Table of Contents
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Maintenance Manual -
Booms
S Booms
Z Booms
Refer to the inside cover for a list of models
included in this manual.
This manual includes detailed
procedures for each
maintenance inspection.
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Part No. 1268489
Rev B1
April 2016
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Chapters
Table of Contents
Related Manuals for Genie S-150
Summarization of Contents
Introduction
Important Information for Maintenance
Read safety rules and operating instructions before maintenance. Basic skills needed; complex tasks require dealer service.
Compliance and Design Life
Machine classification as per ISO 16368 and design life statement.
Technical Publications
Information on manual accuracy, product improvements, and reader feedback.
Contact Us
Provides Genie's website and technical publications email address.
Models Included in This Manual
Identify Correct Procedure by Model
Guidance on finding model-specific procedures and serial number identification.
Safety Rules
General Safety Rules and Warnings
Emphasizes danger warnings and conditions required before performing maintenance.
Personal Safety Precautions
Awareness of hazards, use of PPE, and awareness of crushing hazards.
Workplace Safety Practices
Safe practices for sparks, tools, work areas, lifting devices, fasteners, and fluid disposal.
Performance Specifications
Function Speeds by Model
Details operational speeds for boom and turntable functions across various models.
Drive Speeds by Model
Specifies machine drive speeds in different configurations and conditions.
Torque Specifications
Tire and Wheel Torque Specifications
Torque values for lug nuts and tire pressure guidelines.
TRAX Torque Specifications
Torque values for TRAX model components like sprockets and hubs.
Engine Specifications
Engine Operator and Maintenance Manuals References
Lists Genie part numbers for engine-specific manuals.
Deutz Engine Specifications
Details for Deutz D2011L03i, TD2011L04i, D 2.9 L4, TD 2.9 L4 engines.
Perkins Engine Specifications
Details for Perkins 403D-11, 403F-11, 404D-22, 404F-22, 404F-22T, 804D-33, 854F-34T engines.
Ford Engine Specifications
Details for Ford DSG-423 and MSG-425 engines.
Kubota Engine Specifications
Details for Kubota D1105-E3B, D1105-E4B, WG972, Z482-E engines.
GM Engine Specifications
Details for GM .998L and 3.0L engines.
Continental Engine Specifications
Details for Continental TME27 engine.
Cummins Engine Specifications
Details for Cummins B3.3T engine.
Hydraulic Specifications
Hydraulic Relief Valve Pressure by Model
Specifies relief valve pressures for various hydraulic functions and models.
Traction and Steer/Axle Manifolds Pressure
Pressure settings for traction, steer/axle manifolds, and oscillate relief.
Hydraulic and Drive Hub Fluid Capacities
Lists fluid capacities for drive hubs, turntable, hydraulic tank, and system.
Hydraulic Oil Specifications
Requirements for hydraulic oils, including cleanliness and water content.
Hydraulic Hose and Fitting Torque Specifications
Torque values for Seal-Lok, JIC, and SAE O-ring boss fittings.
Hydraulic Torque Procedure
Steps for correctly torquing Seal-Lok and JIC fittings.
Maintenance Procedures
Observe and Obey Critical Rules
Mandatory rules for maintenance: qualified personnel, tagging damage, using approved parts.
Machine Configuration for Procedures
Required machine setup: level surface, key off, wheels chocked, etc.
Symbols and Legends
Explanation of safety symbols and maintenance procedure symbols.
Maintenance Schedule Overview
Division of procedures into commissioning, quarterly, annual, and programmed intervals.
Pre-Delivery Preparation Report
Fundamentals of Pre-Delivery Preparation
Responsibility, purpose, and handling of damaged machines during pre-delivery.
Instructions for Pre-Delivery Report
Guidance on using the report form and the legend for results.
Scheduled Maintenance Inspection Report - Booms
Drive Chassis Inspection Checklist
Checks for tires, wheels, lug nuts, axle pads, and drive hub oil.
Turntable Mechanicals and Hydraulics Inspection
Checks for hydraulic oil, filters, turntable bearing, and bolts.
Electrical System Inspection
Checks for electrical wiring, contactors, and battery condition.
Engine Inspection Checklist
Checks for exhaust system, generator belts, pulleys, and engine RPM.
Boom(s) and Platform Inspection
Checks for jib rotate bearing, platform overload, and boom cables.
Functions and Controls Inspection
Checks for bulletins, ground override, alarms, power systems, idle select, fuel select, and sensors.
Commissioning Procedures
C-1 Perform 50 Hour Service
One-time maintenance sequence for the first 50 hours of usage.
C-2 Perform Engine Maintenance - 50 Hours
Specific engine maintenance tasks for the 50-hour service.
C-3 Perform 150 Hour Service
One-time maintenance sequence for the first 150 hours of usage.
