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. Refer to the inside cover for a list of models Part No.
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
March 2022 Maintenance Manual Introduction Models included in this manual SX-105 XC from SX105D-101 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. SX-150 from SX15015-100 to SX15016H-499 from SX150H-500 Models Serial number...
Page 4 Maintenance Manual March 2022 Introduction Z-30/20N, Z- from Z30N14-15222 to Z30N16F-18899 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199 from Z30N16D-104 to Z30N16D-199 from Z4525N-57200 to Z4525N-58604 30/20N RJ 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
March 2022 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 March 2022 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 March 2022 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 3/2022 All Sections Add S80J model Annual...
Page 8: Safety Rules
Maintenance Manual March 2022 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 March 2022 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
March 2022 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 March 2022 Table of Contents Section 3 Maintenance Procedures ................35 Introduction ...................... 35 Maintenance Schedule ..................37 Pre-Delivery Preparation Report ............... 38 Scheduled Maintenance Inspection Report - Quarterly or Frequent ....39 Scheduled Maintenance Inspection Report - Annual ......... 40 Programmed Maintenance Inspection Report - Booms ........
Page 12 March 2022 Table of Contents Q-20 Confirm the Proper Brake Configuration ..........68 Q-21 Test the Drive Brakes ................68 Q-22 Test the Drive Speed – Stowed Position ..........69 Q-23 Test the Drive Speed - Raised or Extended Position ........ 69 Q-24 Test the Drive Speed –...
Page 13 March 2022 Table of Contents Annual Maintenance Procedures ..............108 A-1 Grease the Turntable Rotation Bearing and Rotate Gear ......108 A-2 Check the Turntable Rotation Bearing Bolts ..........109 A-3 Inspect for Turntable Bearing Wear ............111 A-4 Check the Extendable Axle - S-100, S-105, S-120 and S-125 ....112 A-5 Perform Maintenance- Jib Rotate Bearing ..........
Page 14 March 2022 Table of Contents Programmed Maintenance Procedures............143 P0-1 Check the Track Tension and Fastener Torque, TraX Models - S-60, S-65, S-60 XC, S-65 XC, Z-62 Models ........... 143 P0-2 Check the Track Tension and Fastener Torque, TraX Models - S-40, S-45, S-40 XC, S-45 XC Models ............
Page 15 March 2022 Table of Contents P3-1 Perform Engine Maintenance – 3000 Hours ........... 175 P4-1 Perform Engine Maintenance – 4000 Hours ........... 177 P5-1 Perform Engine Maintenance – 5000 Hours ........... 177 P6-1 Perform Engine Maintenance – 6000 Hours ........... 178 P12-1 Perform Engine Maintenance –...
Page 16 Maintenance Manual March 2022 This page intentionally left blank. ® Booms • Z ® Booms Part No. 1268489GT...
Page 17: Performance Specifications
March 2022 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 March 2022 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
March 2022 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. Function S-40, S-45, S- S-60, S-65, S- S-60HF, S-65HF, S-60J S-80, S-85, S- S-80, S-85...
Page 20 Maintenance Manual March 2022 Performance Specifications Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function speeds are shown in seconds. Function S-80J S-80XC, S-85XC, Z-30N, Z-30N Z-34 BE Z-34N, Z-34 Z-33 S-80HF, S-85HF (DC models) Primary boom 65 - 70 75 - 83...
Page 21 March 2022 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 March 2022 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 March 2022 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 March 2022 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
March 2022 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, 40HF, S-45HF, S- S-60X, S-60XC to S-60J, S-60XC S-80XC, S-85XC 40XC, S-45XC 45000 from S60XCH- (all models)
Page 26 Maintenance Manual March 2022 Performance Specifications Note: Drive speeds are shown in seconds. S-100, S-105, S- SX-135XC, SX-150, Function S-80J Z-30N, Z30N RJ Z-33 120, S-125, S- SX-180 100HD, S-120HD, SX-105XC, SX- 125XC 2WD models, 6 - 8 8.5 - 10.5 40 ft / 12,2 m 40 ft / 12,2 m Stowed position...
Page 27 March 2022 Maintenance Manual Performance Specifications Note: Drive speeds are shown in seconds. Function Z-34N, Z34DC, Z- Z-34 IC Z-40N, Z-40N RJ Z-45/25, Z-45/25J Z-45/25 IC, Z- 34BE (DC and BE 45/25J IC, Z-51, Z- models) 45HF, Z-45XC, Z- 45 DC/FE 2WD models, 6 - 8 8.5 - 10.5...
