Maintenance Manual - 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. 1268489GT
included in this manual.
Rev J
May 2020
Maintenance Manual May 2020
Introduction
Intro ductio n Intro ductio n
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 future printings of this and all other manuals.
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly Contact Us:
recommend that maintenance be performed at an Internet: www.genielift.com
authorized Genie dealer service center. E-mail: [email protected]
Compliance
Copyright © 2015 by Terex Corporation
Machine Classification
1268489GT Rev J, May 2020
Group B/Type 3 as defined by ISO 16368
First Edition, Ninth Printing
Machine Design Life Genie, "S" and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
Unrestricted with proper operation, inspection and
"TraX" and "XC" are trademarks of Terex South Dakota, Inc.
scheduled maintenance.
ii S® Booms • Z® Booms Part No. 1268489GT

May 2020 Maintenance Manual
Introduction
SX-105 XC from SX105D-101

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

Introduction
Z-30/20N, Z- from Z30N14-15222 to Z30N16F-18899 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199

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

Introduction
Identifying the Correct Procedure

for your Model
Unless otherwise noted, each procedure will apply
to all models. Procedures that only apply to
specific models or options will include the
information in the procedure title.
Examples of procedures that apply to specific
models:
• Test the Engine Idle Select - Engine
Models
• Test the Turntable Level Sensor - Z-80/60
• ALC600 Models, include the following
models: S-40HF, S-45HF, S-40 XC, S-45
XC, S-60HF, S-65HF, S-60J, S-60 XC from
S60XCH-45001, S-65 XC, S-80HF, S-
85HF, S-80 XC and S-85 XC.
• ALC1000 Models, include the following
models: S-100, S-100HD, S-105, S-120, S-
120HD, S-125, SX-105 XC, SX-125 XC,
SX-135 XC, SX-150, SX-180, Z-80/60, Z-
135/70 and ZX-135/70.
Examples of procedures that apply to all models:
• Test the Drive Speed – Stowed Position
• Inspect the Tires, Wheels and Lug Nut
Torque
Find additional Manuals for your

Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Part No. 1268489GT S® Booms • Z® Booms v

Introduction
Revision History
Revision Date Section Procedure / Description
A 9/2015 Initial Release
A1 10/2015 Quarterly Q-27 Test the Primary Angle Sensor
A2 11/2015 Specifications Hydraulic and Drive Hub Capacities
A3 11/2015 Introduction Updated Z-80/60 serial number for models included
A4 12/2015 Quarterly Q-17 Inspect the Calibration Decal
A5 1/2016 Specifications Performance Spec. Z62
B 3/2016 All Sections Add Z-60 DC/FE
Specifications Add Kubota D1105-E4B, GM .998L, GM 3.0L.
Update Deutz D2.9 L4 and Perkins 404F engine rpm's
B1 4/2016 Quarterly Q-7 Check the Generator Belts, Pulleys and voltage - Bi-
Energy Models
Annual A-3 Inspect for Turntable Bearing Wear
B2 6/2016 Specifications Tires and Wheels, add Z60 DC/FE
B3 9/2016 Introduction Models Included
C 11/2016 All Sections Add SX-135 XC
C1 12/2016 Quarterly Q-26 Test the Secondary Boom Angle Sensor
D 2/2017 Quarterly Q-36 Inspect and Adjust Boom Cables
Annual A-3 Inspect Turntable Bearing Wear
A-11, A-12, A-13 Inspect Boom Cables
Programmed P12-2 Remove and Inspect Boom Cables
E 3/2017 All Sections Add SX-125 XC. Add Z-45 XC CE/AS Models
E1 3/2017 Programmed Remove 10 year cable inspection
F 6/2017 All Sections Add S80/85 XC, SX-105 XC
Specifications Add Deutz D436 L3i CN3 Engine
F1 4/2018 Specifications Deutz TD2011 Engine Specifications
G 10/2018 All Sections Add S60XC, S-65XC, S-80HF, S-85HF Models
Add Perkins 404F-E22T, 404F-E22TA Engine
H 5/2019 All Sections Add S60/S65/Z45XC ANSI/CSA, S60/65HF, S40/S45XC
Models
Quarterly Q-17, Q-33
Reference Examples:
Section – Specifications Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Maintenance, (procedure) the update.
vi S® Booms • Z® Booms Part No. 1268489GT

Introduction
Revision History (continued)

Revision Date Section Procedure / Description
J 2/2020 All Sections Add S40/45HF, S60J, Z45DC/FE, Z45HF models. Add
Deutz TD/TCD 2.2 L3 engine
Specifications Hydraulic Specifications
Annual A-11, A-12, A-13
Programmed P0-6, P1-1
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. 1268489GT S® Booms • Z® Booms vii

Safety Rules
Secti on 1 Safety Rul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when
maintenance and repair procedures are
performed.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
viii S® Booms • Z® Booms Part No. 1268489GT

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 approved fire extinguisher within easy
alert personnel to potential reach.
personal injury hazards. Obey all
safety messages that follow this Be sure that all tools and working areas
symbol to avoid possible injury or are properly maintained and ready for
death. use. Keep work surfaces clean and free
of debris that could get into machine
Indicates a imminently hazardous components and cause damage.
situation which, if not avoided,
will result in death or serious Be sure any forklift, overhead crane or
injury. other lifting or supporting device is fully
capable of supporting and stabilizing the
Indicates a potentially hazardous weight to be lifted. Use only chains or
situation which, if not avoided, straps that are in good condition and of
could result in death or serious ample capacity.
injury.
Be sure that fasteners intended for one
Indicates a potentially hazardous time use (i.e., cotter pins and self-locking
situation which, if not avoided, nuts) are not reused. These components
may cause minor or moderate may fail if they are used a second time.
injury.
Be sure to properly dispose of old oil or
Indicates a potentially hazardous other fluids. Use an approved container.
situation which, if not avoided, Please be environmentally safe.
may result in property damage.
Be sure that your workshop or work area
Be sure to wear protective eye wear and is properly ventilated and well lit.
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards

such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
Part No. 1268489GT S® Booms • Z® Booms ix

May 2020
Table of Contents
Introduction Introduction ...................................................................................................... ii

Important Information ..........................................................................................ii
Models included in this manual........................................................................... iii
Identifying the Correct Procedure for your Model ................................................ v
Find additional Manuals for your Model .............................................................. v
Revision History .................................................................................................vi
Section 1 Safety Rules .................................................................................................. viii

General Safety Rules ....................................................................................... viii
Section 2 Performance Specifications ............................................................................ 1

Function Speeds - S-100, S-105 and S-100HD .................................................. 1
Function Speeds - S-120, S-125 and S-120HD .................................................. 2
Function Speeds - All Other Models ................................................................... 3
Drive Speeds ..................................................................................................... 9
Torque Specifications .................................................................................... 12

Tires and Wheels ............................................................................................. 12
TraX Torque Specifications .............................................................................. 14
Engine Specifications .................................................................................... 15

Engine Operator and Maintenance Manuals ..................................................... 15
Deutz Engine Models ....................................................................................... 16
Perkins Engine Models..................................................................................... 17
Ford Engine Models ......................................................................................... 19
Kubota Engine Models ..................................................................................... 20
GM Engine Models........................................................................................... 21
Continental Engine Models............................................................................... 21
Cummins Engine Models ................................................................................. 22
Hydraulic Specifications................................................................................ 23
Hydraulic Relief Valves .................................................................................... 23
Hydraulic and Drive Hub Fluid Capacities ......................................................... 26
Hydraulic Oil Specifications .............................................................................. 28
Hydraulic Hose and Fitting Torque Specifications ............................................. 31
Torque Procedure ............................................................................................ 32
x S® Booms • Z® Booms Part No. 1268489GT

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Table of Contents
Section 3 Maintenance Procedures ............................................................................... 34

Introduction ...................................................................................................... 34
Maintenance Schedule ..................................................................................... 36
Pre-Delivery Preparation Report ....................................................................... 37
Scheduled Maintenance Inspection Report - Quarterly or Frequent ................... 38
Scheduled Maintenance Inspection Report - Annual ......................................... 39
Programmed Maintenance Inspection Report - Booms ..................................... 40
Commissioning Procedures .......................................................................... 41

C-1 Perform 50 Hour Service............................................................................ 41
C-2 Perform Engine Maintenance – 50 Hours ................................................... 41
C-3 Perform 150 Hour Service .......................................................................... 42
Part No. 1268489GT S® Booms • Z® Booms xi

May 2020
Table of Contents
Quarterly Maintenance Procedures............................................................... 43

Q-1 Check for Open Bulletins and Owner Registration ..................................... 43
Q-2 Battery inspection...................................................................................... 44
Q-3 Inspect the Electrical Wiring ...................................................................... 46
Q-4 Inspect the Electrical Contactors - DC / Bi-Energy Models ......................... 47
Q-5 Check the Exhaust System........................................................................ 48
Q-6 Inspect the Tires, Wheels and Lug Nut Torque .......................................... 49
Q-7 Check the Generator Belts and Pulleys, Bi-Energy Models ........................ 49
Q-8 Check the Oscillate Directional Valve Linkage (if equipped) ....................... 51
Q-9 Visual Inspection of the Hydraulic Oil ......................................................... 51
Q-10 Inspect the Hydraulic Filters..................................................................... 52
Q-11 Check and Adjust the Engine RPM .......................................................... 53
Q-12 Test the Ground Control Override ............................................................ 59
Q-13 Test the Alarm Package (if equipped) ...................................................... 59
Q-14 Test the Emergency Power System ......................................................... 60
Q-15 Test the Engine Idle Select - Engine Models ............................................ 61
Q-16 Test the Fuel Select Operation - Gasoline/LPG Models ........................... 62
xii S® Booms • Z® Booms Part No. 1268489GT

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Table of Contents
Q-17 Inspect the Calibration Decal - ALC1000 Models...................................... 63

Q-18 Test the Recovery Mode System - ALC-1000 Models............................... 64
Q-19 Test the Platform Self-leveling ................................................................. 66
Q-20 Confirm the Proper Brake Configuration ................................................... 66
Q-21 Test the Drive Brakes .............................................................................. 67
Q-22 Test the Drive Speed – Stowed Position .................................................. 67
Q-23 Test the Drive Speed - Raised or Extended Position ................................ 68
Q-24 Test the Drive Speed – Raised and Extended, ALC1000 Models.............. 69
Q-25 Test the Turntable Level Sensor - Z-80/60, Z-135/70, ZX-135/70,
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180 ........................... 70
Q-26 Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70 ......... 73
Q-27 Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70.............. 75
Q-28 Test the Primary Boom Angle Sensor -
Q-29 Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70,
Q-30 Test the Primary Boom Angle Sensor - Z-80/60 ....................................... 86
Q-31 Test the Safety Envelope and Circuits - Z-80/60....................................... 87
Q-32 Check the Safety Envelope Limit Switches and Angle Sensor -
S-60X, S-80X, and S-60XC to S60XC-45000 ............................................ 89
Q-33 Test the Safety Envelope and Circuits -
S-100, S-105, S-120 and S-125 ................................................................ 91
Q-34 Test the Aircraft Protection System (if equipped) ...................................... 97
Q-35 Test the Operator Protection Alarm (if equipped) ...................................... 99
Q-36 Inspect the Boom Extend/Retract Cables - All Models .............................. 99
Q-37 Test the Recovery Mode System - ALC-600 Models............................... 100
Q-38 Test the Turntable Level Sensor - S-40HF, S-45HF, S-40XC, S-45XC, S-
60HF, S-65HF, S-60J, S-60XC from S60XCH-45001, S-65XC,
S-80HF, S-85HF, S-80XC, S-85XC ......................................................... 101
Q-39 Test the Primary Boom Angle Sensor - S-40HF, S-45HF, S-40XC,
S-45XC, S-60HF, S-65HF, S-60J, S-60XC from S60XCH-45001,
S-65XC, S-80HF, S-85HF, S-80XC, S-85XC ........................................... 103
Part No. 1268489GT S® Booms • Z® Booms xiii

May 2020
Table of Contents
Annual Maintenance Procedures ................................................................ 105

A-1 Grease the Turntable Rotation Bearing and Rotate Gear ......................... 105
A-2 Check the Turntable Rotation Bearing Bolts ............................................. 106
A-3 Inspect for Turntable Bearing Wear .......................................................... 108
A-4 Check the Extendable Axle - S-100, S-105, S-120 and S-125 .................. 109
A-5 Perform Maintenance- Jib Rotate Bearing ............................................... 110
A-6 Test the Bypass/Recovery Key Switch - ALC1000 Models ....................... 111
A-7 Grease the Platform Overload Mechanism (if equipped)........................... 113
A-8 Test the Platform Overload System - All Models,
(excludes ALC1000, S-60HC, S-60 HF, S-65 HF, S-60XC,
S-80HF, S-85HF, S-80XC, S-85XC and Z-45XC models)........................ 114
A-9 Test the Platform Overload System - ALC1000 Models ............................ 116
A-10 Test the Platform Load Sense System - S-60 HC ................................... 117
A-11 Inspect the Boom Extend/Retract Cables and Sheaves -
S-60/65 and S-80/85 Models .................................................................. 118
A-12 Inspect the Boom Extend/Retract Cables and Sheaves -
S-100, S-105, S-120, S-125, SX-105XC and SX-125XC ......................... 120
A-13 Inspect the Boom Extend and Retract Cables and Sheaves -
SX-135XC, SX-150 and SX-180 ............................................................. 122
A-14 Check the Drive Hub Oil Level and Fastener Torque .............................. 126
A-15 Test the Dual Capacity and Platform Overload System -
SX-105XC, SX-125XC and SX-135XC.................................................... 130
Z-45XC Models ...................................................................................... 132
S-40XC, S-45XC, S-60HF, S-65HF, S-60XC from S60XCH-45001,
S-65XC, S-80HF, S-85HF, S-80XC, S-85XC .......................................... 133
A-18 Test the Platform Overload System -
S-40HF, S-45HF, Z-45HF, Z-45 DC/FE from Z45EM-101........................ 135
A-19 Perform Engine Maintenance ................................................................. 136
A-20 Perform Engine Maintenance ................................................................. 136
xiv S® Booms • Z® Booms Part No. 1268489GT

May 2020
Table of Contents
Programmed Maintenance Procedures ....................................................... 137

P0-1 Check the Track Tension and Fastener Torque, TraX Models -
S-60, S-65, S-60 XC, S-65 XC, Z-62 Models ........................................... 137
P0-2 Check the Track Tension and Fastener Torque, TraX Models -
S-40, S-45, S-40 XC, S-45 XC Models .................................................... 138
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125 ............. 140
P0-4 Continental Engine Maintenance – Under 1000 Hours ............................ 141
P0-5 Cummins Engine Maintenance – Under 1000 Hours............................... 142
P0-6 Deutz Engine Maintenance – Under 1000 Hours .................................... 143
P0-7 Ford Engine Maintenance – Under 1000 Hours ...................................... 144
P0-8 Kubota Engine Maintenance – Under 1000 Hours .................................. 145
P0-9 Perkins Engine Maintenance – Under 1000 Hours .................................. 147
P0-10 GM .998L Engine Maintenance – Under 1000 Hours ............................ 148
P0-11 GM 3.0L Engine Maintenance – Under 1000 Hours .............................. 149
P1-1 Perform Engine Maintenance – 1000 Hours ........................................... 150
P1-2 Replace the Drive Hub Oil ...................................................................... 152
P2-2 Test or Replace the Hydraulic Oil ........................................................... 157
P2-3 Replace the Hydraulic Filters .................................................................. 158
P2-4 Check the Free-wheel Configuration....................................................... 160
P2-5 Check the Boom Wear Pads .................................................................. 162
P2-6 Check the Extendable Axle Wear Pads -
S-100, S-105, S-120, S-125, S-100HD and S-120HD .............................. 165
P2-7 Check the Turntable Rotation Gear Backlash ......................................... 165
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models,
Except S-60, S-65, Z-60 DC/FE and Z-62 ............................................... 166
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models -
S-60, S-65, Z-60 DC/FE and Z-62 ........................................................... 168
Part No. 1268489GT S® Booms • Z® Booms xv

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Table of Contents

P12-1 Perform Engine Maintenance – 12000 Hours ....................................... 172
P12-2 Remove and Inspect the Boom Extend/Retract Cables ........................ 173
Cable Replacement Criteria ...................................................................... 175
xvi S® Booms • Z® Booms Part No. 1268489GT

Performance Specifications
Secti on 2 Perfor man ce Speci ficatio ns
Function Speeds - S-100, S-

105 and S-100HD Models
Note: Function speeds are maximum from platform
controls with maximum rated load in platform.
Function speeds are shown in seconds.
Primary boom up/down, 80 - 88
(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
fully raised position
(0 to 100 ft / 0 to 30.5 m)
Primary boom retract, 120 - 140
(100 to 0 ft / 30.5 to 0 m)
Jib boom up/down, 28 - 32
(S-105 models)
Turntable rotate, 360° 170 - 190
boom horizontal and fully
retracted
Turntable rotate, 63 - 70
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
Platform level ANSI/CSA 3 - 5
(10° range of motion) AS/CE 20 - 22
Part No. 1268489GT 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.
Function speeds are shown in seconds.
(retracted)
(time from fully stowed to the
fully raised position)
extended to >100 ft / 30.5 m
Primary boom extend, 170 - 190
(0 to 100 ft / 0 to 30.5 m)
Primary boom retract, 170 - 190
(100 to 0 ft / 30.5 to 0 m)
Jib boom up/down, 28 - 32
(S-125 models)
Turntable rotate, 360° 170 - 190
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
2 S® Booms • Z® Booms Part No. 1268489GT

Function Speeds - All Other Models

Note: Function speeds are maximum from platform controls with maximum rated load in platform. Function
speeds are shown in seconds.
Function S-40, S-45, S- S-60, S-65, S- S-60HF, S-65HF, S-60J S-80, S-85, S- S-80, S-85
40HF, S-45HF, 60HC, S-60X, S- S-60XC from 80X (AS/CE
S-40XC, S- 60XC to 45000 S60XCH-45001, (ANSI/CSA models)
45XC (all models) S-65XC models)
(all models) (all models)
Primary boom up 50 - 60 60 - 70 65 - 75 60 - 66 57 - 65 75 - 83
Primary boom 50 - 60 60 - 70 65 - 75 60 - 66 61 - 69 75 - 83
down
Primary boom 30 - 60 58 - 66 58 - 66 30 - 33 59 - 67 59 - 67
extend
Primary boom 15 - 35 53 - 62 53 - 62 30 - 33 57 - 65 57 - 65
retract
Jib boom up 35 - 45 60 - 70 48 - 53 25 - 35 25 - 35 25 - 35
(S-45) (S-65) (S-65XC/HF) (S-85) (S-85)
25 - 35
(S-45XC)
Jib boom down 20 - 30 40 - 50 28 - 33 15 - 25 15 - 25 15 - 25
(S-45) (S-65) (S-65XC/HF) (S-85) (S-85)
25 - 35
(S-45XC)
Turntable rotate 70 - 100 78 - 86 78 - 86 67 - 84 90 - 103 90 - 103
stowed
Turntable rotate 120 - 140 125 - 165 125 - 165 107 - 118 210 - 250 210 - 250
extended
Platform rotate 6 - 10 8 - 12 5 - 15 18 - 22 8 - 12 8 - 12
(S-40/45)
8 - 12
(S-40/45XC)
(10° range of AS/CE 20 - 22
motion)

