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Terex Genie Lift Guard S-40, Maintenance Manual

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Maintenance Manual

 

March 2022

 

Programmed Maintenance Procedures 

 

 

164 

S

®

 Booms • Z

®

 Booms

 

Part No. 1268489GT 

 

 

P2-3 

Replace the Hydraulic Filters 

 

 

 

Genie requires that this procedure be performed 

every 2000 hours. 
Perform this procedure more often if dusty 

conditions exist. 
Replacement of the hydraulic filters is essential for 

good machine performance and service life. A dirty 

or clogged filter may cause the machine to perform 

poorly and continued use may cause component 

damage. Extremely dirty conditions may require 

that the filter be replaced more often. 
Note: There are four types of hydraulic filters: tank 

return filter, medium pressure filter, high pressure 

filter and drive motor case drain filter. The quantity 

and type of filter(s) may vary by model. 

 

Bodily injury hazard. Beware of 

hot oil. Contact with hot oil may 

cause severe burns. 

Note: Perform this procedure with the engine off. 

Hydraulic return filter

 

Note: The return filter may be mounted in the top 

of the hydraulic tank (internally) or outside of the 

tank (externally). 

Internal:

 

1  Locate the hydraulic return filter housing 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  Rotate the filter element clockwise to lock it in 

place. 

8  Install the filter housing cap. 
9  Use a permanent ink marker to write the date 

and number of hours from the hour meter on 

the oil filter housing. 

10  Inspect the filter housings and related 

components to be sure that there are no 

leaks. 

External:

 

1  Locate the hydraulic return filter. 
2  Place a suitable container under the filter(s). 
3  Remove the filter with an oil filter wrench. 
4  Apply a thin layer of fresh oil to the gasket of 

the new oil filter. 

5  Install the new hydraulic return filter element 

and tighten it securely by hand. 

6  Clean up and properly dispose of any oil that 

may have spilled during the installation 

procedure. 

7  Use a permanent ink marker to write the date 

and number of hours from the hour meter on 

the oil filter. 

8  Inspect the filter housings and related 

components to be sure that there are no 

leaks. 

Summary of Contents for Genie Lift Guard S-40

Page 1: ...each 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 J1 March 2022 ...

Page 2: ...pliance 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 ...

Page 3: ...0TX16D 639 from S65TX13 26296 to S65TX16H 36399 from S65TX14D 101 to S65TX16D 639 from S60H S60X S60TX S65TXH 36400 from S60XCH 36400 to S60XCH 45000 from S60XCH S65XCH 45001 from S60 S60TX S60XD 640 from S60JH 101 from S60M 400 from S65XCM 101 from S65TXM 101 S 80 S 85 S 80X S 80XC S 85XC S 80HF S 85HF S 80J from S80 85 80X15 12264 to16H 13999 from S80 85 80X15D 101 to 16D 339 from S80 85 80XH 14...

Page 4: ... Z452516D 939 from Z4525D 940 from Z4525M 6700 from Z4525N 57200 to Z4525N 58604 from Z4525F 58605 Z 45 25 IC Z 45 25J IC Z 45HF Z 45XC from Z452513A 47001 to Z452516N 57199 from Z452514B 3301 to Z452516M 6699 from Z452513D 101 to Z452516D 939 from Z4525D 940 from Z4525M 6700 from Z4525N 57200 to Z4525N 58604 from Z4525F 58605 from Z4525XCF 101 from Z4525XCM 101 Z 45 25 J BE from Z452513A 48153 to...

Page 5: ...0 Models include the following models S 40HF S 45HF S 40 XC S 45 XC S 60HF S 65HF S 60J S 60 XC from S60XCH 45001 S 65 XC S 80HF S 85HF S 80J 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 Pos...

Page 6: ...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 Quarterly Q 36 Inspect and Adjust Boom Cables Annual A 3 Inspect Turntable Bearing Wear A 11 A 12 A 13 Inspect Boom Cables Programmed P12 2 Remove and Inspect Boom Cables E 3 2017 All Sections Add SX 125 XC Add Z 45 XC CE AS Models...

Page 7: ...HF S60J Z45DC FE Z45HF models Add Deutz TD TCD 2 2 L3 engine Specifications Hydraulic Specifications Annual A 11 A 12 A 13 Programmed P0 6 P1 1 J1 3 2022 All Sections Add S80J model Annual A 8 A 9 A 15 A 16 A 17 A 18 Reference Examples Section Specifications Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Maintenance procedure ...

Page 8: ...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 9: ...ushing 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 flamm...

Page 10: ...unction Speeds S 120 S 125 and S 120HD 2 Function Speeds All Other Models 3 Drive Speeds 9 Torque Specifications 13 Tires and Wheels 13 TraX Torque Specifications 15 Engine Specifications 16 Engine Operator and Maintenance Manuals 16 Deutz Engine Models 17 Perkins Engine Models 18 Ford Engine Models 20 Kubota Engine Models 21 GM Engine Models 22 Continental Engine Models 22 Cummins Engine Models 2...

