Genie S Series Maintenance Manual Download

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Maintenance Manual

October 2018

Annual Maintenance Procedures

108

Booms • Z

Booms

Part No. 1268489GT

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.

11 Lower the platform and remove the weight.
12 Remove the dial indicator from the machine.

Illustration 2

1 measuring surface
2 dial indicator mounting surface

A-6

Test the Key Switches - ALC1000

Models

Genie specifications require that this procedure be

performed annually.
Proper key switch action and response is essential

to safe machine operation. Failure of either key

switch to function properly could cause a

hazardous operating situation.
This maintenance procedure applies to the

following models:

S-100,

S-100HD, S-105, S-120,

S-120HD, S-125, SX-105 XC, SX-125 XC, SX-135

XC, SX-150, SX-180, Z-80/60, Z-135/70 and

ZX-135/70.

There are two key switches on the machine - the

Main key switch and the Bypass/Recovery key

switch.
The Main key switch controls machine operation

from the ground or platform controls.
When the Bypass/Recovery key switch is turned to

the bypass position, the primary boom can be

elevated with the axles retracted (if equipped with

retractable axles). This feature of the machine is

especially helpful for storage purposes or when

loading the machine for transport.

Summary of Contents for S Series

Page 1: ...ach maintenance inspection Z 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 included in this manual Part No 1268489GT Rev G October 2018 ...

Page 2: ...liance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers a...

Page 3: ...C from SX125D 101 SX 135 XC from SX135H 101 SX 150 from SX15015 100 to Sx15016H 499 from SX150H 500 SX 180 from SX18014 101 to SX18016H 599 from SX180H 600 Z 30 20N Z 30 20N RJ from Z30N14 15222 to Z30N16F 18899 from Z30N16D 104 to Z30N16D 199 from Z30NF 18900 from Z30ND 200 Z 33 18 from Z331815M 101 to Z331816M 1299 from Z3318M 1300 Z 34 22 DC from Z3414 9686 to Z3416F 11999 Z34F 12000 Z 34 22 N ...

Page 4: ... Sensor Z 80 60 ALC600 Models include the following models S 60 XC from S60XCH 45001 and S60XCM 101 S 65 XC S 80 HF S 85 HF S 80 XC and S 85 XC ALC1000 Models include the following models S 100 S 100HD S 105 S 120 S 120HD S 125 SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Examples of procedures that apply to all models Test the Drive Speed Stowed Position Inspect the ...

Page 5: ...98L GM 3 0L Update Deutz D2 9 L4 and Perkins 404F engine rpm s B1 4 2016 Quarterly Q 7 Check the Generator Belts Pulleys and voltage Bi Energy Models Annual A 3 Inspect for Turntable Bearing Wear B2 6 2016 Specifications Tires and Wheels add Z60 DC FE B3 9 2016 Introduction Models Included C 11 2016 All Sections Add SX 135 XC C1 12 2016 Quarterly Q 26 Test the Secondary Boom Angle Sensor D 2 2017 ...

Page 6: ... cable inspection F 6 2017 All Sections Add S80 85 XC SX 105 XC Specifications Add Deutz D436 L3i CN3 Engine F1 4 2018 Specifications Deutz TD2011 Engine Specifications G 10 2018 All Sections Add S60XC S 65XC S 80HF S 85HF Models Add Perkins 404F E22T 404F E22TA Engine Reference Examples Section Specifications Electronic Version Click on any content or procedure in the Table of Contents to view th...

Page 7: ...ry Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations Yo...

Page 8: ...crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from fla...

Page 9: ...al Safety Rules vii Section 2 Performance Specifications 1 Function Speeds S 100 S 105 and S 100HD 1 Function Speeds S 120 S 125 and S 120HD 2 Function Speeds All Other Models 3 Drive Speeds 9 Torque Specifications 12 Tires and Wheels 12 TraX Torque Specifications 13 Engine Specifications 14 Engine Operator and Maintenance Manuals 14 Deutz Engine Models 15 Perkins Engine Models 16 Ford Engine Mode...

Page 10: ...cations 29 Torque Procedure 30 Section 3 Maintenance Procedures 32 Introduction 32 Maintenance Schedule 34 Pre Delivery Preparation Report 35 Scheduled Maintenance Inspection Report Quarterly or Frequent 36 Scheduled Maintenance Inspection Report Annual 37 Programmed Maintenance Inspection Report Booms 38 Commissioning Procedures 39 C 1 Perform 50 Hour Service 39 C 2 Perform Engine Maintenance 50 ...

Page 11: ...he Hydraulic Oil 49 Q 10 Inspect the Hydraulic Filters 50 Q 11 Check and Adjust the Engine RPM 51 Q 12 Test the Ground Control Override 56 Q 13 Test the Alarm Package if equipped 57 Q 14 Test the Emergency Power System 58 Q 15 Test the Engine Idle Select Engine Models 58 Q 16 Test the Fuel Select Operation Gasoline LPG Models 60 Q 17 Inspect the Calibration Decal ALC1000 Models 61 Q 18 Test the Re...

Page 12: ...imary Boom Angle Sensor Z 80 60 84 Q 31 Test the Safety Envelope and Circuits Z 80 60 85 Q 32 Check the Safety Envelope Limit Switches and Angle Sensor S 60X S 80X and S 60XC to S60XC 45000 87 Q 33 Test the Safety Envelope and Circuits S 100 S 105 S 120 and S 125 89 Q 34 Test the Aircraft Protection System if equipped 95 Q 35 Test the Operator Protection Alarm if equipped 97 Q 36 Inspect the Boom ...

Page 13: ... S 85HF S 80XC S 85XC and Z 45XC models 111 A 9 Test the Platform Overload System ALC1000 Models 113 A 10 Test the Platform Load Sense System S 60 HC 114 A 11 Inspect the Boom Extend Retract Cables S 60 65 and S 80 85 Models 115 A 12 Inspect the Boom Extend Retract Cables S 100 S 105 S 120 S 125 SX 105 XC and SX 125 XC 117 A 13 Inspect the Boom Extend and Retract Cables SX 135 XC SX 150 and SX 180...

Page 14: ... 1000 Hours 141 P1 1 Perform Engine Maintenance 1000 Hours 142 P1 2 Replace the Drive Hub Oil 143 P2 1 Perform Engine Maintenance 2000 Hours 146 P2 2 Test or Replace the Hydraulic Oil 148 P2 3 Replace the Hydraulic Filters 149 P2 4 Check the Free wheel Configuration 151 P2 5 Check the Boom Wear Pads 153 P2 6 Check the Extendable Axle Wear Pads S 100 S 105 S 120 S 125 S 100HD and S 120HD 156 P2 7 C...

Page 15: ...ion 100 100 Primary boom up down extended to 80 ft 24 4 m time from 53 envelope limit to the fully raised position 50 55 Primary boom extend fully raised position 0 to 100 ft 0 to 30 5 m 120 140 Primary boom retract fully raised position 100 to 0 ft 30 5 to 0 m 120 140 Jib boom up down S 105 models 28 32 Turntable rotate 360 boom horizontal and fully retracted 170 190 Turntable rotate boom horizon...

Page 16: ...elope limit to the fully raised position 50 55 Primary boom up down extended to 100 ft 30 5 m time from 68 envelope limit to the fully raised position 24 28 Primary boom extend fully raised position 0 to 100 ft 0 to 30 5 m 170 190 Primary boom retract fully raised position 100 to 0 ft 30 5 to 0 m 170 190 Jib boom up down S 125 models 28 32 Turntable rotate 360 boom horizontal and fully retracted 1...

