci ficatio ns 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 18: Function Speeds - S-120, S-125 And S-120Hd
Maintenance Manual May 2020 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 19: Function Speeds - All Other Models
May 2020 Maintenance Manual Performance Specifications Function Speeds - All Other Models Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. S-40, S-45, S- S-60, S-65, S- S-60HF, S-65HF, S-80, S-85, S- S-80, S-85 Function...
Page 20 Maintenance Manual May 2020 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function S-80XC, S-85XC, Z-30N, Z-30N RJ Z-34 BE Z-34N, Z-34 Z-33 S-80HF, S-85HF (DC models) 36 - 40 Primary boom up 75 - 83...
Page 21 May 2020 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-45HF, (DC, BE models) (IC models) Z-45XC Primary boom up 15 - 21...
Page 22 Maintenance Manual May 2020 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 23 May 2020 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 24 Maintenance Manual May 2020 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 100 - 110 / 82°...
Page 25: Drive Speeds
May 2020 Maintenance Manual Performance Specifications Drive Speeds Note: Drive speeds are shown in seconds. Function S-40, S-45, S- S-60, S-65, S-60HC, S-60HF, S-65HF, S-80, S-85, S- S-80HF, S-85HF, S- 40HF, S-45HF, S- S-60X, S-60XC to S-60J, S-60XC 80XC, S-85XC 40XC, S-45XC 45000 from S60XCH-...
Page 26 Maintenance Manual May 2020 Performance Specifications Note: Drive speeds are shown in seconds. Function S-100, S-105, S- SX-135XC, SX-150, Z-30N, Z30N RJ Z-33 Z-34N, Z34DC, Z- 120, S-125, S- SX-180 34BE 100HD, S-120HD, SX-105XC, SX- 125XC 2WD models, 6 - 8 8.5 - 10.5 6 - 8 Stowed position...
Page 27 May 2020 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-45HF, Z- 45XC, Z-45 DC/FE 2WD models, 8.5 - 10.5 6.1 - 7.1 8 - 10 6 - 6.8...
Page 28: Torque Specifications
Maintenance Manual May 2020 Torque Specifications Tires and Wheels Torque values are listed as dry. The retaining fasteners must be coated with a mineral based lubricant when removed. If a retaining fastener is removed, the torque value is reduced. Refer to the Service and Repair Manual that is appropriate for your machine.
Page 29 May 2020 Maintenance Manual Torque Specifications Tires and Wheels, continued Torque values are listed as dry. The retaining fasteners must be coated with a mineral based lubricant when removed. If a retaining fastener is removed, the torque value is reduced. Refer to the Service and Repair Manual that is appropriate for your machine.
Page 30: Trax Torque Specifications
Maintenance Manual May 2020 Torque Specifications TraX™ Torque Specifications Sprocket to hub adapter fasteners 3/4-16 UNF nuts, dry 317 ft-lbs 430 Nm 3/4 -16 UNF nuts, lubricated 281 ft-lbs 381 Nm 1/2-13 FHS screws, dry 80 ft-lbs 108 Nm 1/2-13 FHS screws, lubricated 60 ft-lbs 81 Nm Hub adapter to drive hub fasteners...
Page 31: Engine Specifications
May 2020 Maintenance Manual Engine Specifications Engine Operator and Ford DSG-423 Genie part number 119488GT Maintenance Manuals Diagnostic Manual Deutz D2011L03i and TD2011L04i Genie part number 119494GT Genie part number 139320GT Ford MSG-425 Deutz TD 2.2 L3 and TCD 2.2 L3 Genie part number 215322GT Genie part number...
Page 32: Deutz Engine Models
Maintenance Manual May 2020 Engine Specifications Deutz Engine Models TD 2.2 L3 Low idle, standby 1000 rpm D2011 L03i • D436 L3i CN3 1000 Hz Low idle 1500 rpm Low idle, function enable 1500 rpm 313 Hz 1500 Hz High idle 2500 rpm High idle 2500 rpm...
Page 33: Perkins Engine Models
May 2020 Maintenance Manual Engine Specifications Perkins Engine Models D 2.9 L4 Low idle, standby 1000 rpm 403D-11 1000 Hz Low idle 1500 rpm Low idle, function enable 1500 rpm 150 Hz 1500 Hz High idle 2800 rpm High idle 2500 rpm 280 Hz 2500 Hz...
Page 34 Maintenance Manual May 2020 Engine Specifications 404D-22T 404F-E22T Low idle (standby) 1000 rpm Low idle (standby) 1000 500 Hz 500 Hz Low idle (with function enable) 1500 rpm Low idle (with function enable) 1500 rpm 750 Hz 750 Hz High idle High idle 2500 rpm 2500 rpm...
Page 35: Ford Engine Models
May 2020 Maintenance Manual Engine Specifications Ford Engine Models 854F-E34T Low idle (standby) 1000 rpm DSG-423 (SX-105 XC, SX-125 XC, SX- 500 Hz 135 XC, SX-150, SX-180, Z-135, Low idle 1600 rpm ZX-135) 53.3 Hz High idle 2500 rpm 100/105/120/125/100HD/120HD) 83.3 Hz Low idle (with function enable) 1500 rpm...
Page 36: Kubota Engine Models
Maintenance Manual May 2020 Engine Specifications Kubota Engine Models WG-972 Low idle 1600 rpm D1105-E3B 266.7 Hz Low idle 1250 rpm High idle 3000 rpm 208.3 Hz 500 Hz High idle 3000 rpm Oil capacity (including filter) 3 quarts 500 Hz 2,8 liters Oil capacity (including filter) 5.4 quarts...