Function S-80XC, S-85XC, Z-30N, Z-30N RJ Z-34 BE Z-34N, Z-34 Z-33
S-80HF, S-85HF (DC models)
Primary boom up 75 - 83 14 - 22 14 - 22 16 - 22 36 - 40
(retracted)
48 - 52
(extended)
Primary boom 110 - 115 12 - 20 12 - 20 13 - 20 46 - 50
down (retracted)
55 - 59
(extended)
Primary boom 59 - 67 15 - 19 12 - 18 11 - 15 18 - 20
extend
Primary boom 57 - 65 10 - 14 12 - 18 13 - 17 18 - 20
retract
Secondary boom X 11 - 18 11 - 18 15 - 22 20 - 24
up
Secondary boom X 7 - 15 7 - 15 11 - 18 20 - 24
down
Jib boom up 25 - 35 19 - 23 23 - 29 20 - 24 X
(S-85XC/HF)
Jib boom down 15 - 25 17 - 21 20 - 26 18 - 22 X
(S-85XC/HF)
Jib boom rotate X 13 - 17 X X X
(Z-30N RJ)
Turntable rotate 95 - 103 62 - 72 62 - 72 62 - 72 62 - 65
stowed
Turntable rotate 210 - 250 X X X X
extended Raised or extended
Platform rotate 40 - 50 5 - 11 5 - 11 5 - 11 X
Platform level ANSI/CSA 3 - 5 10 - 12
(10° range of AS/CE 20 - 22
motion)

Function Z-34 IC Z-40N, Z-40N Z-45/25, Z-45/25J Z-45/25, Z-45/25J Z-45HF,
RJ (DC, BE models) (IC models) Z-45XC
Primary boom up 15 - 21 26 - 30 32 - 40 26 - 30 26 - 30
Primary boom down 13 - 19 26 - 30 26 - 30 26 - 30 26 - 30
Primary boom extend 24 - 30 18 - 22 14 - 18 18 - 26 12 - 20
Primary boom retract 14 - 20 18 - 22 17 - 21 18 - 26 12 - 20
Secondary boom up 15 - 21 32 - 36 38 - 46 26 - 30 26 - 30
Secondary boom down 11 - 17 32 - 36 38 - 46 26 - 30 26 - 30
Jib boom up 24 - 30 16 - 20 32 - 40 45 - 55 40 - 44
(Z45J)
Jib boom down 15 - 21 16 - 20 26 - 30 25 - 35 24 - 28
(Z45J)
Jib boom rotate X 16 - 20 X X X
(Z40N RJ)
Platform rotate 5 - 11 10 - 14 6 - 10 10 - 14 10 - 14
Function Z-45 Z-51 Z-60 Z-62 Z-80

(DC / FE) (DC / FE) (all models)
Primary boom up 26 - 30 36 - 40 60 - 70 60 - 65 60 - 70
(retracted)
80 - 96
(extended)
Primary boom down 26 - 30 36 - 40 60 - 70 65 - 70 75 - 85
(retracted)
80 - 96
(extended)
Primary boom extend 12 - 20 18 - 26 41 - 49 40 - 50 48 - 52
Primary boom retract 12 - 20 18 - 26 31 - 39 45 - 50 38 - 52
Secondary boom up 26 - 30 26 - 30 31 - 39 40 - 45 38 - 48
Secondary boom down 26 - 30 26 - 30 31 - 39 45 - 50 38 - 48
Jib boom up 13 - 17 45 - 55 13 - 17 68 - 73 23 - 33
Jib boom down 13 - 17 25 - 35 13 - 17 77 - 82 21 - 31
(stowed) (stowed) (retracted)
62 - 83 240 - 245 200 - 240
(extended) (extended) (extended)
Platform rotate 10 - 14 10 - 14 10 - 14 12 - 17 10 - 14
Platform level 6-7 ANSI/CSA 3 - 5

Function Z-135 ZX-135
Primary boom up/down 88 - 105 110 - 125
Primary boom extend/retract 38 - 42 35 - 48
Secondary boom up/down 80 - 95 80 - 95
Secondary boom extend/retract 88 - 98 88 - 98
Jib boom up/down 38 - 43 38 - 43
Jib boom extend/retract 27 - 38 27 - 38
Turntable rotate stowed 88 - 92 88 - 92
Turntable rotate 160 - 180 160 - 180
(jib or primary boom extended)
(jib and primary boom extended)
Platform rotate 20 - 25 20 - 25

Function SX-105 XC SX-125 XC SX-135 XC
Primary boom 80 - 88 / 83° 80 - 88 / 83° 88 - 94 / 75°
up/down, (stowed)
Primary boom 100 - 110 / 83° 100 - 110 / 83° 26 - 29 / 10°
up/down string pot = 120 in / 305cm string pot = 120 in / 305cm string pot = 138 in / 351cm
Primary boom 33 - 38 / 20° 33 - 38 / 20° 24 - 27 / 10°
Primary boom 40 - 45 / 20° 40 - 45 / 20° 34 - 37 / 10°
Primary boom 18 - 23 / 5° 18 - 23 / 5° 21 - 24 / 5°
Primary boom X 25 - 30 / 5° X
up/down string pot= 582 in / 1478cm
Primary boom extend 120 - 140 170 - 190 30 - 33
0 - 100 in / 254cm
Primary boom retract 120 - 140 170 - 190 30 - 33
100 in / 254cm - 0
Jib boom up/down 28 - 32 28 - 32 60 - 65
(retracted)
122 - 130
(extended)
Jib boom X X 50 - 60
extend/retract
Jib boom rotate X X X
Turntable rotate, 170 - 190 170 - 190 17 - 23
(stowed) drive enable to drive enable, 30°
Turntable rotate 31 - 35 31 - 35 28 - 34
drive enable to drive enable, 30° drive enable to drive enable, 30° drive enable to drive enable. 30°
string pot > 80 ft / 24m string pot = 12 in / 30.5cm string pot = 12 in / 30.5cm
Turntable rotate 54.5 - 60 54.5 - 60 48 - 54
drive enable to drive enable, 30° drive enable to drive enable, 30° drive enable to drive enable, 30°
string pot > 256 in / 650cm string pot > 256 in / 650cm string pot = 137 in / 348cm
Platform rotate 37 - 47 37 - 47 20 - 24

Function SX-150 SX-180
Primary boom 80 - 88 / 82° 80 - 88 / 82°
up/down, (stowed)
Primary boom 100 - 110 / 82° 100 - 110 / 82°
up/down string pot = 76 in / 193cm string pot = 76 in / 193cm
Primary boom 45 - 50 / 20° 45 - 50 / 20°
Primary boom 71 - 80 / 20° 71 - 80 / 20°
Primary boom 26 - 31 / 5° 26 - 31 / 5°
Primary boom X 34 39 / 5°
up/down string pot = 596 in / 1514cm
Primary boom extend 30 - 33 30 - 33
0 - 100 in / 254cm
Primary boom retract 30 - 33 30 - 33
100 in / 254cm - 0
Jib boom up/down 58 - 62 58 - 62
Jib boom rotate 28 - 32 28 - 32
(stowed) drive enable to drive enable drive enable to drive enable
drive enable to drive enable, 80° drive enable to drive enable, 80°
string pot = 36 in / 91.4cm string pot = 36 in / 91.4
string pot = 76 in / 193cm string pot = 75 ft / 22.8m
(above 75 ft / 22.8m) (above 75 ft / 22.8m)
string pot = 258 in / 655cm string pot = 258 in / 655cm
(above 125 ft / 38.1m) (above 125 ft / 38.1m)
Platform rotate 20 - 24 20 - 24

Drive Speeds
Note: Drive speeds are shown in seconds.
Function S-40, S-45, S- S-60, S-65, S-60HC, S-60HF, S-65HF, S-80, S-85, S- S-80HF, S-85HF, S-
40HF, S-45HF, S- S-60X, S-60XC to S-60J, S-60XC 80X 80XC, S-85XC
40XC, S-45XC 45000 from S60XCH-
(all models) (all models) 45001, S-65XC
(all models)
2WD models, 5.2 - 5.9 6.1 - 7.8 X 7.9 - 8.5 X
Stowed position 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
4WD models, 5.2 - 5.9 8 - 10.5 sec 8 - 10.5 sec 8 - 10.5 9 - 11

Stowed position 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
(S-40/45)
6.8 - 7.4
40 ft / 12,2 m
(S-40/45XC)
High flotation X X 8 - 10.5 sec 11 - 13 9 - 11
tires, 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
Stowed position
2WD or 4WD, 40 - 45 40 - 45 38 - 45 40 - 45 55 - 60
Raised or 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
extended
2WD or 4WD, X X X X X
Raised and
extended
TraX models, 9 - 11 10.7 - 13.6 10.7 - 13.6 X X
TraX models, 40 - 45 55 - 62 55 - 62 X X
Raised or 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
extended
Braking distance, 3 - 4 ft 3 - 6 ft 3 - 6 ft 3 - 6 ft 3 - 6 ft
high range on 0,9 - 1,2 m 0,9 - 1,8 m 0,9 - 1,8 m 0,9 - 1,8 m 0,9 - 1,8 m
paved surface

Function S-100, S-105, S- SX-135XC, SX-150, Z-30N, Z30N RJ Z-33 Z-34N, Z34DC, Z-
120, S-125, S- SX-180 34BE
100HD, S-120HD,
SX-105XC, SX-
125XC
2WD models, X X 6-8 8.5 - 10.5 6-8
4WD models, 40 - 45 9 - 12 X X X
Stowed position 40 ft / 12,2 m 40 ft / 12,2 m
(SX135XC)
9.8 - 11.8
40 ft / 12,2 m
(SX-150/180)
2WD or 4WD, 72.4 - 81.3 67 - 70 42 - 48 50 - 55 42 - 48
Raised or 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
extended (SX-135XC)
68 - 75.5
40 ft / 12,2 m
(SX-150/180)
2WD or 4WD, X 275.5 - 293.3 X 190 - 195 X
Raised and 40 ft / 12,2 m 40 ft / 12,2 m
extended (SX-150/180)
Braking distance, 4 - 6 ft 4 - 6 ft 2 - 4 ft 5 - 7 ft 2 - 4 ft
high range on 1,2 - 1,8 m 1,2 - 1,8 m 0,6 - 1,2 m 1,5 - 2 m 0,6 - 1,2 m
paved surface

Function Z-34 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, Z-45HF, Z-
45XC, Z-45 DC/FE
2WD models, 8.5 - 10.5 6.1 - 7.1 8 - 10 6 - 6.8
Stowed position 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
(ANSI / CSA)
7.3 - 8.3
40 ft / 12,2 m
AS / CE)
4WD models, 8.5 - 10.5 X X 6 - 6.8
High flotation tires, 8.5 - 10.5 X X 6 - 6.8
2WD or 4WD, 40 - 45 40 - 45 42 - 48 42 - 48
Raised or extended 40 ft / 12m2 m 40 ft / 12,2 m 40 ft / 12,2 m 40 ft / 12,2 m
87 - 93
40 ft / 12,2 m
(Z-45 DC/FE, Z-
45XC)
Braking distance, 3 - 4 ft 5 - 7 ft 5 - 7 ft 3 - 6 ft
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-60 Z-62 Z-80 Z-135, ZX-135

(DC / FE) (all models)
2WD models, 13.6 - 14.5 6.1 - 7.8 X X
4WD models, 13.6 - 14.5 8 - 10.5 8.7 - 9.3 8.9 - 9.6
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 8 - 10.5 13.6 - 14.5 X
2WD or 4WD, 40 - 45 40 - 45 RT Tires 40 - 45
Raised or extended 40 ft / 12,2 m 40 ft / 12,2 m 40 - 45 40 ft / 12,2 m
(raised only) 40 ft / 12,2 m
High flotation tires,
62 - 70
40 ft / 12,2 m
2WD or 4WD, X X X 66 - 70
Raised and extended 40 ft / 12,2 m
Primary and
secondary raised, and
primary or jib
extended
TraX models, X 10.7 - 13.6 X X
Stowed position 40 ft / 12,2 m
TraX models, X 55 - 62 X X
Raised or extended 40 ft / 12,2 m
Braking distance, X 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 dry. The retaining fasteners must be coated with a mineral based lubricant
when removed. If a retaining fastener is removed, the torque value is reduced. Refer to the Service and
Repair Manual that is appropriate for your machine.
Fastener description ZP Color - yellow, gold or silver ZAB Color - dull gray
SHC Color - Black ZAG
Model Lug nut Drive hub Tire pressure Tire pressure Tire pressure
torque torque rough terrain high flotation industrial
S-40, S-45, S-40HF, S-45HF, S- 240 ft-lbs ZP - 210 ft-lbs 45 psi / 3,1 bar 38 psi / 2,6 bar X
40XC, S-45XC 325 Nm 285 Nm
ZAG - 180 ft-lbs
244 Nm
S-60, S-65, S-60HC, S-60X, S- 240 ft-lbs ZP - 210 ft-lbs 70 psi / 4,8 bar 60 psi / 4,1 bar X
60XC to 45000 325 Nm 285 Nm
ZAG - 180 ft-lbs
244 Nm
S-60HF, S-65HF, S-60J, S-60XC 240 ft-lbs ZAG - 180 ft-lbs X 100 psi / 6,9 bar X
from S60XCH-45001, S-65XC 325 Nm 244 Nm
S-80, S-85, S-80X 420 ft-lbs ZP - 230 ft-lbs X 70 psi / 4,8 bar X
569 Nm 313 Nm
ZAB - 228 ft-lbs
310 Nm
S-80XC, S-85XC, S-80HF, S-85HF 420 ft-lbs ZAB - 228 ft-lbs X 100 psi / 6,9 bar X
569 Nm 310 Nm
S-100, S-100HD, S-105, S-120, S- 420 ft-lbs SHC - 230 ft-lbs X X X
120HD, S-125 569 Nm 313 Nm
SX-105XC, SX-125XC, SX-135XC, 320 ft-lbs ZAB - 228 ft-lbs X X X
SX-150, SX-180 434 Nm 310 Nm
Z-30N, Z-30N RJ 125 ft-lbs SHC - 240 ft-lbs X X X
169 Nm 325 Nm
ZAB - 203 ft-lbs
275 Nm
Z-33 125 ft-lbs SHC - 240 ft-lbs X X X
169 Nm 325 Nm
Z-34N, Z-34DC, Z-34BE 125 ft-lbs SHC - 240 ft-lbs X X 100 psi / 6,9 bar
169 Nm 325 Nm (Z-34DC / BE)
ZAB - 203 ft-lbs
275 Nm
Z-34 IC 125 ft-lbs SHC - 240 ft-lbs 45 psi / 3,1 bar 44 psi / 3,0 bar 100 psi / 6,9 bar
169 Nm 325 Nm
ZAB - 203 ft-lbs
275 Nm

Tires and Wheels, continued

Torque values are listed as dry. The retaining fasteners must be coated with a mineral based lubricant
when removed. If a retaining fastener is removed, the torque value is reduced. Refer to the Service and
Repair Manual that is appropriate for your machine.
Model Lug nut Drive hub Tire pressure Tire pressure Tire pressure
torque torque rough terrain high flotation industrial
Z-40N, Z-40N RJ 125 ft-lbs SHC - 240 ft-lbs X X X
169 Nm 325 Nm
ZAB - 203 ft-lbs
275 Nm
Model Z-45/25, Z-45/25J, Z-45 125 ft-lbs SHC - 240 ft-lbs X X X
DC/FE 169 Nm 325 Nm
(DC and BE models) ZAB - 203 ft-lbs
275 Nm
Z-45/25 IC, Z-45/25J IC, Z-45HF, Z- 125 ft-lbs SHC - 240 ft-lbs 60 psi / 4,1 bar 38 psi / 2,6 bar X
45 XC, Z-51 169 Nm 325 Nm
ZAB - 203 ft-lbs
275 Nm
Z-60/37 DC/FE 240 ft-lbs ZAB - 203 ft-lbs X X X
325 Nm 275 Nm
Z-62 240 ft-lbs ZP - 210 ft-lbs 70 psi / 4,8 bar 60 psi / 4,1 bar X
325 Nm 285 Nm
ZAG - 180 ft-lbs
244 Nm
Z-80 420 ft-lbs ZP - 230 ft-lbs X X X
569 Nm 313 Nm
ZAB - 228 ft-lbs
310 Nm
Z-135 420 ft-lbs SHC - 230 ft-lbs X X X
569 Nm 313 Nm
ZX-135 420 ft-lbs SHC - 230 ft-lbs X X X
to serial number ZX13515-2584 569 Nm 313 Nm
ZAB - 228 ft-lbs
310 Nm
ZX-135 320 ft-lbs SHC - 230 ft-lbs X X X
from serial number ZX13515-2585 434 Nm 313 Nm
ZAB - 228 ft-lbs
310 Nm

TraX™ Torque Specifications

Sprocket to hub adapter fasteners
3/4-16 UNF nuts, dry 317 ft-lbs
430 Nm
3/4 -16 UNF nuts, lubricated 281 ft-lbs
381 Nm
1/2-13 FHS screws, dry 80 ft-lbs
108 Nm
1/2-13 FHS screws, lubricated 60 ft-lbs
81 Nm
Hub adapter to drive hub fasteners
S-60, S-65, Z-62, S-60XC from S60XCH-
45001, S-65XC
Lug nut torque, dry 240 ft-lbs
325 Nm
Lug nut torque, lubricated 180 ft-lbs
244 Nm
S-40, S-45, S-40XC, S-45XC
Lug nut torque, dry 240 ft-lbs
325 Nm
Lug nut torque, lubricated 180 ft-lbs
244 Nm
Sprocket bearing hub fasteners
1-14 bolts, GR 8, dry 650 ft-lbs
881 Nm
1-14 bolts, GR 8, lubricated 488 ft-lbs
662 Nm
Idler 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

Genie part number 119488GT
Maintenance Manuals
Diagnostic Manual
Deutz D2011L03i and TD2011L04i Genie part number 119494GT
Ford MSG-425
Deutz TD 2.2 L3 and TCD 2.2 L3 Genie part number 215322GT
Diagnostic Manual
Deutz D 2.9 L4 and TD 2.9 L4 Genie part number 162067GT
Kubota D1105-E3B
Perkins 403D-11 Genie part number 229761GT
Genie part number 131661GT Kubota D1105-E4B
Perkins 403F-11 Genie part number 1273089GT
Kubota WG-972
Perkins 404D-22 and 404D-22T Genie part number 227584GT
Kubota Z482-E
Perkins 404F-22 and 404F-22T Genie part number 139420GT
Continental TME27
Perkins 404F-E22T and 404F-E22TA Genie part number 111901GT
Cummins B3.3T
Perkins 804D-33 Genie part number 139324GT
GM 3.0L
Perkins 854F-E34T Genie part number 1273154GT
Perkins 1104D-44T