Page 17: ...F S 85HF Primary boom up 50 60 60 70 65 75 57 65 75 83 75 83 Primary boom down 50 60 60 70 65 75 61 69 75 83 110 115 Primary boom extend 30 60 58 66 58 66 59 67 59 67 59 67 Primary boom retract 15 35 53 62 53 62 57 65 57 65 57 65 Jib boom up 35 45 S 45 60 70 S 65 48 53 S 65 25 35 S 85 25 35 S 85 25 35 S 85XC HF Jib boom down 20 30 S 45 40 50 S 65 28 33 S 65 15 25 S 85 15 25 S 85 15 25 S 85XC HF Tu...

Page 18: ...22 36 40 retracted 48 52 extended Primary boom down 12 20 12 20 13 20 46 50 retracted 55 59 extended Primary boom extend 15 19 12 18 11 15 18 20 Primary boom retract 10 14 12 18 13 17 18 20 Secondary boom up 11 18 11 18 15 22 20 24 Secondary boom down 7 15 7 15 11 18 20 24 Jib boom up 19 23 23 29 20 24 X Jib boom down 17 21 20 26 18 22 X Jib boom rotate 13 17 Z 30N RJ X X X Turntable rotate 62 72 ...

Page 19: ... down 15 21 16 20 26 30 Z45J 25 35 24 28 Jib boom rotate X 16 20 Z40N RJ X X X Turntable rotate 62 72 62 68 95 125 62 68 67 73 Platform rotate 5 11 10 14 6 10 6 10 12 16 Platform level 10 range of motion ANSI CSA AS CE 3 5 20 22 Function Z 51 Z 60 DC FE Z 62 all models Z 80 Primary boom up 36 40 60 70 60 65 60 70 retracted 80 96 extended Primary boom down 36 40 60 70 65 70 75 85 retracted 80 96 ex...

Page 20: ...oom up down 88 105 110 125 Primary boom extend retract 38 42 35 48 Secondary boom up down 80 95 80 95 Secondary boom extend retract 88 98 88 98 Jib boom up down 38 43 38 43 Jib boom extend retract 27 38 27 38 Turntable rotate stowed 88 92 88 92 Turntable rotate jib or primary boom extended 160 180 160 180 Turntable rotate jib and primary boom extended 280 350 280 350 Platform rotate 20 25 20 25 Pl...

Page 21: ...m 18 23 5 string pot 345 in 876cm 21 24 5 string pot 357 in 907cm Primary boom up down X 25 30 5 string pot 582 in 1478cm X Primary boom extend 120 140 170 190 30 33 0 100 in 254cm Primary boom retract 120 140 170 190 30 33 100 in 254cm 0 Jib boom up down 28 32 28 32 60 65 retracted 122 130 extended Jib boom extend retract X X 50 60 Jib boom rotate X X X Turntable rotate stowed 170 190 170 190 17 ...

Page 22: ...34 39 5 string pot 596 in 1514cm Primary boom extend 0 100 in 254cm 30 33 30 33 Primary boom retract 100 in 254cm 0 30 33 30 33 Jib boom up down 58 62 58 62 Jib boom rotate 28 32 28 32 Turntable rotate stowed 38 42 drive enable to drive enable 38 42 drive enable to drive enable Turntable rotate 63 70 drive enable to drive enable 80 string pot 36 in 91 4cm 63 70 drive enable to drive enable 80 stri...

Page 23: ...2 2 m 8 10 5 sec 40 ft 12 2 m 8 10 5 sec 40 ft 12 2 m 8 10 5 40 ft 12 2 m 9 11 40 ft 12 2 m High flotation tires Stowed position X X X 11 13 40 ft 12 2 m 9 11 40 ft 12 2 m 2WD or 4WD Raised or extended 40 45 40 ft 12 2 m 40 45 40 ft 12 2 m 38 45 40 ft 12 2 m 40 45 40 ft 12 2 m 55 60 40 ft 12 2 m 2WD or 4WD Raised and extended X X X X X TRAX models Stowed position 9 11 40 ft 12 2 m 10 7 13 6 40 ft ...

Page 24: ...0 5 40 ft 12 2 m 6 8 40 ft 12 2 m 4WD models Stowed position 40 45 40 ft 12 2 m SX 135XC 9 12 SX 150 SX 180 9 8 11 8 40 ft 12 2 m X X X 2WD or 4WD Raised or extended 72 4 81 3 40 ft 12 2 m SX 135XC 67 70 SX 150 SX 180 68 75 5 40 ft 12 2 m 42 48 40 ft 12 2 m 50 55 40 ft 12 2 m 42 48 40 ft 12 2 m 2WD or 4WD Raised and extended X SX 150 SX 180 275 5 293 3 40 ft 12 2 m X 190 195 40 ft 12 2 m X Braking...

Page 25: ...on paved surface 3 4 ft 0 9 1 2 m 5 7 ft 1 5 2 m 5 7 ft 1 5 2 m 3 6 ft 0 9 1 8 m Function Z 60 DC FE Z 62 all models Z 80 Z 135 ZX 135 2WD models Stowed position 13 6 14 5 40 ft 12 2 m 6 1 7 8 40 ft 12 2 m X X 4WD models Stowed position 13 6 14 5 40 ft 12 2 m 8 10 5 40 ft 12 2 m 8 7 9 3 40 ft 12 2 m 8 9 9 6 40 ft 12 2 m High flotation tires Stowed position X 8 10 5 40 ft 12 2 m 13 6 14 5 40 ft 12 ...

Page 26: ...S 85XC S 80HF S 85HF 320 ft lbs 434 Nm X 100 psi 6 9 bar X S 100 S 100HD S 105 S 120 S 120HD S 125 320 ft lbs 434 Nm X X X SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 320 ft lbs 434 Nm X X X Z 30N Z 30N RJ 95 ft lbs 129 Nm X X X Z 33 94 ft lbs 127 Nm X X X Z 34N Z 34DC Z 34BE 95 ft lbs 129 Nm X X 100 psi 6 9 bar Z 34DC BE Z 34 IC 95 ft lbs 129 Nm 45 psi 3 1 bar 44 psi 3 0 bar 100 psi 6 9 bar Z 40N...

Page 27: ...bs 81 Nm Hub adapter to drive hub fasteners S 60 S 65 Z 62 S 60XC from S60XCH 45001 and S60XCM 101 S 65XC Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs 244 Nm S 40 S 45 Lug nut torque dry 230 ft lbs 312 Nm Lug nut torque lubricated 170 ft lbs 230 Nm Sprocket bearing hub fasteners 1 14 bolts GR 8 dry 650 ft lbs 881 Nm 1 14 bolts GR 8 lubricated 488 ft lbs 662 Nm Idler an...

Page 28: ...ns 404F E22T and 404F E22TA Genie part number 1289513GT Perkins 804D 33 Genie part number 111332GT Perkins 854F E34T Genie part number 1263971GT Perkins 1104D 44T Genie part number 107526GT Ford DSG 423 Genie part number 119488GT Diagnostic Manual Genie part number 119494GT Ford MSG 425 Genie part number 215322GT Diagnostic Manual Genie part number 162067GT Kubota D1105 E3B Genie part number 22976...

Page 29: ...m D 2 9 L4 Low idle standby 1000 rpm 1000 Hz Low idle with function enable 1500 rpm 1500 Hz High idle 2500 rpm 2500 Hz Oil capacity including filter 9 4 quarts 9 liters Engine coolant capacity 10 quarts 9 4 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm TD 2 9 L4 Low idle standby S 80 85XC SX 105 125 135XC SX 125 XC SX 150 180 Z 135 ZX 135 S 100 105 120 125 100HD 120HD 1000 rpm 1000 Hz Low ...