Page 37: Gm Engine Models
May 2020 Maintenance Manual Engine Specifications GM Engine Models Continental Engine Models .998L TME27 Low idle 1100 rpm Low idle 1600 rpm 36.6 Hz 53.3 Hz High idle 3000 rpm High idle 2500 rpm 100 Hz 83.3 Hz Oil capacity (including filter) Oil capacity (including filter) 3.2 quarts 7 quarts...
Page 38: Cummins Engine Models
Maintenance Manual May 2020 Engine Specifications Cummins Engine Models B3.3T Low idle 1300 rpm 229.7 Hz High idle 2350 rpm 415 Hz Oil capacity (including filter) 9 quarts 8,5 liters Engine coolant capacity 9.1 quarts 10,1 liters Fan belt deflection 0.375 to0.5 inches 9 to12 mm Unit ships with 15W-40.
Page 39: Hydraulic Specifications
May 2020 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 2600 psi 2200 psi...
Page 40 Maintenance Manual May 2020 Hydraulic Specifications System Primary Secondary Secondary Primary Secondary Turntable Proportional Platform Model relief boom boom boom up boom boom rotate relief level down down extend extend 3000 psi 1600 psi 1600 psi 1800 psi 1100 psi Z-30N, Z-30N RJ 207 bar 110 bar...
Page 41 May 2020 Maintenance Manual Hydraulic Specifications Traction and Steer/Axle Manifolds, and Oscillate Relief Valve Pressure / Bar Hot oil relief valve Model Oscillate relief Axle extend pressure S-40, S-45 280 psi 950 psi (all models) 19,3 bar 66 bar 280 psi 850 psi S-40HF, S-45HF, S-40XC, S-45XC 19,3 bar...
Page 42: Hydraulic And Drive Hub Fluid Capacities
Maintenance Manual May 2020 Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Hydraulic tank Hydraulic system Model Drive hub Drive hub rotation drive (including tank) 20 fl oz 20 fl oz 8 fl oz...
Page 43 May 2020 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) 25.5 fl oz 8 gallons 11 gallons Z-45/25, Z-45/25J EW1 type 17 fl oz 750 cc 30 liters 41 liters...
Page 44: Hydraulic Oil Specifications
Maintenance Manual May 2020 Hydraulic Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. 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 45 May 2020 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 46 Maintenance Manual May 2020 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 47: Hydraulic Hose And Fitting Torque Specifications
May 2020 Maintenance Manual Hydraulic Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) 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...
Page 48: Torque Procedure
Maintenance Manual May 2020 Hydraulic Specifications JIC 37° fittings Torque Procedure Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
Page 49 May 2020 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 50: Maintenance Procedures
Maintenance Manual May 2020 Maintenance Procedures Secti on 3 Maint enan ce Pro ced ures Machine Configuration:  Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface Observe and Obey: •...
Page 51 May 2020 Maintenance Manual Maintenance Procedures Maintenance Symbols Legend About This Section Note: The following symbols have been used in This section contains detailed procedures for each this 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 52: Maintenance Schedule
Maintenance Manual May 2020 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 53: Pre-Delivery Preparation Report
May 2020 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 54: Scheduled Maintenance Inspection Report - Quarterly Or Frequent
May 2020 Scheduled - Quarterly Maintenance Inspection Report – Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Y = yes, N = no, remove from service Make copies of this report to use for each Inspection Type Legend inspection.
Page 55: Scheduled Maintenance Inspection Report - Annual
May 2020 Scheduled - Annual Maintenance Inspection Report – Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection. Inspection Type Legend Select the appropriate procedures for the type of...
Page 56: Programmed Maintenance Inspection Report - Booms
May 2020 Programmed 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 Make copies of this report to use for each Legend hours.
Page 57: Commissioning Procedures
May 2020 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 58: Perform 150 Hour Service
Maintenance Manual May 2020 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 59: Quarterly Maintenance Procedures
May 2020 Maintenance Manual Quarterly Maintenance Procedures Machines purchased in ASIA, North America and Latin America: Check for Open Bulletins and Go to ASIA, North America and Latin America Owner Registration Bulletins (https://www.gogenielift.com/) Genie specifications require that this procedure be performed quarterly.
Page 60: Battery Inspection
Maintenance Manual May 2020 Quarterly Maintenance Procedures Models without maintenance-free or sealed batteries: 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.
Page 61 May 2020 Maintenance Manual Quarterly Maintenance Procedures Perform an equalizing charge OR fully charge the battery(s) and allow the battery(s) to rest at least 6 hours. Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer.
Page 62: Inspect The Electrical Wiring
Maintenance Manual May 2020 Quarterly Maintenance Procedures • Cable tracks Inspect the Electrical Wiring • Cables on the primary, secondary and jib booms • Jib boom/platform rotate manifold • Inside of the platform control box Genie specifications require that this procedure be performed quarterly.
Page 63: Inspect The Electrical Contactors - Dc / Bi-Energy Models
May 2020 Maintenance Manual Quarterly Maintenance Procedures From serial numbers Inspect the Electrical Contactors Z-45 DC / FE models Z45EM-101 Z6016N-101 Z-60 DC / FE models - DC / Bi-Energy Models Z60H-701 Z60M-101 Open the turntable cover and remove the fuse Genie specifications require that this procedure be box cover.
Page 64: Check The Exhaust System
Maintenance Manual May 2020 Quarterly Maintenance Procedures Visually inspect the contact points of the contactor for the following items: Check the Exhaust System • Excessive burns Genie specifications require that this procedure be • Excessive arcs performed quarterly. • Excessive pitting Maintaining the exhaust system is essential to good engine performance and service life.