Quarterly Maintenance Procedures
Q-1 Check for Open Bulletins and Owner Registration
Procedure to check for mandatory bulletins and owner information.
Q-2 Battery Inspection
Procedure to inspect battery condition, connections, and specific gravity.
Q-3 Inspect the Electrical Wiring
Check electrical wiring for damage like burns, chafing, corrosion, or pinching.
Q-4 Inspect Electrical Contactor - DC / Bi-Energy Models
Inspect electrical contact points for burns, arcs, or pitting.
Q-5 Check the Exhaust System
Inspect the exhaust system for tightness, cracks, and leaks.
Q-6 Inspect Tires, Wheels, and Lug Nut Torque
Check tire treads, sidewalls, wheels, and lug nut torque.
Q-7 Check Generator Belts, Pulleys, and Voltage - Bi-Energy Models
Inspect generator belts, pulleys, alignment, and voltage output.
Q-8 Check Oscillate Directional Valve Linkage
Inspect linkage for proper axle oscillation function.
Q-9 Visual Inspection of Hydraulic Oil
Visually inspect hydraulic oil for color, appearance, and contamination.
Q-10 Inspect the Hydraulic Filters
Check filter condition indicators or replace filters if not equipped.
Q-11 Check and Adjust Engine RPM
Verify and adjust engine low and high idle RPM settings.
Q-12 Test Ground Control Override
Test the function allowing ground personnel to operate the machine.
Q-13 Test Alarm Package (if equipped)
Test travel, descent alarms, and flashing beacon.
Q-14 Test Emergency Power System (excludes ALC-1000)
Test the backup power system for safe machine operation.
Q-15 Test Engine Idle Select Operation
Test the function allowing selection between low and high idle speeds.
Q-16 Test Fuel Select Operation - Gasoline/LPG Models
Test the ability to select and switch between gasoline and LPG fuels.
Q-17 Inspect Calibration Decal - Specific Models
Check the condition and legibility of the calibration decal.
Q-18 Test Recovery System - ALC-1000 Models
Test the system that allows platform lowering in emergencies.
Q-19 Test Platform Self-leveling
Verify automatic platform leveling during boom operation.
Q-20 Confirm Proper Brake Configuration
Check drive hub disconnect caps to ensure they are engaged.
Q-21 Test the Drive Brakes
Verify smooth, jerk-free operation of the drive brakes.
Q-22 Test Drive Speed – Stowed Position
Measure machine drive speed in the stowed position.
Q-23 Test Drive Speed – Raised or Extended Position
Measure machine drive speed in raised or extended boom positions.
Q-24 Test Drive Speed – Raised and Extended, ALC1000 Models
Measure drive speed in raised/extended state for ALC1000 models.
Q-25 Test Turntable Level Sensor - Specific Models
Test turntable level sensor accuracy using a digital level.
Q-26 Test Secondary Boom Angle Sensor - Specific Models
Test the secondary boom angle sensor for proper function and calibration.
Q-27 Test Primary Boom Angle Sensor - Specific Models
Test the primary boom angle sensor for proper function and calibration.
Q-28 Test Primary Boom Angle Sensor - SX-150 and SX-180
Test the primary boom angle sensor for SX-150/SX-180 models.
Q-29 Test Safety Envelope Limit Switches - Specific Models
Test safety limit switches for boom extension and retraction.
Q-30 Test Primary Boom Angle Sensor - Z-80/60
Test the primary boom angle sensor for Z-80/60 model.
Q-31 Test Safety Envelope and Circuits - Z-80/60
Test safety envelope circuits for Z-80/60 model.
Q-32 Check Safety Envelope Limit Switches and Angle Sensor - S-60X, S-60XC and S-80X
Test safety limit switches and angle sensor for specific models.
Q-33 Test Safety Envelope and Circuits - S-100, S-105, S-120, S-125, S-100HD and S-120HD
Test safety envelope and circuits for specific models.
Q-34 Test Aircraft Protection System (if equipped)
Test the aircraft protection system for proximity detection.
Q-35 Test Operator Protection Alarm (if equipped)
Test the operator protection alarm for proper function.
Annual Maintenance Procedures
A-1 Grease Turntable Rotation Bearing and Rotate Gear
Lubricate turntable bearing and rotate gear for performance and service life.
A-2 Check Turntable Rotation Bearing Bolts
Verify proper torque on turntable bearing bolts to prevent unsafe conditions.
A-3 Inspect for Turntable Bearing Wear
Check turntable bearing for wear to prevent unsafe conditions and damage.
A-4 Check Extendable Axle Wear Pads
Inspect axle wear pads for condition and shim as necessary.
A-5 Perform Maintenance – Jib Rotate Bearing
Grease and check jib rotate bearing for wear and proper function.