Page 28 Maintenance Manual March 2022 Performance Specifications Note: Drive speeds are shown in seconds. Function Z-60 Z-62 Z-80 Z-135, ZX-135 (DC / FE) (all models) 2WD models, 13.6 - 14.5 6.1 - 7.8 40 ft / 12,2 m 40 ft / 12,2 m Stowed position 4WD models, 13.6 - 14.5...
Page 29: Torque Specifications
March 2022 Maintenance Manual 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 30 Maintenance Manual March 2022 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 31: Trax Torque Specifications
March 2022 Maintenance Manual 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 32: Engine Specifications
Maintenance Manual March 2022 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 33: Deutz Engine Models
March 2022 Maintenance Manual 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 34: Perkins Engine Models
Maintenance Manual March 2022 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 35 March 2022 Maintenance Manual 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 36: Ford Engine Models
Maintenance Manual March 2022 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 37: Kubota Engine Models
March 2022 Maintenance Manual 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 38: Gm Engine Models
Maintenance Manual March 2022 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 39: Cummins Engine Models
March 2022 Maintenance Manual 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 40: Hydraulic Specifications
Maintenance Manual March 2022 Hydraulic Specifications Hydraulic Relief Valve Pressure Function Manifold Relief Valve Pressure / Bar System Primary Secondary Secondary Primary Secondary Turntable Proportional Platform Model relief boom boom boom up boom boom rotate relief level down down extend extend S-40 2600 psi...
Page 41 March 2022 Maintenance Manual 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 3000 psi 1600 psi 1600 psi 1800 psi 1100 psi 207 bar 110 bar...
Page 42 Maintenance Manual March 2022 Hydraulic Specifications Traction and Steer/Axle Manifolds, and Oscillate Relief Valve Pressure / Bar Hot oil relief valve Model Oscillate relief Axle extend pressure 280 psi 950 psi S-40, S-45 19,3 bar 66 bar (all models) S-40HF, S-45HF, S-40XC, S-45XC 280 psi 850 psi (all models)
Page 43: Hydraulic And Drive Hub Fluid Capacities
March 2022 Maintenance Manual Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Model Turntable Hydraulic tank Hydraulic system Drive hub Drive hub rotation drive (including tank) 20 fl oz 20 fl oz 8 fl oz...
Page 44 Maintenance Manual March 2022 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 (DC and BE models) 17 fl oz 750 cc 30 liters...
Page 45: Hydraulic Oil Specifications
March 2022 Maintenance Manual 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 46 Maintenance Manual March 2022 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 cSt @ 104°F / 40°C 15.0...
Page 47 March 2022 Maintenance Manual 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 cSt @ 104°F / 40°C 44.4 cSt @ 0°F / -18°C...
Page 48: Hydraulic Hose And Fitting Torque Specifications
Maintenance Manual March 2022 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 49: Torque Procedure
March 2022 Maintenance Manual Hydraulic Specifications Torque Procedure JIC 37° fittings 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 50 Maintenance Manual March 2022 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 51: Maintenance Procedures
March 2022 Maintenance Manual Maintenance Procedures Machine Configuration: Secti on 3 Maint enan ce Pro ced ures Unless otherwise specified, perform each  procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed •...
Page 52 Maintenance Manual March 2022 Maintenance Procedures About This Section Maintenance Symbols Legend 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 53: Maintenance Schedule
March 2022 Maintenance Manual 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 54: Pre-Delivery Preparation Report
Maintenance Manual March 2022 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 55: Scheduled Maintenance Inspection Report - Quarterly Or Frequent
Scheduled - Quarterly March 2022 Maintenance Inspection Report – Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Inspection Type Legend Y = yes, N = no, remove from service Make copies of this report to use for each acceptable inspection.
Page 56: Scheduled Maintenance Inspection Report - Annual
Scheduled - Annual March 2022 Maintenance Inspection Report – Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by (print) Inspector signature Inspection Type Legend Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection. Select the appropriate procedures for the type of A = annual inspections R = repaired...