Page 65: Inspect The Tires, Wheels And Lug Nut Torque
May 2020 Maintenance Manual Quarterly Maintenance Procedures Inspect the Tires, Wheels and Check the Generator Belts, Lug Nut Torque Pulleys and voltage - Bi-Energy Models Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly.
Page 66 Maintenance Manual May 2020 Quarterly Maintenance Procedures Check to be sure the engine pulley and the Check the generator belts for proper tension. generator pulley are aligned within If the belt deflection is not within specification, specification using a straightedge. Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine, How to Adjust the Generator Belts.
Page 67: Check The Oscillate Directional Valve Linkage (If Equipped)
May 2020 Maintenance Manual Quarterly Maintenance Procedures Check the Oscillate Directional Visual Inspection of the Hydraulic Valve Linkage (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed quarterly. performed quarterly. Note: Perform this test only on models equipped Replacement or testing of the hydraulic oil is with an oscillating axle.
Page 68: Inspect The Hydraulic Filters
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-10 Collect a sample of hydraulic oil and place in a clear container. Visually inspect the Inspect the Hydraulic Filters hydraulic oil for the following: Genie specifications require that this procedure be • Color: oil should be a clear, light-honey performed quarterly.
Page 69: Check And Adjust The Engine Rpm
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-11 Models without Filter Condition Indicator: Check and Adjust the Engine Note: Models without a filter condition indicator cannot be inspected. At the required maintenance interval, replace the filters. Hydraulic Tank Cap (if equipped): Remove the breather cap from the hydraulic Engine specifications require that this procedure tank.
Page 70 Maintenance Manual May 2020 Quarterly Maintenance Procedures Models with ALC-600 operating system: Models with ALC-1000 operating system: Note: Use the following chart to identify the Note: Use the following chart to identify the description of each LCD screen control button description of each LCD screen control button used in this procedure.
Page 71 May 2020 Maintenance Manual Quarterly Maintenance Procedures Tighten the lock nut. Kubota WG-972: Low rpm idle adjustment: Loosen the core clamp screw so the cable moves freely. Hold the throttle lever against the low idle adjustment screw. Turn the adjustment screw clockwise to increase low rpm or counterclockwise to decrease low rpm.
Page 72 Maintenance Manual May 2020 Quarterly Maintenance Procedures Kubota Z482-E 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. Tighten the lock nut.
Page 73 May 2020 Maintenance Manual Quarterly Maintenance Procedures Deutz TD2011L04i Perkins 403D-11 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 1 high idle solenoid 4 low idle adjustment screw 2 high idle adjustment nut 3 low idle adjustment screw ®...
Page 74 Maintenance Manual May 2020 Quarterly Maintenance Procedures Perkins 1104D-44T Perkins 404D-22 1 low idle adjustment screw 2 lock nut 3 high idle adjustment screw 4 high idle solenoid 1 high idle solenoid 2 high idle adjustment nut Cummins B3.3T 3 lock nut 4 low idle adjustment screw Perkins 804D-33 1 low idle adjustment screw...
Page 75: Test The Ground Control Override
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-12 Q-13 Test the Ground Control Override Test the Alarm Package (if equipped) Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. A properly functioning ground control override is essential to safe machine operation.
Page 76: Test The Emergency Power System
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-14 All Models: Test the Emergency Power Activate the boom down function, hold for a moment and then release it. System (excludes ALC-600 and ALC-1000 Result: The descent alarm should sound when the down function is activated. Models) Complete this step for each boom that applies: Primary, Secondary and Jib Booms.
Page 77: Test The Engine Idle Select - Engine Models
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-15 Push and release the rpm select button until low rpm is selected (turtle symbol). Test the Engine Idle Select Result: The engine should return to low idle. Operation - Engine Models Genie specifications require that this procedure be performed quarterly.
Page 78: Test The Fuel Select Operation - Gasoline/Lpg Models
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-16 All other models: Test the Fuel Select Operation - Pull out the red Emergency Stop button to the on position at both the ground and platform Gasoline/LPG Models controls. Start the engine from the ground controls. Move the rpm select toggle switch to the high Genie specifications require that this procedure be idle (rabbit symbol) position and activate...
Page 79: Inspect The Calibration Decal - Alc1000 Models
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-17 Move the fuel select switch to LPG. Inspect the Calibration Decal - Restart the engine and allow it to run at low idle. ALC-1000 Models Press down the foot switch to allow the Genie specifications require that this procedure be engine to run at high idle.
Page 80: Test The Recovery Mode System - Alc-1000 Models
Maintenance Manual May 2020 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 operator in the platform is unable to lower the platform using the platform controls, system failure or emergency situations.
Page 81 May 2020 Maintenance Manual Quarterly Maintenance Procedures Remove the key from the main key switch and insert the key into the bypass/recovery key switch. 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 before serial number Z13512-1712.
Page 82: Test The Platform Self-Leveling
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-19 Q-20 Test the Platform Self-leveling Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed quarterly. Genie specifications require that this procedure be performed quarterly. ALC-1000 Models: Proper brake configuration is essential to safe Automatic platform self-leveling throughout the full operation and good machine performance.
Page 83: Test The Drive Brakes
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-21 Q-22 Test the Drive Speed – Stowed Test the Drive Brakes Position 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.
Page 84: Test The Drive Speed - Raised Or Extended Position
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-23 Continue at full speed and note the time when Test the Drive Speed – Raised or the machine reference point crosses the finish line. Refer to Specifications, Drive Speed Extended Position Specifications. Lower the boom to the stowed position and extend the primary boom 4 feet / 1.2 m.