Page 30: ... 6 liters Engine coolant capacity 13 3 quarts 12 6 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm 404D 22T Low idle standby 1000 rpm 500 Hz Low idle with function enable 1500 rpm 750 Hz High idle 2500 rpm 1250 Hz Oil capacity including filter 9 4 to 11 2 quarts 8 9 to 10 6 liters Engine coolant capacity 13 3 quarts 12 6 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm 404F 22 Low idle ...

Page 31: ...elt deflection 3 8 to 1 2 inch 9 to 12 mm 854F E34T Low idle standby SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 Z 135 ZX 135 S 100 105 120 125 100HD 120HD 1000 rpm 500 Hz Low idle with function enable SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 Z 135 ZX 135 S 100 105 120 125 100HD 120HD 1500 rpm 750 Hz High idle 2500 rpm 1250 Hz Oil capacity including filter 7 7 quarts 7 3 liters Engine coolant c...

Page 32: ...n 3 8 to 1 2 inch 9 to 12 mm Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Unit ships with an Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants Kubota Engine Models D1105 E3B Low idle 1250 rpm 208 3 Hz H...

Page 33: ...t ships with an Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants GM Engine Models 998L Low idle 1100 rpm 36 6 Hz High idle 3000 rpm 100 Hz Oil capacity including filter 3 2 quarts 3 liters Engine coolant capacity 5 quarts 4 7 liters Spark plug gap 0 039 to 0 047 inches 1 to 1 2 mm 3 0L Low idle standby 1000 rpm 33 3 Hz Low idle ...

Page 34: ... Manual for your engine Unit ships with an Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants 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 3 8 to1 2 inch 9 to12 mm Unit ships with...

Page 35: ...950 psi 134 bar X X X X S 60 S 65 S 60HC S 60X S 60XC to 45000 all models 3000 psi 207 bar X X X X X X X X S 60 65X from S60XCH 45001 and S60XCM 101 S 65XC all models 3200 psi 221 bar X X X 2300 psi 159 bar X X X 3500 psi 241 bar S 80 S 85 S 80X 3200 psi 221 bar 2400 psi 165 bar X X 2400 psi 165 bar X X X X S 80XC S 85XC S80HF S85HF 3200 psi 221 bar 2600 psi 179 bar X X 2400 psi 165 bar X X X X S ...

Page 36: ...i 110 bar X 1800 psi 124 bar X 1100 psi 76 bar X X Z 34 IC 3200 psi 221 bar 1600 psi 110 bar 1600 psi 110 bar X X X X X X Z 40N Z 40N RJ X 2100 psi 145 bar X X X X 1800 psi 124 bar 50 3000 psi 3 4 207 bar 2500 psi 172 bar Z 45 25 Z 45 25J DC and BE models 3200 psi 221 bar X 2100 psi 145 bar X X X X X X Z 45 25 IC Z 45 25J IC Z 45 XC 3200 psi 221 bar X 2100 psi 145 bar X X X X X 2500 psi 172 bar Z ...

Page 37: ...65XC all models 280 psi 19 3 bar 600 psi 41 4 bar X S 80 S 85 S 80X S 80XC S 85XC S 80HF S 85HF 280 psi 19 3 bar 950 psi 66 bar X S 100 S 100HD S 105 S 120 S 120HD S 125 280 psi 19 3 bar X 1800 psi 124 bar SX 105 XC SX 125 XC SX 135 XC 240 psi 16 5 bar X 2400 psi 165 bar SX 150 SX 180 250 psi 17 2 bar X 2400 psi 165 bar Z 34 IC 2WD 170 psi 11 7 bar 4WD 150 psi 10 3 bar X X Z 45 25 IC Z 45 25J IC Z...

Page 38: ...ons 151 liters 50 gallons 189 liters S 80XC S 85XC S 80HF S 85HF X 30 5 fl oz 902 cc 43 fl oz 1262 cc 40 gallons 151 liters 64 gallons 242 liters S 100 S 105 S 120 S 125 S 100HD S 120HD X 47 fl oz 1390 cc 93 fl oz 2750 cc 55 gallons 208 liters 80 gallons 303 liters SX 105XC SX 125XC SX 135XC X 67 fl oz 1981 cc 43 fl oz 1262 cc 60 gallons 227 liters 138 gallons 522 liters SX 150 X 67 fl oz 1981 cc ...

Page 39: ... IC Z 45 XC 24 fl oz 710 cc 24 fl oz 710 cc 25 5 fl oz 750 cc 22 gallons 83 liters 28 gallons 106 liters Z 51 X steer end 17 fl oz 503 cc non steer end 42 fl oz 1242 cc 25 5 fl oz 750 cc 22 gallons 83 liters 28 gallons 106 liters Z 60 DC FE 24 fl oz 710 cc 24 fl oz 710 cc 43 fl oz 1262 cc 18 gallons 68 liters 21 gallons 80 liters Z 62 all models 20 fl oz 591 cc 20 fl oz 591 cc 43 fl oz 1262 cc 35 ...

Page 40: ...Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range I...

Page 41: ... below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A h...

Page 42: ...Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C...

Page 43: ... 16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE...

Page 44: ...eated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex...

Page 45: ...rrect number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex...

Page 46: ... damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Machine Configuration Unless otherwise specified perform each procedure with the machine in ...

Page 47: ...if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Maintenance Symbols Legend Note The following symbols have been used in this manual to help ...

Page 48: ...maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Instruction Examples Commissioning Example Quarterly and Annually Example Programmed Example und...

Page 49: ...y qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after ea...

Page 50: ...ide Q 12 Test the Alarm Package if equipped Q 13 Test the Emergency Power System Q 14 Test the Engine Idle Select Operation Q 15 Test Fuel Select Operation Gas LPG Models Q 16 Inspect the Calibration Decal ALC1000 Models Q 17 Test the Recovery System ALC 1000 Models Q 18 Test the Platform Self leveling Q 19 Test the Drive Brakes Q 21 Test the Drive Speed Stowed Position Q 22 Test the Drive Speed R...

Page 51: ...endable Axle Wear Pads if equipped A 4 Check Drive Hub Oil Level and Fastener Torque A 14 Turntable Mechanicals and Hydraulics Grease the Turntable Rotation Bearing A 1 Check Turntable Bearing Bolts A 2 Inspect for Turntable Bearing Wear A 3 Boom s and Platform Jib Rotate Bearing if equipped A 5 Grease the Platform Overload Mechanism A 7 Test Platform Overload All Models Except ALC1000 and S 60HC ...

Page 52: ...50 Check the Track Tension and Fastener Torque S 40 and S 45 Models P0 2 50 Grease the Extendable Axles if equipped P0 3 50 Engines Continental Under 1000 HRS P0 4 Engines Cummins Under 1000 HRS P0 5 Engines Deutz Under 1000 HRS P0 6 Engines Ford Under 1000 HRS P0 7 Engines Kubota Under 1000 HRS P0 8 Engines Perkins Under 1000 HRS P0 9 Engines GM 998L Under 1000 HRS P0 10 Engines GM 3 0L Under 100...

Page 53: ...P1 2 Replace the Drive Hub Oil P2 3 Replace the Hydraulic Filters C 2 Perform Engine Maintenance 50 Hours The 50 hour maintenance procedure is a one time sequence of procedures to be performed after the first 50 hours of usage After this interval refer to the maintenance inspection report for continued scheduled maintenance Ford Models Oil coolant fuel exhaust and vacuum hoses check for leaks dama...

Page 54: ...50 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 1 Perform the following maintenance procedures Q 9 Visual Inspection of the Hydraulic Oil Q 10 Inspect the Hydraulic Filters ...