Page 11: ...ect the Electrical Wiring 47 Q 4 Inspect the Electrical Contactors DC Bi Energy Models 48 Q 5 Check the Exhaust System 49 Q 6 Inspect the Tires Wheels and Lug Nut Torque 50 Q 7 Check the Generator Belts and Pulleys Bi Energy Models 50 Q 8 Check the Oscillate Directional Valve Linkage if equipped 52 Q 9 Visual Inspection of the Hydraulic Oil 52 Q 10 Inspect the Hydraulic Filters 53 Q 11 Check and A...

Page 12: ...e Sensor SX 105XC SX 125XC SX 135XC SX 150 and SX 180 79 Q 29 Test the Safety Envelope Limit Switches Z 135 70 ZX 135 70 SX 105XC SX 125XC SX 135XC SX 150 and SX 180 84 Q 30 Test the Primary Boom Angle Sensor Z 80 60 88 Q 31 Test the Safety Envelope and Circuits Z 80 60 89 Q 32 Check the Safety Envelope Limit Switches and Angle Sensor S 60X S 80X and S 60XC to S60XC 45000 91 Q 33 Test the Safety E...

Page 13: ...C 121 A 11 Inspect the Boom Extend Retract Cables and Sheaves S 60 65 S 80 85 and S 80J Models 122 A 12 Inspect the Boom Extend Retract Cables and Sheaves S 100 S 105 S 120 S 125 SX 105XC and SX 125XC 125 A 13 Inspect the Boom Extend and Retract Cables and Sheaves SX 135XC SX 150 and SX 180 127 A 14 Check the Drive Hub Oil Level and Fastener Torque 130 A 15 Test the Dual Capacity and Platform Over...

Page 14: ...rs 151 P0 9 Perkins Engine Maintenance Under 1000 Hours 153 P0 10 GM 998L Engine Maintenance Under 1000 Hours 154 P0 11 GM 3 0L Engine Maintenance Under 1000 Hours 155 P1 1 Perform Engine Maintenance 1000 Hours 156 P1 2 Replace the Drive Hub Oil 158 P1 3 Perform Engine Maintenance 1500 Hours 161 P2 1 Perform Engine Maintenance 2000 Hours 161 P2 2 Test or Replace the Hydraulic Oil 163 P2 3 Replace ...

Page 15: ...e 3000 Hours 175 P4 1 Perform Engine Maintenance 4000 Hours 177 P5 1 Perform Engine Maintenance 5000 Hours 177 P6 1 Perform Engine Maintenance 6000 Hours 178 P12 1 Perform Engine Maintenance 12000 Hours 178 P12 2 Remove and Inspect the Boom Extend Retract Cables 179 Cable Replacement Criteria 181 ...

Page 16: ...Maintenance Manual March 2022 xvi S Booms Z Booms Part No 1268489GT This page intentionally left blank ...

Page 17: ...tion 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 horizo...

Page 18: ...lope 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 17...

Page 19: ...models Primary boom up 50 60 60 70 65 75 60 66 57 65 75 83 Primary boom down 50 60 60 70 65 75 60 66 61 69 75 83 Primary boom extend 30 60 58 66 58 66 30 33 59 67 59 67 Primary boom retract 15 35 53 62 53 62 30 33 57 65 57 65 Jib boom up 35 45 S 45 25 35 S 45XC 60 70 S 65 48 53 S 65XC HF 25 35 25 35 S 85 25 35 S 85 Jib boom down 20 30 S 45 25 35 S 45XC 40 50 S 65 28 33 S 65XC HF 15 25 15 25 S 85 1...

Page 20: ... 50 retracted 55 59 extended Primary boom extend 45 50 59 67 15 19 12 18 11 15 18 20 Primary boom retract 45 50 57 65 10 14 12 18 13 17 18 20 Secondary boom up X X 11 18 11 18 15 22 20 24 Secondary boom down X X 7 15 7 15 11 18 20 24 Jib boom up 30 35 25 35 S 85XC HF 19 23 23 29 20 24 X Jib boom down 30 35 15 25 S 85XC HF 17 21 20 26 18 22 X Jib boom rotate X X 13 17 Z 30N RJ X X X Turntable rotat...

Page 21: ... 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 10 14 10 14 Platform level 10 range of motion ANSI CSA AS CE 3 5 20 22 Function Z 45 DC FE Z 51 Z 60 DC FE Z 62 all models Z 80 Primary boom up 26 30 36 40 60 70 60 65 60 70 retracted 80 96 extended Primary boom down 26 30 36 40 60 70 65 70 75 85 retracted 80 96 extended Primar...

Page 22: ...om 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 Pla...

Page 23: ... 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 2...

Page 24: ...4 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 strin...

Page 25: ...0 45 6 8 7 4 40 ft 12 2 m S 40 45XC 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 8 10 5 sec 40 ft 12 2 m 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 model...