Deutz Engine Models TD 2.2 L3

Low idle, standby 1000 rpm
D2011 L03i • D436 L3i CN3 1000 Hz
Low idle 1500 rpm Low idle, function enable 1500 rpm
313 Hz 1500 Hz
High idle 2500 rpm High idle 2500 rpm
521.7 Hz 2500 Hz
Oil capacity (including filter) 9.5 quarts Oil capacity (including filter) 8 quarts
9 liters 7,6 liters
Fan belt deflection 0.375 to 0.5 inches Engine coolant capacity 2.2 gallons
9 to 12 mm 8,3 liters
TD2011 L04i Fan belt deflection Automatic tensioning
Low idle (S-60/65 TraX, S- 1500 rpm TCD 2.2 L3
80/85/80X with generator, S- 450 Hz
80/85HF, S-80/85XC, S- Low idle, standby 1000 rpm
100/105/120/125/100HD/120HD, 1000 Hz
Z-62, Z-80, Z-135, ZX-135 to Low idle, function enable 1500 rpm
serial number 2530) 1500 Hz
Low idle (S-80/85/80X without 1300 rpm High idle 2500 rpm
generator, SX-105/125/135XC, 390 Hz 2500 Hz
SX-150/180, ZX-135 from serial
number 2531) Oil capacity (including filter) 8 quarts
7,6 liters
High idle 2450 rpm
(SX-105/125/135 XC, SX- 735 Hz Engine coolant capacity 2.5 gallons
150/180) 9,5 liters
High idle (S-60/65 TraX, S- 2350 rpm Fan belt deflection Automatic tensioning
80/85/80X, S-80/85HF, S- 705 Hz
80/85XC, S-
100/105/120/125/100HD/120HD,
Z-62, Z-80, Z-135, ZX-135)
Oil capacity (including filter) 12.8 quarts
12,1 liters
Fan belt deflection 0.375 to 0.5 inches
9 to 12 mm

D 2.9 L4 Perkins Engine Models

Low idle, standby 1000 rpm
1000 Hz 403D-11
Low idle, function enable 1500 rpm Low idle 1500 rpm
1500 Hz 150 Hz
2500 Hz 280 Hz
Oil capacity (including filter) 9.4 quarts Oil capacity (including filter) 4.3 quarts
9 liters 4,1 liters
Engine coolant capacity 2.5 gallons Engine coolant capacity 3.3 quarts
9,5 liters 3,1 liters
Fan belt deflection 0.375 to 0.5 inches Fan belt deflection 0.312 inches
9 to 12 mm 8 mm
TD 2.9 L4 403F-11
Low idle, standby 1000 rpm Low idle 1500 rpm
(S-80/85XC, SX-105/125/135XC, 1000 Hz 150 Hz
SX-125 XC, SX-150/180, Z-135, High idle 2800 rpm
ZX-135) 280 Hz
(S-
100/105/120/125/100HD/120HD)
4,4 liters
Low idle, function enable 1500 rpm
Engine coolant capacity 3.3 quarts
(S-80/85HF, S-80/85XC, SX- 1500 Hz
105/125/135XC, SX-150/180, Z- 3,1 liters
135, ZX-135) (S- Fan belt deflection 0.187 inches
100/105/120/125/100HD/120HD) 5 mm
Low idle (all other models) 1000 rpm 404D-22
1000 Hz
Low idle (Z-45/25 and Z-45/25 J) 1500 rpm
High idle 2500 rpm 265 Hz
2500 Hz
Low idle (all other models) 1300 rpm
Oil capacity (including filter) 9.4 quarts 229.7 Hz
9 liters
High idle 2500 rpm
Engine coolant capacity 2.8 gallons 441.7 Hz
10,6 liters
Oil capacity (including filter) 9.4 to 11.2 quarts
Fan belt deflection 0.375 to 0.5 inches 8,9 to 10,6 liters
9 to 12 mm
Unit ships with 15W-40. Extreme operating 12,6 liters
temperatures may require the use of alternative Fan belt deflection 0.375 to 0.5 inches
engine oils. For oil requirements, refer to the 9 to 12 mm
Engine Operator Manual for your engine.
Unit ships with Ethylene Glycol engine coolant.
Consult your local supplier for compatibility before
mixing alternative engine coolants.

404D-22T 404F-E22T
Low idle (standby) 1000 rpm Low idle (standby) 1000
500 Hz 500 Hz
Low idle (with function enable) 1500 rpm Low idle (with function enable) 1500 rpm
750 Hz 750 Hz
1250 Hz 1250 Hz
Oil capacity (including filter) 9.4 to 11.2 quarts Oil capacity (including filter) 9.2 to 11.2 quarts
8,9 to 10,6 liters 8,9 to 10,6 liters
Engine coolant capacity 13.3 quarts Engine coolant capacity 8.8 quarts
Fan belt deflection 0.375 to 0.5 inches Fan belt deflection 0.375 to 0.5 inches
9 to 12 mm 9 to 12 mm
404F-22 404F-E22TA
Low idle (standby) 1000 rpm Low idle (standby) 1000
500 Hz 500 Hz
Low idle (with function enable) 1500 rpm Low idle (with function enable) 1500 rpm
750 Hz 750 Hz
1250 Hz 1250 Hz
Oil capacity (including filter) 9.4 to 11.2 quarts Oil capacity (including filter) 9.2 to 11.2 quarts
8,9 to 10,6 liters 8,9 to 10,6 liters
Engine coolant capacity 13.3 quarts Engine coolant capacity 9.8 quarts
Fan belt deflection 0.375 to 0.5 inches Fan belt deflection 0.375 to 0.5 inches
9 to 12 mm 9 to 12 mm
404F-22T 804D-33
Low idle 1300 rpm Low idle (with generator) 1400 rpm
650 Hz 284.7 Hz
High idle 2300 rpm Low idle (without generator) 1650 rpm
1150 Hz 335.5 Hz
Oil capacity (including filter) 9.4 to 11.2 quarts High idle 2300 rpm
8,9 to 10,6 liters 467.7 Hz
Engine coolant capacity 13.3 quarts Oil capacity (including filter) 10.6 quarts
12,6 liters 10 liters
Fan belt deflection 0.375 to 0.5 inches Engine coolant capacity 12.5 quarts
9 to 12 mm 11,8 liters
9 to 12 mm

854F-E34T Ford Engine Models

Low idle (standby) 1000 rpm
(SX-105 XC, SX-125 XC, SX- 500 Hz DSG-423
135 XC, SX-150, SX-180, Z-135, Low idle 1600 rpm
ZX-135) 53.3 Hz
(S-
High idle 2500 rpm
100/105/120/125/100HD/120HD)
83.3 Hz
Low idle (with function enable) 1500 rpm
Oil capacity (including filter) 4 quarts
(SX-105 XC, SX-125 XC, SX- 750 Hz
135 XC, SX-150, SX-180, Z-135, 3,8 liters
ZX-135) Engine coolant capacity 10 quarts
(S- 9,5 liters
100/105/120/125/100HD/120HD) Spark plug gap 0.049 to 0.053 inches
High idle 2500 rpm 1,25 to 1,35 mm
1250 Hz Fan belt deflection 0.375 to 0.5 inches
Oil capacity (including filter) 7.7 quarts 9 to 12 mm
7,3 liters
MSG-425
Low idle 1500 rpm
15,6 liters
50 Hz
High idle 2500 rpm
9 to 12 mm
83.3 Hz
1104D-44T Oil capacity (including filter) 6.7 quarts
Low idle 1300 rpm 6,4 liters
314.2 Hz Engine coolant capacity 10 quarts
High idle 2450 rpm 9,5 liters
(SX-135 XC, SX-150 and SX- 592 Hz Spark plug gap 0.049 to 0.053 inches
180)
1,25 to 1,35 mm
High idle (all other models) 2350 rpm Fan belt deflection 0.375 to 0.5 inches
568 Hz 9 to 12 mm
Unit ships with 15W-40. Extreme operating
9,8 liters
temperatures may require the use of alternative
Engine coolant capacity 9.5 quarts engine oils. For oil requirements, refer to the
9 liters Engine Operator Manual for your engine.
9 to 12 mm Unit ships with Ethylene Glycol engine coolant.
engine oils. For oil requirements, refer to the

Kubota Engine Models WG-972

Low idle 1600 rpm
D1105-E3B 266.7 Hz
Low idle 1250 rpm High idle 3000 rpm
208.3 Hz 500 Hz
High idle 3000 rpm Oil capacity (including filter) 3 quarts
500 Hz 2,8 liters
Oil capacity (including filter) 5.4 quarts Engine coolant capacity 0.61 quarts
Engine coolant capacity 3.3 quarts Spark plug gap 0.024 to 0.028 inches
3,1 liters 0,6 to 0,7 mm
Fan belt deflection 0.312 inches Fan belt deflection 0.312 inches
8 mm 8 mm
D1105-E4B Z482-E
Low idle 1250 rpm Low idle 2000 rpm
(Z34 IC) 208.3 Hz 333.3 Hz
Low idle 2150 rpm High idle 3000 rpm
(Z60 FE) 358.3 Hz 500 Hz
High idle 3000 rpm Oil capacity (including filter) 2.64 quarts
500 Hz 2,5 liters
Oil capacity (including filter) 5.4 quarts Engine coolant capacity 3 quarts
Engine coolant capacity 3.3 quarts Fan belt deflection 0.312 inches
3,1 liters 8 mm
Fan belt deflection 0.312 inches
8 mm
D1803-CR-TIE4 temperatures may require the use of alternative
Low idle, standby 1200 rpm engine oils. For oil requirements, refer to the
200 Hz Engine Operator Manual for your engine.
Low idle, function enable 1500 rpm Unit ships with Ethylene Glycol engine coolant.
250 Hz
High idle 2700 rpm mixing alternative engine coolants.
450 Hz
8,1 liters
Engine coolant capacity 10 quarts
9,5 liters
Fan belt deflection 0.437 inches
11 mm

GM Engine Models Continental Engine Models

.998L TME27
Low idle 1100 rpm Low idle 1600 rpm
36.6 Hz 53.3 Hz
100 Hz 83.3 Hz
Oil capacity (including filter) 3.2 quarts Oil capacity (including filter) 7 quarts
3 liters 6,6 liters
Engine coolant capacity 5 quarts Engine coolant capacity 10.7 quarts
Spark plug gap 0.039 to 0.047 inches Spark plug gap 0.032 inches
1 to 1,2 mm 0,8 mm
3.0L Fan belt deflection 0.5 inches
12 mm
Low idle (standby) 1000 rpm
33.3 Hz Unit ships with 15W-40. Extreme operating
Low idle (with function enable) 1500 rpm temperatures may require the use of alternative
50 Hz engine oils. For oil requirements, refer to the
High idle 2500 rpm
83.3 Hz Unit ships with Ethylene Glycol engine coolant.
Oil capacity (including filter) 5 quarts Consult your local supplier for compatibility before
4,7 liters mixing alternative engine coolants.
Engine coolant capacity 12 quarts
11,4 liters
Spark plug gap 0.035 inches
0,89 mm

Cummins Engine Models

B3.3T
Low idle 1300 rpm
229.7 Hz
High idle 2350 rpm
415 Hz
Oil capacity (including filter) 9 quarts
8,5 liters
10,1 liters
Fan belt deflection 0.375 to0.5 inches
9 to12 mm

Hydraulic Specifications
Hydraulic Relief Valve Pressure

Function Manifold Relief Valve Pressure / Bar
Model System Primary SecondarySecondary Primary SecondaryTurntableProportional Platform
relief boom boom boom up boom boom rotate relief level
down down extend extend
S-40 2600 psi 2200 psi X X 1950 psi X X X X
(all models) 179 bar 152 bar 134 bar
S-45 2900 psi 2200 psi X X 1950 psi X X X X
(all models) 200 bar 152 bar 134 bar
S-40HF, S-45HF, S- 3200 psi X X X 1950 psi X X X 3500 psi
40XC, S-45XC 221 bar 134 bar 241 bar
S-60, S-65, S-60HC, 3000 psi X X X X X X X X
S-60X 207 bar
S-60XC to 45000
(all models)
S-60HF, S-65HF, S- 3200 psi X X X 2300 psi X X X 3500 psi
60XC from S60XCH- 221 bar 159 bar 241 bar
45001, S-65XC
(all models)
S-60J 3200 psi X X X 2000 psi X X X 3000 psi
221 bar 138 bar 207 bar
S-80, S-85, S-80X 3200 psi 2400 psi X X 2400 psi X X X X
221 bar 165 bar 165 bar
S-80HF, S-85HF, S- 3200 psi 2600 psi X X 2400 psi X X X X
80XC, S-85XC 221 bar 179 bar 165 bar
S-100, S-100HD, S- 2600 psi X X X X X X X 3000 psi
105, S-120, S- 179.3 bar 207 bar
120HD, S-125
SX-105 XC, SX-125 3200 psi X X X 1950 psi X X X X
XC 221 bar 134 bar
SX-135 XC 3200 psi X X X 2350 psi X X X X
221 bar 162 bar
SX-150, SX-180 3200 psi X X X 2500 psi X X X X
221 bar 172 bar

Model System Primary SecondarySecondary Primary SecondaryTurntableProportional Platform

relief boom boom boom up boom boom rotate relief level
down down extend extend
Z-30N, 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 50 - 3000 psi X
130 bar 130 bar 3,4 - 207 bar
Z-34N, 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, 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, Z-45/25J 3200 psi X 2100 psi X X X X X X
(DC and BE models) 221 bar 145 bar
Z-45/25 IC, Z-45/25J 3200 psi X 2100 psi X X X X X ANSI /
IC, Z-45HF, Z-45 XC 221 bar 145 bar CSA
3500 psi
241 bar
CE
3000 psi
207 bar
Z-45 DC/FE X X 2100 psi X X X X 50 - 3200 psi 3500 psi
145 bar 3,4 - 221 bar 241 bar
Z-51 3200 psi X 2100 psi X X X X X 2500 psi
221 bar 145 bar 172 bar
Z-60 DC / FE X X X X 1250 psi X X 50 - 3000 psi 2800 psi
86 bar 3,4 - 207 bar 193 bar
Z-62 3000 psi X X X X X X X 2800 psi
(all models) 207 bar 193 bar
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, 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 valve Oscillate relief Axle extend
pressure
S-40, S-45 280 psi 950 psi X
(all models) 19,3 bar 66 bar
S-40HF, S-45HF, S-40XC, S-45XC 280 psi 850 psi
(all models) 19,3 bar 58,6 bar
S-60, S-65, S-60HC, S-60X 280 psi 800 psi X
S-60XC to 45000 19,3 bar 55 bar
(all models)
S-60HF, S-65HF, S-60XC from 280 psi 600 psi X
S60XCH-45001, S-65XC 19,3 bar 41,4 bar
(all models)
S-60J 280 psi 650 psi X
19,3 bar 45 bar
S-80, S-85, S-80HF, S-85HF, S-80X, S- 280 psi 950 psi X
80XC, S-85XC 19,3 bar 66 bar
S-100, S-100HD, S-105, S-120, S- 280 psi X 1800 psi
120HD, S-125 19,3 bar 124 bar
SX-105 XC, SX-125 XC, SX-135 XC 240 psi X 2400 psi
16,5 bar 165 bar
SX-150, 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, Z-45HF, Z-45 250 psi X X
XC, Z-51 17,2 bar
Z-45 DC/FE X 500 psi X
34,5 bar
Z-60 DC / FE X 400 psi X
28 bar
Z-62 280 psi 650 psi X
(all models) 19,3 bar 45 bar
Z-80 280 psi 800 psi X
19,3 bar 55 bar
Z-135, 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

Drive hub Drive hub rotation drive (including tank)
hub
S-40, S-45 20 fl oz 20 fl oz 8 fl oz 45 gallons 55 gallons
(all models) 591 cc 591 cc 237 cc 170 liters 208 liters
S-40HF, S-45HF, S-40XC, S-45XC 20 fl oz 20 fl oz 8 fl oz 38 gallons 50 gallons
S-60, S-65, S-60HC, S-60X 20 fl oz 20 fl oz 43 fl oz 45 gallons 55 gallons
S-60XC to 45000 591 cc 591 cc 1262 cc 170 liters 208 liters
(all models)
S-60HF, S-65HF, S-60XCH from 20 fl oz 20 fl oz 43 fl oz 40 gallons 57 gallons
S60XCH-45001, S-65XC 591 cc 591 cc 1262 cc 151 liters 216 liters
(all models)
S-60J 24.5 fl oz 24.5 fl oz 8 fl oz 21 gallons 25 gallons
725 cc 725 cc 237 cc 80 liters 95 liters
S-80, S-85, S-80X 23 fl oz 30.5 fl oz 43 fl oz 40 gallons 50 gallons

S-80HF, S-85HF, S-80XC, S-85XC X 30.5 fl oz 43 fl oz 40 gallons 64 gallons
902 cc 1262 cc 151 liters 242 liters
S-100, S-105, S-120, S-125, S- X 47 fl oz 93 fl oz 55 gallons 80 gallons
100HD, S-120HD 1390 cc 2750 cc 208 liters 303 liters
SX-105XC, SX-125XC, SX-135XC X 67 fl oz 43 fl oz 60 gallons 138 gallons
SX-150 X 67 fl oz 43 fl oz 110 gallons 175 gallons
SX-180 X 67 fl oz 43 fl oz 110 gallons 225 gallons
Z-30N, 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, 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, Z-40N RJ 23 fl oz X 5 fl oz 8 gallons 11 gallons

Hydraulic and Drive Hub Fluid Capacities, continued

Model 2WD 4WD Turntable Hydraulic tank Hydraulic system
Drive hub Drive hub rotation drive (including tank)
hub
Z-45/25, Z-45/25J EW1 type X 25.5 fl oz 8 gallons 11 gallons
(DC and BE models) 17 fl oz 750 cc 30 liters 41 liters
503 cc
W1 type
23 fl oz
680 cc
Z-45/25 IC, Z-45/25J IC, Z-45HF, Z- 24 fl oz 24 fl oz 25.5 fl oz 22 gallons 28 gallons
45 XC 710 cc 710 cc 750 cc 83 liters 106 liters
Z-45 DC/FE X 24 fl oz 25.5 fl oz 10.5 gallons 17 gallons
Z-51 X steer end 25.5 fl oz 22 gallons 28 gallons
17 fl oz 750 cc 83 liters 106 liters
503 cc
non-steer
end
42 fl oz
1242 cc
Z-60 (DC / FE) 24 fl oz 24 fl oz 43 fl oz 18 gallons 21 gallons
Z-62 20 fl oz 20 fl oz 43 fl oz 35 gallons 45 gallons
Z-80 X 30.5 fl oz 40 fl oz 45 gallons 80 gallons
Z-135, 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 Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
Brookfield Viscosity cSt @ -40°F / -40°C 510
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310 Pour point -81°F / -63°C
Flash point 375°F / 190°C Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C
temperature Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage

Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Fluid Properties Properties
ISO Grade 46 ISO Grade 46
Viscosity index 154 Viscosity index 192
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 8.0 cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C 46
Flash point cSt @ 0°F / -18°C 1300
482°F / 250°C
Pour point Flash point None
-49°F / -45°C
Pour point -81°F / -63°C
temperature Maximum continuous operating 189°F / 87°C
temperature
Shell Tellus S4 VX Fluid

Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
temperature

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™
SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends -4 14 ft-lbs / 19 Nm
be 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
-24 184 ft-lbs / 249,5 Nm
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
Adjustable Fitting Non-adjustable fitting
-24 230 ft-lbs / 315 Nm
1 jam nut
JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2
-6 9/16-18 1 1/2 -4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm
-12 1 1/16-12 1 1/4
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
1 Replace the O-ring. The O-ring must be
hand tight, 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 2 reference mark
in 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
Secti on 3 Maint enan ce Pro ced ures
Machine Configuration:
 Unless otherwise specified, perform each
procedure with the machine in the following
configuration:
• Machine parked on a firm, level surface
Observe and Obey: • Key switch in the off position with the key
 Maintenance inspections shall be completed removed
by a person trained and qualified on the
• The red Emergency Stop button in the off
maintenance of this machine.
position at both the ground and platform
 Scheduled maintenance inspections shall be controls
completed as specified on the Maintenance
• Wheels chocked
inspection Reports. The frequency and extent
of periodic examinations and tests may also • All external AC power supply disconnected
depend on national regulations. from the machine
Failure to perform each • Machine in the stowed position
procedure as presented and
• Turntable secured with the turntable rotation
scheduled may cause death,
lock
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
scheduled maintenance inspection. this 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

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

situation which, if not avoided, required to perform this procedure.
may cause minor or moderate
injury.
Indicates a potentially hazardous

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

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

Maintenance 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 Legend
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.
Programmed: A series of maintenance Specific Interval: blank box is the interval to
procedures to be performed during a Pre-Delivery be completed and the  marks the interval
Preparation or based on machine operating hours. as not required.
The description of the procedure or

Maintenance Inspection Report checklist to be completed.
The maintenance inspection report contains
checklists for each type of scheduled inspection. The procedure number or checklist to be
completed.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed Check box to indicate status of inspection.
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
Specific interval is not required for this
regulations and requirements.
procedure.
Instruction Examples
General area of the machine to complete
Commissioning Example: the procedure.
If this box has a designated time interval:

this is the specific time interval to complete
the procedure or checklist.
Quarterly and Annually Example:
If this box is empty: the maintenance
checklist will include multiple time intervals,
use this box to write in the specific interval
for the inspection completed.

Pre-Delivery Preparation Report
Fundamentals Instructions
It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check
in the appropriate box after each part is
A damaged or modified machine must never be completed. Follow the instructions in the operator’s
used. If damage or any variation from factory manual.
delivered condition is discovered, the machine
must be tagged and removed from service. If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
Repairs to the machine may only be made by a After repair, place a check in the R box.
qualified service technician, according to the
manufacturer's specifications. Legend
Y = yes, acceptable
Scheduled maintenance inspections shall be N = no, remove from service
performed by qualified service technicians, R = repaired
according to the manufacturer's specifications and Comments
the requirements listed in the responsibilities
manual.
Pre-delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
May 2020
Scheduled - Quarterly
Maintenance Inspection Report – Booms
Model Hour meter Date

Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Inspection Type Legend Y = yes, N = no, remove from service Make copies of this report to use for each
Q = quarterly or frequent acceptable inspection.
inspections Select the appropriate procedures for the type of
R = repaired  = not applicable inspection(s) to perform.
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 ✓ Functions and Controls, continued ✓

Inspect the Tires, Wheels and Lug Nut Torque Q-6 Test the Drive Brakes Q-21
Check the Oscillate Valve Linkage (if equipped) Q-8 Test the Drive Speed – Stowed Position Q-22
Confirm the Proper Brake Configuration Q-20 Test the Drive Speed – Raised or Extended Position Q-23
Turntable Mechanicals and Hydraulics Test the Drive Speed – Raised and Extended Position - Q-24
ALC1000 Models
Visual Inspection of the Hydraulic Oil Q-9
Test the Turntable Level Sensor - Z-135/70, ZX-135/70, Q-25
Inspect the Hydraulic Filters Q-10 SX-105XC, SX-125XC, SX-135XC, SX-150, SX-180
Electrical Test the Secondary Boom Angle Sensor - Z-135/70, ZX- Q-26
Inspect Electrical Contactors - DC / Bi-Energy Models Q-4 135/70
Battery Inspection Q-2 Test the Primary Boom Angle Sensor - Z-135/70 and ZX- Q-27
135/70
Inspect the Electrical Wiring Q-3
Test the Primary Boom Angle Sensor - Q-28
Engine SX-105XC, SX-125XC, SX-135XC, SX-150, SX-180
Check the Exhaust System Q-5 Test the Safety Envelope Limit Switches - Z-135/70, ZX- Q-29
Check Generator Belts/Pulleys - Bi-Energy Models Q-7 135/70, SX-105XC, SX-125XC, SX-135XC, SX-150, SX-
180
Check and Adjust the Engine RPM Q-11
Test the Primary Boom Angle Sensor - Z-80/60 Q-30
Boom(s) and Platform
Test the Safety Envelope and Circuits - Z-80/60 Q-31
Inspect and Adjust Boom Cables - All Models Q-36
(for first 12 months of ownership) Check the Safety Envelope Limit Switches and Angle Q-32
Sensor - S-60X, S-80X, to S60XCH-45000
Functions and Controls ✓
Test the Safety Envelope and Circuits - S-100, S-105, S- Q-33
Check for Open Bulletins and Owner Registration Q-1 120, S-125
Test the Ground Control Override Q-12 Test the Aircraft Protection System (if equipped) Q-34
Test the Alarm Package (if equipped) Q-13 Test the Operator Protection Alarm (if equipped) Q-35
Test the Emergency Power System Q-14 Test the Recovery System - ALC600 models Q-37
Test the Turntable Level Sensor - S-40HF, S-45HF, S- Q-38
Test the Engine Idle Select Operation Q-15
40XC, S-45XC, S-60HF, S-65HF, S-60J, S-60XC from
Test Fuel Select Operation - Gas/LPG Models Q-16 S60XCH-45001, S-65XC, S-80HF, S-85HF, S-80XC, S-
85XC
Inspect the Calibration Decal - ALC1000 Models Q-17
Test the Primary Boom Angle Sensor - S-40HF, S-45HF, Q-39
Test the Recovery System - ALC-1000 Models Q-18 S-40XC, S-45XC, S-60HF, S-65HF, S-60J, S-60XC from
Test the Platform Self-leveling Q-19 S60XCH-45001, S-65XC, S-80HF, S-85HF, S-80XC, S-
85XC
38 S® Booms • Z® Booms Maintenance Manual Part No. 1268489GT

May 2020
Scheduled - Annual

Inspection Type Legend Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection.
A = annual inspections Select the appropriate procedures for the type of
R = repaired  = not applicable inspection(s) to perform.
Confirm all applicable quarterly maintenance procedures Confirm all applicable quarterly and annual maintenance
have been included and completed with the annual procedures have been included and completed with the
inspection. 2 year inspection.
Drive Chassis ✓ Perform Every 2 Years
Extendable Axle Wear Pads (if equipped) A-4 Engines ✓
Check Drive Hub Oil Level and Fastener Torque A-14
Perform Engine Maintenance - Kubota D1803 A-20
Turntable Mechanicals and Hydraulics
Grease the Turntable Rotation Bearing A-1
Check Turntable Bearing Bolts A-2
Inspect for Turntable Bearing Wear A-3
Boom(s) and Platform

Jib Rotate Bearing (if equipped) A-5
Grease the Platform Overload Mechanism A-7
Test Platform Overload - All Models, Except ALC1000 and A-8
S-60HC Models
Test Platform Overload - (ALC1000 models) A-9
Test Platform Overload - (S-60 HC models) A-10
Test Platform Overload - S-40HF, S-45HF, S-60J, Z-45HF, A-18
Z-45 DC/FE from Z45EM-101
Test Dual Capacity / Overload - SX-105XC, SX-125XC, A-15
SX-135 XC
Test Dual Capacity / Overload - Z-45XC A-16
Test Dual Capacity / Overload - S-40XC, S-45XC, S-60HF, A-17
S-65HF, S-60XC from S60XCH-45001, S-65XC, S-80HF,
S-85HF, S-80XC, S-85XC
Inspect Boom Cables - All S-60, S-80 Models A-11
Inspect Boom Cables - S-100 to S-125, S-100HD, S- A-12
120HD, SX-105XC, SX-125XC
Inspect Boom Cables - SX-135XC, SX-150, SX-180 A-13
Functions and Controls
Test the Bypass/Recovery Key Switch A-6
Engines
Perform Engine Maintenance - Kubota D1803 A-19
Part No. 1268489GT S® Booms • Z® Booms Maintenance Manual 39

May 2020
Programmed

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 Select the appropriate procedures for the type
The onetime procedures will be completed at 50 or 150 hours. service of inspection(s) to perform.
R = repaired
 = not applicable
Commissioning 50 150 Programmed Maintenance Hours are in thousands
50 Hour Service - all models C-1 

All models Perform every: 1 2 3 4 5 6 12
Engines - Ford, Kubota, Perkins Models C-2 
Engines - all models, 1000 Hours P1-1      
Perform 150 Hour Service C-3 
Replace the Drive Hub Oil P1-2      
Engines - Kubota D1803, 1500 P1-3      
Programmed Maintenance - Under 1000 HRS Status Enter Hours
Hours
Engines - all models, 2000 Hours P2-1      
Check the Track Tension and Fastener Torque P0-1 50
- S-60, S-65 and Z-62 Models
Test or Replace the Hydraulic Oil P2-2      
Check the Track Tension and Fastener Torque P0-2 50 Replace the Hydraulic Filters P2-3      
- S-40 and S-45 Models
Check the Free-wheel P2-4      
Grease the Extendable Axles - (if equipped) P0-3 50 Configuration
Engines - Continental Under 1000 HRS P0-4 Check the Boom Wear Pads P2-5      
Engines - Cummins Under 1000 HRS P0-5 Check the Extendable Axle Wear P2-6      
Pads
Engines - Deutz Under 1000 HRS P0-6
Check Turntable Gear Backlash - P2-7      
Engines - Ford Under 1000 HRS P0-7 ALC1000 Models
Engines - Kubota Under 1000 HRS P0-8 Grease the Steer Axle Wheel P2-8      
Bearings, 2WD Models (except Z-
Engines - Perkins Under 1000 HRS P0-9 62, S-60, S-65)
Engines - GM .998L Under 1000 HRS P0- Grease the Steer Axle Wheel P2-9      
10 Bearings, 2WD Models - Z-62, S-
60, S-65
Engines - GM 3.0L Under 1000 HRS P0-
11 Engines - all models, 3000 Hours P3-1      
Engines - Perkins models, 4000 P4-1      
Hours
Engines - GM models, 5000 Hours P5-1      
Hours
Hours
Remove and Inspect Boom cables P12-2 every 12 years
or
every 3 years after
first 12 years if not
replaced
40 S® Booms • Z® Booms Maintenance Manual Part No. 1268489GT

Commissioning 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 • Electrical wiring - check for chafing or
and Rotate Gear damage
Kubota Models:
A-2 Check the Turntable Rotation Bearing
Bolts • Engine oil - replace
A-5 Check the Jib Rotator Fastener Torque • Oil filter - replace
(SX-150 and SX-180 models)
GM .998L
P1-2 Replace the Drive Hub Oil
• Cylinder head bolts - torque
P2-3 Replace the Hydraulic Filters (40.5 ft-lbs / 55 Nm)
• Valve clearance - check/adjust
Perkins 404F-E22T, 404F-E22TA
• Fan clearance - check
Required maintenance procedures and additional
engine information are available in the
manufacturer's manuals. Refer to Specifications,
Engine Operator and Maintenance Manuals.

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

(http://genielift.com.au/contact) 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 the specific gravity reading for each cell as
engine and machine performance and operational follows:
safety. Improper fluid levels or damaged cables
and connections can result in engine and • Add 0.004 to the reading of each cell for
component damage and hazardous conditions. every 10° F / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each
Electrocution/burn hazard. cell for every 10° F / 5.5° C below 80° F /
Contact with electrically charged 26.7° 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 its 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
• All wire harness connectors to platform
Maintaining electrical wiring in good condition is control box
essential to safe operation and good machine
performance. Failure to find and replace burnt, • Battery compartment
chafed, corroded or pinched wires could result in • Battery separator
unsafe operating conditions and may cause
component damage. • Battery charger
• Contactor
Electrocution/burn hazard.
Contact with electrically charged • Motor controller
serious injury. Remove all rings, • Electric motor
watches and other jewelry. • Pump motor
1 Inspect the following areas for burnt, chafed, • Limit switches
corroded pinched and loose wires:
• Rotary sensors
Note: Inspection areas will vary by model.
2 Inspect for a lite, even coating of dielectric
• Engine wiring harness grease on all harness connections.
• Engine relay block Note: Do not apply excessive amounts of dielectric

grease to harness connectors, pins or sockets.
• Hydraulic manifold wiring
Note: Do not apply dielectric grease to a engine
• All wire harness connectors to ground ECU/ECM or engine harness connectors.
control box
• Inside of the ground control box
• Turntable area

Q-4 From serial numbers
Inspect the Electrical Contactors Z-45 DC / FE models Z45EM-101
- DC / Bi-Energy Models Z-60 DC / FE models Z6016N-101

Z60H-701
Z60M-101
Genie specifications require that this procedure be 1 Open the turntable cover and remove the fuse
performed quarterly. box cover.
Maintaining the electrical contactor in good

condition is essential to safe machine
performance. Failure to locate a worn or damaged
contactor could result in unsafe operating
conditions and may cause component damage.
Z-30N, Z-33, Z-34, Z-40 and Z-45 models:
1 Remove the drive chassis cover from the non-
steer end of the machine and locate the
electrical contactor(s).
2 Locate the electrical contactor mounted on
the fuse bracket.
3 Visually inspect the contact points of the
contactor for the following items: Z-45 DC / FE
• Excessive burns
• Excessive arcs
• Excessive pitting
Electrocution/burn hazard.
Contact with electrically charged
serious injury. Remove all rings,
watches and other jewelry.
Note: Replace the contactor if any damage is

found.
Z-60 DC / FE
1 fuse box
2 fuse box cover
3 battery box


2 Visually inspect the contact points of the Q-5
contactor for the following items:
Check the Exhaust System
• Excessive burns
• Excessive arcs performed quarterly.
• Excessive pitting Maintaining the exhaust system is essential to
Electrocution/burn hazard. good engine performance and service life.
Contact with electrically charged Operating the engine with a damaged or leaking
circuits could result in death or exhaust system can cause component damage
serious injury. Remove all rings, and unsafe operating conditions.
watches and other jewelry.
Bodily injury hazard. Do not
Note: Replace the contactor if any damage is inspect while the engine is
found. running. Remove the key to
secure from operation.
Burn hazard. Beware of hot

engine components. Contact
with hot engine components
may result in severe burns.
1 Be sure that all nuts and bolts are tight.

2 Inspect all welds for cracks.
3 Inspect for exhaust leaks; i.e., carbon buildup
around seams and joints.

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.
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 Bodily injury hazard. Do not
fashion. inspect while the engine is
running. Remove the key to
Bodily injury hazard. An over- secure from operation.
inflated tire can explode and
could cause death or serious Bodily injury hazard. Beware of
injury. hot engine components.
Contact with hot engine
Tip-over hazard. Do not use components may cause severe
temporary flat tire repair burns.
products.
Note: Charging the batteries with the engine does
Note: The tires on some machines are foam-filled not fully charge the batteries. Periodically, use the
or solid rubber and do not need air added to them. AC battery charger to fully charge the batteries.
Note: Refer to Specifications. Torque 1 Be sure that all fasteners and cables on the
Specifications, Tires and Wheels. generator are tight.
2 Remove the engine flywheel cover mounting
1 Check all tire treads and sidewalls for cuts,
fasteners, then remove the cover.
cracks, punctures and unusual wear.
3 Be sure that the pulley mounting fasteners are
2 Check each wheel for damage, bends and
tight and that the pulleys show no signs of
cracked welds.
damage or unusual wear.
3 Check each lug nut for proper torque.
4 Check the pressure in each air-filled tire.

4 Check to be sure the engine pulley and the 7 Check the generator belts for proper tension.
generator pulley are aligned within If 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
3 maximum pulley offset
8 Check the torque of the pulley retaining nut on
4 generator pulley the generator.
Note: If alignment does not meet specification, Generator pulley 80-90 ft-lbs
Refer to Repair Procedure in the appropriate retaining nut torque 108-122 Nm
Service and Repair Manual for your machine, How
Engine pulley retaining bolts 108 in-lbs
to Install the Engine Drive Pulley to adjust the 12.2 Nm
pulley alignment.
Pulley alignment, maximum offset 0.0625 inch 9 Connect the positive lead of a multi meter to
1.58 mm the positive post on the back of the alternator.
5 Inspect the generator belts for: Connect the negative lead to the negative
post. Set the meter to DC voltage.
• Cracking
10 Start the engine from the ground controls.
• Glazing
Result: The voltage does not exceed 54V DC.
• Separation Note: To adjust the voltage regulator, Refer to
• Breaks Repair Procedure in the appropriate Service and
Repair Manual for your machine, How to Adjust
6 Replace both belts if any damage is found. the Generator Voltage Regulator.