Page 57: Programmed Maintenance Inspection Report - Booms
Programmed March 2022 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 58: Commissioning Procedures
Maintenance Manual March 2022 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 59: Perform 150 Hour Service
March 2022 Maintenance Manual 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 60: Quarterly Maintenance Procedures
Maintenance Manual March 2022 Quarterly Maintenance Procedures Machines purchased in ASIA, North America and Latin America: Check for Open Bulletins and Owner Registration Go to ASIA, North America and Latin America Bulletins (https://www.gogenielift.com/) Genie specifications require that this procedure be performed quarterly.
Page 61: Battery Inspection
March 2022 Maintenance Manual 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 62 Maintenance Manual March 2022 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 63: Inspect The Electrical Wiring
March 2022 Maintenance Manual Quarterly Maintenance Procedures • Cable tracks 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.
Page 64: Inspect The Electrical Contactors - Dc / Bi-Energy Models
Maintenance Manual March 2022 Quarterly Maintenance Procedures From serial numbers Inspect the Electrical Contactors Z-45 DC / FE models Z45EM-101 - DC / Bi-Energy Models Z-60 DC / FE models Z6016N-101 Z60H-701 Z60M-101 Open the turntable cover and remove the fuse Genie specifications require that this procedure be box cover.
Page 65: Check The Exhaust System
March 2022 Maintenance Manual 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 66: Inspect The Tires, Wheels And Lug Nut Torque
Maintenance Manual March 2022 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 67 March 2022 Maintenance Manual 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 68: Check The Oscillate Directional Valve Linkage (If Equipped)
Maintenance Manual March 2022 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 69: Inspect The Hydraulic Filters
March 2022 Maintenance Manual 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 70: Check And Adjust The Engine Rpm
Maintenance Manual March 2022 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 71 March 2022 Maintenance Manual 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 72 Maintenance Manual March 2022 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 73 March 2022 Maintenance Manual 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 74 Maintenance Manual March 2022 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 75 March 2022 Maintenance Manual 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 Cummins B3.3T 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Perkins 804D-33 1 low idle adjustment screw...
Page 76: Test The Ground Control Override
Maintenance Manual March 2022 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 77: Test The Emergency Power System
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-14 All Models: Test the Emergency Power Activate the boom down function, hold for a System moment and then release it. (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 78: Test The Engine Idle Select - Engine Models
Maintenance Manual March 2022 Quarterly Maintenance Procedures Q-15 Push and release the rpm select button until low rpm is selected (turtle symbol). Test the Engine Idle Select Operation - Engine Models Result: The engine should return to low idle. Genie specifications require that this procedure be performed quarterly.
Page 79: Test The Fuel Select Operation - Gasoline/Lpg Models
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-16 All other models: Test the Fuel Select Operation - Pull out the red Emergency Stop button to the Gasoline/LPG Models on position at both the ground and platform 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 80 Maintenance Manual March 2022 Quarterly Maintenance Procedures Move the fuel select switch to LPG. Restart the engine and allow it to run at low idle. Press down the foot switch to allow the engine to run at high idle. Result: The engine should start promptly and operate smoothly in low and high idle.
Page 81: Inspect The Calibration Decal - Alc1000 Models
March 2022 Maintenance Manual 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 82: Test The Recovery Mode System - Alc-1000 Models
Maintenance Manual March 2022 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 83: Test The Platform Self-Leveling
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-19 Remove the key from the main key switch and insert the key into the bypass/recovery key Test the Platform Self-leveling 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- Genie specifications require that this procedure be 135 before serial number Z13512-1712.
Page 84: Confirm The Proper Brake Configuration
Maintenance Manual March 2022 Quarterly Maintenance Procedures 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.
Page 85: Test The Drive Speed - Stowed Position
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-22 Q-23 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.
Page 86: Test The Drive Speed - Raised And Extended, Alc1000 Models
Maintenance Manual March 2022 Quarterly Maintenance Procedures Q-24 Continue at full speed and note the time when the machine reference point crosses the finish Test the Drive Speed – Raised line. Refer to Specifications, Drive Speed and Extended Position, ALC1000 Specifications.
Page 87 March 2022 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...
Page 88: Test The Turntable Level Sensor
Maintenance Manual March 2022 Quarterly Maintenance Procedures Note: Use the following chart to identify the Q-25 description of each LCD screen control button Test the Turntable Level Sensor - used in this procedure. Z-80/60, Z-135/70, ZX-135/70, SX- 105XC, SX-125XC, SX-135XC, SX- 150 and SX-180 Genie specifications require that this procedure be Plus...