Page 85: Test The Drive Speed - Raised And Extended, Alc1000 Models
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-24 SX-150 and SX-180 Test the Drive Speed – Raised Note: This procedure will require 2 people to perform. and Extended Position, ALC1000 Models Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. Access the MACHINE STATUS menu on the ground control box and scroll down until Genie specifications require that this procedure be...
Page 86: Test The Turntable Level Sensor
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-25 Z-80/60, Z-135/70 and ZX-135/70 Test the Turntable Level Sensor - Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart. Z-80/60, Z-135/70, ZX-135/70, SX- 105XC, SX-125XC, SX-135XC, SX- Press down the foot switch and raise the primary boom greater than 10 degrees and...
Page 87 May 2020 Maintenance Manual Quarterly Maintenance Procedures Note: Use the following chart to identify the Note: Perform this procedure with the booms in description of each LCD screen control button the fully stowed position and the axles fully used in this procedure. extended.
Page 88 Maintenance Manual May 2020 Quarterly Maintenance Procedures Turn the key switch to ground control and pull Place a digital level that has been calibrated out the red Emergency Stop button to the on to gravity on the Y axis of the turntable. position at both ground and platform controls.
Page 89: Test The Secondary Boom Angle Sensor - Z-135/70 And Zx-135/70
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-26 Press the plus and minus buttons at the same time on the LCD screen to enter the Test the Secondary Boom Angle MACHINE STATUS screen. Press the enter Sensor - Z-135/70 and ZX-135/70 or previous button until SECONDARY BOOM ANGLE is displayed.
Page 90 Maintenance Manual May 2020 Quarterly Maintenance Procedures Lower the secondary boom to 65°. 10 Lower the secondary boom to 20°. 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 65°. level is within ±...
Page 91: Test The Primary Boom Angle Sensor - Z-135/70 And Zx-135/70
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-27 Note: Use the following chart to identify the description of each LCD screen control button Test the Primary Boom Angle used in this procedure. Sensor - Z-135/70 and ZX-135/70 Genie specifications require that this procedure be performed quarterly.
Page 92 Maintenance Manual May 2020 Quarterly Maintenance Procedures Raise the primary boom while watching the Lower the primary boom to -50°. display screen. Result: The reading at the display and digital Continue to raise the primary boom until it level is within ± 2° of each other and of -50°. stops at approximately 58°.
Page 93: Test The Primary Boom Angle Sensor
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-28 10 Raise the primary boom to 10°. Test the Primary Boom Angle Result: The reading at the display and digital level is within ± 2° of each other and of 10°. Sensor - SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180 Result: The reading at the display and digital level is greater than ±...
Page 94 Maintenance Manual May 2020 Quarterly Maintenance Procedures SX-105XC and SX-125XC Lower the primary boom to 57°. 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 95 May 2020 Maintenance Manual Quarterly Maintenance Procedures SX-135XC Lower the primary boom to 23°. 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 96 Maintenance Manual May 2020 Quarterly Maintenance Procedures Lower the primary boom to 59°. Lower the primary boom to 25°. 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 59°. level is within ±...
Page 97 May 2020 Maintenance Manual Quarterly Maintenance Procedures SX-150 and SX-180 Lower the primary boom to 66°. 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 98: Test The Safety Envelope Limit Switches - Z-135/70, Zx-135/70,
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-29 Lower the primary boom to 32°. Test the Safety Envelope Limit Result: The reading at the display and digital level is within ± 2° of each other and of 32°. Switches, Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX-135XC, Result: The reading at the display and digital level is greater than ±...
Page 99 May 2020 Maintenance Manual Quarterly Maintenance Procedures Z-135/70 and ZX-135/70 Models: Connect the leads from a multimeter with continuity checking capability to pins 1 and Secondary Boom #1 Retracted Safety Limit 2 at the Deutsch connector of the limit switch Switch, LSS1RS cable.
Page 100 Maintenance Manual May 2020 Quarterly Maintenance Procedures Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX- 13 Locate and disconnect the Deutsch connector 135XC, SX-150 and SX-180 Models to LSS1RS. Result: The alarm should sound. Turntable Rotate Safety Limit Switch, LST1S Result: The LCD screen should display the Locate the turntable rotate safety limit switch message SEC BOOM RETRACTED SAFETY (LST1S) at the center of the turntable.
Page 101 May 2020 Maintenance Manual Quarterly Maintenance Procedures Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX- 10 Choose an axle extend safety limit switch to 135XC, 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 102: Test The Primary Boom Angle Sensor - Z-80/60
Maintenance Manual May 2020 Quarterly Maintenance Procedures Q-30 Start the engine from the ground controls. Test the Primary Boom Angle 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°.
Page 103: Test The Safety Envelope And Circuits - Z-80/60
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-31 Locate the Deutsch connectors from the secondary safety retract switch (LSS1RS) Test the Safety Envelope and near the chassis at the platform end of the 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.
Page 104 Maintenance Manual May 2020 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 secondary boom above 60°...
Page 105: Check The Safety Envelope Limit Switches And Angle Sensor - S-60X, S-80X, And S-60Xc To S60Xc-45000
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-32 Turn and hold the function enable switch to the restricted maximum platform capacity and Check the Safety Envelope Limit raise the primary boom until it is fully Switches and Angle Sensor - S- elevated.
Page 106 Maintenance Manual May 2020 Quarterly Maintenance Procedures Platform controls: Measuring Tape: S-60X and S-60XC Models: Note: Start this procedure with the boom fully retracted and in the stowed position. Measure the distance between the center of the pivot pins as shown. The distance should Pull out the red Emergency Stop button to the be 171 inches / 434 cm ±...
