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-180
Summarization of Contents
Maintenance Manual - Booms
Cover Page / Introduction
Title page of the maintenance manual for Genie Booms.
Introduction
Important Information
Read, understand and obey safety rules and operating instructions before maintenance.
Compliance
Details machine classification and design life requirements.
Technical Publications
Information on accuracy, product improvements, and how to report errors.
Contact Us
Provides contact information for Genie technical publications.
Model Identification and Procedures
Models Included in this Manual
Chart to identify specific serial numbers for models covered in this manual.
Identifying the Correct Procedure for your Model
Guidance on how procedures apply to specific models or options.
Find Additional Manuals for your Model
Instructions on how to locate other Genie service and operator manuals.
Revision History
Revision History Details
Details revisions, dates, sections, and descriptions of updates to the manual.
Safety Rules
Danger - General Safety
Warning about death or serious injury from not following manual rules.
Maintenance Prerequisites
Conditions required before performing maintenance on the machine.
Safety Rules (Continuation)
Personal Safety Guidelines
Awareness of hazards, use of signal words, protective gear, and hazards like crushing.
Workplace Safety Practices
Safety measures for work areas, tools, lifting devices, fasteners, and disposal.
Performance Specifications
Function Speeds - S-100, S-105, S-100HD Models
Maximum platform control speeds with rated load for specific S models.
Performance Specifications (Continuation)
Function Speeds - S-120, S-125, S-120HD Models
Maximum platform control speeds with rated load for specific S models.
Performance Specifications (Continuation)
Function Speeds - All Other Models
Maximum platform control speeds with rated load for various other models.
Performance Specifications (Continuation)
Drive Speeds Specifications
Table detailing drive speeds for various models in different configurations.
Torque Specifications
Tires and Wheels Torque
Torque values and tire pressure specifications for various models.
Engine Specifications
Engine Operator and Maintenance Manuals List
List of Genie part numbers for engine manuals.
Engine Specifications (Continuation)
Deutz Engine Models Specifications
Specifications for Deutz D2011L03i and TD2011L04i engines.
Engine Specifications (Continuation)
Perkins Engine Models Specifications
Specifications for various Perkins engine models.
Engine Specifications (Continuation)
Kubota Engine Models Specifications
Specifications for Kubota D1105-E3B, D1105-E4B, WG972, and Z482-E engines.
Engine Specifications (Continuation)
GM Engine Models Specifications
Specifications for GM .998L and 3.0L engines.
Continental Engine Models Specifications
Specifications for Continental TME27 engine.
Engine Specifications (Continuation)
Cummins Engine Models Specifications
Specifications for Cummins B3.3T engine.
Hydraulic Specifications
Hydraulic Relief Valve Pressure
Manifold relief valve pressures for various models.
Hydraulic Specifications (Continuation)
Traction and Steer/Axle Manifolds and Oscillate Relief Valve Pressure
Relief valve pressures for traction, steer/axle, and oscillate systems.
Hydraulic Specifications (Continuation)
Hydraulic and Drive Hub Fluid Capacities
Capacities for drive hubs, turntable hubs, and hydraulic tanks.
Hydraulic Specifications (Continuation)
Hydraulic Oil Specifications
Genie specifications for hydraulic oils, cleanliness, water content, and recommended fluids.
Hydraulic Specifications (Continuation)
Hydraulic Hose and Fitting Torque Specifications
Torque specifications for Seal-Lok, JIC 37°, and SAE O-ring Boss Port fittings.
Maintenance Procedures
Observe and Obey: Maintenance Rules
General rules and warnings for performing maintenance procedures.
Machine Configuration for Maintenance
Required machine setup for performing procedures.
Maintenance Procedures (Continuation)
About This Section: Maintenance Procedures
Details procedures, safety warnings, and step-by-step instructions for maintenance.
Safety Symbols Legend
Explanation of safety symbols used in the manual.
Maintenance Symbols Legend
Explanation of symbols used in maintenance procedures.
Maintenance Procedures (Continuation)
Maintenance Schedule Overview
Overview of maintenance intervals: Commissioning, Quarterly, Annually, Programmed.
Maintenance Inspection Report Examples
Examples of how to use maintenance inspection reports.
Pre-Delivery Preparation Report
Pre-Delivery Preparation Fundamentals
Responsibility for pre-delivery preparation and machine condition checks.
Pre-Delivery Preparation Instructions
Steps for completing the pre-delivery inspection report.
Scheduled Maintenance Inspection Report - Booms
Drive Chassis Inspection
Checklists for inspecting tires, wheels, brakes, and drive hub.