Page 89 March 2022 Maintenance Manual Quarterly Maintenance Procedures Note: Perform this procedure with the booms in Turn the key switch to ground control and pull the fully stowed position and the axles fully out the red Emergency Stop button to the on extended.
Page 90: Test The Secondary Boom Angle Sensor - Z-135/70 And Zx-135/70
Maintenance Manual March 2022 Quarterly Maintenance Procedures Q-26 Place a digital level that has been calibrated to gravity on the Y axis of the turntable. Test the Secondary Boom Angle Result: The reading at the display and digital Sensor - Z-135/70 and ZX-135/70 level is within ±...
Page 91 March 2022 Maintenance Manual Quarterly Maintenance Procedures Press the plus and minus buttons at the Lower the secondary boom to 65°. same time on the LCD screen to enter the Result: The reading at the display and digital MACHINE STATUS screen. Press the enter level is within ±...
Page 92: Test The Primary Boom Angle Sensor - Z-135/70 And Zx-135/70
Maintenance Manual March 2022 Quarterly Maintenance Procedures Q-27 10 Lower the secondary boom to 20°. Test the Primary Boom Angle Result: The reading at the display and digital level is within ± 2° of each other and of 20°. Sensor - Z-135/70 and ZX-135/70 Result: The reading at the display and digital Genie specifications require that this procedure be level is greater than ±...
Page 93 March 2022 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 display screen. used in this procedure. Continue to raise the primary boom until it stops at approximately 58°.
Page 94 Maintenance Manual March 2022 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 95: Test The Primary Boom Angle Sensor
March 2022 Maintenance Manual Quarterly Maintenance Procedures SX-105XC and SX-125XC Q-28 Test the Primary Boom Angle Turn the key switch to ground control and pull out the red Emergency Stop button to the on Sensor - SX-105XC, SX-125XC, position at both ground and platform controls. SX-135XC, SX-150 and SX-180 Start the engine from the ground controls.
Page 96 Maintenance Manual March 2022 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 97 March 2022 Maintenance Manual Quarterly Maintenance Procedures SX-135XC 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 98 Maintenance Manual March 2022 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 99 March 2022 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 100: Test The Safety Envelope Limit Switches - Z-135/70, Zx-135/70,
Maintenance Manual March 2022 Quarterly Maintenance Procedures Z-135/70 and ZX-135/70 Models: Q-29 Test the Safety Envelope Limit Secondary Boom #1 Retracted Safety Limit Switch, LSS1RS Switches, Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX-135XC, Working at the platform end of the turntable, support and secure the lower turntable riser SX-150 and SX-180 Models end cover to a suitable lifting device.
Page 101 March 2022 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 to LSS1RS. 2 at the Deutsch connector of the limit switch Result: The alarm should sound. cable.
Page 102 Maintenance Manual March 2022 Quarterly Maintenance Procedures Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX- Connect the leads from a multimeter with 135XC, 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 103 March 2022 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 104: Test The Primary Boom Angle Sensor - Z-80/60
Maintenance Manual March 2022 Quarterly Maintenance Procedures Q-30 Start the engine from the ground controls. Test the Primary Boom Angle Raise the primary boom. The display will Sensor - Z-80/60 begin showing a boom angle of 40°. Continue raising the primary boom until the Genie specifications require that this procedure be display shows 65°.
Page 105: Test The Safety Envelope And Circuits - Z-80/60
March 2022 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 106 Maintenance Manual March 2022 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 107: Check The Safety Envelope Limit Switches And Angle Sensor - S-60X, S-80X, And S-60Xc To S60Xc-45000
March 2022 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 108 Maintenance Manual March 2022 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 109: Test The Safety Envelope And Circuits
March 2022 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 110 Maintenance Manual March 2022 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 111 March 2022 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 112 Maintenance Manual March 2022 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 113 March 2022 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 114 Maintenance Manual March 2022 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 115: Test The Aircraft Protection System (If Equipped)
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-34 All Models: Test the Aircraft Protection 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.
Page 116 Maintenance Manual March 2022 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 117: Test The Operator Protection Alarm (If Equipped)
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-35 Test the Operator Protection Alarm (if equipped) Genie specifications require that this procedure be performed quarterly. Testing the operator protection alarm (OPA) is important for proper operation. Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls.
