Maintenance Manual - Booms: S Booms Z Booms

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 Part No. 1268489
included in this manual.
Rev A4
December 2015
Maintenance Manual December 2015
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Genie of errors
and user. and send in suggestions for improvement. All
communications will be carefully considered for
Basic mechanical, hydraulic and electrical skills are future printings of this and all other manuals.
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these Contact Us:
instances, we strongly recommend that
maintenance be performed at an authorized Genie Internet: www.genielift.com
dealer service center. E-mail: awp.techpub@terex.com
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life

Unrestricted with proper operation, inspection and
scheduled maintenance.
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.
ii S Booms • Z Booms Part No. 1268489

December 2015 Maintenance Manual
Introduction
Models included in this manual Identifying the Correct Procedure

Use the following chart to identify the specific for your Model
serial number for models included in this manual.
Unless otherwise noted, each procedure will apply
Models Serial number to all models. Procedures that only apply to
specific models or options will include the
S-40 / S-45 from S4015-20505
information in the procedure title.
S-60 / S-65 (all models) from S6013-26296
from S6014D-101 Examples of procedures that apply to specific
S-80 / S-85 from S80/85/80X15-12264 models:
S-100 / S-105 from S10015D-1001
from S10515D-1012 • Test the Engine Idle Select - Engine
S-120 / S-125 from S12015D-1012
Models
from S12515D-984
• Test the Turntable Level Sensor - Z-80/60
S-100HD / S-120HD from S100HD14D-200
from S120HD14D-201 • ALC1000 Models, include the following
SX-150 from SX15015-100 models: S-100, S-100HD, S-105, S-120,
SX-180 from SX18014-100
S-120HD, S-125, SX-150, SX-180, Z-80/60,
Z-135/70 and ZX-135/70.
Z-30/20N (RJ) from Z30N14-15222
Z-33/18 from Z331815M-101 Examples of procedures that apply to all models:
Z-34/22 DC from Z3414-9686 • Test the Drive Speed – Stowed Position
Z-34/22 N from Z34N14-10984
• Inspect the Tires, Wheels and Lug Nut
Z-34/22 IC from Z3406-4800
Torque
Z-34/22 BE from Z3414-9686
Z-40/23N RJ from Z40N13-1902 Find additional Manuals for your
Z-45/25(J) DC from Z452513A-48153
from Z452513B-3078 Model
from Z452513D-101
Go to http://www.genielift.com
Z-45/25(J) IC from Z452513A-47001
from Z452514B-3301 Use the links to locate Service Manuals,
Z-45/25(J) BE from Z452513A-48153 Maintenance Manuals, Service and Repair
Z-51/30J from Z513014B-1201 Manuals, Parts Manuals and Operator's Manuals.
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)
Part No. 1268489 S Booms • Z Booms iii

Introduction
Revision History
Revision Date Section Procedure / Description
A 9/2015 Initial Release
A1 10/2015 Quarterly Q-27 Test the Primary Boom 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
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Maintenance, (procedure)
the update.
iv S Booms • Z Booms Part No. 1268489

Introduction
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
Section – Maintenance, (procedure)
the update.
Part No. 1268489 S Booms • Z Booms v

Safety Rules
Section 1 Safety R ules
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.
vi S Booms • Z Booms Part No. 1268489

Safety Rules
Personal Safety Workplace Safety

Any person working on or around a machine must Any person working on or around a machine must
be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal
safety and the continued safe operation of the safety and the continued safe operation of the
machine should be your top priority. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the machine, lighted tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
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.
Part No. 1268489 S Booms • Z Booms vii

December 2015
Table of Contents
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
Section 1 Safety Rules......................................................................................................... vi

General Safety Rules .............................................................................................vi
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 .......................................................................................................... 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
Continental Engine Models .................................................................................. 15
Cummins Engine Models ..................................................................................... 16
Hydraulic Specifications ................................................................................... 17

Hydraulic Relief Valves ........................................................................................ 17
Hydraulic and Drive Hub Fluid Capacities ........................................................... 19
Hydraulic Specification ......................................................................................... 20
Hydraulic Hose and Fitting Torque Specifications ............................................... 22
Torque Procedure ................................................................................................ 23
viii S Booms • Z Booms Part No. 1268489

December 2015
Table of Contents
Section 3 Maintenance Procedures ................................................................................... 25

Introduction ........................................................................................................... 25
Maintenance Schedule ......................................................................................... 27
Scheduled Maintenance Inspection Report - Booms ........................................... 28
Programmed Maintenance Inspection Report - Booms ....................................... 29
Commisioning Procedures................................................................................ 30
C-1 Perform 50 Hour Service ............................................................................... 30
C-2 Perform Engine Maintenance – 50 Hours ..................................................... 30
C-3 Perform 150 Hour Service ............................................................................. 31
Quarterly Maintenance Procedures .................................................................. 32

Q-1 Check for Open Bulletins............................................................................... 32
Q-2 Battery inspection .......................................................................................... 33
Q-3 Inspect the Electrical Wiring .......................................................................... 35
Q-4 Inspect the Electrical Contactor..................................................................... 36
Q-5 Check the Exhaust System ........................................................................... 36
Q-6 Inspect the Tires, Wheels and Lug Nut Torque............................................. 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 ............................................................ 39
Q-10 Inspect the Hydraulic Filters ........................................................................ 40
Q-11 Check and Adjust the Engine RPM ............................................................. 41
Q-12 Test the Ground Control Override ............................................................... 46
Q-13 Test the Alarm Package (if equipped) ......................................................... 47
Q-14 Test the Emergency Power System ............................................................ 48
Q-15 Test the Engine Idle Select - Engine Models .............................................. 48
Q-16 Test the Fuel Select Operation - Gasoline/LPG Models ............................. 50
Part No. 1268489 S Booms • Z Booms ix

December 2015
Table of Contents
Q-17 Inspect the Calibration Decal –

SX-150, SX-180, Z-135/70 and ZX-135/70 Models ..................................... 51
Q-18 Test the Recovery Mode System - ALC-1000 Models ............................... 52
Q-19 Test the Platform Self-leveling .................................................................... 53
Q-20 Confirm the Proper Brake Configuration ..................................................... 54
Q-21 Test the Drive Brakes ................................................................................. 54
Q-22 Test the Drive Speed – Stowed Position .................................................... 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 ................................................... 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 ...................................... 66
Q-30 Test the Primary Boom Angle Sensor - Z-80/60 ......................................... 70
Q-31 Test the Turntable Level Sensor - Z-80/60 ................................................. 71
Q-32 Check the Safety Envelope Limit Switches and Angle Sensor -
S-60X, S-60XC and S-80X........................................................................... 73
Q-33 Test the Safety Envelope and Circuits -
S-100, S-105, S-120 and S-125 ................................................................... 75
Q-34 Test the Aircraft Protection System (if equipped) ....................................... 81
Q-35 Test the Operator Protection Alarm (if equipped) ....................................... 83
x S Booms • Z Booms Part No. 1268489

December 2015
Table of Contents
Annual Maintenance Procedures...................................................................... 84

A-1 Grease the Turntable Rotation Bearing and Rotate Gear ............................. 84
A-2 Check the Turntable Rotation Bearing Bolts ................................................. 85
A-3 Inspect for Turntable Bearing Wear ............................................................... 86
A-4 Check the Extendable Axle - S-100, S-105, S-120 and S-125 ...................... 87
A-5 Perform Maintenance- Jib Rotate Bearing ................................................... 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 ...................................... 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 .................................................................................. 96
A-12 Inspect the Boom Extend/Retract Cables -
S-100, S-105, S-120 and S-125 Models ...................................................... 98
A-13 Inspect the Boom Extend and Retract Cables -
SX-150 and SX-180 Models ......................................................................... 99
A-14 Check the Drive Hub Oil Level and Fastener Torque ................................ 101
Part No. 1268489 S Booms • Z Booms xi

December 2015
Table of Contents
Programmed Maintenance Procedures ......................................................... 104

P0-1 Check the Track Tension and Fastener Torque,
TRAX Models - S-60, S-65 and Z-62 Models ............................................ 104
P0-2 Check the Track Tension and Fastener Torque,
TRAX Models - S-40 and S-45 Models ...................................................... 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...................................... 110
P0-7 Ford Engine Maintenance – Under 1000 Hours........................................ 111
P0-8 Kubota Engine Maintenance – Under 1000 Hours.................................... 112
P0-9 Perkins Engine Maintenance – Under 1000 Hours ................................... 113
P1-1 Perform Engine Maintenance – 1000 Hours ............................................. 114
P1-2 Replace the Drive Hub Oil ......................................................................... 115
P2-2 Test or Replace the Hydraulic Oil ............................................................. 119
P2-3 Replace the Hydraulic Filters .................................................................... 120
P2-4 Check the Free-wheel Configuration ......................................................... 122
P2-5 Check the Boom Wear Pads ..................................................................... 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 Check the Turntable Rotation Gear Backlash ........................................... 127
P2-8 Grease the Steer Axle Wheel Bearings,
All 2WD Models (except Z-62/40 and S-60 / S-65) .................................... 128
P2-9 Grease the Steer Axle Wheel Bearings,
2WD Models - Z-62/40 and S-60 / S-65 ..................................................... 130
P12-1 Perform Engine Maintenance – 12000 Hours ......................................... 133
P12-2 Replace the Boom Extend/Retract Cables -
S-100HD and S-120HD .............................................................................. 134
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 ................................................................................... 134
xii S Booms • Z Booms Part No. 1268489

Performance Specifications
Section 2 Performanc e Specific ati ons
Function Speeds - S-100,

S-105 and S-100HD Models
Note: Function speeds are maximum from platform
controls with maximum rated load in platform.
Primary boom up/down, 80 - 88 seconds
(retracted)
extended to >4 ft / >1.2 m
(time from fully stowed to the
fully raised position)
(time from 53° envelope limit to
the fully raised position)
Primary boom extend, 120 - 140 seconds
fully raised position
(0 to 100 ft / 0 to 30.5 m)
Primary boom retract, 120 - 140 seconds
(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
Turntable rotate, 63 - 70 seconds
boom horizontal and extended drive enable to drive enable
>0 ft / >0 m
boom fully raised and extended drive enable to drive enable
>80 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
Part No. 1268489 S Booms • Z Booms 1

Function Speeds - S-120,

S-125 and S-120HD Models
Note: Function speeds are maximum from platform
controls with maximum rated load in platform.
(retracted)
(time from fully stowed to the
fully raised position)
extended to >100 ft / 30.5 m
Primary boom extend, 170 - 190 seconds
(0 to 100 ft / 0 to 30.5 m)
Primary boom retract, 170 - 190 seconds
(100 to 0 ft / 30.5 to 0 m)
Jib boom up/down, 28 - 32 seconds
(S-125 models)
Turntable rotate, 360° 170 - 190 seconds
boom horizontal and fully
retracted
boom horizontal and extended drive enable to drive enable
>0 ft / >0 m
boom fully raised and extended drive enable to drive enable
>80 ft / >24.4 m
Platform rotate 18 - 22 seconds
2 S Booms • Z Booms Part No. 1268489

Function Speeds - All Other Models

Note: Function speeds are maximum from platform controls with maximum rated load in platform.
Function S-40, S-45 S-60, S-65, S-60HC, S-80, S-85, S-80X S-80, S-85
(includes TRAX S-60X, S-60XC (ANSI/CSA models) (AS/CE models)
models) (includes TRAX
models)
Primary boom up 50 - 60 seconds 60 - 70 seconds 57 - 65 seconds 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 6 - 10 seconds 8 - 12 seconds 8 - 12 seconds 8 - 12 seconds
Function Z-30N, Z-30N RJ Z-34 BE Z-34N, Z-34 Z-33

(DC models)
(retracted)
48 - 52 second
(extended)
(retracted)
55 - 59 seconds
(extended)
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 5 - 11 seconds 5 - 11 seconds 5 - 11 seconds X
Platform level ANSI/CSA 3 - 5 seconds 10 - 12 seconds

Function Z-34 IC Z-40N, Z-40N RJ Z-45/25, Z-45/25J Z-45/25, Z-45/25J
(DC, BE models) (IC models)
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 X X
(Z40N RJ)
Turntable rotate 62 - 72 seconds 62 - 68 seconds 95 - 125 seconds 62 - 68 seconds
Platform rotate 5 - 11 seconds 10 - 14 seconds 6 - 10 seconds 6 - 10 seconds
Function Z-51 Z-62 Z-80

(includes TRAX models)
Primary boom up 36 - 40 seconds 60 - 70 seconds 60 - 70 seconds
(retracted)
80 - 96 seconds
(extended)
Primary boom down 36 - 40 seconds 60 - 70 seconds 75 - 85 seconds
(retracted)
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 114 - 126 seconds
(stowed) (retracted)
125 - 165 seconds 200 - 240 seconds
(extended) (extended)
Platform rotate 6 - 10 seconds 10 - 14 seconds 10 - 14 seconds

Function Z-135 ZX-135
Primary boom up/down 88 - 105 seconds 110 - 125 seconds
Primary boom extend/retract 38 - 42 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 27 - 38 seconds
Turntable rotate stowed 88 - 92 seconds 88 - 92 seconds
Turntable rotate 160 - 180 seconds 160 - 180 seconds
(jib or primary boom extended)
Turntable rotate 280 - 350 seconds 280 - 350 seconds
(jib and primary boom extended)
Platform rotate 20 - 25 seconds 20 - 25 seconds

Function SX-150 SX-180
Primary boom up/down, 80 - 88 seconds 80 - 88 seconds
(stowed) 82° 82°
string pot = 76 in / 193 cm 82° 82°
string pot = 158 in / 401 cm 20° 20°
string pot = 238 in / 605 cm 20° 20°
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, 30 - 33 seconds 30 - 33 seconds
0 - 100 in / 254 cm
Primary boom retract, 30 - 33 seconds 30 - 33 seconds
100 in / 254 cm - 0
Jib boom up/down 58 - 62 seconds 58 - 62 seconds
Jib boom rotate 28 - 32 seconds 28 - 32 seconds
Turntable rotate, 38 - 42 seconds 38 - 42 seconds
drive enable to drive enable (80°)
(stowed)
string pot = 36 in / 91.4 cm)
string pot = 76 in / 193 cm
(above 75 ft / 22.8 m)
string pot = 258 in / 655 cm
(above 125 ft / 38.1 m)
Platform rotate 20 - 24 seconds 20 - 24 seconds

Drive Speeds
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 40 ft / 12.2 m 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 / 12.2 m
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 - 6 ft
high range on paved surface 0.9 - 1.2 m 0.9 - 1.8 m 0.9 - 1.8 m 1.2 - 1.8 m
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
4WD models, 9.8 - 11.8 seconds X X X
2WD or 4WD, 68 - 75.5 seconds 42 - 48 sec 50 - 55 seconds 42 - 48 seconds
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
high range on paved surface 1.2 - 1.8 m 0.6 - 1.2 m 1.5 - 2 m 0.6 - 1.2 m

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 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 / 12.2 m
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
High flotation tires, 8.5 - 10.5 seconds X X 6 - 6.8 seconds
2WD or 4WD, 40 - 45 seconds 40 - 45 seconds 42 - 48 seconds 42 - 48 seconds
high range on paved surface 0.9 - 1.2 m 1.5 - 2 m 1.5 - 2 m 0.9 - 1.8 m
Function Z-62 Z-80 Z-135, ZX-135

(includes TRAX models)
2WD models, 6.1 - 7.8 seconds X X
4WD models, 8 - 10.5 seconds 8.7 - 9.3 seconds 8.9 - 9.6 seconds
High flotation tires, 8 - 10.5 seconds 13.6 - 14.5 seconds X
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
TRAX models, 55 - 62 seconds X X
Raised or extended 40 ft / 12.2 m
Braking distance, 3 - 6 ft 4 - 6 ft 4 - 6 ft
high range on paved surface 0.9 - 1.8 m 1.2 - 1.8 m 1.2 - 1.8 m

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-lbs 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-lbs 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-lbs 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
434 Nm
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

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=lbs
508 Nm
3/4-10 bolts, GR 8, lubricated 281 ft-lbs
381 Nm

Engine Specifications
Engine Operator and Ford DSG-423
Maintenance Manuals Genie part number 119488

Diagnostic Manual
Deutz D2011L03i and TD2011L04i
Genie part number 119494
Ford MSG-425
Deutz D 2.9 L4 and TD 2.9 L4
Diagnostic Manual
Perkins 403D-11
Kubota D1105-E3B
Perkins 403F-11
Kubota WG-972
Perkins 404D-22
Kubota Z482-E
Perkins 404F-22 and 404F-22T
Continental TME27
Perkins 804D-33
Cummins B3.3T
Perkins 854F-E34T
Perkins 1104D-44T

Deutz Engine Models D 2.9 L4

Low idle 1500 rpm
D2011 L03i 1500 Hz
Low idle 1500 rpm 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) 9.5 quarts Engine coolant Ethylene Glycol
9 liters
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 2.9 L4
450 Hz
Low idle (standby) 1000 rpm
Low idle (all other models) 1300 rpm (SX-150, SX-180, Z-135, ZX-135) 1000 Hz
390 Hz
Low idle (with function enable) 1500 rpm
High idle (SX-150 and SX-180) 2450 rpm (SX-150, SX-180, Z-135, ZX-135) 1500 Hz
735 Hz
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
9 to 12 mm Oil capacity (including filter) 9.4 quarts
9 liters
Engine coolant capacity 11.1 quarts
10.5 liters
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.

