Genie S-40 TRAX User manual

Maintenance Manual -
Booms
S Booms
This manual includes detailed
procedures for each
maintenance inspection.
Z Booms
For Repair procedures, Fault
Codes, Electrical and Hydraulic
Schematics, refer to the
appropriate Service and Repair
Manual for your machine.
Refer to the inside cover for a list of models
included
in this manual.
Part No. 1268489
Rev B
1
April 2016

Maintenance Manual April 2016
Introduction
ii S Booms • Z Booms Part No. 1268489
Intr od ucti o n Intr od ucti o n
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.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest
degree of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Copyright © 2015 by Terex Corporation
1268489 Rev B, March 2016
First Edition, Second 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.

April 2016 Maintenance Manual
Introduction
Part No. 1268489 S Booms • Z Booms iii
Models included in this manual
Use the following chart to identify the specific serial
number for models included in this manual.
Models
Serial number
S
-40 / S-45
from S4015
-20505
S
-60 / S-65 (all models)
from S6013
-26296
from S6014D
-101
S
-80 / S-85
from S80/85/80X15
-12264
S
-100 / S-105
from S10015D
-1001
from S10515D
-1012
S
-120 / S-125
from S12015D
-1012
from S12515D
-984
S
-100HD / S-120HD
from S100HD14D
-200
from S120HD14D
-201
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
-60/37 DC / Z-60/37 FE
from Z6016N
-101
Z
-62/40
from Z6215A
-101
Z
-80/60
from Z8013
-4592
Z
-135/70
from Z13505
-101 to
Z13513
-2000
ZX
-135/70
from ZX13514
-2533
(includes 2463, 2469, 2531)
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 that apply to specific
models:
•Test the Engine Idle Select - Engine
Models
•Test the Turntable Level Sensor - Z-80/60
•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:
•Test the Drive Speed – Stowed Position
•Inspect the Tires, Wheels and Lug Nut
Torque
Find additional Manuals for your
Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.

Maintenance Manual April 2016
Introduction
iv S Booms • Z Booms Part No. 1268489
Revision History
Revision Date Section Procedure / Description
A 9/2015 Initial Release
A1 10/2015 Quarterly Q-27 Test the Primary Angle Sensor
A2 11/2015 Specifications Hydraulic and Drive Hub Capacities
A3 11/2015 Introduction Updated Z-80/60 serial number for models included
A4 12/2015 Quarterly Q-17 Inspect the Calibration Decal
A5 1/2016 Specifications Performance Spec. Z62
B 3/2016 Add Z-60 DC/FE
Specifications Add Kubota D1105-E4B, GM .998L, GM 3.0L.
Update Deutz D2.9 L4 and Perkins 404F enigine rpm’s.
B1 4/2016 Quarterly Q-7 Check the Generator Belts, Pulleys and voltage -
Bi-Energy Models
Annual A-3 Inspect for Turntable Bearing Wear
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Maintenance, (procedure)

April 2016 Maintenance Manual
Introduction
Part No. 1268489 S Booms • Z Booms v
Revision History (continued)
Revision Date Section Procedure / Description
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Maintenance, (procedure)

Maintenance Manual April 2016
Safety Rules
vi S Booms • Z Booms Part No. 1268489
Section 1 Safet y R ul es
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:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

April 2016 Maintenance Manual
Safety Rules
Part No. 1268489 S Booms • Z Booms vii
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.
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.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
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
warrants it.
Be aware of potential crushing hazards
such as moving parts, free sw
inging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from 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 ful
ly
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. Thes
e 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.

April 2016
Table of Contents
viii S Booms • Z Booms Part No. 1268489
Introduction Introduction .......................................................................................................... ii
Important Information ..............................................................................................ii
Models included in this manual..............................................................................iii
Identifying the Correct Procedure for your Model ..................................................iii
Find additional Manuals for your Model .................................................................iii
Revision History .....................................................................................................iv
Section 1 Safety Rules......................................................................................................... vi
General Safety Rules .............................................................................................vi
Section 2Performance Specifications................................................................................ 1
Function Speeds - S-100, S-105 and S-100HD..................................................... 1
Function Speeds - S-120, S-125 and S-120HD..................................................... 2
Function Speeds - All Other Models ...................................................................... 3
Drive Speeds.......................................................................................................... 7
Torque Specifications ......................................................................................... 9
Tires and Wheels ................................................................................................... 9
TRAX Torque Specifications................................................................................ 10
Engine Specifications........................................................................................ 11
Engine Operator and Maintenance Manuals ....................................................... 11
Deutz Engine Models ........................................................................................... 12
Perkins Engine Models ........................................................................................ 13
Ford Engine Models ............................................................................................. 14
Kubota Engine Models ......................................................................................... 15
GM Engine Models .............................................................................................. 16
Continental Engine Models .................................................................................. 16
Cummins Engine Models ..................................................................................... 17
Hydraulic Specifications ................................................................................... 18
Hydraulic Relief Valves ........................................................................................ 18
Hydraulic and Drive Hub Fluid Capacities ........................................................... 20
Hydraulic Oil Specifications ................................................................................. 23
Hydraulic Hose and Fitting Torque Specifications ............................................... 26
Torque Procedure ................................................................................................ 27