Page 118 Maintenance Manual March 2022 Quarterly Maintenance Procedures The boom extend/retract cables and sheaves are Q-36 responsible for the extension and retraction of the Inspect and Adjust the Boom boom tubes. Inspecting for foreign objects, Extend/Retract Cables - All damage and/or improper adjustment of the boom extend/retract cables and related components on a Models regular basis is essential to good machine...
Page 119: Test The Recovery Mode System - Alc600 Models
March 2022 Maintenance Manual Quarterly Maintenance Procedures Q-37 Test the Recovery System - ALC600 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 120: Test The Turntable Level Sensor - Alc600 Models
Maintenance Manual March 2022 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. ALC600 Models Genie specifications require that this procedure be performed quarterly.
Page 121 March 2022 Maintenance Manual 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 122: Test The Primary Boom Angle Sensor - Alc600 Models
Maintenance Manual March 2022 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 - ALC600 Models level is within ±...
Page 123 March 2022 Maintenance Manual 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 124: Annual Maintenance Procedures
Maintenance Manual March 2022 Annual Maintenance Procedures Models with Worm Drive Gear: Grease the Turntable Rotation Locate the 2 grease fittings on top of the Bearing and Rotate Gear worm drive housing. 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 125: Check The Turntable Rotation Bearing Bolts
March 2022 Maintenance Manual Annual Maintenance Procedures Raise the boom and remove the safety chock OR lifting device. Check the Turntable Rotation Bearing Bolts Lower the boom to the stowed position. Using a star pattern, confirm that each lower bearing mounting bolt is torqued in sequence to specification.
Page 126 Maintenance Manual March 2022 Annual Maintenance Procedures Model and Serial Range Torque Model and Serial Range Torque 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 from Z6016N-101 to Z30ND-329 from Z60H-701 from Z30N16F-17574...
Page 127: Inspect For Turntable Bearing Wear
March 2022 Maintenance Manual 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 128: Check The Extendable Axle - S-100, S-105, S-120 And S-125
Maintenance Manual March 2022 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 129: Perform Maintenance- Jib Rotate Bearing
March 2022 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 130: Test The Bypass/Recovery Key Switch - Alc1000 Models
Maintenance Manual March 2022 Annual Maintenance Procedures 10 Note the reading on the dial indicator. Result: The measurement is less than 0.063 inch / 1,6 mm. The bearing is good. Result: The measurement is more than 0.063 inch / 1,6 mm. The bearing is worn and needs to be replaced.
Page 131 March 2022 Maintenance Manual Annual Maintenance Procedures When the Bypass/Recovery key switch is turned and held to the recovery position, the emergency Test the Key Switches - ALC1000 power unit turns on and starts a sequence to lower Models the platform. This feature of the machine is especially helpful if the operator in the platform Genie specifications require that this procedure be cannot lower the boom, if the platform controls...
Page 132 Maintenance Manual March 2022 Annual Maintenance Procedures Note: Perform this procedure on a firm, level 11 Raise the primary boom 3 ft / 1 m. surface with the machine in the stowed position. Result: The primary boom should raise. Open the ground controls side turntable side 12 Remove the key from the bypass/recovery cover.
Page 133: Grease The Platform Overload Mechanism (If Equipped)
March 2022 Maintenance Manual Annual Maintenance Procedures Grease the Platform Overload Test the Platform Overload Mechanism (if equipped) System - (if equipped) Genie specifications require that this procedure be Genie specifications require that this procedure be performed annually OR when the machine fails to performed annually.
Page 134 Maintenance Manual March 2022 Annual Maintenance Procedures Note: Alternate method for achieving rated load in Engine Models: Turn the key switch to the platform is to attach a hanging scale to the ground control and pull out the red bottom of the platform and apply load using a Emergency Stop button to the on position at winch or ratchet until the readout displays the both the ground and platform controls.
Page 135: Test The Platform Overload System - Alc1000 Models
March 2022 Maintenance Manual Annual Maintenance Procedures Using emergency power, test all machine functions from the ground controls. Test the Platform Overload Result: All ground control functions operate System - ALC1000 Models normally. Remove the test weight or the rated load from the platform.
Page 136 Maintenance Manual March 2022 Annual Maintenance Procedures Note: Alternate method for achieving rated load in Place a test weight on the platform floor using the platform is to attach a hanging scale to the a suitable lifting device. Place the weight near bottom of the platform and apply load using a the center entry point of the platform, as far winch or ratchet until the readout displays the...
