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Quarterly Maintenance Procedures

1. a P tQu Unt l Programmed Maintenance Procedures P0 6 Deutz Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals This maintenance schedule applies to the following Deutz Engines Deutz D2011L03i Deutz TD2011L04i Deutz D 2 9 L4 Deutz TD 2 9 L4 Deutz Engines Hour Intervals Procedure Not required Daily 250 500 Oil level check Coolant level check Oil fuel and coolant systems check for leaks e e Fuel system filter water separator inspect drain Air filter discharge valve clean Exhaust system inspect Check clean the oil cooler and cooling fins Deutz 2011 Models Engine oil and filter replace Air filter replace Valve clearance check adjust Engine coolant test add Air intake pipes inspect V belts inspect Fuel filter separator replace Lo Qai 1 1 1 1 1 110 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual ccrtc A s
2. M S M N C ME O l Performance Specifications Function Speeds All Other Models Note Function speeds are maximum from platform controls with maximum rated load in platform Function Primary boom up S 40 S 45 includes TRAX models 50 60 seconds S 60 S 65 S 60HC S 60X S 60XC includes TRAX models 60 70 seconds S 80 S 85 S 80X ANSI CSA models 57 65 seconds S 80 S 85 AS CE models 75 83 seconds Primary boom down 50 60 seconds 60 70 seconds 61 69 seconds 75 83 seconds Primary boom extend 30 60 seconds 58 66 seconds 59 67 seconds 59 67 seconds Primary boom retract 15 35 seconds 53 62 seconds 57 65 seconds 57 65 seconds Jib boom up 35 45 seconds 60 70 seconds 25 35 seconds 25 35 seconds S 45 S 65 S 85 S 85 Jib boom down 20 30 seconds 40 50 seconds 15 25 seconds 15 25 seconds S 45 S 65 S 85 S 85 Turntable rotate stowed 70 100 seconds 78 86 seconds 90 103 seconds 90 103 seconds Turntable rotate extended 120 140 seconds 125 165 seconds 210 250 seconds 210 250 seconds Platform rotate Platform level 10 range of motion 6 10 seconds 8 12 seconds 8 12 seconds ANSI CSA 3 5 seconds AS CE 20 22 seconds 8 12 seconds Function Primary boom up
3. a P tQu Unt l Programmed Maintenance Procedures P0 8 Kubota Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals This maintenance schedule applies to the following Kubota Engines Kubota D 1105 E3B Kubota WG972 Kubota Z482 E Kubota Engines Hour Intervals Procedure Not required Daily 50 75 100 150 200 400 500 Coolant level check og co e e S Cil level check Q Q Fuel hoses and clamp bands check Q S amp I AI AJA 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 a QV S S9 9 3 S8S8 Fuel filter element type clean SS A S 9 93 3 82 Oil filter cartridge replace Z482 Oil filter cartridge replace D1105 WG972 Engine oil replace D1105 WG972 Radiator hoses and clamps check SS AIA AIA SS S S mms Intake air line check SS S AIAN SS S mms Fuel filter cartridge replace Air cleaner element replace Fan belt replace
4. 7 Activate the foot switch and operate each boom function Result No boom functions operate 1 low idle adjustment screw 2 high idle adjustment nut 3 high idle solenoid Lo Gail 1 1 1 1 1 46 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 13 All Models Test the Alarm Package 2 Activate the boom down function hold for a if equipped moment and then release it ae Result The descent alarm should sound when Genie specifications require that this procedure be the down function is activated performed quarterly Complete this step for each boom that applies The alarm package includes Primary Secondary and Jib Booms e Travel alarm 3 Turn the key switch to platform controls e Descent alarm Result The flashing beacon should be on and flashing e Flashing beacon abs Al dab installed to alert 4 Press down the foot switch Activate the boom EE MEE down function hold for a moment and then operators and ground personnel of machine uw release it proximity and motion The alarm package is installed on the turntable covers Result The descent alarm should sound when the down function is activated Note The alarms and beacon will operate with the engine running or not running Complete this step for each boom that applies Primary Secondary and Jib Booms 1 Turn the key switch to ground control and pull cut he red Emer
5. h vi S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Personal 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 A ADANGER Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING _ ndicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous iod Part No 1268489 situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation Safety Rules 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 Ww M gt warrants it f 3 NA Be aware of potential crushing hazards s
6. eese 84 A 1 Grease the Turntable Rotation Bearing and Rotate Gear 84 A 2 Check the Turntable Rotation Bearing Bolts sess 85 A 3 Inspect for Turntable Bearing Wear ssssseee en 86 A 4 Check the Extendable Axle S 100 S 105 S 120 and 8 125 87 A 5 Perform Maintenance Jib Rotate Bearing sese 88 A 6 Test the Bypass Recovery Key Switch ALC1000 Models 89 A 7 Grease the Platform Overload Mechanism if equipped 91 A 8 Test the Platform Overload System All Models Except ALC1000 and S 60HC Models uusesss 92 A 9 Test the Platform Overload System ALC1000 Models 94 A 10 Test the Platform Load Sense System S 60 HC 95 A 11 Inspect the Boom Extend Retract Cables S 60 and S 80 Models ssssssssssssseseeeeen ennt 96 A 12 Inspect the Boom Extend Retract Cables S 100 S 105 S 120 and S 125 Models sseeesseeee 98 A 13 Inspect the Boom Extend and Retract Cables SX 150 and SX 180 Models sse 99 A 14 Check the Drive Hub Oil Level and Fastener Torque 101 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms xi September 2015 namK EEE gt A Table of Contents Programmed Maintenance Proced
7. Engine coolant capacity 13 3 quarts Fan belt deflection 5 16 inch 12 6 liters 8 mm Fan belt deflection 3 8 to 1 2 inch 403F 11 9 to 12 mm Low idle 1500 rpm 404F 22T 265 Hz x Low idle 1300 rpm High idle 2800 rpm 650 Hz 494 7 Hz ENS High idle 2300 rpm Oil capacity including filter 4 6 quarts 1150 Hz 4 4 liters Oil capacity including filter 9 4 to 11 2 quarts Engine coolant capacity 3 3 quarts 8 9 to 10 6 liters 3 1 liters Engine coolant Ethylene Glycol Fan belt deflection 3 16 inch 5 mm Engine coolant capacity 13 3 quarts 12 6 liters 14040 22 Fan belt deflection 3 8 to 1 2 inch Low idle Z 45 25 and Z 45 25 J 1500 rpm 9 to 12 mm 265 Hz 804D 33 Low idle all other models 1300 rpm 229 7 HZ Low idle with generator 1400 rpm 284 7 Hz High idle 2500 rpm 441 7 Hz Low idle without generator 1650 rpm 335 5 Hz Oil capacity including filter 9 4 to 11 2 quarts 8 9 to 10 6 liters High idle 2300 rpm 467 7 Hz Engine coolant capacity 13 3 quarts EE 12 6 liters Oil capacity including filter 10 6 quarts 10 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Engine coolant capacity 12 5 quarts 11 8 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Genie Part No 1268489 S Booms Z Booms 13 Maintenance Manual September 2015 Engine Specifications 854F E34T Low idle standby 1000 rpm SX 150 SX 180 Z 135 ZX 135 50
8. Cleaning of water jacket radiator interior Removal of sediment in fuel tank Recharging battery QAI AIAI AI AIAI 55 mmus QLRJVJlVPRPLRIRI amp Damage in electric wiring and loose connections check S S8 AI AI SS o s QI SAIAS AISA A TAISIJA AIAI AIAI AI AIAI S AIAI SIAI AISA A TATATA SINAIA IAI AIAI S AINI AI S AA Q ASIAT SS IAI AIAI AIAI AIAJ A 89059 SIAI AIA AI AIAI AIAI Al Ayy S S S9 A SAI AAJA AIAI AIAI A AIA Valve clearance check Genie 112 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Dece aasam O OoOo O P U MAMMM ERMU EMT Programmed Maintenance Procedures P0 9 Perkins Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals This maintenance schedule applies to the following Perkins Engines Perkins 403D 11 Perkins 403F 11 Perkins 404D 22 Perkins 404F 22 Perkins 404F 22T Perkins 804D 33 Perkins 854F 34T Perkins 1104D 44T Perkins Engine Hour Intervals Procedure Not required Daily 50 Air filter discharge valve clean oa e e Oil fuel an
9. Result The reading at the display and digital level is greater than 2 of each other and of 15 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 Fully lower the primary boom until it stops at approximately 2 6 Result The reading at the display and digital level is within 2 of each other and of 2 6 Result The reading at the display and digital level is greater than 2 of each other and of 2 6 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 Q 29 Test the Safety Envelope Limit Switches Z 135 70 ZX 135 70 SX 150 and SX 180 Models Genie specifications require that this procedure be performed quarterly Testing the machine envelope safety limit switches is critical to safe machine operation If the boom is allowed to operate when a safety switch is not functioning correctly the machine stability could be compromised and may tip over Note Perform this procedure with the boom in the stowed position Note Perform this procedure with the axles extended Note Two people will be required to perform this procedure Note Use the following chart to identify the description of each LCD screen control button used in this pr
10. ssessseeee iii Find additional Manuals for your Model ssseeeeeee n iii Section 1 CLA teRR RR vi General Safety Rules tei etes e entra de Rea aea de ana dana vi Function Speeds S 100 S 105 and S 100HD sssssssssssss 1 Function Speeds S 120 S 125 and S 120HD sss 2 Function Speeds All Other Models ssssssssssssseeenee 3 Drive Speeds e ce ir a EUR FUR AREE a E TREE ERR ARIETE BRTEERMIE 7 Torque Specifications canet un cosecevanedneden aa ru Rent den rna araa 9 Tires and Wheels iei d utet ei es Had es en E elated 9 TRAX Torque Specifications ssssssssssssssseeeeeneeeenen nnn 10 Engine Specificatlons eicere nnt en RH RIEE ERAI RE eR FERES REOR 11 Engine Operator and Maintenance Manuals see 11 Deutz Engine Models sssssesseeneeeene eene enne 12 Perkins Engine Models 1 ed iiec rette eid Decet a a Dee RAE Sex ad ains 13 F rd Engine du enc 14 Kubota Engine Models essssssseeneeeneeene nennen nenne 15 Continental Engine Models essesseiseseeee estes een tn nnn nnt 15 Cummins Engine Models 2 2 tie ota dene taeda da estate 16 Hydraulic Specifications eeeeeeeeeeeeeeeee nennen nnne nnn nnt 17 Hydraulic Relief Valves
11. 8 immediately lower the primary Result The reading at the display and digital boom Failure to lower the boom level is within 2 of each other and of 49 could cause the machine to tip over resulting in death or serious amp Result The reading at the display and digital Lower the primary boom to 49 injury Refer to Repair Procedure level is greater than 2 of each other and of in the appropriate Service and 49 The primary boom angle sensor must be Repair Manual for your machine calibrated Refer to Repair Procedure in the How to Calibrate the Primary appropriate Service and Repair Manual for Boom Angle Sensor your machine How to Calibrate the Primary Boom Angle Sensor Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 65 Maintenance Manual September 2015 Quarterly Maintenance Procedures o 10 11 66 Lower the primary boom to 32 Result The reading at the display and 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 Lower the primary boom to 15 Result The reading at the display and digital level is within 2 of each other and of 15
12. Maintenance Manuals Genie part number 119488 Diagnostic Manual Deutz D2011L03i and TD2011L04i Genie part number 119494 Genie part number 139320 Deutz D 2 9 L4 and TD 2 9 L4 iani cds sid diia Genie part number 215322 Genie part number 1251561 Diagnostic Manual Perkins dp Genie part number 162067 Genie part number 131661 Kubota D1105 E3B Perkins 36M Genie part number 229761 Genie part number 1262169 Kubota WG 972 Perkins 404022 Genie part number 227584 Genie part number 94890 Kubota Z482 E Perkins 404F 22 and 404F 22T Genie part number 139420 Genie part number 1251562 i Continental TME27 Perkins 803033 Genie part number 111901 Genie part number 111332 Cummins B3 3T FUNIS aes Genie part number 139324 Genie part number 1263971 Perkins 1104D 44T Genie part number 107526 Genie Part No 1268489 S Booms Z Booms 11 Maintenance Manual September 2015 Engine Specifications Deutz Engine Models D 2 9 L4 Low idle 1500 rpm D2011 L03i 1500 Hz Low idle 1500rpm High idle 2500 rpm 313 Hz 2500 Hz High idle 2500 rpm Oil capacity including filter 9 4 quarts 521 7 Hz 9 liters Oil capacity including filter E Engine coolant Ethylene Glycol iters Engine coolant capacity 10 quarts Fan belt deflection 3 8 to 1 2 inch 9 4 liters 9 to 12 mm Fan belt deflection 3 8 to 1 2 inch TD2011 L04i 9 to 12 mm Low idle Z 80 1500 rpm TD 29 L4 450 Hz i
13. Z Booms 63 Maintenance Manual September 2015 Quarterly Maintenance Procedures 10 11 12 64 Raise the primary boom to 10 Result The reading at the display 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 Raise the primary boom to 40 Result The reading at the display and digital level is within 2 of each other and of 40 Result The reading at the display and digital level is greater than 2 of each other and of 40 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 Fully 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 Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor Q 28 Test the Primary Boom Angle Sensor SX
14. nM M per Programmed Maintenance Procedures PO0 7 Ford Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator 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 Oil level check e e Coolant level check e Oil fuel and coolant systems check for leaks e S amp S A amp I A A SS A A Ql Ql Ss Oil coolant fuel exhaust and vacuum hoses check for leaks damage or deterioration Q Q Electrical wiring check for chafing or damage Engine belts check adjust Q Fuel filters check replace Engine oil replace Oil filter replace Air filter replace Spark plugs clean adjust replace SS S S3 S S S 3 Loose or missing fasteners tighten replace PCV valve check PCV hoses tubes and fittings clean SIAI A 8 S 3 S8 SS 3 QV A SI S AIAI aJ SIAI A VJ AIAJ Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 111 Maintenance Manual September 2015 ma
15. 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 W 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 communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure s Indicates that a cold motor pump or engine will be required to perform this procedure Eg Indicates that a warm engine will be required to perform this procedure E Genie 26 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Maintenance Schedule The maintenance procedures have been divided into subsections that include Commissioning Quarterly Annually and Programmed maintenance intervals The maintenance inspection report has been divided into general areas of the machine that include Drive Chassis Booms and Platform Functions and Controls Engine and Turntable Failure to perform these procedures may result in poor performance component damage and un
16. 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 position Start the engine Z 80 Z 135 and ZX 135 models 2 Fully raise the secondary boom then extend it approximately 4 ft 1 2 m All models 3 Raise the primary boom approximately 15 then extend it approximately 4 ft 1 2 m 4 Turn the key switch to the off position to turn off the engine Turn the key switch back to ground controls Note If this procedure is performed with the main key switch in the off position an active latched safety fault will be set and will have to be cleared Genie 52 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 5 Remove the key from the main key switch and insert the key into the bypass recovery key Switch Note The bypass recovery key switch is located on the front panel in the lower right corner on Z 80 before serial number Z8013 3911 and Z 135 before serial number Z13512 1712 6 Turn and hold the bypass recovery key switch to the recovery position The switch must be held in the recovery position Result The emergency power unit will turn on and the boom will begin the following recovery sequence SX 150 SX 180 S 100 105 120 125 S 100 120HD
17. Primary boom down Z 30N Z 30N RJ 14 22 seconds 12 20 seconds 2 34 BE 14 22 seconds 12 20 seconds Z 34N Z 34 DC models 16 22 seconds 13 20 seconds 2 33 36 40 seconds retracted 48 52 second extended 46 50 seconds retracted 55 59 seconds extended Primary boom extend 15 19 seconds 12 18 seconds 11 15 seconds 18 20 seconds Primary boom retract 10 14 seconds 12 18 seconds 13 17 seconds 18 20 seconds Secondary boom up 11 18 seconds 11 18 seconds 15 22 seconds 20 24 seconds Secondary boom down 7 15 seconds 7 15 seconds 11 18 seconds 20 24 seconds Jib boom up 19 23 seconds 23 29 seconds 20 24 seconds x Jib boom down 17 21 seconds 20 26 seconds 18 22 seconds X Jib boom rotate 13 17 seconds X X X Z 30N RJ Turntable rotate 62 72 seconds 62 72 seconds 62 72 seconds 62 65 seconds Platform rotate Platform level 10 range of motion 5 11 seconds 5 11 seconds 5 11 seconds X ANSI CSA 3 5 seconds ASICE 20 22 seconds 10 12 seconds Part No 1268489 Genie ATEREX BRAND S Booms Z Booms Maintenance Manual September 2015 Performance Specifications Note Function speeds are maximum from platform controls with maximum rated load in platform Function Primary boom up
18. Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Deutz Models All Models e Injection valve replace e Toothed belt replace e V belt and tensioning pulley replace D 2 9 and TD 2 9 Models e Aftercooler core clean test e Turbocharger compressor outlet clean e Charge air cooler entry drain lube oil condensate Ford Models e Coolant filler cap clean replace Genie ATEREX BRAND S Booms Z Booms 131 Maintenance Manual September 2015 Programmed Maintenance Procedures Perkins Models 403D 11 403F 11 404D 22 404F 22 404F 22T 804D 1104D 44T e Water pump inspect e Fuel Injector test change e Cooling system coolant Heavy Duty change 403F 11 e Coolant temperature regulator replace 404F 22 404F 22T e Coolant temperature regulator replace e Diesel particulate filter clean e Glow plugs ARD combustion replace e Radiator cap inspect replace 854F 34T e Alternator inspect e Alternator and fan belts replace e Diesel particulate filter clean e Radiator cap inspect replace Kubota Models 132 2482 E D 1105 E3B e Turbocharger inspect e Injection pump check e Fuel injection timing check P4 1 Perform Engine Maintenance 4000 Hours Engine specifications require that this procedure be performed every 4000 hour
19. e Engine mounts check e Hoses and clamps check Glow plugs check e V belts re tension renew e Cold starting device if equipped check e Battery and cable connectors check e Engine valve lash inspect adjust D 2 9 and TD 2 9 Models e Coolant additive concentration check Perkins Models All Models e Alternator and fan belts replace e Engine valve lash inspect adjust e Engine crankcase breather replace 403D 11 404F 22 e Turbocharger inspect 804D 33 e Alternator inspect e Starting motor inspect e Turbocharger inspect 854F Models e Water pump inspect e Engine crankcase breather replace Kubota Models WG972 e Spark plug replace e Coolant and vacuum lock hose of LPG vaporizer check e Radiator coolant L L C replace e Cleaning water jacket and radiator interior e Valve clearance check e Cleaning cylinder head e Valve seats check e Air cleaner element replace Gasoline fuel hose and clamp bands replace e Carburetor and fuel tank inside clean Z482 E D 1105 e Fuel injection nozzle injection pressure check Genie 114 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures 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 th
20. 80 96 seconds extended Primary boom extend 18 22 seconds 40 50 seconds 48 52 seconds Primary boom retract 18 22 seconds 35 40 seconds 38 52 seconds Secondary boom up 36 40 seconds 40 45 seconds 38 48 seconds Secondary boom down 36 40 seconds 40 45 seconds 38 48 seconds Jib boom up 45 55 seconds 68 73seconds 23 33 seconds Jib boom down 25 35 seconds 77 82 seconds 21 31 seconds Turntable rotate 82 88 seconds 78 86 seconds stowed 125 165 seconds extended 114 126 seconds retracted 200 240 seconds extended Platform rotate 6 10 seconds 10 14 seconds 10 14 seconds Platform level 10 range of motion ANSI CSA 3 5 seconds AS CE 20 22 seconds Genie A TEREX BRAND S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Performance Specifications Note Function speeds are maximum from platform controls with maximum rated load in platform Function Primary boom up down Primary boom extend retract Z 135 88 105 seconds 38 42 seconds 110 125 seconds 35 48 seconds Secondary boom up down 80 95 seconds 80 95 seconds Secondary boom extend retract 88 98 seconds 88 98 seconds Jib boom up down 38 43 seconds 38 43 seconds Jib boom extend retract 27 38 seconds
21. 87 C temperature Maximum continuous operating 124 F 51 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Ganie Part No 1268489 S Booms Z Booms 21 Maintenance Manual September 2015 Hydraulic Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Seal Lok Fittings hose end ORFS 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 SAE Dash Size Torque 4 10 ft Ibs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft Ibs 54 2 Nm 10 60 ft Ibs 81 3 Nm 12 85 ft Ibs 115 Nm 16 110 ft Ibs 150 Nm 20 140 ft lbs 190 Nm 24 180 ft Ibs 245 Nm JIC 37 Fittings swivel nut or hose connection Adjustable Fittin
22. P0 3 50 Engines all models 2000 Hours P2 4 elolo g Engines Continental Under 1000 HRS P0 4 Test or Replace the Hydraulic Oil P2 2 l l l g Engines Cummins Under 1000 HRS P0 5 Replace the Hydraulic Filters P23 2 eolo o Engines Deutz Under 1000 HRS P0 6 Check the Free wheel Configuration P2 4 gg olooc og Engines Ford Under 1000 HRS PO 7 Check the Boom Wear Pads P2 5 eouooogg Engines Kubota Under 1000 HRS P0 8 Check the Extendable Axle Wear P 6 9oo o9g Engines Perkins Under 1000 HRS P0 9 Pads Check Turntable Gear Backlash P2 7 DIDID S ALC1000 Models Grease Steer Axle Wheel Bearings P2 8 2WD Models except Z 62 S 60 S 65 Grease Steer Axle Wheel Bearings P2 9 2WD Models Z 62 S 60 S 65 S S S s sf s S amp Engines all models 3000 Hours P3 1 alg Engines all models 4000 Hours P4 1 DID o Engines all models 6000 Hours P6 1 oio Go 2 Engines all models 12000 Hours P12 1 O l2O DllD Replace Boom cables P12 2 Replace every S 100HD and S 120HD 7 years Replace Boom cables S 60 Models P12 3 Replace every S 80 Models S 100 S 105 S 120 10 years S 125 SX 150 SX 180 enie ATEREX BRAND Part No 1268489 S Booms Z Booms Maintenance Manual 29 Maintenance Manual September 2015 Commisioning Procedures C 1 Perform 50 Hour Service The 50 hour maintenance procedure is a one time sequence of
23. Refer to Maintenance Procedure Replace the Hydraulic Filters Genie 40 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Models without Filter Condition Indicator Note Models without a filter condition indicator cannot be inspected At the required maintenance interval replace the filters Hydraulic Tank Cap if equipped 1 Remove the breather cap from the hydraulic tank 2 Check for proper venting Result Air passes through the breather cap Proceed to step 4 amp Result If air does not pass through the cap clean or replace the cap Proceed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air Repeat this procedure beginning with step 2 4 Install the breather cap onto 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 apply to the following engine models The engine RPM is controlled by the ECM and can only be adjusted by re progra