April 2016
Table of Contents
Part No. 1268489 S Booms • Z Booms ix
Section 3 Maintenance Procedures...................................................................................29
Introduction...........................................................................................................29
Maintenance Schedule.........................................................................................31
Pre-Delivery Preparation Report ..........................................................................32
Scheduled Maintenance Inspection Report - Booms ...........................................33
Programmed Maintenance Inspection Report - Booms .......................................34
Commissioning Procedures..............................................................................35
C-1 Perform 50 Hour Service ...............................................................................35
C-2 Perform Engine Maintenance – 50 Hours .....................................................35
C-3 Perform 150 Hour Service .............................................................................36
Quarterly Maintenance Procedures..................................................................37
Q-1 Check for Open Bulletins and Owner Registration .......................................37
Q-2 Battery inspection..........................................................................................38
Q-3 Inspect the Electrical Wiring ..........................................................................40
Q-4 Inspect the Electrical Contactor - DC / Bi-Energy Models ............................41
Q-5 Check the Exhaust System ...........................................................................42
Q-6 Inspect the Tires, Wheels and Lug Nut Torque.............................................42
Q-7 Check the Generator Belts and Pulleys, Bi-Energy Models..........................43
Q-8 Check the Oscillate Directional Valve Linkage (if equipped) ........................44
Q-9 Visual Inspection of the Hydraulic Oil............................................................45
Q-10 Inspect the Hydraulic Filters ........................................................................46
Q-11 Check and Adjust the Engine RPM .............................................................47
Q-12 Test the Ground Control Override ...............................................................52
Q-13 Test the Alarm Package (if equipped) .........................................................52
Q-14 Test the Emergency Power System ............................................................53
Q-15 Test the Engine Idle Select - Engine Models ..............................................54
Q-16 Test the Fuel Select Operation - Gasoline/LPG Models .............................55

April 2016
Table of Contents
x S Booms • Z Booms Part No. 1268489
Q-17 Inspect the Calibration Decal - ALC1000 Models ....................................... 56
Q-18 Test the Recovery Mode System - ALC-1000 Models ............................... 57
Q-19 Test the Platform Self-leveling .................................................................... 59
Q-20 Confirm the Proper Brake Configuration..................................................... 59
Q-21 Test the Drive Brakes ................................................................................. 60
Q-22 Test the Drive Speed – Stowed Position .................................................... 60
Q-23 Test the Drive Speed - Raised or Extended Position ................................. 61
Q-24 Test the Drive Speed – Raised and Extended, ALC1000 Models.............. 62
Q-25 Test the Turntable Level Sensor -
Z-135/70, ZX135/70, SX-150 and SX-180 ................................................... 63
Q-26 Test the Secondary Boom Angle Sensor - Z-135/70 and ZX135/70 .......... 65
Q-27 Test the Primary Boom Angle Sensor - Z-135/70 and ZX135/70 ............... 67
Q-28 Test the Primary Boom Angle Sensor - SX-150 and SX-180 ..................... 70
Q-29 Test the Safety Envelope Limit Switches -
Z-135/70, ZX135/70, SX-150 and SX-180 Models ...................................... 72
Q-30 Test the Primary Boom Angle Sensor - Z-80/60......................................... 76
Q-31 Test the Safety Envelope and Circuits - Z-80/60 ........................................ 77
Q-32 Check the Safety Envelope Limit Switches and Angle Sensor -
S-60X, S-60XC and S-80X........................................................................... 79
Q-33 Test the Safety Envelope and Circuits -
S-100, S-105, S-120 and S-125................................................................... 81
Q-34 Test the Aircraft Protection System (if equipped) ....................................... 87
Q-35 Test the Operator Protection Alarm (if equipped) ....................................... 89