Page 137: Test The Platform Load Sense System - S-60 Hc
March 2022 Maintenance Manual Annual Maintenance Procedures Remove the weight or rated load from the A-10 platform. Test the Platform Load Sense Result: There is no audible alarm. Platform System - S-60 HC overload is not displayed on the LCD screen at the ground controls.
Page 138: S-60/65, S-80/85 And S-80J Models
Maintenance Manual March 2022 Annual Maintenance Procedures Start the engine from the ground controls. Using a suitable lifting device, place an appropriate test weight equal to 340,2 kg on to the center of the platform floor. Result: The amber restricted range of motion LED at the platform controls should come on and the engine should continue to run.
Page 139: Inspect The Boom Extend/Retract Cables And Sheaves
March 2022 Maintenance Manual Annual Maintenance Procedures A-11 This maintenance procedure applies to the following models: S-60, S-65, S-60 TraX, S-65 Inspect the Boom Extend/Retract TraX, S-60HC, S-60HF, S-65HF, S-60X, S-60XC, Cables and Sheaves - S-60/65, S- S-65XC, S-80, S-85, S-80X, S-80HF, S-85HF, S- 80/85 and S-80J (includes HF, X, 80J, S-80XC, S-85XC XC and TraX models)
Page 140 Maintenance Manual March 2022 Annual Maintenance Procedures S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, Visually inspect the cables, sheaves and S-65XC, S-60 TraX and S-65 TraX, S-80, S- related components through the inspection holes for the following: 85, S-80X, S-80HF, S-85HF, S-80J, S-80XC, S-85XC: Install the cover at the pivot end of •...
Page 141: Inspect The Boom Extend/Retract Cables And Sheaves
March 2022 Maintenance Manual Annual Maintenance Procedures Remove the boom end cover from the pivot A-12 end of the boom. Inspect the Boom Extend/Retract Cables and Sheaves - S-100, S- 105, S-120, S-125, S-100HD, S- 120HD, SX-105XC and SX-125XC Models Genie specifications require that this procedure be performed annually.
Page 142 Maintenance Manual March 2022 Annual Maintenance Procedures Visually inspect the cables, sheaves and Install the plastic cover at the pivot end of the related components through the inspection boom and access panels on the sides of the holes for the following: boom.
Page 143: Inspect The Boom Extend And Retract Cables And Sheaves -
March 2022 Maintenance Manual Annual Maintenance Procedures A-13 SX-135XC models: Inspect the Boom Extend/Retract Note: Properly adjusted extend/retract cables will maintain a relationship of the gap between boom Cables and Sheaves - SX-135XC, tubes #2 and #3. SX-150 and SX-180 Models Start the engine from the ground controls.
Page 144 Maintenance Manual March 2022 Annual Maintenance Procedures SX-150 and SX-180 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 and boom tubes #3 and #4.
Page 145 March 2022 Maintenance Manual Annual Maintenance Procedures Measure the distance between boom tubes #2 and #3 using points (9) and (10) in the illustration. The gap should be 1 in / 2.6 cm to 1.5 in /3.9 cm greater than dimension "A"...
Page 146: Check The Drive Hub Oil Level And Fastener Torque
Maintenance Manual March 2022 Annual Maintenance Procedures All models: A-14 Check the Drive Hub Oil Level Note: This procedure will require the use of an aerial work platform. and Fastener Torque Remove the cover from the pivot end of the boom.
Page 147 March 2022 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 148 Maintenance Manual March 2022 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 149 March 2022 Maintenance Manual Annual Maintenance Procedures Torque values are listed as dry. The retaining Model and Serial Range Torque ft-lbs / Nm fasteners must be coated with a mineral based lubricant when removed. If a retaining fastener is S-80, S-80HF, S-80J, S-80X, S-80XC, S-85, S-85HF, S-85XC removed, the torque value is reduced.
Page 150: Test The Dual Capacity And Platform Overload System - Sx-105Xc, Sx-125Xc And Sx-135Xc
Maintenance Manual March 2022 Annual Maintenance Procedures A-15 Model and Serial Range Torque 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 Models from Z5130M-2036 106 / 143 Z-60DC, Z-60FE from Z6016N-101...