Perkins Engine Models 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 Oil capacity (including filter) 9.4 to 11.2 quarts
4.1 liters 8.9 to 10.6 liters
Engine coolant capacity 3.3 quarts Engine coolant Ethylene Glycol
3.1 liters
Fan belt deflection 5/16 inch 12.6 liters
8 mm
403F-11 9 to 12 mm
Low idle 1500 rpm 404F-22T
265 Hz
Low idle 1300 rpm
High idle 2800 rpm 650 Hz
494.7 Hz
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
404D-22
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
12.6 liters Oil capacity (including filter) 10.6 quarts
10 liters
9 to 12 mm Engine coolant capacity 12.5 quarts
11.8 liters
9 to 12 mm

854F-E34T Ford Engine Models

Low idle (standby) 1000 rpm
(SX-150, SX-180, Z-135, ZX-135) 500 Hz DSG-423
Low idle (with function enable) 1500 rpm Low idle 1500 rpm
(SX-150, SX-180, Z-135, ZX-135) 750 Hz 313 Hz
High idle 2500 rpm High idle 2500 rpm
1250 Hz 521.7 Hz
Oil capacity (including filter) 7.7 quarts Oil capacity (including filter) 4 quarts
7.3 liters 3.8 liters
Engine coolant Ethylene Glycol Engine coolant capacity 10 quarts
9.5 liters
15.6 liters Spark plug gap 0.049 to 0.053 inches
1.25 to 1.35 mm
9 to 12 mm Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
1104D-44T
MSG-425
Low idle 1300 rpm
314.2 Hz Low idle 1500 rpm
50 Hz
High idle (SX-150 and SX-180) 2450 rpm
592 Hz High idle 2500 rpm
83.3 Hz
High idle (all other models) 2350 rpm
568 Hz Oil capacity (including filter) 6.7 quarts
6.4 liters
Oil capacity (including filter) 10.4 quarts
13 liters Engine coolant capacity 10 quarts
9.5 liters
9.8 liters Spark plug gap 0.049 to 0.053 inches
1.25 to 1.35 mm
9 to 12 mm Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
temperatures may require the use of alternative Unit ships with 15W-40. Extreme operating
engine oils. For oil requirements, refer to the temperatures may require the use of alternative
Engine Operator Manual for your engine. engine oils. For oil requirements, refer to the

Kubota Engine Models Continental Engine Models

D1105-E3B TME27
Low idle 1250 rpm Low idle 1600 rpm
53.3 Hz
High idle 3000 rpm
High idle 2500 rpm
83.3 Hz
5.1 liters
Engine coolant capacity 3.3 quarts Oil capacity (including filter) 7 quarts
6.6 liters
3.1 liters
Fan belt deflection 5/16 inch Engine coolant capacity 10.7 quarts
10.1 liters
8 mm
Spark plug gap 0.032 inches
WG-972 0.8 mm
Low idle 1600 rpm 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
8 mm
Z482-E
Low idle 2000 rpm
High idle 3000 rpm
2.5 liters
2.8 liters
8 mm

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
10.1 liters
Fan belt deflection 3/8 to1/2 inch
9 to12 mm

Hydraulic Specifications
Hydraulic Relief Valve Pressure

Function Manifold Relief Valve Pressure / Bar
Model System Primary Secondary Secondary Primary Secondary Turntable Proportional Platform
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 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

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
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
4WD - 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
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

Hydraulic and Drive Hub Fluid Capacities

Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5
Model 2WD 4WD Turntable Hydraulic tank Hydraulic system

wheel drive wheel drive rotation drive (including tank)
hub
S-40 and S-45 20 fl oz 20 fl oz 8 fl oz 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
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
Z-34N and Z-34DC 24.5 fl oz X X 4 gallons 6 gallons
Z-34BE 17.5 fl oz X X 4 gallons 6 gallons
Z-34 IC 17 fl oz 17 fl oz X 19 gallons 22 gallons
Z-40N and Z-40N RJ 23 fl oz X 5 fl oz 8 gallons 11 gallons
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 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
Z-135 and ZX-135 X 47 fl oz 40 fl oz 65 gallons 123 gallons

Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie
Product Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have 3 UCON Hydrolube HP-5046D
the same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
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.

Chevron Rando HD Premium Oil Continued use of Chevron

5606A hydraulic fluid, or
MV Fluid Properties equivalent, when ambient
ISO Grade 32 temperatures are consistently
above 32°F / 0°C may result in
Viscosity index 200 component damage
Kinematic Viscosity
cSt @ 200°F / 100°C 7.5
cSt @ 104°F / 40°C 33.5
Brookfield Viscosity
Petro-Canada Environ MV 46
cP @ -4°F / -20°C 1040 Fluid Properties
cP @ -22°F / -30°C 3310
ISO Grade 46
Flash point 375°F / 190°C
Viscosity index 154
Pour point -58°F / -50°C
Kinematic Viscosity
Maximum continuous operating 171°F / 77°C cSt @ 200°F / 100°C 8.0
temperature
cSt @ 104°F / 40°C 44.4
Note: An hydraulic oil heating system is Flash point 482°F / 250°C
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Maximum continuous operating 180°F / 82°C
Note: Do not operate the machine when the temperature
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
UCON Hydrolube HP-5046 Fluid
Chevron 5606A Hydraulic Oil Properties
Fluid Properties ISO Grade 46
Viscosity index 192
ISO Grade 15
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
Flash point None
cSt @ -40°F / -40°C 510
Flash point 180°F / 82°C
temperature
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.

Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque
specifications require that fittings and hose ends be -4 14 ft-lbs / 19 Nm
torqued to specification when they are removed -6 23 ft-lbs / 31.2 Nm
and installed or when new hoses or fittings are
-8 36 ft-lbs / 54.2 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings
-16 125 ft-lbs / 169.5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204.7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249.5 Nm
-4 10 ft-lbs / 13.6 Nm
-6 30 ft-lbs / 40.7 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm Adjustable Fitting Non-adjustable fitting
1 jam nut
JIC 37° Fittings

(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
SAE O-ring Boss Port
(tube fitting - installed into Steel)
-4 7/16-20 2
SAE Dash Size Torque
-6 9/16-18 1¼
-4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-8 3/4-16 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
-10 7/8-14 1 37° (Non-adj) 22 ft-lbs / 30 Nm
-12 1 1/16-12 1 -6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm

Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten
the hex nut to the body hex fitting to hand tight,
1 Replace the O-ring. The O-ring must be
approximately 30 in-lbs / 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.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.

3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight. Illustration 1
5 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
6 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.

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 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.

Maintenance Procedures
Machine Configuration:
Section 3 Maintenanc e Proc edures
 Unless otherwise specified, perform each

procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Maintenance inspections shall be completed • The red Emergency Stop button in the off
by a person trained and qualified on the position at both ground and platform controls
maintenance of this machine.
• Wheels chocked
 Scheduled maintenance inspections shall be
completed as specified on the Maintenance • All external AC power supply disconnected
inspection Reports. The frequency and extent from the machine
of periodic examinations and tests may also • Machine in the stowed position
depend on national regulations.
• Turntable secured with the turntable rotation
Failure to perform each lock
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 been out of service for a
period longer than 3 months must complete the
quarterly inspection.

About This Section Maintenance Symbols Legend

This section contains detailed procedures for each Note: The following symbols have been used in this
scheduled maintenance inspection. manual to help communicate the intent of the
instructions. When one or more of the symbols
Each procedure includes a description, safety appear at the beginning of a maintenance
warnings and step-by-step instructions. procedure, it conveys the meaning below.
Symbols Legend Indicates that tools will be required to

perform this procedure.
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety Indicates that new parts will be required to
messages that follow this symbol perform this procedure.
to avoid possible injury or death.
Indicates a imminently hazardous Indicates that dealer service will be

situation which, if not avoided, will required to perform this procedure.
result in death or serious injury.
Indicates a potentially hazardous Indicates that a cold motor/pump or engine

situation which, if not avoided, will be required to perform this procedure.
could result in death or serious
injury.
Indicates that a warm engine will be
Indicates a potentially hazardous required to perform this procedure.
situation which, if not avoided,
may cause minor or moderate
injury.

situation which, if not avoided,
may result in property damage.
Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.

Maintenance Schedule Programmed Example (under 1000 HRS):

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.
Programmed Example:
Failure to perform these procedures may result in
poor performance, component damage and unsafe
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 Instructions
50 and 150 hour intervals. Use the following detailed descriptions to identify
the intended use of the maintenance inspection
Quarterly and Annually: A series of maintenance reports.
procedures to be performed quarterly or annually.
1 Specific Interval: blank box is the interval to be
Programmed: A series of maintenance
completed and the ∅ marks the interval as not
procedures to be performed based on machine
required.
operating hours.
2 The description of the procedure or checklist
Maintenance Inspection Report to be completed.
The maintenance inspection report contains 3 The procedure number or checklist to be
checklists for each type of scheduled inspection. completed.
Make copies of the Maintenance Inspection Report 4 Check box to indicate status of inspection.
to use for each inspection. Maintain completed 5 Specific interval is not required for this
forms for a minimum of 4 years or in compliance procedure.
with your employer, jobsite and governmental
regulations and requirements. 6 General area of the machine to complete the
procedure.
Instruction Examples
7 If this box has a designated time interval: this
Commissioning Example: 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
Quarterly and Annually Example:
inspection completed.

December 2015
Scheduled
Maintenance Inspection Report – Booms
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 procedures for the type of
N = no, remove from service inspection(s) to perform.
Annual Inspections = "A"
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 ∅ Test Fuel Select Operation - Gas/LPG Models Q-16
Turntable Mechanicals and Hydraulics Intervals Q A Inspect the Calibration Decal - ALC1000 Models Q-17
Visual Inspection of the Hydraulic Oil Q-9 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 Bolts A-2 ∅
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 – Raised and Extended Q-24
Battery Inspection Q-2 Position - ALC1000 Models
Inspect the Electrical Wiring Q-3 Test the Turntable Level Sensor - Z-135/70, Q-25
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 Q-11
Test the Primary Boom Angle Sensor - SX-150 and Q-28
Boom(s) and Platform Intervals Q A 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
Grease the Platform Overload Mechanism A-7 ∅
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
Angle Sensor - S-60X, S-60XC and S-80
Test Platform Overload - (S-60 HC models) A-10 ∅
Test the Safety Envelope and Circuits - S-100, Q-33
Inspect Boom Cables - All S-60, S-80 Models A-11 ∅ S-105, S-120 and S-125
Inspect Boom Cables - S-100 to S-125 Models A-12 ∅ Test the Aircraft Protection System (if equipped) Q-34
Inspect Boom Cables - SX-150 and SX-180 A-13 ∅
Test the Operator Protection Alarm (if equipped) Q-35
Test the Bypass/Recovery Key Switch A-6 ∅
28 S Booms • Z Booms Maintenance Manual Part No. 1268489

December 2015
Programmed
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 ∅

Models
50 Hour Service - all C-1 ∅
models 150 Hour Service C-3 ∅
Programmed Maintenance - Under 1000 HRS Status Enter Programmed Maintenance Hours are in thousands
Hours
Check the Track Tension and Fastener Torque P0-1 50 All models Perform every: 1 2 3 4 6 12
- S-60, S-65 and Z-62 Models
Engines - all models, 1000 Hours P1-1 ∅ ∅ ∅ ∅ ∅
Check the Track Tension and Fastener Torque P0-2 50
- S-40 and S-45 Models Replace the Drive Hub Oil P1-2 ∅ ∅ ∅ ∅ ∅
Grease the Extendable Axles - (if equipped) P0-3 50 Engines - all models, 2000 Hours P2-1 ∅ ∅ ∅ ∅ ∅
Engines - Continental Under 1000 HRS P0-4 Test or Replace the Hydraulic Oil P2-2 ∅ ∅ ∅ ∅ ∅
Engines - Cummins Under 1000 HRS P0-5 Replace the Hydraulic Filters P2-3 ∅ ∅ ∅ ∅ ∅
Engines - Deutz Under 1000 HRS P0-6 Check the Free-wheel Configuration P2-4 ∅ ∅ ∅ ∅ ∅
Engines - Ford Under 1000 HRS P0-7 Check the Boom Wear Pads P2-5 ∅ ∅ ∅ ∅ ∅
Engines - Kubota Under 1000 HRS P0-8 Check the Extendable Axle Wear P2-6 ∅ ∅ ∅ ∅ ∅
Pads
Engines - Perkins Under 1000 HRS P0-9
Check Turntable Gear Backlash - P2-7 ∅ ∅ ∅ ∅ ∅
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
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
Part No. 1268489 S Booms • Z Booms Maintenance Manual 29

Commisioning Procedures
C-1 C-2
Perform 50 Hour Service Perform Engine Maintenance -
50 Hours
The 50 hour maintenance procedure is a one time

sequence of procedures to be performed after the The 50 hour maintenance procedure is a one time
first 50 hours of usage. After this interval, refer to sequence of procedures to be performed after the
the maintenance inspection report for continued first 50 hours of usage. After this interval, refer to
scheduled maintenance. the maintenance inspection report for continued
1 Perform the following maintenance scheduled maintenance.
procedures: Ford Models
All Models:
• Oil, coolant, fuel, exhaust and vacuum
Q-6 Inspect the Tires, Wheels and Lug Nut hoses - check for leaks, damage or
Torque deterioration
A-1 Grease the Turntable Rotation Bearing and • Electrical wiring - check for chafing or
Rotate Gear damage
A-2 Check the Turntable Rotation Bearing Kubota Models

Bolts • Engine oil - replace
A-5 Check the Jib Rotator Fastener Torque • Oil filter - replace
(SX-150 and SX-180 models)
Required maintenance procedures and additional
P1-2 Replace the Drive Hub Oil engine information are available in the
manufactures manuals. Refer to Specifications,
P2-3 Replace the Hydraulic Filters Engine Operator and Maintenance Manuals.

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 hours of usage. After this interval, refer to
the maintenance tables for continued scheduled
maintenance.
1 Perform the following maintenance

procedures:
Q-9 Visual Inspection of the Hydraulic Oil
Q-10 Inspect the Hydraulic Filters

Quarterly Maintenance Procedures
Q-1 Machines purchased in ASIA, North America

and Latin America:
Check for Open Bulletins and
Owner Registration Go to ASIA, North America and
Latin America Bulletins
(https://www.gogenielift.com/)
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 1 Select "Customer Login" to login or select
against our bulletin database. Using the links below "Request New Access" to create a new
you can view any open bulletins for your machine(s) account.
that require mandatory and immediate work to be 2 At the homepage, select "Unit Configuration"
completed. and enter your machine serial number.
Note: If you are unable to access this information 3 Press the "Lookup" button to view your
on our websites, please contact your local Genie machine configuration and to check for open
representative using the contact information bulletins.
provided on the back cover of this manual.
4 Complete all required bulletins shown for your
1 Locate the serial number plate or label on your specific machine serial number.
machine and document your Genie machine
Machines purchased in Europe, Middle East,
serial number (exactly as its displayed on the
Africa, and Russia:
serial plate or label).
2 Confirm that Genie has the current machine Go to EMEAR Bulletins
owner information on file by contacting our (http://www.genielift.co.uk/en/sales-and-suppo
warranty department at 1-800-536-1800 or rt/bulletin-campaigns/index.htm)
use the link included in this procedure to
download and complete a New Owner
Registration Form.
3 Using the link provided, check for current
bulletins for your machine(s).
Machines purchased in Australia: 1 Enter your machine serial number and press
search to check for open bulletins.
Go to Australia Bulletins
(http://genielift.com.au/contact) 2 Complete all required bulletins shown for your
specific machine serial number.
1 Contact any one of the Genie Service centers
around Australia to arrange for factory trained
technicians to attend to your equipment
needs.

Q-2 Models without maintenance-free or sealed

batteries:
Battery Inspection
5 Put on protective clothing and eye wear.
6 Remove the battery vent caps and check the
specific gravity of each battery cell with a
Genie specifications require that this procedure be hydrometer. Note the results.
7 Check the ambient air temperature and adjust
Proper battery condition is essential to good engine the specific gravity reading for each cell as
and machine performance and operational safety. follows:
Improper fluid levels or damaged cables and
connections can result in engine and component • Add 0.004 to the reading of each cell for
damage and hazardous conditions. every 10° F / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell
Electrocution/burn hazard.
for every 10° F / 5.5° C below 80° F / 26.7°
Contact with electrically charged
C.
circuits could result in death or
serious injury. Remove all rings, Result: All battery cells display an adjusted
watches and other jewelry. specific gravity of 1.277 or higher. The battery
is fully charged. Proceed to step 11.
Bodily injury hazard. Batteries Result: One or more battery cells display a
contain acid. Avoid spilling or specific gravity of 1.276 or below. Proceed to
contacting battery acid. step 8.
Neutralize battery acid spills with
baking soda and water.
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 Be sure that the battery separator wire
connections are tight (if equipped).

8 Perform an equalizing charge OR fully charge

the battery(s) and allow the battery(s) to rest at
least 6 hours.
9 Remove the battery vent caps and check the
specific gravity of each battery cell with a
hydrometer. Note the results.
10 Check the ambient air temperature and adjust
the specific gravity reading for each cell as
follows:
• Add 0.004 to the reading of each cell for
every 10° F / 5.5° C above 80° F / 26.7° C.
• 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.
Result: 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.
11 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.
12 Install the vent caps and neutralize any
electrolyte that may have spilled.

Q-3 • Cable tracks
Inspect the Electrical Wiring • Cables on the primary, secondary and jib
booms
• Jib boom/platform rotate manifold
Genie specifications require that this procedure be • Inside of the platform control box
performed quarterly. • All wire harness connectors to platform
Maintaining electrical wiring in good condition is control box
essential to safe operation and good machine • Battery compartment
performance. Failure to find and replace burnt,
chafed, corroded or pinched wires could result in • Battery separator
unsafe operating conditions and may cause • Battery charger
component damage.
• Contactor
Contact with electrically charged • Motor controller
circuits could result in death or • Electric motor
serious injury. Remove all rings,
watches and other jewelry. • Pump motor
• Limit switches
1 Inspect the following areas for burnt, chafed,
corroded pinched and loose wires: • Rotary sensors
Note: Inspection areas will vary by model. 2 Inspect for a liberal coating of dielectric grease
on all harness connections.
• Engine wiring harness
• Engine relay block
• Hydraulic manifold wiring
• All wire harness connectors to ground
control box
• Inside of the ground control box
• Turntable area

Q-4 Q-5
Inspect the Electrical Contactor - Check the Exhaust System
DC and Bi-Energy Models Genie specifications require that this procedure be
Maintaining the exhaust system is essential to
Genie specifications require that this procedure be good engine performance and service life.
performed quarterly. Operating the engine with a damaged or leaking
exhaust system can cause component damage
Maintaining the electrical contactor in good and unsafe operating conditions.
condition is essential to safe machine performance.
Failure to locate a worn or damaged contactor Bodily injury hazard. Do not
could result in unsafe operating conditions and may inspect while the engine is
cause component damage. running. Remove the key to
secure from operation.
1 Remove the drive chassis cover from the
non-steer end of the machine and locate the Burn hazard. Beware of hot
electrical contactor(s). engine components. Contact
2 Locate the electrical contactor mounted on the with hot engine components
fuse bracket. may result in severe burns.
3 Visually inspect the contact points of the 1 Be sure that all nuts and bolts are tight.
contactor for the following items:
2 Inspect all welds for cracks.
• Excessive burns
3 Inspect for exhaust leaks; i.e., carbon buildup
• Excessive arcs around seams and joints.
• Excessive pitting
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.
Note: Replace the contactor if any damage is

found.