Page 26: ...12 2 m 9 12 40 ft 12 2 m SX135XC 9 8 11 8 40 ft 12 2 m SX 150 180 X X 2WD or 4WD Raised or extended 38 45 40 ft 12 2 m 72 4 81 3 40 ft 12 2 m 67 70 40 ft 12 2 m SX 135XC 68 75 5 40 ft 12 2 m SX 150 180 42 48 40 ft 12 2 m 50 55 40 ft 12 2 m 2WD or 4WD Raised and extended X X 275 5 293 3 40 ft 12 2 m SX 150 180 X 190 195 40 ft 12 2 m TraX models Stowed position 11 9 12 4 40 ft 12 2 m X X X X TraX mo...

Page 27: ...6 1 7 1 40 ft 12 2 m ANSI CSA 7 3 8 3 40 ft 12 2 m AS CE 8 10 40 ft 12 2 m 6 6 8 40 ft 12 2 m 4WD models Stowed position X 8 5 10 5 40 ft 12 2 m X X 6 6 8 40 ft 12 2 m High flotation tires Stowed position X 8 5 10 5 40 ft 12 2 m X X 6 6 8 40 ft 12 2 m 2WD or 4WD Raised or extended 42 48 40 ft 12 2 m 40 45 40 ft 12m2 m 40 45 40 ft 12 2 m 42 48 40 ft 12 2 m 42 48 40 ft 12 2 m 87 93 40 ft 12 2 m Z 45...

Page 28: ... High flotation tires Stowed position X 8 10 5 40 ft 12 2 m 13 6 14 5 40 ft 12 2 m X 2WD or 4WD Raised or extended 40 45 40 ft 12 2 m raised only 40 45 40 ft 12 2 m RT Tires 40 45 40 ft 12 2 m High flotation tires 62 70 40 ft 12 2 m 40 45 40 ft 12 2 m 2WD or 4WD Raised and extended X X X 66 70 40 ft 12 2 m Primary and secondary raised and primary or jib extended TraX models Stowed position X 10 7 ...

Page 29: ... 45000 240 ft lbs 325 Nm ZP 210 ft lbs 285 Nm ZAG 180 ft lbs 244 Nm 70 psi 4 8 bar 60 psi 4 1 bar X S 60HF S 65HF S 60J S 60XC from S60XCH 45001 S 65XC 240 ft lbs 325 Nm ZAG 180 ft lbs 244 Nm X 100 psi 6 9 bar X S 80 S 85 S 80X 420 ft lbs 569 Nm ZP 230 ft lbs 313 Nm ZAB 228 ft lbs 310 Nm X 70 psi 4 8 bar X S 80XC S 85XC S 80HF S 85HF S 80J 420 ft lbs 569 Nm ZAB 228 ft lbs 310 Nm X 100 psi 6 9 bar ...

Page 30: ...275 Nm X X X Model Z 45 25 Z 45 25J Z 45 DC FE DC and BE models 125 ft lbs 169 Nm SHC 240 ft lbs 325 Nm ZAB 203 ft lbs 275 Nm X X X Z 45 25 IC Z 45 25J IC Z 45HF Z 45 XC Z 51 125 ft lbs 169 Nm SHC 240 ft lbs 325 Nm ZAB 203 ft lbs 275 Nm 60 psi 4 1 bar 38 psi 2 6 bar X Z 60 37 DC FE 240 ft lbs 325 Nm ZAB 203 ft lbs 275 Nm X X X Z 62 240 ft lbs 325 Nm ZP 210 ft lbs 285 Nm ZAG 180 ft lbs 244 Nm 70 ps...

Page 31: ...81 Nm Hub adapter to drive hub fasteners S 60 S 65 Z 62 S 60XC from S60XCH 45001 S 65XC S 80J Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs 244 Nm S 40 S 45 S 40XC S 45XC Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs 244 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 ...

Page 32: ... part number 1251562GT Perkins 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...

Page 33: ...dle SX 105 125 135 XC SX 150 180 2450 rpm 735 Hz High idle S 60 65 TraX S 80 85 80X S 80 85HF S 80 85XC S 100 105 120 125 100HD 120HD Z 62 Z 80 Z 135 ZX 135 2350 rpm 705 Hz Oil capacity including filter 12 8 quarts 12 1 liters Fan belt deflection 0 375 to 0 5 inches 9 to 12 mm TD 2 2 L3 Low idle standby 1000 rpm 1000 Hz Low idle function enable 1500 rpm 1500 Hz High idle 2500 rpm 2500 Hz Oil capac...

Page 34: ... 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 Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants Perkins Engine Models 403D 11 Low idle 1500 rpm 150 Hz High idle 2800 rpm 280 H...

Page 35: ...2 quarts 8 9 to 10 6 liters Engine coolant capacity 13 3 quarts 12 6 liters Fan belt deflection 0 375 to 0 5 inches 9 to 12 mm 404F E22T Low idle standby 1000 500 Hz Low idle with function enable 1500 rpm 750 Hz High idle 2500 rpm 1250 Hz Oil capacity including filter 9 2 to 11 2 quarts 8 9 to 10 6 liters Engine coolant capacity 8 8 quarts 8 3 liters Fan belt deflection 0 375 to 0 5 inches 9 to 12...