A-6 Test Key Switches - ALC1000 Models
Verify function of main and bypass/recovery key switches.
A-7 Grease Platform Overload Mechanism
Lubricate platform overload mechanism for safe operation.
A-8 Test Platform Overload System - Except ALC1000 & S-60HC
Test platform overload system function for specific models.
A-9 Test Platform Overload System - ALC1000 Models
Test platform overload system function for ALC1000 models.
A-10 Test Platform Load Sense System - S-60 HC
Test the platform load sensing system for S-60 HC model.
A-11 Inspect Boom Extend/Retract Cables - S-60 and S-80 Models
Inspect boom cables and related components for wear and damage.
A-12 Inspect Boom Extend/Retract Cables - S-100 to S-120 Models
Inspect boom cables and related components for wear and damage.
A-13 Inspect Boom Extend/Retract Cables - SX-150 and SX-180 Models
Inspect boom cables and related components for wear and damage.
A-14 Check Drive Hub Oil Level and Fastener Torque
Check drive hub oil level and torque of mounting bolts.
Programmed Maintenance Procedures
P0-1 Check Track Tension and Fastener Torque - TRAX Models S-60, S-65, Z-62
Check track tension and torque of fasteners for TRAX models.
P0-2 Check Track Tension and Fastener Torque - TRAX Models S-40, S-45
Check track tension and torque of fasteners for TRAX models.
P0-3 Grease Extendable Axles - S-100, S-105, S-120, S-125, S100HD and S-120HD
Grease sliding wear pads on extendable axles.
P0-4 Continental Engine Maintenance – Under 1000 Hours
Maintenance schedule for Continental TME27 engines.
P0-5 Cummins Engine Maintenance – Under 1000 Hours
Maintenance schedule for Cummins B3.3T engines.
P0-6 Deutz Engine Maintenance – Under 1000 Hours
Maintenance schedule for Deutz engines.
P0-7 Ford Engine Maintenance – Under 1000 Hours
Maintenance schedule for Ford MSG 425 and DSG 423 engines.
P0-8 Kubota Engine Maintenance – Under 1000 Hours
Maintenance schedule for Kubota engines.
P0-9 Perkins Engine Maintenance – Under 1000 Hours
Maintenance schedule for Perkins engines.
P0-10 GM .998L Engine Maintenance – Under 1000 Hours
Maintenance schedule for GM .998L engines.
P0-11 GM 3.0L Engine Maintenance – Under 1000 Hours
Maintenance schedule for GM 3.0L engines.
P1-1 Perform Engine Maintenance – 1000 Hours
Engine maintenance tasks required at 1000-hour intervals.
P1-2 Replace the Drive Hub Oil
Procedure to drain and refill drive hub oil.
P2-1 Perform Engine Maintenance – 2000 Hours
Engine maintenance tasks required at 2000-hour intervals.
P2-2 Test or Replace the Hydraulic Oil
Test hydraulic oil condition or replace it if necessary.
P2-3 Replace the Hydraulic Filters
Procedure to replace hydraulic filters (tank, medium, high pressure, case drain).
P2-4 Check the Free-wheel Configuration
Verify proper engagement/disengagement of the free-wheel mechanism.
P2-5 Check the Boom Wear Pads
Inspect and measure boom wear pads, shim or replace as needed.
P2-6 Check Extendable Axle Wear Pads - S-100 to S-120HD Models
Inspect axle wear pads for condition and shim as needed.
P2-7 Check Turntable Rotation Gear Backlash - ALC1000 Models
Measure turntable rotation gear backlash for proper adjustment.
P2-8 Grease Steer Axle Wheel Bearings - 2WD Models (Excl. S-60, S-65, Z-60, Z-62)
Grease steer axle wheel bearings for 2WD models.
P2-9 Grease Steer Axle Wheel Bearings - 2WD Models S-60, S-65, Z-60, Z-62
Grease steer axle wheel bearings for specific 2WD models.
P3-1 Perform Engine Maintenance – 3000 Hours
Engine maintenance tasks required at 3000-hour intervals.
P4-1 Perform Engine Maintenance – 4000 Hours
Engine maintenance tasks required at 4000-hour intervals.
P5-1 Perform Engine Maintenance – 5000 Hours
Engine maintenance tasks required at 5000-hour intervals.
P6-1 Perform Engine Maintenance – 6000 Hours
Engine maintenance tasks required at 6000-hour intervals.
P12-1 Perform Engine Maintenance – 12000 Hours
Engine maintenance tasks required at 12000-hour intervals.
P12-2 Replace Boom Extend/Retract Cables - S-100HD and S-120HD
Procedure to replace boom cables for specific models.
P12-3 Replace Boom Extend/Retract Cables - S-60, S-80, S-100, S-105, S-120, S-125, SX-150 and SX-180
Procedure to replace boom cables for various models.
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