Q-6 Q-7
Inspect the Tires, Wheels and Check the Generator Belts,
Lug Nut Torque Pulleys and voltage -
Bi-Energy Models
Genie specifications require that this procedure be performed quarterly.
Maintaining the generator belts and the pulleys is
Maintaining the tires and wheels, including proper essential to good generator performance and
wheel fastener torque, is essential to safe service life. The generator will not operate properly
operation and good performance. Tire and/or with loose or defective belts and continued use
wheel failure could result in a machine tip-over. may cause component damage.
Component damage may also result if problems
are not discovered and repaired in a timely fashion. Bodily injury hazard. Do not
inspect while the engine is
Bodily injury hazard. An running. Remove the key to
over-inflated tire can explode secure from operation.
and could cause death or serious
injury. Bodily injury hazard. Beware of
hot engine components.
Tip-over hazard. Do not use Contact with hot engine
temporary flat tire repair components may cause severe
products. burns.
Note: The tires on some machines are foam-filled Note: Charging the batteries with the engine does
or solid rubber and do not need air added to them. not fully charge the batteries. Periodically, use the
AC battery charger to fully charge the batteries.
1 Check all tire treads and sidewalls for cuts,
cracks, punctures and unusual wear. 1 Be sure that all fasteners and cables on the
generator are tight.
2 Check each wheel for damage, bends and
cracked welds. 2 Remove the engine flywheel cover mounting
fasteners, then remove the cover.
3 Check each lug nut for proper torque. Refer to
Specifications, Tire and Wheel Specifications. 3 Be sure that the pulley mounting fasteners are
tight and that the pulleys show no signs of
4 Check the pressure in each air-filled tire. damage or unusual wear.

4 Check to be sure the engine pulley and the 7 Check the generator belts for proper tension. If
generator pulley are aligned within the belt deflection is not within specification,
specification using a straightedge. Refer to Repair Procedure in the appropriate
Service and Repair Manual for your machine,
How to Adjust the Generator Belts.
1 engine pulley
2 generator belts
3 generator pulley
Belt deflection, maximum allowable 1/4 inch

1 engine pulley 6.5 mm
2 straightedge
8 Check the torque of the pulley retaining nut on
3 maximum pulley offset
the generator.
4 generator pulley
Generator pulley 80-90 ft-lbs
Note: If alignment does not meet specification, retaining nut torque 108-122 Nm
Refer to Repair Procedure in the appropriate
Engine pulley retaining bolts 108 in-lbs
Service and Repair Manual for your machine, How 12.2 Nm
to Install the Engine Drive Pulley to adjust the
pulley alignment. 9 Connect the positive lead of a multi meter to
the positive post on the back of the alternator.
Pulley alignment, maximum offset 0.0625 inch Connect the negative lead to the negative
1.58 mm post. Set the meter to DC voltage.
5 Inspect the generator belts for: 10 Start the engine from the ground controls.
• Cracking Result: The voltage does not exceed 54V DC.
• Glazing
• Separation
• Breaks
6 Replace both belts if any damage is found.

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 Genie specifications require that this procedure be
performed quarterly. performed quarterly.
Note: Perform this test only on models equipped Replacement or testing of the hydraulic oil is
with an oscillating axle. essential for good machine performance and
service life. Dirty oil and a clogged suction strainer
Proper axle oscillation is essential to safe machine may cause the machine to perform poorly and
operation. If the oscillate directional valve linkage is continued use may cause component damage.
not operating correctly, the stability of the machine Extremely dirty conditions may require oil changes
is compromised and it may tip over. to be performed more often. For hydraulic oil
specifications, Refer to Specifications, Hydraulic
1 Remove the drive chassis cover and the axle
Specifications.
covers from the non-steer end of the drive
chassis. Note: Before replacing the hydraulic oil, the oil may
2 Locate the oscillate directional valve inside of be tested by an oil distributor for specific levels of
the non-steer axle and inspect the linkage for contamination to verify that changing the oil is
the following: necessary. Replace the oil when it fails the test.
Refer to Maintenance Procedure, Test or Replace
• Lock nut is tight against yoke the Hydraulic Oil.
• Yoke clevis pins are installed
• Cotter pins are installed through clevis pins
• Linkage is properly attached to directional
valve

1 Collect a sample of hydraulic oil and place in a Q-10

clear container. Visually inspect the hydraulic
oil for the following:
Inspect the Hydraulic Filters
• Color: oil should be a clear, light-honey
colored
• Appearance, oil should be clear and not Maintaining the high pressure hydraulic filter in
cloudy or visibly distorts the view through good condition is essential to good system
the sight glass or container performance and safe machine operation. The filter
condition indicator will show when the hydraulic
• Contains no particles, foreign objects, or flow is bypassing a clogged filter. If the filter is not
other contamination frequently checked and replaced, impurities will
remain in the hydraulic system and cause
• The hydraulic oil can be inspected by smell
component damage.
(can smell “hot” but not “burnt”) or rubbing
between fingers (should feel viscous and Note: There are four types of hydraulic filters: tank
free of any rough feel due to particles). return filter, medium pressure filter, high pressure
If the hydraulic oil passes all of the above filter and drive motor case drain filter. The quantity
inspections, continue the scheduled and type of filter(s) may vary by model.
maintenance intervals. Models with Filter Condition Indicator:
If the hydraulic oil fails any of the above
1 Start the engine from the ground controls.
inspections, the hydraulic oil must be tested by
an oil distributor or replaced. 2 Set the engine idle to high rpm (rabbit symbol).
Note: If the hydraulic oil was not replaced at or 3 Visually inspect the filter condition indicator.
before the 2000 hour maintenance interval, the oil
must be tested every quarter by an oil distributor Result: The filter condition indicator is
until the oil fails the test and is replaced. After the operating in the green area.
oil has been replaced, continue the scheduled Result: The filter condition indicator is
quarterly maintenance inspection. operating in the red area. This indicates that
the hydraulic filter is being bypassed and the
Note: When replacing the hydraulic oil, it is
filter should be replaced. Refer to
recommended that all hydraulic filters be replaced
Maintenance Procedure, Replace the
at the same time.
Hydraulic Filters.

Models without Filter Condition Indicator: Q-11

Note: Models without a filter condition indicator Check and Adjust the Engine
cannot be inspected. At the required maintenance RPM
interval, replace the filters.
Hydraulic Tank Cap (if equipped):
1 Remove the breather cap from the hydraulic Engine specifications require that this procedure be
tank. performed quarterly.
2 Check for proper venting. Maintaining the engine rpm at the proper setting for
Result: Air passes through the breather cap. both low and high idle is essential to good engine
Proceed to step 4. performance and service life. The machine will not
operate properly if the rpm is incorrect and
Result: If air does not pass through the cap, continued use may cause component damage.
clean or replace the cap. Proceed to step 3.
Note: These procedures do not apply to the
Note: When checking for positive tank cap venting, following engine models. The engine RPM is
air should pass freely through the cap. controlled by the ECM and can only be adjusted by
3 Using a mild solvent, carefully wash the cap re-programming the ECM. If RPM or service is
venting system. Dry using low pressure required, please contact Genie Product Support.
compressed air. Repeat this procedure Continental Models: TME27
beginning with step 2.
Ford Models: DSG-423 • MSG-425
4 Install the breather cap onto the hydraulic
tank. 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.

Models with ALC-1000 operating system: Kubota WG-972:

Note: Use the following chart to identify the Low rpm idle adjustment:
description of each LCD screen control button used
in this procedure. 1 Loosen the core clamp screw so the cable
moves freely.
2 Hold the throttle lever against the low idle
adjustment screw.
3 Turn the adjustment screw clockwise to
Plus Minus Previous Enter increase low rpm or counterclockwise to
decrease low rpm.
4 While holding the throttle lever against the low
2 Press the enter or previous button on the idle adjustment screw, tighten the core clamp
LCD screen until engine rpm is displayed. screw.
Result: Low idle rpm is correct. Continue with High rpm idle adjustment:
step 3.
1 Loosen the lock nut on the high idle
Result: Low idle rpm is not correct. Follow the
adjustment nut.
low rpm idle procedure for your engine model.
2 Turn the high idle adjustment nut clockwise to
3 Press and hold the function enable/high speed
increase the high rpm or counterclockwise to
button. Note the engine rpm on the display.
decrease high rpm.
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 function enable toggle switch to the
high idle (rabbit symbol) position and check
the rpm.
Result: High idle rpm is correct.
Result: High idle rpm is not correct. Follow the
high rpm idle procedure for your engine
model.

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

adjustment nut.
2 Turn the high idle adjustment nut
counterclockwise to increase the rpm or
clockwise to decrease the rpm.
3 Tighten the lock nut.
Kubota D1105-E3B
1 core clamp screw

2 throttle lever
1 high idle solenoid
3 low idle adjustment screw
4 lock nut
3 lock nut
5 high idle adjustment nut


Kubota Z482-E Deutz TD2011L04i
1 low idle adjustment screw (not shown)

4 fuel shut off solenoid
3 lock nut
Deutz D2011L03i 4 low idle adjustment screw

3 lock nut

Perkins 403D-11 Perkins 404D-22

3 lock nut
Perkins 804D-33

3 lock nut


Perkins 1104D-44T Q-12
Test the Ground Control Override
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 Push in the platform red Emergency Stop

1 low idle adjustment screw button to the off position.
2 lock nut
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 Start the 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.
7 Activate the foot switch and operate each
boom function.
Result: No boom functions operate.


Q-13 All Models:
Test the Alarm Package 2 Activate the boom down function, hold for a
moment and then release it.
(if equipped)
Result: The descent alarm should sound when
Genie specifications require that this procedure be the down function is activated.
Complete this step for each boom that applies:
The alarm package includes: Primary, Secondary and Jib Booms.
• Travel alarm 3 Turn the key switch to platform controls.
• Descent alarm Result: The flashing beacon should be on and
flashing.
• Flashing beacon
4 Press down the foot switch. Activate the boom
Alarms and a beacon are installed to alert down function, hold for a moment and then
operators and ground personnel of machine 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
out the red Emergency Stop button to the on 5 Press down the foot switch. Move the drive
position at both ground and platform controls. control handle off center, hold for a moment
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.
Z-135/70 and ZX-135/70 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.

Q-14 Q-15
Test the Emergency Power Test the Engine Idle Select
System Operation - Engine Models
(excludes ALC-1000 Models) Genie specifications require that this procedure be
A properly operating engine idle select function is
Genie specifications require that this procedure be essential to good engine performance and safe
performed quarterly. machine operation. There are two settings.
Testing the emergency power system regularly is Low idle (turtle symbol) allows the operator to
essential to safe machine operation if the primary control individual boom functions. Drive functions
power source fails. will operate at low idle on most models, but at
reduced performance.
out the red Emergency Stop button to the on High idle (rabbit symbol) should be used for
position at both the ground and platform normal machine operation.
controls. S-100, S-105, S-120, S-125, S-100HD, S-120HD,
2 At the ground controls, break the security tie SX-150, SX-180, Z-80/60, Z-135/70 and
and lift the emergency power switch cover (if ZX-135/70 Models:
equipped).
1 Turn the key switch to ground controls.
3 Simultaneously hold the emergency power
switch on and operate each boom function 2 Pull out the red Emergency Stop button to the
through a partial cycle. on position at both the ground and platform
controls.
Result: All boom functions operate.
4 Close the emergency power switch cover and
secure the cover with a security tie (if 4 Push and release the rpm select button until
equipped). high rpm is selected (rabbit symbol).
5 Turn the key switch to platform controls. Result: The engine should change to high idle.
6 At the 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).

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.
3 Move the rpm select toggle switch to the high
idle (rabbit symbol) position and activate
function enable.
Result: The engine should change to high idle.
4 Release function enable.
Result: The engine should return to low idle.
5 Turn the key switch to platform controls.
1 low idle indicator light
6 Move the engine idle select switch to foot
2 foot switch activated high idle indicator light
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
idle.
7 Push the engine rpm select switch until low
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
switch activated low idle (turtle symbol).
Result: The engine should remain at low idle.
Result: The engine should change to low idle.
9 Push the engine idle select switch until high
idle (rabbit symbol) is selected.
Result: The engine should change to high idle.

Q-16 5 Move the fuel select switch to LPG.

Test the Fuel Select Operation - 6 Restart the engine and allow it to run at low
Gasoline/LPG Models idle.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
Note: The engine may hesitate momentarily and
The ability to select and switch between gasoline then continue to run on the selected fuel if the fuel
and LPG fuels as needed is essential to safe source is switched while the engine is running.
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 At the platform controls, move the fuel select

switch to gasoline and then move the engine
idle control switch to foot switch activated high
idle (rabbit and foot switch symbol).
2 Start the engine from the platform controls and
allow it to run at low idle.
3 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate 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.

Q-17
Inspect the Calibration Decal –
SX-150, SX-180, Z-135/70 and
ZX-135/70 Models
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.
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.
2 Open the turntable cover on the ground
controls side of the machine.
3 Open the ground control box.
4 Verify the ground control panel is equipped
with the required calibration decal.
Result: The control box is equipped with the ANSI and CSA
required decal and is legible and in good
condition.
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

Q-18
Test the Recovery System -
ALC-1000 Models
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 1 Run
platform. 2 Bypass
3 Recovery
Note: If any boom safety limit switches are
faulty, the primary boom will only retract and 1 Turn the key switch to the ground control and
not lower. 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.

5 Remove the key from the main key switch and Q-19
insert the key into the bypass/recovery key
switch.
Test the Platform Self-leveling
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 Genie specifications require that this procedure be
Z-135 before serial number Z13512-1712. performed quarterly.
6 Turn and hold the bypass/recovery key switch ALC-1000 Models:
to the recovery position. The switch must be
held in the recovery position. Automatic platform self-leveling throughout the full
cycle of primary boom raising and lowering is
Result: The emergency power unit will turn on essential for safe machine operation. The platform
and the boom will begin the following recovery is maintained level by the communication between
sequence. the platform level sensor and the turntable level
SX-150, SX-180, S-100/105/120/125, sensor. If the platform becomes out of level, the
S-100/120HD: computer at the platform controls will open the
appropriate solenoid valve(s) at the platform
• The primary boom will retract manifold to maintain a level platform.
• The primary boom will lower All other models:
Z-135 and ZX-135: Automatic platform self-leveling throughout the full
cycle of boom raising and lowering is essential for
• The primary boom will retract
safe machine operation. The platform is maintained
• The secondary boom will retract at level by the platform leveling slave cylinder
which operates in a closed loop hydraulic circuit
• The primary boom will lower with the master cylinder located at the base of the
Note: It is not necessary to fully lower the primary boom. A platform self-leveling failure creates an
boom. unsafe working condition for platform and ground
personnel.
Z-80/60:
1 At the ground controls, lower the boom to the
• The primary boom will retract stowed position.
• The primary boom will lower 2 Activate function enable and adjust the
platform to a level position.
• The secondary boom will retract
3 Raise and lower the primary boom through a
7 Turn the bypass/recovery key switch to the run
full cycle.
position.
Result: The platform should remain level at all
8 Remove the key from the bypass/recovery key times to within ±5 degrees.
switch and insert the key into the main key
switch.
9 Start the engine and return the boom to the
stowed position.

Q-20 Q-21
Confirm the Proper Brake Test the Drive Brakes
Configuration

performed quarterly. Proper brake action is essential to safe machine
operation. The drive brake function should operate
Proper brake configuration is essential to safe
smoothly, free of hesitation, jerking and unusual
operation and good machine performance.
noise. Hydraulically and electrically released,
Hydrostatic brakes, hydraulically and electrically
spring applied individual wheel brakes can appear
released, spring-applied individual wheel brakes
to operate normally when they are actually not fully
can appear to operate normally when they are
operational.
actually not fully operational.
1 Locate the drive hub disconnect cap. 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.
Note: Select a test area that is firm, level and free

of obstructions.
1 Mark a 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.
1 models with tires 3 Bring the machine to top drive speed before
2 models with TRAX reaching the test line. Release the drive
joystick when your reference point on the
2 Check each drive hub disconnect cap to be machine crosses the test line.
sure it is in the engaged position.
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.
1 brake disengaged position

2 brake engaged position

Q-22 Q-23
Test the Drive Speed – Stowed Test the Drive Speed – Raised or
Position Extended Position
Genie specifications require that this procedure be Genie specifications require that this procedure be
performed quarterly. performed quarterly.
Proper drive function is essential to safe machine Proper drive function is essential to safe machine
operation. The drive function should respond operation. The drive function should respond
quickly and smoothly to operator control. Drive quickly and smoothly to operator control. Drive
performance should also be free of hesitation, performance should also be free of hesitation,
jerking and unusual noise over the entire jerking and unusual noise over the entire
proportionally controlled speed range. proportionally controlled speed range.Note: Select
a test area that is firm, level and free of
Note: Perform this procedure with the machine on obstructions.
a firm, level surface that is free of obstructions.
1 Create start and finish lines by marking two
Note: Perform this procedure with the machine in lines on the ground 40 feet / 12.2 m apart.
the stowed position.
2 Press down the foot switch and raise the
1 Create start and finish lines by marking two primary boom greater than 10 degrees above
lines on the ground 40 feet / 12.2 m apart. horizontal.
2 Choose a point on the machine (i.e., contact 3 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use patch of a tire) as a visual reference for use
when crossing the start and finish lines. when crossing the start and finish lines.
3 Bring the machine to top drive speed before 4 Bring the machine to top drive speed before
reaching the start line. Begin timing when your reaching the start line. Begin timing when your
reference point on the machine crosses the reference point on the machine crosses the
start line. 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.

5 Continue at full speed and note the time when Q-24

Test the Drive Speed – Raised
Specifications. and Extended Position, ALC1000
6 Lower the boom to the stowed position and Models
extend the primary boom 4 feet / 1.2 m.
patch of a tire) as a visual reference for use Genie specifications require that this procedure be
when crossing the start and finish lines. performed quarterly.
8 Bring the machine to top drive speed before
Proper drive function is essential to safe machine
reaching the start line. Begin timing when your
operation. The drive function should respond
reference point on the machine crosses the
quickly and smoothly to operator control. Drive
start line.
performance should also be free of hesitation,
9 Continue at full speed and note the time when jerking and unusual noise over the entire
the machine reference point crosses the finish proportionally controlled speed range.
Specifications. Note: Perform this procedure with the machine on
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.
patch of a tire) as a visual reference for use
when crossing the start and finish lines.
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
Specifications.

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

Note: This procedure will require 2 people to 1 Create start and finish lines by marking two
perform. lines on the ground 40 feet / 12.2 m apart.
1 Create start and finish lines by marking two 2 Press down the foot switch and raise the
lines on the ground 40 feet / 12.2 m apart. primary boom greater than 10 degrees and
the secondary boom greater than 20 degrees.
2 Access the MACHINE STATUS menu on the
ground control box and scroll down until 3 Z-80/60: Extend the primary boom 12 inches /
LENGTH SENSOR EXTENSION is displayed. 0.3 m.
3 Raise and extend the primary boom until the Z-135/70 and ZX-135/70: Extend the primary
displays reads at least 258 in / 656 cm. The boom 12 inches / 0.3 m and the jib boom
boom will be extended approximately 120 ft / 12 inches / 0.3 m.
36.6 m.
4 Choose a point on the machine (i.e., contact patch of a tire) as a visual reference for use
patch of a tire) as a visual reference for use when crossing the start and finish lines.
when crossing the start and finish lines.
5 Bring the machine to top drive speed before reaching the start line. Begin timing when your
reaching the start line. Begin timing when your reference point on the machine crosses the
reference point on the machine crosses the start line.
start line.
6 Continue at full speed and note the time when the machine reference point crosses the finish
the machine reference point crosses the finish line. Refer to Specifications, Drive Speed
line. Refer to Specifications, Drive Speed Specifications.
Specifications.