Page 55: ...department at 1 800 536 1800 or use the link included in this procedure to download and complete a New Owner Registration Form 3 Using the link provided check for current bulletins for your machine s Machines purchased in Australia Go to Australia Bulletins http genielift com au contact 1 Contact any one of the Genie Service centers around Australia to arrange for factory trained technicians to at...

Page 56: ...tors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery retainers and cable connections are tight 4 Be sure that the battery separator wire connections are tight if equipped Models without maintenance free or sealed batteries 5 Put on protective clothing and eye wear 6 Remove the battery vent caps and check the specific...

Page 57: ...ells display a specific gravity from 1 218 to 1 269 The battery is still usable but at a lower performance The battery will need to be recharged more often Proceed to step 11 Result One or more battery cells display a specific gravity from 1 217 to 1 173 The battery is approaching the end of its life Proceed to step 11 Result The difference in specific gravity readings between cells is greater tha...

Page 58: ...eas for burnt chafed corroded pinched and loose wires Note Inspection areas will vary by model Engine wiring harness Engine relay block Hydraulic manifold wiring All wire harness connectors to ground control box Inside of the ground control box Turntable area Cable tracks Cables on the primary secondary and jib booms Jib boom platform rotate manifold Inside of the platform control box All wire har...

Page 59: ...lectrical contactor mounted on the fuse bracket 3 Visually inspect the contact points of the contactor for the following items Excessive burns Excessive arcs Excessive pitting Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found Z 60 DC FE models 1 Op...

Page 60: ...round seams and joints Q 6 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed quarterly Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repa...

Page 61: ... does not fully charge the batteries Periodically use the AC battery charger to fully charge the batteries 1 Be sure that all fasteners and cables on the generator are tight 2 Remove the engine flywheel cover mounting fasteners then remove the cover 3 Be sure that the pulley mounting fasteners are tight and that the pulleys show no signs of damage or unusual wear 4 Check to be sure the engine pull...

Page 62: ...e ground controls Result The voltage does not exceed 54V DC Note To adjust the voltage regulator Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Generator Voltage Regulator Q 8 Check the Oscillate Directional Valve Linkage if equipped Genie specifications require that this procedure be performed quarterly Note Perform this test only on mode...

Page 63: ...ydraulic oil and place in a clear container Visually inspect the hydraulic oil for the following Color oil should be a clear light honey colored Appearance oil should be clear and not cloudy or visibly distorts the view through the sight glass or container Contains no particles foreign objects or other contamination The hydraulic oil can be inspected by smell can smell hot but not burnt or rubbing...

Page 64: ...m rabbit symbol 3 Visually inspect the filter condition indicator Result The filter condition indicator is operating in the green area Result The filter condition indicator is operating in the red area This indicates that the hydraulic filter is being bypassed and the filter should be replaced Refer to Maintenance Procedure Replace the Hydraulic Filters Models without Filter Condition Indicator No...

Page 65: ...3i CN3 Perkins Models 403F 11 404D 22T 404F 22 404F 22T 404F E22T 404F E22TA 854F 34T Note Some procedures may require two people Note For engine RPM information refer to Specifications Engine Specifications for your engine model Models with ALC 600 operating system Note Use the following chart to identify the description of each LCD screen control button used in this procedure Home Maintenance Fa...

Page 66: ...achometer to the engine Start the engine from the ground controls and check the rpm Result Low idle rpm is correct Continue with step 2 Result Low idle rpm is not correct Follow the low rpm idle procedure for your engine model 2 Move the function enable toggle switch to the high idle rabbit symbol position and check the rpm Result High idle rpm is correct Result High idle rpm is not correct Follow...

Page 67: ...1 Loosen the lock nut on the low idle adjustment screw 2 Turn the adjustment screw clockwise to increase low rpm or counterclockwise to decrease low rpm 3 Tighten the lock nut High rpm idle adjustment 1 Loosen the lock nut on the high idle adjustment nut 2 Turn the high idle adjustment nut counterclockwise to increase the rpm or clockwise to decrease the rpm 3 Tighten the lock nut Kubota D1105 E3B...

Page 68: ...1 low idle adjustment screw not shown 2 high idle adjustment nut 3 high idle solenoid 4 fuel shut off solenoid Deutz D2011L03i 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Deutz TD2011L04i 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw ...

Page 69: ...55 Perkins 403D 11 1 high idle solenoid 2 high idle adjustment nut 3 low idle adjustment screw Perkins 404D 22 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Perkins 804D 33 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw ...

Page 70: ...s whether or not the Emergency Stop button on the platform controls is in the on or off position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Push in the platform red Emergency Stop button to the off position 2 Turn the key switch to ground controls 3 Pull out the red Emergency Stop button to the on position at the gr...

Page 71: ...Models Result The alarm should sound twice The flashing beacon should be on and flashing All other models Result The flashing beacon should be on and flashing All Models 2 Activate the boom down function hold for a moment and then release it Result The descent alarm should sound when the down function is activated Complete this step for each boom that applies Primary Secondary and Jib Booms 3 Turn...

Page 72: ...eously hold the emergency power switch on and operate each boom function through a partial cycle Result All boom functions operate 8 Close the emergency power switch cover and secure the cover with a security tie if equipped Q 15 Test the Engine Idle Select Operation Engine Models Genie specifications require that this procedure be performed quarterly A properly operating engine idle select functi...

Page 73: ... remain at low idle 10 Press down the foot switch Result The engine should change to high idle All other models 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Start the engine from the ground controls 3 Move the rpm select toggle switch to the high idle rabbit symbol position and activate function enable Result The engine should change to hig...

Page 74: ...ting temperature 1 At the platform controls move the fuel select switch to gasoline and then move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform controls and allow it to run at low idle 3 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothl...

Page 75: ...es to the following models S 100 S 105 S 120 S 125 S 100HD S 120HD SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 1 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 2 Open the turntable cover on the ground controls side of the machine 3 Open the ground control box 4 Verify the ground control pan...

Page 76: ...is procedure with the machine on a firm level surface with the axles extended Note Perform this procedure with all weight tools equipment and personnel removed from the platform Note If any boom safety limit switches are faulty the primary boom will only retract and not lower 1 Run 2 Bypass 3 Recovery 1 Turn the key switch to the ground control and pull out the red Emergency Stop button to the on ...

Page 77: ...the main key switch 9 Start the engine and return the boom to the stowed position Q 19 Test the Platform Self leveling Genie specifications require that this procedure be performed quarterly ALC 1000 Models Automatic platform self leveling throughout the full cycle of primary boom raising and lowering is essential for safe machine operation The platform is maintained level by the communication bet...

Page 78: ...ine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically and electrically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational Collision hazard Be sure that the machine is not in free wheel or partial free wheel configuration Refer to maintenance procedure Confirm...

Page 79: ...timing when your reference point on the machine crosses the start line 4 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications Q 23 Test the Drive Speed Raised or Extended Position Genie specifications require that this procedure be performed quarterly Proper drive function is essential to safe machine o...

Page 80: ...e function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range This maintenance procedure applies to the following models S 100 S 105 S 120 S 125 SX 105 XC SX 125 XC SX 135 XC S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Note Perform this procedure...

Page 81: ...e start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications Z 80 60 Z 135 70 and ZX 135 70 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Press down the foot switch and raise the primary boom greater than 10 degrees and the secondary boom greater than 2...

Page 82: ...om the level sensor The level sensor signal is used to control the maximum working height of the primary and secondary booms Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note A properly calibrated digital level is essential to p...

Page 83: ...us button on the LCD screen until TURNTABLE LEVEL SENSOR X DIRECTION is displayed Result The reading at the display and digital level is within 1 of each other Result The reading at the display and digital level is greater than 1 of each other The level sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Level Senso...