24. Z 34 IC 15 21 seconds Z 40N Z 40N RJ 26 30 seconds Z 45 25 Z 45 25J DC BE models 32 40 seconds Z 45 25 Z 45 25J IC models 24 28 seconds Primary boom down Primary boom extend 13 19 seconds 24 30 seconds 26 30 seconds 18 22 seconds 26 30 seconds 14 18 seconds 24 28 seconds 18 22 seconds Primary boom retract 14 20 seconds 18 22 seconds 17 21 seconds 18 22 seconds Secondary boom up 15 21 seconds 32 36 seconds 38 46 seconds 24 28 seconds Secondary boom down 11 17 seconds 32 36 seconds 38 46 seconds 24 28 seconds Jib boom up 24 30 seconds 16 20 seconds 32 40 seconds 45 55 seconds Z45J Jib boom down 15 21 seconds 16 20 seconds 26 30 seconds 25 35 seconds Z45J Jib boom rotate X 16 20 seconds Z40N RJ X X Turntable rotate 62 72 seconds 62 68 seconds 95 125 seconds 62 68 seconds Platform rotate Platform level 5 11 seconds 10 14 seconds ANSI CSA 6 10 seconds 3 5 seconds 6 10 seconds 10 range of motion AS CE 20 22 seconds Function Primary boom up Z 51 36 40 seconds Z 62 includes TRAX models 60 70 seconds Z 80 60 70 seconds retracted 80 96 seconds extended Primary boom down 36 40 seconds 60 70 seconds 75 85 seconds retracted
25. and Wheels Specifications Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 129 Maintenance Manual September 2015 Programmed Maintenance Procedures P2 9 Grease the Steer Axle Wheel Bearings 2WD Models Z 62 40 S 60 S 65 Genie requires that this procedure be performed every 2000 hours Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be 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 there is no side to side or up and down movement continue with step 10 and grease the wheel bearings Result Ifthere is side to side or up and down movement continue to step 10 and replace the wheel bearings with new ones Note When replacing a wheel bear
26. be 201 75 inches 512 cm x 2 0 inch 5 cm Digital Protractor Place the digital protractor on the turntable chassis and reset the protractor to 0 Place the protractor on top of the primary boom The J bd p J protractor should display 58 2 amp Result The primary boom angle is not within specifications Consult Genie Product Support 1 restricted maximum platform capacity 2 unrestricted maximum platform capacity 3 Raise the primary boom until it is fully elevated 4 Extend the primary boom until it is fully extended 5 Lower the primary boom until it stops Result The boom will automatically stop after 10 degrees and the unrestricted platform capacity light will flash Result The primary boom does not stop after 10 degrees Calibrate the boom angle sensor Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine 1 Measure between the centers of these How to Calibrate the Boom angle Sensor pivot pins Gri 1 1 1 1 74 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 6 Move the primary boom down joystick off center and retract the primary boom until the unrestricted platform capacity light stops flashing Result Primary boom down should return to normal operation 7 Lower the primary boom 5 feet 1 5 m and activate primary boom extend Result Primary boom extend
27. e The primary boom will retract e The primary boom will lower Z 135 and ZX 135 e The primary boom will retract e The secondary boom will retract e The primary boom will lower Note It is not necessary to fully lower the primary boom Z 80 60 e The primary boom will retract e The primary boom will lower e The secondary boom will retract 7 Turn the bypass recovery key switch to the run position 8 Remove the key from the bypass recovery key switch and insert the key into the main key switch 9 Startthe 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 between the platform level sensor and the turntable level sensor If the platform becomes out of level the computer at the platform controls will open the appropriate solenoid valve s at the platform manifold to maintain a level platform All other models Automatic platform self leveling throughout the full cycle of boom raising and lowering is essential for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the
28. extend safety limit switch 9 Start the engine from the platform controls and fully extend the axles Turn the machine off Genie Part No 1268489 S Booms Z Booms 69 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 30 Test the Primary Boom Angle Sensor Z 80 60 Genie specifications require that this procedure be performed quarterly A properly functioning primary boom angle sensor PBAS is essential to safe machine operation The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the secondary boom and gravity The ECM at the ground controls TCON monitors the position and angle of the primary boom using the signal from PBAS The PBAS signal is used to control the ramping of the primary boom as well as velocity control limiting the speed of the primary boom to 1 3 feet 0 4 meters per second Note Perform this procedure with the machine on a firm level surface Note Use the following chart to identify the description of each LCD screen control button used in this procedure a Enter Plus Minus Previous 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 Pressthe enter or previous button on the LCD screen until primary boom angle is displayed Start the engine from the ground controls 4 Rai
29. 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 must be tested before starting this procedure Refer to Maintenance Procedure Test the Turntable Level Sensor 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 proper machine calibration Refer to the manufactures calibration information Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 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 Startthe engine from the ground controls 3 Press the plus and minus buttons at the same time on the LCD screen to enter the MACHINE STATUS screen Press the enter or previous button until SECONDARY BOOM ANGLE is displayed 4 Raise the secondary boom until it is fully elevated and it just starts to extend Do not continue to extend the boom 5 Zero a digital level to the Y axis of the turntable Refer to Maintenance Procedure Test the Turntable Le
30. 10 Choose an axle extend safety limit switch to test Axle Extended Safety Limit Switches LSFA1ES is and LSRA1ES 11 Locate and disconnect the Deutsch connector to the axle extend limit switch 1 Start the engine from the ground controls and lower the boom to the stowed position 12 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 Turn the key switch to platform controls 2 at the Deutsch connector of the limit switch From the platform controls drive the machine cable in either direction and fully retract the axles Result The limit switch should have Turn the machine off continuity 4 Choose an axle extend safety limit switch to i Result The limit switch does not have test continuity The limit switch is faulty and needs 5 Locate and disconnect the deutsch connector to be replaced to the axle extend limit switch 13 Remove the multimeter leads and connect the 6 Connect the leads from a multimeter with Deutsch connector to the limit switch continuity checking capability to pins 1 and 14 Repeat steps 11 through 13 for the other axle 2 at the Deutsch connector of the limit switch extend safety limit switch cable Result The limit switch should not have continuity amp 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
31. 150 and SX 180 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 primary boom angle sensor signal is used to control the ramping of the primary boom limiting the speed of the primary boom to 2 3 feet 0 7 meters per second Note The turntable level sensor must be tested before starting this procedure Refer to Maintenance Procedures Test the Turntable Level Sensor 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 proper machine calibration Refer to the manufactures calibration information Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 Enter o 4 Plus Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position and the axles fully extended Minus Previous Genie S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Main
32. 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently 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 Hydraulic Specifications Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties Fluid Properties ISO Grade 46 ISO Grade 15 Viscosity index 192 Tm Kinematic Viscosity Viscosity index 300 cSt 149 F 65 C 22 Kinematic Viscosity cSt 104 F 40 C 46 cSt 200 F 100 C 5 5 cSt 0 F 18 C 1300 cSt 104 F 40 C 15 0 cSt 40 F 40 C sig Hae pent None Flash point 180 F 82 c Pour point EO RE Pour point 81 F 63 C Maximum continuous operating 189 F
33. 2000 hour maintenance interval the oil must be tested every quarter by an oil distributor until the oil fails the test and is replaced After the oil has been replaced continue the 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 high pressure hydraulic filter in good condition is essential to good system performance and safe machine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage 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 Models with Filter Condition Indicator Start the engine from the ground controls Set the engine idle to high rpm rabbit symbol Visually inspect the filter condition indicator O V N gt Result The filter condition indicator is operating in the green area amp i 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
34. 27 38 seconds Turntable rotate stowed 88 92 seconds 88 92 seconds Turntable rotate jib or primary boom extended 160 180 seconds 160 180 seconds Turntable rotate jib and primary boom extended 280 350 seconds 280 350 seconds Platform rotate 20 25 seconds 20 25 seconds Platform level 10 range of motion ANSI CSA ASICE 3 5 seconds 20 22 seconds Part No 1268489 Genie ATEREX BRAND S Booms Z Booms Maintenance Manual September 2015 Performance Specifications Note Function speeds are maximum from platform controls with maximum rated load in platform Function SX 150 SX 180 Primary boom up down 80 88 seconds 80 88 seconds stowed 82 82 Primary boom up down 100 110 seconds 100 110 seconds string pot 76 in 193 cm 82 82 Primary boom up down 45 50 seconds 45 50 seconds string pot 158 in 401 cm 20 20 Primary boom up down 71 80 seconds 71 80 seconds string pot 238 in 605 cm 20 20 Primary boom up down 26 31 seconds 26 31 seconds string pot 370 in 940 cm 5 5 Primary boom up down x 34 39 seconds string pot 596 in 1514 cm 5 Primary boom extend 0 100 in 254 cm 30 33 seconds 30 33 seconds Primary boom retract 100 in 254 cm 0 30 33 seconds 30 33 seconds Jib boom up down 58 62 seconds 58 62 seconds Jib b
35. 3 tensioner assembly 4 idler wheel Genie S Booms Z Booms September 2015 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 operation Tighten the jam nut Check the torque of the track assembly fasteners Refer to Specifications TRAX Torque Specifications Raise the machine remove the jack stands and lower the machine Repeat this procedure for each track assembly Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures PO0 3 2 Thoroughly pump grease into each grease fitting When grease is pumped into each Grease the Extendable Axles fitting a hose directs this lubrication to the top S 100 S 105 S 120 S 125 or bottom wear pad S100HD and S 120HD 3 Cycle the extending axles in and out ote Genie recommends that the extending axles F N Geni ds that th di be cycled in and out at least once a week Manufacturer specifications require that this procedure be performed every 50 hours Lubricating the front and rear axles helps to ensure the smooth operation of the axles over the lifetime of the product Two fittings on each axle are provided to apply greas
36. Gear Genie specifications require that this procedure be performed annually Perform this procedure more often if dusty conditions exist and when operating the machine in high temperature environments Frequent application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will 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 Grease each tooth on the outside of the turntable rotation bearing Models with Worm Drive Gear 1 Locate the 2 grease fittings on top of the worm drive housing 1 grease fittings 2 Pump grease into the gear until you see it coming out of the side of the gear housing Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Genie 84 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures A 2 Check the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed annually Main
37. JIC 37 Fitting table in this section to determine the correct 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 fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Lo Qai 1 1 1 1 1 24 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Observe and Obey v M A WARNING NAN N K Part No 1268489 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed as specified on the Maintenance inspection Reports The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial 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 b
38. Nm Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 103 Maintenance Manual September 2015 Programmed Maintenance Procedures PO 1 5 Visually inspect the section of track under the Check the Track Tension and node Fastener Torque TRAX Models ae There should be less than 1 inch 5 cm of gap between the bogey wheels and S 60 S 65 and Z 62 Models the inside surface of the track Proceed to step 12 Result There is 1 inch 2 5 cm or more of gap between the bogey wheels and the inside Manufacturer specifications require that this surface of the track Proceed to step 6 procedure be performed every 50 hours Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life The machine will not operate properly with a track that is incorrectly tensioned Continued use of a machine with incorrectly tensioned tracks may cause component damage 1 Thoroughly clean the track assembly 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 Ibs 10 000 kg under the drive chassis between the tracks at the other end of 1 bogey wheels the machine 4 Liftthe machine until the tracks are off the 6 Locate the grease plug on the track tension ground and then place jack stands under the cylinder L
39. No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 5 Push and release the rpm select button until All other models low rpm is selected turtle symbol 1 Pull out the red Emergency Stop button to the Result The engine should return to low idle on position at both the ground and platform controls 2 Startthe engine from the ground controls 3 Move the rpm select toggle switch to the high om of idle rabbit symbol position and activate Qe function enable Result The engine should change to high idle 4 Release function enable 8 Result The engine should return to low idle 5 Turn the key switch to platform controls ee h idle indicator liaht 6 Move the engine idle select switch to foot in hae M E DN ML Switch activated high idle rabbit and foot 3 engine rpm select button switch symbol 6 Turn the key switch to platform controls Result The engine should not change to high 7 Push the engine rpm select switch until low iale idle turtle symbol is selected 7 Press down the foot switch Result The engine should remain at low idle Result The engine should change to high idle 8 Press down the foot switch 8 Move the engine rpm select switch to foot Result The engine should remain at low idle Snitch SGBYERGCHOW idle ime syne 9 Push the engine idle select switch until high Pest ne endeared ITO O MON ole idle rabbit symbol is selected Result The engine should cha
40. Raised and Extended Q 24 Battery Inspection Q2 Position ALC1000 Models Inspect the Electrical Wiring Q 3 Test the Turntable Level Sensor Z 135 70 Q 25 A ZX135 70 SX 150 and SX 180 Engine Intervals Q A Test the Secondary Boom Angle Sensor Q 26 Check the Exhaust System Q 5 Z 135 70 and ZX135 70 Check Generator Belts Pulleys Bi Energy Models Q 7 Test the Primary Boom Angle Sensor Q 27 Z 135 70 and ZX135 70 Check and Adjust Engine RPM 11 gocan Jas Engine 2 Test the Primary Boom Angle Sensor Q 28 Boom s and Platform Intervals Q A SX 150 and SX 180 Jib Rotate Bearing if equipped A 5 Test the Safety Envelope Limit Switches Q 29 Z 135 70 ZX135 70 SX 150 and SX 180 G the Platfi Overload Mechani A 7 ER E MAS T SIM Test the Primary Boom Angle Sensor Z 80 60 Q 30 Test Platform Overload All Models Except A 8 ALC1000 and S 60HC Models Test the Safety Envelope and Circuits Z 80 60 Q 31 Test Platform Overload ALC1000 models A 9 Check the Safety Envelope Limit Switches and Q 32 Test Platform Overload S 60 HC models A 10 g Angle Sensor DN Vect UR ucc Inspect Boom Cables All S 60 S 80 Models A 11 o eee aCe SEHEN Inspect Boom Cables S 100 to S 125 Models A 12 Test the Aircraft Protection System if equipped Q 34 tB Cables SX 150 and SX 180 A 13 OPES SA Test the Operator Protection Alarm if equipped Q 35 Test the Bypass Recovery Key Switch A 6 Genie S Booms Z Booms Maintenance M
41. S 60X S 60XC S 60 TRAX and S 65 TRAX S 80 S 85 S 80X Install the cover at the pivot end of the boom S 60 HC 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 Note Be sure the cable from the string potentiometer is correctly routed around the small pulley before installing the boom end cover 7 Install the access panels on the sides of the boom 8 Startthe engine from the ground controls and fully retract and lower the boom to the stowed position 9 Turn the key switch to platform controls 10 Extend the boom approximately 2 feet 0 6 m 11 Retract the boom While retracting the boom visually inspect the number 2 and number 3 boom tubes Result The number 2 boom tube should not move more than 1 2 inch 13 mm before the number 3 boom tube begins to retract Note If the number 2 boom tube moves more than 1 2 inch 13 mm before the number 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 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 97 Maintenance Manual September 2015 Annual Maintenance Procedures A 12 I
42. S Booms Z Booms QIQVPRPRIQ _ A AI AISI 39S SIAISIANAISNI AAI QJ QIN SIAISIAISN A I AIA SIAISIAIS Fuel filter replace Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures P0 5 Cummins Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Cummins B3 3T Hour Intervals Procedure Not required Oil fuel and coolant systems check for leaks Daily 250 500 Fuel water separator drain Oil level check Coolant level check Drive belt inspect Cooling fan inspect S amp A A amp A S amp I A QI Engine oil replace Oil filter replace Valve lash clearance adjust initial one time interval with oil change Air intake system inspect Air cleaner restriction check Q amp Q AISI AIAI AIAI A A AJA Fuel filter replace Fuel supply lines vent Injection pump vent Cooling system check Genie ATEREX BRAND Part No 1268489 S Booms Z Booms QVIVIQVPRIRQPRI RIV QIVJVlB 109 Maintenance Manual September 2015 ma
43. X X X X X X X S 60X and S 60XC 207 bar includes TRAX models S 80 S 85 and 3200 psi 2400 psi x x 2400 psi X X X X S 80X 221 bar 165 bar 165 bar S 100 S 100HD 2600 psi X X X X X X X 3000 psi S 105 S 120 179 3 bar 207 bar S 120HD and S 125 SX 150 and SX 180 3200 psi X X X 2500 psi X X X X 221 bar 172 bar Z 30N and Z 30N RJ 3000 psi 1600 psi 1600 psi X 1800 psi X 1100 psi X X 207 bar 110 bar 110 bar 124 bar 76 bar Z 33 X 1885 psi 1885 psi X X X X 50 3000 psi X 130 bar 130 bar 3 4 207 bar Z 34N and Z 34 DC 3200 psi 1600 psi 1600 psi X 1800 psi X 1100 psi X X 221 bar 110 bar 110 bar 124 bar 76 bar Z 34 BE 3200 psi 1400 psi 1600 psi X 1800 psi X 1100 psi X X 221 bar 96 5 bar 110 bar 124 bar 76 bar Z 34 IC 3200 psi 1600 psi 1600 psi X X X X X X 221 bar 110 bar 110 bar Z 40N and Z 40N RJ X 2100 psi X X X x 1800 psi 50 3000 psi 2500 psi 145 bar 124 bar 3 4 207 bar 172 bar Z 45 25 and 3200 psi X 2100 psi X X X X X X Z 45 25J 221 bar 145 bar DC and BE models Z 45 25 IC and 3200 psi X 2100 psi X X X X X 2500 psi Z 45 25J IC 221 bar 145 bar 172 bar Z 51 3200 psi X 2100 psi X X x X X 2500 psi 221 bar 145 bar 172 bar Z 62 3000 psi x x x x X X x 2800 psi includes TRAX 207 bar 193 bar models Z 80 3200 psi 1300 psi 2500 psi 2500 psi 1300 psi 2600 psi X X 3000 psi 221 bar 89 6 bar 172 bar 172 bar 89 6 bar 179 bar 207 bar Z 135 and ZX 135 3100 psi x x x 2600 psi X X X X 213 7 bar 179 bar Genie ATEREX BR
44. base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 At the ground controls lower the boom to the stowed position 2 Activate function enable and adjust the platform to a level position 3 Raise and lower the primary boom through a full cycle Result The platform should remain level at all times to within 5 degrees Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 53 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 20 Confirm the Proper Brake Configuration Genie specifications require that this procedure be performed quarterly Proper brake configuration is essential to safe operation and good machine performance Hydrostatic brakes hydraulically and electrically released spring applied individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Locate the drive hub disconnect cap 1 models with tires 2 models with TRAX 2 Check each drive hub disconnect cap to be sure it is in the engaged position 1 brake disengaged position 2 brake engaged position Q 21 Test the Drive Brakes Genie specifications require that this procedure be performed quarterly Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically and electrically relea
45. engine Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 15 Maintenance Manual September 2015 rac A m EVA 75 19 0 Engine Specifications Cummins Engine Models B3 3T Low idle 1300 rpm 368 Hz High idle 2350 rpm 666 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 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 Genie 16 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual mcrr mc aw M ER M o a l Hydraulic Specifications Hydraulic Relief Valve Pressure Function Manifold Relief Valve Pressure Bar Model System Primary SecondarySecondary Primary SecondaryTurntableProportionalPlatform relief boom boom boom up boom extend rotate relief level down down extend S 40 2600 psi 2200 psi X X 1950 psi X X X X includes TRAX 179 bar 152 bar 134 bar models S 45 2900 psi 2200 psi X X 1950 psi X X X X includes TRAX 200 bar 152 bar 134 bar models S 60 S 65 S 60HC 3000 psi X
46. engine All Models Except ALC1000 and from the ground controls and level the platform Do not turn the engine off S 60HC Models DC Models Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground Genie specifications require that this procedure be end pianorm connais a performed annually OR when the machine fails to 3 Determine the maximum platform capacity lift the maximum rated load Refer to the machine serial plate Testing the platform overload system regularly is 4 Using a suitable lifting device place a test essential to safe machine operation Continued use weight equal to that of the available capacity in of an improperly operating platform overload one of the locations shown Refer to system could result in the system not sensing an Illustration 1 overloaded platform condition Machine stability could be compromised resulting in the machine tipping over Result The platform overload indicator lights should be off at both the ground and platform controls the alarm should not sound and the This maintenance procedure applies to the engine should continue to run following models S 40 S 45 S 60 S 65 S 80 S 85 Z 45 25 J Z 51 30J Z 30 20N RJ Z 34 22 Z 34 22 N Z 34 22 IC Z 40 23N RJ Z 45 25 J DC Z 45 25 J Bi Energy Z 62 40 and models equipped with the 340 kg capacity option Note Perform this procedure with the boom fully
47. exit appears 38 Select YES then press the enter button 39 Restart the engine retract the boom so it is extended less than 75 feet 22 9 m and then lower the boom sufficient to gain access to LSB3EO Note LSB3EO is located on top of boom tube number 2 at the platform end of the machine Genie ATEREX BRAND S Booms Z Booms TT Maintenance Manual September 2015 Quarterly Maintenance Procedures 76 feet 23 2 m Length Safety Switch LSBAES 40 41 Disconnect the 75 feet 22 9 m safety switch LSB3EO Start the engine and activate the function enable high RPM button and extend the boom to 76 feet 23 2 m Result The engine should stop and the boom extend function should be disabled Result If the engine does not stop and the boom continues to extend the LSB4ES switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired AWARNING Bodily injury hazard If the boom 42 43 45 46 47 48 78 extends to more than 76 feet 23 2 m without stopping the engine stop immediately and retract the boom until the boom is extended to less than 75 feet 22 9 m Failure to retract the boom could result in death or serious injury Using emergency power retract the boom until the boom is extended to less than 75 feet 22 9 m Re connect the harness plug to LSB3EO With the key switch off press and hold the enter button and turn the key switch to th