Page 107: Test The Safety Envelope And Circuits
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-33 Move the primary boom down joystick off center and retract the primary boom until the Test the Safety Envelope and unrestricted platform capacity light stops Circuits - S-100, S-105, S-120, S- flashing. 125, S-100HD and S-120HD Result: Primary boom down should return to normal operation.
Page 108 Maintenance Manual May 2020 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 109 May 2020 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 110 Maintenance Manual May 2020 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 111 May 2020 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 the axle extend proximity switch LSAX1EO 45°...
Page 112 Maintenance Manual May 2020 Quarterly Maintenance Procedures 63 Disconnect the circle-end axle extend safety 68 Remove the wire jumper installed in step switch LSAX1ES and install a wire jumper 63 and connect the Deutsch connector to between pin 1 and pin 2 of the Deutsch LSAX2ES.
Page 113: Test The Aircraft Protection System (If Equipped)
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-34 All Models: Test the Aircraft Protection Move the yellow bumper at the bottom of the platform 4 inches/10 cm in any direction. System (if equipped) Genie specifications require that this procedure be performed quarterly.
Page 114 Maintenance Manual May 2020 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 / 1 m. toggle 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 115: Test The Operator Protection Alarm (If Equipped)
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-35 Q-36 Test the Operator Protection 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.
Page 116: Test The Recovery Mode System - Alc-600 Models
Maintenance Manual May 2020 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 operator in the platform is unable to lower the platform using the platform controls, system failure or emergency situations.
Page 117: Test The Turntable Level Sensor - S-40Hf, S-45Hf, S-40Xc, S-45Xc, S- 60Hf, S-65Hf, S-60J, S-60Xc From S60Xch-45001, S-65Xc
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-38 Note: Use the following chart to identify the description of each LCD screen control button Test the Turntable Level Sensor - used in this procedure. S-40HF, S-45HF, S-40XC, S-45XC, S-60HF, S-65HF, S-60J, S-60XC from S60XCH-45001, S-65XC, S- 80HF, S-85HF, S-80XC, S-85XC.
Page 118 Maintenance Manual May 2020 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 119: Test The Primary Boom Angle Sensor - S-40Hf, S-45Hf, S-40Xc
May 2020 Maintenance Manual Quarterly Maintenance Procedures Q-39 Place a digital level that has been calibrated to gravity on the Y axis of the turntable. Test the Primary Boom Angle Result: The reading at the display and digital Sensor - S-40HF, S-45HF, S-40XC, level is within ±...
Page 120 Maintenance Manual May 2020 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 position while watching the display screen. used in this procedure. Result: The reading at the display and digital level is within ±...
Page 121: Annual Maintenance Procedures
May 2020 Maintenance Manual Annual Maintenance Procedures Models with Worm Drive Gear: Grease the Turntable Rotation 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 122: Check The Turntable Rotation Bearing Bolts
Maintenance Manual May 2020 Annual Maintenance Procedures Raise the boom and remove the safety chock OR lifting device. Check the Turntable Rotation Lower the boom to the stowed position. Bearing Bolts Using a star pattern, confirm that each lower bearing mounting bolt is torqued in sequence to specification.
Page 123 May 2020 Maintenance Manual Annual Maintenance Procedures Torque Torque Model and Serial Range Model and Serial Range ft-lbs / Nm ft-lbs / Nm Z-30N, Z-30N RJ Z-60DC, Z-60FE to Z30N16F-17573 210 / 285 from Z60M-101 180 / 244 to Z30ND-329 from Z6016N-101 from Z60H-701 from Z30N16F-17574...
Page 124: Inspect For Turntable Bearing Wear
Maintenance Manual May 2020 Annual Maintenance Procedures Place a dial indicator between the drive chassis and the turntable at a point that is Inspect for Turntable Bearing directly under, or inline with, the boom and no Wear more than 1 inch / 2.5 cm from the bearing. Note: To obtain an accurate measurement, place the dial indicator no more than 1 inch / 2.5 cm from the turntable rotation bearing.
Page 125: Check The Extendable Axle - S-100, S-105, S-120 And S-125
May 2020 Maintenance Manual Annual Maintenance Procedures Note the reading on the dial indicator. Check the Extendable Axle - S- Result: The measurement is less than specification. The bearing is good. 100, S-100HD, S-105, S-120, S- 120HD and S-125 Result: The measurement is more than specification.
Page 126: Perform Maintenance- Jib Rotate Bearing
Maintenance Manual May 2020 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 127: Test The Bypass/Recovery Key Switch - Alc1000 Models
May 2020 Maintenance Manual Annual Maintenance Procedures 10 Note the reading on the dial indicator. Test the Key Switches - ALC1000 Result: The measurement is less than 0.063 inch / 1,6 mm. The bearing is good. Models Result: The measurement is more than Genie specifications require that this procedure be 0.063 inch / 1,6 mm.
Page 128 Maintenance Manual May 2020 Annual Maintenance Procedures a safe position when the safety switches have Note: Perform this procedure on a firm, level been tripped. surface with the machine in the stowed position. Open the ground controls side turntable side cover.
Page 129: Grease The Platform Overload Mechanism (If Equipped)
May 2020 Maintenance Manual Annual Maintenance Procedures 11 Raise the primary boom 3 ft / 1 m. Grease the Platform Overload Result: The primary boom should raise. Mechanism (if equipped) 12 Remove the key from the bypass/recovery key switch and insert the key into the main key switch.
