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Genie Z-60/37 FE
Terex Genie Z-60/37 FE Manuals
Manuals and User Guides for Terex Genie Z-60/37 FE. We have
4
Terex Genie Z-60/37 FE manuals available for free PDF download: Maintenance Manual, Service And Repair Manual
Terex Genie Z-60/37 FE Maintenance Manual (198 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 8 MB
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
29
Tires and Wheels
29
Trax Torque Specifications
31
Engine Specifications
32
Engine Operator and Maintenance Manuals
32
Deutz Engine Models
33
Perkins Engine Models
34
Ford Engine Models
36
Kubota Engine Models
37
GM Engine Models
38
Continental Engine Models
38
Cummins Engine Models
39
Hydraulic Specifications
40
Hydraulic Relief Valves
40
Hydraulic and Drive Hub Fluid Capacities
43
Hydraulic Oil Specifications
45
Hydraulic Hose and Fitting Torque Specifications
48
Torque Procedure
49
Maintenance Procedures
51
Introduction
51
Maintenance Schedule
53
Pre-Delivery Preparation Report
54
Scheduled Maintenance Inspection Report - Quarterly or Frequent
55
Scheduled Maintenance Inspection Report - Annual
56
Programmed Maintenance Inspection Report - Booms
57
Commissioning Procedures
58
Perform 50 Hour Service
58
Perform Engine Maintenance - 50 Hours
58
Perform 150 Hour Service
59
Quarterly Maintenance Procedures
60
Check for Open Bulletins and Owner Registration
60
Battery Inspection
61
Inspect the Electrical Wiring
63
Inspect the Electrical Contactors - DC / Bi-Energy Models
64
Check the Exhaust System
65
Inspect the Tires, Wheels and Lug Nut Torque
66
Check the Generator Belts and Pulleys, Bi-Energy Models
66
Check the Oscillate Directional Valve Linkage (if Equipped)
68
Visual Inspection of the Hydraulic Oil
68
Inspect the Hydraulic Filters
69
Check and Adjust the Engine RPM
70
Test the Ground Control Override
76
Test the Alarm Package (if Equipped)
76
Test the Emergency Power System
77
Test the Engine Idle Select - Engine Models
78
Test the Fuel Select Operation - Gasoline/Lpg Models
79
Inspect the Calibration Decal - ALC1000 Models
81
Test the Recovery Mode System - ALC-1000 Models
82
Test the Platform Self-Leveling
83
Confirm the Proper Brake Configuration
84
Test the Drive Brakes
84
Test the Drive Speed - Stowed Position
85
Test the Drive Speed - Raised or Extended Position
85
Test the Drive Speed - Raised and Extended, ALC1000 Models
86
Test the Turntable Level Sensor
88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
88
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
90
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
92
Test the Primary Boom Angle Sensor
95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
95
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
100
Test the Primary Boom Angle Sensor - Z-80/60
104
Test the Safety Envelope and Circuits - Z-80/60
105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
107
Test the Safety Envelope and Circuits
109
And S-125
109
Test the Aircraft Protection System (if Equipped)
115
Test the Operator Protection Alarm (if Equipped)
117
Inspect the Boom Extend/Retract Cables - All Models
117
Test the Recovery Mode System - ALC600 Models
119
Test the Turntable Level Sensor - ALC600 Models
120
Test the Primary Boom Angle Sensor - ALC600 Models
122
Annual Maintenance Procedures
124
Grease the Turntable Rotation Bearing and Rotate Gear
124
Check the Turntable Rotation Bearing Bolts
125
Inspect for Turntable Bearing Wear
127
Check the Extendable Axle - S-100, S-105, S-120 and S-125
128
Perform Maintenance- Jib Rotate Bearing
129
Test the Bypass/Recovery Key Switch - ALC1000 Models
130
Grease the Platform Overload Mechanism (if Equipped)
133
Test the Platform Overload System - (if Equipped)
133
Test the Platform Overload System - ALC1000 Models
135
Test the Platform Load Sense System - S-60 HC
137
S-60/65, S-80/85 and S-80J Models
138
Inspect the Boom Extend/Retract Cables and Sheaves
139
Inspect the Boom Extend/Retract Cables and Sheaves
141
S-100, S-105, S-120, S-125, SX-105XC and SX-125XC
141
Inspect the Boom Extend and Retract Cables and Sheaves -
143
Check the Drive Hub Oil Level and Fastener Torque
146
Test the Dual Capacity and Platform Overload System - SX-105XC, SX-125XC and SX-135XC
150
Test the Dual Capacity and Platform Overload System - Z-45XC Models
152
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
154