48. grease into the worm gear grease fitting until fresh grease is visible at one sealing lip or bearing cap Illustration 1 1 bearing lubrication fitting 2 worm gear lubrication fitting 3 sealing lip Jib Rotator Bearing Wear 5 Place a 750 Ib 340 kg weight in the platform and raise the jib until it is horizontal and parallel with the boom 6 Place the dial indicator on the side of the rotator bearing housing and measure the bearing as shown in illustration 2 7 Using a forklift raise the platform and jib components so there is no weight on the rotator bearing 8 Adjust the dial indicator needle to the zero position 9 Lower the forklift allowing the platform and jib assembly to settle Genie 88 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 10 Note the reading on the dial indicator Result The measurement is less than 0 063 inch 1 6 mm The bearing is good w 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 saf
49. gt 24 4 m time from 53 envelope limit to the fully raised position 50 55 seconds Primary boom up down extended to gt 100 ft 30 5 m time from 68 envelope limit to the fully raised position 24 28 seconds Primary boom extend fully raised position 0 to 100 ft 0 to 30 5 m 170 190 seconds Primary boom retract fully raised position 100 to 0 ft 30 5 to 0 m Jib boom up down S 125 models Turntable rotate 360 boom horizontal and fully retracted 170 190 seconds 28 32 seconds 170 190 seconds Turntable rotate boom horizontal and extended gt 0 ft gt Om 63 70 seconds drive enable to drive enable Turntable rotate boom fully raised and extended gt 80 ft 24 4 m 109 120 seconds drive enable to drive enable Platform rotate 18 22 seconds Platform level 10 range of motion ANSI CSA 3 5 seconds AS CE 20 22 seconds 120 ft 36 6 m 110 ft 33 5 m 100 ft 30 5 m 90 ft 27 4 m 80 ft 24 4m 70 ft 21 3m 60 ft 18 3 m 50 ft 15 2 m 40 ft 12 2 m 30 ft 9 1 m 20ft 6 1 m 10ft 3m 0ft 0m Genie A TEREX BRAND S Booms Z Booms 65 50 wg 4 0l u0 uo ug uol w p9 u0c u 6 uo uzecL uor uzsL uoc ueer woo ugic uo Part No 1268489 September 2015 Maintenance Manual Dece c r
50. less than 5 16 inches 40 6 cm Press the enter or previous button on the LCD screen until TURNTABLE LEVEL SENSOR Y DIRECTION is displayed Genie ATEREX BRAND Place a digital level that has been calibrated to gravity on the Y axis of the turntable 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 positive degree downhill slope ZX 135 70 shown negative degree uphill slope ZX 135 70 shown A DANGER Tip over hazard If the Y axis is not within 1 failure to calibrate the level sensor 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 Level Sensor S Booms Z Booms 59 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 26 Test the Secondary Boom Angle Sensor Z 135 70 and ZX135 70 Genie specifications require that 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
51. models IC Z 51 2WD models 8 5 10 5 seconds ANSI CSA 8 10 seconds 6 6 8 seconds Stowed position 40 ft 12 2 m 6 1 7 1 seconds 40 ft 12 2 m 40 ft 12 2m 40 ft 12 2 m AS CE 7 3 8 3 seconds 40 ft 12 2 m 4WD models 8 5 10 5 seconds X X 6 6 8 seconds Stowed position 40 ft 12 2m 40 ft 12 2m High flotation tires 8 5 10 5 seconds X X 6 6 8 seconds Stowed position 40 ft 12 2 m 40 ft 12 2 m 2WD or 4WD 40 45 seconds 40 45 seconds 42 48 seconds 42 48 seconds Raised or extended 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m Braking distance 3 A4ft 5 Tft 5 Tft 3 6ft high range on paved surface 0 9 1 2m 1 5 2m 1 5 2m 0 9 1 8m Function Z 62 Z 80 Z 135 ZX 135 includes TRAX models 2WD models 6 1 7 8 seconds X X Stowed position 40 ft 12 2 m 4WD models 8 10 5 seconds 8 7 9 3 seconds 8 9 9 6 seconds Stowed position 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m High flotation tires 8 10 5 seconds 13 6 14 5 seconds X Stowed position 40 ft 12 2 m 40 ft 12 2 m 2WD or 4WD 40 45 seconds RT Tires 40 45 seconds Raised or extended 40 ft 12 2 m 40 45 seconds 40 ft 12 2 m 40 ft 12 2 m High flotation tires 62 70 seconds 40 ft 12 2 m 2WD or 4WD X X 66 70 seconds Raised and extended 40 ft 12 2 m Primary and secondary raised and primary or jib extended TRAX models 10 7 13 6 seconds X X Stowed position 40 ft 12 2 m TRAX models 55 62 seconds X X R
52. procedures to be performed after the first 50 hours of usage After this interval refer to the maintenance inspection report for continued scheduled maintenance 1 Berform the following maintenance procedures All Models Q 6 Inspect the Tires Wheels and Lug Nut Torque A 1 Grease the Turntable Rotation Bearing and Rotate Gear A 2 Check the Turntable Rotation Bearing Bolts A 5 Check the Jib Rotator Fastener Torque SX 150 and SX 180 models 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 e Oil coolant fuel exhaust and vacuum hoses check for leaks damage or deterioration e Electrical wiring check for chafing or damage Kubota Models e Engine oil replace e Oil filter replace Required maintenance procedures and additional engine information are available in the manufactures manuals Refer to Specifications Engine Operator and Maintenance Manuals Genie 30 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Commisioning Procedures C 3 Perform 150 Hour Service The 150 hour maintenance procedure is a one time sequence of procedures to be performed after the first 150
53. pulleys show no signs of damage or unusual wear Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 37 Maintenance Manual September 2015 Quarterly Maintenance Procedures 4 Check to be sure the engine pulley and the generator pulley are aligned within specification using a straightedge 0 Ope a 1 engine pulley 2 straightedge 3 maximum pulley offset 4 generator pulley Note If alignment does not meet specification Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Install the Engine Drive Pulley to adjust the pulley alignment 0 0625 inch 1 58 mm Pulley alignment maximum offset 5 Inspect the generator belts for e Cracking e Glazing e Separation e Breaks 6 Replace both belts if any damage is found 7 Check the generator belts for proper 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 a l O A f 9 f N 1 engine pulley 2 generator belts 3 generator pulley 1 4 inch 6 5 mm Belt deflection maximum allowable 8 Check the torque of the pulley retaining nut on the generator Generator pulley 80 90 ft lbs retaining nut torque 108 122 Nm Engine pulley retaining bolts 108 in Ibs 12 2 Nm 9 Connect the positive lead of a multi meter to the po
54. retracted and in the stowed position and with the machine on a firm level surface illustration 1 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 Lo Qai 1 1 1 92 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 5 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Engine Models Result The platform overload indicator lights should be off at both the ground and platform controls the alarm should not sound and the engine 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 6 Add additional weight to the platform that is equal to but does not exceed 1596 of the maximum rated load Secure the additional weight Refer to the machine serial plate 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 turn off 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 2 second delay before the overload indicator lights flash a
55. specifications require that this procedure be performed quarterly Proper battery condition is essential to good engine and machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine and component damage and hazardous conditions Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A WARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water A WARNING Note Fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Open the side covers 2 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors 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 Besure that the battery separator wire connections are tight if equipped Gon ATEREX BRAND Part No 1268489 batteries 5 Puton protective clothing and eye wear 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 7 Check the ambient air temperature and adjust the specific gravity read
56. that apply to specific models e Test the Engine Idle Select Engine Models e Test the Turntable Level Sensor Z 80 60 e ALC1000 Models include the following models S 100 S 100HD S 105 S 120 S 120HD S 125 SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Examples of procedures that apply to all models e Test the Drive Speed Stowed Position e Inspect the Tires Wheels and Lug Nut Torque SX 150 from SX15015 100 SX 180 from SX18014 100 Z 30 20N RJ from Z30N14 15222 Z 33 18 from Z331815M 101 Z 34 22 DC from Z3414 9686 Z 34 22 N from Z34N14 10984 Z 34 22 IC from Z3406 4800 Z 34 22 BE from Z3414 9686 Z 40 23N RJ from Z40N13 1902 Z 45 25 J DC from Z452513A 48153 from Z452513B 3078 from Z452513D 101 Z 45 25 J IC from Z452513A 47001 from Z452514B 3301 Z 45 25 J BE from Z452513A 48153 Z 51 30J from Z513014B 1201 Z 62 40 from Z6215A 101 Z 80 60 from Z8015 5654 Z 135 70 from Z13505 101 to 13512 2000 ZX 135 70 from ZX13514 2533 includes 2463 2469 2531 Part No 1268489 Genie S Booms Z Booms iii Find additional Manuals for your Model Go to http www genielift com Use the links to locate Operator s Parts Maintenance and Service and Repair manuals Maintenance Manual September 2015 pa a a QUE Introduction Revision History Revision Date Section Procedure Description A 9 2015 Initial Release R
57. the displays reads at least 258 in 656 cm The boom will be extended approximately 120 ft 36 6 m Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications Genie ATEREX BRAND 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 Press down the foot switch and raise the primary boom greater than 10 degrees and the secondary boom greater than 20 degrees Z 80 60 Extend the primary boom 12 inches 0 3 m Z 135 70 and ZX 135 70 Extend the primary boom 12 inches 0 3 m and the jib boom 12 inches 0 3 m Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications S Booms Z Booms 57 Maintenance M
58. the fully raised position 20 ft 6 1m Primary boom extend 120 140 seconds fully raised position 0 to 100 ft 0 to 30 5 m Primary boom retract 120 140 seconds 0ft 0m fully raised position 100 to 0 ft 30 5 to 0 m Jib boom up down 28 32 seconds S 105 models Turntable rotate 360 170 190 seconds boom horizontal and fully retracted 1oit 3m j l W g uot w0 40 Uug uoL uprg uoc w r6 u0E uec Wuor Wucst Wwoc uggr uoo ugic uoZ Turntable rotate 63 70 seconds boom horizontal and extended drive enable to drive enable gt 0 ft gt Om Turntable rotate 109 120 seconds boom fully raised and extended drive enable to drive enable 280 ft 24 4 m Platform rotate 18 22 seconds Platform level ANSI CSA 3 5 seconds 10 range of motion AS CE 20 22 seconds Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 1 Maintenance Manual September 2015 Performance Specifications Function Speeds S 120 S 125 and S 120HD Models Note Function speeds are maximum from platform controls with maximum rated load in platform Primary boom up down retracted 80 88 seconds Primary boom up down extended to gt 4 ft gt 1 2 m time from fully stowed to the fully raised position 100 100 seconds Primary boom up down extended to gt 80 ft
59. will stop and the unrestricted platform capacity light will start flashing 8 Activate primary boom extend and raise the primary boom until the unrestricted platform capacity light stops flashing Result Primary boom extend should return to normal operation 9 Return the machine to the fully stowed position Q 33 Test the Safety Envelope and Circuits S 100 S 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 control button used in this procedure 4 ad Plus Minus Previous Enter 1 Startthe engine from the ground controls 2 Raise the boom to approximately 60 S 100 S 105 and S 100HD Models Proceed to step 28 101 feet 30 8 m Length Safety Switch LSB2RS 3 Extend the boom to more than 80 feet 24 4 m 4 Push in the red Emergency Stop button to the off position 5 Plugin the LSB2RS test jumper between the lower limit switch and the function manifold J2 and J4 connectors on the ground control box 6 Pull out the red Emergency Stop button to the on position and start the engine Genie ATER
60. 0 Hz Low idle with function enable 1500 rpm SX 150 SX 180 Z 135 ZX 135 750 Hz High idle 2500 rpm 1250 Hz Oil capacity including filter 7 7 quarts 7 3 liters Engine coolant Ethylene Glycol Engine coolant capacity 16 5 quarts 15 6 liters Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm 1104D 44T Low idle 1300 rpm 314 2 Hz High idle SX 150 and SX 180 2450 rpm 592 Hz High idle all other models 2350 rpm 568 Hz Oil capacity including filter 10 4 quarts 13 liters Engine coolant capacity 14 quarts 9 8 liters Fan belt deflection 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 Ford Engine Models DSG 423 Low idle 1500 rpm 313 Hz High idle 2500 rpm 521 7 Hz Oil capacity including filter 4 quarts 3 8 liters Engine coolant capacity 10 quarts 9 5 liters 0 049 to 0 053 inches 1 25 to 1 35 mm 3 8 to 1 2 inch Spark plug gap Fan belt deflection 9 to 12 mm MSG 425 Low idle 1500 rpm 50 Hz High idle 2500 rpm 83 3 Hz Oil capacity including filter 6 7 quarts 6 4 liters Engine coolant capacity 10 quarts 9 5 liters 0 049 to 0 053 inches 1 25 to 1 35 mm 3 8 to 1 2 inch 9 to 12 mm Spark plug gap Fan belt deflection Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative en
61. 0 ft 12 2m 40 ft 12 2 m High flotation tires X X 11 13 seconds X Stowed position 40 ft 12 2 m 2WD or 4WD 40 45 seconds 40 45 seconds 40 45 seconds 40 45 seconds Raised or extended 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m 2WD or 4WD X X X 72 4 81 3 seconds Raised and extended 40 ft 12 2 m TRAX models 9 11 seconds 10 7 13 6 seconds X X Stowed position 40 ft 12 2 m 40 ft 12 2m TRAX models 40 45 seconds 55 62 seconds X X Raised or extended 40 ft 12 2 m 40 ft 12 2 m Braking distance 3 4 ft 3 6 ft 3 6 ft 4 6ft high range on paved surface 0 9 1 2m 0 9 1 8m 0 9 1 8m 1 2 1 8m Function SX 150 SX 180 Z 30N Z30N RJ Z 33 Z 34N Z34DC Z 34BE 2WD models x 6 8 seconds 8 5 10 5 seconds 6 8 seconds Stowed position 40 ft 12 2m 40 ft 12 2m 40 ft 12 2 m 4WD models 9 8 11 8 seconds X X X Stowed position 40 ft 12 2 m 2WD or 4WD 68 75 5 seconds 42 48 sec 50 55 seconds 42 48 seconds Raised or extended 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2m 40 ft 12 2 m 2WD or 4WD 275 5 293 3 seconds X 190 195 seconds X Raised and extended 40 ft 12 2 m 40 ft 12 2 m Braking distance 4 6ft 2 4ft 5 7ft 2 4ft high range on paved surface 1 2 1 8 m 0 6 1 2m 1 5 2m 0 6 1 2m Genie Part No 1268489 S Booms Z Booms 7 Maintenance Manual September 2015 Performance Specifications Function Z 43 IC Z 40N Z 40N RJ Z 45 25 Z 45 25J Z 45 25 IC Z 45 25J DC and BE
62. 2 of each other and of 35 The secondary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Secondary Boom Angle Sensor Genie Part No 1268489 S Booms Z Booms 61 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 27 Test the Primary Boom Angle Sensor Z 135 70 and ZX135 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 primary boom angle sensor signal is used to control the ramping of the primary boom limiting the speed of the primary boom to 2 3 feet 0 7 meters per second Note The turntable level sensor and secondary boom angle sensor must be tested before starting this procedure Refer to Maintenance Procedures Test the Turntable Level Sensor and Test the Secondary Boom Angle Sensor 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 proper machine calibration Refer to the manufactures calibration infor
63. 30 Lower the boom to approximately 60 Extend the boom to approximately 95 feet 28 96 m Disconnect the 53 proximity switch L58B13AO and install a wire jumper between pin 3 and pin 4 of the Deutsch connector Activate the function enable high RPM button and lower the boom to 50 Result The engine should stop and the boom down function should be disabled Result If the engine does not stop and the boom continues to lower to less than 50 the LSB8AS switch is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired A WARNING Bodily injury hazard If the boom Part No 1268489 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 Result the angle of the boom should be greater than 50 32 Using emergency power raise the boom until the boom angle is greater than 53 33 Remove the wire jumper installed in step 29 and connect the Deutsch connector to LSB13AO 34 With the key switch off press and hold the enter button and turn the key switch to the on position Release the enter button after five seconds and press the minus minus previous previous buttons 35 Press the previous button until clear all safety switch faults appears 36 Select YES then press the enter button 37 Press the previous button until
64. 5 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 810 Fax 0049 4221 491 820 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 461 7 3375 1660 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Singapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm
65. 5 Models Manufacturer specifications require that this procedure be performed every 50 hours Maintaining proper track tension and properly torqued fasteners is essential to good machine performance and service life The machine will not operate properly with a track that is incorrectly tensioned Continued use of a machine with incorrectly tensioned tracks may cause component damage 1 Thoroughly clean the track assembly of any dirt rocks clay etc 2 Chock the tracks at one end of the machine to prevent the machine from rolling 3 Centera lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks at the other end of the machine 4 Liftthe machine until the tracks are off the ground and then place jack stands under the drive chassis for support Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 105 Maintenance Manual emarmart CECI OM m n antn Programmed Maintenance Procedures 106 Visually inspect the section of track under the 6 bogey wheels Result There should be less than 1 inch 2 5 cm of gap between the bogey wheels and the inside surface of the track Proceed to step f Result There is 1 inch 2 5 cm or more of gap between the bogey wheels and the inside surface of the track Proceed to step 6 7 8 9 10 3 1 half sprocket 2 bogey wheels
66. 62 40 0 063 inch 1 6 mm Z 30 20N Z 34 22 all Z 40 23 Z 45 25 all 0 055 inch Z 51 30 1 4 mm Z 33 18 0 043 inch 1 1 mm S 80 all S 100 S 100HD S 105 S 120 0 118 inch S 120HD S 125 Z 80 Z 135 70 ZX 135 70 3 0 mm 8 Move the boom s to the positions indicated in step 3 Visually inspect the dial indicator to be sure the needle returns to the zero position 9 Remove the dial indicator and rotate the turntable 90 10 Repeat steps 4 through 9 until the rotation 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 safe machine operation Wear pads are placed on axle tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Startthe engine from the platform controls and extend the axles Measure each axle wear pad Replace any wear pad if it is less than specification If a wear pad is not less than specification shim as necessary to obtain minimum clearance and no drag Extend and retra
67. AND Part No 1268489 S Booms Z Booms 17 Maintenance Manual September 2015 DEAE C q mU Qt Hydraulic Specifications Traction and Steer Axle Manifolds and Oscillate Relief Valve Pressure Bar Model Hot oil relief Oscillate relief Axle extend S 40 and S 45 280 psi 950 psi X includes TRAX models 19 3 bar 66 bar S 60 S 65 S 60HC S 60X and S 60XC 280 psi 800 psi X includes TRAX models 19 3 bar 55 bar S 80 S 85 and S 80X 280 psi 950 psi X 19 3 bar 66 bar S 100 S 100HD S 105 S 120 S 120HD 280 psi X 1800 psi and S 125 19 3 bar 124 bar SX 150 and SX 180 250 psi X 2400 psi 17 2 bar 165 bar Z 34 IC 2WD 170 psi X X 11 7 bar AWD 150 psi 10 3 bar Z 45 25 IC Z 45 25J IC and Z 51 250 psi X X 17 2 bar Z 62 280 psi 800 psi X includes TRAX models 19 3 bar 55 bar Z 80 280 psi 800 psi X 19 3 bar 55 bar Z 135 and ZX 135 250 psi X 2400 psi 17 2 bar 165 bar Genie A TEREX BRAND 18 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual mcrr marc Je A P a O l Hydraulic Specifications Hydraulic and Drive Hub Fluid Capacities Model 2WD 4WD Turntable Hydraulic tank Hydraulic system wheel drive wheel drive rotation drive including tank h
68. D 33 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 45 Maintenance Manual September 2015 Quarterly Maintenance Procedures Perkins 1104D 44T Q 12 Test the Ground Control Override Genie specifications require that this procedure be performed quarterly A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls 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 Pushin the platform red Emergency Stop 1 low idle adjustment screw button to the off position ocn 2 Turn the key switch to ground controls 3 high idle adjustment screw 4 high idle solenoid 3 Pull out the red Emergency Stop button to the on position at the ground controls 4 Startthe engine and operate each boom Cummins B3 3T function through a partial cycle Result All boom functions should operate 5 From the platform activate the foot switch 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
69. EX BRAND Part No 1268489 S Booms Z Booms 75 Maintenance Manual September 2015 Quarterly Maintenance Procedures 7 Disconnect the 68 proximity switch LSB14AO 65 Angle Safety Switch LSB9AS and install a wire jumper between pin 3 and pin 4 of the Deutsch connector 14 Raise the boom to the maximum angle Result The display will show gt 68 deg at the 15 Fully extend the boom ground controls 16 Disconnect the 68 proximity switch LSB14AO 8 Activate the function enable high RPM button and install a wire jumper between pin 3 and and extend the boom to 101 feet 30 8 m pin 4 of the Deutsch connector Result The engine should stop and the boom 17 Activate the function enable high RPM button extend function should be disabled and lower the boom to 65 Bi Result If the engine does not stop and the Result The engine should stop and the boom boom continues to extend the LSB2RS switch down function should be disabled is out of adjustment or the wiring circuit is W Result If the engine does not stop and the faulty and will need to be replaced or repaired boom continues to lower to less than 65 the TEE LSB9AS switch is out of adjustment or the Bodil h A WARNING cn wiring is faulty and will need to be replaced or 30 8 m without stopping the repaired engine stop immediately and Bodily injury hazard If the retract the boom until the boom A WARNING Ses und to less than 65 boom could result in death or boom unti
70. Enter Plus Secondary Boom 1 Angle Safety Limit Switch LSS2AS 4 Minus Previous 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 Startthe engine from the ground controls Press the plus minus buttons on the LCD screen to activate status mode 4 Pressthe enter or previous button on the LCD screen until secondary boom length is displayed 5 Fully raise the secondary boom and extend the secondary boom approximately 2 feet 61 cm 6 Remove the fasteners from the turntable riser cover at the platform end of the secondary boom Remove the cover 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 the secondary boom The connection will be marked with red zip ties on the wire assembly Disconnect the connectors 9 Install a wire jumper between pin 1 and pin 2 of the Deutsch connector on the wire harness removed in step 8 10 Install a second wire jumper between pin 3 and pin 4 of the Deutsch connector on the wire harness Result The display should show OFT 11 Press and hold the high speed function enable butto