Turntable Mechanicals and Hydraulics Inspection
Checklists for inspecting turntable bearings, oil, and filters.
Electrical System Inspection
Checklists for inspecting electrical contactors, wiring, and batteries.
Engine System Inspection
Checklists for inspecting exhaust, generator belts, pulleys, and engine RPM.
Boom(s) and Platform Inspection
Checklists for inspecting jib bearings, platform overload, and boom cables.
Functions and Controls Inspection
Checklists for testing various system functions and sensors.
Programmed Maintenance Inspection Report - Booms
Commissioning Procedures
One-time maintenance procedures for 50 and 150 hours.
Programmed Maintenance - Under 1000 HRS
Scheduled maintenance tasks based on operating hours.
Programmed Maintenance Intervals
Scheduled maintenance tasks for various hour intervals.
Commissioning Procedures
C-1 Perform 50 Hour Service
One-time maintenance tasks after the first 50 hours of usage.
C-2 Perform Engine Maintenance - 50 Hours
One-time engine maintenance tasks after the first 50 hours of usage.
Commissioning Procedures (Continuation)
C-3 Perform 150 Hour Service
One-time maintenance tasks after the first 150 hours of usage.
Quarterly Maintenance Procedures
Q-1 Check for Open Bulletins and Owner Registration
Procedure to check for required bulletins and update owner information.
Quarterly Maintenance Procedures (Continuation)
Q-2 Battery Inspection
Procedure for inspecting battery condition, fluid levels, and connections.
Quarterly Maintenance Procedures (Continuation)
Q-3 Inspect the Electrical Wiring
Procedure to inspect electrical wiring for damage, corrosion, or loose connections.
Quarterly Maintenance Procedures (Continuation)
Q-4 Inspect the Electrical Contactor - DC / Bi-Energy Models
Procedure to inspect electrical contactors for burns, arcs, or pitting.
Quarterly Maintenance Procedures (Continuation)
Q-5 Check the Exhaust System
Procedure to check exhaust system for tightness, leaks, and cracks.
Q-6 Inspect Tires, Wheels, and Lug Nut Torque
Procedure to inspect tires, wheels, and check lug nut torque.
Quarterly Maintenance Procedures (Continuation)
Q-7 Check Generator Belts, Pulleys, and Voltage - Bi-Energy Models
Procedure to check generator belts, pulleys, alignment, and voltage.
Quarterly Maintenance Procedures (Continuation)
Q-8 Check Oscillate Directional Valve Linkage (if equipped)
Procedure to inspect oscillate directional valve linkage for proper operation.
Quarterly Maintenance Procedures (Continuation)
Q-9 Visual Inspection of the Hydraulic Oil
Procedure to visually inspect hydraulic oil for color, appearance, and contamination.
Quarterly Maintenance Procedures (Continuation)
Q-10 Inspect the Hydraulic Filters
Procedure to inspect hydraulic filters and check filter condition indicators.
Quarterly Maintenance Procedures (Continuation)
Q-11 Check and Adjust Engine RPM
Procedure to check and adjust engine low and high idle RPM.
Quarterly Maintenance Procedures (Continuation)
Q-12 Test the Ground Control Override
Procedure to test the ground control override function for safe operation.
Q-13 Test the Alarm Package (if equipped)
Procedure to test travel, descent, and flashing beacon alarms.
Quarterly Maintenance Procedures (Continuation)
Q-14 Test the Emergency Power System (excludes ALC-1000 Models)
Procedure to test the emergency power system for safe machine operation.
Quarterly Maintenance Procedures (Continuation)
Q-15 Test Engine Idle Select Operation - Engine Models
Procedure to test the engine idle select function for proper performance.
Quarterly Maintenance Procedures (Continuation)
Q-16 Test Fuel Select Operation - Gasoline/LPG Models
Procedure to test fuel selection and switching for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-17 Inspect Calibration Decal - SX-150, SX-180, Z-135/70, ZX-135/70
Procedure to inspect calibration decals for legibility and presence.
Quarterly Maintenance Procedures (Continuation)
Q-18 Test Recovery System - ALC-1000 Models
Procedure to test the recovery system for lowering the platform in emergencies.
Quarterly Maintenance Procedures (Continuation)
Q-19 Test Platform Self-leveling
Procedure to test automatic platform self-leveling for safe operation.
Q-20 Confirm Proper Brake Configuration
Procedure to ensure proper brake configuration for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-21 Test the Drive Brakes
Procedure to test drive brake operation for smooth, safe performance.