Q-25 Note: Perform this procedure with the booms in the

fully stowed position and the axles fully extended.
Test the Turntable Level Sensor -
Z-135/70, ZX-135/70, SX-150 and 1 Place the machine on a firm surface that has a
side slope greater than 2° (6.5 inches /
SX-180 16.5 cm) but less than 5° (16 inches /
Genie specifications require that this procedure be 40.6 cm).
performed quarterly. 2 Place a digital level that has been calibrated to
gravity on the X axis of the turntable.
A properly functioning level sensor (SCON) is
essential to safe machine operation. The ECM at Note: Illustrations are shown from the platform end
the ground controls (TCON) monitors the position of the machine.
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 positive degree side slope (ZX-135/70 shown)
manufactures calibration information.
Note: Use the following chart to identify the
in this procedure.
Plus Minus Previous Enter
negative degree side slope (ZX-135/70 shown)
X axis (ZX-135/70 shown)
Y axis (ZX-135/70 shown)

3 Turn the key switch to ground control and pull 7 Place a digital level that has been calibrated to
out the red Emergency Stop button to the on gravity on the Y axis of the turntable.
position at both ground and platform controls.
Result: The reading at the display and digital
4 Press the enter or previous button on the level is within ± 1° of each other.
LCD screen until TURNTABLE LEVEL
SENSOR X-DIRECTION is displayed.
level is greater than ± 1° of each other. The
Result: The reading at the display and digital level sensor must be calibrated. Refer to
level is within ± 1° of each other. Repair Procedure in the appropriate Service
and Repair Manual for your machine, How to
Result: The reading at the display and digital Calibrate the Level Sensor.
level is greater than ± 1° of each other. The
level sensor must be calibrated. Refer to
Repair Procedure in the appropriate Service
Calibrate the Level Sensor.
Tip-over hazard. If the X axis is
not within ± 1°, failure to properly
calibrate the level sensor could positive degree downhill slope (ZX-135/70 shown)
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.
negative degree uphill slope (ZX-135/70 shown)
5 Place the machine on a firm surface that has
an uphill or downhill slope greater than 2° Tip-over hazard. If the Y axis is
(6.5 inches / 16.5 cm) but less than 5° not within ± 1°, failure to
(16 inches / 40.6 cm). calibrate the level sensor could
6 Press the enter or previous button on the cause the machine to tip over
LCD screen until TURNTABLE LEVEL resulting in death or serious
SENSOR Y-DIRECTION is displayed. injury. Refer to Repair Procedure
How to Calibrate the Level
Sensor.

Q-26 3 Press the plus and minus buttons at the

same time on the LCD screen to enter the
Test the Secondary Boom Angle MACHINE STATUS screen. Press the enter
Sensor - Z-135/70 and ZX135/70 or previous button until SECONDARY BOOM
ANGLE is displayed.
performed quarterly. 4 Raise the secondary boom until it is fully
elevated and it just starts to extend. Do not
A properly functioning secondary boom angle continue to extend the boom.
sensor is essential to safe machine operation. The
ECM at the ground controls (TCON) monitors the 5 Zero a digital level to the Y axis of the
position and angle of the secondary boom using turntable. Refer to Maintenance Procedure,
the signal from the secondary boom angle sensor. Test the Turntable Level Sensor.
The secondary boom angle sensor signal is used
6 Place the digital level on top of the secondary
to control the ramping of the secondary boom.
boom close to the pivot end of the secondary
Note:The turntable level sensor must be tested boom.
before starting this procedure. Refer to Result: The reading at the display and digital
Maintenance Procedure, Test the Turntable Level level is equal to or greater than 75.5°.
Sensor.
Note: A digital level will be required to perform this level is less than 75.5°. The secondary boom
procedure. angle sensor must be calibrated. Refer to
Calibrate the Secondary Boom Angle Sensor.
cable harnesses. Tip-over hazard. If the boom is
not equal to or greater than
75.5°, immediately lower the
to proper machine calibration. Refer to the
secondary boom. Failure to
lower the boom could cause the
Note: Use the following chart to identify the machine to tip over resulting in
description of each LCD screen control button used death or serious injury. Refer to
in this procedure. Repair Procedure in the
appropriate Service and Repair
Manual for your machine, How to
Calibrate the Secondary Boom
Angle Sensor.

out the red Emergency Stop button to the on

7 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 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 of
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.
8 Lower the secondary boom to 50°. 11 Fully lower the secondary boom until it stops
at approximately -3.5°.
level is within ± 2° of each other and of 50°. 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 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
Secondary Boom Angle Sensor.
9 Lower the secondary boom to 35°.
level is within ± 2° of each other and of 35°.
level is greater than ± 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

Q-27 Note: Use the following chart to identify the

Test the Primary Boom Angle in this procedure.
Sensor - Z-135/70 and ZX135/70
A properly functioning primary boom angle sensor
is essential to safe machine operation. The ECM at Plus Minus Previous Enter
the ground controls (TCON) monitors the position Note: Perform this procedure with the machine on
and angle of the primary boom using the signal a firm, level surface with the booms in the fully
from the primary boom angle sensor. The primary stowed position and the axles fully extended.
boom angle sensor signal is used to control the
ramping of the primary boom, limiting the speed of 1 Turn the key switch to ground control and pull
the primary boom to 2.3 feet / 0.7 meters per out the red Emergency Stop button to the on
second. position at both ground and platform controls.
Note:The turntable level sensor and secondary 2 Start the engine from the ground controls.
boom angle sensor must be tested before starting 3 Press the enter or previous button on the
this procedure. Refer to Maintenance Procedures, LCD screen until PRIMARY BOOM ANGLE
Test the Turntable Level Sensor and Test the TO GRAVITY DEGREES is displayed.
4 Place a digital level that has been calibrated to
Note: A digital level will be required to perform this gravity on top of the primary boom.
procedure.
cable harnesses.
to proper machine calibration. Refer to the

5 Raise the primary boom while watching the 8 Lower the primary boom to -50°.
display screen.
6 Continue to raise the primary boom until it level is within ± 2° of each other and of -50°.
stops at approximately 58°.
Result: The reading at the display and digital level is greater than ± 2° of each other and of
level is within ± 2° of each other and of 58°. -50°. The primary boom angle sensor must be
calibrated. Refer to Repair Procedure in the
Result: The reading at the display and digital appropriate Service and Repair Manual for
your machine, How to Calibrate the Primary
58°. The primary boom angle sensor must be
Boom Angle Sensor.
Boom Angle Sensor.
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
How to Calibrate the Primary
Boom Angle Sensor.
7 Fully raise the secondary boom. The boom is

fully raised when the cylinder is fully extended
and the boom stops moving.
9 Raise the primary boom to -20°.

level is within ± 2° of each other and of -20°.
-20°. The primary boom angle sensor must be
Boom Angle Sensor.

10 Raise the primary boom to 10°. Q-28

Result: The reading at the display and digital Test the Primary Boom Angle
level is within ± 2° of each other and of 10°. Sensor - SX-150 and SX-180
calibrated. Refer to Repair Procedure in the A properly functioning primary boom angle sensor
appropriate Service and Repair Manual for is essential to safe machine operation. The ECM at
your machine, How to Calibrate the Primary the ground controls (TCON) monitors the position
Boom Angle Sensor. and angle of the primary boom using the signal
11 Raise the primary boom to 40°. from the primary boom angle sensor. The primary
boom angle sensor signal is used to control the
Result: The reading at the display and digital ramping of the primary boom, limiting the speed of
level is within ± 2° of each other and of 40°. the primary boom to 2.3 feet / 0.7 meters per
Result: The reading at the display and digital second.
level is greater than ± 2° of each other and of Note:The turntable level sensor must be tested
40°. The primary boom angle sensor must be before starting this procedure. Refer to
calibrated. Refer to Repair Procedure in the Maintenance Procedures, Test the Turntable Level
appropriate Service and Repair Manual for Sensor.
Boom Angle Sensor. Note: A digital level will be required to perform this
procedure.
12 Fully raise the primary boom until it stops at
approximately 58°. Note: A kit is available through Genie Product
cable harnesses.
level is greater than ± 2° of each other and of Note: A properly calibrated digital level is essential
58°. The primary boom angle sensor must be to proper machine calibration. Refer to the
calibrated. Refer to Repair Procedure in the manufactures calibration information.
your machine, How to Calibrate the Primary description of each LCD screen control button used
Boom Angle Sensor. in this procedure.

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 7 Lower the primary boom to 66°.
3 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
4 Place a digital level that has been calibrated to your machine, How to Calibrate the Primary
gravity on top of the primary boom. Boom Angle Sensor.
5 Raise the primary boom while watching the

display screen.
6 Continue to raise the primary boom until it
stops at approximately 80°.
Boom Angle Sensor.
Tip-over hazard. If the boom is
not within ± 2° of 80°, 8 Lower the primary boom to 49°.
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 Result: The reading at the display and digital
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.

9 Lower the primary boom to 32°. Q-29

Result: The reading at the display and digital Test the Safety Envelope Limit
level is within ± 2° of each other and of 32°. Switches, Z-135/70, ZX-135/70,
Result: The reading at the display and digital SX-150 and SX-180 Models
32°. The primary boom angle sensor must be Genie specifications require that this procedure be
calibrated. Refer to Repair Procedure in the performed quarterly.
your machine, How to Calibrate the Primary Testing the machine envelope safety limit switches
Boom Angle Sensor. is critical to safe machine operation. If the boom is
allowed to operate when a safety switch is not
10 Lower the primary boom to 15°. functioning correctly, the machine stability could be
compromised and may tip over.
level is within ± 2° of each other and of 15°. Note: Perform this procedure with the boom in the
Result: The reading at the display and digital stowed position.
level is greater than ± 2° of each other and of Note: Perform this procedure with the axles
15°. The primary boom angle sensor must be extended.
appropriate Service and Repair Manual for Note: Two people will be required to perform this
your machine, How to Calibrate the Primary procedure.
Boom Angle Sensor.
11 Fully lower the primary boom until it stops at description of each LCD screen control button used
approximately -2.6°. in this procedure.
level is within ± 2° of each other and of -2.6°.
-2.6°. The primary boom angle sensor must be Plus Minus Previous Enter
Boom Angle Sensor.

Z-135/70 and ZX-135/70 Models: 6 Start the engine from the ground controls.
Secondary Boom #1 Retracted Safety Limit 7 Fully raise the secondary boom. Do not extend
Switch, LSS1RS the boom. Turn the machine off.
8 Locate and disconnect the Deutsch connector
1 Working at the platform end of the turntable, to LSS1RS.
support and secure the lower turntable riser
end cover to a suitable lifting device. 9 Connect the leads from a multimeter with
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.
Crushing hazard. The turntable Result: The limit switch should not have
riser lower cover could become continuity.
unbalanced and fall when
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.
4 Remove the 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.
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
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.
5 Locate the secondary boom #1 retracted 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.

13 Locate and disconnect the Deutsch connector Z-135/70, ZX-135/70, SX-150 and SX-180 Models
to LSS1RS.
Turntable Rotate Safety Limit Switch, LST1S
Result: The alarm should sound.
Result: The LCD screen should display the 1 Locate the turntable rotate safety limit switch
message SEC BOOM RETRACTED SAFETY (LST1S) at the center of the turntable.
SWITCH DISCONNECTED FAULT. Note: The turntable rotate safety limit switch
Result: The alarm doesn't sound and the LCD (LST1S) is located between the two operational
screen doesn't display a Fault message. The turntable rotate limit switches. It can easily be
limit switch is faulty and needs to be replaced. identified by the orange and red tie wraps attached
to the limit switch cable.
Note: A P30 Power Fault and a P11 Power Fault
will also display as a result of this test. 2 Locate and disconnect the deutsch connector
to LST1S.
14 Re-connect the Deutsch connector to
LSS1RS. 3 Connect the leads from a multimeter with
Result: The LCD screen displays SEC 2 at the Deutsch connector of the limit switch
LSS1RS FAULT. cable.
Result: The LCD screen doesn't display the Result: The limit switch should have
Fault message. The limit switch is faulty and continuity.
needs to be replaced.
Result: The limit switch does not have
15 Turn the engine off. continuity. The limit switch is faulty and needs
16 With the key switch off, press and hold the to be replaced.
enter button and turn the key switch to the on 4 Remove the multimeter leads and connect the
position. Release the enter button after five Deutsch connector to the limit switch.
seconds and press the
(minus)(minus)(previous)(previous) buttons 5 Start the engine and rotate the turntable more
in that order. than 15°. Turn the engine off
17 Press the previous button until clear all safety 6 Locate and disconnect the Deutsch connector
switch faults appears. to LST1S.
18 Select YES, then press the enter button. 7 Connect the leads from a multimeter with
19 Press the previous button until EXIT appears. 2 at the Deutsch connector of the limit switch
cable.
20 Select YES, then press the enter button.
Result: The limit switch should not have
21 Install the secondary boom end covers. 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°.
Deutsch connector to LST1S.

Z-135/70, ZX-135/70, SX-150 and SX-180 Models 10 Choose an axle extend safety limit switch to
test.
Axle Extended Safety Limit Switches, LSFA1ES
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
2 Turn the key switch to platform controls. 2 at the Deutsch connector of the limit switch
3 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 Result: The limit switch does not have
test. continuity. The limit switch is faulty and needs
to be replaced.
5 Locate and disconnect the deutsch connector
to the axle extend limit switch. 13 Remove the multimeter leads and connect the
Deutsch connector to the limit switch.
6 Connect the leads from a multimeter with
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.
Result: The limit switch does have continuity.
The limit switch is faulty and needs to be
replaced.
Deutsch connector to the limit switch.
8 Repeat steps 5 through 7 for the other axle
extend safety limit switch.
fully extend the axles. Turn the machine off.

Q-30 3 Start the engine from the ground controls.

Test the Primary Boom Angle 4 Raise the primary boom. The display will begin
Sensor - Z-80/60 showing a boom angle of 40°.
Genie specifications require that this procedure be 5 Continue raising the primary boom until the
performed quarterly. display shows 65°.
Result: The primary boom should stop.
A properly functioning primary boom angle sensor
(PBAS) is essential to safe machine operation. The Result: The primary boom does not stop.
primary boom angle sensor is used to limit the Immediately release the function enable
angle of the primary boom relative to the angle of button and lower the boom. Calibrate the limit
the secondary boom and gravity. The ECM at the switch. Refer to Repair Procedure in the
ground controls (TCON) monitors the position and appropriate Service and Repair Manual for
angle of the primary boom using the signal from your machine, How to Calibrate the Primary
PBAS. The PBAS signal is used to control the Boom Limit Switch.
ramping of the primary boom as well as velocity
control, limiting the speed of the primary boom to Tip-over hazard. If the boom
1.3 feet / 0.4 meters per second. does not stop at 65°,
immediately release the function
Note: Perform this procedure with the machine on enable button and lower the
a firm, level surface. primary boom. Failure to lower
the boom could cause the
Note: Use the following chart to identify the machine to tip over resulting in
description of each LCD screen control button used death or serious injury.
in this procedure.

2 Press the enter or previous button on the
LCD screen until primary boom angle is
displayed.

Q-31 7 Locate the Deutsch connectors from the

secondary safety retract switch (LSS1RS)
Test the Safety Envelope and near the chassis at the platform end of the
Circuits - Z-80/60 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
Testing the machine safety envelope is critical to secondary boom #1 retract operational limit
safe machine operation. If the boom is allowed to switch (LSS1RO) at the end of the secondary
operate when a safety switch is not functioning boom.The connection will be marked with red
correctly, the machine stability is compromised and zip ties on the wire assembly. Disconnect the
may tip over. For limit switch and angle sensor connectors.
information, Refer to appropriate Service and
Repair Manual for your machine. 9 Install a wire jumper between pin 1 and pin
2 of the Deutsch connector on the wire
Note: Use the following chart to identify the harness removed in step 8.
in this procedure. 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 = 0FT.
11 Press and hold the high speed function enable
Plus Minus Previous Enter button and lower the secondary boom.
Secondary Boom #1 Angle Safety Limit Switch, Result: The secondary boom should lower to
LSS2AS 60° and the engine should stop.
1 Turn the key switch to ground control and pull Result: If the engine does not stop at 60° and
out the red Emergency Stop button to the on the secondary boom continues to lower, the
position at both ground and platform controls. secondary boom #2 angle safety limit switch
(LSS2AS) is out of adjustment or the wiring
2 Start the engine from the ground controls. circuit is faulty and will need to be replaced or
repaired. Immediately remove the machine
3 Press the (plus)(minus) buttons on the LCD
from service until repairs are made.
screen to activate status mode.
4 Press the enter or previous button on the Bodily injury hazard. If the
LCD screen until secondary boom length is secondary boom lowers to less
displayed. than 60° without stopping the
engine, stop immediately and
5 Fully raise the secondary boom and extend raise the secondary boom above
the secondary boom approximately 2 feet / 60°. Failure to raise the
61 cm. secondary boom could result in
death or serious injury.
6 Remove the fasteners from the turntable riser
cover at the platform end of the secondary
boom. Remove the cover.