Page 36: ...se of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Unit ships with Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants Ford Engine Models DSG 423 Low idle 1600 rpm 53 3 Hz High idle 2500 rpm 83 3 Hz Oil capacity including filter 4 quarts 3 8 liters Engine coolant capacity 10 quart...

Page 37: ...city including filter 8 6 quarts 8 1 liters Engine coolant capacity 10 quarts 9 5 liters Fan belt deflection 0 437 inches 11 mm WG 972 Low idle 1600 rpm 266 7 Hz High idle 3000 rpm 500 Hz Oil capacity including filter 3 quarts 2 8 liters Engine coolant capacity 0 61 quarts 2 36 liters Spark plug gap 0 024 to 0 028 inches 0 6 to 0 7 mm Fan belt deflection 0 312 inches 8 mm Z482 E Low idle 2000 rpm ...

Page 38: ...uire the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Unit ships with Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative engine coolants Continental Engine Models TME27 Low idle 1600 rpm 53 3 Hz High idle 2500 rpm 83 3 Hz Oil capacity including filter 7 quarts 6 6 liters Engine coolant ca...

Page 39: ...5 liters Engine coolant capacity 9 1 quarts 10 1 liters Fan belt deflection 0 375 to0 5 inches 9 to12 mm Unit ships with 15W 40 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 Ethylene Glycol engine coolant Consult your local supplier for compatibility before mixing alternative en...

Page 40: ... 134 bar X X X 3500 psi 241 bar 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 60HF S 65HF S 60XC from S60XCH 45001 S 65XC all models 3200 psi 221 bar X X X 2300 psi 159 bar X X X 3500 psi 241 bar S 60J S 80J 3200 psi 221 bar X X X 2000 psi 138 bar X X X 3000 psi 207 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 80HF S 85...

Page 41: ...200 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 45HF Z 45 XC 3200 psi 221 bar X 2100 psi 145 bar X X X X X ANSI CSA 3500 psi 241 bar CE 3000 psi 207 bar Z 45 DC FE X X 2100 psi 14...

Page 42: ...80 psi 19 3 bar 600 psi 41 4 bar X S 60J 280 psi 19 3 bar 650 psi 45 bar X S 80J 280 psi 19 3 bar 750 psi 51 7 bar S 80 S 85 S 80HF S 85HF S 80X S 80XC S 85XC 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...

Page 43: ... 80J X 24 5 fl oz 725 cc 8 fl oz 237 cc 23 gallons 87 liters 27 gallons 102 liters S 80 S 85 S 80X 23 fl oz 680 cc 30 5 fl oz 902 cc 43 fl oz 1262 cc 40 gallons 151 liters 50 gallons 189 liters S 80HF S 85HF S 80XC S 85XC 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...

Page 44: ... 25 5 fl oz 750 cc 22 gallons 83 liters 28 gallons 106 liters Z 45 DC FE X 24 fl oz 710 cc 25 5 fl oz 750 cc 10 5 gallons 40 liters 17 gallons 65 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 f...

Page 45: ...olube 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 its maximum allowable range If the...

Page 46: ...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 hy...

Page 47: ...hell 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 48: ... 8 3 4 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 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 49 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 S...

Page 49: ...ated 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 50: ...rect 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 51: ...al 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 i...

Page 52: ...f 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 c...

Page 53: ...aintenance 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 unde...

Page 54: ... 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 eac...

Page 55: ...istration Q 1 Test the Ground Control Override 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 Functions and Controls continued Test the Drive ...

Page 56: ...table 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 Models A 8 Test Platform Overload ALC1000 models A 9 Test Platform Overload S 60 HC models A 10 Test Platform Overload S 40HF S 45HF S 60J S 80J Z 45HF Z 45 DC FE from Z45EM 101 A...

Page 57: ... 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 1000 HRS P0 11 Programmed Maintenance Hours are in ...

Page 58: ...1 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 damag...

Page 59: ...0 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 60: ...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 61: ...ors 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 62: ...lls 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 than...

Page 63: ...as 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 harn...

Page 64: ...ive chassis cover from the non steer end of the machine and locate the electrical contactor s 2 Locate the electrical 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 ...

Page 65: ...aust System Genie specifications require that this procedure be performed quarterly Maintaining the exhaust system is essential to good engine performance and service life Operating the engine with a damaged or leaking exhaust system can cause component damage and unsafe operating conditions Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bur...

Page 66: ... each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque 4 Check the pressure in each air filled tire Q 7 Check the Generator Belts Pulleys and voltage Bi Energy Models Genie specifications require that this procedure be performed quarterly Maintaining the generator belts and the pulleys is essential to good generator performance and service life The generator will not...

Page 67: ...roper tension If the belt deflection is not within specification Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Adjust the Generator Belts 1 engine pulley 2 generator belts 3 generator pulley Belt deflection maximum allowable 1 4 inch 6 5 mm 8 Check the torque of the pulley retaining nut on the generator Generator pulley retaining nut torque 80 90 ft...