71. Genie A TEREX BRAND Maintenance Manual Booms This manual includes detailed procedures for each maintenance inspection For Repair procedures Fault Codes Electrical and Hydraulic Schematics Refer to the appropriate Service and Repair Manual for your machine Refer to the inside cover for a list of models Part No 1268489 included in this manual RevA September 2015 Maintenance Manual September 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance be performed at an authorized Genie dealer service center 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 are encouraged to notify Genie of errors and send in suggestions for improvement All communications will
72. Low idle standby 1000 rpm Low idle all other models 1300 rpm SX 150 SX 180 Z 135 ZX 135 1000 Hz 390 H E Low idle with function enable 1500 rpm High idle SX 150 and SX 180 mod SX 150 SX 180 Z 135 ZX 135 1500 Hz Zz Low idle all other models 1000 rpm High idle all other models 2350 rpm 1000 Hz 705 Hz High idle 2500 rpm Oil capacity including filter 12 8 quarts 2500 Hz 12 1 liters Engine coolant Ethylene Glycol Fan belt deflection 3 8 to 1 2 inch m EE 9 to 12 mm Oil capacity including filter 9 4 quarts 9 liters Engine coolant capacity 11 1 quarts 10 5 liters Fan belt deflection 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 Genie 12 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Perkins Engine Models Engine Specifications 404F 22 Low idle Z 45 25 and Z 45 25 J 1500 rpm 403D 11 750 Hz Low idle 1500 rpm Low idle all other models 1300 rpm 265 Hz 650 Hz High idle 2800 rpm High idle 2500 rpm 494 Hz 1250 Hz Oil capacity including filter 4 3 quarts Ojl capacity including filter 9 4 to 11 2 quarts 4 1 liters 8 9 to 10 6 liters Engine coolant capacity rds Engine coolant Ethylene Glycol 1 liters
73. NG _ ip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled or solid rubber and do not need air added to them 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Specifications Tire and Wheel Specifications 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 operate properly with loose or defective belts and continued use may cause component damage A WARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Bodily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns Note Charging the batteries with the engine 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 Besure that the pulley mounting fasteners are tight and that the
74. Part No 1268489 S Booms Z Booms 101 Maintenance Manual September 2015 Annual Maintenance Procedures 6 Attach a lifting strap from an overhead crane 10 2000 Ibs 1000 kg to the center point of the track assembly above the sprocket 11 12 13 7 Remove the remaining sprocket retaining 14 fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside 15 A CAUTION Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 16 9 Locate the hub disconnect pin in the center of the drive hub Manually depress the pin and 17 rotate the drive hub until the plugs are one on top and the other at 90 degrees 18 19 1 drive hub plugs Genie 102 S Booms Z Booms Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole Install the plug s into the drive hub Check the torque of the drive hub mounting bolts Refer to Specifications Machine Torque Specifications Attach a lifting strap from an overhead crane to the center point of the track assembly above the sprocket Install the track assembly onto the drive hub adapter while guiding the hub adapter studs into the sprocket of the track
75. 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 There should be no side to side or up and down movement Skip to step 10 if there is no movement Genie 128 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut 7 Tighten the castle nut to specification to seat the bearings S 40 S 45 Z 45 25 IC Z 30 20N 35 ft lbs Z 34 22N Z 33 18 Z 34 22 IC 47 Nm Z 34 22 BE Z 40 23 Z 45 25 DC Z 45 25 158 ft Ibs BE 214 Nm 8 Loosen the castle nut and re tighten to specification S 40 S 45 Z 45 25 IC Z 30 20N 8 ft lbs Z 34 22N Z 33 18 Z 34 22 IC 11 Nm Z 34 22 BE Z 40 23 Z 45 25 DC Z 45 25 35 ft Ibs BE 47Nm 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result If there is no side to side or up and down movement continue with step 11 and grease the wheel bearings m Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be re
76. Result No boom drive or steer functions operate Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 81 Maintenance Manual September 2015 Quarterly Maintenance Procedures 10 11 12 13 14 15 16 82 Activate and hold the aircraft protection override switch Activate each function control handle or toggle Switch Result All boom drive and steer functions operate Fully retract the primary boom Raise the primary boom to 5 above horizontal Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction Activate each function control handle or toggle Switch Result No boom drive or steer functions operate Activate and hold the aircraft protection override switch Activate each function control handle or toggle switch Result All boom drive and steer functions operate Lower the primary boom to the stowed position Articulated Z Booms 17 18 19 20 21 Genie S Booms Z Booms Raise the secondary boom approximately 3 ft 1m Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction Activate each function control handle or toggle switch Result No boom drive or steer functions operate Activate and hold the aircraft protection override switch Activate each function control handle or toggle switch Result All boom drive and steer functions operate Lower the se
77. achine configured to free wheel without operator knowledge may cause death or serious injury and property damage Models with 2 wheel steer will be referenced with Non steer and steer wheels Models with 4 wheel steer will be referenced with Circle end and Square end wheels Collision hazard Select a work site that is firm and level A WARNING Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h Non steer or Circle end wheels 1 Chock the steer square end wheels to prevent 3 Liftthe 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 fla He 1 brake disengaged position 2 brake engaged position 5 Manually rotate each non steer circle end wheel Result Each non steer circle end wheel 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 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel or track to check for engagement Lift the machine and remove the jack stands the machine from rolling AWARNING Collision hazard Failure to e re engage the drive hubs could 2 Models with 2 wheel steer Center a lifting result in death or serio
78. act Cables SX 150 and SX 180 Models Genie specifications require that this procedure be performed annually Failure to maintain proper adjustment of the cables could result in unsafe operating conditions and may cause component damage The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise Note Properly adjusted extend retract cables will maintain a relationship of the gap between boom tubes 2 and 3 and boom tubes 3 and 4 1 Start the engine from the ground controls 2 Fully raise the boom then extend the boom approximately 15 ft 4 6 m 3 Fully retract the boom and lower to the horizontal position 4 Stopthe engine Measure the distance between boom tubes 1 and 2 measuring from the points identified as 11 and 12 in the illustration This is dimension A Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 99 Maintenance Manual September 2015 Annual Maintenance Procedures 6 Measure the distance between boom tubes 2 and 3 using points 9 and 10 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 cm Result The distance between boom tubes 2 and 3 is 1 in 2 6 cm to 1 5 in 3 9 cm greater than dimension A The
79. aised or extended 40 ft 12 2 m Braking distance 3 6ft 4 6ft 4 6ft high range on paved surface 0 9 1 8 m 1 2 1 8m 1 2 1 8m Genie A TEREX BRAND S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Torque Specifications Tires and Wheels Torque values are listed as lubricated unless otherwise noted Lug nuts must be coated with a mineral based lubricant when removed and replaced on the machine Model Lug nut Tire pressure Tire pressure high Tire pressure torque rough terrain flotation industrial S 40 and S 45 170 ft Ibs 45 psi 3 1 bar 38 psi 2 6 bar X includes TRAX models 230 Nm S 60 S 65 S 60HC S 60X and 180 ft Ibs 70 psi 4 8 bar 60 psi 4 1 bar X S 60XC includes TRAX models 244 Nm S 80 S 85 and S 80X 320 ft lbs X 70 psi 4 8 bar X 434 Nm S 100 S 100HD S 105 S 120 320 ft lbs X X X S 120HD and S 125 434 Nm SX 150 and SX 180 320 ft lbs X X X 434 Nm Z 30N and Z 30N RJ 95 ft lbs X X X 129 Nm Z 33 94 ft lbs X X X 127 Nm Z 34N Z 34DC and 95 ft lbs X X 100 psi 6 9 bar Z 34BE 129 Nm Z 34DC BE Z 34 IC 95 ft Ibs 45 psi 3 1 bar 44 psi 3 0 bar 100 psi 6 9 bar 129 Nm Z 40N and Z 40N RJ 94 ft lbs X X X 127 Nm Z 45 25 and Z 45 25J 94 ft lbs X X X DC and BE models 127 Nm Z 45 25 IC Z 45 25J IC and Z 51 94 ft lbs 60 psi 4 1 bar 38 psi 2 6 bar X 127 Nm Z 62 180 ft lbs 70 psi 4 8 bar 60 psi 4 1 bar X includes TRAX m
80. anual Part No 1268489 G i Programmed September 2015 Q Q A TEREX BRAND Maintenance Inspection Report Booms Model Hour meter Date Serial number Inspector company Machine owner Inspected by print Inspector signature Programmed maintenance will be completed based on machine Legend Make copies of this report to use for each hours This program includes the onetime or commissioning Y yes acceptable inspection procedures for new products N no remove from service Select the appropriate procedures for the type of The onetime procedures will be completed at 50 or 150 hours R repaired inspection s to perform not applicable If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a R in the box Commissioning 50 150 Engines Ford Kubota C 2 Model 50 Hour Service all C4 o SES models 150 Hour Service C 3 Programmed Maintenance Under 1000 HRS Status iid Programmed Maintenance Hours are in thousands ours Check the Track Tension and Fastener Torque PO 1 50 All models Performevery 1 2 3 4 6 12 S 60 S 65 and Z 62 Models poe Engines all models 1000 Hours P1 1 DIDID DI D Check the Track Tension and Fastener Torque PO 2 50 I S E S S 40 and S 45 Models Replace the Drive Hub Oil P1 2 DIDID S Grease the Extendable Axles if equipped
81. anual September 2015 Quarterly Maintenance Procedures Q 25 Test the Turntable Level Sensor Z 135 70 ZX 135 70 SX 150 and SX 180 Genie specifications require that this procedure be performed quarterly A properly functioning level sensor SCON is essential to safe machine operation The ECM at the ground controls TCON monitors the position and angle of the machine using the signal from 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 proper machine calibration Refer to the manufactures calibration information Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 a Plus Minus Previous Enter fF 1 E E BIS E IU X axis ZX 135 70 shown Y axis ZX 135 70 shown Note Perform this procedure with the booms in the fully stowed position and the axles fully extended 1 Place the machine on a firm surface that has a side slope gre
82. ar pad is still within specification shim as necessary to obtain minimum clearance with zero binding 2 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Note Always maintain 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 Wear pad specifications Minimum Top and side wear pads 0 50 inch platform end of boom 12 7 mm Bottom wear pads 0 625 inch platform end of boom 15 9 mm Top and side wear pads 0 50 inch pivot end of boom 12 7 mm Bottom wear pads 0 625 inch pivot end of boom 15 9 mm S 80 S 85 S 80X Boom wear pad specifications Boom number one Minimum Bottom wear pads 0 50 inch extension end of boom 12 7 mm Top and side wear pads 0 625 inch extension end of boom 15 9 mm Boom number two Top bottom and side wear pads 0 50 inch extension end of boom 12 7 mm Bottom wear pads 0 50 inch pivot end of boom 12 7 mm Top and side wear pads 0 625 inch pivot end of boom 15 9 mm Boom number three Top bottom and side wear pads 0 50 inch pivot end of boom 12 7 mm S 100 S 105 S 120 S 125 S 100HD S 120HD Boom wear pad specifications 0 50 inch 12 7 mm LLL Ge 124 S Booms Z Boo
83. assembly Install as many sprocket retaining fasteners as possible to the hub adapter and torque to specification Refer to Specifications TRAX Torque Specifications Raise the machine remove the jack stands lower the machine 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 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to specification Refer to Specification TRAX Torque Specifications Repeat this procedure for each drive hub Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures Turntable rotate drive hub 1 Remove the plug located on the side of the hub and check the oil level and check the oil level Result The oil level should be even with the bottom of the side hole 1 fill plug 2 drain plug 3 mounting fasteners 2 If necessary remove the fill plug and add oil until the oil level is even with the bottom of the drain plug 3 Apply pipe thread sealant to the plug s and install the plug s in the drive hub 4 Check the torque of the turntable drive hub mounting fasteners Torque specifications S 40 all models 170 ft Ibs 230 Nm S 60 all models S 80 all models 80 ft lbs S 100 S 105 S 120 S 125 S 100HD 108 Nm S 120HD Z 45 25 all models and Z 51 SX 150 SX 180 Dry 95 ft lbs 129
84. ater than 2 6 5 inches 16 5 cm but less than 5 16 inches 40 6 cm 2 Place a digital level that has been calibrated to gravity on the X axis of the turntable Note Illustrations are shown from the platform end of the machine negative degree side slope ZX 135 70 shown Genie 58 S Booms Z Booms Part No 1268489 Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 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 Press the enter or previous 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 ADANGER Tip over hazard If the X axis is not within 1 failure to properly calibrate the level sensor 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 Level Sensor Place the machine on a firm surface that has an uphill or downhill slope greater than 2 6 5 inches 16 5 cm but
85. be carefully considered for future printings of this and all other manuals Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Genio ii S Booms Z Booms Contact Us Internet www genielift com E mail awp techpub terex com Copyright 2015 by Terex Corporation 1268489 Rev A September 2015 First Edition First Printing Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries S and Z are trademarks of Terex South Dakota Inc Part No 1268489 September 2015 Maintenance Manual Models included in this manual Use the following chart to identify the specific serial number for models included in this manual Introduction Models Serial number S 40 S 45 from 84015 20505 S 60 S 65 all models from S6013 26296 from S6014D 101 S 80 S 85 from 80 85 80X15 12264 S 100 S 105 from 10015D 1001 from 10515D 1012 120 S 125 from 12015D 1012 from 12515D 984 S 100HD S 120HD from S100HD14D 200 from 120HD14D 201 Identifying the Correct Procedure for your Model Unless otherwise noted each procedure will apply to all models Procedures that only apply to specific models or options will include the information in the procedure title Examples of procedures
86. boom tube is in tolerance Proceed to step 8 W Result The distance between boom tubes 2 and Z3 is less then 1 in 2 6 cm or more than 1 5 in 3 8 cm greater than dimension A 7 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 8 Measure the distance between boom tubes 3 and 4 using points 7 and 8 as shown in the illustration Result The distance between boom tubes 3 and 4 is 1 in 2 6 cm to 1 5 in 3 9 cm 1 Boom tube 1 greater than dimension A The boom tube is in 2 Boom tube 2 tolerance Return the boom to service 3 Boom tube 3 amp Result The distance between boom tubes 4 Boom tube 4 3 and 4 is less then 1 in 2 6 cm or more 5 Boom 4 retract bolt than 1 5 in 3 8 cm greater than dimension 6 Boom 3 retract bolt A Boom 4 measuring edge 9 The boom tubes need to be adjusted Refer to 8 Boom 3 measuring surface Repair Procedure in the appropriate Service 9 Boom 3 measuring edge and Repair Manual for your machine How to 10 Boom 2 measuring surface Adjust the Boom Extend Retract Cables 11 Boom 1 measuring edge 12 Boom 2 measuring edge Lo Gaii 1 1 1 1 1 100 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures A 14 Check the Drive Hub Oil Level and Fastener Torque Genie specifications require that t
87. chine fully stowed and the counterweight at the square end of the machine Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Rotate the turntable until the boom is centered between the circle end wheels 2 Apply approximately 20 Ibs 89 N of side force to the platform moving the platform to one side as far as it will go 3 Using a feeler gauge measure the gap between the swing hub pinion gear and the turntable rotation bearing at the center tooth on one of the drive hubs The gap should be measured on one side of the pinion gear on the center tooth Note The pinion gear can be accessed on the outside of the chassis under the pinion gear guard Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 127 Maintenance Manual September 2015 Programmed Maintenance Procedures S 100 S 100HD S 105 S 120 S 120HD and 125 Result The gap is between 0 010 inch 0 254 mm and 0 022 inch 0 559 mm The backlash is within tolerance Result The gap is less than 0 010 inch 0 254 mm or more than 0 022 inch 0 559 mm The 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 SX 150 and SX 180 Result The gap is between 0 016 inch 0 406 mm and 0 024 inch 0 62 mm The backlash is within tolerance R Result The gap is less t
88. ck the Turntable Rotation Gear Backlash sss 127 P2 8 Grease the Steer Axle Wheel Bearings All 2WD Models except Z 62 40 and S 60 8 65 128 P2 9 Grease the Steer Axle Wheel Bearings 2WD Models Z 62 40 and S 60 S 65 sss 130 P3 1 Perform Engine Maintenance 3000 Hours sse 131 P4 1 Perform Engine Maintenance 4000 Hours 132 P6 1 Perform Engine Maintenance 6000 Hours see 133 P12 1 Perform Engine Maintenance 12000 Hours sese 133 P12 2 Replace the Boom Extend Retract Cables S 100HD and S 120HD ie artes eco hi eit d eee 134 P12 3 Replace the Boom Extend Retract Cables S 60 Models S 80 Models S 100 S 105 S 120 S 125 E OUO 134 Lo Gaii S 1 xii S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Performance Specifications 110 ft 33 5 m Function Speeds S 100 S 105 and S 100HD Models 100 305 m 90 ft 27 4m Note Function speeds are maximum from platform Ec controls with maximum rated load in platform 80 ft 24 4 m 53 50 Primary boom up down 80 88 seconds retracted A Primary boom up down 100 100 seconds 601 183 m extended to gt 4 ft 1 2 m time from fully stowed to the 50ft 15 2m fully raised position Primary boom up down 50 55 seconds 40ft 122m extended to gt 80 ft 224 4 m time from 53 envelope limit to 30ft 9 1m
89. condary boom to the stowed position Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 35 Test the Operator Protection Alarm if equipped Genie specifications require that this procedure be performed quarterly Testing the operator protection alarm OPA is important for proper operation 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 Startthe engine 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 the beacon will flash Boom functions are disabled and the engine will shut down engine models After 10 seconds a continuous audible alarm will sound 5 Press the reset button Result The audible alarm and flashing beacon turn off Engine can be started engine models Boom functions operate Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 83 Maintenance Manual September 2015 Annual Maintenance Procedures A 1 Grease the Turntable Rotation Bearing and Rotate
90. ct the axles through the 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 Minimum 0 4375 inch 11 11 mm Wear pad specifications Extendable axle wear pad Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 87 Maintenance Manual September 2015 Annual Maintenance Procedures A 5 Perform Maintenance Jib Rotate Bearing SX 150 and SX 180 Jib rotate bearing specifications require that these procedures be performed annually Periodic inspection of jib bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn jib bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm level surface Check the Jib Rotator Fastener torque 1 Using a star pattern confirm that each jib rotator outer mounting bolt is torqued in sequence to specification 2 Repeatthe procedure for the inner mounting bolts 200 ft lbs 271 Nm Jib boom rotate bearing bolts 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
91. d control box Inside of the ground control box e Turntable area Genie ATEREX BRAND Part No 1268489 Cable tracks Cables on the primary secondary and jib booms Jib boom platform rotate manifold Inside of the platform control box All wire harness connectors to platform control box Battery compartment Battery separator Battery charger Contactor Motor controller Electric motor Pump motor Limit switches Rotary sensors Inspect for a liberal coating of dielectric grease on all harness connections S Booms Z Booms 35 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 4 Inspect the Electrical Contactor DC and Bi Energy Models Genie specifications require that this procedure be performed quarterly Maintaining the electrical contactor in good condition is essential to safe machine performance Failure to locate a worn or damaged contactor could result in unsafe operating conditions and may cause component damage 1 Remove the drive 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 e Excessive burns e Excessive arcs e Excessive pitting AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rin
92. d and retract cables are responsible for the extension and retraction of the boom tube s 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 Replace the boom extend and retract cables Refer to the appropriate Service and Repair Manual for repair procedure How to Replace the Boom Extend Retract Cables P12 3 Replace the Boom Extend Retract Cables S 60 Models S 80 Models S 100 S 105 S 120 S 125 SX 150 and SX 180 Genie specifications require that this procedure be performed every 10 years The boom extend and retract cables are responsible for the extension and retraction of the boom tube s 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 Replace the boom extend and retract cables Refer to the appropriate Service and Repair Manual for repair procedure How to Replace the Boom Extend Retract Cables Genie 134 S Booms Z Booms Part No 1268489 Genie Sweden Phone 0046 3157 5101 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 900 808 110 Fax 0034 93
93. d coolant systems check for leaks Alternator belt inspect adjust replace Coolant level check add Oil level check Fuel system filter water separator drain SIAI 9S AIAI IASA Engine air precleaner check drain Fuel tank water sediment drain S amp I 9 SA 98 3 9 998 Hoses and clamps inspect replace Battery electrolyte level check Cooling system supplement additive test add Engine oil and filter replace Fuel system filter s replace Radiator clean Air cleaner element clean replace QIVPRIVIQIQVIJQl AJA SINAIS SISIA Fan clearance check Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 113 Maintenance Manual September 2015 Programmed Maintenance Procedures P1 1 Perform Engine Maintenance 1000 Hours Engine specifications require that this procedure be performed every 1000 hours Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Continental TME27 e Spark plugs replace e O2 sensors replace Cummins Models e Drive belt tension measure e Drive belt check Deutz Models All Models e Fuel system primary filter water separator element replace e Fuel system secondary filter replace e Hoses and clamps inspect replace e By pass oil filter replace