Q-8 Q-9
Check the Oscillate Directional Visual Inspection of the Hydraulic
Valve Linkage (if equipped) 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 continued use may cause component damage.
is not operating correctly, the stability of the Extremely dirty conditions may require oil changes
machine is compromised and it may tip over. to be performed more often. For hydraulic oil
1 Remove the drive chassis cover and the axle specifications, Refer to Specifications, Hydraulic
covers from the non-steer end of the drive Specifications.
chassis. Note: Before replacing the hydraulic oil, the oil
2 Locate the oscillate directional valve inside of may be tested by an oil distributor for specific
the non-steer axle and inspect the linkage for levels of contamination to verify that changing the
the following: oil is necessary. Replace the oil when it fails the
test. Refer to Maintenance Procedure, Test or
• Lock nut is tight against yoke Replace 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 Q-10

a clear container. Visually inspect the
hydraulic oil for the following:
Inspect the Hydraulic Filters
• Color: oil should be a clear, light-honey
colored
Maintaining the hydraulic filter in good condition is
• Appearance, oil should be clear and not
essential to good system performance and safe
cloudy or visibly distorts the view through
machine operation. The filter condition indicator
the sight glass or container
will show when the hydraulic flow is bypassing a
• Contains no particles, foreign objects, or clogged filter. If the filter is not frequently checked
other contamination and replaced, impurities will remain in the
hydraulic system and cause component damage.
• The hydraulic oil can be inspected by smell
(can smell “hot” but not “burnt”) or rubbing Note: There are four types of hydraulic filters: tank
between fingers (should feel viscous and return filter, medium pressure filter, high pressure
free of any rough feel due to particles) filter and drive motor case drain filter. The quantity
If the hydraulic oil passes all of the above and type of filter(s) may vary by model.
inspections, continue the scheduled Models with Filter Condition Indicator:
maintenance intervals.
If the hydraulic oil fails any of the above
inspections, the hydraulic oil must be tested 2 Set the engine idle to high rpm (rabbit
by an oil distributor or replaced. 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
Result: The filter condition indicator is
must be tested every quarter by an oil distributor
operating in the green area.
until the oil fails the test and is replaced. After the
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
tank. be performed quarterly.
2 Check for proper venting. Maintaining the engine rpm at the proper setting
Result: Air passes through the breather cap. for both low and high idle is essential to good
Proceed to step 4. engine 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
3 Using a mild solvent, carefully wash the cap by 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 GM Models: .998L • 3.0L
beginning with step 2.
Continental Models: TME27
4 Install the breather cap onto the hydraulic
tank. Kubota Models: D1803-CR-TIE4
Ford Models: DSG-423 • MSG-425
Deutz Models: TD 2.2 L3 • TCD 2.2 L3 • D 2.9 L4
• TD 2.9 L4 • D436 L3i CN3
Perkins Models: 403F-11 • 404D-22T • 404F-22 •
404F-22T • 404F-E22T • 404F-E22TA • 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-600 operating system: Models with ALC-1000 operating system:
Note: Use the following chart to identify the Note: Use the following chart to identify the
description of each LCD screen control button description of each LCD screen control button
used in this procedure. used in this procedure.
Plus Minus Previous Enter

Home Maintenance Faults Settings
2 Press the enter or previous button on the
LCD screen until engine rpm is displayed.
Result: Low idle rpm is correct. Continue with
step 3.
Low idle High idle Gauges Result: Low idle rpm is not correct. Follow the
1 Start the engine from the ground controls. low rpm idle procedure for your engine model.
2 Press the Home button on the display. Press 3 Press and hold the function enable/high
button 2 under the engine idle icon and select speed button. Note the engine rpm on the
low idle. display.
3 Press button 1 under the gauges icon. Scroll Result: High idle rpm is correct.
down to RPM and press Ok. Result: High idle rpm is not correct. Follow the
Result: Low idle rpm is correct. Continue with high rpm idle procedure for your engine
step 4. model.
Result: Low idle rpm is not correct. Follow the All other models:
low rpm idle procedure for your engine model.
1 Connect a tachometer to the engine. Start the
4 Press button 2 under the engine idle icon and engine from the ground controls and check
select high idle. the rpm.
Result: High idle rpm is correct. Result: Low idle rpm is correct. Continue with
step 2.
Result: High idle rpm is not correct. Follow the
high rpm idle procedure for your engine Result: Low idle rpm is not correct. Follow the
model. 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.

Kubota WG-972: 3 Tighten the lock nut.
Low rpm idle adjustment:

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

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

All other engine models: Kubota Z482-E
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. 1 low idle adjustment screw (not shown)
3 Tighten the lock nut. 2 high idle adjustment nut
Kubota D1105-E3B, D1105-E4B 4 fuel shut off solenoid
Deutz D2011L03i

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


Deutz TD2011L04i Perkins 403D-11

3 lock nut
4 low idle adjustment screw 1 high idle solenoid

Perkins 404D-22 Perkins 1104D-44T

2 lock nut
3 high idle adjustment screw

2 high idle adjustment nut Cummins B3.3T
3 lock nut
Perkins 804D-33

1 high idle solenoid 2 high idle adjustment nut
2 high idle adjustment nut 3 high idle solenoid
3 lock nut

Q-12 Q-13
Test the Ground Control Override Test the Alarm Package (if
Genie specifications require that this procedure be equipped)
performed quarterly. Genie specifications require that this procedure be
A properly functioning ground control override is performed quarterly.
essential to safe machine operation. The ground The alarm package includes:
control override function is intended to allow
ground personnel to operate the machine from the • Travel alarm
ground controls whether or not the Emergency
Stop button on the platform controls is in the on or • Descent alarm
off position. This function is particularly useful if • Flashing beacon
the operator at the platform controls cannot return
the boom to the stowed position. Alarms and a beacon are installed to alert
operators and ground personnel of machine
1 Push in the platform red Emergency Stop proximity and motion. The alarm package is
button to the off position. installed on the turntable covers.
2 Turn the key switch to ground controls. Note: The alarms and beacon will operate with the
3 Pull out the red Emergency Stop button to the engine running or not running.
on position at the ground controls.
1 Turn the key switch to ground control and pull
4 From the ground controls, operate each boom out the red Emergency Stop button to the on
function through a partial cycle. position at both ground and platform controls.
Result: All boom functions should operate. S-40HF, S-45HF, S-60HF, S-65HF, S60J, S-
60XC from S60XCH-45001 and S60XCM-
5 From the platform, activate the foot switch 101, S-65XC, S-80HF, S-85HF, S-80XC, S-
and operate each boom function. 85XC, S-100, S-105, S-120, S-125, S-100HD,
Result: No boom functions operate. S-120HD, SX-105XC, SX-125XC, SX-135XC,
SX-150, SX-180, Z-80/60, Z-135/70 and ZX-
6 Pull out the red Emergency stop button to the 135/70 Models:
on position at the platform controls.
Result: The alarm should sound twice. The
7 Activate the foot switch and operate each flashing beacon should be on and flashing.
boom function.
All other models:
Result: No boom functions operate.
Result: The flashing beacon should be on and
flashing.

All Models: Q-14

2 Activate the boom down function, hold for a Test the Emergency Power
moment and then release it. System
Result: The descent alarm should sound (excludes ALC-600 and ALC-1000
when the down function is activated.
Models)
Complete this step for each boom that
applies: Primary, Secondary and Jib Booms.
3 Turn the key switch to platform controls.
Result: The flashing beacon should be on and performed quarterly.
flashing.
Testing the emergency power system regularly is
4 Press down the foot switch. Activate the boom essential to safe machine operation if the primary
down function, hold for a moment and then power source fails.
release it.
Result: The descent alarm should sound
out the red Emergency Stop button to the on
when the down function is activated.
Complete this step for each boom that controls.
applies: Primary, Secondary and Jib Booms.
2 At the ground controls, break the security tie
5 Press down the foot switch. Move the drive and lift the emergency power switch cover (if
control handle off center, hold for a moment equipped).
and then release it. Move the drive control
3 Simultaneously hold the emergency power
handle off center in the opposite direction,
switch on and operate each boom function
hold for a moment and then release it.
through a partial cycle.
Result: The travel alarm should sound when
Result: All boom functions operate.
the drive control handle is moved off center in
either direction. 4 Close the emergency power switch cover and
secure the cover with a security tie (if
equipped).
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).

Q-15 5 Push and release the rpm select button until

low rpm is selected (turtle symbol).
Test the Engine Idle Select
Operation - Engine Models Result: The engine should return to low idle.

A properly operating engine idle select function is
essential to good engine performance and safe
machine operation. There are two settings.
Low idle (turtle symbol) allows the operator to
control individual boom functions. Drive functions
will operate at low idle on most models, but at
reduced performance.
High idle (rabbit symbol) should be used for
normal machine operation. 1 low idle indicator light
2 foot switch activated high idle indicator
S-40HF, S-45HF, S-40XC, S-45XC, S-60HF, S- light
65HF, S-60J, S-60XC from S60XCH-45001 and 3 engine rpm select button
S60XCM-101, S-65XC, S-80HF, S-85HF, S-80XC,
S-85XC, S-100, S-105, S-120, S-125, S-100HD, 6 Turn the key switch to platform controls.
S-120HD, SX-105XC, SX-125XC, SX-135XC, SX-
7 Push the engine rpm select switch until low
150, SX-180, Z-80/60, Z-135/70 and ZX-135/70
idle (turtle symbol) is selected.
Models:
Result: The engine should remain at low idle.
1 Turn the key switch to ground controls.
8 Press down the foot switch.
2 Pull out the red Emergency Stop button to the
on position at both the ground and platform Result: The engine should remain at low idle.
controls. 9 Push the engine idle select switch until high
3 Start the engine from the ground controls. idle (rabbit symbol) is selected.
4 Push and release the rpm select button until Result: The engine should remain at low idle.
high rpm is selected (rabbit symbol). 10 Press down the foot switch.
Result: The engine should change to high Result: The engine should change to high
idle. idle.

All other models: Q-16

1 Pull out the red Emergency Stop button to the Test the Fuel Select Operation -
on position at both the ground and platform Gasoline/LPG Models
controls.
3 Move the rpm select toggle switch to the high
idle (rabbit symbol) position and activate performed quarterly.
function enable.
Result: The engine should change to high The ability to select and switch between gasoline
idle. and LPG fuels as needed is essential to safe
machine operation. A fuel selection can be made
4 Release function enable. when the engine is running or not. Switching
malfunctions and/or the failure of the engine to
Result: The engine should return to low idle.
start and run properly in both fuel modes and
5 Turn the key switch to platform controls. through all idle speeds can indicate fuel system
problems that could develop into a hazardous
6 Move the engine idle select switch to foot
situation.
switch activated high idle (rabbit and foot
switch symbol). Note: Perform this test after checking the gasoline
Result: The engine should not change to high and LPG fuel levels, and warming the engine to
idle. normal operating temperature.
7 Press down the foot switch. 1 At the platform controls, move the fuel select
switch to gasoline and then move the engine
Result: The engine should change to high idle control switch to foot switch activated high
idle. idle (rabbit and foot switch symbol).
8 Move the engine rpm select switch to foot 2 Start the engine from the platform controls
switch activated low idle (turtle symbol). and allow it to run at low idle.
Result: The engine should change to low idle. 3 Press down the foot switch to allow the
engine to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
4 Release the foot switch and shut the engine
off by pushing in the red Emergency Stop
button in to the off position.

5 Move the fuel select switch to LPG. Q-17

6 Restart the engine and allow it to run at low Inspect the Calibration Decal -
idle. ALC-1000 Models
7 Press down the foot switch to allow the Genie specifications require that this procedure be
engine to run at high idle. performed quarterly.
Result: The engine should start promptly and
Maintaining the safety decal in good condition is
operate smoothly in low and high idle.
mandatory for safe machine operation. Decals
Note: The engine may hesitate momentarily and alert operators and personnel to the many possible
then continue to run on the selected fuel if the fuel hazards associated with using this machine. They
source is switched while the engine is running. also provide users with operation and
maintenance information. An illegible decal will fail
to alert personnel of a procedure or hazard and
could result in unsafe operating conditions.
This maintenance procedure applies to the
following models: SX-105XC, SX-125XC, SX-
135XC, SX-150, SX-180, Z-135/70 and ZX-
135/70.
1 Turn the key switch to the off position and
push in the red Emergency Stop button to the
off position at the ground controls.
2 Open the turntable cover on the ground
controls side of the machine.
3 Open the ground control box.
4 Verify the ground control panel is equipped
with the required calibration decal.
Result: The control box is equipped with the
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.

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.
following models: S-100, S-105, S-120, S-125, S-
100HD, S-120HD, SX-105XC, SX-125XC, SX-
1 calibration decal
135XC, SX-150, SX-180, Z-80/60, Z-135/70 and
ZX-135/70.
Note: Perform this procedure with the machine on
a firm, level surface with the axles extended.
Note: Perform this procedure with all weight, tools,
equipment and personnel removed from the
platform.
Note: If any boom safety limit switches are
faulty, the primary boom will only retract and
ANSI / CSA not lower.
CE / AUS

5 Remove the key from the main key switch and

insert the key into the bypass/recovery key
switch.
Note: The bypass/recovery key switch is located
on the front panel in the lower right corner on Z-
80 before serial number Z8013-3911 and Z-
135 before serial number Z13512-1712.
6 Turn and hold the bypass/recovery key switch
to the recovery position. The switch must be
held in the recovery position.
Result: The emergency power unit will turn on
and the boom will begin the following recovery
sequence.
SX-105XC, SX-125XC, SX-135XC, SX-150, SX-
180, S-100/105/120/125, S-100/120HD:
• The primary boom will retract

• The primary boom will lower
Z-135 and ZX-135:
1 Run
2 Bypass
• The primary boom will retract
3 Recovery • The secondary boom will retract
1 Turn the key switch to the ground control and • The primary boom will lower
pull out the red Emergency Stop button to the Note: It is not necessary to fully lower the primary
on position. Start the engine. boom.
Z-80, Z-135 and ZX-135 models:
Z-80/60:
2 Fully raise the secondary boom then extend it
approximately 4 ft / 1.2 m. • The primary boom will retract
All models: • The primary boom will lower
3 Raise the primary boom approximately 15° • The secondary boom will retract
then extend it approximately 4 ft / 1.2 m. 7 Turn the bypass/recovery key switch to the
4 Turn the key switch to the off position to turn run position.
off the engine. Turn the key switch back to 8 Remove the key from the bypass/recovery
ground controls. key switch and insert the key into the main
Note: If this procedure is performed with the main key switch.
key switch in the off position an active latched 9 Start the engine and return the boom to the
safety fault will be set and will have to be cleared. stowed position.

Q-19 Q-20
Test the Platform Self-leveling Confirm the Proper Brake
Configuration

ALC-1000 Models: performed quarterly.
Automatic platform self-leveling throughout the full Proper brake configuration is essential to safe
cycle of primary boom raising and lowering is operation and good machine performance.
essential for safe machine operation. The platform Hydrostatic brakes, hydraulically and electrically
is maintained level by the communication between released, spring-applied individual wheel brakes
the platform level sensor and the turntable level can appear to operate normally when they are
sensor. If the platform becomes out of level, the actually not fully operational.
computer at the platform controls will open the 1 Locate the drive hub disconnect cap.
appropriate solenoid valve(s) at the platform
manifold to maintain a level platform.
All other models:
Automatic platform self-leveling throughout the full
cycle of boom raising and lowering is essential for
safe machine operation. The platform is
maintained at level by the platform leveling slave
cylinder which operates in a closed loop hydraulic
circuit with the master cylinder located at the base
of the boom. A platform self-leveling failure creates
an unsafe working condition for platform and
ground personnel.
1 models with tires
1 At the ground controls, lower the boom to the
stowed position. 2 models with TRAX
2 Activate function enable and adjust the 2 Check each drive hub disconnect cap to be
platform to a level position. sure it is in the engaged position.
3 Raise and lower the primary boom through a
full cycle.
Result: The platform should remain level at all
times to within ±5 degrees.
1 brake disengaged position

2 brake engaged position

Q-21 Q-22
Test the Drive Brakes Test the Drive Speed – Stowed
Position

Proper brake action is essential to safe machine performed quarterly.
operation. The drive brake function should operate Proper drive function is essential to safe machine
smoothly, free of hesitation, jerking and unusual operation. The drive function should respond
noise. Hydraulically and electrically released, quickly and smoothly to operator control. Drive
spring applied individual wheel brakes can appear performance should also be free of hesitation,
to operate normally when they are actually not fully jerking and unusual noise over the entire
operational. proportionally controlled speed range.
Collision hazard. Be sure that the Note: Perform this procedure with the machine on
machine is not in free-wheel or a firm, level surface that is free of obstructions.
partial free-wheel configuration.
Refer to maintenance procedure, Note: Perform this procedure with the machine in
Confirm the Proper Brake the stowed position.
Configuration.
1 Create start and finish lines by marking two
Note: Select a test area that is firm, level and free lines on the ground 40 feet / 12.2 m apart.
of obstructions. 2 Choose a point on the machine (i.e., contact
1 Mark a test line on the ground for reference. patch of a tire) as a visual reference for use
when crossing the start and finish lines.
2 Choose a point on the machine (i.e., contact
patch of a tire) as a visual reference for use 3 Bring the machine to top drive speed before
reaching the start line. Begin timing when
when crossing the test line.
your reference point on the machine crosses
3 Bring the machine to top drive speed before the start line.
reaching the test line. Release the drive
4 Continue at full speed and note the time when
joystick when your reference point on the
machine crosses the test line. the machine reference point crosses the finish
line. Refer to Specifications, Drive Speed
4 Measure the distance between the test line Specifications.
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.

Q-23 5 Continue at full speed and note the time when

the machine reference point crosses the finish
Test the Drive Speed – Raised or line. Refer to Specifications, Drive Speed
Extended Position Specifications.
6 Lower the boom to the stowed position and
extend the primary boom 4 feet / 1.2 m.
Genie specifications require that this procedure be 7 Choose a point on the machine (i.e., contact
performed quarterly. patch of a tire) as a visual reference for use
Proper drive function is essential to safe machine
operation. The drive function should respond 8 Bring the machine to top drive speed before
quickly and smoothly to operator control. Drive reaching the start line. Begin timing when
performance should also be free of hesitation, your reference point on the machine crosses
jerking and unusual noise over the entire the start line.
proportionally controlled speed range.Note: Select 9 Continue at full speed and note the time when
a test area that is firm, level and free of the machine reference point crosses the finish
obstructions. line. Refer to Specifications, Drive Speed
1 Create start and finish lines by marking two Specifications.
lines on the ground 40 feet / 12.2 m apart.
2 Press down the foot switch and raise the
primary boom greater than 10 degrees above
horizontal.
patch of a tire) as a visual reference for use
4 Bring the machine to top drive speed before
the start line.

Q-24 SX-150 and SX-180

Test the Drive Speed – Raised Note: This procedure will require 2 people to
and Extended Position, ALC1000 perform.
Models 1 Create start and finish lines by marking two
2 Access the MACHINE STATUS menu on the
ground control box and scroll down until
Genie specifications require that this procedure be LENGTH SENSOR EXTENSION is displayed.
3 Raise and extend the primary boom until the
Proper drive function is essential to safe machine displays reads at least 258 in / 656 cm. The
operation. The drive function should respond boom will be extended approximately 120 ft /
quickly and smoothly to operator control. Drive 36.6 m.
performance should also be free of hesitation,
jerking and unusual noise over the entire 4 Choose a point on the machine (i.e., contact
proportionally controlled speed range. patch of a tire) as a visual reference for use
following models: S-100, S-105, S-120, S-125, SX-
105XC, SX-125XC, SX-135XC, S-100HD, S- reaching the start line. Begin timing when
120HD, SX-150, SX-180, Z-80/60, Z-135/70 and
the start line.
ZX-135/70.
Note: Perform this procedure with the machine on the machine reference point crosses the finish
a firm, level surface that is free of obstructions. line. Refer to Specifications, Drive Speed
S-100, S-105, S-120, S-125, SX-105XC, SX- Specifications.
125XC, SX-135XC, S-100HD and S-120HD
1 Create start and finish lines by marking two
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
the start line.
Specifications.