Page 84: ...at this procedure be performed quarterly A properly functioning secondary boom angle sensor is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the secondary boom using the signal from the secondary boom angle sensor The secondary boom angle sensor signal is used to control the ramping of the secondary boom Note The turntable level sensor m...

Page 85: ...s injury Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Secondary Boom Angle Sensor 7 Lower the secondary boom to 65 Result The reading at the display and digital level is within 2 of each other and of 65 Result The reading at the display and digital level is greater than 2 of each other and of 65 The secondary boom angle sensor must be...

Page 86: ...e Secondary Boom Angle Sensor Q 27 Test the Primary Boom Angle Sensor Z 135 70 and ZX 135 70 Genie specifications require that this procedure be performed quarterly A properly functioning primary boom angle sensor is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from the primary boom angle sensor The pri...

Page 87: ...he primary boom 5 Raise the primary boom while watching the display screen 6 Continue to raise the primary boom until it stops at approximately 58 Result The reading at the display and digital level is within 2 of each other and of 58 Result The reading at the display and digital level is greater than 2 of each other and of 58 The primary boom angle sensor must be calibrated Refer to Repair Proced...

Page 88: ... and digital level is within 2 of each other and of 10 Result The reading at the display and digital level is greater than 2 of each other and of 10 The primary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 11 Raise the primary boom to 40 Result The reading at the display a...

Page 89: ...f each LCD screen control button used in this procedure Plus Minus Previous Enter Note Perform this procedure with the booms in the fully stowed position and the axles fully extended SX 105 XC and SX 125 XC 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Start the engine from the ground controls 3 Press th...

Page 90: ...and digital level is within 2 of each other and of 23 Result The reading at the display and digital level is greater than 2 of each other and of 23 The primary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 10 Lower the primary boom to 6 Result The reading at the display and...

Page 91: ...Calibrate the Primary Boom Angle Sensor Tip over hazard If the boom is not within 2 of 75 immediately lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 7 Lower the primary boom to 59 Result The...

Page 92: ...or must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor SX 150 and SX 180 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Start the engine from the ground controls 3 Press the enter or previous button on th...

Page 93: ...nd digital level is within 2 of each other and of 32 Result The reading at the display and digital level is greater than 2 of each other and of 32 The primary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 10 Lower the primary boom to 15 Result The reading at the display and...

Page 94: ...rntable support and secure the lower turntable riser end cover to a suitable lifting device 2 Remove the lower cover retaining fasteners and remove the lower cover from turntable Crushing hazard The turntable riser lower cover could become unbalanced and fall when removed from the turntable if not properly supported and secured to the lifting device 3 Support and secure the upper turntable riser e...

Page 95: ...acket through the entire length of travel Result The roller arm of the limit switch is damaged Replace the limit switch roller arm or limit switch Note The limit switch ramp bracket is attached to the number 4 boom tube 13 Locate and disconnect the Deutsch connector to LSS1RS Result The alarm should sound Result The LCD screen should display the message SEC BOOM RETRACTED SAFETY SWITCH DISCONNECTE...

Page 96: ...nnector of the limit switch cable Result The limit switch should have continuity Result The limit switch does not have continuity The limit switch is faulty and needs to be replaced 4 Remove the multimeter leads and connect the Deutsch connector to the limit switch 5 Start the engine and rotate the turntable more than 15 Turn the engine off 6 Locate and disconnect the Deutsch connector to LST1S 7 ...

Page 97: ... switch should not have continuity Result The limit switch does have continuity The limit switch is faulty and needs to be replaced 7 Remove the multimeter leads and connect the Deutsch connector to the limit switch 8 Repeat steps 5 through 7 for the other axle extend safety limit switch 9 Start the engine from the platform controls and fully extend the axles Turn the machine off 10 Choose an axle...

Page 98: ...entify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Press the enter or previous button on the LCD screen until primary boom angle is displayed 3 Start the engine from the ground controls 4 Raise the primar...

Page 99: ...platform end of the secondary boom Remove the cover 7 Locate the Deutsch connectors from the secondary safety retract switch LSS1RS near the chassis at the platform end of the secondary boom The connection will be marked with yellow zip ties on the wire assembly Disconnect the connectors 8 Locate the Deutsch connectors from the secondary boom 1 retract operational limit switch LSS1RO at the end of...

Page 100: ... marked with purple zip ties on the wire assembly Disconnect the connectors 21 Locate the Deutsch connectors from the secondary boom 2 angle operational limit switch LSS2AO on the inside of the turntable riser The connection will be marked with green zip ties on the wire assembly Disconnect the connectors 22 Install a wire jumper between pins 1 and 2 of the Deutsch connector on the wire harness re...

Page 101: ...with the boom fully retracted and in the stowed position Ground controls 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Start the engine from the ground controls 3 Turn and hold the function enable switch to the restricted maximum platform capacity and raise the primary boom until it is fully elevated 1 restricted maximum platform capacity 2...

Page 102: ...uct Support 1 Measure between the centers of these pivot pins Platform controls Note Start this procedure with the boom fully retracted and in the stowed position 1 Pull out the red Emergency Stop button to the on position and start the engine 2 Select the restricted maximum platform capacity with the toggle switch 1 restricted maximum platform capacity 2 unrestricted maximum platform capacity 3 R...

Page 103: ...105 S 120 S 125 S 100HD and S 120HD Genie specifications require that this procedure be performed quarterly Testing the machine safety envelope is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability is compromised and may tip over Note Use the following chart to identify the description of each LCD screen cont...

Page 104: ...gency Stop button to the off position 12 Remove the LSB2RS test jumper between the lower limit switch and the function manifold J2 and J4 connectors on the ground control box 13 Pull out the red Emergency Stop button to the on position and start the engine 65 Angle Safety Switch LSB9AS 14 Raise the boom to the maximum angle 15 Fully extend the boom 16 Disconnect the 68 proximity switch LSB14AO and...

Page 105: ...is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired Bodily injury hazard If the boom lowers to less than 50 without stopping the engine stop immediately and raise the boom until the boom is elevated to greater than 53 Failure to raise the boom could result in death or serious injury 31 Measure the angle of the boom Result the angle of the boom should be gr...

Page 106: ...until clear all safety switch faults appears 46 Select YES then press the enter button 47 Press the previous button until exit appears 48 Select YES then press the enter button Cable Break Safety Switch LSB6S 49 Start the engine and activate the function enable high RPM button and retract the boom until the boom is extended to less than 2 feet 0 6 m 50 Remove the boom end cover from the pivot end ...

Page 107: ...7 Retract both axles approximately 1 foot 0 3 m 58 Remove the access cover from each axle 59 Disconnect the square end axle extend safety switch LSAX1ES and install a wire jumper between pin 3 and pin 4 of the deutsch connector 60 Place a metal washer over the target area of the axle extend proximity switch LSAX1EO and place a metal washer over the target area of the axle extend proximity switch L...

Page 108: ... button and attempt to extend the boom Result The boom should not extend to more than 3 feet 0 9 m Result If the boom extends to more than 3 feet 0 9 m the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired Bodily injury hazard If the boom extends to more than 3 feet 0 9 m stop immediately and retract the boom until the boom is ...

Page 109: ...e fully stowed position 1 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 Engine powered models 2 Start the engine from the platform controls All Models 3 Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction 1 yellow bumper 4 Activate each function control handle or toggle...

Page 110: ...eer functions operate 14 Activate and hold the aircraft protection override switch 15 Activate each function control handle or toggle switch Result All boom drive and steer functions operate 16 Lower the primary boom to the stowed position Articulated Z Booms 17 Raise the secondary boom approximately 3 ft 1 m 18 Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction 1...