Q-22 Test Drive Speed – Stowed Position
Procedure to test drive speed in stowed position for proper performance.
Quarterly Maintenance Procedures (Continuation)
Q-23 Test Drive Speed – Raised or Extended Position
Procedure to test drive speed in raised/extended positions for proper performance.
Quarterly Maintenance Procedures (Continuation)
Q-24 Test Drive Speed – Raised and Extended Position, ALC1000 Models
Procedure to test drive speed in raised/extended positions for ALC1000 models.
Quarterly Maintenance Procedures (Continuation)
Q-25 Test Turntable Level Sensor - Z-135/70, ZX-135/70, SX-150, SX-180
Procedure to test the turntable level sensor for safe machine operation.
Quarterly Maintenance Procedures (Continuation)
Q-26 Test Secondary Boom Angle Sensor - Z-135/70, ZX135/70
Procedure to test the secondary boom angle sensor for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-27 Test Primary Boom Angle Sensor - Z-135/70, ZX135/70
Procedure to test the primary boom angle sensor for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-28 Test Primary Boom Angle Sensor - SX-150, SX-180
Procedure to test the primary boom angle sensor for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-29 Test Safety Envelope Limit Switches, Z-135/70, ZX-135/70, SX-150, SX-180
Procedure to test safety envelope limit switches for machine stability.
Quarterly Maintenance Procedures (Continuation)
Q-30 Test Primary Boom Angle Sensor - Z-80/60
Procedure to test the primary boom angle sensor for safe operation.
Quarterly Maintenance Procedures (Continuation)
Q-31 Test Safety Envelope and Circuits - Z-80/60
Procedure to test safety envelope switches and circuits for machine stability.
Quarterly Maintenance Procedures (Continuation)
Q-32 Check Safety Envelope Limit Switches and Angle Sensor - S-60X, S-60XC, S-80X
Procedure to check safety envelope limit switches and angle sensor.
Quarterly Maintenance Procedures (Continuation)
Q-33 Test Safety Envelope and Circuits - S-100, S-105, S-120, S-125, S-100HD, S-120HD
Procedure to test safety envelope and circuits for specific S models.
Quarterly Maintenance Procedures (Continuation)
Q-34 Test Aircraft Protection System (if equipped)
Procedure to test the aircraft protection system for machine and property damage.
Quarterly Maintenance Procedures (Continuation)
Q-35 Test Operator Protection Alarm (if equipped)
Procedure to test the operator protection alarm for proper operation.
Annual Maintenance Procedures
A-1 Grease Turntable Rotation Bearing and Rotate Gear
Procedure to grease turntable bearing and rotate gear for performance and life.
Annual Maintenance Procedures (Continuation)
A-2 Check Turntable Rotation Bearing Bolts
Procedure to check torque of turntable bearing mounting bolts.
Annual Maintenance Procedures (Continuation)
A-3 Inspect for Turntable Bearing Wear
Procedure to inspect turntable bearing for wear using a dial indicator.
Annual Maintenance Procedures (Continuation)
A-4 Check Extendable Axle - S-100, S-100HD, S-105, S-120, S-120HD, S-125
Procedure to check axle wear pads and extend/retract axles.
Annual Maintenance Procedures (Continuation)
A-5 Perform Maintenance – Jib Rotate Bearing - SX-150, SX-180
Procedures for checking jib rotator fastener torque and greasing the jib rotator.
Annual Maintenance Procedures (Continuation)
A-6 Test Key Switches - ALC1000 Models
Procedure to test main and bypass/recovery key switches for safe operation.
Annual Maintenance Procedures (Continuation)
A-7 Grease Platform Overload Mechanism (if equipped)
Procedure to grease platform overload mechanism for safe operation.
A-8 Test Platform Overload System - Except ALC1000, S-60HC Models
Procedure to test platform overload system for safe operation.
Annual Maintenance Procedures (Continuation)
A-9 Test Platform Overload System - ALC1000 Models
Procedure to test platform overload system for safe operation on ALC1000 models.
Annual Maintenance Procedures (Continuation)
A-10 Test Platform Load Sense System - S-60 HC
Procedure to test platform load sense system for safe operation.
Annual Maintenance Procedures (Continuation)
A-11 Inspect Boom Extend/Retract Cables - S-60, S-80 Models
Procedure to inspect boom extend/retract cables for damage and proper function.