Test the Platform Overload System - S-40HF, S-45HF, S-60J
156
S-80J, Z-45HF, Z-45 DC/FE from Z45EM-101
156
Perform Engine Maintenance
158
Programmed Maintenance Procedures
159
P0-1 Check the Track Tension and Fastener Torque, Trax Models
159
XC, S-65 XC, Z-62 Models
159
P0-2 Check the Track Tension and Fastener Torque, Trax Models - S-40, S-45, S-40 XC, S-45 XC Models
160
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125
162
P0-4 Continental Engine Maintenance - under 1000 Hours
163
P0-5 Cummins Engine Maintenance - under 1000 Hours
164
P0-6 Deutz Engine Maintenance - under 1000 Hours
165
P0-7 Ford Engine Maintenance - under 1000 Hours
166
P0-8 Kubota Engine Maintenance - under 1000 Hours
167
P0-9 Perkins Engine Maintenance - under 1000 Hours
169
P0-10 GM .998L Engine Maintenance - under 1000 Hours
170
P0-11 GM 3.0L Engine Maintenance - under 1000 Hours
171
P1-1 Perform Engine Maintenance - 1000 Hours
172
P1-2 Replace the Drive Hub Oil
174
P1-3 Perform Engine Maintenance - 1500 Hours
177
P2-1 Perform Engine Maintenance - 2000 Hours
177
P2-2 Test or Replace the Hydraulic Oil
179
P2-3 Replace the Hydraulic Filters
180
P2-4 Check the Free-Wheel Configuration
182
P2-5 Check the Boom Wear Pads
184
P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD
187
P2-7 Check the Turntable Rotation Gear Backlash
187
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62
188
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models
190
DC/FE and Z-62
190
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Terex Genie Z-60/37 FE Maintenance Manual (192 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 5 MB
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
28
Tires and Wheels
28
Trax Torque Specifications
30
Engine Specifications
31
Engine Operator and Maintenance Manuals
31
Deutz Engine Models
32
Perkins Engine Models
33
Ford Engine Models
35
Kubota Engine Models
36
GM Engine Models
37
Continental Engine Models
37
Cummins Engine Models
38
Hydraulic Specifications
39
Hydraulic Relief Valves
39
Hydraulic and Drive Hub Fluid Capacities
42
Hydraulic Oil Specifications
44
Hydraulic Hose and Fitting Torque Specifications
47
Torque Procedure
48
Maintenance Procedures
50
Introduction
50
Maintenance Schedule
52
Pre-Delivery Preparation Report
53
Scheduled Maintenance Inspection Report - Quarterly or Frequent
54
Scheduled Maintenance Inspection Report - Annual
55
Programmed Maintenance Inspection Report - Booms
56
Commissioning Procedures
57
Perform 50 Hour Service
57
Perform Engine Maintenance - 50 Hours
57
Perform 150 Hour Service
58
Quarterly Maintenance Procedures
59
Check for Open Bulletins and Owner Registration
59
Battery Inspection
60
Inspect the Electrical Wiring
62
Inspect the Electrical Contactors - DC / Bi-Energy Models
63
Check the Exhaust System
64
Inspect the Tires, Wheels and Lug Nut Torque
65
Check the Generator Belts and Pulleys, Bi-Energy Models
65
Check the Oscillate Directional Valve Linkage (if Equipped)
67
Visual Inspection of the Hydraulic Oil
67
Inspect the Hydraulic Filters
68
Check and Adjust the Engine RPM
69
Test the Ground Control Override
75
Test the Alarm Package (if Equipped)
75
Test the Emergency Power System
76
Test the Engine Idle Select - Engine Models
77
Test the Fuel Select Operation - Gasoline/Lpg Models
78
Inspect the Calibration Decal - ALC1000 Models
79
Test the Recovery Mode System - ALC-1000 Models
80
Test the Platform Self-Leveling
82
Confirm the Proper Brake Configuration
82
Test the Drive Brakes
83
Test the Drive Speed - Stowed Position
83
Test the Drive Speed - Raised or Extended Position
84
Test the Drive Speed - Raised and Extended, ALC1000 Models
85
Test the Turntable Level Sensor
86
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
86
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
89
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
91
Test the Primary Boom Angle Sensor
93
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
93
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
98
Test the Primary Boom Angle Sensor - Z-80/60
102
Test the Safety Envelope and Circuits - Z-80/60
103
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
105
Test the Safety Envelope and Circuits
107
And S-125
107
Test the Aircraft Protection System (if Equipped)
113
Test the Operator Protection Alarm (if Equipped)
115
Inspect the Boom Extend/Retract Cables - All Models
115
Test the Recovery Mode System - ALC-600 Models