Page 111: ...m functions operate Q 36 Inspect and Adjust the Boom Extend Retract Cables All Models Genie specifications require that this procedure be performed quarterly for the first year of ownership or after the boom extend or retract cables have been replaced After the first year this quarterly inspection is not required Refer to the Annual Inspection procedure appropriate for your machine Manufacturers s...

Page 112: ...CH 45001 and S60XCM 101 S 65 XC S 80 HF S 85 HF S 80 XC and S 85 XC Note Perform this procedure with all weight tools equipment and personnel removed from the platform 1 ground controls 2 recovery switch 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Start the engine and raise the primary boom to the horizontal position and extend it approxi...

Page 113: ...e using the signal from the level sensor The level sensor signal is used to control the maximum working height of the primary boom Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note A properly calibrated digital level is essentia...

Page 114: ...ata Navigate to the Turntable Tilt Roll Data Result The reading at the display and digital level is within 1 of each other Result The reading at the display and digital level is greater than 1 of each other The level sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Turntable Level Sensor Tip over hazard If the X ...

Page 115: ...e and Repair Manual for your machine How to Calibrate the Turntable Level Sensor Q 39 Test the Primary Boom Angle Sensor S 60 XC from S60XCH 45001 and S60XCM 101 S 65 XC S 80 HF S 85 HF S 80 XC S 85 XC Genie specifications require that this procedure be performed quarterly A properly functioning primary boom angle sensor is essential to safe machine operation The ECM at the ground controls GCON mo...

Page 116: ... within 2 of each other and of 10 Result The reading at the display and digital level is greater than 2 of each other and of 10 The primary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 7 Raise the primary boom to the fully elevated position while watching the display scree...

Page 117: ...result in component damage 1 Locate the grease fitting for the turntable rotate bearing 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Models with Drive Gear Apply grease to each tooth of the drive gear located under the turntable Models with Worm Drive Gear...

Page 118: ...linder and all moving parts when lowering the boom Component damage hazard Do not apply excessive force to the safety chock or damage may occur Note The lift cylinder safety chock is available through Genie Parts Department 2 Turn the key switch to the off position 3 Using a star pattern confirm that each turntable mounting bolt is torqued in sequence to specification 4 Raise the boom and remove t...

Page 119: ...not extend the boom Z Booms Using the ground controls raise the primary and secondary booms to full height Do not extend the primary boom Z 80 60 Z 135 70 and ZX 135 70 Using the ground controls fully raise but do not extend the primary boom and jib The secondary riser should remain in its stowed position 4 Place a dial indicator between the drive chassis and the turntable at a point that is direc...

Page 120: ...spaced areas 90 apart 11 Lower the boom s to the stowed position and turn the machine off 12 Remove the dial indicator from the machine A 4 Check the Extendable Axle S 100 S 100HD S 105 S 120 S 120HD and S 125 Genie specifications require that this procedure be performed annually Maintaining the axle wear pads in good condition is essential to safe machine operation Wear pads are placed on axle tu...

Page 121: ...ification 2 Repeat the procedure for the inner mounting bolts Jib boom rotate bearing bolts 200 ft lbs 271 Nm Grease the Jib Rotator 3 While rotating the jib pump grease into each bearing lubricating grease fitting until fresh grease is visible at the outer seal 4 While rotating the jib pump grease into the worm gear grease fitting until fresh grease is visible at one sealing lip or bearing cap Il...

Page 122: ... key switch action and response is essential to safe machine operation Failure of either key switch to function properly could cause a hazardous operating situation This maintenance procedure applies to the following models S 100 S 100HD S 105 S 120 S 120HD S 125 SX 105 XC SX 125 XC SX 135 XC SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 There are two key switches on the machine the Main key switch...

Page 123: ...gency Stop button to the on position at both the ground and platform controls 3 At the ground controls turn the bypass recovery key switch to the run position 4 Turn the main key switch to ground control start the engine and then turn the key switch to platform control 5 Check any machine function from the ground controls Result The machine functions should not operate 6 Turn the main key switch t...

Page 124: ...witch and insert the key into the main key switch Close the turntable side cover A 7 Grease the Platform Overload Mechanism if equipped Genie specifications require that this procedure be performed annually Perform this procedure more often if dusty conditions exist Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly g...

Page 125: ... option Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface 1 Remove all weight tools accessories and equipment from the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 2 Engine Models Turn the key switch to ground control and pull out the red Emergency...

Page 126: ...ining location on the platform Refer to Illustration 1 Engine Models Result The platform overload indicator lights should be flashing at both the ground and platform controls the alarm should sound and the engine should not start and run DC Models Result The platform overload indicator lights should be flashing at both the ground and platform controls and the alarm should sound Note There may be a...

Page 127: ...atform controls Start the engine from the ground controls and level the platform Do not turn the engine off 3 Determine the maximum platform capacity Refer to the machine serial plate 4 Using a suitable lifting device place a test weight equal to that of the available capacity in one of the locations shown Refer to Illustration 1 Result The platform overload indicator light should be off at platfo...

Page 128: ...te There may be an 2 second delay before the overload indicator lights and alarm turn off 10 Start the engine and test all machine functions from the ground controls Result All ground control functions should operate normally 11 Using a suitable lifting device remove all test weights from the platform A 10 Test the Platform Load Sense System S 60 HC Genie specifications require that this procedure...

Page 129: ...ct Cables S 60 65 and S 80 85 Models Genie specifications require that this procedure be performed annually Manufacturers specifications require that this procedure be performed by personnel that are competent in cable wire rope inspection Note Additional or more frequent inspections may be required due to the following exposed to hostile or corrosive environmental conditions boom is overloaded su...

Page 130: ...located on the side of the boom at the platform end of the machine Remove the covers 5 Visually inspect the cables and components through the inspection holes for the following Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Cables are on all sheaves Extend cable break limit switch arm is centered in the pivot plate Ca...

Page 131: ... 3 boom tube begins to retract the boom extend retract cables need to be adjusted Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Boom Extend Retract Cables A 12 Inspect the Boom Extend Retract Cables S 100 S 105 S 120 S 125 S 100HD S 120HD SX 105 XC and SX 125 XC Models Genie specifications require that this procedure be performed annually...

Page 132: ...rials on the cable Split or cracked cable ends Cables are on all sheaves Cables have equal tension Cables at end of adjustment range Broken or damaged sheaves Unusual or excessive wear All fasteners in place and secure Note A flashlight and inspection mirror may be necessary to thoroughly inspect the above items or an endoscope inspection camera Note Refer to Maintenance Procedure P12 2 Cable Repl...

Page 133: ...Adjust the Boom Extend Retract Cables A 13 Inspect the Boom Extend Retract Cables SX 135 XC SX 150 and SX 180 Models Genie specifications require that this procedure be performed annually Manufacturers specifications require that this procedure be performed by personnel that are competent in cable wire rope inspection Note Additional or more frequent inspections may be required due to the followin...

Page 134: ...asuring surface 5 Boom 2 measuring edge 6 Boom 2 measuring surface 7 Boom 3 measuring edge 6 Measure the distance between boom tubes 2 and 3 using points 6 and 7 in the illustration The gap should be 1 in 2 6 cm to 1 5 in 3 9 cm greater than dimension A Note As an example if the dimension A is 1 25 in 3 2 cm then the gap between boom tubes 2 and 3 should be between 2 25 in 5 7 cm and 2 75 in 7 1 c...

Page 135: ... then extend the boom approximately 15 ft 4 6 m 3 Fully retract the boom and lower to the horizontal position 4 Stop the engine 5 Measure and record the distance between boom tubes 1 and 2 measuring from the points identified as 11 and 12 in the illustration This is dimension A 1 Boom tube 1 2 Boom tube 2 3 Boom tube 3 4 Boom tube 4 5 Boom 4 retract bolt 6 Boom 3 retract bolt 7 Boom 4 measuring ed...