12 Remove the key from the main key switch, 21 Locate the Deutsch connectors from the
insert it into the bypass/recovery key switch, secondary boom #2 angle operational limit
turn the key to Bypass mode and raise the switch (LSS2AO) on the inside of the turntable
secondary boom above 60° using emergency riser. The connection will be marked with
power. green zip ties on the wire assembly.
Disconnect the connectors.
13 Remove the wire jumpers installed in steps
9 and 10 and connect the wire harness to 22 Install a wire jumper between pins 1 and 2 of
LSS1RO removed in step 8. the Deutsch connector on the wire harness
removed in step 21.
14 Fully raise the secondary boom and extend
the secondary boom approximately 1 foot / Result: The display should show at 65
30.5 cm. DEGREES.
15 Turn the bypass/recovery key switch back to 23 Press and hold the low speed function enable
run, return the key to the main key switch and button and extend the secondary boom.
start the engine from the ground controls.
Result: The secondary boom should extend
16 Re-connect the Deutsch connector from the no more than 12 inches / 30.5 cm and stop.
secondary safety retract switch (LSS1RS) The engine should stop and the display will
removed in step 7. show P9B SAFETY FAULT and P11 SAFETY
FAULT.
Secondary Boom #1 Retracted Safety Limit
Switch, LSS1RS Result: If the engine does not stop and the
secondary boom continues to extend, the
17 Press the (plus)(minus) buttons on the LCD secondary boom #1 retracted safety limit
screen to activate status mode. switch (LSS1RS) is out of adjustment or the
wiring circuit is faulty and will need to be
18 Press the enter or previous button on the
replaced or repaired.
LCD screen until secondary boom length is
displayed. Bodily injury hazard. If the
19 Raise the secondary boom until the display secondary boom continues to
shows >=35 DEGREES. extend without stopping the
engine, stop immediately and
20 Locate the Deutsch connectors from the retract the secondary boom.
secondary boom #2 angle safety limit switch Failure to retract the secondary
(LSS2AS) on the inside of the turntable riser. boom could result in death or
The connection will be marked with purple zip serious injury.
ties on the wire assembly. Disconnect the
connectors. 24 Remove the wire jumpers installed in step
22 and connect the wire harness to LSS2AO.
25 Re-connect the Deutsch connector from the
secondary boom #2 angle safety limit switch
(LSS2AS) removed in step 20.

Q-32 3 Turn and hold the function enable switch to the

restricted maximum platform capacity and
Check the Safety Envelope Limit raise the primary boom until it is fully elevated.
Switches and Angle Sensor -
S-60X, S-60XC and S-80X

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.
1 restricted maximum platform capacity
a firm, level surface with all weight, tools and 2 unrestricted maximum platform capacity
equipment removed from the platform. 4 Extend the primary boom until it is fully
extended.
Note: Start this procedure with the boom fully
retracted and in the stowed position. 5 Lower the primary boom until it stops.
Ground controls: Result: The boom will automatically stop after

10 degrees.
1 Turn the key switch to ground control and pull Result: The primary boom does not stop after
out the red Emergency Stop button to the on 10 degrees. Check limit switches LST3O and
position. LST3S.
2 Start the engine from the ground controls. 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).

7 Measuring Tape: Platform controls:

S-60X and S-60XC Models: Note: Start this procedure with the boom fully
retracted and in the stowed position.
Measure the distance between the center of
the pivot pins as shown. The distance should 1 Pull out the red Emergency Stop button to the
be 171 inches / 434 cm ± 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
be 201.75 inches / 512 cm ± 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
protractor should display 58° ± 2°.
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

6 Move the primary boom down joystick off Q-33

center and retract the primary boom until the
unrestricted platform capacity light stops
Test the Safety Envelope and
flashing. Circuits - S-100, S-105, S-120,
Result: Primary boom down should return to S-125, S-100HD and S-120HD
normal operation.
7 Lower the primary boom 5 feet / 1.5 m and performed quarterly.
activate primary boom extend.
Testing the machine safety envelope is critical to
Result: Primary boom extend will stop and the safe machine operation. If the boom is allowed to
unrestricted platform capacity light will start operate when a safety switch is not functioning
flashing. correctly, the machine stability is compromised and
may tip over.
8 Activate primary boom extend and raise the
primary boom until the unrestricted platform Note: Use the following chart to identify the
capacity light stops flashing. description of each LCD screen control button used
Result: Primary boom extend should return to in this procedure.
normal operation.
9 Return the machine to the fully stowed
position.

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 Plug in the LSB2RS test jumper between the
lower limit switch and the function manifold
(J2 and J4 connectors on the ground control
box).
on position and start the engine.

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 ">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°.
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 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
LSB9AS switch is out of adjustment or the
Bodily injury hazard. If the boom
wiring is faulty and will need to be replaced or
extends to more than 101 feet /
repaired.
30.8 m without stopping the
engine, stop immediately and Bodily injury hazard. If the
retract the boom until the boom boom lowers to less than 65°
is extended to less than 100 feet without stopping the engine,
/ 30.5 m. Failure to retract the stop immediately and raise the
boom could result in death or boom until the boom is
serious injury. elevated to greater than 68°.
Failure to raise the boom could
9 Using emergency power, retract the boom result in death or serious injury.
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°.
LSB14AO.
19 Using emergency power, raise the boom until
11 Push in the 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 LSB14AO.
(J2 and J4 connectors on the ground control
box).
on position and start the engine.

21 With the key switch off, press and hold the 31 Measure the angle of the boom.
enter button and turn the key switch to the on
Result: the angle of the boom should be
position. Release the enter button after five
greater than 50°.
(minus)(minus)(previous)(previous) 32 Using emergency power, raise the boom until
buttons. the boom angle is greater than 53°.
22 Press the previous button until clear all safety 33 Remove the wire jumper installed in step
switch faults appears. 29 and connect the Deutsch connector to
LSB13AO.
34 With the key switch off, press and hold the
24 Press the previous button until exit appears.
enter button and turn the key switch to the on
25 Select YES, then press the enter button. position. Release the enter button after five
26 Start the engine. (minus)(minus)(previous)(previous)
50° Angle Safety Switch, LSB8AS: buttons.
27 Lower the boom to approximately 60°. 35 Press the previous button until clear all safety
switch faults appears.
28 Extend the boom to approximately 95 feet /
28.96 m. 36 Select YES, then press the enter button.
29 Disconnect the 53° proximity switch LSB13AO 37 Press the previous button until exit appears.
and install a wire jumper between pin 3 and 38 Select YES, then press the enter button.
pin 4 of the Deutsch connector.
39 Restart the engine, retract the boom so it is
30 Activate the function enable/high RPM button extended less than 75 feet / 22.9 m and then
and lower the boom to 50°. lower the boom sufficient to gain access to
Result: The engine should stop and the boom LSB3EO.
down function should be disabled. Note: LSB3EO is located on top of boom tube
Result: If the engine does not stop and the number 2 at the platform end of the machine.
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
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.

76 feet / 23.2 m Length Safety Switch, LSB4ES: Cable Break Safety Switch, LSB6S:
40 Disconnect the 75 feet / 22.9 m safety switch 49 Start the engine and activate the function
LSB3EO. enable/high RPM button and retract the boom
until the boom is extended to less than 2 feet /
41 Start the engine and activate the function 0.6 m.
enable/high RPM button and extend the boom
to 76 feet / 23.2 m. 50 Remove the boom end cover from the pivot
end of the boom.
Result: The engine should stop and the boom
extend function should be disabled. 51 Remove the arm from the cable break limit
switch LSB6S.
Result: If the engine does not stop and the
boom continues to extend, the LSB4ES switch Note: LSB6S is located at the end of the boom
is out of adjustment or the wiring circuit is tubes at the pivot end of the boom.
faulty and will need to be replaced or repaired.
52 Place the arm removed in step 51 back on the
Bodily injury hazard. If the boom LSB6S switch 180° opposite its original
extends to more than 76 feet/ position. Rotate the head of the switch 45°
23.2 m without stopping the clockwise and activate the function
engine, stop immediately and enable/high RPM button and attempt to
retract the boom until the boom is extend the boom.
extended to less than 75 feet /
22.9 m. Failure to retract the Result: The boom extend function should be
boom could result in death or disabled.
serious injury. Result: If the boom extends, the LSB6S switch
or wiring circuit is faulty and will need to be
42 Using emergency power, retract the boom replaced or repaired.
until the boom is extended to less than 75 feet
/ 22.9 m. Bodily injury hazard. If the boom
extends at all, stop immediately
43 Re-connect the harness plug to LSB3EO. and retract the boom until the
44 With the key switch off, press and hold the boom is extended to less than
enter button and turn the key switch to the on 2 feet / 0.6 m. Failure to retract
position. Release the enter button after five the boom could result in death or
seconds and press the serious injury.
(minus)(minus)(previous)(previous)
buttons. 53 Activate the function enable/high RPM button
and attempt to retract the boom.
45 Press the previous button until clear all safety
Result: The boom retract function should be
switch faults appears.
enabled.
Result: If the boom does not retract, the
47 Press the previous button until exit appears. LSB6S switch or wiring circuit is faulty and will
need to replaced or repaired.

54 Allow the switch to return to its neutral 60 Place a metal washer over the target area of
position, then rotate the head of the switch 45° the axle extend proximity switch LSAX1EO
counter clockwise and activate the function and place a metal washer over the target area
enable/high RPM button and attempt to of the axle extend proximity switch LSAX2EO
extend the boom. to close the contacts.
Result: The boom extend function should be Result: The axle extend indicator light at the
disabled. ground and platform controls should be
illuminated.
Result: If the boom extends, the LSB6S switch
or wiring circuit is faulty and will need to be
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. Proximity switch
1 target area
55 Reinstall the arm onto LSB6S in its original
61 Activate the function enable/high RPM button
position.
and attempt to extend the boom.
Axle Extend Safety Switch, LSAX1ES and Result: The boom should not extend to more
LSAX2ES and than 3 feet / 0.9 m.
3 feet / 0.9 m Safety Switch, LSB3RS and Result: If the boom extends to more than
3 feet / 0.9 m, the LSAX1ES or LSAX2ES
11° Angle Safety Switch, LSB7DS:
switch are out of adjustment or the wiring
56 Fully retract and lower the boom to the stowed circuit is faulty and will need to be replaced or
position. repaired.
57 Retract both axles approximately 1 foot / Bodily injury hazard. If the boom
0.3 m. extends to more than 3 feet/
0.9 m, stop immediately and
58 Remove the access cover from each axle. retract the boom until the boom is
59 Disconnect the square-end axle extend safety extended to less than 2 feet/
switch LSAX1ES and install a wire jumper 0.6 m. Failure to retract the boom
between pin 3 and pin 4 of the deutsch could result in death or serious
connector. injury.

62 Activate the function enable/high RPM button 66 Activate the function enable/high RPM button
and attempt to raise the boom. and attempt to raise the boom.
Result: The boom should not raise to more Result: The boom should not raise to more
than 11°. than 11°.
Result: If the boom continues to raise, the Result: If the boom continues to raise, the
LSAX1ES or LSAX2ES switch are out of LSAX1ES or LSAX2ES switch are out of
adjustment or the wiring circuit is faulty and adjustment or the wiring circuit is faulty and
will need to be replaced or repaired. will need to be replaced or repaired.
Bodily injury hazard. If the boom Bodily injury hazard. If the boom
raises to more than 11°, stop raises to more than 11°, stop
immediately and lower the boom immediately and lower the boom
until the boom is less than 11°. until the boom is less than 11°.
See Repair Section. Failure to Failure to lower the boom could
retract the boom could result in result in death or serious injury.
death or serious injury.
67 Remove the wire lumper installed in step
63 Remove the wire jumper installed in step 64 and connect the Deutsch connector to
59 and connect the Deutsch connector to LSAX2ES.
LSAX1ES.
64 Disconnect the circle-end axle extend safety
switch LSAX2ES and install a wire jumper
between pin 3 and pin 4 of the Deutsch
connector.
65 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.
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.

Q-34 All Models:

Test the Aircraft Protection 3 Move the yellow bumper at the bottom of the
System (if equipped) platform 4 inches / 10 cm in any direction.

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

position at both the ground and platform
controls.
Engine powered models:
2 Start the engine from the platform controls. 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 /
1 m.
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.
Result: No boom, drive or steer functions
operate.

8 Activate and hold the aircraft protection Articulated (Z) Booms:

override switch.
17 Raise the secondary boom approximately 3 ft /
9 Activate each function control handle or toggle 1 m.
switch.
18 Move the yellow bumper at the bottom of the
Result: All boom, drive and steer functions platform 4 inches / 10 cm in any direction.
operate.
10 Fully retract the primary boom. switch.
11 Raise the primary boom to 5° above Result: No boom, drive or steer functions
horizontal. operate.
12 Move the yellow bumper at the bottom of the 20 Activate and hold the aircraft protection
platform 4 inches / 10 cm in any direction. override switch.
13 Activate each function control handle or toggle 21 Activate each function control handle or toggle
switch. switch.
Result: No boom, drive or steer functions Result: All boom, drive and steer functions
operate. operate.
14 Activate and hold the aircraft protection 22 Lower the secondary boom to the stowed
override switch. position.
switch.
Result: All boom, drive and steer functions
operate.
16 Lower the primary boom to the stowed
position.

Q-35
Test the Operator Protection
Alarm (if equipped)
Testing the operator protection alarm (OPA) is
important for proper operation.
1 Turn the key switch to platform control and pull

position at both the ground and platform
controls.
Engine powered models:
2 Start the 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.

Annual Maintenance Procedures
A-1 Models with Worm Drive Gear:

Grease the Turntable Rotation 1 Locate the 2 grease fittings on top of the worm
Bearing and Rotate Gear drive housing.

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 1 grease fittings
result in component damage.
2 Pump grease into the gear until you see it
1 Locate the grease fitting for the turntable coming out of the side of the gear housing.
rotate bearing.
Grease Specification
2 Pump grease into the turntable rotation Chevron Ultra-duty grease, EP NLGI 1 (lithium based)
bearing. Rotate the turntable in increments of or equivalent
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.

A-2 3 Using a star pattern, confirm that each

turntable mounting bolt is torqued in sequence
Check the Turntable Rotation to specification.
Bearing Bolts
4 Raise the boom and remove the safety chock
OR lifting device.
5 Lower the boom to the stowed position.
performed annually. 6 Using a star pattern, confirm that each lower
bearing mounting bolt is torqued in sequence
Maintaining proper torque on the turntable bearing to specification.
bolts is essential to safe machine operation.
Improper bolt torque could result in an unsafe Z-62 160 ft-lbs
217 Nm
operating condition and component damage
Z-135 and ZX-135 180 ft-lbs
Note: Access to the upper and lower turntable (5/8-11 SHC) 244 Nm
bearing bolts will vary depending on model. Z-135 and ZX-135 320 ft-lbs
(3/4-10 SHC) 434 Nm
1 S Booms and Z-45/25 (J) IC, DC Bi-Energy:
Raise the (primary) boom and place a safety S-40, S-45 160 ft-lbs
chock on the lift cylinder rod. Carefully lower (includes TRAX modesl) 217 Nm
the boom onto the lift cylinder safety chock OR S-60 S-65, S-60X, S-60XC 180 ft-lbs
support the boom assembly with a suitable (includes TRAX models) 244 Nm
lifting device. (to serial number S6015A-29677)
Z Booms: Raise the secondary boom and S-60 S-65, S-60X, S-60XC 160 ft-lbs
place a safety chock on the lift cylinder rods.
(from serial number S6015A-29678)
Carefully lower the boom onto the lift cylinder
safety chock OR support the boom assembly SX-150 and SX-180 455 ft-lbs
with a suitable lifting device. 617 Nm
All other models 180 ft-lbs
Crushing hazard. Keep hands 244 Nm
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.

A-3 4 Place a dial indicator between the drive

chassis and the turntable at a point that is
Inspect for Turntable Bearing directly under, or inline with, the boom and no
Wear 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.
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.
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. 1 turntable
2 dial indicator
2 Torque the turntable bearing bolts to
specification. Refer to Maintenance 3 drive chassis
Procedure, Check the Turntable Rotation 4 turntable rotation bearing
Bearing Bolts.
5 Adjust the dial indicator needle to the "zero"
3 S-Booms: Using the ground controls, raise position.
the boom to full height. Do not extend the
boom. 6 S-Booms: Fully extend the boom and lower to
a horizontal position.
Z-Booms: Using the ground controls, raise
the primary and secondary booms to full Z-Booms: Lower the secondary boom to the
height. Do not extend the primary boom. stowed position and lower the primary boom to
a horizontal position. Fully extend the primary
Z-80/60, Z-135/70 and ZX-135/70: Using the boom.
ground controls, fully raise, but do not extend,
the primary boom and jib. The secondary riser Z-80/60, Z-135/70 and ZX-135/70: Raise the
should remain in its stowed position. secondary riser, but do not extend it. Move the
primary boom and jib to horizontal and fully
extend.

7 Note the reading on the dial indicator. A-4

Result: The measurement is less than Check the Extendable Axle -
specification. The bearing is good. S-100, S-100HD, S-105, S-120,
Result: The measurement is more than S-120HD and S-125
specification. The bearing is worn and needs
to be replaced.
Models Measurement
S-40 (all), S-60 (all), SX150, SX180, Z-62/40 0.063 inch Genie specifications require that this procedure be
1.6 mm performed annually.
Z-30/20N, Z-34/22 (all), Z-40/23, Z-45/25 (all), 0.055 inch
Z-51/30 1.4 mm
Maintaining the axle wear pads in good condition is
essential to safe machine operation. Wear pads
Z-33/18 0.043 inch
1.1 mm
are placed on axle tube surfaces to provide a low
friction, replaceable wear pad between moving
S-80 (all), S-100, S-100HD, S-105, S-120, 0.118 inch
3.0 mm
parts. Improperly shimmed wear pads or continued
S-120HD, S-125, Z-80, Z-135/70, ZX-135/70
use of worn out wear pads may result in
8 Move the boom(s) to the positions indicated in component damage and unsafe operating
step 3. Visually inspect the dial indicator to be conditions.
sure the needle returns to the "zero" position.
9 Remove the dial indicator and rotate the extend the axles.
turntable 90°.
2 Measure each axle wear pad.
10 Repeat steps 4 through 9 until the rotation
bearing has been checked in at least four 3 Replace any wear pad if it is less than
equally spaced areas 90° apart. specification. If a wear pad is not less than
specification, shim as necessary to obtain
11 Lower the boom(s) to the stowed position and minimum clearance and no drag.
turn the machine off.
4 Extend and retract the axles through the entire
12 Remove the dial indicator from the machine. 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.
Wear pad specifications Minimum

Extendable axle wear pad 0.4375 inch
11.11 mm

A-5 4 While rotating the jib, pump grease into the

worm gear grease fitting until fresh grease is
Perform Maintenance – visible at one sealing lip or bearing cap.
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 Illustration 1
retracted and in the stowed position and with the 1 bearing lubrication fitting
machine on a firm, level surface. 2 worm gear lubrication fitting
3 sealing lip
Check the Jib Rotator Fastener torque
Jib Rotator Bearing Wear
1 Using a star pattern, confirm that each jib
rotator outer mounting bolt is torqued in 5 Place a 750 lb / 340 kg weight in the platform
sequence to specification. and raise the jib until it is horizontal and
parallel with the boom.
2 Repeat the procedure for the inner mounting
bolts. 6 Place the dial indicator on the side of the
rotator bearing housing and measure the
Jib boom rotate bearing bolts 200 ft-lbs
bearing as shown in illustration 2.
271 Nm
Grease the Jib Rotator 7 Using a forklift, raise the platform and jib
components so there is no weight on the
3 While rotating the jib, pump grease into each rotator bearing.
bearing lubricating grease fitting until fresh
8 Adjust the dial indicator needle to the "zero"
grease is visible at the outer seal.
position..
9 Lower the forklift, allowing the platform and jib
assembly to settle.

