Terex Genie Lift Guard S-40 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. 1268489GT
Rev J
May 2020

Maintenance Manual May 2020
Introduction
ii S®Booms • Z®Booms Part No. 1268489GT
Introduction 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.
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: awp.techpu[email protected]
Copyright © 2015 by Terex Corporation
1268489GT Rev J, May 2020
First Edition, Ninth Printing
Genie, "S" and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
"TraX" and "XC" are trademarks of Terex South Dakota, Inc.

May 2020 Maintenance Manual
Introduction
Part No. 1268489GT 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, S-
40HF, S-45HF,
S-40XC,
S-45XC
from S4015-20505 to S4016H-23499
from S4515-20505 to S4516H-23499
from S40H-23500 from S45H-23500
from S40XCH-101
from S45XCH-101
S-60, S-65, S-
60HF, S-65HF,
S-60J, S-60X,
S-60XC, S-
65XC
from S6013-26296 to S6016-31260
from S6016N-31261 to S6016N-35000
from S6016H-35001 to S6016H-36399
from S6014D-101 to S6016D-639
from S6016M-101 to S6016M-399
from S60X13-26296 to S60X16H-36399
from S60XC13-26296 to S60XC16H-36399
from S60HC13-26296 to S60HC15A-
29544 from S60TX13-26296 to S60TX16H-
36399
from S60TX14D-101 to S60TX16D-639
from S65TX13-26296 to S65TX16H-36399
from S65TX14D-101 to S65TX16D-639
from S60H/S60X/S60TX/S65TXH-36400
from S60XCH-36400 to S60XCH-45000
from S60XCH/S65XCH-45001
from S60/S60TX/S60XD-640
from S60JH-101
from S60M-400
from S65XCM-101
from S65TXM-101
S-80, S-85, S-
80X, S-80XC,
S-85XC. S-
80HF, S-85HF
from S80/85/80X15-12264 to16H-13999
from S80/85/80X15D-101 to 16D-339
from S80/85/80XH-14000
from S80/85/80XD-340
from S80/85XCH-101
S-100, S-105
from S10015D-1001 to S10016D-1549
from S10515D-983 to S10516D-1549
from S100D-1550
from S105D-1550
S-120, S-125
from S12015D-1012 to S12016D-1549
from S12515D-984 to S12516D-1549
from S120D-1550
from S125D-1550
S-100HD,
S-120HD
from S100HD14D-200 to S100HD16D-229
from S120HD14D-201 to S120HD16D-229
from S100/S120HDD-230
SX-105 XC
from SX105D-101
SX-125 XC
from SX125D-101
SX-135 XC
from SX135H-101
SX-150
from SX15015-100 to SX15016H-499
from SX150H-500
SX-180
from SX18014-101 to SX18016H-599
from SX180H-600

Maintenance Manual May 2020
Introduction
iv S®Booms • Z®Booms Part No. 1268489GT
Z-30/20N, Z-
30/20N RJ
from Z30N14-15222 to Z30N16F-18899
from Z30N16D-104 to Z30N16D-199
from Z30NF-18900
from Z30ND-200
Z-33/18
from Z331815M-101 to Z331816M-1299
from Z3318M-1300
Z-34/22 DC
from Z3414-9686 to Z3416F-11999
from Z34F-12000
Z-34/22 N
from Z34N14-10984 to Z34N16F-13999
from Z34N15D-102 to Z34N16D-279
from Z34NF-14000
from Z34ND-280
Z-34/22 IC
from Z3406-4800 to Z3413-9460
from Z3413-9461 to Z3415-10688
from Z3416F-10689 to Z3416F-11999
from Z34F-12000
Z-34/22 BE
from Z3414-9686 to Z3416F-11999
from Z34F-12000
Z-40/23N RJ
from Z40N13-1902 to Z40N16N-4499
from Z40NN-4500
Z-45/25 DC, Z-
45/25J DC
from Z452513A-48153 to Z452516N-57199
from Z452513B-3078 to Z452516M-6699
from Z452513D-101 to Z452516D-939
from Z4525D-940
from Z4525M-6700
from Z4525N-57200 to Z4525N-58604
from Z4525F-58605
Z-45/25 IC, Z-
45/25J IC, Z-
45HF, Z-45XC
from Z452513A-47001 to Z452516N-57199
from Z452514B-3301 to Z452516M-6699
from Z452513D-101 to Z452516D-939
from Z4525D-940
from Z4525M-6700
from Z4525N-57200 to Z4525N-58604
from Z4525F-58605
from Z4525XCF-101
from Z4525XCM-101
Z-45/25(J) BE
from Z452513A-48153 to Z452516N-57199
from Z4525N-57200 to Z4525N-58604
from Z4525F-58605
from Z4525M-6700
Z-45 DC, Z-45
FE
from Z45EM-101
Z-51/30J
from Z513014B-1201 to Z5130M-2000
from Z5130M-2000
Z-60/37 DC,
Z-60/37 FE
from Z6016N-101 to Z6016N-599
from Z60N-600 to Z60N-700
from Z60H-701
Z-62/40
from Z6215A-101 to Z6216N-2999
from Z6216D-101 to Z6216D-149
from Z6216M-101 to Z6216M-399
from Z62D-150
from Z62H-3000
from Z62M-400
Z-80/60
from Z8013-4592 to Z8016H-6399
from Z80H-6400
Z-135/70
from Z13505-101 to Z13513-2000
ZX-135/70
from ZX13514-2533 to ZX13516H-3199
(includes 2463, 2469, 2531)
from ZX135H-3200