Page 130: Test The Platform Overload System - All Models
Maintenance Manual May 2020 Annual Maintenance Procedures Engine Models: Turn the key switch to ground control and pull out the red Test the Platform Overload Emergency Stop button to the on position at System - All Models (if equipped), both the ground and platform controls. Start (excludes ALC1000, S-40HF, S- the engine from the ground controls and level the platform.
Page 131 May 2020 Maintenance Manual 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 132: Test The Platform Overload System - Alc1000 Models
Maintenance Manual May 2020 Annual Maintenance Procedures Using a suitable lifting device, place a test weight equal to that of the available capacity Test the Platform Overload in one of the locations shown. Refer to System - ALC1000 Models Illustration 1. Result: The platform overload indicator light should be off at platform controls and there should be no error message displayed at the...
Page 133: Test The Platform Load Sense System - S-60 Hc
May 2020 Maintenance Manual Annual Maintenance Procedures A-10 Carefully move the test weights to each remaining location on the platform. Refer to Test the Platform Load Sense Illustration 1. System - S-60 HC Result: The platform overload indicator light is on at the platform and PLATFORM OVERLOAD displayed at the ground control LCD screen.
Page 134: Inspect The Boom Extend/Retract Cables And Sheaves
Maintenance Manual May 2020 Annual Maintenance Procedures A-11 Start the engine from the ground controls. Inspect the Boom Extend/Retract Using a suitable lifting device, place an appropriate test weight equal to 340,2 kg on Cables and Sheaves - S- to the center of the platform floor. 60/65 and S-80/85 (includes HF, Result: The amber restricted range of motion X, XC and TraX models)
Page 135 May 2020 Maintenance Manual Annual Maintenance Procedures This maintenance procedure applies to the Visually inspect the cables, sheaves and following models: S-60, S-65, S-60 TraX, S-65 related components through the inspection TraX, S-60HC, S-60HF, S-65HF, S-60X, S-60XC, holes for the following: S-65XC, S-80, S-85, S-80X, S-80HF, S-85HF, S- •...
Page 136: Inspect The Boom Extend/Retract Cables And Sheaves - S-100, S-105, S-120, S-125, Sx-105Xc And Sx-125Xc
Maintenance Manual May 2020 Annual Maintenance Procedures A-12 S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, S-65XC, S-60 TraX and S-65 TraX, S-80, S- Inspect the Boom Extend/Retract 85, S-80X, S-80HF, S-85HF, S-80XC, S- Cables and Sheaves - S-100, S- 85XC: Install the cover at the pivot end of the boom.
Page 137 May 2020 Maintenance Manual Annual Maintenance Procedures Remove the boom end cover from the pivot Visually inspect the cables, sheaves and end of the boom. related components through the inspection holes for the following: • Frayed or broken wire strands •...
Page 138: Inspect The Boom Extend And Retract Cables And Sheaves -
Maintenance Manual May 2020 Annual Maintenance Procedures A-13 Install the plastic cover at the pivot end of the boom and access panels on the sides of the Inspect the Boom Extend/Retract boom. Cables and Sheaves - SX-135XC, Start the engine from the platform controls. SX-150 and SX-180 Models Extend the boom approximately 2 feet / 0.6 m.
Page 139 May 2020 Maintenance Manual Annual Maintenance Procedures SX-135XC 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 140 Maintenance Manual May 2020 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 141 May 2020 Maintenance Manual 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 142: Check The Drive Hub Oil Level And Fastener Torque
Maintenance Manual May 2020 Annual Maintenance Procedures A-14 Install the plug(s) into the drive hub. Check the Drive Hub Oil Level Check the torque of the drive hub mounting fasteners. Refer to Torque Specifications, and Fastener Torque Tires and Wheels. Repeat this procedure for each drive hub.
Page 143 May 2020 Maintenance Manual Annual Maintenance Procedures Models with TraX: Attach a lifting strap from an overhead crane (2000 lbs / 1000 kg) to the center-point of the Select the drive hub to be serviced. Loosen track assembly, above the sprocket. and remove as many sprocket retaining fasteners as possible from the hub adapter.
Page 144 Maintenance Manual May 2020 Annual Maintenance Procedures Turntable rotate drive hub: 10 Remove the plug located at 90 degrees and check the oil level. Remove the plug located on the side of the Result: The oil level should be even with the hub and check the oil level and check the oil bottom of the plug hole.
Page 145 May 2020 Maintenance Manual Annual Maintenance Procedures Torque values are listed as dry. The retaining Torque Model and Serial Range ft-lbs / Nm fasteners must be coated with a mineral based lubricant when removed. If a retaining fastener is S-80, S-80HF, S-80X, S-80XC, S-85, S-85HF, S-85XC removed, the torque value is reduced.
Page 146: Test The Dual Capacity And Platform Overload System - Sx-105Xc, Sx-125Xc And Sx-135Xc
Maintenance Manual May 2020 Annual Maintenance Procedures A-15 Torque Model and Serial Range ft-lbs / Nm Test the Dual Capacity and Z-51 Platform Overload System - SX- to Z513014B-1517 113 / 153 105XC, SX-125XC and SX-135XC to Z5130M-2035 from Z5130M-2036 106 / 143 Models Z-60DC, Z-60FE...
Page 147 May 2020 Maintenance Manual 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 148: Test The Dual Capacity And Platform Overload System - Z-45Xc Models
Maintenance Manual May 2020 Annual Maintenance Procedures A-16 Start the engine and extend the primary boom. Test the Dual Capacity and Result: The primary boom should fully extend Platform Overload System - and retract. Z-45XC Models Add an additional 150 lbs / 68 kg to the platform.