10 Note the reading on the dial indicator. A-6

Result: The measurement is less than Test the Key Switches - ALC1000
0.063 inch / 1.6 mm. The bearing is good. Models
Result: The measurement is more than
0.063 inch / 1.6 mm. The bearing is worn and
performed annually.
needs to be replaced.
11 Lower the platform and remove the weight. Proper key switch action and response is essential
to safe machine operation. Failure of either key
12 Remove the dial indicator from the machine. switch to function properly could cause a
hazardous operating situation.
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.
Illustration 2
1 measuring surface
2 dial indicator mounting surface


When the Bypass/Recovery key switch is turned Note: Perform this procedure on a firm, level
and held to the recovery position, the emergency surface with the machine in the stowed position.
power unit turns on and starts a sequence to lower
the platform. This feature of the machine is 1 Open the ground controls side turntable side
especially helpful if the operator in the platform cover.
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 on position at both the ground and platform
tripped. controls.
3 At the ground controls, turn the
bypass/recovery key switch to the run
position.
4 Turn the main key switch to ground control,
start the engine and then turn the key switch to
platform control.
5 Check any machine function from the ground
controls.
Result: The machine functions should not
operate.
6 Turn the main key switch to ground control.
7 Check any machine function from the platform
controls.
Result: The machine functions should not
operate.
8 Turn the main key switch to the off position.
Result: The engine should stop and no
functions should operate.
1 Run
2 Bypass
9 Turn the main key switch to ground control
and start the engine.
3 Recovery
10 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Note: The main key switch must remain in the
ground control position.

11 Raise the primary boom 3 ft / 1 m. A-7

Result: The primary boom should raise. Grease the Platform Overload
12 Remove the key from the bypass/recovery key Mechanism (if equipped)
switch.
13 Turn the main key switch to the off position.
14 Remove the key from the main key switch and performed annually.
insert the key into the bypass/recovery key
switch. Perform this procedure more often if dusty
conditions exist.
15 Turn and hold the bypass/recovery key switch
to the recovery position. The switch must be Application of lubrication to the platform overload
held in the recovery position. mechanism is essential to safe machine operation.
Continued use of an improperly greased platform
Result: The primary boom lowers to the
overload mechanism could result in the system not
stowed position.
sensing an overloaded platform condition and will
16 Turn the bypass/recovery key switch to the run result in component damage.
position.
1 Locate the grease fittings on each pivot pin of
17 Remove the key from the bypass/recovery key the platform overload assembly.
switch. 2 Thoroughly pump grease into each grease
fitting.
Close the turntable side cover.
Chevron Ultra-duty grease, EP NLGI 1 (lithium based)
or equivalent

A-8 2 Engine Models: Turn the key switch to

ground control and pull out the red Emergency
Test the Platform Overload Stop button to the on position at both the
System - ground and platform controls. Start the 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 and platform controls. Level the platform.
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
Result: The platform overload indicator lights
could be compromised resulting in the machine
should be off at both the ground and platform
tipping over.
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
retracted and in the stowed position and with the
machine on a firm, level surface.
1 Remove all weight, tools, accessories and illustration 1

equipment from the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.

5 Carefully move the test weights to each 8 Using emergency power, test all machine
remaining location on the platform. Refer to functions from the ground controls.
Illustration 1.
Result: All ground control functions should
Engine Models: Result: The platform operate normally.
overload indicator lights should be off at both
9 Using emergency power, test all machine
the ground and platform controls, the alarm
functions from the platform controls.
should not sound and the engine should
continue to run. Result: All platform control functions should
operate normally.
DC Models: Result: The platform overload
indicator lights should be off at both the 10 Using a suitable lifting device, lift the additional
ground and platform controls and the alarm test weight from the platform.
should not sound.
Result: The platform overload indicator lights
6 Add additional weight to the platform that is should turn off at both the ground and platform
equal to, but does not exceed 15% of the controls and the alarm should not sound.
maximum rated load. Secure the additional
Note: There may be an 2 second delay before the
weight. Refer to the machine serial plate.
overload indicator lights and alarm turn off.
Engine Models: Result: The platform
overload indicator lights should be flashing at 11 Engine Models: Start the engine and test all
both the ground and platform controls, the machine functions from the ground controls.
alarm should sound and the engine should DC Models: Test all machine functions from
turn off. the ground controls.
DC Models: Result: The platform overload Result: All ground control functions should
indicator lights should be flashing at both the operate normally.
ground and platform controls and the alarm
should sound. 12 Using a suitable lifting device, remove all test
weights from the platform.
Note: There may be a 2 second delay before the
overload indicator lights flash and 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.
sounds.

A-9 4 Using a suitable lifting device, place a test

weight equal to that of the available capacity in
Test the Platform Overload one of the locations shown. Refer to
System - ALC1000 Models Illustration 1.
Result: The platform overload indicator light
should be off at platform controls and there
should be no error message displayed at the
Genie specifications require that this procedure be ground control LCD screen. The alarm should
performed annually OR when the machine fails to not sound and the engine should continue to
lift the maximum rated load. run.
Testing the platform overload system regularly is
of an improperly operating platform overload
system could result in the system not sensing an
tipping over.
S-100HD, S-120HD, SX-150, SX-180, Z-80/60, illustration 1
Z-135/70 and ZX-135/70.
5 Carefully move the test weights to each
Note: Perform this procedure with the boom fully remaining location on the platform. Refer to
retracted and in the stowed position and with the Illustration 1.
machine on a firm, level surface.
1 Remove all weight, tools, accessories and should be off at platform controls and there
equipment from the platform. should be no error message displayed at the
ground control LCD screen. The alarm should
not sound and the engine should continue to
run.
inaccurate test.
6 Add additional weight to the platform that is
2 Turn the key switch to ground control and pull equal to, but does not exceed 15% of the
out the red Emergency Stop button to the on maximum rated load. Secure the additional
position at both the ground and platform weight. Refer to the machine serial plate.
controls. Start the engine from the ground
controls and level the platform. Do not turn the Result: The platform overload indicator light is
engine off. on at the platform and PLATFORM OVERLOAD is
displayed at the ground control LCD screen.
3 Determine the maximum platform capacity. The alarm is sounding and the engine should
Refer to the machine serial plate. not start and run.
sounds.

7 Carefully move the test weights to each A-10

remaining location on the platform. Refer to
Illustration 1.
Test the Platform Load Sense
Result: The platform overload indicator light is
System - S-60 HC
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. Genie specifications require that this procedure be
performed annually OR when the machine fails to
Note: There may be a 2 second delay before the lift the maximum rated load.
sounds. Testing the platform overload system regularly is
8 Using emergency power, test all machine of an improperly operating platform overload
functions from the ground controls. system could result in the system not sensing an
Result: All ground control functions should not
operate.
tipping over.
Note: Z-135 models before serial number
471 and with software revision 1.00 will not Note: Be sure that no load sense system faults
function using the auxiliary pump. exist prior to performing this procedure.
Note: On a properly functioning machine, the LEDs
Note: Z-80 and Z-135 models, all functions
on both control modules, located next to the ground
should operate except for primary boom
control box, should be off.
extend.
1 Remove all weight, tools, accessories and
9 Using a suitable lifting device, lift the additional
equipment from the platform.
test weight from the platform.
should turn off at platform controls, there
inaccurate test.
should be no error message displayed at the
ground control LCD screen and the alarm 2 Turn the key switch to ground control and pull
should not sound. out the red Emergency Stop button to the on
Note: There may be an 2 second delay before the position at both ground and platform controls.
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.

3 Start the engine from the ground controls. A-11

4 Using a suitable lifting device, place an Inspect the Boom Extend/Retract
appropriate test weight equal to 340.2 kg on to Cables - S-60 and S-80 Models
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. Genie specifications require that this procedure be
performed annually.
5 Using a suitable lifting device, place an
additional appropriate test weight equal to The boom extend/retract cables are responsible for
227.2 to 231.3 kg on to the center of the the extension and retraction of the boom tubes.
platform floor. The total weight in the platform Inspecting for foreign objects, damage and/or
must equal 567.4 to 571.5 kg. improper adjustment of the boom extend/retract
Result: The alarm should sound and the cables and related components on a regular basis
engine should turn off. The platform overload is essential to good machine performance and safe
indicator light should be on at both the ground machine operation. The boom extend and retract
and platform controls. functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
6 Using a suitable lifting device, remove all test
weights from the platform. This maintenance procedure applies to the
following models: S-60, S-65, S-60 TRAX, S-65
7 Push in the ground controls red Emergency TRAX, S-60 HC, S-60X, S-60XC, S-80, S-85,
Stop button to the off position, then pull the red S-80X
Emergency Stop button out to the on position
to reset the control system. 1 Raise the boom to horizontal and fully extend
the boom.
2 After the boom is fully extended, lower the
boom until the platform is at chest height. Turn
the machine 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 cover 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.

4 Remove the retaining fasteners from the 6 S-60, S-65, S-60X, S-60XC, S-60 TRAX and
access covers located on the side of the boom S-65 TRAX, S-80, S-85, S-80X: Install the
at the platform end of the machine. Remove cover at the pivot end of the boom.
the covers.
S-60 HC: Install the boom end cover at the
5 Visually inspect the cables and components pivot end of the boom while guiding the small
through both inspection holes for the following: cable from the string potentiometer into the
• Frayed or broken wire strands slot of the cover.
• Kinks in the cables Component damage hazard. The

cable from the string potentiometer
• Corrosion can become damaged if it is
kinked or pinched.
• Paint or foreign materials on the cable
Note: Be sure the cable from the string
• Split or cracked cable ends potentiometer is correctly routed around the small
pulley before installing the boom end cover.
• Cables are on all pulleys
• Extend cable break limit switch arm is 7 Install the access panels on the sides of the
centered in the pivot plate boom.
• Cables have equal tension 8 Start the engine from the ground controls and
fully retract and lower the boom to the stowed
• Cables at end of adjustment range position.
• No broken or damaged pulleys 9 Turn the key switch to platform controls.
• No unusual or excessive pulley wear 10 Extend the boom approximately 2 feet / 0.6 m.
• All fasteners in place and secure 11 Retract the boom. While retracting the boom,
visually inspect the number 2 and number
• S-60 HC: String potentiometer cable break
3 boom tubes.
limit switch arm is securely attached to end
of cable Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the
Note: A flashlight and inspection mirror may be number 3 boom tube begins to retract.
necessary to thoroughly inspect the above items.
Note: If the number 2 boom tube moves more than
Note: A pulley groove gauge should be used to 1/2 inch / 13 mm before the number 3 boom tube
check the condition of the pulleys. begins to retract, the boom extend/retract cables
need to be adjusted. Refer to Repair Procedure in
the appropriate Service and Repair Manual for your
machine, How to Adjust the Boom Extend/Retract
Cables.

A-12 2 Remove the retaining fasteners from the

access covers located on the side of the boom
Inspect the Boom Extend/Retract at the platform end of the machine. Remove
Cables - S-100, S-105, S-120, the covers.
S-125, S-100HD and S-120HD 3 Visually inspect the cables and components
Models through both inspection holes for the following:
• Frayed or broken wire strands
• Kinks or crushed cables
Genie specifications require that this procedure be • Corrosion
performed annually.
• Paint or foreign materials on the cable
The boom extend/retract cables are responsible for
the extension and retraction of the number 3 boom • Split or cracked cable ends
tube on the S-100, S-105 and S-100HD, and the • Cables are on all pulleys
numbers 2 and 3 boom tubes on the S-120,
S-125 and S-120HD. Inspecting for foreign objects, • Cables have equal tension
damage and/or improper adjustment of the boom
• Cables at end of adjustment range
extend/retract cables on a regular basis is essential
to good machine performance and safe machine • No broken or damaged pulleys
operation. The boom extend and retract functions
should operate smoothly and be free of hesitation, • No unusual or excessive pulley wear
jerking and unusual noise. • All fasteners in place and secure
Note: Perform this procedure with the boom in the Note: A flashlight and inspection mirror may be
stowed position. necessary to thoroughly inspect the above items
Note: Perform this procedure with the engine off. Note: A pulley groove gauge should be used to
check the condition of the pulleys.
1 Remove the boom end cover from the pivot
end of the boom. 4 Replace the cables if any damage is found.
5 At the pivot end of the boom, visually inspect
for the following:
• The red locking bracket is securely installed
over the cable adjustment bolts.
1 boom end cover

2 side access covers
3 cable ends (located underneath the boom)

6 Install the plastic cover at the pivot end of the A-13

boom and access panels on the sides of the
boom.
Inspect the Boom Extend/Retract
Cables - SX-150 and SX-180
7 Start the engine from the platform controls.
Models
8 Extend the boom approximately 2 feet / 0.6 m.
9 Retract the boom. While retracting the boom,
visually inspect the number 2 and number
3 boom tubes. Genie specifications require that this procedure be
performed annually.
Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the Failure to maintain proper adjustment of the cables
number 3 boom tube begins to retract. could result in unsafe operating conditions and may
cause component damage. The boom extend and
Note: If the number 2 boom tube moves more than
retract functions should operate smoothly and be
1/2 inch / 13 mm before the number 3 boom tube
free of hesitation, jerking and unusual noise.
begins to retract, the boom extend/retract cables
need to be adjusted. Refer to Repair Procedure in Note: Properly adjusted extend/retract cables will
the appropriate Service and Repair Manual for your maintain a relationship of the gap between boom
machine, How to Adjust the Boom Extend/Retract tubes #2 and #3 and boom tubes #3 and #4.
Cables.
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 Stop the engine.
5 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".


#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 boom tube is in
tolerance. Proceed to step 8.
#2 and #3 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
Adjust the Boom Extend/Retract Cables.
#3 and #4 using points 7 and 8 as shown in
the illustration.
#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 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".
7 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.

A-14 Models with TRAX:

Check the Drive Hub Oil Level 1 Select the drive hub to be serviced. Loosen
and Fastener Torque and remove as many sprocket retaining
fasteners as possible from the hub adapter.

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 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 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive
chassis between the tracks.
5 Lift the machine until the tracks are off the
1 drive hub plugs ground and place jack stands under the drive
chassis for support.
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.
5 Check the torque of the drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
6 Repeat this procedure for each drive hub.

6 Attach a lifting strap from an overhead crane 10 Remove the plug located at 90 degrees and
(2000 lbs / 1000 kg) to the center-point of the check the oil level.
track assembly, above the sprocket.
bottom of the plug hole.
11 If necessary, remove the top plug and add oil
side plug hole.
12 Install the plug(s) into the drive hub.
13 Check the torque of the drive hub mounting
bolts. Refer to Specifications, Machine Torque
Specifications.
7 Remove the remaining sprocket retaining 14 Attach a lifting strap from an overhead crane
fasteners from the hub adapter. to the center-point of the track assembly,
above the sprocket.
8 Carefully remove the track assembly from the
drive hub and set aside. 15 Install the track assembly onto the drive hub
adapter while guiding the hub adapter studs
Crushing hazard. The track into the sprocket of the track assembly. Install
assembly could become as many sprocket retaining fasteners as
unbalanced and fall when possible to the hub adapter and torque to
removed from the machine if specification. Refer to Specifications, TRAX
not properly supported by the Torque Specifications.
overhead crane.
16 Raise the machine, remove the jack stands
9 Locate the hub disconnect pin in the center of lower the machine.
the drive hub. Manually depress the pin and 17 Drive the machine in either direction just until
rotate the drive hub until the plugs are one on the remaining sprocket retaining fasteners can
top and the other at 90 degrees. be installed onto the drive hub adapter. Turn
the machine off.
18 Install the remaining sprocket retaining
fasteners to the drive hub adapter and torque
to specification. Refer to Specification, TRAX
Torque Specifications.
1 drive hub plugs

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.
bottom of the side hole.
1 fill plug
2 drain plug
3 mounting fasteners
2 If necessary, remove the fill plug and add oil

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-lbs
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 Nm

Programmed Maintenance Procedures
P0-1 5 Visually inspect the section of track under the

bogey wheels.
Check the Track Tension and
Result: There should be less than 1 inch /
Fastener Torque, TRAX Models - 2.5 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.
chassis between the tracks at the other end of
1 bogey wheels
the machine.
4 Lift the 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. Loosen the plug, but do not remove
drive chassis for support. it.
1 grease zerk
2 grease plug

7 Locate the grease zerk fitting on the other side P0-2

of the track tension cylinder.
Check the Track Tension and
8 Pump grease into the grease zerk fitting of the Fastener Torque, TRAX Models -
tension cylinder until grease, free from air,
comes out of the grease plug. Securely tighten S-40 and S-45 Models
the grease plug. Do not overtighten.
9 Continue to pump grease into the grease zerk
fitting just until the idler wheel moves. Check Manufacturer specifications require that this
the track tension. procedure be performed every 50 hours.
10 If necessary, continue to pump grease into the
Maintaining proper track tension and properly
cylinder until the track has proper tension.
torqued fasteners is essential to good machine
Component damage hazard. performance and service life. The machine will not
Do not over tighten the track. operate properly with a track that is incorrectly
Over tightening the track will tensioned. Continued use of a machine with
cause the machine to lose incorrectly tensioned tracks may cause component
power during operation. damage.
Note: If the track becomes too tight, loosen the 1 Thoroughly clean the track assembly of any
grease plug on the cylinder to remove grease and dirt, rocks, clay, etc.
loosen the track. 2 Chock the tracks at one end of the machine to
prevent the machine from rolling.
11 Clean up any grease that may have spilled.
12 Check the torque of the track assembly
fasteners. Refer to Specifications, TRAX
chassis between the tracks at the other end of
the machine.
and lower the machine.
ground and then place jack stands under the
14 Repeat this procedure for each track drive chassis for support.
assembly.
Chevron Ultra-duty grease, EP NLGI 1 (lithium based)
or equivalent

5 Visually inspect the section of track under the 6 Loosen the tensioner jam nut and idler axle
bogey wheels. bolts on both sides of the tensioner wheel and
tighten the tensioner nut until there is between
Result: There should be less than 1 inch /
0.75 - 1 inch / 1.9 - 2.5 cm of gap between the
2.5 cm of gap between the bogey wheels and
bogey wheels and the inside surface of the
the inside surface of the track. Proceed to step
track.
7.
Result: There is 1 inch / 2.5 cm or more of gap Component damage hazard.
between the bogey wheels and the inside Do not over tighten the track.
surface of the track. Proceed to step 6. Over tightening the track will
cause the machine to lose
power during operation.
7 Tighten the jam nut.