Page 68: ...is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve Q 9 Visual Inspection of the Hydraulic Oil Genie specifications require that this procedure be performed quarterly Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction s...

Page 69: ... scheduled quarterly maintenance inspection Note When replacing the hydraulic oil it is recommended that all hydraulic filters be replaced at the same time Q 10 Inspect the Hydraulic Filters Genie specifications require that this procedure be performed quarterly Maintaining the hydraulic filter in good condition is essential to good system performance and safe machine operation The filter conditio...

Page 70: ...to the hydraulic tank Q 11 Check and Adjust the Engine RPM Engine specifications require that this procedure be performed quarterly Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Note These procedures do not...

Page 71: ... Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter 1 Start the engine from the ground controls 2 Press the enter or previous button on the LCD screen until engine rpm is displayed Result Low idle rpm is correct Continue with step 3 Result Low idle rpm is not correct Follow the low rpm idle procedure for your engin...

Page 72: ...to increase low rpm or counterclockwise to decrease low rpm 4 While holding the throttle lever against the low idle adjustment screw tighten the core clamp screw High rpm idle adjustment 1 Loosen the lock nut on the high idle adjustment nut 2 Turn the high idle adjustment nut clockwise to increase the high rpm or counterclockwise to decrease high rpm 3 Tighten the lock nut 1 core clamp screw 2 thr...

Page 73: ...e 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 D1105 E4B 1 high idle solenoid 2 low idle adjustment screw 3 lock nut 4 high idle adjustment nut Kubota Z482 E 1 low idle adjustment screw not shown 2 high idle adjustment nut 3 high idle...

Page 74: ...ance Procedures 58 S Booms Z Booms Part No 1268489GT Deutz TD2011L04i 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Perkins 403D 11 1 high idle solenoid 2 high idle adjustment nut 3 low idle adjustment screw ...

Page 75: ...djustment 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 Perkins 1104D 44T 1 low idle adjustment screw 2 lock nut 3 high idle adjustment screw 4 high idle solenoid Cummins B3 3T 1 low idle adjustment screw 2 high idle adjustment nut 3 high idle solenoid ...

Page 76: ...witch and operate each boom function Result No boom functions operate 6 Pull out the red Emergency stop button to the on position at the platform controls 7 Activate the foot switch and operate each boom function Result No boom functions operate Q 13 Test the Alarm Package if equipped Genie specifications require that this procedure be performed quarterly The alarm package includes Travel alarm De...

Page 77: ...r in either direction Q 14 Test the Emergency Power System excludes ALC 600 and ALC 1000 Models Genie specifications require that this procedure be performed quarterly Testing the emergency power system regularly is essential to safe machine operation if the primary power source fails 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ...

Page 78: ...80 60 Z 135 70 and ZX 135 70 Models 1 Turn the key switch to ground controls 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Start the engine from the ground controls 4 Push and release the rpm select button until high rpm is selected rabbit symbol Result The engine should change to high idle 5 Push and release the rpm select button until low ...

Page 79: ...ine LPG Models Genie specifications require that this procedure be performed quarterly The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made when the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indi...

Page 80: ...tart the engine and allow it to run at low idle 7 Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Note The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running ...

Page 81: ... maintenance procedure applies to the following models SX 105XC SX 125XC SX 135XC SX 150 SX 180 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 panel is equipped with the...

Page 82: ... 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 po...

Page 83: ... 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 betwee...

Page 84: ...ne 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 85: ...iming 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 op...

Page 86: ...ive 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 105XC SX 125XC SX 135XC S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Note Perform this procedure ...

Page 87: ... 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 20...

Page 88: ...rom 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 58351GT This kit includes a digital level with a magnetic base and cable harnesses Note A properly calibrated digital level is essential t...

Page 89: ...s 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 Sensor...

Page 90: ... 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 mus...

Page 91: ... 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 92: ...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 prima...

Page 93: ...e 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 Procedu...

Page 94: ...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 an...

Page 95: ... 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 105XC and SX 125XC 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 e...

Page 96: ...nd 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 97: ...alibrate 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 98: ...r 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 the...

Page 99: ...d 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 100: ...able 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 end ...

Page 101: ...cket 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 DISCONNECTED...

Page 102: ...ector 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 Co...

Page 103: ...witch 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 e...

Page 104: ...ntify 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 primary...

Page 105: ...latform 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 106: ...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 rem...

Page 107: ...ith 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 108: ...ct 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 Ra...

Page 109: ...05 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 contr...

Page 110: ...ency 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 111: ...s 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 gre...

Page 112: ...ntil 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 o...

Page 113: ... 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 LSAX2EO to close the contacts Result The axle ex...

Page 114: ...ould 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 extended to less than 2 feet 0 6 m Failure to retract the...