Page 149: S-65Xc, S-80Hf, S-85Hf, S-80Xc, S-85Xc
May 2020 Maintenance Manual Annual Maintenance Procedures A-17 Using a suitable lifting device, remove all test weights from the platform. Test the Dual Capacity and Result: There is no audible alarm. The Platform Overload System - S- platform overload indicator light should turn 40XC, S-45XC, S-60HF, S-65HF, off at the ground controls.
Page 150 Maintenance Manual May 2020 Annual Maintenance Procedures Remove all weight, tools, accessories and Add additional weight to the platform. equipment from the platform. S-80HF, S-85HF models: 370 lbs / 168 kg. Note: Failure to remove all weight, tools and All other models: 320 lbs / 145 kg. accessories from the platform will result in an inaccurate test.
Page 151: Test The Platform Overload System - S-40Hf, S-45Hf, Z-45Hf, Z-45 Dc/Fe From Z45Em-101
May 2020 Maintenance Manual Annual Maintenance Procedures A-18 Using a suitable lifting device, place an appropriate test weight equal to that of the Test the Platform Overload maximum platform capacity at the center of System - the platform floor. S-40HF, S-45HF, S-60J, Z-45HF, Note: The test weight may be within -0% / +5%.
Page 152: Perform Engine Maintenance
Maintenance Manual May 2020 Annual Maintenance Procedures A-19 A-20 Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this procedure Engine specifications require that this procedure be performed annually. be performed every two years. Required maintenance procedures and additional Required maintenance procedures and additional engine information are available in the engine information are available in the...
Page 153 May 2020 Maintenance Manual Programmed Maintenance Procedures P0-1 Visually inspect the section of track under the bogey wheels. Check the Track Tension and Result: There is less than 1 inch / 2,5 cm of Fastener Torque, TraX Models - gap between the bogey wheels and the inside S-60, S-65, S-60XC, S-65XC and surface of the track.
Page 154 Maintenance Manual May 2020 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, S-45, S-40XC, S-45XC comes out of the grease plug.
Page 155 May 2020 Maintenance Manual 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 is less than 1 inch / 2,5 cm of 0.75 - 1 inch / 1,9 - 2,5 cm of gap between the gap between the bogey wheels and the inside...
Page 156 Maintenance Manual May 2020 Programmed Maintenance Procedures P0-3 Grease the Extendable Axles - S- 100, S-105, S-120, S-125, S100HD and S-120HD Manufacturer specifications require that this procedure be performed every 50 hours. Lubricating the front and rear axles helps to ensure the smooth operation of the axles over the lifetime of the product.
Page 157 May 2020 Maintenance Manual 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 158 Maintenance Manual May 2020 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 159 May 2020 Maintenance Manual 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 160 Maintenance Manual May 2020 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 161 May 2020 Maintenance Manual 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 162 Maintenance Manual May 2020 Programmed Maintenance Procedures Kubota Engines, continued Hour Intervals  = Not required Daily       500  Procedure         Fuel/Water separator - replace, D1803  ...
Page 163 May 2020 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 164 Maintenance Manual May 2020 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 165 May 2020 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 166 Maintenance Manual May 2020 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 •...
Page 167 May 2020 Maintenance Manual Programmed Maintenance Procedures Perkins Models All Models: • Alternator and fan belts - replace • Engine valve lash – inspect/adjust • Engine crankcase breather - replace 403D-11, 404F-22 • Turbocharger - inspect 804D-33 • Alternator - inspect •...
Page 168 Maintenance Manual May 2020 Programmed Maintenance Procedures P1-2 Drive the machine until one of the two plugs is at the highest point. Replace the Drive Hub Oil Drive hub specifications require that this procedure be performed after the first 50 hours of operation. After the initial oil replacement, specifications require that this procedure be performed every 1000 hours.
Page 169 May 2020 Maintenance Manual Programmed Maintenance Procedures Locate the hub disconnect pin in the center of Models with TraX: the drive hub. Manually depress the pin and Select the drive hub to be serviced. Loosen rotate the drive hub until one of the two plugs and remove as many sprocket retaining is at the lowest point.
Page 170 Maintenance Manual May 2020 Programmed Maintenance Procedures 16 Raise the machine, remove the jack stands Remove the drive hub mounting bolts from lower the machine. the drive hub assembly. Carefully remove the turntable rotate drive hub assembly from the 17 Drive the machine in either direction just until machine.
Page 171 May 2020 Maintenance Manual P1-3 P2-1 Perform Engine Maintenance – Perform Engine Maintenance – 1500 Hours 2000 Hours Engine specifications require that this procedure Engine specifications require that this procedure be performed every 1500 hours. be performed every 2000 hours. Required maintenance procedures and Required maintenance procedures and additional engine information are available in the...
Page 172 Maintenance Manual May 2020 Deutz Models Kubota Models All Models: Z482-E, D1105, WG972 • V-Belts - replace • Radiator coolant (L.L.C.) - replace • Battery - replace D436 L3i, D2011, TD2011 • Glow plugs - replace • Radiator hoses and clamp bands - replace TD 2.2 L3, TCD 2.2 L3, D 2.9 L4, TD 2.9 L4 •...
Page 173 May 2020 Maintenance Manual P2-2 Testing the oil: Test or Replace the Hydraulic Complete the hydraulic oil testing with an oil distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must be tested every quarter by an oil Genie requires that this procedure be performed distributor until the oil fails the test and is every 2000 hours.
Page 174 Maintenance Manual May 2020 P2-3 Push the filter element down to be sure the O-ring on the element is fully seated into the 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.