8 Check the torque of the track assembly
fasteners. Refer to Specifications, TRAX
and lower the machine.
10 Repeat this procedure for each track
assembly.
1 half sprocket
2 bogey wheels
3 tensioner assembly
4 idler wheel

P0-3 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.
Note: Genie recommends that the extending axles
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 grease the top and bottom sliding
wear pads.
1 Locate the grease fittings on the extendable

axles covers.
1 Top wear pad grease fitting

2 Side wear pad grease fitting

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 50 100 250 500
Visual inspection of engine ∅ ∅ ∅ ∅
Oil level - check ∅ ∅ ∅ ∅
Air cleaner - check ∅ ∅ ∅ ∅
PCV system - check ∅ ∅ ∅ ∅
Coolant level - check ∅ ∅ ∅ ∅
Oil, fuel and coolant systems - check for leaks ∅ ∅ ∅ ∅
Air filter discharge valve - clean ∅ ∅ ∅ ∅
Fan belt tension - check ∅ ∅ ∅ ∅
Battery - check ∅ ∅ ∅ ∅
Engine oil - replace ∅ ∅ ∅ ∅
Oil filter - replace ∅ ∅ ∅ ∅
Harness connections - check ∅ ∅ ∅ ∅
Cooling system - check ∅ ∅ ∅ ∅
Air filter - replace ∅ ∅ ∅ ∅
PCV valve - check ∅ ∅ ∅ ∅
Valve tappet clearance - adjust ∅ ∅ ∅ ∅
Fuel system - check ∅ ∅ ∅ ∅
Fuel pump - check ∅ ∅ ∅ ∅
Fuel filter - replace ∅ ∅ ∅ ∅

P0-5
Cummins Engine Maintenance – Under 1000 Hours
Cummins B3.3T Hour Intervals

Procedure ∅ = Not required Daily 250 500
Oil, fuel and coolant systems - check for leaks ∅ ∅
Fuel-water separator - drain ∅ ∅
Oil level - check ∅ ∅
Coolant level - check ∅ ∅
Drive belt - inspect ∅ ∅
Cooling fan - inspect ∅ ∅
Engine oil - replace ∅ ∅
Oil filter - replace ∅ ∅
Valve lash clearance - adjust (initial, one-time interval with oil change) ∅ ∅
Air intake system - inspect ∅ ∅
Air cleaner restriction - check ∅ ∅
Fuel filter - replace ∅ ∅
Fuel supply lines - vent ∅ ∅
Injection pump - vent ∅ ∅
Cooling system - check ∅ ∅

P0-6
Deutz Engine Maintenance – Under 1000 Hours
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

Coolant level - check ∅ ∅
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 ∅ ∅

P0-7
Ford Engine Maintenance – Under 1000 Hours
This maintenance schedule applies to the following Ford Engines:
Ford MSG 425 Ford DSG 423
Ford Engines Hour Intervals

Procedure ∅ = Not required Daily 100 200 400 800
Oil level - check ∅ ∅ ∅ ∅
Coolant level - check ∅ ∅ ∅ ∅
Oil, fuel and coolant systems - check for leaks ∅ ∅ ∅ ∅
Oil, coolant, fuel, exhaust and vacuum hoses - check for leaks, damage or ∅ ∅ ∅ ∅
deterioration
Electrical wiring - check for chafing or damage ∅ ∅ ∅ ∅
Engine belts - check/adjust ∅ ∅ ∅ ∅
Fuel filters - check/replace ∅ ∅ ∅ ∅
Engine oil - replace ∅ ∅ ∅ ∅
Oil filter - replace ∅ ∅ ∅ ∅
Air filter - replace ∅ ∅ ∅ ∅
Spark plugs - clean/adjust/replace ∅ ∅ ∅ ∅
Loose or missing fasteners - tighten/replace ∅ ∅ ∅ ∅
PCV valve - check ∅ ∅ ∅ ∅
PCV hoses, tubes and fittings - clean ∅ ∅ ∅ ∅

P0-8
Kubota Engine Maintenance – Under 1000 Hours
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 75 100 150 200 400 500 800
Coolant level - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Oil level - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Fuel hoses and clamp bands - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Engine oil - replace, Z482 ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Fan belt tension and damage - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Battery electrolyte level - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Spark plug - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Air cleaner element - clean
∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
(Replace the element after 6 times cleaning)
Fuel filter (element type) - clean ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Oil filter cartridge - replace, Z482 ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Oil filter cartridge - replace, D1105, WG972 ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Engine oil - replace, D1105, WG972 ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Radiator hoses and clamps - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Intake air line - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Fuel filter cartridge - replace ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Air cleaner element - replace ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Fan belt - replace ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Cleaning of water jacket (radiator interior) ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Removal of sediment in fuel tank ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Recharging battery ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Damage in electric wiring and loose connections - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅
Valve clearance - check ∅ ∅ ∅ ∅ ∅ ∅ ∅ ∅

P0-9
Perkins Engine Maintenance – Under 1000 Hours
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

Air filter discharge valve - clean ∅ ∅
Alternator belt - inspect/adjust/replace ∅ ∅
Coolant level – check/add ∅ ∅
Fuel system filter/water separator – drain ∅ ∅
Engine air precleaner - check/drain ∅ ∅
Fuel tank water/sediment - drain ∅ ∅
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 ∅ ∅
Fan clearance - check ∅ ∅

P1-1 Perkins Models

Perform Engine Maintenance – All Models:
1000 Hours • Alternator and fan belts - replace
• Engine valve lash – inspect/adjust
• Engine crankcase breather - replace
Engine specifications require that this procedure be
performed every 1000 hours. 403D-11, 404F-22
Required maintenance procedures and additional • Turbocharger - inspect

engine information are available in the 804D-33
manufacturer's manuals. Refer to Specifications,
Engine Operator and Maintenance Manuals. • Alternator - inspect
Continental TME27 • Starting motor - inspect

• Turbocharger - inspect
• Spark plugs - replace
854F Models
• O2 sensors - replace
• Water pump - inspect
Cummins Models
• Engine crankcase breather - replace
• Drive belt tension - measure
Kubota Models
• Drive belt - check
WG972
Deutz Models
• Spark plug - replace
All Models:
• Coolant and vacuum lock hose of LPG
• Fuel system primary filter (water separator) vaporizer - check
element – replace
• Radiator coolant (L.L.C.) - replace
• Fuel system secondary filter – replace
• Cleaning water jacket and radiator interior
• Hoses and clamps – inspect/replace
• Valve clearance - check
• By-pass oil filter - replace
• Cleaning cylinder head
• Engine mounts - check
• Valve seats - check
• Hoses and clamps - check
• Air cleaner element - replace
• Glow plugs - check
• Gasoline fuel hose and clamp bands -
• V-belts - re-tension/renew replace
• Cold starting device (if equipped) - check • Carburetor and fuel tank inside - clean
• Battery and cable connectors - check Z482-E, D-1105
• Engine valve lash – inspect/adjust • Fuel injection nozzle injection pressure -
D 2.9 and TD 2.9 Models: check
• Coolant (additive concentration) - check

P1-2 3 Drive the machine until one of the two plugs is

at the highest point.
Replace the Drive Hub Oil
Drive hub specifications require that this procedure

be performed after the first 50 hours of operation.
After the initial oil replacement, specifications
require that this procedure 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 1 drive hub plugs
lowest point. 2 middle plug
2 Remove the plugs and drain the oil into a
4 Drive hubs with 2 plugs: Fill the hub until the
suitable container.
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.
5 Install the plugs into the drive hub.

Models with TRAX: 9 Locate the hub disconnect pin in the center of
the drive hub. Manually depress the pin and
1 Select the drive hub to be serviced. Loosen rotate the drive hub until one of the two plugs
and remove as many sprocket retaining is at the lowest point.
fasteners as possible from the hub adapter.
2 Drive the machine in either direction just
enough to access the remaining fasteners. Do
not remove the the retaining fasteners.
3 Chock the tracks at the opposite end of the
machine to prevent the machine from rolling.
chassis between the tracks.
ground and place jack stands under the drive
1 drive hub plug
chassis for support.
6 Attach a lifting strap from an overhead crane 10 Remove the plugs and drain the oil into a
(2000 lbs / 1000 kg) to the center-point of the suitable container.
track assembly, above the sprocket. 11 Manually depress the hub disconnect pin and
7 Remove the remaining sprocket retaining rotate the drive hub until the plugs are one on
fasteners from the hub adapter. top and the other at 90 degrees.
8 Carefully remove the track assembly from the 12 Fill the hub until the oil level is even with the
drive hub and set aside. bottom of the side plug hole. Refer to
Specifications, Hydraulic Specifications.
Crushing hazard. The track
assembly could become 13 Install the plugs into the drive hub.
unbalanced and fall when 14 Attach a lifting strap from an overhead crane
removed from the machine if to the center-point of the track assembly,
not properly supported by the above the sprocket.
overhead crane.
15 Install the track assembly onto 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

16 Raise the machine, remove the jack stands 4 Remove the drive hub mounting bolts from the
lower the machine. drive hub assembly. Carefully remove the
turntable rotate drive hub assembly from the
17 Drive the machine in either direction just until
machine.
the remaining sprocket retaining fasteners can
be installed onto the drive hub adapter. Turn Note: If equipped with two turntable rotation drive
the machine off. hub assemblies, do not remove them both at the
same time.
18 Install the remaining sprocket retaining
fasteners to the drive hub adapter and torque Crushing hazard. The turntable
to specification. Refer to Specification, TRAX rotate drive hub assembly could
Torque Specifications. become unbalanced and fall
19 Repeat this procedure for each drive hub. when removed from the machine
if not properly supported by the
Turntable Rotate Drive Hub: lifting device.
1 Secure the turntable from rotating with the 5 Remove the plug from the side of the drive
turntable rotation lock pin. hub. Drain the oil from the hub into a suitable
2 Tag, disconnect and plug the hydraulic hoses container.
to the drive hub drive motor and brake. 6 Install the drive hub assembly onto the
Bodily injury hazard. Spraying machine. Lubricate and torque the drive hub
hydraulic oil can penetrate and mounting bolts to specification. Refer to
burn skin. Loosen hydraulic Specifications, Machine Torque
connections very slowly to allow Specifications.
the oil pressure to dissipate 7 Fill the drive hub with oil. Apply pipe thread
gradually. Do not allow oil to sealant to the plug. Install the plug. Refer to
squirt or spray. Specifications, Hydraulic Specifications.
3 Attach a suitable lifting device to the lifting eye 8 If equipped with two turntable rotation drive
of one turntable rotate drive hub assembly. 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
Adjust the Turntable Rotation Gear Backlash.

P2-1 Perkins Models

Perform Engine Maintenance – All Models
2000 Hours • Alternator - inspect
• Engine mounts - inspect
• Starting Motor - inspect
Engine specifications require that this procedure be
performed every 2000 hours. • Engine crankcase breather - replace
Required maintenance procedures and additional Perkins 854F-34T

engine information are available in the • Water pump - inspect
manufacturer's manuals. Refer to Specifications,
Engine Operator and Maintenance Manuals. • Turbocharger - inspect
Cummins Models • Aftercooler core - inspect

Perkins 1104D-44T
• Cooling system - flush
• Aftercooler core - inspect
• Valve clearance - check/adjust
Deutz Models
All Models
• Cooling system coolant - replace
• V-Belts - replace
Kubota Models
• Glow plugs - replace
Z482-E, D1105, WG972
D 2.9 and TD 2.9 Models
• Radiator coolant (L.L.C.) - replace
• Cooling system coolant - replace
• Battery - replace
• Extended life coolant (ELC) - replace
• Radiator hoses and clamp bands - replace
• Fuel pipes and clamp bands - replace
• Intake air line - replace
WG972
• Fuel filter - replace
• LPG fuel hose and clamp bands - replace
• Coolant and vacuum lock hose of LPG
vaporizer - replace

P2-2 Testing the oil:

Test or Replace the Hydraulic Oil 1 Complete the hydraulic oil testing with an oil
distributor.
If the hydraulic oil passes testing at the
2000 hour maintenance interval, the oil must
Genie requires that this procedure be performed
be tested every quarter by an oil distributor
every 2000 hours.
until the oil fails the test and is replaced.
Replacement or testing of the hydraulic oil is If the hydraulic oil fails testing at the 2000 hour
essential for good machine performance and maintenance interval, the oil must be replaced.
service life. Dirty oil and a clogged suction strainer After the oil has been replaced, continue the
or hydraulic filters may cause the machine to scheduled quarterly maintenance inspection.
perform poorly and continued use may cause
component damage. Extremely dirty conditions Replacing the hydraulic oil:
may require oil changes to be performed more
frequently. 1 Remove the drain plug from the hydraulic tank
and completely drain the tank into a container
Note: Before replacing the hydraulic oil, the oil may of suitable capacity. Refer to Specifications,
be tested by an oil distributor for specific levels of Hydraulic Fluid Capacities Specifications.
contamination to verify that changing the oil is
2 Fill the tank with the proper hydraulic oil for
necessary. If the hydraulic oil is not replaced at the
your machine. Refer to Specifications,
2000 hour inspection, test the oil quarterly.
Hydraulic Specifications.
Replace the oil when it fails the test.
3 Engine Models: Prime the pump. Refer to
Note: When removing a hose assembly or fitting, Repair Procedure in the appropriate Service
the O-ring (if equipped) on the fitting and/or hose and Repair Manual for your machine, How to
end must be replaced. All connections must be Prime the Pump.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 4 Clean up any oil that may have spilled.
Specifications.
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.

P2-3 6 Push the filter element down to be sure the

O-ring on the element is fully seated into the
Replace the Hydraulic Filters housing.
7 Rotate the filter element clockwise to lock it in
place.
8 Install the filter housing cap.
every 2000 hours.
9 Use a permanent ink marker to write the date
Perform this procedure more often if dusty and number of hours from the hour meter on
conditions exist. the oil filter housing.
Replacement of the hydraulic filters is essential for 10 Inspect the filter housings and related
good machine performance and service life. A dirty components to be sure that there are no leaks.
or clogged filter may cause the machine to perform
poorly and continued use may cause component External:
damage. Extremely dirty conditions may require
1 Locate the hydraulic return filter.
that the filter be replaced more often.
2 Place a suitable container under the filter(s).
Note: There are four types of hydraulic filters: tank
return filter, medium pressure filter, high pressure 3 Remove the filter with an oil filter wrench.
filter and drive motor case drain filter. The quantity
4 Apply a thin layer of fresh oil to the gasket of
and type of filter(s) may vary by model.
the new oil filter.
Bodily injury hazard. Beware of 5 Install the new hydraulic return filter element
hot oil. Contact with hot oil may and tighten it securely by hand.
cause severe burns.
6 Clean up any oil that may have spilled during
Note: Perform this procedure with the engine off. the installation procedure.
Hydraulic return filter 7 Use a permanent ink marker to write the date
and number of hours from the hour meter on
Note: The return filter may be mounted in the top of the oil filter.
the hydraulic tank (internally) or outside of the tank
(externally). 8 Inspect the filter housings and related
components to be sure that there are no leaks.
Internal:
1 Locate the hydraulic return filter housing on

top of the hydraulic tank.
2 Remove the cap from the filter housing.
3 Lift the handle on the filter element and rotate
the element counterclockwise to release the
element from the housing.
4 Remove the filter element from the housing.
5 Install the new filter element into the filter
housing.

Medium and high pressure filters Case drain filter:

Note: The medium pressure filter is for the charge Note: The case drain filter is for the charge pump.
pump and the high pressure filter is for all machine
functions except the drive circuit and oscillating 1 Open the engine side turntable cover and
axle circuit. locate the case drain filter mounted to the
engine tray near the hydraulic pumps.
1 Locate the medium and high pressure filters.
2 Place a suitable container under the filter(s).
2 Place a suitable container under each filter.
3 Remove the case drain filter housing by using
3 Remove the filter housings by using a wrench a wrench on the nut provided on the bottom of
on the nut provided on the bottom of the the housing.
housings.
4 Remove the case drain element from the
4 Remove the filter elements from the housings. housing.
5 Inspect the housing seals and replace them if 5 Inspect the housing seal and replace it if
necessary. necessary.
6 Install the new filter elements into the 6 Install the new case drain filter element into
housings and tighten them securely. 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. 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 8 Use a permanent ink marker to write the date
the oil filter housings. and number of hours from the hour meter on
the oil filter.
9 Inspect the filter housings and related
components to be sure that there are no leaks. 9 Start the 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.

P2-4 3 Lift the wheels or tracks off the ground and

then place jack stands under the drive chassis
Check the Free-wheel for support.
Configuration
4 Disengage the drive hubs by turning over the
drive hub disconnect caps on each non-steer /
circle-end wheel hub.
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 machine 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. 5 Manually rotate each non-steer / circle-end
wheel.
Models with 4 wheel steer will be referenced with
Circle-end and Square-end wheels. Result: Each non-steer / circle-end wheel
should rotate with minimum effort.
Collision hazard. Select a work Note: TRAX Models: Due to the additional
site that is firm and level. components of the track system, which increase
rotational friction, the track may not be able to be
Component damage hazard. If rotated manually.
the machine must be towed, do
not exceed 2 mph / 3.2 km/h. 6 Re-engage the drive hubs by turning over the
hub disconnect caps. Rotate each wheel or
Non-steer or Circle-end wheels: track to check for engagement. Lift the
machine and remove the jack stands.
1 Chock the steer/square-end wheels to prevent
the machine from rolling. Collision hazard. Failure to
re-engage the drive hubs could
2 Models with 2 wheel steer: Center a lifting result in death or serious injury
jack of ample capacity (20,000 lbs / 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 lbs / 16000 kg)
under each of the steer yokes at the circle-end
of the machine.

Steer or Square-end wheels: 4WD Models 12 Re-engage the drive hubs by turning over the
hub disconnect caps. Rotate each wheel or
7 Chock the non-steer / circle-end wheels or track to check for engagement. Raise the
tracks to prevent the machine from rolling. machine, remove the jack stands and lower
8 Models with 2 wheel steer: Center a lifting the machine.
jack of ample capacity (20,000 lbs / 10,000 kg)
Collision hazard. Failure to
under the drive chassis between the steer
re-engage the drive hubs could
tires.
result in death or serious injury
Models with 4 wheel steer: Place a lifting and property damage.
jack of ample capacity (35,000 lbs / 16000 kg)
under each of the steer yokes at the Models with Hydraulic Pump free-wheel valve:
square-end of the machine.
13 Be sure the free-wheel valve on the drive
9 Lift the wheels or tracks off the ground and pump is closed (clockwise).
then place jack stands under the drive chassis
Note: The free-wheel valve should always remain
for support.
closed.
10 Disengage the drive hubs by turning over the
drive hub disconnect caps on each steer /
square-end wheel hub.