Page 151 March 2022 Maintenance Manual Annual Maintenance Procedures Note: Alternate method for achieving rated load in Using a suitable lifting device, place a test the platform is to attach a hanging scale to the weight of 550 lbs / 250 kg near the center bottom of the platform and apply load using a point of the platform as far away from the winch or ratchet until the readout displays the...
Page 152: Test The Dual Capacity And Platform Overload System - Z-45Xc Models
Maintenance Manual March 2022 Annual Maintenance Procedures A-16 Add an additional 320 lbs / 145 kg weight or load to the platform. Test the Dual Capacity and Result: There is an audible alarm. Platform Platform Overload System - overload is displayed on the LCD screen at Z-45XC Models the ground controls.
Page 153 March 2022 Maintenance Manual Annual Maintenance Procedures Note: If test weights are not available, you may Add an additional 150 lbs / 68 kg of weight or use an industrial scale to weigh available objects load to the platform. until it equals the platform’s maximum capacity. Result: The restricted range of motion indicator light is on at the ground controls.
Page 154: Test The Dual Capacity And Platform Overload System - S-40Xc, S-45Xc, S-60Hf, S-65Hf, S-60Xc From S60Xch-45001, S-65Xc, S-80Hf, S-85Hf, S-80Xc, S-85Xc
Maintenance Manual March 2022 Annual Maintenance Procedures A-17 Remove all weight, tools, accessories and equipment from the platform. Test the Dual Capacity and Platform Overload System - S- Note: Failure to remove all weight, tools and accessories from the platform will result in an 40XC, S-45XC, S-60HF, S-65HF, inaccurate test.
Page 155 March 2022 Maintenance Manual Annual Maintenance Procedures Note: Alternate method for achieving rated load in Add additional weight or load to the platform. the platform is to attach a hanging scale to the S-80HF, S-85HF models: 370 lbs / 168 kg. bottom of the platform and apply load using a winch or ratchet until the readout displays the All other models: 320 lbs / 145 kg.
Page 156: Test The Platform Overload System - S-40Hf, S-45Hf, S-60J
Maintenance Manual March 2022 Annual Maintenance Procedures A-18 Place a test weight on the platform floor using a suitable lifting device. Place the weight near Test the Platform Overload the center entry point of the platform, as far System - away from the operator controls as possible.
Page 157 March 2022 Maintenance Manual Annual Maintenance Procedures Note: Alternate method for achieving rated load in Remove the weight or rated load from the the platform is to attach a hanging scale to the platform. bottom of the platform and apply load using a Result: There is no audible alarm.
Page 158: Perform Engine Maintenance
Maintenance Manual March 2022 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 159: Programmed Maintenance Procedures
March 2022 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, S- surface of the track.
Page 160: P0-2 Check The Track Tension And Fastener Torque, Trax Models - S-40, S-45, S-40 Xc, S-45 Xc Models
Maintenance Manual March 2022 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 161 March 2022 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 162: P0-3 Grease The Extendable Axles - S-100, S-105, S-120 And S-125
Maintenance Manual March 2022 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 163: P0-4 Continental Engine Maintenance - Under 1000 Hours
March 2022 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 164: P0-5 Cummins Engine Maintenance - Under 1000 Hours
Maintenance Manual March 2022 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 165: P0-6 Deutz Engine Maintenance - Under 1000 Hours
March 2022 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 166: P0-7 Ford Engine Maintenance - Under 1000 Hours
Maintenance Manual March 2022 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 167: P0-8 Kubota Engine Maintenance - Under 1000 Hours
March 2022 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 168 Maintenance Manual March 2022 Programmed Maintenance Procedures Kubota Engines, continued Hour Intervals Procedure Daily 50 100 150 200 400 500 ∅ = Not required Fuel/Water separator - replace, D1803 ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅ Air cleaner element - replace ∅...
Page 169: P0-9 Perkins Engine Maintenance - Under 1000 Hours
March 2022 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 170: P0-10 Gm .998L Engine Maintenance - Under 1000 Hours
Maintenance Manual March 2022 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 171: P0-11 Gm 3.0L Engine Maintenance - Under 1000 Hours
March 2022 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 172: P1-1 Perform Engine Maintenance - 1000 Hours
Maintenance Manual March 2022 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 173 March 2022 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 174: P1-2 Replace The Drive Hub Oil
Maintenance Manual March 2022 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 175 March 2022 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 176 Maintenance Manual March 2022 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 177: P1-3 Perform Engine Maintenance - 1500 Hours
March 2022 Maintenance Manual Programmed Maintenance Procedures 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 additional Required maintenance procedures and additional engine information are available in the...