May 2020 Maintenance Manual
Introduction
Part No. 1268489GT S®Booms • Z®Booms v
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
•ALC600 Models, include the following
models: S-40HF, S-45HF, S-40 XC, S-45
XC, S-60HF, S-65HF, S-60J, S-60 XC from
S60XCH-45001, S-65 XC, S-80HF, S-
85HF, S-80 XC and S-85 XC.
•ALC1000 Models, include the following
models: S-100, S-100HD, S-105, S-120, S-
120HD, S-125, SX-105 XC, SX-125 XC,
SX-135 XC, SX-150, SX-180, Z-80/60, Z-
135/70 and ZX-135/70.
Examples of procedures that apply to all models:
•Test the Drive Speed –Stowed Position
•Inspect the 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 May 2020
Introduction
vi S®Booms • Z®Booms Part No. 1268489GT
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
All Sections
Add Z-60 DC/FE
Specifications
Add Kubota D1105-E4B, GM .998L, GM 3.0L.
Update Deutz D2.9 L4 and Perkins 404F engine rpm's
B1
4/2016
Quarterly
Q-7 Check the Generator Belts, Pulleys and voltage - Bi-
Energy Models
Annual
A-3 Inspect for Turntable Bearing Wear
B2
6/2016
Specifications
Tires and Wheels, add Z60 DC/FE
B3
9/2016
Introduction
Models Included
C
11/2016
All Sections
Add SX-135 XC
C1
12/2016
Quarterly
Q-26 Test the Secondary Boom Angle Sensor
D
2/2017
Quarterly
Q-36 Inspect and Adjust Boom Cables
Annual
A-3 Inspect Turntable Bearing Wear
A-11, A-12, A-13 Inspect Boom Cables
Programmed
P12-2 Remove and Inspect Boom Cables
E
3/2017
All Sections
Add SX-125 XC. Add Z-45 XC CE/AS Models
E1
3/2017
Programmed
Remove 10 year cable inspection
F
6/2017
All Sections
Add S80/85 XC, SX-105 XC
Specifications
Add Deutz D436 L3i CN3 Engine
F1
4/2018
Specifications
Deutz TD2011 Engine Specifications
G
10/2018
All Sections
Add S60XC, S-65XC, S-80HF, S-85HF Models
Add Perkins 404F-E22T, 404F-E22TA Engine
H
5/2019
All Sections
Add S60/S65/Z45XC ANSI/CSA, S60/65HF, S40/S45XC
Models
Quarterly
Q-17, Q-33
Reference Examples:
Section –Specifications
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section –Maintenance, (procedure)

May 2020 Maintenance Manual
Introduction
Part No. 1268489GT S®Booms • Z®Booms vii
Revision History (continued)
Revision
Date
Section
Procedure / Description
J
2/2020
All Sections
Add S40/45HF, S60J, Z45DC/FE, Z45HFmodels. Add
Deutz TD/TCD 2.2 L3 engine
Specifications
Hydraulic Specifications
Annual
A-11, A-12, A-13
Programmed
P0-6, P1-1
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 May 2020
Safety Rules
viii S®Booms • Z®Booms Part No. 1268489GT
Section 1 SafetyRul 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.

May 2020 Maintenance Manual
Safety Rules
Part No. 1268489GT S®Booms • Z®Booms ix
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 swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Workplace Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Be sure to keep sparks, flames and
lighted tobacco away from 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.

May 2020
Table of Contents
x S®Booms • Z®Booms Part No. 1268489GT
Introduction Introduction......................................................................................................ii
Important Information..........................................................................................ii
Models included in this manual...........................................................................iii
Identifying the Correct Procedure for your Model................................................ v
Find additional Manuals for your Model .............................................................. v
Revision History.................................................................................................vi
Section 1 Safety Rules.................................................................................................. viii
General Safety Rules.......................................................................................viii
Section 2 Performance Specifications............................................................................1
Function Speeds - S-100, S-105 and S-100HD ..................................................1
Function Speeds - S-120, S-125 and S-120HD ..................................................2
Function Speeds - All Other Models ...................................................................3
Drive Speeds.....................................................................................................9
Torque Specifications....................................................................................12
Tires and Wheels.............................................................................................12
TraX Torque Specifications..............................................................................14
Engine Specifications....................................................................................15
Engine Operator and Maintenance Manuals.....................................................15
Deutz Engine Models.......................................................................................16
Perkins Engine Models.....................................................................................17
Ford Engine Models.........................................................................................19
Kubota Engine Models.....................................................................................20
GM Engine Models...........................................................................................21
Continental Engine Models...............................................................................21
Cummins Engine Models .................................................................................22
Hydraulic Specifications................................................................................ 23
Hydraulic Relief Valves ....................................................................................23
Hydraulic and Drive Hub Fluid Capacities.........................................................26
Hydraulic Oil Specifications..............................................................................28
Hydraulic Hose and Fitting Torque Specifications............................................. 31
Torque Procedure............................................................................................32