94. dditional 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 A WARNING Collision hazard Failure to re engage the drive hubs could result in death or serious injury and property damage Models with Hydraulic Pump free wheel valve 13 Be sure the free wheel valve on the drive pump is closed clockwise Note The free wheel valve should always remain closed 1 drive pump 2 screwdriver 3 lift pump 4 free wheel valve Note The location of the free wheel valve may vary by model Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 123 Maintenance Manual September 2015 Programmed Maintenance Procedures P2 5 Check the Boom Wear Pads Genie requires that this procedure be performed every 2000 hours Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions 1 Measure each wear pad Replace the wear pad once it reaches the minimum allowable thickness If the we
95. de turntable side cover 2 Pulloutthe red Emergency Stop button to the on position at both the ground and platform controls 3 Atthe ground controls turn the bypass recovery key switch to the run position 4 Turnthe 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 Turnthe main key switch to ground control 7 Check any machine function from the platform controls Result The machine functions should not operate 8 Turnthe main key switch to the off position Result The engine should stop and no functions should operate 9 Turnthe 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 Genie 90 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual 11 12 13 14 15 16 17 Part No 1268489 Annual Maintenance Procedures Raise the primary boom 3 ft 1 m Result The primary boom should raise Remove the key from the bypass recovery key Switch and insert the key into the main key Switch Turn the main key switch to the off position Remove the key from the main key switch and insert t
96. de wear pads 0 625 inch pivot end of boom platform end of boom 15 9 mm Models with rotating jib boom Bottom wear pad 0 375 inch All wear pads 0 375 inch platform end of boom 9 5 mm 9 5 mm Top bottom and side wear pads 0 375 inch pivot end of boom 9 5 mm Ganie Part No 1268489 S Booms Z Booms 125 Maintenance Manual September 2015 Programmed Maintenance Procedures Z 45 25 J IC DC BE Z 51 30J Primary boom wear pad specifications Top bottom and side wear pads platform end of boom Side and bottom wear pads pivot end of boom Top wear pads pivot end of boom Z 80 60 Boom wear pad specifications Primary boom Top bottom and side wear pads Primary and secondary extension boom Top wear pads Side wear pads Secondary boom Top wear pads Side and bottom wear pads 126 Z 135 70 ZX 135 70 Note The minimum shim clearance for the secondary Minimum i boom wear pads is 0 070 inch 1 8 mm and the 0 625 inch maximum allowable shim clearance is 0 25 inch 15 9 mm 6 4 mm 0 50 inch Note The minimum shim clearance for the jib boom and 12 7 mm primary boom wear pads is 0 070 inch 1 8 mm and the 0 625 inch maximum allowable shim clearance is 0 188 inch 159mm mm Primary boom wear pad Minimum specifications Minimum Top bottom and side wear pads 0 625 inch platform end of boom 15 9 mm z Top and bottom
97. e Dirty oil and a clogged suction strainer or hydraulic filters may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the 2000 hour inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Testing the oil 1 Complete the hydraulic oil testing with an oil distributor Ifthe 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 R 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 quarterly maintenance inspection Replacing the hydraulic oil 1 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Specifications Hydraulic Fluid Capaciti
98. e remove all test weights from the platform Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 93 Maintenance Manual September 2015 Annual Maintenance Procedures A 9 Test the Platform Overload System ALC1000 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 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 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 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 Turnthe key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform 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 mach
99. e 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 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 Genie ATEREX BRAND S Booms Z Booms 89 Part No 1268489 Maintenance Manual September 2015 Annual Maintenance Procedures When the Bypass Recovery key switch is turned and held to the recovery position the emergency power unit turns on and starts a sequence to lower the platform This feature of the machine is especially helpful if the operator in the platform cannot lower the boom if the platform controls become inoperative or for returning the machine to a safe position when the safety switches have been tripped 1 Run 2 Bypass 3 Recovery Note Perform this procedure on a firm level surface with the machine in the stowed position 1 Open the ground controls si
100. e on position Release the enter button after five seconds and press the minus minus previous previous buttons Press the previous button until clear all safety Switch faults appears Select YES then press the enter button Press the previous button until exit appears 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 of the boom 51 Remove the arm from the cable break limit switch LSB6S Note LSB6S is located at the end of the boom tubes at the pivot end of the boom 52 Place the arm removed in step 51 back on the LSB6S switch 180 opposite its original position Rotate the head of the switch 45 clockwise and activate the function enable high RPM button and attempt to extend the boom Result The boom extend function should be disabled W Result If the boom extends the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired A WARNING Bodily injury hazard If the boom extends at all stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury 53 Activate the function enable high RPM button and attempt to retract the boom Result The boom retract
101. e 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 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 107 Maintenance Manual September 2015 Programmed Maintenance Procedures P0 4 Continental Engine Maintenance Under 1000 Hours Additional engine maintenance is required Refer to the Programmed Maintenance Inspection Report for the specific intervals that apply Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Continental TME27 Hour Intervals Procedure Not required Daily 100 250 a e e 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 QQ SS 9 S9 Fan belt tension check Battery check SI AISI ANIANI AIA AJA Engine oil replace Oil filter replace SI AISI AIAI SIAI A A AJA Harness connections check Cooling system check Air filter replace SS 89 359 QJ QI S9 QQ QJ AAJA PCV valve check Valve tappet clearance adjust Fuel system check Fuel pump check 108 Genie
102. ed in step 7 Secondary Boom 1 Retracted Safety Limit Switch LSS1RS 17 18 19 20 72 Press the plus minus buttons on the LCD screen to activate status mode Press the enter or previous button on the LCD screen until secondary boom length is displayed Raise the secondary boom until the display shows gt 35 DEGREES Locate the Deutsch connectors from the secondary boom 2 angle safety limit switch LSS2AS on the inside of the turntable riser The connection will be marked with purple zip ties on the wire assembly Disconnect the connectors 21 22 23 24 25 Genie S Booms Z Booms 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 Install a wire jumper between pins 1 and 2 of the Deutsch connector on the wire harness removed in step 21 Result The display should show at 65 DEGREES Press and hold the low speed function enable button and extend the secondary boom Result The secondary boom should extend no more than 12 inches 30 5 cm and stop The engine should stop and the display will show P9B SAFETY FAULT and P11 SAFETY FAULT Result If the engine does not stop and the secondary boom continues to extend the secondary boom 1 retracted safety limit switch LSS1RS is out of adjustment or the
103. eemennne 36 Q 5 Check the Exhaust System sssssssssssssseeee eee 36 Q 6 Inspect the Tires Wheels and Lug Nut Torque ssssseseee 37 Q 7 Check the Generator Belts and Pulleys Bi Energy Models 37 Q 8 Check the Oscillate Directional Valve Linkage if equipped 39 Q 9 Visual Inspection of the Hydraulic Oil eee 39 Q 10 Inspect the Hydraulic Filters 40 Q 11 Check and Adjust the Engine RPM sess 41 Q 12 Test the Ground Control Override see 46 Q 13 Test the Alarm Package if equipped 47 Q 14 Test the Emergency Power System sssssssee eee 48 Q 15 Test the Engine Idle Select Engine Models sseeeeesess 48 Q 16 Test the Fuel Select Operation Gasoline LPG Models 50 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms ix September 2015 namK EEE gt A Table of Contents Q 17 Inspect the Calibration Decal ALC1000 Models sess 51 Q 18 Test the Recovery Mode System ALC 1000 Models 52 Q 19 Test the Platform Self leveling e 53 Q 20 Confirm the Proper Brake Configuration ssessseeeee 54 Q 21 Test the Drive Brakes centenis itte 54 Q 22 Test the Drive Speed Stowed Position ssssss
104. een out of service for a period longer than 3 months must complete th quarterly inspection Maintenance Procedures Machine Configuration Vl Unless otherwise specified perform each procedure with the machine in the following configuration e Genie ATEREX BRAND S Booms Z Booms Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Machine in the stowed position Turntable secured with the turntable rotation lock 25 Maintenance Manual September 2015 Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury
105. eference Examples Section Specifications Electronic Version Section Maintenance procedure Click on any content or R in the Table of Contents to view e update Genie gt gt h S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual nere P BR A Qa i 2 qe Introduction Revision History continued Revision Date Section Procedure Description Reference Examples Section Specifications Electronic Version Section Maintenance procedure Click on any content or iir onis Table of Contents to view Genie ATEREX BRAND Part No 1268489 S Booms Z Booms V Maintenance Manual September 2015 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury 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 MI You are trained and qualified to perform maintenance on this machine M You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations e applicable governmental regulations Vl You have the appropriate tools lifting equipment and a suitable workshop Genie
106. ely and lower the boom until the boom is less than 11 See Repair Section Failure to retract the boom could result in death or serious injury Remove the wire jumper installed in step 59 and connect the Deutsch connector to LSAX1ES Disconnect the circle end axle extend safety switch LSAX2ES and install a wire jumper between pin 3 and pin 4 of the Deutsch connector Activate the function enable high RPM 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 extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury 66 A WARNING 67 Genie S Booms Z Booms Activate the function enable high RPM button and attempt to raise the boom Result The boom should not raise to more than 11 Result If the boom continues to raise 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 raises to more than 11 stop immediately and lower the boom until the boom is less than 11 Failure to lower the boom c
107. enance Manual September 2015 Quarterly Maintenance Procedures 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 FAULT Result The alarm doesn t sound and the LCD screen doesn t display a Fault message The limit switch is faulty and needs to be replaced Note A P30 Power Fault and a P11 Power Fault will also display as a result of this test 14 Re connect the Deutsch connector to LSS1RS Result The LCD screen displays SEC LSS1RS FAULT Result The LCD screen doesn t display the Fault message The limit switch is faulty and needs to be replaced 15 Turn the engine off 16 With the key switch off press and hold the enter button and turn the key switch to the on position Release the enter button after five seconds and press the minus minus previous previous buttons in that order 17 Press the previous button until clear all safety Switch faults appears 18 Select YES then press the enter button 19 Press the previous button until EXIT appears 20 Select YES then press the enter button 21 Install the secondary boom end covers Z 135 70 ZX 135 70 SX 150 and SX 180 Models Turntable Rotate Safety Limit Switch LST1S 1 Locate the turntable rotate safety limit switch LST1S at the center of the turntable Note The turntable rotate safety limit sw
108. er retaining fasteners and remove the cover S 60 HC Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kinked or pinched Genie 96 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 4 Remove the retaining fasteners from the access covers 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 both inspection holes for the following e Frayed or broken wire strands e Kinks in the cables e Corrosion e Paint or foreign materials on the cable e Split or cracked cable ends e Cables are on all pulleys e Extend cable break limit switch arm is centered in the pivot plate e Cables have equal tension e Cables at end of adjustment range e No broken or damaged pulleys e No unusual or excessive pulley wear e All fasteners in place and secure e S 60 HC String potentiometer cable break limit switch arm is securely attached to end of cable Note A flashlight and inspection mirror may be necessary to thoroughly inspect the above items Note A pulley groove gauge should be used to check the condition of the pulleys S 60 S 65
109. es Specifications 2 Fil the tank with the proper hydraulic oil for your machine Refer to Specifications Hydraulic Specifications 3 Engine Models Prime the pump Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Prime the Pump 4 Clean up any oil that may have spilled Note When replacing the hydraulic oil it is recommended that the hydraulic tank be cleaned using a mild solvent and all hydraulic filters and strainers be replaced Note Always use pipe thread sealant when installing the suction hose fittings and the drain plug Note After the oil has been replaced continue the scheduled quarterly maintenance inspection Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 119 Maintenance Manual September 2015 Programmed Maintenance Procedures 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 qua
110. esses isssseeeieeee ennt tn neni nn nnne nnns 17 Hydraulic and Drive Hub Fluid Capacities sssseee 19 Hydraulic Specification sssssssssseeseeene eene 20 Hydraulic Hose and Fitting Torque Specifications ssseeeesess 22 Torque ProcedUre io eter te eoa b anc ECHO SERE nas Lee pe IR ee E I A TER 23 Genie viii S Booms Z Booms Part No 1268489 September 2015 A c NA SSeS Table of Contents Inirentie e m 25 Maintenance Schedule teens enint reda eR R ARE nea SA EE 27 Scheduled Maintenance Inspection Report BOOMS sssssssssssss 28 Programmed Maintenance Inspection Report BOOMS ssssssssss 29 Commisioning Procedures eeeeeeeeeeeeneeeeeenen nennen nnne nennen nnns 30 C 1 Perform 50 Hour Service ssssssssssee eene nennen menn 30 C 2 Perform Engine Maintenance 50 Hours sesseeee 30 C 3 Perform 150 Hour Service eeesseeessseeeeese eene nnne nnn tnnt 31 Quarterly Maintenance Procedures seen 32 Q 1 Check for Open Bulletins sess 32 Q2 Battery InSpectlor eoi eoe Eee dte d Ee Ran iecit t oer eue 33 Q 3 Inspect the Electrical Wiring eese 35 Q 4 Inspect the Electrical Contactor sssssssseeee
111. f 65 The secondary boom angle sensor must 20 The secondary boom angle sensor must be calibrated Refer to Repair Procedure in the be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for appropriate Service and Repair Manual for your machine How to Calibrate the your machine How to Calibrate the Secondary Boom Angle Sensor Secondary Boom Angle Sensor Lower the secondary boom to 50 11 Fully lower the secondary boom until it stops Result The reading at the display and digital SE approximation level is within 2 of each other and of 50 Result The reading at the display and digital Result The reading at the display and digital level is within 2 of each other and of 3 5 level is greater than 2 of each other and of R Result The reading at the display and digital 50 The secondary boom angle sensor must level is greater than 2 of each other and of be calibrated Refer to Repair Procedure in the 3 5 The secondary boom angle sensor must appropriate Service and Repair Manual for be calibrated Refer to Repair Procedure in the your machine How to Calibrate the appropriate Service and Repair Manual for Secondary Boom Angle Sensor your machine How to Calibrate the Lower the secondary boom to 35 SPEODRSIg POIMANJE HENSON Result The reading at the display and digital level is within 2 of each other and of 35 Result The reading at the display and digital level is greater than
112. f the machine death or serious injury calibration Open the ground control box ANSI and CSA 4 Verify the ground control panel is equipped with the required calibration decal Result The control box is equipped with the required decal and is legible and in good condition w Result The control box is not equipped with the required decal or is illegible or in poor condition Remove the machine from service until the decal is replaced Note Contact your authorized Genie distributor or Genie if a replacement is required CE and AUS Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 51 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 18 Test the Recovery System ALC 1000 Models Genie specifications require that this procedure be performed quarterly A properly functioning recovery system is essential to safe machine operation The Recovery mode allows the platform to be lowered in the event the operator in the platform is unable to lower the platform using the platform controls system failure or emergency situations This maintenance procedure applies to the following models S 100 S 105 S 120 S 125 S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Note Perform this 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
113. function should be enabled Result If the boom does not retract the LSB6S switch or wiring circuit is faulty and will need to replaced or repaired Genie hJM 1 L 1 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 54 Allow the switch to return to its neutral position then rotate the head of the switch 45 counter clockwise and activate the function enable high RPM button and attempt to extend the boom Result The boom extend function should be disabled mi Result If the boom extends the LSB6S switch or wiring circuit is faulty and will need to be replaced or repaired A WARNING Bodily injury hazard If the boom extends at all stop immediately and retract the boom until the boom is extended to less than 2 feet 0 6 m Failure to retract the boom could result in death or serious injury 55 Reinstall the arm onto LSB6S in its original position Axle Extend Safety Switch LSAX1ES and LSAX2ES and 3 feet 0 9 m Safety Switch LSB3RS and 11 Angle Safety Switch LSB7DS 56 Fully retract and lower the boom to the stowed position 57 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 Gon ATEREX BRAND 60 61 Place a meta
114. g 1 jam nut Non adjustable fitting SAE O ring Boss Port tube fitting installed into Steel Torque 15 ft lbs 20 3 Nm 26 ft lbs 35 3 Nm 22 ft lbs 30 Nm 35 ft lbs 47 5 Nm 29 ft lbs 39 3 Nm 60 ft lbs 81 3 Nm 52 ft lbs 70 5 Nm 100 ft lbs 135 6 Nm 85 ft lbs 115 3 Nm 135 ft lbs 183 Nm 200 ft lbs 271 2 Nm 250 ft lbs 339 Nm 305 ft lbs 413 5 Nm SAE Dash Size Thread Size Flats 4 7116 20 2 lt SAE Dash Size 6 9 16 18 14 4 ORFS 37 Adj 8 3 4 16 1 ORFS Non adj 10 7 8 14 1 37 Non adj 12 1 1 16 12 1 6 ORFS Adj Non adj 16 1 5 16 12 1 RIA Noni 8 ORFS Adj Non adj 19612 i 37 Adj Non adj T812 1 40 ORFS Adj Non adj 37 Adj Non adj 12 All types 16 All types 20 All types 24 All types Genie 22 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual aware BR a r P i i 0007 Hydraulic Specifications Torque Procedure JIC37 fittings 1 Align the tube flare hex nut against the nose Seal Lok fittings of the fitting body body hex fitting and tighten 1 Note The O ring in Parker Seal Lok fittings and hose end are custom size O rings They are not standard size O ri
115. gallons 28 gallons 17 fl oz 148 cc 83 liters 106 liters 503 cc non steer end 42 fl oz 1242 cc Z 62 20 fl oz 20 fl oz 43 fl oz 35 gallons 45 gallons includes TRAX models 591 cc 591 cc 1262 cc 132 liters 170 liters Z 80 X 30 5 fl oz 40 fl oz 45 gallons 80 gallons 902 cc 1183 cc 170 liters 208 liters Z 135 and ZX 135 x 47 fl oz 40 fl oz 65 gallons 123 gallons 1390 cc 1183 cc 246 liters 465 liters Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 19 Maintenance Manual September 2015 Hydraulic Specifications Hydraulic Oil Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Shell Donax TG Dexron III Chevron 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instruction
116. gency Stop button othe on 5 Eee hare o eeri ora ome iti t both latf i pos Henan i i a and then release it Move the drive control Z 80 60 S 100 S 105 S 120 S 125 handle off center in the opposite direction S 100HD S 120HD SX 150 SX 180 hold for a moment and then release it Ae aS ana AAt 0 Models Result The travel alarm should sound when Result The alarm should sound twice The the drive control handle is moved off center in flashing beacon should be on and flashing either direction All remaining models Result The flashing beacon should be on and flashing Genie Part No 1268489 S Booms Z Booms 47 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 14 Test the Emergency Power System excludes 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 ground and platform controls 2 Atthe ground controls break the security tie and lift the emergency power switch cover if equipped 3 Simultaneously hold the emergency power switch on and operate each boom function through a partial cycle Result All boom functions operate 4 Close the emergency power switch cover and secure the cover with a securit
117. gine from the ground controls restricted maximum platform capacity and raise the primary boom until it is fully elevated 1000 Ibs 500 Ibs 454 kg 221 kg ox MERE 1 restricted maximum platform capacity 2 unrestricted maximum platform capacity 4 Extend the primary boom until it is fully extended 5 Lower the primary boom until it stops Result The boom will automatically stop after 10 degrees g Result The primary boom does not stop after 10 degrees Check limit switches LST3O and LST3S 6 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls Note The following step can be done using a measuring tape or a digital protractor Genie part number 58377 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 73 Maintenance Manual September 2015 Quarterly Maintenance Procedures 7 Measuring Tape Platform controls S 60X and S 60XC Models Note Start this procedure with the boom fully Measure the distance between the center of retracted and in the stowed position the pivot pins as shown The distance should 1 Pull out the red Emergency Stop button to the be 171 inches 434 cm x 2 0 inch 5 cm on position and start the engine S 80X Models 2 Select the restricted maximum platform Measure the distance between the center of capacity with the toggle switch the pivot pins as shown The distance should