Page 136: ... cm greater than dimension A The boom tubes need to be adjusted Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Boom Extend Retract Cables All models Note This procedure will require the use of an aerial work platform 1 Remove the cover from the pivot end of the boom 2 From the ground controls raise the boom to the horizontal position and f...

Page 137: ... add oil until the oil level is even with the bottom of the side plug hole 4 Install the plug s into the drive hub 5 Check the torque of the drive hub mounting bolts Refer to Specifications Machine Torque Specifications 6 Repeat this procedure for each drive hub Models with TRAX 1 Select the drive hub to be serviced Loosen and remove as many sprocket retaining fasteners as possible from the hub ad...

Page 138: ...ve the top plug and add oil until the oil level is even with the bottom of the side plug hole 12 Install the plug s into the drive hub 13 Check the torque of the drive hub mounting bolts Refer to Specifications Machine Torque Specifications 14 Attach a lifting strap from an overhead crane to the center point of the track assembly above the sprocket 15 Install the track assembly onto the drive hub ...

Page 139: ...5 XC SX 135 XC SX 150 SX 180 Dry 95 ft lbs 129 Nm A 15 Test the Dual Capacity and Platform Overload System SX 105 XC SX 125 XC and SX 135 XC Models Genie specifications require that this procedure be performed annually OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operati...

Page 140: ...stem Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 6 Extend the jib Result The jib does not extend 7 Add an additional 320 lbs 145 kg to the platform Result There is an audible alarm Platform overload is displayed on the LCD screen at the ground controls Platform indicator light is flashing at the platform controls Result Engine does not start a...

Page 141: ...stricted range of motion indicator light is on at ground controls Result The restricted range of motion light is on at the ground controls Calibrate the overload system Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Platform Overload System 4 Start the engine and extend the primary boom Result The primary boom should fully extend and re...

Page 142: ...require that this procedure be performed annually OR when the machine fails to lift the maximum rated load Testing the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tippi...

Page 143: ...ocedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Platform Overload System 5 Add additional weight to the platform S 80 HF S 85 HF models 370 lbs 168 kg All other models 320 lbs 145 kg Result There is an audible alarm Platform overload icon is displayed on the LCD screen at the ground controls Platform indicator light is flashing at the platform controls Re...

Page 144: ... of any dirt rocks clay etc 2 Chock the tracks at one end of the machine to prevent the machine from rolling 3 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the tracks at the other end of the machine 4 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support 5 Visually inspect the section of t...

Page 145: ... Refer to Specifications TRAX Torque Specifications 13 Raise the machine remove the jack stands and lower the machine 14 Repeat this procedure for each track assembly Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent P0 2 Check the Track Tension and Fastener Torque TRAX Models S 40 and S 45 Models Manufacturer specifications require that this procedure be perform...

Page 146: ...y wheels 3 tensioner assembly 4 idler wheel 6 Loosen the tensioner jam nut and idler axle bolts on both sides of the tensioner wheel and tighten the tensioner nut until there is between 0 75 1 inch 1 9 2 5 cm of gap between the bogey wheels and the inside surface of the track Component damage hazard Do not over tighten the track Over tightening the track will cause the machine to lose power during...

Page 147: ... of the axles over the lifetime of the product Two fittings on each axle are provided to apply grease the top and bottom sliding wear pads 1 Locate the grease fittings on the extendable axles covers 1 Top wear pad grease fitting 2 Side wear pad grease fitting 2 Thoroughly pump grease into each grease fitting When grease is pumped into each fitting a hose directs this lubrication to the top or bott...

Page 148: ...anufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Continental TME27 Hour Intervals Procedure Not required Daily 50 100 250 500 Visual inspection of engine Oil level check Air cleaner check PCV system check Coolant level check Oil fuel and coolant systems check for leaks Air filter discharge valve clean Fan belt tension check Battery check Engine oil replace Oil ...

Page 149: ...ilable in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Cummins B3 3T Hour Intervals Procedure Not required Daily 250 500 Oil fuel and coolant systems check for leaks Fuel water separator drain Oil level check Coolant level check Drive belt inspect Cooling fan inspect Engine oil replace Oil filter replace Valve lash clearance adjust initial one time int...

Page 150: ...d Maintenance Manuals This maintenance schedule applies to the following Deutz Engines D2011 L03i TD2011 L04i D 2 9 L4 TD 2 9 L4 D436 L3i CN3 Deutz Engines Hour Intervals Procedure Not required Daily 250 500 Oil level check Coolant level check Oil fuel and coolant systems check for leaks Fuel system filter water separator inspect drain Air filter discharge valve clean Exhaust system inspect Check ...

Page 151: ...r and Maintenance Manuals This maintenance schedule applies to the following Ford Engines Ford MSG 425 Ford DSG 423 Ford Engines Hour Intervals Procedure Not required Daily 100 200 400 800 Oil level check Coolant level check Oil fuel and coolant systems check for leaks Oil coolant fuel exhaust and vacuum hoses check for leaks damage or deterioration Electrical wiring check for chafing or damage En...

Page 152: ...ta Z482 E Kubota Engines Hour Intervals Procedure Not required Daily 50 75 100 150 200 400 500 800 Coolant level check Oil level check Fuel hoses and clamp bands check Engine oil replace Z482 Fan belt tension and damage check Battery electrolyte level check Spark plug check Air cleaner element clean Replace the element after 6 times cleaning Fuel filter element type clean Oil filter cartridge repl...

Page 153: ...D 11 Perkins 403F 11 Perkins 404D 22 Perkins 404D 22T Perkins 404F 22 Perkins 404F 22T Perkins 404F E22T Perkins 404F E22TA Perkins 804D 33 Perkins 854F 34T Perkins 1104D 44T Perkins Engine Hour Intervals Procedure Not required Daily 50 500 Air filter discharge valve clean Oil fuel and coolant systems check for leaks Alternator belt inspect adjust replace Coolant level check add Oil level check Fu...

Page 154: ...00 800 Coolant level check Oil level check Oil fuel and coolant systems check for leaks Fan belt tension and damage check Radiator hoses and clamps check Intake manifold check for vacuum leaks LPG system check for leaks Radiator clean Radiator hoses and clamps check Engine oil and filter replace LPG Vaporizer drain clean PCV valve check Air cleaner element clean replace Timing belt check Electrica...

Page 155: ... procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals GM 3 0L Engine Hour Intervals Procedure Not required Daily 100 150 200 250 400 800 Coolant level check Oil level check Oil fuel and coolant systems check for leaks Radiator clean LPG Vaporizer drain clean Air cleaner element clean replace Engine ...

Page 156: ...inental TME27 Spark plugs replace O2 sensors replace Cummins Models Drive belt tension measure Drive belt inspect GM 3 0L Fan belt inspect replace Radiator hoses and clamps check PCV system check Deutz Models All Models Fuel system primary filter water separator element replace Fuel system secondary filter replace Hoses and clamps inspect replace By pass oil filter replace Engine mounts inspect Gl...

Page 157: ...Valve seats check Air cleaner element replace Gasoline fuel hose and clamp bands replace Carburetor and fuel tank inside clean Z482 E D 1105 Fuel injection nozzle injection pressure check P1 2 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 ...

Page 158: ...ng fasteners as possible from the hub adapter 2 Drive the machine in either direction just enough to access the remaining fasteners Do not remove the the retaining fasteners 3 Chock the tracks at the opposite end of the machine to prevent the machine from rolling 4 Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the tracks 5 Lift the machine until the t...