116
Test the Turntable Level Sensor - S-40HF, S-45HF, S-40XC, S-45XC, S- 60HF, S-65HF, S-60J, S-60XC from S60XCH-45001, S-65XC
117
S-80Hf, S-85Hf, S-80Xc, S-85Xc
117
Test the Primary Boom Angle Sensor - S-40HF, S-45HF, S-40XC
119
S-45XC, S-60HF, S-65HF, S-60J, S-60XC from S60XCH-45001
119
S-65Xc, S-80Hf, S-85Hf, S-80Xc, S-85Xc
119
Annual Maintenance Procedures
121
Grease the Turntable Rotation Bearing and Rotate Gear
121
Check the Turntable Rotation Bearing Bolts
122
Inspect for Turntable Bearing Wear
124
Check the Extendable Axle - S-100, S-105, S-120 and S-125
125
Perform Maintenance- Jib Rotate Bearing
126
Test the Bypass/Recovery Key Switch - ALC1000 Models
127
Grease the Platform Overload Mechanism (if Equipped)
129
Test the Platform Overload System - All Models
130
S-80HF, S-85HF, S-80XC, S-85XC and Z-45XC Models)
130
Test the Platform Overload System - ALC1000 Models
132
Test the Platform Load Sense System - S-60 HC
133
Inspect the Boom Extend/Retract Cables and Sheaves
134
S-60/65 and S-80/85 Models
134
Inspect the Boom Extend/Retract Cables and Sheaves - S-100, S-105, S-120, S-125, SX-105XC and SX-125XC
136
Inspect the Boom Extend and Retract Cables and Sheaves -
138
Check the Drive Hub Oil Level and Fastener Torque
142
Test the Dual Capacity and Platform Overload System - SX-105XC, SX-125XC and SX-135XC
146
Test the Dual Capacity and Platform Overload System - Z-45XC Models
148
Test the Dual Capacity and Platform Overload System
148
S-65Xc, S-80Hf, S-85Hf, S-80Xc, S-85Xc
149
Test the Platform Overload System - S-40HF, S-45HF, Z-45HF, Z-45 DC/FE from Z45EM-101
151
Perform Engine Maintenance
152
Terex Genie Z-60/37 FE Maintenance Manual (185 pages)
Brand:
Terex
| Category:
Boom Lifts
| Size: 4 MB
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
29
Tires and Wheels
29
Trax Torque Specifications
31
Engine Specifications
32
Engine Operator and Maintenance Manuals
32
Deutz Engine Models
33
Perkins Engine Models
34
Ford Engine Models
36
Kubota Engine Models
37
GM Engine Models
38
Continental Engine Models
38
Cummins Engine Models
39
Hydraulic Specifications
40
Hydraulic Relief Valves
40
Hydraulic and Drive Hub Fluid Capacities
43
Hydraulic Oil Specifications
45
Hydraulic Hose and Fitting Torque Specifications
48
Torque Procedure
49
Maintenance Procedures
51
Introduction
51
Maintenance Schedule
53
Pre-Delivery Preparation Report
54
Scheduled Maintenance Inspection Report - Quarterly or Frequent
55
Scheduled Maintenance Inspection Report - Annual
56
Programmed Maintenance Inspection Report - Booms
57
Commissioning Procedures
58
Perform 50 Hour Service
58
Perform Engine Maintenance - 50 Hours
58
Perform 150 Hour Service
59
Quarterly Maintenance Procedures
60
Check for Open Bulletins and Owner Registration
60
Battery Inspection
61
Inspect the Electrical Wiring
63
Inspect the Electrical Contactors - DC / Bi-Energy Models
64
Check the Exhaust System
65
Inspect the Tires, Wheels and Lug Nut Torque
66
Check the Generator Belts and Pulleys, Bi-Energy Models
66
Check the Oscillate Directional Valve Linkage (if Equipped)
68
Visual Inspection of the Hydraulic Oil
68
Inspect the Hydraulic Filters
69
Check and Adjust the Engine RPM
70
Test the Ground Control Override
76
Test the Alarm Package (if Equipped)
76
Test the Emergency Power System
77
Test the Engine Idle Select - Engine Models
78
Test the Fuel Select Operation - Gasoline/Lpg Models
79
Inspect the Calibration Decal - ALC1000 Models
81
Test the Recovery Mode System - ALC-1000 Models
82
Test the Platform Self-Leveling
83
Confirm the Proper Brake Configuration
84
Test the Drive Brakes
84
Test the Drive Speed - Stowed Position
85
Test the Drive Speed - Raised or Extended Position
85
Test the Drive Speed - Raised and Extended, ALC1000 Models
86
Test the Turntable Level Sensor
88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
88
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
90
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
92
Test the Primary Boom Angle Sensor
95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
95
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
100
Test the Primary Boom Angle Sensor - Z-80/60
104
Test the Safety Envelope and Circuits - Z-80/60
105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
107
Test the Safety Envelope and Circuits
109
And S-125
109
Test the Aircraft Protection System (if Equipped)
115
Test the Operator Protection Alarm (if Equipped)