Page 175 May 2020 Maintenance Manual Medium and high pressure filters Case drain filter: Note: The medium pressure filter is for the Note: The case drain filter is for the charge charge pump and the high pressure filter is for pump. all machine functions except the drive circuit and Open the engine side turntable cover and oscillating axle circuit.
Page 176 Maintenance Manual May 2020 P2-4 Lift the wheels or tracks off the ground and then place jack stands under the drive Check the Free-wheel chassis for support. Configuration Disengage the drive hubs by turning over the drive hub disconnect caps on each non- steer / circle-end wheel hub.
Page 177 May 2020 Maintenance Manual Steer or Square-end wheels: 4WD Models 12 Re-engage the drive hubs by turning over the hub disconnect caps. Rotate each Chock the non-steer / circle-end wheels or wheel or track to check for engagement. tracks to prevent the machine from rolling. Raise the machine, remove the jack stands Models with 2 wheel steer: Center a lifting and lower the machine.
Page 178 Maintenance Manual May 2020 P2-5 S-40, S-45, S-40HF, S-45HF, S-40XC, S45XC, S-60, S-65, S-60HF, S-65HF, S-60J, S-60X, S- Check the Boom Wear Pads 60XC, S-65XC Boom wear pad specifications Minimum Top and side wear pads 0.50 inch Genie requires that this procedure be performed (platform end of boom) 12,7 mm every 2000 hours.
Page 179 May 2020 Maintenance Manual SX-105XC, SX-125XC, SX-135XC, SX-150, SX- Z-33/18 Primary boom wear pad Minimum specifications Primary boom wear pad specifications Minimum Top wear pads 0.6875 inch Platform end (platform end of boom) 17,46 mm Bottom and side wear pads 0.63 in Side wear pads 0.5625 inch...
Page 180 Maintenance Manual May 2020 Z-45/25 (J) IC, BE, DC, Z-45 DC/FE, Z-45XC, Z- Z-135/70, ZX-135/70 51/30J Note: The minimum shim clearance for the secondary boom wear pads is 0.070 inch / Primary boom wear pad specifications Minimum 1,8 mm and the maximum allowable shim Top, bottom and side wear pads 0.625 inch clearance is 0.25 inch / 6,4 mm.
Page 181 May 2020 Maintenance Manual P2-6 P2-7 Check the Extendable Axle Check the Turntable Rotation Wear Pads - S-100, S-105, S-120, Gear Backlash - ALC1000 S-125, S-100HD and S-120HD Models Genie requires that this procedure be performed every 2000 hours. Genie requires that this procedure be performed Properly adjusted turntable rotation gear every 2000 hours.
Page 182 Maintenance Manual May 2020 P2-8 S-100, S-100HD, S-105, S-120, S-120HD and S-125 Grease the Steer Axle Wheel Result: The gap is between 0.010 inch / Bearings, All 2WD Models 0,254 mm and 0.022 inch / 0,559 mm. The (except S-60, S-65, Z-60 DC/FE backlash is within tolerance.
Page 183 May 2020 Maintenance Manual Remove the dust cap from the hub. 15 Place the large inner bearing into the rear of Remove the cotter pin from the castle nut. the hub. Tighten the castle nut to specification, to 16 Install a new bearing grease seal into the seat the bearings.
Page 184 Maintenance Manual May 2020 P2-9 Check for wheel bearing wear by attempting to move the wheel hub side to side, then up Grease the Steer Axle Wheel and down. Bearings, 2WD Models - Result: If there is no side to side or up and S-60, S-65, Z-60 DC/FE and Z-62 down movement, continue with step 10 and grease the wheel bearings.
Page 185 May 2020 Maintenance Manual 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 186 Maintenance Manual May 2020 Perkins Models Kubota Models 403D-11, 403F-11, 404D-22, 404F-22, Z482-E, D1105 404F-22T, 804D, 1104D-44T • Turbocharger - inspect • Water pump - inspect • Injection pump - check • Fuel Injector - test/change • Fuel injection timing - check •...
Page 187 May 2020 Maintenance Manual P4-1 P5-1 Perform Engine Maintenance – Perform Engine Maintenance – 4000 Hours 5000 Hours Engine specifications require that this procedure Engine specifications require that this procedure be performed every 4000 hours. be performed every 6,000 hours. Required maintenance procedures and Required maintenance procedures and additional engine information are available in the...
Page 188 Maintenance Manual May 2020 P6-1 P12-1 Perform Engine Maintenance – Perform Engine Maintenance – 6000 Hours 12000 Hours Engine specifications require that this procedure Engine specifications require that this procedure be performed every 6,000 hours. be performed every 12000 hours. Required maintenance procedures and Required maintenance procedures and additional engine information are available in the...
Page 189 May 2020 Maintenance Manual P12-2 Remove the boom extend and retract cables. Refer to the appropriate Service and Remove and Inspect the Boom Repair Manual for repair procedure, How to Extend/Retract Cables Replace the Boom Extend/Retract Cables. Inspect the sheaves for the following: •...
Page 190 Maintenance Manual May 2020 correct incorrect Inspect the cables for the following: Cable Diameter Specifications • Frayed or broken wire strands Nominal Minimum Model • Kinks or crushed cables Diameter Diameter • Corrosion S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, S- 65XC, S-80, S-85 and S-80X (includes TraX™...
Page 191 May 2020 Maintenance Manual Cable Re place men t Crit eria 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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Terex Genie S-40 Maintenance Manual

Safety Rules

Performance Specifications

Torque Specifications

Engine Specifications

Hydraulic Specifications

Maintenance Procedures

Commissioning Procedures

Quarterly Maintenance Procedures

Annual Maintenance Procedures

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