Page 159: ... track assembly Install as many sprocket retaining fasteners as possible to the hub adapter and torque to specification Refer to Specifications TRAX Torque Specifications 16 Raise the machine remove the jack stands lower the machine 17 Drive the machine in either direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter Turn the machine off 18 Inst...

Page 160: ...uipped with two turntable rotation drive hub assemblies repeat steps 2 through 7 for the other turntable rotate drive hub assembly 9 Adjust turntable rotation gear backlash Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Turntable Rotation Gear Backlash P2 1 Perform Engine Maintenance 2000 Hours Engine specifications require that this proce...

Page 161: ...ct Starting motor inspect Perkins 854F 34T Water pump inspect Turbocharger inspect Aftercooler core inspect Perkins 1104D 44T Aftercooler core inspect Turbocharger inspect Water pump inspect Cooling system coolant replace Kubota Models Z482 E D1105 WG972 Radiator coolant L L C replace Battery replace Radiator hoses and clamp bands replace Fuel pipes and clamp bands replace Intake air line replace ...

Page 162: ...l 1 Complete the hydraulic oil testing with an oil distributor If the hydraulic oil passes testing at the 2000 hour maintenance interval the oil must be tested every quarter by an oil distributor until the oil fails the test and is replaced If the hydraulic oil fails testing at the 2000 hour maintenance interval the oil must be replaced After the oil has been replaced continue the scheduled quarte...

Page 163: ... on top of the hydraulic tank 2 Remove the cap from the filter housing 3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing 4 Remove the filter element from the housing 5 Install the new filter element into the filter housing 6 Push the filter element down to be sure the O ring on the element is fully seated into the housing 7 Rota...

Page 164: ...re that there are no leaks Case drain filter Note The case drain filter is for the charge pump 1 Open the engine side turntable cover and locate the case drain filter mounted to the engine tray near the hydraulic pumps 2 Place a suitable container under the filter s 3 Remove the case drain filter housing by using a wrench on the nut provided on the bottom of the housing 4 Remove the case drain ele...

Page 165: ...er Center a lifting jack of ample capacity 20 000 lbs 10 000 kg under the drive chassis between the non steer tires or tracks Models with 4 wheel steer Place a lifting jack of ample capacity 35 000 lbs 16000 kg under each of the steer yokes at the circle end of the machine 3 Lift the wheels or tracks off the ground and then place jack stands under the drive chassis for support 4 Disengage the driv...

Page 166: ...hub 1 brake disengaged position 2 brake engaged position 11 Manually rotate each steer square end wheel or track Result Each steer square end wheel or track should rotate with minimum effort Note TRAX Models Due to the additional components of the track system which increase rotational friction the track may not be able to be rotated manually 12 Re engage the drive hubs by turning over the hub dis...

Page 167: ...squareness between the outer and inner boom tubes SX 150 SX 180 3 Grease the platform end bottom wear pads with a suitable lubricant SX 150 Grease the 1 and 2 boom tubes SX 180 Grease the 0 and 1 boom tubes S 40 S 45 S 60 S 65 S 60X S 60XC S 65XC Wear pad specifications Minimum Top and side wear pads platform end of boom 0 50 inch 12 7 mm Bottom wear pads platform end of boom 0 625 inch 15 9 mm To...

Page 168: ...ottom and side wear pads pivot end of boom 0 625 inch 15 9 mm Top wear pads pivot end of boom 0 375 inch 9 5 mm Models with rotating jib boom All wear pads 0 375 inch 9 5 mm Z 33 18 Primary boom wear pad specifications Minimum Top wear pads platform end 0 6875 inch 17 46 mm Side wear pads platform end 0 5625 inch 14 29 mm Bottom wear pads platform end 0 625 inch 15 9 mm Top and side wear pads pivo...

Page 169: ... boom wear pads is 0 070 inch 1 8 mm and the maximum allowable shim clearance is 0 25 inch 6 4 mm Note The minimum shim clearance for the jib boom and primary boom wear pads is 0 070 inch 1 8 mm and the maximum allowable shim clearance is 0 188 inch 4 8 mm Primary boom wear pad specifications Minimum Top bottom and side wear pads platform end of boom 0 625 inch 15 9 mm Top and side wear pads pivot...

Page 170: ... entire range of motion to check for tight spots that may cause binding or scraping of the axle tubes Note Always maintain squareness between the outer and inner axle tubes P2 7 Check the Turntable Rotation Gear Backlash ALC1000 Models Genie requires that this procedure be performed every 2000 hours Properly adjusted turntable rotation gear backlash is essential for good machine performance and se...

Page 171: ...e backlash needs to be adjusted Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Turntable Rotation Gear Backlash 4 Repeat the procedure for the other turntable rotation hub P2 8 Grease the Steer Axle Wheel Bearings All 2WD Models except S 60 S 65 Z 60 DC FE and Z 62 Genie requires that this procedure be performed every 2000 hours Perform th...

Page 172: ...off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14 Pack both bearings with clean fresh grease 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush 17 Slide...

Page 173: ... performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If th...

Page 174: ... occur 15 Place the outer bearing into the hub 16 Install the outer ring 17 Install the shims 18 Install the cover and torque the retaining fastener to 383 ft lbs 519 Nm 19 Install the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Machine Specifications P3 1 Perform Engine Maintenance 3000 Hours Engine specifications require that this procedure be perfo...

Page 175: ...replace Exhaust gas recirculation valve clean Water pump inspect Cooling system coolant Heavy Duty change 854F 34T Alternator inspect Alternator and fan belts replace Diesel particulate filter clean Radiator cap inspect replace Kubota Models Z482 E D 1105 E3B Turbocharger inspect Injection pump check Fuel injection timing check P4 1 Perform Engine Maintenance 4000 Hours Engine specifications requi...

Page 176: ...in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals GM 3 0L Cooling system coolant replace P6 1 Perform Engine Maintenance 6000 Hours Engine specifications require that this procedure be performed every 6 000 hours Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Op...

Page 177: ...that this procedure be performed by personnel that are competent in cable wire rope inspection Note If the cables pass inspection and are not replaced the cables must be removed and inspected every 3 years until all boom cables have been replaced Note Additional or more frequent inspections may be required due to the following exposed to hostile or corrosive environmental conditions boom is overlo...

Page 178: ...on of the sheaves Note If one or more sheaves require replacement the sheaves must be replaced as a set 1 good condition 2 too tight replace 3 too loose replace 3 Inspect the cables for the following Frayed or broken wire strands Kinks or crushed cables Corrosion Paint or foreign materials on the cable Split or cracked cable ends Number of broken wires in one rope lay Replace All strands of one ro...

Page 179: ...es 10 5 mm S 80HF S 85HF S 80XC and S 85XC Extend 50 inches 12 7 mm 475 inches 12 mm Retract 438 inches 11 13 mm 416 inches 10 5 mm S 100 105 120 125 and SX 125 XC Extend 625 inches 15 875 mm 594 inches 15 mm Retract 375 inches 9 5 mm 357 inches 9 mm SX 135 XC Extend 625 inches 15 875 mm 594 inches 15 mm Retract 50 inches 12 7 mm 475 inches 12 mm SX 150 and SX 180 Extend Boom 3 625 inches 15 875 m...

Page 180: ...oms Z Booms Part No 1268489GT Cabl e R epl acement Criteria Cable Replacement Criteria Note The cables must be replaced if any condition shown below is observed other than normal wear Note The cables must be replaced as a set normal wear abrasion broken wires rust birdcaging ...

Page 181: ...ber 2018 Maintenance Manual Part No 1268489GT S Booms Z Booms 167 This page intentionally left blank S Booms Z Booms Part No 1268489GT Maintenance M anual October 2018 Maintenance Inspection R eport Boom s ...

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