Page 178 Maintenance Manual March 2022 Programmed Maintenance Procedures Deutz Models Kubota Models All Models: Z482-E, D1105, WG972 • V-Belts - replace • Radiator coolant (L.L.C.) - replace D436 L3i, D2011, TD2011 • Battery - replace • 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 179: P2-2 Test Or Replace The Hydraulic Oil
March 2022 Maintenance Manual Programmed Maintenance Procedures P2-2 Testing the oil: Test or Replace the Hydraulic Oil Complete the hydraulic oil testing with an oil distributor. If the hydraulic oil passes testing at the 2000 hour maintenance interval, the oil must Genie requires that this procedure be performed be tested every quarter by an oil distributor every 2000 hours.
Page 180: P2-3 Replace The Hydraulic Filters
Maintenance Manual March 2022 Programmed Maintenance Procedures 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.
Page 181 March 2022 Maintenance Manual 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 182: P2-4 Check The Free-Wheel Configuration
Maintenance Manual March 2022 Programmed Maintenance Procedures P2-4 Lift the wheels or tracks off the ground and then place jack stands under the drive chassis Check the Free-wheel for support. Configuration Disengage the drive hubs by turning over the drive hub disconnect caps on each non-steer / circle-end wheel hub.
Page 183 March 2022 Maintenance Manual Programmed Maintenance Procedures Lift the wheels or tracks off the ground and 12 Re-engage the drive hubs by turning over the then place jack stands under the drive chassis hub disconnect caps. Rotate each wheel or for support.
Page 184: P2-5 Check The Boom Wear Pads
Maintenance Manual March 2022 Programmed Maintenance Procedures 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 Genie requires that this procedure be performed Top and side wear pads 0.50 inch every 2000 hours.
Page 185 March 2022 Maintenance Manual Programmed Maintenance Procedures 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 186 Maintenance Manual March 2022 Programmed Maintenance Procedures 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 / 1,8 mm Primary boom wear pad specifications Minimum and the maximum allowable shim clearance is Top, bottom and side wear pads...
Page 187: P2-6 Check The Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100Hd And S-120Hd
March 2022 Maintenance Manual Programmed Maintenance Procedures P2-6 P2-7 Check the Extendable Axle Wear 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...
Page 188: P2-8 Grease The Steer Axle Wheel Bearings, All 2Wd Models, Except S-60, S-65, Z-60 Dc/Fe And Z-62
Maintenance Manual March 2022 Programmed Maintenance Procedures P2-8 S-100, S-100HD, S-105, S-120, S-120HD and S- Grease the Steer Axle Wheel Bearings, All 2WD Models Result: The gap is between 0.010 inch / 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 189 March 2022 Maintenance Manual 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 190: P2-9 Grease The Steer Axle Wheel Bearings, 2Wd Models
Maintenance Manual March 2022 Programmed Maintenance Procedures 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 191 March 2022 Maintenance Manual 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 192 Maintenance Manual March 2022 Programmed Maintenance Procedures 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 193 March 2022 Maintenance Manual Programmed Maintenance Procedures 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 additional Required maintenance procedures and additional engine information are available in the...
Page 194 Maintenance Manual March 2022 Programmed Maintenance Procedures 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 additional Required maintenance procedures and additional engine information are available in the...
Page 195 March 2022 Maintenance Manual Programmed Maintenance Procedures P12-2 Remove the boom extend and retract cables. Refer to the appropriate Service and Repair Remove and Inspect the Boom Manual for repair procedure, How to Replace Extend/Retract Cables the Boom Extend/Retract Cables. Inspect the sheaves for the following: •...
Page 196 Maintenance Manual March 2022 Programmed Maintenance Procedures Inspect the cables for the following: Inspect the cable diameter. Measure the diameter in multiple locations along the cable. • Frayed or broken wire strands Note: Calipers will be required to perform this •...
Page 197 March 2022 Maintenance Manual Programmed Maintenance Procedures Cable Re place men t Crit eria Cable Replacement Criteria SX-135 XC Extend .625 inches .594 inches Note: The cables must be replaced if any condition 15.875 mm 15 mm shown below is observed other than normal wear. Retract .50 inches .475 inches...

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Terex Genie S-40 Maintenance Manual

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