Z-80/60, Z-135/70 and ZX-135/70 Q-25

1 Create start and finish lines by marking two Test the Turntable Level Sensor -
lines on the ground 40 feet / 12.2 m apart. Z-80/60, Z-135/70, ZX-135/70, SX-
2 Press down the foot switch and raise the 105XC, SX-125XC, SX-135XC, SX-
primary boom greater than 10 degrees and
the secondary boom greater than 20 degrees.
150 and SX-180
3 Z-80/60: Extend the primary boom 12 inches /
0.3 m. performed quarterly.
Z-135/70 and ZX-135/70: Extend the primary A properly functioning level sensor (SCON) is
boom 12 inches / 0.3 m and the jib boom essential to safe machine operation. The ECM at
12 inches / 0.3 m. the ground controls (TCON) monitors the position
and angle of the machine using the signal from the
4 Choose a point on the machine (i.e., contact level sensor. The level sensor signal is used to
patch of a tire) as a visual reference for use control the maximum working height of the primary
when crossing the start and finish lines. and secondary booms.
5 Bring the machine to top drive speed before Note: A digital level will be required to perform this
reaching the start line. Begin timing when procedure.
the start line. Note: A kit is available through Genie Product
Support (Genie part number 58351GT). This kit
includes a digital level with a magnetic base and
cable harnesses.
Specifications. Note: A properly calibrated digital level is essential
to proper machine calibration. Refer to the
manufactures calibration information.


Note: Use the following chart to identify the Note: Perform this procedure with the booms in
description of each LCD screen control button the fully stowed position and the axles fully
used in this procedure. extended.
1 Place the machine on a firm surface that has
a side slope greater than 2° (6.5 inches /
16.5 cm) but less than 5° (16 inches /
40.6 cm).
Plus Minus Previous Enter 2 Place a digital level that has been calibrated
to gravity on the X axis of the turntable.
Note: Illustrations are shown from the platform end
of the machine.
X axis (ZX-135/70 shown)
Y axis (ZX-135/70 shown)
positive degree side slope (ZX-135/70 shown)
negative degree side slope (ZX-135/70 shown)

3 Turn the key switch to ground control and pull 7 Place a digital level that has been calibrated
out the red Emergency Stop button to the on to 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
Calibrate the Level Sensor.
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 positive degree downhill slope (ZX-135/70 shown)
sensor could cause the machine
to tip over resulting in death or
serious injury. Refer to Repair
Procedure in the appropriate
Service and Repair Manual for
your machine, How to Calibrate
the Level Sensor.
negative degree uphill slope (ZX-135/70 shown)
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
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 ZX-135/70 or previous button until SECONDARY BOOM
Genie specifications require that this procedure be 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
Note: A kit is available through Genie Product
Support (Genie part number 58351GT). This kit Calibrate the Secondary Boom Angle Sensor.
cable harnesses. Tip-over hazard. If the boom is
not equal to or greater than
Note: A properly calibrated digital level is essential 75.5°, immediately lower the
to proper machine calibration. Refer to the secondary boom. Failure to
manufactures calibration information. 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 death or serious injury. Refer to
used in this procedure. Repair Procedure in the
appropriate Service and Repair
Manual for your machine, How
to Calibrate the Secondary
Boom Angle Sensor.


7 Lower the secondary boom to 65°. 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°.
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 be calibrated. Refer to Repair Procedure in
the appropriate Service and Repair Manual the appropriate Service and Repair Manual
for your machine, How to Calibrate the for 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 -3.5°. The secondary boom angle sensor
the appropriate Service and Repair Manual must be calibrated. Refer to Repair Procedure
for your machine, How to Calibrate the in the appropriate Service and Repair Manual
Secondary Boom Angle Sensor. for 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

description of each LCD screen control button
Test the Primary Boom Angle used in this procedure.
Sensor - Z-135/70 and ZX-135/70
A properly functioning primary boom angle sensor
is essential to safe machine operation. The ECM Plus Minus Previous Enter
at the ground controls (TCON) monitors the Note: Perform this procedure with the machine on
position and angle of the primary boom using the a firm, level surface with the booms in the fully
signal from the primary boom angle sensor. The stowed position and the axles fully extended.
primary boom angle sensor signal is used to
control the ramping of the primary boom, limiting 1 Turn the key switch to ground control and pull
the speed of the primary boom to 2.3 feet / out the red Emergency Stop button to the on
0.7 meters per 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
Note: A digital level will be required to perform this to gravity on top of the primary boom.
procedure.
cable harnesses.
Note: A properly calibrated digital level is essential

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
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
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-105XC, SX-125XC,
Result: The reading at the display and digital SX-135XC, SX-150 and SX-180
10°. The primary boom angle sensor must be Genie specifications require that this procedure be
calibrated. Refer to Repair Procedure in the performed quarterly.
is essential to safe machine operation. The ECM
Boom Angle Sensor.
at the ground controls (TCON) monitors the
11 Raise the primary boom to 40°. position and angle of the primary boom using the
signal from the primary boom angle sensor. The
Result: The reading at the display and digital primary boom angle sensor signal is used to
control the ramping of the primary boom, limiting
Result: The reading at the display and digital the speed of the primary boom to 2.3 feet /
level is greater than ± 2° of each other and of 0.7 meters per second.
calibrated. Refer to Repair Procedure in the Note: The turntable level sensor must be tested
appropriate Service and Repair Manual for before starting this procedure. Refer to
your machine, How to Calibrate the Primary Maintenance Procedures, Test the Turntable Level
Boom Angle Sensor. Sensor.
12 Fully raise the primary boom until it stops at Note: A digital level will be required to perform this
approximately 58°. procedure.
Result: The reading at the display and digital Note: A kit is available through Genie Product
level is within ± 2° of each other and of 58°. Support (Genie part number 58351GT). This kit
cable harnesses.
58°. The primary boom angle sensor must be Note: A properly calibrated digital level is essential
calibrated. Refer to Repair Procedure in the to proper machine calibration. Refer to the
appropriate Service and Repair Manual for manufactures calibration information.
Boom Angle Sensor. Note: Use the following chart to identify the
used in this procedure.

Note: Perform this procedure with the booms in
the fully stowed position and the axles fully
extended.

SX-105XC and SX-125XC 7 Lower the primary boom to 57°.

1 Turn the key switch to ground control and pull Result: The reading at the display and digital
out the red Emergency Stop button to the on level is within ± 2° of each other and of 57°.
2 Start the engine from the ground controls. level is greater than ± 2° of each other and of
3 Press the enter or previous button on the 57°. The primary boom angle sensor must be
LCD screen until PRIMARY BOOM ANGLE calibrated. Refer to Repair Procedure in the
TO GRAVITY DEGREES is displayed. appropriate Service and Repair Manual for
4 Place a digital level that has been calibrated Boom Angle Sensor.
to gravity on top of the primary boom.
5 Raise the primary boom while watching the

display screen.
6 Continue to raise the primary boom until it
Boom Angle Sensor.
8 Lower the primary boom to 40°.
Tip-over hazard. If the boom is Result: The reading at the display and digital
not within ± 2° of 74°,
boom. Failure to lower the boom Result: The reading at the display and digital
could cause the machine to tip level is greater than ± 2° of each other and of
over resulting in death or serious 40°. The primary boom angle sensor must be
injury. Refer to Repair calibrated. Refer to Repair Procedure in the
Procedure in the appropriate appropriate Service and Repair Manual for
Service and Repair Manual for your machine, How to Calibrate the Primary
your machine, How to Calibrate Boom Angle Sensor.

9 Lower the primary boom to 23°. SX-135XC

Result: The reading at the display and digital 1 Turn the key switch to ground control and pull
level is within ± 2° of each other and of 23°. out the red Emergency Stop button to the on
level is greater than ± 2° of each other and of 2 Start the engine from the ground controls.
23°. The primary boom angle sensor must be 3 Press the enter or previous button on the
calibrated. Refer to Repair Procedure in the LCD screen until PRIMARY BOOM ANGLE
appropriate Service and Repair Manual for TO GRAVITY DEGREES is displayed.
Boom Angle Sensor. 4 Place a digital level that has been calibrated
Result: The reading at the display and digital 5 Raise the primary boom while watching the
level is greater than ± 2° of each other and of display screen.
calibrated. Refer to Repair Procedure in the 6 Continue to raise the primary boom until it
appropriate Service and Repair Manual for stops at approximately 75°.
your machine, How to Calibrate the Primary Result: The reading at the display and digital
Boom Angle Sensor. level is within ± 2° of each other and of 75°.
11 Fully lower the primary boom until it stops at Result: The reading at the display and digital
approximately -9.5°. level is greater than ± 2° of each other and of
Result: The reading at the display and digital level your machine, How to Calibrate the Primary
is greater than ± 2° of each other and of -9.5°. The Boom Angle Sensor.
primary boom angle sensor must be calibrated.
Refer to Repair Procedure in the appropriate Tip-over hazard. If the boom is
Service and Repair Manual for your machine, How not within ± 2° of 75°,
to Calibrate the Primary Boom Angle Sensor. immediately lower the primary

7 Lower the primary boom to 59°. 9 Lower the primary boom to 25°.
level is within ± 2° of each other and of 59°. level is within ± 2° of each other and of 25°.
level is greater than ± 2° of each other and of level is greater than ± 2° of each other and of
59°. The primary boom angle sensor must be 25°. The primary boom angle sensor must be
calibrated. Refer to Repair Procedure in the 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 Primary your machine, How to Calibrate the Primary
Boom Angle Sensor. Boom Angle Sensor.
Boom Angle Sensor.
11 Fully lower the primary boom until it stops at
approximately -5°.
8 Lower the primary boom to 40°. -5°. The primary boom angle sensor must be
Result: The reading at the display and digital appropriate Service and Repair Manual for
level is within ± 2° of each other and of 40°. your machine, How to Calibrate the Primary
Result: The reading at the display and digital Boom Angle Sensor.
Boom Angle Sensor.

SX-150 and SX-180 7 Lower the primary boom to 66°.

1 Turn the key switch to ground control and pull Result: The reading at the display and digital
out the red Emergency Stop button to the on level is within ± 2° of each other and of 66°.
2 Start the engine from the ground controls. level is greater than ± 2° of each other and of
3 Press the enter or previous button on the 66°. The primary boom angle sensor must be
LCD screen until PRIMARY BOOM ANGLE calibrated. Refer to Repair Procedure in the
TO GRAVITY DEGREES is displayed. appropriate Service and Repair Manual for
4 Place a digital level that has been calibrated Boom Angle Sensor.
5 Raise the primary boom while watching the

display screen.
6 Continue to raise the primary boom until it
Boom Angle Sensor.
Tip-over hazard. If the boom is 8 Lower the primary boom to 49°.
not within ± 2° of 80°, Result: The reading at the display and digital
immediately lower the primary level is within ± 2° of each other and of 49°.
could cause the machine to tip Result: The reading at the display and digital
over resulting in death or serious level is greater than ± 2° of each other and of
injury. Refer to Repair 49°. The primary boom angle sensor must be
Procedure in the appropriate calibrated. Refer to Repair Procedure in the
Service and Repair Manual for appropriate Service and Repair Manual for
your machine, How to Calibrate your machine, How to Calibrate the Primary
the Primary Boom Angle Sensor. 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-105XC, SX-125XC, SX-135XC,
32°. The primary boom angle sensor must be SX-150 and SX-180 Models
calibrated. Refer to Repair Procedure in the Genie specifications require that this procedure be
appropriate Service and Repair Manual for performed quarterly.
Boom Angle Sensor. Testing the machine envelope safety limit switches
is critical to safe machine operation. If the boom is
10 Lower the primary boom to 15°. allowed to operate when a safety switch is not
Result: The reading at the display and digital functioning correctly, the machine stability could
level is within ± 2° of each other and of 15°. be compromised and may tip over.
Result: The reading at the display and digital Note: Perform this procedure with the boom in the
level is greater than ± 2° of each other and of stowed position.
calibrated. Refer to Repair Procedure in the Note: Perform this procedure with the axles
appropriate Service and Repair Manual for extended.
your machine, How to Calibrate the Primary Note: Two people will be required to perform this
Boom Angle Sensor. procedure.
11 Fully lower the primary boom until it stops at
Note: Use the following chart to identify the
approximately -2.6°.
Result: The reading at the display and digital used in this procedure.
-2.6°. The primary boom angle sensor must
be calibrated. Refer to Repair Procedure in
the appropriate Service and Repair Manual Plus Minus Previous Enter
Primary Boom Angle Sensor.


Z-135/70 and ZX-135/70 Models: 9 Connect the leads from a multimeter with
Secondary Boom #1 Retracted Safety Limit continuity checking capability to pins 1 and
Switch, LSS1RS 2 at the Deutsch connector of the limit switch
cable.
1 Working at the platform end of the turntable,
Result: The limit switch should not have
support and secure the lower turntable riser
continuity.
end cover to a suitable lifting device.
Result: The limit switch does have continuity.
2 Remove the lower cover retaining fasteners
The limit switch is faulty and needs to be
and remove the lower cover from turntable.
replaced.
Crushing hazard. The turntable 10 Remove the multimeter leads and connect the
riser lower cover could become Deutsch connector to the limit switch.
unbalanced and fall when
removed from the turntable if 11 Start the engine from the ground controls.
not properly supported and 12 Extend the secondary boom while visually
secured to the lifting device. inspecting the roller arm of the limit switch.
Continue to extend the boom until the limit
3 Support and secure the upper turntable riser switch arm is released by the limit switch
end cover to a suitable lifting device. ramp bracket.
4 Remove the upper cover retaining fasteners Result: The roller arm of the limit switch
and remove the upper cover from turntable. remains centered with the limit switch ramp
Crushing hazard. The turntable bracket through the entire length of travel.
riser upper cover could become Result: The roller arm of the limit switch does
unbalanced and fall when not remain centered with the limit switch ramp
removed from the turntable if bracket through the entire length of travel.
not properly supported and Adjust or replace the limit switch ramp bracket
secured to the lifting device. to ensure the limit switch roller arm remains
centered with the limit switch ramp bracket
5 Locate the secondary boom #1 retracted through the entire length of travel.
safety limit switch (LSS1RS) inside the
secondary boom tube. Result: The roller arm of the limit switch is
damaged. Replace the limit switch roller arm
Note: The secondary boom #1 retracted safety or limit switch.
limit switch (LSS1RS) is attached to the number
1 boom tube and can easily be identified by the Note: The limit switch ramp bracket is attached to
blue and red tie wraps attached to the limit switch the number 4 boom tube.
cable.
7 Fully raise the secondary boom. Do not
extend the boom. Turn the machine off.
8 Locate and disconnect the Deutsch connector
to LSS1RS.

13 Locate and disconnect the Deutsch connector Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX-
to LSS1RS. 135XC, SX-150 and SX-180 Models
Result: The alarm should sound. Turntable Rotate Safety Limit Switch, LST1S
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
Note: A P30 Power Fault and a P11 Power Fault to the limit switch cable.
will also display as a result of this test. 2 Locate and disconnect the deutsch connector
14 Re-connect the Deutsch connector to to LST1S.
LSS1RS. 3 Connect the leads from a multimeter with
Result: The LCD screen displays SEC continuity checking capability to pins 1 and
LSS1RS FAULT. 2 at the Deutsch connector of the limit switch
cable.
Result: The LCD screen doesn't display the
Fault message. The limit switch is faulty and Result: The limit switch should have
needs to be replaced. continuity.
15 Turn the engine off. Result: The limit switch does not have
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
position. Release the enter button after five 4 Remove the multimeter leads and connect the
seconds and press the Deutsch connector to the limit switch.
(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 6 Locate and disconnect the Deutsch connector
safety 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 continuity checking capability to pins 1 and
appears. 2 at the Deutsch connector of the limit switch
cable.
20 Select YES, then press the enter button.
21 Install the secondary boom end covers. continuity.
replaced OR the mounting position of the limit
switch needs to be adjusted until it activates
when the turntable is rotated more than 15°.
8 Remove the multimeter leads and connect the
Deutsch connector to LST1S.

Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX- 10 Choose an axle extend safety limit switch to
135XC, SX-150 and SX-180 Models test.
Axle Extended Safety Limit Switches, LSFA1ES 11 Locate and disconnect the Deutsch connector
and LSRA1ES to the axle extend limit switch.
1 Start the engine from the ground controls and 12 Connect the leads from a multimeter with
lower the boom to the stowed position. continuity checking capability to pins 1 and
2 at the Deutsch connector of the limit switch
2 Turn the key switch to platform controls. cable.
3 From the platform controls, drive the machine Result: The limit switch should have
in either direction and fully retract the axles. continuity.
Turn the machine off.
Result: The limit switch does not have
4 Choose an axle extend safety limit switch to continuity. The limit switch is faulty and needs
test. to be replaced.
5 Locate and disconnect the deutsch connector 13 Remove the multimeter leads and connect the
to the axle extend limit switch. Deutsch connector to the limit switch.
6 Connect the leads from a multimeter with 14 Repeat steps 11 through 13 for the other axle
continuity checking capability to pins 1 and extend safety limit switch.
2 at the Deutsch connector of the limit switch
cable.
continuity.
replaced.
7 Remove the multimeter leads and connect the
Deutsch connector to the limit switch.
8 Repeat steps 5 through 7 for the other axle
extend safety limit switch.
9 Start the engine from the platform controls
and fully extend the axles. Turn the machine
off.