118. gine oils For oil requirements refer to the Engine Operator Manual for your engine Genie 14 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Kubota Engine Models Engine Specifications Continental Engine Models D1105 E3B TME27 Low idle 1250 rpm Low idle 1600 rpm High idle 3000 rpm 53 3 Hz Oil capacity including filter 5 4 quarts High idle pecu 5 1 liters aiias Engine coolant capacity 3 3 quarts Oil capacity including filter ig 3 1 liters wee Fan belt deflection 5 16 inch Engine coolant capacity 10 7 quarts 8 10 1 liters mm WG 972 Spark plug gap Mir e Low idle 1600rPM Fan belt deflection 1 2 inch High idle 3000 rpm 12 mm Oil capacity including filter 3 quarts Unit ships with 15W 40 Extreme operating 2 8 liters temperatures may require the use of alternative Engine coolant capacity 0 61 quarts engine oils For oil requirements refer to the 2 36 liters Engine Operator Manual for your engine Spark plug gap 0 024 to 0 028 inches 0 6 to 0 7 mm Fan belt deflection 5 16 inch 8 mm 2482 E Low idle 2000 rpm High idle 3000 rpm Oil capacity including filter 2 64 quarts 2 5 liters Engine coolant capacity 3 quarts 2 8 liters Fan belt deflection 5 16 inch 8mm 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
119. gs watches and other jewelry Note Replace the contactor if any damage is found Q 5 Check the Exhaust 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 A WARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation A CAUTION Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 1 Besure that all nuts and bolts are tight Inspect all welds for cracks Inspect for exhaust leaks i e carbon buildup around seams and joints Genie 36 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 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 repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNI
120. han 0 016 inch 0 406 mm or more than 0 024 inch 0 62 mm The 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 Z 135 70 and ZX 135 70 Result The gap is between 0 013 inch 0 33 mm and 0 023 inch 0 58 mm The backlash is within tolerance Result The gap is less than 0 013 inch 0 33 mm or more than 0 023 inch 0 58 mm The 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 Z 62 40 S 60 S 65 Genie requires that this procedure be performed every 2000 hours Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be 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
121. he key into the bypass recovery key Switch Turn and hold the bypass recovery key switch to the recovery position The switch must be held in the recovery position Result The primary boom lowers to the stowed position Turn the bypass recovery key switch to the run position Remove the key from the bypass recovery key switch 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 greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Locate the grease fittings on each pivot pin of the platform overload assembly 2 Thoroughly pump grease into each grease fitting Grease Specification Chevron Ultra duty grease EP NLGI 1 lithium based or equivalent Genie ATEREX BRAND S Booms Z Booms 91 Maintenance Manual September 2015 Annual Maintenance Procedures A 8 2 Engine Models Turn the key switch to Test the Platform Overload ground control and pull out the red Emergency Stop button to the on position at both the System ground and platform controls Start the
122. he upper cover retaining fasteners and remove the upper cover from turntable 12 Extend the secondary boom while visually inspecting the roller arm of the limit switch AWARNING Crushing hazard The turntable Continue to extend the boom until the limit riser upper cover could become switch arm is released by the limit switch ramp unbalanced and fall when bracket removed from the turntable if s not properly supported and Result The roller arm of the limit switch secured to the lifting device remains centered with the limit switch ramp bracket through the entire length of travel 9 Locate the secondary boom 1 retracted W Result The roller arm of the limit switch does safety limit switch LSS1RS inside the not remain centered with the limit switch ramp secondary boom tube bracket through the entire length of travel Note The secondary boom 1 retracted safety limit Adjust or replace the limit switch ramp bracket switch LSS1RS is attached to the number 1 boom to ensure the limit switch roller arm remains tube and can easily be identified by the blue and centered with the limit switch ramp bracket red tie wraps attached to the limit switch cable 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 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 67 Maint
123. his procedure be performed quarterly Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Models with tires 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 1 drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole 3 If necessary remove the top plug and 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 Check the torque of the drive hub mounting bolts Refer to Specifications Machine Torque Specifications 6 Repeatthis 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 adapter 1 sprocket retaining fasteners 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 Centera lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks 5 Liftthe machine until the tracks are off the ground and place jack stands under the drive chassis for support Genie ATEREX BRAND
124. hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Berform the following maintenance procedures Q 9 Visual Inspection of the Hydraulic Oil Q 10 Inspect the Hydraulic Filters Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 31 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 1 Check for Open Bulletins and Owner Registration Genie specifications require that this procedure be performed quarterly Completing required bulletins is essential to safe machine operation An important way to ensure your machine has no open bulletins is to frequently check the serial number of your Genie machine against our bulletin database Using the links below you can view any open bulletins for your machine s that require mandatory and immediate work to be completed Note If you are unable to access this information on our websites please contact your local Genie representative using the contact information provided on the back cover of this manual 1 Locate the serial number plate or label on your machine and document your Genie machine serial number exactly as its displayed on the serial plate or label 2 Confirm that Genie has the current machine owner information on file by contacting our warranty 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
125. illed 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 Inspectthe filter housings and related components to be sure that there are no leaks Genie 120 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual wer P n 5T m a EU i Programmed Maintenance Procedures Medium and high pressure filters Note The medium pressure filter is for the charge pump and the high pressure filter is for all machine functions except the drive circuit and oscillating axle circuit 1 Locate the medium and high pressure filters 2 Place a suitable container under each filter 3 Remove the filter housings by using a wrench on the nut provided on the bottom of the housings 4 Remove the filter elements from the housings Inspect the housing seals and replace them if necessary 6 Install the new filter elements into the housings and tighten them securely 7 Clean up any oil that may have spilled during the installation procedure 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter housings 9 Inspectthe filter housings and related components to be sure that there are no leaks Case drain filter Note The case drain filter is for the charge pump 1 Open the engi
126. includes TRAX modesl 217 Nm S 60 S 65 S 60X S 60XC 180 ft lbs includes TRAX models 244 Nm to serial number S6015A 29677 S 60 S 65 S 60X S 60XC 160 ft lbs includes TRAX models 217 Nm from serial number S6015A 29678 SX 150 and SX 180 455 ft lbs 617 Nm All other models 180 ft lbs 244 Nm Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 85 Maintenance Manual September 2015 Annual Maintenance Procedures A 3 Inspect for Turntable Bearing Wear Genie specifications require that this procedure be performed annually Periodic inspection of turntable bearing wear is essential to safe machine operation good machine performance and service life Continued use of a worn turntable bearing could create an unsafe operating condition resulting in death or serious injury and component damage Note Perform this procedure with the machine on a firm level surface with the boom in the stowed position 1 Grease the turntable bearing Refer to Maintenance Procedure Grease the Turntable Bearing and Rotate Gear 2 Torque the turntable bearing bolts to specification Refer to Maintenance Procedure Check the Turntable Rotation Bearing Bolts 3 S Booms Using the ground controls raise the boom to full height Do 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 g
127. ine 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 platform controls and there should be no error message displayed at the ground control LCD screen The alarm should not sound and the engine should continue to run illustration 1 5 Carefully move the test weights to each remaining location on the platform Refer to Illustration 1 Result The platform overload indicator light should be off at platform controls and there should be no error message displayed at the ground control LCD screen The alarm should not sound and the engine should continue to run 6 Add additional weight to the platform that is equal to but does not exceed 15 of the maximum rated load Secure the additional weight Refer to the machine serial plate Result The platform overload indicator light is on at the platform and PLATFORM OVERLOAD is displayed at the ground control LCD screen The alarm is sounding and the engine should not start and run Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds Genie 94 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 7 Carefully move the test weights to each remaining location on the platform Refer
128. ing both the inner and outer bearings must be replaced 6 Remove the cover from the hub retaining fastener washer cover shim outer ring outer bearing hub inner bearing inner seal 10 spindle o o 004 ON gt Genie 130 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual 10 11 12 13 14 15 16 17 18 19 Part No 1268489 Programmed Maintenance Procedures Remove the shims Gently pry the outer ring out of the hub Pull the hub off of the spindle The outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the inner oil seal out of the hub Remove the inner bearing Pack both bearings with clean fresh grease Place the large inner bearing into the rear of the hub Install a new inner oil seal into the hub by pressing it evenly into the hub until it is flush Slide the hub onto the spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur Place the outer bearing into the hub Install the outer ring Install the shims Install the cover and torque the retaining fastener to 383 ft lbs 519 Nm 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 performed every 3000 hours
129. ing for each cell as follows e Add 0 004 to the reading of each cell for every 10 F 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 F 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 276 or below Proceed to step 8 iQ S Booms Z Booms 33 Maintenance Manual September 2015 Quarterly Maintenance Procedures 10 11 12 34 Perform an equalizing charge OR fully charge the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 F 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 F 5 5 C below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One or more battery cells 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 Re
130. is procedure be performed every 1000 hours Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil may cause the machine to perform poorly and continued 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 Part No 1268489 Genie ATEREX BID 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 bottom of the lowest plug hole Refer to Specifications Hydraulic Specifications Drive hubs with 3 plugs Fill the hub until the oil level is even with the bottom of the middle plug hole Refer to Specifications Hydraulic Specifications Install the plugs into the drive hub 6 Repeatthis procedure for each drive hub S Booms Z Booms 115 Maintenance Manual September 2015 Programmed Maintenance Procedures Models with TRAX 1 A CAUTION 116 Select the drive hub to be serviced Loosen and remove as many sprocket retaining fasteners as possible from the hub adapter Drive the machine in either direction just enough to access the remaining fasteners Do not remove the the retaining fasteners Chock the tracks at the opposite end
131. itch LST1S is located between the two operational turntable rotate limit switches It can easily be identified by the orange and red tie wraps attached to the limit switch cable 2 Locate and disconnect the deutsch connector to LST1S 3 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should have continuity wi 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 Connect the leads from a multimeter with continuity checking capability to pins 1 and 2 at the Deutsch connector of the limit switch cable Result The limit switch should not have continuity Result The limit switch does have continuity The limit switch is faulty and needs to be replaced OR the mounting position of the limit switch needs to be adjusted until it activates when the turntable is rotated more than 15 8 Remove the multimeter leads and connect the Deutsch connector to LST1S Genie 68 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Z 135 70 ZX 135 70 SX 150 and SX 180 Models
132. l engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Cummins Models e Cooling system flush e Valve clearance check adjust Deutz Models All Models e V Belts replace e Glow plugs replace D 2 9 and TD 2 9 Models e Cooling system coolant replace e Extended life coolant ELC replace Perkins Models All Models e Alternator inspect e Engine mounts inspect e Starting Motor inspect e Engine crankcase breather replace Perkins 854F 34T e Water pump inspect e Turbocharger inspect e Aftercooler core inspect Perkins 1104D 44T e Aftercooler core inspect e Turbocharger inspect e Water pump inspect e Cooling system coolant replace Kubota Models Z482 E D1105 WG972 e Radiator coolant L L C replace e Battery replace e Radiator hoses and clamp bands replace e Fuel pipes and clamp bands replace e Intake air line replace WG972 e Fuel filter replace e LPG fuel hose and clamp bands replace e Coolant and vacuum lock hose of LPG vaporizer replace Genie 118 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures P2 2 Test or Replace the Hydraulic Oil Genie requires that this procedure be performed every 2000 hours Replacement or testing of the hydraulic oil is essential for good machine performance and service lif
133. l the boom is Serious Injury elevated to greater than 68 Failure to raise the boom could until the boom is extended to approximately 95 feet 29 m 18 Measure the angle of the boom 10 Remove the wire jumper installed in step Result The angle of the boom should be 7 and connect the Deutsch connector to greater than 65 LSB14A0 19 Using emergency power raise the boom until 11 a dius red Emergency Stop button to the the boom angle is greater than 68 off position 20 Remove the wire jumper installed in step 12 Remove the LSB2RS test jumper between the 16 and connect the Deutsch connector to lower limit switch and the function manifold LSB14A0 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 Genie 76 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 21 With the key switch off press and hold the 31 Measure the angle of the boom 22 23 24 25 26 enter button and turn the key switch to the on position Release the enter button after five seconds and press the minus minus previous previous buttons Press the previous button until clear all safety switch faults appears Select YES then press the enter button Press the previous button until exit appears Select YES then press the enter button Start the engine 50 Angle Safety Switch LSB8AS 27 28 29
134. l 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 extend indicator light at the ground and platform controls should be illuminated Proximity switch 1 target area Activate the function enable high RPM 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 A WARNING 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 boom could result in death or serious injury Part No 1268489 S Booms Z Booms 79 Maintenance Manual September 2015 Quarterly Maintenance Procedures 62 Bi Activate the function enable high RPM button and attempt to raise the boom Result The boom should not raise to more than 11 Result If the boom continues to raise the LSAX1ES or LSAX2ES switch are out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired AWARNING Bodily injury hazard If the boom 63 65 AWARNING 80 raises to more than 11 stop immediat
135. loor 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 test weights from the platform 7 Push in the ground controls red Emergency Stop button to the off position then pull the red Emergency Stop button out to the on position to reset the control system A 11 Inspect the Boom Extend Retract Cables S 60 and S 80 Models Genie specifications require that this procedure be performed annually The boom extend retract cables are responsible for the extension and retraction of the boom tubes 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 This maintenance procedure applies to the following models S 60 S 65 S 60 TRAX S 65 TRAX S 60 HC S 60X S 60XC S 80 S 85 S 80X 1 Raise the boom to horizontal and fully extend the boom 2 Afterthe boom is fully extended lower the boom until the platform is at chest height Turn the machine off 3 S 60 S 65 S 60X S 60XC S 60 TRAX and S 65 TRAX S 80 S 85 S 80X Remove the boom end cov
136. mation Note Use the following chart to identify the description of each LCD screen control button used in this procedure 4 a Enter Plus Minus Previous Note Perform this procedure with the machine on a firm level surface with the booms in the fully stowed position and the axles fully extended 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 Startthe engine from the ground controls Press the enter or previous button on the LCD screen until PRIMARY BOOM ANGLE TO GRAVITY DEGREES is displayed 4 Place a digital level that has been calibrated to gravity on top of the primary boom 58 Genie 62 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Raise the primary boom while watching the 8 Fully lower the primary boom until it stops at display screen approximately 50 Continue to raise the primary boom until it Result The reading at the display and digital stops at approximately 58 level is within 2 of each other and of 50 Result The reading at the display and digital 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 greate
137. mming the ECM If RPM or service is required please contact Genie Product Support Continental Models TME27 Ford Models DSG 423 MSG 425 Deutz Models D 2 9 L4 TD 2 9 L4 Perkins Models 403F 11 404F 22 404F 22T 854F 34T Note Some procedures may require two people Note For engine RPM information refer to Specifications Engine Specifications for your engine model Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 41 Maintenance Manual September 2015 Quarterly Maintenance Procedures Models with ALC 1000 operating system Note Use the following chart to identify the description of each LCD screen control button used in this procedure 2 Pressthe 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 1 low rpm idle procedure for your engine model 3 Press and hold the function enable high speed 2 button Note the engine rpm on the display Result High idle rpm is correct Result High idle rpm is not correct Follow the high rpm idle procedure for your engine model All other models 1 Connect a tachometer 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 fu
138. ms Part No 1268489 September 2015 Maintenance Manual c RT P P A se gs Programmed Maintenance Procedures SX 150 SX 180 Z 33 18 Primary boom wear pad specifications Minimum Primary boom wear pad Minimum specifications Platform end Bottom and side wear pads 0 63 in Top wearpads platform ena E lle 16 mm M Top wear pads 0 35 in Side wear pads platform end goi een 1 to 2 2 to 3 SX180 0 to 1 9mm Top wear pads 3 to 4 0 47 in Bottom wear pads platform end 0 625 inch 15 9 mm 12 mm Pivot end Top and side wear pads pivot end oe Top wear pads E Bottom wear pads pivot end 0 81 inch 20 64 mm Side wear pads 0 47 in 12 mm Z 34 22 IC Z 34 22 Bi Energy Grease Specification Primary boom wear pad specifications Minimum Lube a Boom grease Top side and bottom wear pads platform 0 625 inch Genie part number 110147 end 15 9 mm Z 30 20N RJ Z 34 22N Z 34 22DC Bottom wear pads pivot end 0 50 inch 12 7 mm Models without rotating jib boom Top wear pads pivot end 0 625 inch Primary boom wear pad specifications Minimum 15 9 mm Top bottom and side wear pads 0 625 inch Side wear pads pivot end 0 375 inch extension end of boom 15 9 mm 9 5 mm Z 40 23N RJ Bottom and side wear pads 0 625 inch pivot end of boom 15 9 mm Primary boom wear pad Minimum specifications Top wear pads E d Top and si
139. n all pulleys e Cables have equal tension e Cables at end of adjustment range e No broken or damaged pulleys e No unusual or excessive pulley wear e All fasteners in place and secure Note A flashlight and inspection mirror may be necessary to thoroughly inspect the above items Note A pulley groove gauge should be used to check the condition of the pulleys 4 Replace the cables if any damage is found 5 Atthe pivot end of the boom visually inspect for the following e The red locking bracket is securely installed over the cable adjustment bolts Genie 98 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 6 Install the plastic cover at the pivot end of the boom and access panels on the sides of the boom 7 Startthe engine from the platform controls Extend the boom approximately 2 feet 0 6 m Retract the boom While retracting the boom visually inspect the number 2 and number 3 boom tubes Result The number 2 boom tube should not move more than 1 2 inch 13 mm before the number 3 boom tube begins to retract Note If the number 2 boom tube moves more than 1 2 inch 13 mm before the number 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 13 Inspect the Boom Extend Retr
140. n and lower the secondary boom Result The secondary boom should lower to 60 and the engine should stop bd Result If the engine does not stop at 60 and the secondary boom continues to lower the secondary boom 2 angle safety limit switch LSS2AS is out of adjustment or the wiring circuit is faulty and will need to be replaced or repaired Immediately remove the machine from service until repairs are made ADANGER Bodily injury hazard If the secondary boom lowers to less than 60 without stopping the engine stop immediately and raise the secondary boom above 60 Failure to raise the secondary boom could result in death or serious injury Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 71 Maintenance Manual September 2015 Quarterly Maintenance Procedures 12 13 14 15 16 Remove the key from the main key switch insert it into the bypass recovery key switch turn the key to Bypass mode and raise the secondary boom above 60 using emergency power Remove the wire jumpers installed in steps 9 and 10 and connect the wire harness to LSS1RO removed in step 8 Fully raise the secondary boom and extend the secondary boom approximately 1 foot 30 5 cm Turn the bypass recovery key switch back to run return the key to the main key switch and start the engine from the ground controls Re connect the Deutsch connector from the secondary safety retract switch LSS1RS remov