1 drive pump
2 screwdriver
11 Manually rotate each steer / square-end wheel 3 lift pump
or track. 4 free-wheel valve
Result: Each steer / square-end wheel or track Note: The location of the free-wheel valve may vary
should rotate with minimum effort. by model.
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.

P2-5 S-40 / S-45 / S-60 / S-65

Check the Boom Wear Pads 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
every 2000 hours.
Maintaining the boom wear pads in good condition (pivot end of boom) 12.7 mm
is essential to safe machine operation. Wear pads Bottom wear pads 0.625 inch
are placed on boom tube surfaces to provide a low (pivot end of boom) 15.9 mm
friction, replaceable wear pad between moving
parts. Improperly shimmed wear pads or continued S-80 / S-85 / S-80X
use of extremely worn wear pads may result in
Boom wear pad specifications
component damage and unsafe operating
conditions. Boom number one Minimum
1 Measure each wear pad. Replace the wear (extension end of boom) 12.7 mm
pad once it reaches the minimum allowable
thickness. If the wear pad is still within
(extension end of boom) 15.9 mm
specification, shim as necessary to obtain
minimum clearance with zero binding. Boom number two
Top, bottom and side wear pads 0.50 inch
2 Extend and retract the boom through the (extension end of boom) 12.7 mm
entire range of motion to check for tight spots
that may cause binding or scraping of the Bottom wear pads 0.50 inch
(pivot end of boom) 12.7 mm
boom.
Note: Always maintain squareness between the (pivot end of boom) 15.9 mm
outer and inner boom tubes.
Boom number three
SX-150 / SX-180 Top, bottom and side wear pads 0.50 inch
3 Grease the platform end bottom wear pads
with a suitable lubricant. S-100 / S-105 / S-120 / S-125
S-100HD / S-120HD
SX-150: Grease the #1 and #2 boom tubes.
Boom wear pad specifications 0.50 inch
SX-180: Grease the #0 and #1 boom tubes. 12.7 mm

SX-150 / SX-180 Z-33/18
Primary boom wear pad specifications Minimum Primary boom wear pad Minimum
specifications
Platform end
Top wear pads - platform end 0.6875 inch
Bottom and side wear pads 0.63 in
17.46 mm
16 mm
Side wear pads - platform end 0.5625 inch
Top wear pads 0.35 in
14.29 mm
(#1 to #2; #2 to #3)(SX180 #0 to #1) 9 mm
Bottom wear pads - platform end 0.625 inch
Top wear pads(#3 to #4) 0.47 in
15.9 mm
12 mm
Top and side wear pads - pivot end 0.69 inch
Pivot end
17.46 mm
Top wear pads 0.63 in
Bottom wear pads - pivot end 0.81 inch
16 mm
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 0.375 inch
9.5 mm Top and side wear pads 0.625 inch
(platform end of boom)
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

Z-45/25 (J) IC, DC, BE, Z-51/30J Z-135/70, ZX-135/70
Primary boom wear pad specifications Minimum Note: The minimum shim clearance for the secondary
boom wear pads is 0.070 inch / 1.8 mm and the
Top, bottom and side wear pads (platform 0.625 inch maximum allowable shim clearance is 0.25 inch /
end of boom) 15.9 mm 6.4 mm.
Side and bottom wear pads 0.50 inch Note: The minimum shim clearance for the jib boom and
(pivot end of boom) 12.7 mm primary boom wear pads is 0.070 inch / 1.8 mm and the
Top wear pads 0.625 inch maximum allowable shim clearance is 0.188 inch /
(pivot end of boom) 15.9 mm 4.8 mm.
Primary boom wear pad Minimum
Z-80/60
specifications
Boom wear pad specifications Minimum Top, bottom and side wear pads 0.625 inch
Primary boom
Top and bottom wear pads 0.50 inch
Top, bottom and side wear pads 0.625 inch (pivot end of boom) 12.7 mm
15.9 mm
Side wear pads 0.375 inch
Primary and secondary extension boom (pivot end of boom) 9.5 mm
Top wear pads 0.625 inch Secondary boom wear pad Minimum
15.9 mm
specifications
12.7 mm
(extension end of boom) 9.5 mm
Secondary boom Side wear pads 0.50 inch
Top wear pads 0.50 inch (extension end of boom) 12.7 mm
12.7 mm Bottom wear pads 7/8 inch
Side and bottom wear pads 0.875 inch (extension end of boom) 22 mm
22.22 mm Top and bottom wear pads 0.625 inch
Jib boom wear pad specifications Minimum
Bottom and side wear pads 0.625 inch

P2-6 P2-7
Check the Extendable Axle Wear Check the Turntable Rotation
Pads - S-100, S-105, S-120, S-125, Gear Backlash - ALC1000 Models
S-100HD and S-120HD Genie requires that this procedure be performed
every 2000 hours.
Properly adjusted turntable rotation gear backlash
Genie requires that this procedure be performed is essential for good machine performance and
every 2000 hours. service life. Improperly adjusted turntable rotation
gear backlash will cause the machine to perform
Maintaining the axle wear pads in good condition is poorly and continued use will cause component
essential to safe machine operation. Wear pads damage. The turntable rotation drive hubs are
are placed on axle tube surfaces to provide a low mounted on an adjustable plate on the swing
friction, replaceable wear pad between moving chassis behind the fixed side cover at the ground
parts. Improperly shimmed wear pads or continued controls side of the machine.
use of worn out wear pads may result in
component damage and unsafe operating Note: Perform this procedure with the machine fully
conditions. stowed and the counterweight at the square end of
the machine.
Note: Be sure that the axles are fully extended
before attempting this procedure. Note: Perform this procedure with the machine on
1 Measure each wear pad.
1 Rotate the turntable until the boom is centered
Wear pad specifications Minimum between the circle end wheels.
Top, side and bottom wear pads 0.437 inch 2 Apply approximately 20 lbs / 89 N of side force
1.12 mm to the platform, moving the platform to one
2 Replace any wear pad if it is less than side as far as it will go.
specification. If a wear pad is not less than 3 Using a feeler gauge, measure the gap
specification, shim as necessary to obtain between the swing hub pinion gear and the
minimum clearance and no drag. turntable rotation bearing at the center tooth
Note: If the wear pads are still within specification. on one of the drive hubs. The gap should be
Refer to Repair Procedure in the appropriate measured on one side of the pinion gear on
Service and Repair Manual for your machine, How the center tooth.
to Shim the Extendable Axles. Note: The pinion gear can be accessed on the
Note: If any wear pads are replaced, refer to Repair outside of the chassis under the pinion gear guard.
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.

S-100, S-100HD, S-105, S-120, S-120HD and P2-8

S-125
Grease the Steer Axle Wheel
Result: The gap is between 0.010 inch / Bearings, All 2WD Models
0.254 mm and 0.022 inch / 0.559 mm. The
backlash is within tolerance. (except Z-62/40, S-60, S-65)
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 Genie requires that this procedure be performed
Repair Procedure in the appropriate Service every 2000 hours.
Adjust the Turntable Rotation Gear Backlash. Perform this procedure more often if dusty
conditions exist.
SX-150 and SX-180
Maintaining the steer axle wheel bearings is
Result: The gap is between 0.016 inch /
essential for safe machine operation and service
0.406 mm and 0.024 inch / 0.62 mm. The
life. Operating the machine with loose or worn
backlash is within tolerance.
wheel bearings may cause an unsafe operating
Result: The gap is less than 0.016 inch / condition and continued use may result in
0.406 mm or more than 0.024 inch / 0.62 mm. component damage. Extremely wet or dirty
The backlash needs to be adjusted. Refer to conditions or regular steam cleaning and pressure
Repair Procedure in the appropriate Service washing of the machine may require that this
and Repair Manual for your machine, How to procedure be performed more often.
Adjust the Turntable Rotation Gear Backlash.
1 Loosen the wheel lug nuts. Do not remove
Z-135/70 and ZX-135/70 them.
Result: The gap is between 0.013 inch / 2 Block the non-steer wheels, then center a
0.33 mm and 0.023 inch / 0.58 mm. The lifting jack under the steer axle.
backlash is within tolerance.
3 Raise the machine 6 inches / 15 cm and place
Result: The gap is less than 0.013 inch / blocks under the drive chassis for support.
0.33 mm or more than 0.023 inch / 0.58 mm.
The backlash needs to be adjusted. Refer to 4 Remove the lug nuts. Remove the tire and
Repair Procedure in the appropriate Service wheel assembly.
and Repair Manual for your machine, How to 5 Check for wheel bearing wear by attempting to
Adjust the Turntable Rotation Gear Backlash. move the wheel hub side to side, then up and
4 Repeat the procedure for the other turntable down.
rotation hub. Result: There should be no side to side or up
and down movement.
Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove 15 Place the large inner bearing into the rear of
the cotter pin from the castle nut. the hub.
7 Tighten the castle nut to specification, to seat 16 Install a new bearing grease seal into the hub
the bearings. by pressing it evenly into the hub until it is
flush.
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 17 Slide the hub onto the yoke spindle.
Z-34/22 BE, Z-40/23, Z-45/25 DC, Z-45/25 158 ft lbs
BE 214 Nm Component damage hazard. Do
not apply excessive force or
8 Loosen the castle nut and re-tighten to damage to the lip of the seal
specification. may occur.
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 18 Place the outer bearing into the hub.
Z-34/22 BE, Z-40/23, Z-45/25 DC, Z-45/25 35 ft lbs 19 Install the washer and castle nut.
BE 47 Nm
20 Tighten the slotted nut to specification, to seat
9 Check for wheel bearing wear by attempting to
the bearings.
move the wheel hub side to side, then up and
down. 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
Result: If there is no side to side or up and
Z-34/22 BE, Z-40/23, Z-45/25 DC, Z-45/25 158 ft lbs
down movement, continue with step 11 and
BE 214 Nm
grease the wheel bearings.
21 Loosen the castle nut and re-tighten to
Result: If there is side to side or up and down specification.
movement, continue to step 11 and replace
the wheel bearings with new ones. 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
Note: When replacing a wheel bearing, both the
Z-34/22 BE, Z-40/23, Z-45/25 DC, Z-45/25 35 ft lbs
inner and outer bearings, including the pressed-in BE 47 Nm
races, must be replaced.
22 Install a new cotter pin. Bend the cotter pin to
10 Remove the dust cap from the hub. Remove lock it in.
the cotter pin from the castle nut.
Note: Always use a new cotter pin when installing a
11 Remove the castle nut. castle nut.
12 Pull the hub off of the spindle. The washer and 23 Install the dust cap, then the tire and wheel
outer bearing should fall loose from the hub. assembly. Torque the wheel lug nuts to
13 Place the hub on a flat surface and gently pry specification. Refer to Specifications, Tires
the bearing seal out of the hub. Remove the and Wheels Specifications.
rear bearing.
14 Pack both bearings with clean, fresh grease.

P2-9 5 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and
Grease the Steer Axle Wheel down.
Bearings, 2WD Models - Z-62/40, Result: If there is no side to side or up and
S-60, S-65 down movement, continue with step 10 and
grease the wheel bearings.
Result: If there is side to side or up and down
movement, continue to step 10 and replace
the wheel bearings with new ones.
every 2000 hours.
Note: When replacing a wheel bearing, both the
Perform this procedure more often if dusty inner and outer bearings must be replaced.
conditions exist.
6 Remove the cover from the hub.
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.
1 retaining fastener
3 Raise the machine 6 inches / 15 cm and place 2 washer
blocks under the drive chassis for support.
3 cover
4 Remove the lug nuts. Remove the tire and 4 shim
wheel assembly. 5 outer ring
6 outer bearing
7 hub
8 inner bearing
9 inner seal
10 spindle

7 Remove the shims. P3-1

8 Gently pry the outer ring out of the hub. Perform Engine Maintenance –
9 Pull the hub off of the spindle. The outer 3000 Hours
bearing should fall loose from the hub.
10 Place the hub on a flat surface and gently pry
the inner oil seal out of the hub. Remove the Engine specifications require that this procedure be
inner bearing. performed every 3000 hours.
11 Pack both bearings with clean, fresh grease.
Required maintenance procedures and additional
12 Place the large inner bearing into the rear of engine information are available in the
the hub. manufacturer's manuals. Refer to Specifications,
Engine Operator and Maintenance Manuals.
13 Install a new inner oil seal into the hub by
pressing it evenly into the hub until it is flush. Deutz Models
14 Slide the hub onto the spindle. All Models:
Component damage hazard. Do • Injection valve- replace
not apply excessive force or
damage to the lip of the seal may • Toothed belt - replace
occur. • V-belt and tensioning pulley - replace
15 Place the outer bearing into the hub. D 2.9 and TD 2.9 Models:
16 Install the outer ring. • Aftercooler core - clean/test
17 Install the shims. • Turbocharger compressor outlet- clean
18 Install the cover and torque the retaining • Charge air cooler entry- drain lube
fastener to 383 ft-lbs / 519 Nm. oil/condensate
19 Install the tire and wheel assembly. Torque the Ford Models
wheel lug nuts to specification. Refer to
Specifications, Machine Specifications. • Coolant filler cap - clean/replace

Perkins Models P4-1

403D-11, 403F-11, 404D-22, 404F-22, Perform Engine Maintenance –
404F-22T, 804D, 1104D-44T 4000 Hours
• Fuel Injector - test/change
• Cooling system coolant (Heavy Duty) - Engine specifications require that this procedure be
change performed every 4000 hours.
403F-11 Required maintenance procedures and additional

engine information are available in the
• Coolant temperature regulator - replace manufacturer's manuals. Refer to Specifications,
404F-22, 404F-22T Engine Operator and Maintenance Manuals.
• Coolant temperature regulator - replace Perkins Models
• Diesel particulate filter - clean 854F-34T, 1104D-44T

• Glow plugs (ARD combustion) - replace • Aftercooler core - clean/test
• Radiator cap - inspect/replace
854F-34T
• Alternator - inspect
• Alternator and fan belts - replace
• Diesel particulate filter - clean
• Radiator cap - inspect/replace
Kubota Models
Z482-E, D-1105-E3B
• Injection pump - check
• Fuel injection timing - check

P6-1 P12-1
Perform Engine Maintenance – Perform Engine Maintenance –
6000 Hours 12000 Hours
Engine specifications require that this procedure be Engine specifications require that this procedure be
performed every 6,000 hours. performed every 12000 hours.
Required maintenance procedures and additional Required maintenance procedures and additional
engine information are available in the engine information are available in the
manufacturer's manuals. Refer to Specifications, manufacturer's manuals. Refer to Specifications,
Engine Operator and Maintenance Manuals. Engine Operator and Maintenance Manuals.
Perkins 1104D-44T Perkins Models
• Cooling system coolant extender (ELC) - All models

add
• Cooling system coolant (ELC) - change

P12-2 P12-3
Replace the Boom Extend/Retract Replace the Boom Extend/Retract
Cables - S-100HD and S-120HD Cables - S-60 Models,
S-80 Models, S-100, S-105, S-120,
S-125, SX-150 and SX-180
performed every 7 years.
The boom extend and retract cables are Genie specifications require that this procedure be
responsible for the extension and retraction of the performed every 10 years.
boom tube(s). Replacement of the boom extend
and retract cables, when required, is essential to The boom extend and retract cables are
good machine performance and safe machine responsible for the extension and retraction of the
operation. The boom extend and retract functions boom tube(s). Replacement of the boom extend
should operate smoothly and be free of hesitation, and retract cables, when required, is essential to
jerking and unusual noise. good machine performance and safe machine
operation. The boom extend and retract functions
1 Replace the boom extend and retract cables. should operate smoothly and be free of hesitation,
Refer to the appropriate Service and Repair jerking and unusual noise.
Manual for repair procedure, How to Replace
the Boom Extend/Retract Cables. 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.
S Booms • Z Booms Part No. 1268489 Maintenanc e M anual Decem ber 2015 Maintenanc e Ins pection R eport – Boom s

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Maintenance Manual - Booms

S Booms This manual includes detailed

Z Booms For Repair procedures, Fault

Important Technical Publications

Machine Design Life

Copyright © 2015 by Terex Corporation

Genie is a registered trademark of Terex South Dakota, Inc. in

ii S Booms • Z Booms Part No. 1268489

Models included in this manual Identifying the Correct Procedure

Part No. 1268489 S Booms • Z Booms iii

A2 11/2015 Specifications Hydraulic and Drive Hub Capacities

A4 12/2015 Quarterly Q-17 Inspect the Calibration Decal

iv S Booms • Z Booms Part No. 1268489

Revision History (continued)

Part No. 1268489 S Booms • Z Booms v

Do Not Perform Maintenance

vi S Booms • Z Booms Part No. 1268489

Personal Safety Workplace Safety

Be aware of potential crushing hazards

Part No. 1268489 S Booms • Z Booms vii

Introduction Introduction .......................................................................................................... ii

Section 1 Safety Rules......................................................................................................... vi

Section 2 Performance Specifications................................................................................ 1

Torque Specifications ......................................................................................... 9

Engine Specifications ........................................................................................ 11

Hydraulic Specifications ................................................................................... 17

viii S Booms • Z Booms Part No. 1268489

Section 3 Maintenance Procedures ................................................................................... 25

Quarterly Maintenance Procedures .................................................................. 32

Part No. 1268489 S Booms • Z Booms ix

Q-17 Inspect the Calibration Decal –

x S Booms • Z Booms Part No. 1268489

Annual Maintenance Procedures...................................................................... 84

Part No. 1268489 S Booms • Z Booms xi

Programmed Maintenance Procedures ......................................................... 104

xii S Booms • Z Booms Part No. 1268489

Function Speeds - S-100,

Part No. 1268489 S Booms • Z Booms 1

Function Speeds - S-120,

2 S Booms • Z Booms Part No. 1268489

Function Speeds - All Other Models

Function Z-30N, Z-30N RJ Z-34 BE Z-34N, Z-34 Z-33

Part No. 1268489 S Booms • Z Booms 3

Function Z-51 Z-62 Z-80

4 S Booms • Z Booms Part No. 1268489

Part No. 1268489 S Booms • Z Booms 5

6 S Booms • Z Booms Part No. 1268489

Function SX-150, SX-180 Z-30N, Z30N RJ Z-33 Z-34N, Z34DC,

Part No. 1268489 S Booms • Z Booms 7

Function Z-43 IC Z-40N, Z-40N RJ Z-45/25, Z-45/25J Z-45/25 IC, Z-45/25J

Function Z-62 Z-80 Z-135, ZX-135

8 S Booms • Z Booms Part No. 1268489

Tires and Wheels

Part No. 1268489 S Booms • Z Booms 9

TRAX Torque Specifications

10 S Booms • Z Booms Part No. 1268489

Engine Operator and Ford DSG-423

Maintenance Manuals Genie part number 119488

Part No. 1268489 S Booms • Z Booms 11