Page 115: ... 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 116: ...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 117: ...ine from the platform controls All Models 3 Do not activate the foot switch Press down on the operator protection activation strip Result There is no audible alarm or flashing beacon The engine does not shut down engine models 4 Activate the foot switch Press down on the operator protection activation bar for longer than 0 4 seconds and release Result An intermittent audible alarm will sound and t...

Page 118: ...al or more frequent inspections may be required due to the following exposed to hostile or corrosive environmental conditions boom is overloaded sustains a shock load electrical arcing unused for extended periods The boom extend retract cables and sheaves are responsible for the extension and retraction of the boom tubes Inspecting for foreign objects damage and or improper adjustment of the boom ...

Page 119: ... S 65HF S 60J S 60XC from S60XCH 45001 S 65XC S 80HF S 85HF S 80J S 80XC and S 85XC 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 e...

Page 120: ...y boom This maintenance procedure applies to the following models S 40HF S 45HF S 40XC S 45XC S 60HF S 65HF S 60J S 60XC from S60XCH 45001 S 65XC S 80HF S 85HF S 80J S 80XC and S 85XC Note A digital level will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351GT This kit includes a digital level with a magnetic base and cable harness...

Page 121: ...ta 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 a...

Page 122: ... Turntable Level Sensor Q 39 Test the Primary Boom Angle Sensor ALC600 Models 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 monitors the position and angle of the primary boom using the signal from the primary boom angle sensor This maintenance proce...

Page 123: ...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 screen...

Page 124: ...esult 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 125: ... 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 the safety chock OR lifting device 5 Lower the boom to the stowed position 6 Using a star pattern confirm that each lower bearing mounting bolt is torqued in sequence to specification Torque values are listed as dry The retaining fasteners must be c...

Page 126: ... 45DC Z 45FE Z 45HF Z 45IC Z 45XC to Z4525A 55298 to Z4525B 5452 to Z452516M 6699 to Z452516N 56105 to Z4525D 1646 210 285 from Z4525F 1517 from Z4525M 6700 from Z452516N 56106 from Z4525D 1647 from Z45EM 101 180 244 Z 51 to Z513016B 1517 to Z5130M 2035 210 285 from Z5230M 2036 180 244 Model and Serial Range Torque ft lbs Nm Z 60DC Z 60FE from Z60M 101 from Z6016N 101 from Z60H 701 180 244 Z 62 in...

Page 127: ...ot 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 direct...

Page 128: ... bearing has been checked in at least four equally 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 saf...

Page 129: ...fication 2 Repeat the procedure for the inner mounting bolts Jib boom rotate bearing bolts 230 ft lbs 311 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 Ill...

Page 130: ...ator 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 ...

Page 131: ...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 When t...

Page 132: ...he off position Result The engine should stop and no functions should operate 9 Turn the main key switch to ground control and start the engine 10 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The main key switch must remain in the ground control position 11 Raise the primary boom 3 ft 1 m Result The primary boom ...

Page 133: ...f equipped 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 operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromise...

Page 134: ...ne should continue to run DC Models Result The platform overload indicator lights should be off at both the ground and platform controls and the alarm should not sound Note If test weights are not available you may use an industrial scale to weigh available objects until it equals the platform s maximum capacity Note Alternate method for achieving rated load in the platform is to attach a hanging ...

Page 135: ...ting 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 tipping over This maintenance procedure applies to the following models S 100 S 105 S 120 S 125 S 100HD S 120HD SX ...

Page 136: ...l it equals the platform s maximum capacity Note Alternate method for achieving rated load in the platform is to attach a hanging scale to the bottom of the platform and apply load using a winch or ratchet until the readout displays the appropriate weight 1 platform support 2 hanging scale 3 winch or ratchet 4 anchoring device 5 Add additional weight or load to the platform that is equal to but do...

Page 137: ...um 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 tipping over Note Be sure that no load sense system faults exist prior to performing this procedur...

Page 138: ...ing a suitable lifting device place an additional appropriate test weight equal to 227 2 to 231 3 kg on to the center of the platform floor The total weight in the platform must equal 567 4 to 571 5 kg Result The alarm should sound and the engine should turn off The platform overload indicator light should be on at both the ground and platform controls 6 Using a suitable lifting device remove all ...

Page 139: ...free of hesitation jerking and unusual noise This maintenance procedure applies to the following models S 60 S 65 S 60 TraX S 65 TraX S 60HC S 60HF S 65HF S 60X S 60XC S 65XC S 80 S 85 S 80X S 80HF S 85HF S 80J S 80XC S 85XC 1 Raise the boom to the horizontal position and fully extend the boom 2 After the boom is fully extended lower the boom until the platform is at chest height Turn the machine ...

Page 140: ... 60X S 60XC S 65XC S 60 TraX and S 65 TraX S 80 S 85 S 80X S 80HF S 85HF S 80J S 80XC S 85XC Install the cover at the pivot end of the boom S 60HC Install the boom end cover at the pivot end of the boom while guiding the small cable from the string potentiometer into the slot of the cover Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched ...