Annual Maintenance Procedures (Continuation)
A-12 Inspect Boom Extend/Retract Cables - S-100, S-105, S-120, S-125, S-100HD, S-120HD
Procedure to inspect boom extend/retract cables for damage and proper function.
Annual Maintenance Procedures (Continuation)
A-13 Inspect Boom Extend/Retract Cables - SX-150, SX-180 Models
Procedure to inspect boom extend/retract cables for adjustment and function.
Annual Maintenance Procedures (Continuation)
A-14 Check Drive Hub Oil Level and Fastener Torque
Procedure to check drive hub oil level and fastener torque.
Programmed Maintenance Procedures
P0-1 Check Track Tension and Fastener Torque, TRAX Models - S-60, S-65, Z-62
Procedure to check track tension and fastener torque for TRAX models.
Programmed Maintenance Procedures (Continuation)
P0-2 Check Track Tension and Fastener Torque, TRAX Models - S-40, S-45
Procedure to check track tension and fastener torque for TRAX models.
Programmed Maintenance Procedures (Continuation)
P0-3 Grease Extendable Axles - S-100, S-105, S-120, S-125, S100HD, S-120HD
Procedure to grease extendable axles for smooth operation.
Programmed Maintenance Procedures (Continuation)
P0-4 Continental Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Continental TME27 engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-5 Cummins Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Cummins B3.3T engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-6 Deutz Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Deutz engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-7 Ford Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Ford engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-8 Kubota Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Kubota engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-9 Perkins Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for Perkins engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-10 GM .998L Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for GM .998L engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P0-11 GM 3.0L Engine Maintenance – Under 1000 Hours
Engine maintenance schedule for GM 3.0L engines up to 1000 hours.
Programmed Maintenance Procedures (Continuation)
P1-1 Perform Engine Maintenance – 1000 Hours
Engine maintenance tasks to be performed every 1000 hours.
Programmed Maintenance Procedures (Continuation)
P1-2 Replace the Drive Hub Oil
Procedure to replace drive hub oil after initial 50 hours and then every 1000 hours.
Programmed Maintenance Procedures (Continuation)
P2-1 Perform Engine Maintenance – 2000 Hours
Engine maintenance tasks to be performed every 2000 hours.
Programmed Maintenance Procedures (Continuation)
P2-2 Test or Replace the Hydraulic Oil
Procedure to test or replace hydraulic oil every 2000 hours.
Programmed Maintenance Procedures (Continuation)
P2-3 Replace the Hydraulic Filters
Procedure to replace hydraulic filters (tank, medium, high pressure, case drain) every 2000 hours.
Programmed Maintenance Procedures (Continuation)
P2-4 Check the Free-wheel Configuration
Procedure to check the free-wheel configuration for safe towing.
Programmed Maintenance Procedures (Continuation)
P2-5 Check the Boom Wear Pads
Procedure to check boom wear pad thickness and condition.
Programmed Maintenance Procedures (Continuation)
P2-6 Check Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD, S-120HD
Procedure to check axle wear pads for proper condition.
P2-7 Check Turntable Rotation Gear Backlash - ALC1000 Models
Procedure to check turntable rotation gear backlash for performance.
Programmed Maintenance Procedures (Continuation)
P2-8 Grease Steer Axle Wheel Bearings, All 2WD Models (except S-60, S-65, Z-60 DC/FE, Z-62)
Procedure to grease steer axle wheel bearings for safe operation.
Programmed Maintenance Procedures (Continuation)
P3-1 Perform Engine Maintenance – 3000 Hours
Engine maintenance tasks to be performed every 3000 hours.
Programmed Maintenance Procedures (Continuation)
P4-1 Perform Engine Maintenance – 4000 Hours
Engine maintenance tasks to be performed every 4000 hours.
Programmed Maintenance Procedures (Continuation)
P5-1 Perform Engine Maintenance – 5000 Hours
Engine maintenance tasks to be performed every 5000 hours.
P6-1 Perform Engine Maintenance – 6000 Hours
Engine maintenance tasks to be performed every 6000 hours.
Programmed Maintenance Procedures (Continuation)
P12-1 Perform Engine Maintenance – 12000 Hours
Engine maintenance tasks to be performed every 12000 hours.
P12-2 Replace Boom Extend/Retract Cables - S-100HD, S-120HD
Procedure to replace boom extend/retract cables every 7 years.
Programmed Maintenance Procedures (Continuation)
P12-3 Replace Boom Extend/Retract Cables - S-60, S-80, S-100, S-105, S-120, S-125, SX-150, SX-180
Procedure to replace boom extend/retract cables every 10 years.
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