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

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

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
Genie specifications require that this procedure 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 zip ties on the wire assembly. Disconnect the
and 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.
used 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
Plus Minus Previous Enter enable 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
3 Press the (plus)(minus) buttons on the LCD repaired. Immediately remove the machine
screen to activate status mode. from service until repairs are made.
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
6 Remove the fasteners from the turntable riser death or serious injury.
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
secondary boom above 60° using emergency turntable riser. The connection will be marked
power. with 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
18 Press the enter or previous button on the wiring circuit is faulty and will need to be
LCD screen until secondary boom length is replaced or repaired.
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
Switches and Angle Sensor - S- elevated.
60X, S-80X, and S-60XC to
S60XCH-45000

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
Note: Perform this procedure with the machine on 2 unrestricted maximum platform capacity
a firm, level surface with all weight, tools and
4 Extend the primary boom until it is fully
equipment removed from the platform.
extended.
Note: Start this procedure with the boom fully 5 Lower the primary boom until it stops.
retracted and in the stowed position.
Result: The boom will automatically stop after
Ground controls: 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
Measure the distance between the center of retracted and in the stowed position.
the pivot pins as shown. The distance should 1 Pull out the red Emergency Stop button to the
be 171 inches / 434 cm ± 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
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, S-
Result: Primary boom down should return to 125, S-100HD and S-120HD
normal operation. Genie specifications require that this procedure be
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
Result: Primary boom extend should return to used 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 down function should be disabled.
switch is out of adjustment or the wiring circuit Result: If the engine does not stop and the
is faulty and will need to be replaced or boom continues to lower to less than 65°, the
repaired. LSB9AS switch is out of adjustment or the
wiring is faulty and will need to be replaced or
Bodily injury hazard. If the boom
repaired.
extends to more than 101 feet /
30.8 m without stopping the Bodily injury hazard. If the
engine, stop immediately and boom lowers to less than 65°
retract the boom until the boom without stopping the engine,
is extended to less than 100 feet stop immediately and raise the
/ 30.5 m. Failure to retract the boom until the boom is
boom could result in death or elevated to greater than 68°.
serious injury. Failure to raise the boom could
result in death or serious
9 Using emergency power, retract the boom 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.
Result: the angle of the boom should be
position. Release the enter button after five
greater than 50°.
seconds and press the
(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 33 Remove the wire jumper installed in step
safety 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.
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
replaced or repaired.
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 Note: LSB6S is located at the end of the boom
switch is out of adjustment or the wiring circuit tubes at the pivot end of the boom.
is faulty and will need to be replaced or
repaired. 52 Place the arm removed in step 51 back on the
LSB6S switch 180° opposite its original
Bodily injury hazard. If the boom position. Rotate the head of the switch 45°
extends to more than 76 feet/ clockwise and activate the function
23.2 m without stopping the enable/high RPM button and attempt to
engine, stop immediately and extend the boom.
retract the boom until the boom is
Result: The boom extend function should be
extended to less than 75 feet /
disabled.
22.9 m. Failure to retract the
boom could result in death or Result: If the boom extends, the LSB6S
serious injury. switch or wiring circuit is faulty and will need
to be replaced or repaired.
42 Using emergency power, retract the boom
until the boom is extended to less than 75 feet Bodily injury hazard. If the boom
/ 22.9 m. extends at all, stop immediately
and retract the boom until the
43 Re-connect the harness plug to LSB3EO. boom is extended to less than
44 With the key switch off, press and hold the 2 feet / 0.6 m. Failure to retract
enter button and turn the key switch to the on the boom could result in death or
position. Release the enter button after five serious injury.
(minus)(minus)(previous)(previous) 53 Activate the function enable/high RPM button
buttons. and attempt to retract the boom.
45 Press the previous button until clear all Result: The boom retract function should be
safety switch faults appears. enabled.
46 Select YES, then press the enter button. Result: If the boom does not retract, the
LSB6S switch or wiring circuit is faulty and will
47 Press the previous button until exit appears. 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 the axle extend proximity switch LSAX1EO
45° counter clockwise and activate the and place a metal washer over the target area
function enable/high RPM button and attempt of the axle extend proximity switch LSAX2EO
to 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 replaced or repaired.
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 circuit is faulty and will need to be replaced or
stowed 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 Remove the wire jumper installed in step

59 and connect the Deutsch connector to
LSAX1ES.


63 Disconnect the circle-end axle extend safety 68 Remove the wire jumper installed in step
switch LSAX1ES and install a wire jumper 63 and connect the Deutsch connector to
between pin 1 and pin 2 of the Deutsch LSAX2ES.
connector.
69 Disconnect the circle-end axle extend safety
64 Activate the function enable/high RPM button switch LSAX2ES and install a wire jumper
and attempt to extend the boom. between pin 1 and pin 2 of the Deutsch
Result: The boom should not raise to more connector.
than 11°. 70 Activate the function enable/high RPM button
Result: If the boom continues to raise, the and attempt to raise the boom.
LSAX1ES or LSAX2ES switch are out of Result: The boom should not raise to more
adjustment or the wiring circuit is faulty and than 11°.
will need to be replaced or repaired.
Result: If the boom continues to raise, the
Bodily injury hazard. If the boom LSAX1ES or LSAX2ES switch are out of
raises to more than 11°, stop adjustment or the wiring circuit is faulty and
immediately and lower the boom will need to be replaced or repaired.
until the boom is less than 11°.
Failure to lower the boom could Bodily injury hazard. If the boom
result in death or serious injury. raises to more than 11°, stop
immediately and lower the boom
65 Remove the wire jumper installed in step until the boom is less than 11°.
63 and connect the Deutsch connector to Failure to lower the boom could
LSAX1ES. result in death or serious injury.
66 Disconnect the circle-end axle extend safety 71 Remove the wire lumper installed in step
switch LSAX2ES and install a wire jumper 69 and connect the Deutsch connector to
between pin 3 and pin 4 of the Deutsch LSAX2ES.
connector.
67 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 out the red Emergency Stop button to the
on position at both the ground and platform
controls.
Engine powered models:
2 Start the engine from the platform controls.
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.
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 / 1 m.
toggle 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. toggle 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 21 Activate each function control handle or
toggle switch. toggle 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.
toggle switch.
operate.
16 Lower the primary boom to the stowed
position.

Q-35 Q-36
Test the Operator Protection Inspect and Adjust the Boom
Alarm (if equipped) Extend/Retract Cables - All
Genie specifications require that this procedure be Models
Testing the operator protection alarm (OPA) is
important for proper operation. Genie specifications require that this procedure be
1 Turn the key switch to platform control and performed quarterly for the first year of ownership
pull out the red Emergency Stop button to the or after the boom extend or retract cables have
on position at both the ground and platform been replaced.
controls. After the first year this quarterly inspection is not
Engine powered models: required. Refer to the Annual Inspection procedure
appropriate for your machine.
Manufacturers specifications require that this
All Models: procedure be performed by personnel that are
3 Do not activate the foot switch. Press down competent in cable / wire rope inspection.
on the operator protection activation strip. Note: Additional or more frequent
Result: There is no audible alarm or flashing inspections may be required due to the
beacon. The engine does not shut down following:
(engine models). • exposed to hostile or corrosive
4 Activate the foot switch. Press down on the environmental conditions.
operator protection activation bar for longer • boom is overloaded
than 0.4 seconds and release.
• sustains a shock load
Result: An intermittent audible alarm will
sound and the beacon will flash. Boom • electrical arcing
functions are disabled and the engine will shut
down (engine models). After 10 seconds a • unused for extended periods
continuous audible alarm will sound. The boom extend/retract cables are responsible
5 Press the reset button. for the extension and retraction of the boom tubes.
Inspecting for foreign objects, damage and/or
Result: The audible alarm and flashing improper adjustment of the boom extend/retract
beacon turn off. Engine can be started cables and related components on a regular basis
(engine models). Boom functions operate. is essential to good machine performance and
safe machine operation. The boom extend and
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Refer to the appropriate procedure for your
model:
A-11 All S-60, S-65, S-80 and S-85
A-12 S-100/105/120/125, S-100HD, S-120HD, SX-
105XC and SX-125XC
A-13 SX-135XC, SX-150 and SX-180

Q-37
Test the Recovery System - ALC-
600 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.
following models: S-40HF, S-45HF, S-40XC, S-
45XC, S-60HF, S-65HF, S-60J, S-60XC from
S60XCH-45001, S-65XC, S-80HF, S-85HF, S- 1 ground controls
80XC and S-85XC. 2 recovery switch
Note: Perform this procedure with all weight, tools, 1 Turn the key switch to ground control and pull
equipment and personnel removed from the out the red Emergency Stop button to the on
platform. position.
2 Start the engine and raise the primary boom
to the horizontal position and extend it
approximately 4 ft / 1.2 m.
3 Push in the red Emergency Stop button to the
off position to turn the engine off and pull it
back out to the on position.
4 Press the function enable button and activate
the recovery switch.
Result: The auxiliary power unit will turn on
and the boom will begin the following recovery
sequence.
• The primary boom will retract.
• The primary boom will lower.

Q-38 Note: Use the following chart to identify the

Test the Turntable Level Sensor - used in this procedure.
S-40HF, S-45HF, S-40XC, S-45XC,
S-60HF, S-65HF, S-60J, S-60XC
from S60XCH-45001, S-65XC, S-
80HF, S-85HF, S-80XC, S-85XC.
Home Maintenance Faults Settings
A properly functioning level sensor is essential to
safe machine operation. The ECU at the turntable
controls (TCON) monitors the position and angle
of the machine using the signal from the level
sensor. The level sensor signal is used to control
the maximum working height of the primary boom.
Note: A digital level will be required to perform this
procedure.
X axis (roll)
cable harnesses.
Note: A properly calibrated digital level is essential
Y axis (pitch)

Note: Perform this procedure on a firm, level 3 Turn the key switch to ground control and pull
surface with the machine in the stowed position. out the red Emergency Stop button to the on
a side slope greater than 2° (6.5 inches / 4 Press the Maintenance button and select Real
16.5 cm) but less than 5° (16 inches / Time Data. Navigate to the Turntable Tilt Roll
40.6 cm). Data.
2 Place a digital level that has been calibrated Result: The reading at the display and digital
to gravity on the X axis of the turntable. level is within ± 1° of each other.
level sensor must be calibrated. Refer to
Calibrate the Turntable Level Sensor.
Tip-over hazard. If the X axis is
not within ± 1°, failure to
properly calibrate the level
sensor could cause the machine
to tip over resulting in death or
positive degree side slope serious injury. Refer to Repair
the Turntable Level Sensor.

an uphill or downhill slope greater than 2°
(6.5 inches / 16.5 cm) but less than 5°
(16 inches / 40.6 cm).
6 Navigate to the Turntable Tilt Pitch screen.
negative degree side slope

7 Place a digital level that has been calibrated Q-39

to gravity on the Y axis of the turntable.
Test the Primary Boom Angle
Result: The reading at the display and digital Sensor - S-40HF, S-45HF, S-40XC,
level is within ± 1° of each other.
S-45XC, S-60HF, S-65HF, S-60J,
level is greater than ± 1° of each other. The S-60XC from S60XCH-45001, S-
level sensor must be calibrated. Refer to 65XC, S-80HF, S-85HF, S-80XC,
Repair Procedure in the appropriate Service S-85XC.
Calibrate the Turntable Level Sensor. Genie specifications require that this procedure be
is essential to safe machine operation. The ECM
at the ground controls (GCON) monitors the
position and angle of the primary boom using the
positive degree downhill slope signal from the primary boom angle sensor.
Note: The turntable level sensor must be tested
before starting this procedure. Refer to
Maintenance Procedures, Test the Turntable Level
Sensor.
Note: A digital level will be required to perform this
procedure.
negative degree uphill slope Note: A kit is available through Genie Product
Tip-over hazard. If the Y axis is includes a digital level with a magnetic base and
not within ± 1°, failure to cable harnesses.
calibrate the level sensor could
cause the machine to tip over Note: A properly calibrated digital level is essential
resulting in death or serious to proper machine calibration. Refer to the
injury. Refer to Repair Procedure manufactures calibration information.
in the appropriate Service and
Repair Manual for your machine,
How to Calibrate the Turntable
Level Sensor.

Note: Use the following chart to identify the 7 Raise the primary boom to the fully elevated
description of each LCD screen control button position while watching the display screen.
Home Maintenance Faults Settings appropriate Service and Repair Manual for
Note: Perform this procedure on a firm, level your machine, How to Calibrate the Primary
surface with the machine in the stowed position. Boom Angle Sensor.
1 Place the digital level along the Y axis of the Tip-over hazard. If the boom is
turntable. not within ± 2° of 69°,
Y axis (pitch) Service and Repair Manual for
2 Zero the digital level to the turntable. the Primary Boom Angle Sensor.
3 Place a digital level on top of the pivot end of
the primary boom.
6 Press the Maintenance button on the LCD
screen, select Real-time Data and press OK,
scroll down to BOOM ANGLE and press OK.
-10°. The primary boom angle sensor must be
Boom Angle Sensor.

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

Grease the Turntable Rotation 1 Locate the 2 grease fittings on top of the
Bearing and Rotate Gear worm 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 4 Raise the boom and remove the safety chock

OR lifting device.
Check the Turntable Rotation
Bearing Bolts 5 Lower the boom to the stowed position.
6 Using a star pattern, confirm that each lower
bearing mounting bolt is torqued in sequence
to specification.
Torque values are listed as dry. The retaining
performed annually.
fasteners must be coated with a mineral based
Maintaining proper torque on the turntable bearing lubricant when removed. If a retaining fastener is
bolts is essential to safe machine operation. removed, the torque value is reduced. Refer to the
Improper bolt torque could result in an unsafe Service and Repair Manual that is appropriate for
operating condition and component damage your machine.
Note: Access to the upper and lower turntable Model and Serial Range Torque
bearing bolts will vary depending on model. ft-lbs / Nm
S-40, S-40HF, S-40XC, S-45, S-45HF, S-45XC
1 S Booms, Z-45 DC/FE, Z-45XC and Z-45/25 (includes TraX™ models)
(J) IC, DC, Bi-Energy: Raise the (primary) to S4015-21540 238 / 322
boom and place a safety chock on the lift to S4515-21540
cylinder rod. Carefully lower the boom until it from S4015-21541 180 / 244
is 1 inch / 2,5 cm from the lift cylinder safety from S4515-21541
chock OR support the boom assembly with a from S40XC/45XCH-101
suitable lifting device. S-60, S-60HF, S-60J, S-60X, S-60XC, S-65, S-65HF, S-65XC
(includes TraX™ models)
All other Z Booms: Raise the secondary
to S60/60X/60XC/60TX/65TX 14A-29212 238 / 322
boom and place a safety chock on the lift to S6014D-396
cylinder rods. Carefully lower the boom until it
from S60/60X/60XC/60TX/65TX 14A-29213 180 / 244
is 1 inch / 2,5 cm from the lift cylinder safety from S6014D-397
chock OR support the boom assembly with a from S60TXD-651
suitable lifting device. from S60H-36400
from S60JH-101
Crushing hazard. Keep hands from S60XC/65XC H-45001
away from the cylinder and all from S60M/65TX/65XC M-101
moving parts when lowering the S-80, S-80HF, S-80X, S-80XC, S-85, S-85HF, S-85XC
boom. to S80/80X/S85 H-14097 238 / 322
to S8016D-235
Component damage hazard. Do from S80/80X/85 H-14098 203 / 275
not apply excessive force to the from S80XC/85XC H-101
safety chock or damage may from S8016D-236
occur. S-100, S-105, S-120, S-125, S-100HD, S-120HD
from S100/105/120/125 15D-983 238 / 322
Note: Contact Genie Aftermarket Parts to inquire from S1100HD/120HD 14D-200
about Safety Chock availability for your model. SX-105XC, SX-125XC, SX-135XC
2 Turn the key switch to the off position. from SX105/125 D-101 (top) 359 / 486
from SX135H-101 (bottom) 203 / 275
3 Using a star pattern, confirm that each SX-150, SX-180
turntable mounting bolt is torqued in
from SX15015H-101 515 / 698
sequence to specification. from SX18014-101

Model and Serial Range Torque Model and Serial Range Torque
ft-lbs / Nm ft-lbs / Nm
Z-30N, Z-30N RJ Z-60DC, Z-60FE
to Z30N16F-17573 210 / 285 from Z60M-101 180 / 244
to Z30ND-329 from Z6016N-101
from Z30N16F-17574 180 / 244 from Z60H-701
from Z30ND-330 Z-62 (includes TraX™ models)
Z-33 from Z6215A-101 180 / 244
from Z331815M-101 230 / 313 from Z6216D-101
from Z6216M-101
Z-34BE, Z-34DC, Z-34IC, Z-34N from Z62H-3000
to Z3416F-10791 210 / 285 Z-80
to Z34N16F-12688
to Z80H-7147 238 / 322
from Z3416F-10792 180 / 244
from Z34N16F-12689 from Z80H-7148 203 / 275
from Z34ND-200 Z-135
Z-40N, Z-40N RJ from Z13505-101 (top) 423 / 573
to Z40N16N-3999 210 / 285 (bottom) 238 / 322
from Z40N16N-4000 180 / 244 ZX-135

from Z40NF-4916 to ZX13515-2584 (top) 423 / 573
Z-45BE, Z-45DC, Z-45FE, Z-45HF, Z-45IC, Z-45XC (bottom) 238 / 322
to Z4525A-55298 210 / 285 from ZX13515-2585 (top) 359 / 486

to Z4525B-5452 (bottom) 203 / 275
to Z452516M-6699
to Z452516N-56105
to Z4525D-1646
from Z4525F-1517 180 / 244
from Z4525M-6700
from Z452516N-56106
from Z4525D-1647
from Z45EM-101
Z-51
to Z513016B-1517 210 / 285
to Z5130M-2035
from Z5230M-2036 180 / 244

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.
Note: Perform this procedure with the machine on
a firm, level surface with the boom in the stowed
position.
1 Grease the turntable bearing. Refer to
Maintenance Procedure, Grease the
Turntable Bearing and Rotate Gear. 1 turntable
2 Torque the turntable bearing bolts to 2 dial indicator
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/SX-Booms: Using the ground controls, position.
raise the boom to full height. Do not extend
the boom. 6 S/SX-Booms: Lower the boom to a horizontal
position and fully extend the boom.
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
Z-80/60, Z-135/70 and ZX-135/70: Using the primary 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 - S-
specification. The bearing is good. 100, S-100HD, S-105, S-120, S-
Result: The measurement is more than 120HD and S-125
specification. The bearing is worn and needs
to be replaced.
Models Measurement
S-40/45, S-40/45HF, S-40/45XC, S-60/65, S- 0.063 inch Genie specifications require that this procedure be
60/65HF, S-60J, S-60/65XC, Z-60 DC/FE, Z- 1.6 mm performed annually.
62/40 (includes TraX™ models)
Z-30/20N, Z-34/22 (all), Z-40/23, Z-45/25 (all), 0.055 inch
Maintaining the axle wear pads in good condition
Z-45 DC/FE, Z-45HF, Z-45XC, Z-51/30 1.4 mm is essential to safe machine operation. Wear pads
Z-33/18 0.043 inch
are placed on axle tube surfaces to provide a low
1.1 mm friction, replaceable wear pad between moving
SX-105 XC, SX-125 XC, SX-135 XC 0.094 inch
parts. Improperly shimmed wear pads or continued
2.4 mm use of worn out wear pads may result in
SX-150, SX-180 0.150 inch
component damage and unsafe operating
3.8 mm conditions.
S-80/85, S-80X, S-80/85HF, S-80/85XC, S- 0.118 inch 1 Start the engine from the platform controls
100, S-100HD, S-105, S-120, S-120HD, S- 3.0 mm
125, Z-80, Z-135/70, ZX-135/70 and extend the axles.
2 Measure each axle wear pad.
8 Move the boom(s) to the positions indicated in 3 Replace any wear pad if it is less than
step 3. Visually inspect the dial indicator to be specification. If a wear pad is not less than
sure the needle returns to the "zero" position. specification, shim as necessary to obtain
9 Remove the dial indicator and rotate the minimum clearance and no drag.
turntable 90°. 4 Extend and retract the axles through the
10 Repeat steps 4 through 9 until the rotation entire range of motion to check for tight spots
bearing has been checked in at least four that may cause binding or scraping of the axle
equally spaced areas 90° apart. tubes.
11 Lower the boom(s) to the stowed position and Note: Always maintain squareness between the
turn the machine off. outer and inner axle tubes.
12 Remove the dial indicator from the machine. 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 230 ft-lbs bearing as shown in illustration 2.
311 Nm
7 Using a forklift, raise the platform and jib
Grease the Jib Rotator components so there is no weight on the
rotator bearing.
3 While rotating the jib, pump grease into each
8 Adjust the dial indicator needle to the "zero"
bearing lubricating grease fitting until fresh
position..
grease is visible at the outer seal.
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 Genie specifications require that this procedure be
0.063 inch / 1,6 mm. The bearing is worn and performed annually.
needs to be replaced.
Proper key switch action and response is essential
11 Lower the platform and remove the weight.
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-105XC, SX-125XC, SX-
135XC, 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 When the Bypass/Recovery key switch is turned
2 dial indicator mounting surface and held to the recovery position, the emergency
power unit turns on and starts a sequence to lower
the platform. This feature of the machine is
especially helpful if the operator in the platform
cannot lower the boom, if the platform controls
become inoperative or for returning the machine to


a safe position when the safety switches have Note: Perform this procedure on a firm, level
been tripped. surface with the machine in the stowed position.
1 Open the ground controls side turntable side
cover.
on position at both the ground and platform
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.
1 Run
2 Bypass Result: The machine functions should not
operate.
3 Recovery
8 Turn the main key switch to the off position.
Result: The engine should stop and no
functions should operate.
9 Turn the main key switch to ground control
and start the engine.
10 Remove the key from the main key switch.
Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
Note: The main key switch must remain in the
ground control position.