Page 141: ...s and sheaves are responsible for the extension and retraction of the number 3 boom tube on the S 100 S 105 SX 105XC and S 100HD and the number 2 and 3 boom tubes on the S 120 S 125 S 120HD and SX 125XC Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables on a regular basis is essential to good machine performance and safe machine operation The boom ex...

Page 142: ... set Note If the boom extend or retract cables are replaced quarterly maintenance inspections must be performed for the first year 4 At the pivot end of the boom visually inspect for the following The red locking bracket is securely installed over the cable adjustment bolts 5 Install the plastic cover at the pivot end of the boom and access panels on the sides of the boom 6 Start the engine from t...

Page 143: ... Inspecting for foreign objects damage and or improper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise SX 135XC models Note Properly adjusted extend retract cables will maintain a...

Page 144: ...n boom tubes 2 and 3 is less then 1 in 2 6 cm or more than 1 5 in 3 8 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 SX 150 and SX 180 models Note Properly adjusted extend retract cables will maintain a relationship of the gap between boom tubes 2 and...

Page 145: ... 2 6 cm to 1 5 in 3 9 cm greater than dimension A The boom tube is in tolerance Proceed to step 7 Result The distance between boom tubes 2 and 3 is less then 1 in 2 6 cm or more than 1 5 in 3 8 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 7 Measure ...

Page 146: ...o thoroughly inspect the above items or an endoscope inspection camera Note Refer to Maintenance Procedure P12 2 Cable Replacement Criteria Note If required the extend or retract cables must be replaced as a set Note If the boom extend or retract cables are replaced quarterly maintenance inspections must be performed for the first year A 14 Check the Drive Hub Oil Level and Fastener Torque Genie s...

Page 147: ...er the drive chassis between the tracks 5 Lift the machine until the tracks are off the ground and place jack stands under the drive chassis for support 6 Attach a lifting strap from an overhead crane 2000 lbs 1000 kg to the center point of the track assembly above the sprocket 7 Remove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the d...

Page 148: ...and torque to specification Refer to Torque 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 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to...

Page 149: ...om S6014D 397 from S60TXD 651 from S60H 36400 from S60JH 101 from S60M 65TX 65XC M 101 90 122 Model and Serial Range Torque ft lbs Nm S 80 S 80HF S 80J S 80X S 80XC S 85 S 85HF S 85XC to S80 80X 85 H 14097 to S8016D 235 110 149 from S80 80X 85 H 14098 from S80XC 85XC H 101 from S8016D 236 from S80JH 101 122 165 S 100 S 105 S 120 S 125 S 100HD S 120HD from S100 105 120 125 15D 983 from S100HD 120HD...

Page 150: ... 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 tipping over Note Perform this procedure with...

Page 151: ... scale to weigh available objects until it equals the platform s maximum capacity Note Alternate method for achieving rated load in the platform is to attach a hanging scale to the bottom of the platform and apply load using a winch or ratchet until the readout displays the appropriate weight 1 platform support 2 hanging scale 3 winch or ratchet 4 anchoring device 4 Add an additional 150 lbs 68 kg...

Page 152: ...nually 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 tipping over Note Perform this procedure with th...

Page 153: ...d Repair Manual for your machine How to Calibrate the Platform Overload System Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 5 Add an additional 320 lbs 145 kg weight or load to the platform Result There is an audible alarm and the Platform Overload indicator light is on at the ground controls Engine does not start and run Result There is no aud...

Page 154: ...estricted Platform Overload 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 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 3 Using a suitable lifting device place a test weight o...

Page 155: ...r Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Platform Overload System 5 Add additional weight or load to the platform S 80HF S 85HF models 370 lbs 168 kg All other models 320 lbs 145 kg Result There is an audible alarm Platform overload is displayed on the LCD screen at the ground controls Engine does not start and run Result There is no audible al...

Page 156: ...m the platform Note Failure to remove all weight tools and accessories from the platform will result in an inaccurate test 2 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 3 Place a test weight on the platform floor using a suitable lifting device Place the weight near the center entry point of the platform a...

Page 157: ... is an audible alarm Platform Overload is indicated at the ground controls Result There is no audible alarm Platform Overload is not indicated 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 Note There may be a 2 second delay before the overload indicator light...

Page 158: ...heck Exhaust manifold check A 20 Perform Engine Maintenance Engine specifications require that this procedure be performed every two years Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Kubota Models D1803 Intake air line replace Fuel pipes and clamp bands replace Radiator...

Page 159: ...embly 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...

Page 160: ... 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 S 45 S 40XC S 45XC Models Manufacturer specifications require that this procedure be per...

Page 161: ...els 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 oper...

Page 162: ...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 botto...

Page 163: ...nufacturer 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 f...

Page 164: ...lable 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 inte...

Page 165: ...aintenance schedule applies to the following Deutz Engines D2011 L03i TD2011 L04i TD 2 2 L3 TCD 2 2 L3 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 clean t...

Page 166: ... 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 Eng...

Page 167: ...ng Kubota Engines D 1105 E3B D1105 E4B D1803 CR TIE4 TIE5 WG972 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 Water separator drain Engine oil replace Z482 Fan belt tension and damage check Battery electrolyte level check Spark plug check Air cleaner element clean Replace the elem...