141. nction 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 the high rpm idle procedure for your engine model Genie 42 4 o 4 Plus Minus Previous Enter Start the engine from the ground controls S Booms Z Booms Kubota WG 972 Low rpm idle adjustment 1 Loosen the core clamp screw so the cable moves freely Hold the throttle lever against the low idle adjustment screw Turn the adjustment screw clockwise to increase low rpm or counterclockwise to decrease low rpm While holding the throttle lever against the low idle adjustment screw tighten the core clamp screw High rpm idle adjustment Loosen the lock nut on the high idle adjustment nut Turn the high idle adjustment nut clockwise to increase the high rpm or counterclockwise to decrease high rpm Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures 3 Tighten the lock nut All other engine models Low rpm idle adjustment 1 Loosen the lock nut on the low idle adjustment screw 2 Turnthe 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 Turnthe high idle adjustment nut counterclockwise t
142. nd the alarm sounds 7 Carefully move the test weights to each remaining 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 2 second delay before the overload indicator lights flash and the alarm sounds 8 Using emergency power test all machine functions from the ground controls Result All ground control functions should operate normally 9 Using emergency power test all machine functions from the platform controls Result All platform control functions should operate normally 10 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator lights should turn off at both the ground and platform controls and the alarm should not sound Note There may be an 2 second delay before the overload indicator lights and alarm turn off 11 Engine Models Start the engine and test all machine functions from the ground controls DC Models Test all machine functions from the ground controls Result All ground control functions should operate normally 12 Using a suitable lifting devic
143. ne side turntable cover and locate the case drain filter mounted to the engine tray near the hydraulic pumps N 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 element from the housing 5 Inspect the housing seal and replace it if necessary 6 Install the new case drain filter element into the housing Install the filter housing onto the filter head and tighten it securely 7 Clean up any oil that may have spilled during the installation procedure 8 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 9 Startthe engine from the ground controls 10 Inspect the all of the filter housings and related components to be sure that there are no leaks Tank breather filter if equipped 1 Locate the breather filter on top of the hydraulic tank 2 Remove the filter and install the new hydraulic tank breather filter Tighten securely by hand Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 121 Maintenance Manual September 2015 Programmed Maintenance Procedures P2 4 Check the Free wheel Configuration Genie requires that this procedure be performed every 2000 hours Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A m
144. nge Note Perform this procedure with the machine on a firm level surface that is free of obstructions Note Perform this procedure with the machine in the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 3 Bring the machine to top drive speed before reaching the start line Begin 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 Part No 1268489 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 operation The drive 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 Note Select a test area that is firm level and free of obstructions 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 above horizontal 3 Choose a point on the machine i e contact patch
145. nge to high idle Genie Part No 1268489 S Booms Z Booms 49 Maintenance Manual September 2015 Quarterly Maintenance Procedures Q 16 Test the Fuel Select Operation Gasoline 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 indicate fuel system problems that could develop into a hazardous situation Note Perform this test after checking the gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Atthe 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 Startthe 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 smoothly in low and high idle 4 Release the foot switch and shut the engine off by pushing in the red Emergency Stop button in to the off position 5 Move the fuel select switch to LPG 6 Restart the engine and allow it to run at low idle 7 Press down the foot swi
146. ngs They are available in the O ring field service kit Genie part number 49612 2 3 the hex nut to the body hex fitting to hand tight Replace the O ring The O ring must be approximately 30 in Ibs 3 4 Nm replaced anytime the seal has been broken The O ring cannot be re used if the fitting or 2 Using a permanent ink marker make a hose end has been tightened beyond finger reference mark on one the flats of the hex nut tight and continue the mark onto the body of the hex fitting Refer to Illustration 1 Lubricate the O ring before installation e f Be sure the O ring face seal is seated and E retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Illustration 1 Tighten the nut or fitting to the appropriate 1 hex nut torque Refer to the appropriate torque chart in 2 reference mark this section 3 body hex fitting Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 23 Maintenance Manual September 2015 m A s J J si Hydraulic Specifications 3 Working clockwise on the body hex fitting make a second mark with a permanent ink marker to indicate the proper tightening position Refer to Illustration 2 Note Use the
147. nspect the Boom Extend Retract Cables S 100 S 105 S 120 S 125 S 100HD and S 120HD Models Genie specifications require that this procedure be performed annually The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube on the S 100 S 105 and S 100HD and the numbers 2 and 3 boom tubes on the S 120 125 and S 120HD 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 extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise Note Perform this procedure with the boom in the stowed position Note Perform this procedure with the engine off 1 Remove the boom end cover from the pivot end of the boom 1 boom end cover 2 side access covers 3 cable ends located underneath the boom 2 Remove the retaining fasteners from the access covers located on the side of the boom at the platform end of the machine Remove the covers 3 Visually inspect the cables and components through both inspection holes for the following e Frayed or broken wire strands e Kinks or crushed cables e Corrosion e Paint or foreign materials on the cable e Split or cracked cable ends e Cables are o
148. ntity and type of filter s may vary by model A CAUTION 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 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 Install the new filter element into the filter housing 6 Pushthe 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 Applyathin 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 any oil that may have sp
149. nto the drive hub adapter while guiding the hub adapter studs into the sprocket of the track assembly Install as many sprocket retaining fasteners as possible to the hub adapter and torque to specification Refer to Specifications TRAX Torque Specifications Part No 1268489 September 2015 muwcecr e BR A K tH A Programmed Maintenance Procedures 16 17 18 19 Raise the machine remove the jack stands lower the machine 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 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to specification Refer to Specification TRAX Torque Specifications Repeat this procedure for each drive hub Turntable Rotate Drive Hub 1 2 Secure the turntable from rotating with the turntable rotation lock pin Tag disconnect and plug the hydraulic hoses to the drive hub drive motor and brake AWARNING Bodily injury hazard Spraying 3 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Attach a suitable lifting device to the lifting eye of one turntable rotate drive hub assembly Maintenance Manual 4 Remove the drive hub mounting bolts from the dri
150. o increase the rpm or clockwise to decrease the rpm 3 Tighten the lock nut Kubota D1105 E3B i iv VAL Wl 19 10 aft coh Nye lek nc gu core clamp screw throttle lever low idle adjustment screw lock nut high idle adjustment nut high idle solenoid 1 high idle solenoid 2 low idle adjustment screw 3 lock nut 4 high idle adjustment nut o0 20K Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 43 Maintenance Manual September 2015 Quarterly Maintenance Procedures Kubota Z482 E Deutz TD2011L04i 1 low idle adjustment screw not shown 2 high idle adjustment nut 3 high idle solenoid 4 fuel shut off solenoid 1 high idle solenoid 2 high idle adjustment nut 3 lock nut Deutz D2011L 03i 4 low idle adjustment screw 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw Lo Gaii 1 1 1 1 44 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Perkins 403D 11 Perkins 404D 22 5 27 eoi di 0 2 Q 2 3 1 high idle solenoid 2 high idle adjustment nut 3 lock nut 4 low idle adjustment screw 1 high idle solenoid 2 high idle adjustment nut 3 low idle adjustment screw Perkins 804
151. ocedure P Enter T Plus 4 Minus Previous Genie S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Z 135 70 and ZX 135 70 Models 6 Startthe engine from the ground controls Secondary Boom 1 Retracted Safety Limit 7 Fullyraise the secondary boom Do not extend Switch LSS1RS the boom Turn the machine off Locat i t the Deutsch t 1 Working at the platform end of the turntable Beate and Clsconniee Mie Foute connector to LSS1RS support and secure the lower turntable riser end cover to a suitable lifting device 9 Connect the leads from a multimeter with Ed continuity checking capability to pins 1 and 2 Remove the lower cover retaining fasteners 2 at the Deutsch connector of the limit switch and remove the lower cover from turntable cable AWARNING Crushing hazard The turntable Result The limit switch should not have riser lower cover could become continuity unbalanced and fall when SEPE E removed from the turntable if Result The limit switch does have continuity not properly supported and The limit switch is faulty and needs to be secured to the lifting device replaced 10 Remove the multimeter leads and connect the 3 Support and secure the upper turntable riser Deutsch connector to the limit switch end cover to a suitable lifting device n 11 Start the engine from the ground controls 4 Remove t
152. ocedures for the type of Annual Inspections A N no remove from service inspection s to perform R repaired not applicable If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a R in the box Drive Chassis Intervals Q A Functions and Controls Intervals Q A Inspect Electrical Contactors DC Models Q 4 Check for Open Bulletins and Owner Registration Q 1 Inspect the Tires Wheels and Lug Nut Torque Q 6 Test the Ground Control Override Q 12 Check the Oscillate Valve Linkage if equipped Q 8 Test Alarm Package If Equipped Q 13 Confirm the Proper Brake Configuration Q 20 Test the Emergency Power System Q 14 Extendable Axle Wear Pads if equipped A 4 Test the Engine Idle Select Operation Q 15 Check Drive Hub Oil Level and Fastener Torque A 14 2 Test Fuel Select Operation Gas LPG Models Q 16 Turntable Mechanicals and Hydraulics Intervals Q A Inspect the Calibration Decal ALC1000 Models Q 17 Msual Inspector ofthe Flydtaglles Oil bd Test the Recovery System ALC 1000 Models Q 18 Inspect the Hydraulic Filters Q 10 Test the Platform Self leveling Q 19 Grease the Turntable Rotation Bearing A 1 Test the Drive Brakes Q 21 Check Turntable Bearing Bolt A 2 S e Rt Test Drive Speed Stowed Position Q 22 Inspect for Turntable Bearing Wear A 3 Test Drive Speed Raised or Extended Position Q 23 Electrical Intervals Q A Test the Drive Speed
153. odels 244 Nm Z 80 320 ft lbs X X X 434 Nm Z 135 420 ft lbs X X X 569 Nm ZX 135 420 ft lbs X X X to serial number ZX13515 2584 569 Nm ZX 135 dry torque 320 ft lbs x X X from serial number ZX13515 2585 434 Nm Genie Part No 1268489 ATEREX BRAND S Booms Z Booms Maintenance Manual September 2015 P Punt Torque Specifications TRAX Torque Specifications Sprocket to hub adapter fasteners 3 4 10 nuts GR 8 dry 317 ft lbs 430 Nm 3 4 10 nuts GR 8 lubricated 281 ft lbs 381 Nm 1 2 13 FHS screws dry 80 ft lbs 108 Nm 1 2 13 screws lubricated 60 ft lbs 81 Nm Hub adapter to drive hub fasteners S 60 and S 65 Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs 244 Nm S 40 and 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 and bogey wheel fasteners 3 4 10 bolts GR 8 dry 375 ft Ibs 508 Nm 3 4 10 bolts GR 8 lubricated 281 ft lbs 381 Nm Genie 10 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Engine Operator and Engine Specifications Ford DSG 423
154. of a tire as a visual reference for use when crossing the start and finish lines 4 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Gon ATEREX BRAND S Booms Z Booms 55 Maintenance Manual September 2015 Quarterly Maintenance Procedures 5 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications 6 Lower the boom to the stowed position and extend the primary boom 4 feet 1 2 m 7 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 8 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 9 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Drive Speed Specifications Q 24 Test the Drive Speed Raised and Extended Position ALC1000 Models Genie specifications require that this procedure be performed quarterly Proper drive function is essential to safe machine operation The drive 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 s
155. of the machine to prevent the machine from rolling Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the tracks Lift the machine until the tracks are off the ground and place jack stands under the drive chassis for support Attach a lifting strap from an overhead crane 2000 Ibs 1000 kg to the center point of the track assembly above the sprocket Remove the remaining sprocket retaining fasteners from the hub adapter Carefully remove the track assembly from 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 10 11 12 13 14 15 Genie S Booms Z Booms 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 Remove the plugs and drain the oil into a suitable container Manually depress the hub disconnect pin and rotate the drive hub until the plugs are one on top and the other at 90 degrees Fill the hub until the oil level is even with the bottom of the side plug hole Refer to Specifications Hydraulic Specifications Install the plugs into the drive hub Attach a lifting strap from an overhead crane to the center point of the track assembly above the sprocket Install the track assembly o
156. oom rotate Turntable rotate drive enable to drive enable 80 stowed 28 32 seconds 38 42 seconds 28 32 seconds 38 42 seconds Turntable rotate drive enable to drive enable 80 string pot 36 in 91 4 cm 63 70 seconds 63 70 seconds Turntable rotate drive enable to drive enable 80 string pot 76 in 193 cm above 75 ft 22 8 m 109 120 seconds 109 120 seconds Turntable rotate drive enable to drive enable 80 string pot 258 in 655 cm above 125 ft 38 1 m 155 175 seconds 155 175 seconds Platform rotate Platform level 10 range of motion 20 24 seconds ANSI CSA ASICE Genie A TEREX BRAND S Booms Z Booms 3 5 seconds 20 22 seconds 20 24 seconds Part No 1268489 September 2015 Drive Speeds Maintenance Manual cw XX a RT Performance Specifications Function S 40 S 45 S 60 S 65 S 60HC S 80 S 85 S 80X S 100 S 105 S 120 includes TRAX S 60X S 60XC S 125 S 100HD models includes TRAX S 120HD models 2WD models 5 2 5 9 seconds 6 1 7 8 seconds 7 9 8 5 seconds X Stowed position 40 ft 12 2 m 40 ft 12 2 m 40 ft 12 2 m 4WD models 5 2 5 9 seconds 8 10 5 sec 8 10 5 seconds 8 8 9 3 seconds Stowed position 40 ft 12 2 m 40 ft 12 2 m 4
157. oosen the plug but do not remove drive chassis for support it 1 grease zerk 2 grease plug Lo Gaii 1 1 1 1 h 104 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures 7 Locate the grease zerk fitting on the other side of the track tension cylinder 8 Pump grease into the grease zerk fitting of the tension cylinder until grease free from air comes out of the grease plug Securely tighten the grease plug Do not overtighten 9 Continue to pump grease into the grease zerk fitting just until the idler wheel moves Check the track tension 10 If necessary continue to pump grease into the cylinder until the track has proper tension Component damage hazard Do not over tighten the track Over tightening the track will cause the machine to lose power during operation Note If the track becomes too tight loosen the grease plug on the cylinder to remove grease and loosen the track 11 Clean up any grease that may have spilled 12 Check the torque of the track assembly fasteners 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 4
158. ore attempting this procedure 1 Measure each wear pad Wear pad specifications Minimum Top side and bottom wear pads 0 437 inch 1 12 mm 2 Replace any wear pad if itis less than specification If a wear pad is not less than specification shim as necessary to obtain minimum clearance and no drag Note If the wear pads are still within specification Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Shim the Extendable Axles Note If any wear pads are replaced refer to Repair Procedure in the appropriate Service and Repair Manual for your machine Grease the Extendable Axles 3 Extend and retract the axles through the 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 service life Improperly adjusted turntable rotation gear backlash will cause the machine to perform poorly and continued use will cause component damage The turntable rotation drive hubs are mounted on an adjustable plate on the swing chassis behind the fixed side cover at the ground controls side of the machine Note Perform this procedure with the ma
159. ould result in death or serious injury Remove the wire lumper installed in step 64 and connect the Deutsch connector to LSAX2ES Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 34 Test the Aircraft Protection System if equipped Genie specifications require that this procedure be performed quarterly Testing the machine aircraft protection system is critical to safe machine operation If the boom is allowed to operate when the proximity switch is not functioning correctly it could result in machine and property damage Note Start this procedure with the machine in the 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 Startthe 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 switch Result All boom drive and steer functions operate 5 Extend the primary boom approximately 3 ft 1m 6 Move the yellow bumper at the bottom of the platform 4 inches 10 cm in any direction 7 Activate each function control handle or toggle switch
160. peed range Note Perform this procedure with the machine on a firm level surface that is free of obstructions This maintenance procedure applies to the following models S 100 S 105 S 120 S 125 S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 S 100 S 105 S 120 S 125 S 100HD and S 120HD 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Raise the boom to a horizontal position 3 Extend the primary boom until the envelope alarm and LED are activated 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the 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 Genie 56 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures SX 150 and SX 180 Note This procedure will require 2 people to perform 1 Part No 1268489 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart Access the MACHINE STATUS menu on the ground control box and scroll down until LENGTH SENSOR EXTENSION is displayed Raise and extend the primary boom until
161. placed 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub 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 the hub onto the yoke spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the slotted nut to specification to seat the bearings S 40 S 45 Z 45 25 IC Z 30 20N 35 ft lbs Z 34 22N Z 33 18 Z 34 22 IC 47 Nm Z 34 22 BE Z 40 23 Z 45 25 DC Z 45 25 158 ft Ibs BE 214 Nm 21 Loosen the castle nut and re tighten to specification S 40 S 45 Z 45 25 IC Z 30 20N 8 ft lbs Z 34 22N Z 33 18 Z 34 22 IC 11 Nm Z 34 22 BE Z 40 23 Z 45 25 DC Z 45 25 35 ft Ibs BE 47 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in Note Always use a new cotter pin when installing a castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Specifications Tires
162. r than 2 of each other and of 58 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 ADANGER Tip over hazard If the boom is not within 2 of 58 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 Fully raise the secondary boom The boom is fully raised when the cylinder is fully extended and the boom stops moving level is greater than 2 of each other and of 50 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 58 Raise the primary boom to 20 Result The reading at the display and digital level is within 2 of each other and of 20 Result The reading at the display and digital level is greater than 2 of each other and of 20 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 Genie ATEREX BRAND Part No 1268489 S Booms
163. round 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 directly under or inline with the boom and no more than 1 inch 2 5 cm from the bearing Note To obtain an accurate measurement place the dial indicator no more than 1 inch 2 5 cm from the turntable rotation bearing 0 8 1 turntable 2 dial indicator 3 drive chassis 4 turntable rotation bearing 5 Adjust the dial indicator needle to the zero position 6 S Booms Fully extend the boom and lower to a horizontal position Z Booms Lower the secondary boom to the stowed position and lower the primary boom to a horizontal position Fully extend the primary boom Z 80 60 Z 135 70 and ZX 135 70 Raise the secondary riser but do not extend it Move the primary boom and jib to horizontal and fully extend Genie 86 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Annual Maintenance Procedures 7 Note the reading on the dial indicator Result The measurement is less than specification The bearing is good w Result The measurement is more than specification The bearing is worn and needs to be replaced Models Measurement S 40 all S 60 all SX150 SX180 Z
164. s Required maintenance procedures and additional engine information are available in the manufacturer s manuals Refer to Specifications Engine Operator and Maintenance Manuals Perkins Models 854F 34T 1104D 44T e Aftercooler core clean test Genie S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures 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 Operator and Maintenance Manuals Perkins 1104D 44T e 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 manuals Refer to Specifications Engine Operator and Maintenance Manuals Perkins Models All models e Cooling system coolant ELC change Genie ATEREX BRAND S Booms Z Booms 133 Part No 1268489 Maintenance Manual September 2015 Programmed Maintenance Procedures P12 2 Replace the Boom Extend Retract Cables S 100HD and S 120HD Genie specifications require that this procedure be performed every 7 years The boom exten