117
Inspect the Boom Extend/Retract Cables - All Models
117
Test the Recovery Mode System - ALC600 Models
118
Test the Turntable Level Sensor - ALC600 Models
119
Test the Primary Boom Angle Sensor - ALC600 Models
122
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Terex Genie Z-60/37 FE Service And Repair Manual (125 pages)
Serial Number Range from Z6016N-101 to Z6016N-599, from Z60N-600
Brand:
Terex
| Category:
Boom Lifts
| Size: 5 MB
Table of Contents
Table of Contents
7
Find a Manual for this Model
2
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
11
Machine Specifications
11
Performance Specifications
12
Hydraulic Specification
12
Hydraulic Component Specifications
15
Manifold Component Specifications
16
Kubota D1105 Engine Specifications
17
Machine Torque Specifications
18
Machine Component Weights
18
Hydraulic Hose and Fitting Torque Specifications
19
Torque Procedure
20
Repair Procedures
22
Introduction
22
Observe and Obey
22
About this Section
23
Cailbration Process Steps
24
Platform Controls
25
How to Adjust the Joystick Threshold Setting
26
How to Adjust the Joystick Max-Out Setting
27
How to Adjust the Joystick Ramp Rate Setting
30
How to Calibrate Booms Angle Sensors
31
How to Clear the Fault History
32
Platform Components
32
Platform Leveling Slave Cylinder
32
Bodily Injury Hazard. Spraying
33
Platform Rotator
34
Platform Overload System
35
How to Reset Overload Recovery Message
37
Jib Boom Components
38
Jib Boom
38
Jib Boom Lift Cylinder
39
Primary Boom Components
40
Cable Track
40
How to Repair the Cable Track
41
Primary Boom
41
How to Disassemble the Primary Boom
42
Primary Boom Lift Cylinder
43
Primary Boom Extension Cylinder
44
Platform Leveling Master Cylinder
45
Secondary Boom Components
46
Secondary Boom Lift Cylinder
47
Engines
49
RPM Adjustment
49
How to Replace the Motor Tach Sensor
49
Hydraulic Pumps
50
Function Pump
50
How to Check the Function Pump Calibration
51
Manifolds
52
Function Manifold Components
53
Valve Adjustments - Function Manifold
57
How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor
57
How to Adjust the Platform Level up Relief Valve
58
How to Adjust the Primary Boom Extend Relief Valve
59
Jib Boom / Platform Rotate Manifold Components
60
Turntable Rotation Manifold Components
61
Oscillate Directional Valve Manifold Components
62
How to Set up the Oscillate Directional Valve
63
How to Adjust the Oscillate Reducing Valve
63
Electrocution/Burn Hazard
64
How to Test a Coil Diode
65
Turntable Rotation Components
66
Turntable Rotation Assembly
66
How to Replace the Universal Tilt Sensor
68
How to Calibrate the Universal Tilt Sensor
69
Axle Components
70
Oscillating Axle Cylinders
70
How to Remove the Steer Cylinder
71
Connections very Slowly to Allow
71
Gradually. Do Not Allow Oil to
71
How to Calibrate the Steer Angle Sensor
71
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
71
Squirt or Spray
71
The Oil Pressure to Dissipate
71
Fault Codes
73
Introduction
73
Before Troubleshooting
73
Immediately Tag and Remove from Service a Damaged or Malfunctioning Machine
73
R Immediately Tag and Remove from Service a
73
R Read, Understand and Obey the Safety Rules
73
R Repair any Machine Damage or Malfunction
73
R Troubleshooting and Repair Procedures Shall be
73
Repair any Machine Damage or Malfunction before Operating the Machine
73
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
73
Control System Fault Codes
74
Fault Codes Ground Controls
74
How to Retrieve Control System Fault Codes - Platform Controls
75
Control System Fault Codes
76
Navigation Menus
91
Faults Navigation Menu
92
Options Navigation Menu
93
Settings Navigation Menu
94
Schematics
95
Introduction
95
Electrical Symbol Legend
96
Hydraulic Symbols Legend
97
Electrical Component and Wire Color Legends
98
Kubota Engine Fuse and Relay Module
101
DC Charger Wiring (DC Option)
102
AC Input Wiring (DC Option)
103
CAN BUS Wiring Diagram - DC Models
104
Limit Switch/Angle Sensor Legend
105
Electrical Schematics - Options
107
Wiring Diagram - Options
108
Schematics - Options, 4WD, DC and FE Models
109
Power Cable Wiring Diagram
112
Hydraulic Schematics
113
Hydraulic Schematic, DC and FE Models
113
Electrical Schematics
115
Electrical Schematics, DC/FE Models
116
Ground Control Box Terminal Strip Wiring Diagram
122
Platform Control Box Wiring Diagram
123
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