Page 168: ...ntervals Procedure Not required Daily 50 75 100 150 200 400 500 800 Fuel Water separator replace D1803 Air cleaner element replace Fan belt replace Cleaning of water jacket radiator interior Removal of sediment in fuel tank Recharging battery Damage in electric wiring and loose connections check Valve clearance check D1105 WG972 Z482 ...

Page 169: ... 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 Fue...

Page 170: ...0 800 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 Electrical...

Page 171: ...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 o...

Page 172: ...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 Glow plugs check V belts re ...

Page 173: ...ect Turbocharger inspect 854F Water pump inspect Engine crankcase breather replace Kubota Models D1803 Valve clearance check WG972 Spark plugs replace Coolant and vacuum lock hose of LPG vaporizer replace Radiator coolant L L C replace Cleaning water jacket and radiator interior Valve clearance check Cleaning cylinder head Valve seats check Air cleaner element replace Gasoline fuel hose and clamp ...

Page 174: ...ontinued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 2 middle plug 4 Drive hubs with 2 plugs Fill the hub until the oil level is even with the b...

Page 175: ...om the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 9 Locate the hub disconnect pin in the center of the drive hub Manually depress the pin and rotate the drive hub until one of the two plugs is at the lowest point 1 drive hub plug 10 Remove the plugs and drain the oil into ...

Page 176: ...e turntable rotate drive hub assembly 4 Remove the drive hub mounting bolts from the drive hub assembly Carefully remove the turntable rotate drive hub assembly from the machine Note If equipped with two turntable rotation drive hub assemblies do not remove them both at the same time Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall when removed from the mach...

Page 177: ... require that this procedure be performed every 2000 hours Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Cummins Models Cooling system flush Valve clearance check adjust GM 998L Spark plug wires replace Timing belt replace Bolts nuts and fasteners check tighten GM 3 0L El...

Page 178: ...ngine mounts inspect 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...

Page 179: ... 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 quarter...

Page 180: ...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 Rotat...

Page 181: ...e 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 elem...

Page 182: ...0 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 drive hubs by turning over the drive hub disconnect caps on each non steer circle end wheel hub 1 brake disengaged position 2 brake engaged position 5 Manually rotate each non steer circle end wheel Result Each...

Page 183: ...ls 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 disconnect caps Rotate each wheel or track to check for engagement Raise the machine remove the jack stands and lower the machine Collision hazard Failure to re engage the drive hubs could result in death or ...

Page 184: ...ng or scraping of the boom Note Always maintain squareness between the outer and inner boom tubes S 40 S 45 S 40HF S 45HF S 40XC S45XC S 60 S 65 S 60HF S 65HF S 60J S 60X S 60XC S 65XC Boom 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 Top and side wear pads pivot end of boom 0 50 inch 12 7 mm ...

Page 185: ...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 of boom 0 6875 inch 17 46 mm Side wear pads platform end of boom 0 5625 inch 14 29 mm Bottom wear pads platform end of boom 0 625 inch 15 9 mm Top and side wear pads pivot end of boom 0 69 inch 17 46 mm Bottom wear pads pi...

Page 186: ...dary 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 p...

Page 187: ...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 ser...

Page 188: ...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 this...

Page 189: ...ff 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 190: ...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 the...

Page 191: ...cur 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 performe...

Page 192: ... regulator replace Diesel particulate filter clean Glow plugs ARD combustion replace Radiator cap inspect replace 404F E22T 404F E22TA Coolant temperature regulator 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 ...

Page 193: ...the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Perkins Models 404F E22T 404F E22TA 854F 34T 1104D 44T Aftercooler core clean test P5 1 Perform Engine Maintenance 5000 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 ...

Page 194: ...ufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Perkins models 404F E22T 404F E22TA 1104D 44T Cooling system coolant extender ELC add P12 1 Perform Engine Maintenance 12000 Hours Engine specifications require that this procedure be performed every 12000 hours Required maintenance procedures and additional engine information are available in the manufacturer s ma...

Page 195: ...ed for extended periods The boom extend and retract cables are responsible for the extension and retraction of the boom tubes Inspection and replacement of the boom extend and retract cables when required is essential to good machine performance and safe machine operation The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Remove the ...

Page 196: ...cables are damaged or show excessive wear the cables must be replaced as a set 4 Inspect the cable diameter Measure the diameter in multiple locations along the cable Note Calipers will be required to perform this procedure correct incorrect Cable Diameter Specifications Model Nominal Diameter Minimum Diameter S 60 S 65 S 60HF S 65HF S 60X S 60XC S 65XC S 80 S 85 and S 80X includes TraX models Ext...

Page 197: ...nches 12 7 mm 475 inches 12 mm Retract Boom 4 50 inches 12 7 mm 475 inches 12 mm Note If any section of the cable is below the minimum diameter the cables must be replaced as a set Cable Re place men t Crit eria 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 b...

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