165. s for the approved optional fluids Consult Genie Product Support before use Mineral based Biodegradable Fire resistant 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 If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 40 22 4 14 32 50 68 86 104 122 F 40 30 20 10 O 10 20 30 40 50 C Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie 20 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt
166. safe operating conditions They are essential to safe operation machine performance and service life Commissioning A series of required one time maintenance procedures to be performed at 50 and 150 hour intervals Quarterly and Annually A series of maintenance procedures to be performed quarterly or annually Programmed A series of maintenance procedures to be performed based on machine operating hours Maintenance Inspection Report The 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 Commissioning JA Engine all models APO Qr A A Quarterly and Annually Example A Drive Chassis Nintervats Q A A Inspect the tires wheels and Ae A ge Lug Nut Torque Maintenance Procedures Programmed Example under 1000 HRS Programmed Maintenance Status Enter Under 1000 HRS Hours Check Track Tension Fastener Torque A PO 1 A 50 A Engines Deutz Under 1000 HRS AN PO 2 A A Programmed Example Programmed Maintenance All models 1 2 3 4 N ngine all models 1000 hrs AP JA oo0 o Instructions Use the following detailed descriptions to iden
167. sed 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 the Proper Brake Configuration A WARNING Note Select a test area that is firm level and free of obstructions 1 Marka test line on the ground for reference 2 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 3 Bring the machine to top drive speed before reaching the test line Release the drive joystick when your reference point on the machine crosses the test line 4 Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Genie 54 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 22 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed quarterly Proper drive function is essential to safe machine operation The drive 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 ra
168. sethe primary boom The display will begin showing a boom angle of 40 5 Continue raising the primary boom until the display shows 65 Result The primary boom should stop Result The primary boom does not stop Immediately release the function enable button and lower the boom Calibrate the limit Switch Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Limit Switch ADANGER Tip over hazard If the boom does not stop at 65 immediately release the function enable button and lower the primary boom Failure to lower the boom could cause the machine to tip over resulting in death or serious injury Genie 70 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 31 7 Locate the Deutsch connectors from the Test the Safety Envelope and Circuits Z 80 60 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 For limit switch and angle sensor information Refer to appropriate Service and Repair Manual for your machine Note Use the following chart to identify the description of each LCD screen control button used in this procedure P
169. sitive post on the back of the alternator Connect the negative lead to the negative post Set the meter to DC voltage 10 Start the engine from the ground controls Result The voltage does not exceed 54V DC Genie 38 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 8 Q 9 Check the Oscillate Directional Visual Inspection of the Valve Linkage if equipped Hydraulic Oil Genie specifications require that this procedure be performed quarterly Note Perform this test only on models equipped with an oscillating axle Proper axle oscillation is essential to safe machine operation If the oscillate directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover and the axle covers from the non steer end of the drive chassis 2 Locate the oscillate directional valve inside of the non steer axle and inspect the linkage for the following e Lock nut is tight against yoke e Yoke clevis pins are installed e Cotter pins are installed through clevis pins e Linkage is properly attached to directional valve 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 strainer may cause the machine to perform poorly and continued
170. sssssssss 55 Q 23 Test the Drive Speed Raised or Extended Position 55 Q 24 Test the Drive Speed Raised and Extended ALC1000 Models 56 Q 25 Test the Turntable Level Sensor Z 135 70 ZX135 70 SX 150 and SX 180 sss 58 Q 26 Test the Secondary Boom Angle Sensor Z 135 70 and ZX135 70 60 Q 27 Test the Primary Boom Angle Sensor Z 135 70 and ZX135 70 62 Q 28 Test the Primary Boom Angle Sensor SX 150 and SX 180 64 Q 29 Test the Safety Envelope Limit Switches Z 135 70 ZX135 70 SX 150 and SX 180 Models sss 66 Q 30 Test the Primary Boom Angle Sensor Z 80 60 sss 70 Q 31 Test the Turntable Level Sensor Z 80 60 sse 71 Q 32 Check the Safety Envelope Limit Switches and Angle Sensor S 60X S 60XC and S 80X ssssssssssssseeeneeeen eene 73 Q 33 Test the Safety Envelope and Circuits S 100 S 105 S 120 and 8 125 sss 75 Q 34 Test the Aircraft Protection System if equipped sssesesssss 81 Q 35 Test the Operator Protection Alarm if equipped sessessssse 83 Genie X S Booms Z Booms Part No 1268489 September 2015 cu AAE A W s G A a c co n J Table of Contents Annual Maintenance Procedures
171. sult One or more battery cells display a specific gravity from 1 217 to 1 173 The battery is approaching the end of it s life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill Install the vent caps and neutralize any electrolyte that may have spilled Genie S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 3 Inspect the Electrical Wiring Genie specifications require that this procedure be performed quarterly Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry A WARNING 1 Inspect the following areas for burnt chafed corroded pinched and loose wires Note Inspection areas will vary by model 2 e Engine wiring harness e Engine relay block e Hydraulic manifold wiring e All wire harness connectors to groun
172. taining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage Note Access to the upper and lower turntable bearing bolts will vary depending on model 1 S Booms and Z 45 25 J IC DC Bi Energy Raise the primary boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock OR support the boom assembly with a suitable lifting device Z Booms Raise the secondary boom and place a safety chock on the lift cylinder rods Carefully lower the boom onto the lift cylinder safety chock OR support the boom assembly with a suitable lifting device A WARNING Crushing hazard Keep hands away from the cylinder and all moving parts when lowering the boom 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 the safety chock OR lifting device 5 Lower the boom to the stowed position Using a star pattern confirm that each lower bearing mounting bolt is torqued in sequence to specification Z 62 160 ft lbs 217 Nm Z 135 and ZX 135 180 ft lbs 5 8 11 SHC 244 Nm Z 135 and ZX 135 320 ft lbs 3 4 10 SHC 434 Nm S 40 S 45 160 ft lbs
173. tch 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 Genie 50 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 17 Inspect the Calibration Decal ALC1000 Models Genie specifications require that this procedure be performed quarterly Maintaining the safety decal in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions This maintenance procedure applies to the following models S 100 S 105 S 120 S 125 S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 1 calibration decal 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 Only technicians that have 2 Open the turntable cover on the ground Tip Over Hazard Genie factory service Improper calibration can result in training shall perform controls side o
174. tenance Procedures 1 Turn the key switch to ground control and pull 7 Lower the primary boom to 66 out the red Emergency Stop button to the on oa Dl Result The reading at the display and digital position at both ground and platform controls level is within 2 of each other and of 66 io amp Result The reading at the display and digital Press the enter or previous button on the level is greater than 2 of each other and of LCD screen until PRIMARY BOOM ANGLE 66 The primary boom angle sensor must be TO GRAVITY DEGREES is displayed calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Primary Boom Angle Sensor 4 Place a digital level that has been calibrated to gravity on top of the primary boom 80 5 Raise the primary boom while watching the display screen 6 Continue to raise the primary boom until it stops at approximately 80 Result The reading at the display and digital level is within 2 of each other and of 80 Result The reading at the display and digital level is greater than 2 of each other and of 80 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 FUNT Tip over hazard If the boom is A DANGER not within 2 of 80
175. 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 attend to your equipment needs Machines purchased in ASIA North America and Latin America Go to ASIA North America and Latin America Bulletins https www gogenielift com P3 eRe A TEREX BRAND 1 Select Customer Login to login or select Request New Access to create a new account 2 Atthe homepage select Unit Configuration and enter your machine serial number 3 Press the Lookup button to view your machine configuration and to check for open bulletins 4 Complete all required bulletins shown for your specific machine serial number Machines purchased in Europe Middle East Africa and Russia Go to EMEAR Bulletins http www genielift co uk en sales and suppo rt bulletin campaigns index htm Safety Notices amp Campaign Bulletins Genie SAFETY NOTICES SSH 1 Enter your machine serial number and press search to check for open bulletins 2 Complete all required bulletins shown for your specific machine serial number Genie 32 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 2 Models without maintenance free or sealed Battery Inspection Genie
176. tify the intended use of the maintenance inspection reports 4 Hours are In thousands 6 12 oo 1 Specific Interval blank box is the interval to be completed and the Z marks the interval as not required 2 The description of the procedure or checklist to be completed 3 The procedure number or checklist to be completed 4 Check box to indicate status of inspection 5 Specific interval is not required for this procedure 6 General area of the machine to complete the procedure 7 fthis box has a designated time interval this is the specific time interval to complete the procedure or checklist If this box is empty the maintenance checklist will include multiple time intervals use this box to write in the specific interval for the inspection completed Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 27 Genie A TEREX BRAND Scheduled Maintenance Inspection Report Booms September 2015 28 A TEREX BRAND Model Hour meter Date Serial number Inspector company Machine owner Inspected by print Inspector signature Inspection Type Legend Make copies of this report to use for each inspection Quarterly or Frequent Inspections Q Y yes acceptable Select the appropriate pr
177. to Illustration 1 Result The platform overload indicator light is on at the platform and PLATFORM OVERLOAD is displayed at the ground control LCD screen The alarm is sounding and the engine should not start and run Note There may be a 2 second delay before the overload indicator lights flash and the alarm sounds 8 Using emergency power test all machine functions from the ground controls Result All ground control functions should not operate Note Z 135 models before serial number 471 and with software revision 1 00 will not function using the auxiliary pump Note Z 80 and Z 135 models all functions should operate except for primary boom extend 9 Using a suitable lifting device lift the additional test weight from the platform Result The platform overload indicator light should turn off at platform controls there should be no error message displayed at the ground control LCD screen and the alarm should not sound Note 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 be performed annually OR when the machine fails to lift the maxim
178. ub S 40 and S 45 20 fl oz 20 fl oz 8floz 45 gallons 55 gallons includes TRAX models 591 cc 591 cc 237 cc 170 liters 208 liters S 60 S 65 S 60HC S 60X and 20 fl oz 20 fl oz 43 fl oz 45 gallons 55 gallons S 60XC includes TRAX models 591 cc 591 cc 1262 cc 170 liters 208 liters S 80 S 85 and S 80X 23 fl oz 30 5 fl oz 43 fl oz 40 gallons 50 gallons 680 cc 902 cc 1262 cc 151 liters 189 liters S 100 S 105 S 120 S 125 x 47 fl oz 93 fl oz 55 gallons 80 gallons S 100HD and S 120HD 1390 cc 2750 cc 208 liters 303 liters SX 150 X 67 fl oz 43 fl oz 110 gallons 175 gallons 1981 cc 1262 cc 416 liters 662 liters SX 180 X 67 fl oz 43 fl oz 110 gallons 225 gallons 1981 cc 1262 cc 416 liters 852 liters Z 30N and Z 30N RJ 24 5 fl oz X X 4 gallons 6 gallons 725 cc 15 liters 23 liters Z 33 23 fl oz X X 6 gallons 8 gallons 680 cc 23 liters 30 liters Z 34N and Z 34DC 24 5 fl oz X X 4 gallons 6 gallons 725 cc 15 liters 23 liters Z 34BE 17 5 fl oz X X 4 gallons 6 gallons 518 cc 15 liters 23 liters Z 34 IC 17 fl oz 17 fl oz X 19 gallons 22 gallons 503 cc 503 cc 72 liters 83 liters Z 40N and Z 40N RJ 23 fl oz X 5 fl oz 8 gallons 11 gallons 680 cc 148 cc 30 liters 41 liters Z 45 25 and Z 45 25J EW1 type X 5 fl oz 8 gallons 11 gallons DC and BE models 17 fl oz 148 cc 30 liters 41 liters 503 cc W1 type 23 fl oz 680 cc Z 45 25 IC and Z 45 25J IC 24 fl oz 24 fl oz 5 fl oz 22 gallons 28 gallons 710 cc 710 cc 148 cc 83 liters 106 liters Z 51 x steer end 5 fl oz 22
179. uch as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Genie ATEREX BRAND S Booms Z Booms Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit vii September 2015 ECC EE MN CMM Table of Contents Introduction hiippnipibDnmTP R ii Important Information nicer ere ttn htt nhat dx gd i tau ii Models included in this manual seee eene iii Identifying the Correct Procedure for your Model
180. 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 procedure Note On a properly functioning machine the LEDs on both control modules located next to the ground control box should be off 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 Turnthe key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 95 Maintenance Manual September 2015 Annual Maintenance Procedures Start the engine from the ground controls 4 Using a suitable lifting device place an appropriate test weight equal to 340 2 kg on to the center of the platform floor Result The amber restricted range of motion LED at the platform controls should come on and the engine should continue to run 5 Using 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 f
181. ures eene 104 PO 1 Check the Track Tension and Fastener Torque TRAX Models S 60 S 65 and Z 62 Models seeeeeeeess 104 P0 2 Check the Track Tension and Fastener Torque TRAX Models S 40 and S 45 Models sseee 105 P0 3 Grease the Extendable Axles S 100 S 105 S 120 and S 125 107 P0 4 Continental Engine Maintenance Under 1000 Hours 108 P0 5 Cummins Engine Maintenance Under 1000 Hours 109 P0 6 Deutz Engine Maintenance Under 1000 Hours sess 110 PO 7 Ford Engine Maintenance Under 1000 Hours sees 111 P0 8 Kubota Engine Maintenance Under 1000 Hours sesssss 112 P0 9 Perkins Engine Maintenance Under 1000 Hours sssss 113 P1 1 Perform Engine Maintenance 1000 Hours 114 P1 2 Replace the Drive Hub Oil sss 115 P2 1 Perform Engine Maintenance 2000 Hours 118 P2 2 Test or Replace the Hydraulic Oil seee 119 P2 3 Replace the Hydraulic Filters es 120 P2 4 Check the Free wheel Configuration essseeeee 122 P2 5 Check the Boom Wear Pads sse 124 P2 6 Check the Extendable Axle Wear Pads S 100 S 105 S 120 S 125 S 100HD and S 120HD 127 P2 7 Che
182. us injury jack of ample capacity 20 000 Ibs 10 000 kg and property damage 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 Ibs 16000 kg under each of the steer yokes at the circle end of the machine Genie 122 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual wer P n 5T m a EU i Programmed Maintenance Procedures Steer or Square end wheels 4WD Models 7 Chock the non steer circle end wheels or tracks to prevent the machine from rolling 8 Models with 2 wheel steer Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer tires Models with 4 wheel steer Place a lifting jack of ample capacity 35 000 Ibs 16000 kg under each of the steer yokes at the square end of the machine 9 Lift the wheels or tracks off the ground and then place jack stands under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer square end wheel hub f 9 VES 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 a
183. use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications Refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary Replace the oil when it fails the test Refer to Maintenance Procedure Test or Replace the Hydraulic Oil Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 39 Maintenance Manual September 2015 Quarterly Maintenance Procedures 1 Collect a sample of hydraulic oil and place in a clear container Visually inspect the hydraulic oil for the following e Color oil should be a clear light honey colored e Appearance oil should be clear and not cloudy or visibly distorts the view through the sight glass or container e Contains no particles foreign objects or other contamination e The hydraulic oil can be inspected by smell can smell hot but not burnt or rubbing between fingers should feel viscous and free of any rough feel due to particles Ifthe hydraulic oil passes all of the above inspections continue the scheduled maintenance intervals B Ifthe hydraulic oil fails any of the above inspections the hydraulic oil must be tested by an oil distributor or replaced Note If the hydraulic oil was not replaced at or before the
184. ve 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 A WARNING Crushing hazard The turntable rotate drive hub assembly could become unbalanced and fall when removed from the machine if not properly supported by the lifting device 5 Remove the plug from the side of the drive hub Drain the oil from the hub into a suitable container 6 Install the drive hub assembly onto the machine Lubricate and torque the drive hub mounting bolts to specification Refer to Specifications Machine Torque Specifications 7 Fillthe drive hub with oil Apply pipe thread sealant to the plug Install the plug Refer to Specifications Hydraulic Specifications 8 If equipped 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 Genie ATEREX BRAND Part No 1268489 S Booms Z Booms 117 Maintenance Manual September 2015 Programmed Maintenance Procedures P2 1 Perform Engine Maintenance 2000 Hours Engine specifications require that this procedure be performed every 2000 hours Required maintenance procedures and additiona
185. vel Sensor 6 Place the digital level on top of the secondary boom close to the pivot end of the secondary boom Result The reading at the display and digital level is equal to or greater than 75 5 amp Result The reading at the display and digital level is less than 75 5 The secondary boom angle sensor must be calibrated Refer to Repair Procedure in the appropriate Service and Repair Manual for your machine How to Calibrate the Secondary Boom Angle Sensor ADANGER Tip over hazard If the boom is not equal to or greater than 75 5 immediately lower the secondary 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 Secondary Boom Angle Sensor TA Ganie 60 S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Lower the secondary boom to 65 10 Lower the secondary boom to 20 Result The reading at the display and digital Result The reading at the display and digital level is within 2 of each other and of 65 level is within 2 of each other and of 20 Result The reading at the display and digital R Result The reading at the display and digital level is greater than 2 of each other and of level is greater than 2 of each other and o
186. wear pads 0 50 inch 0 625 inch 15 9 mm pivot end of boom 12 7 mm Side wear pads 0 375 inch pivot end of boom 9 5 mm ln Secondary boom wear pad Minimum a specifications Top wear pads 0 375 inch me extension end of boom 9 5mm Side wear pads 0 50 inch 0 50 inch extension end of boom 12 7 mm 12 7 mm Bottom wear pads 7 8 inch 0 875 inch extension end of boom 22 mm zem Top and bottom wear pads 0 625 inch pivot end of boom 15 9 mm Side wear pads 0 50 inch pivot end of boom 12 7 mm Jib boom wear pad specifications Minimum Bottom and side wear pads 0 625 inch platform end of boom 15 9 mm Top wear pads 0 50 inch platform end of boom 12 7 mm Top and side wear pads 0 375 inch pivot end of boom 9 5 mm Bottom wear pads 0 625 inch pivot end of boom 15 9 mm Genie S Booms Z Booms Part No 1268489 September 2015 Maintenance Manual Programmed Maintenance Procedures P2 6 Check the Extendable Axle Wear Pads S 100 S 105 S 120 S 125 S 100HD and S 120HD Genie requires that this procedure be performed every 2000 hours Maintaining the axle wear pads in good condition is essential to safe machine operation Wear pads are placed on axle tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of worn out wear pads may result in component damage and unsafe operating conditions Note Be sure that the axles are fully extended bef
187. wiring circuit is faulty and will need to be replaced or repaired CY es Bodily injury hazard If the secondary boom continues to extend without stopping the engine stop immediately and retract the secondary boom Failure to retract the secondary boom could result in death or serious injury Remove the wire jumpers installed in step 22 and connect the wire harness to LSS2A0O Re connect the Deutsch connector from the secondary boom 2 angle safety limit switch LSS2AS removed in step 20 Part No 1268489 September 2015 Maintenance Manual Quarterly Maintenance Procedures Q 32 3 Turnand hold the function enable switch to the Check the Safety Envelope Limit Switches and Angle Sensor S 60X S 60XC and S 80X Genie specifications require that this procedure be performed quarterly Testing the safety envelope system regularly is essential to safe machine operation Continued use of an improperly operating safety envelope could result in the system not restricting the range of motion Machine stability could be compromised resulting in the machine tipping over Note Perform this procedure with the machine on a firm level surface with all weight tools and equipment removed from the platform Note Start this procedure 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 Startthe en
188. y tie if equipped 5 Turn the key switch to platform controls 6 Atthe platform controls break the security tie and lift the emergency power switch cover if equipped 7 Press down on the foot switch and simultaneously 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 function is essential to good engine performance and safe machine operation There are two settings Low idle turtle symbol allows the operator to control individual boom functions Drive functions will operate at low idle on most models but at reduced performance High idle rabbit symbol should be used for normal machine operation S 100 S 105 S 120 S 125 S 100HD S 120HD SX 150 SX 180 Z 80 60 Z 135 70 and ZX 135 70 Models 1 Turn the key switch to ground controls 2 Pullout the red Emergency Stop button to the on position at both the ground and platform controls 3 Startthe engine from the ground controls 4 Pushandrelease the rpm select button until high rpm is selected rabbit symbol Result The engine should change to high idle Genie 48 S Booms Z Booms Part

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