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

Result: The primary boom should raise. Grease the Platform Overload
12 Remove the key from the bypass/recovery Mechanism (if equipped)
key switch and insert the key into the main
key 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 result in component damage.
run position.
This maintenance procedure does not apply to the
17 Remove the key from the bypass/recovery following models: S-40HF, S-45HF, S-40XC, S-
key switch and insert the key into the main 45XC, S-60HF, S-65HF, S-60J, S-60XC, S-65XC,
key switch. S-80HF, S-85HF, S-80XC, S-85XC, SX-125XC,
SX-135XC, Z-45XC, Z-45 DC/FE from Z45EM-
Close the turntable side cover. 101.
1 Locate the grease fittings on each pivot pin of
the platform overload assembly.
2 Thoroughly pump grease into each grease
fitting.
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
Test the Platform Overload Emergency Stop button to the on position at
System - All Models (if equipped), both the ground and platform controls. Start
(excludes ALC1000, S-40HF, S- the engine from the ground controls and level
the platform. Do not turn the engine off.
45HF, S-40XC, S-45XC, S-60HC,
DC Models: Turn the key switch to ground
S-60HF, S-65HF, S-60J, S-60 XC, controls and pull out the red Emergency Stop
S-5 XC, S-80HF, S-85HF, S-80XC, button to the on position at both the ground
S-85XC, Z-45HF, Z-45XC, Z45 and platform controls. Level the platform.
DC/FE from Z45EM-101) 3 Determine the maximum platform capacity.
Refer to the machine serial plate.
4 Using a suitable lifting device, place a test
weight equal to that of the available capacity
Genie specifications require that this procedure be in one of the locations shown. Refer to
performed annually OR when the machine fails to Illustration 1.
lift the maximum rated load.
Result: The platform overload indicator lights
Testing the platform overload system regularly is should be off at both the ground and platform
essential to safe machine operation. Continued controls, the alarm should not sound and the
use of an improperly operating platform overload engine should continue to run.
system could result in the system not sensing an
overloaded platform condition. Machine stability
could be compromised resulting in the machine
tipping over.
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-60 DC/FE, Z-
62/40 and models equipped with the 340 kg
capacity option illustration 1
Note: Perform this procedure with the boom fully

retracted and in the stowed position and with the
machine on a firm, level surface.
1 Remove all weight, tools, accessories and
equipment from the platform.
Note: Failure to remove all weight, tools and
accessories from the platform will result in an
inaccurate test.

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
ground and platform controls and the alarm additional 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
equal to, but does not exceed 15% of the platform controls and the alarm should not
maximum rated load. Secure the additional sound.
weight. Refer to the machine serial plate.
Note: There may be an 2 second delay before the
Engine Models: Result: The platform overload indicator lights and alarm turn off.
overload indicator lights should be flashing at
both the ground and platform controls, the 11 Engine Models: Start the engine and test all
alarm should sound and the engine should machine functions from the ground controls.
turn off. DC Models: Test all machine functions from
DC Models: Result: The platform overload the ground controls.
indicator lights should be flashing at both the Result: All ground control functions should
ground and platform controls and the alarm operate normally.
should sound.
12 Using a suitable lifting device, remove all test
Note: There may be a 2 second delay before the weights from the platform.
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.
Note: There may be a 2 second delay before the
sounds.

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

weight equal to that of the available capacity
Test the Platform Overload in 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
ground control LCD screen. The alarm should
performed annually OR when the machine fails to
not sound and the engine should continue to
run.
Testing the platform overload system regularly is
use of an improperly operating platform overload
tipping over.
following models: S-100, S-105, S-120, S-125, S-
100HD, S-120HD, SX-150, SX-180, Z-80/60, Z-
illustration 1
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.
Result: The platform overload indicator light
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
Note: Failure to remove all weight, tools and ground control LCD screen. The alarm should
accessories from the platform will result in an not sound and the engine should continue to
inaccurate test. run.
6 Add additional weight to the platform that is
equal to, but does not exceed 15% of the
maximum rated load. Secure the additional
weight. Refer to the machine serial plate.
controls. Start the engine from the ground
controls and level the platform. Do not turn Result: The platform overload indicator light is
the 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
System - S-60 HC
Result: The platform overload indicator light is
on at the platform and PLATFORM OVERLOAD is
displayed at the ground control LCD screen.
The alarm is sounding and the engine should
not start and run.
Note: There may be a 2 second delay before the lift the maximum rated load.
sounds. Testing the platform overload system regularly is
8 Using emergency power, test all machine use 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: Z-80 and Z-135 models, all functions Note: On a properly functioning machine, the
should operate except for primary boom LEDs on both control modules, located next to the
extend. ground control box, should be off.
9 Using a suitable lifting device, lift the 1 Remove all weight, tools, accessories and
additional test weight from the platform. equipment from the platform.
Result: The platform overload indicator light Note: Failure to remove all weight, tools and
should turn off at platform controls, there accessories from the platform will result in an
should be no error message displayed at the inaccurate test.
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.
operate normally.
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 Cables and Sheaves - S-
to the center of the platform floor.
60/65 and S-80/85 (includes HF,
Result: The amber restricted range of motion
LED at the platform controls should come on X, XC and TraX models)
and the engine should continue to run.
5 Using a suitable lifting device, place an
additional appropriate test weight equal to Genie specifications require that this procedure be
227,2 to 231,3 kg on to the center of the performed annually.
platform floor. The total weight in the platform
must equal 567,4 to 571,5 kg. Manufacturers specifications require that this
procedure be performed by personnel that are
Result: The alarm should sound and the
competent in cable / wire rope and sheave
engine should turn off. The platform overload
inspection.
indicator light should be on at both the ground
and platform controls. Note: Additional or more frequent
6 Using a suitable lifting device, remove all test inspections may be required due to the
weights from the platform. following:
7 Push in the ground controls red Emergency • exposed to hostile or corrosive

Stop button to the off position, then pull the environmental conditions.
red Emergency Stop button out to the on • boom is overloaded
position to reset the control system.
• electrical arcing
• unused for extended periods
The boom extend/retract cables and sheaves are
responsible for the extension and retraction of the
boom tubes. Inspecting for foreign objects,
damage and/or improper adjustment of the boom
extend/retract cables and related components on a
regular basis is essential to good machine
performance and safe machine operation. The
boom extend and retract functions should operate
smoothly and be free of hesitation, jerking and
unusual noise.

This maintenance procedure applies to the 5 Visually inspect the cables, sheaves and
following models: S-60, S-65, S-60 TraX, S-65 related components through the inspection
TraX, S-60HC, S-60HF, S-65HF, S-60X, S-60XC, holes for the following:
S-65XC, S-80, S-85, S-80X, S-80HF, S-85HF, S-
80XC, S-85XC • Frayed or broken wire strands
• Kinks in the cables
1 Raise the boom to the horizontal position and
fully extend the boom. • Corrosion
2 After the boom is fully extended, lower the • Paint or foreign materials on the cable
boom until the platform is at chest height.
Turn the machine off. • Split or cracked cable ends
3 S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, • Cables are on all sheaves
S-65XC, S-60 TraX, S-65 TraX, S-80, S-85, • Extend cable break limit switch arm is
S-80X, S-80HF, S-85HF, S-80XC, S-85XC:
centered in the pivot plate
Remove the boom end cover from the pivot
end of the boom and set aside. • Cables have equal tension
Note: S-60HF, S-65HF, S-60XC from S60XCH- • Cables at end of adjustment range
45001 and S60XCM-101, S-65XC, S-80HF, S-
85HF, S-80XC and S-85XC models. The cable • Broken or damaged sheaves
from the length transducer can become damaged • Unusual or excessive wear
if it is kinked or pinched.
• All fasteners in place and secure
S-60HC: Remove the boom end cover from
the pivot end of the boom while guiding the • S-60HC: String potentiometer cable break
small cable from the string potentiometer out limit switch arm is securely attached to end
of the slot of the cover. Rest the cover and of cable
string potentiometer on the counterweight. Note: A flashlight and inspection mirror may be
Component damage hazard. The necessary to thoroughly inspect the above items,
cable from the string or an endoscope inspection camera.
potentiometer can become
damaged if it is kinked or pinched. Note: Refer to Maintenance Procedure P12-2,
Cable Replacement Criteria.
4 Remove the retaining fasteners from the
access covers located on the side of the Note: If required, the extend or retract cables must
boom at the platform end of the machine. be replaced as a set.
Remove the covers.
Note: If the boom extend or retract cables are
replaced, quarterly maintenance inspections must
be performed for the first year.

6 S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, A-12

S-65XC, S-60 TraX and S-65 TraX, S-80, S-
85, S-80X, S-80HF, S-85HF, S-80XC, S-
Inspect the Boom Extend/Retract
85XC: Install the cover at the pivot end of the Cables and Sheaves - S-100, S-
boom. 105, S-120, S-125, S-100HD, S-
S-60HC: Install the boom end cover at the 120HD, SX-105XC and SX-125XC
pivot end of the boom while guiding the small
cable from the string potentiometer into the
Models
slot of the cover.
Component damage hazard. The
cable from the string Genie specifications require that this procedure be
potentiometer can become performed annually.
damaged if it is kinked or pinched.
Note: Be sure the cable from the string Manufacturers specifications require that this
potentiometer is correctly routed around the small procedure be performed by personnel that are
pulley before installing the boom end cover. competent in cable / wire rope and sheave
inspection.
7 Install the access panels on the sides of the
boom. Note: Additional or more frequent
inspections may be required due to the
8 Start the engine from the ground controls and following:
fully retract and lower the boom to the stowed
position. • exposed to hostile or corrosive
environmental conditions.
• boom is overloaded
10 Extend the boom approximately 2 feet / 0.6 m.
11 Retract the boom. While retracting the boom,
visually inspect the number 2 and number • electrical arcing
3 boom tubes.
Result: The number 2 boom tube should not
move more than 1/2 inch / 13 mm before the The boom extend/retract cables and sheaves are
number 3 boom tube begins to retract. responsible for the extension and retraction of the
number 3 boom tube on the S-100, S-105, SX-
Note: If the number 2 boom tube moves more than 105XC and S-100HD and the number 2 and
1/2 inch / 13 mm before the number 3 boom tube 3 boom tubes on the S-120, S-125, S-120HD and
begins to retract, the boom extend/retract cables SX-125XC. Inspecting for foreign objects, damage
need to be adjusted. Refer to Repair Procedure in and/or improper adjustment of the boom
the appropriate Service and Repair Manual for extend/retract cables on a regular basis is
your machine, How to Adjust the Boom essential to good machine performance and safe
Extend/Retract Cables. machine operation. The boom extend and retract
functions should operate smoothly and be free of
hesitation, jerking and unusual noise.
Note: Perform this procedure with the boom in the
stowed position.
Note: Perform this procedure with the engine off.


1 Remove the boom end cover from the pivot 3 Visually inspect the cables, sheaves and
end of the boom. related components through the inspection
holes for the following:
• Frayed or broken wire strands
• Kinks or crushed cables
• Corrosion
• Paint or foreign materials on the cable
• Split or cracked cable ends
• Cables are on all sheaves
1 boom end cover
2 side access covers • Cables have equal tension
3 cable ends (located underneath the boom) • Cables at end of adjustment range
2 Remove the retaining fasteners from the • Broken or damaged sheaves
access covers located on the side of the
boom at the platform end of the machine. • Unusual or excessive wear
Remove the covers. • All fasteners in place and secure
Note: A flashlight and inspection mirror may be
necessary to thoroughly inspect the above items,
or an endoscope inspection camera.
Note: Refer to Maintenance Procedure P12-2,
Note: If required, the extend or retract cables must
be replaced as a set.
4 At the pivot end of the boom, visually inspect
for the following:
• The red locking bracket is securely installed
over the cable adjustment bolts.

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

boom and access panels on the sides of the
boom.
Inspect the Boom Extend/Retract
Cables and Sheaves - SX-135XC,
SX-150 and SX-180 Models
7 Extend the boom approximately 2 feet / 0.6 m.
8 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 Manufacturers specifications require that this
number 3 boom tube begins to retract. procedure be performed by personnel that are
competent in cable / wire rope and sheave
Note: If the number 2 boom tube moves more than
inspection.
1/2 inch / 13 mm before the number 3 boom tube
begins to retract, the boom extend/retract cables Note: Additional or more frequent
need to be adjusted. Refer to Repair Procedure in inspections may be required due to the
the appropriate Service and Repair Manual for following:
your machine, How to Adjust the Boom
Extend/Retract Cables. • exposed to hostile or corrosive
The boom extend/retract cables and sheaves are
responsible for the extension and retraction of the
boom tubes. Inspecting for foreign objects,
damage and/or improper adjustment of the boom
extend/retract cables and related components on a
regular basis is essential to good machine
performance and safe machine operation. The
boom extend and retract functions should operate
smoothly and be free of hesitation, jerking and
unusual noise.

SX-135XC models: 6 Measure the distance between boom tubes

Note: Properly adjusted extend/retract cables will #2 and #3 using points (6) and (7) in the
maintain a relationship of the gap between boom illustration. The gap should be
tubes #2 and #3. 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
2 Fully raise the boom then extend the boom 1.25 in / 3.2 cm, then the gap between boom tubes
approximately 15 ft / 4.6 m. #2 and #3 should be between 2.25 in / 5.7 cm and
2.75 in / 7.1 cm.
3 Fully retract the boom and lower to the
horizontal position. Result: The distance between boom tubes
4 Stop the engine. #2 and #3 is 1 in / 2.6 cm to 1.5 in /3.9 cm
greater than dimension A. The boom tube is
5 Measure and record the distance between in tolerance.
boom tubes #1 and #2, measuring from the
points identified as (4) and (5) in the Result: The distance between boom tubes
illustration. This is dimension "A". #2 and #3 is less then 1 in / 2.6 cm or more
than 1.5 in / 3.8 cm greater than dimension
"A". The boom tubes need to be adjusted.
Refer to Repair Procedure in the appropriate
How to Adjust the Boom Extend/Retract
Cables.
1 Boom tube #1
2 Boom tube #2
3 Boom tube #3
4 Boom #1 measuring surface
5 Boom #2 measuring edge

SX-150 and SX-180 models:

Note: Properly adjusted extend/retract cables will
maintain a relationship of the gap between boom
tubes #2 and #3 and boom tubes #3 and #4.
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 and record the distance between
boom tubes #1 and #2, measuring from the
points identified as (11) and (12) in the
illustration. This is dimension "A".
1 Boom tube #1
2 Boom tube #2
3 Boom tube #3
4 Boom tube #4
5 Boom #4 retract bolt
6 Boom #3 retract bolt

6 Measure the distance between boom tubes All models:

#2 and #3 using points (9) and (10) in the Note: This procedure will require the use of an
illustration. The gap should be aerial work platform.
1 in / 2.6 cm to 1.5 in /3.9 cm greater than
dimension "A" 1 Remove the cover from the pivot end of the
boom.
Note: As an example, if the dimension "A" is
1.25 in / 3.2 cm, then the gap between boom tubes 2 From the ground controls, raise the boom to
#2 and #3 should be between 2.25 in / 5.7 cm and the horizontal position and fully extend the
2.75 in / 7.1 cm. boom.
Result: The distance between boom tubes 3 Raise and extend the boom until all the
#2 and #3 is 1 in / 2.6 cm to 1.5 in /3.9 cm inspection holes are visible.
greater than dimension A. The boom tube is Note: The inspection holes are covered with a
in tolerance. Proceed to step 7. black oval decal.
Result: The distance between boom tubes
#2 and #3 is less then 1 in / 2.6 cm or more 4 Remove the black oval decal from the
than 1.5 in / 3.8 cm greater than dimension inspection holes and discard.
"A". The boom tubes need to be adjusted. 5 Visually inspect the cables, sheaves and
Refer to Repair Procedure in the appropriate related components through the inspection
Service and Repair Manual for your machine, holes for the following:
How to Adjust the Boom Extend/Retract
Cables. • Frayed or broken wire strands
7 Measure the distance between boom tubes • Kinks or crushed cables

#3 and #4 using points 7 and 8 as shown in • Corrosion
the illustration.
• Paint or foreign materials on the cable
Result: The distance between boom tubes
#3 and #4 is 1 in / 2.6 cm to 1.5 in / 3.9 cm • Split or cracked cable ends
greater than dimension A. The boom tube is
in tolerance. • Cables are on all sheaves
Result: The distance between boom tubes • Cables at end of adjustment range
#3 and #4 is less then 1 in / 2.6 cm or more • Broken or damaged sheaves
than 1.5 in / 3.8 cm greater than dimension
"A". The boom tubes need to be adjusted. • Unusual or excessive wear
Refer to Repair Procedure in the appropriate • All fasteners in place and secure
How to Adjust the Boom Extend/Retract Note: A flashlight and inspection mirror may be
Cables. necessary to thoroughly inspect the above items,
or an endoscope inspection camera.
Note: Refer to Maintenance Procedure P12-2,
Note: If required, the extend or retract cables must
be replaced as a set.

A-14 4 Install the plug(s) into the drive hub.

Check the Drive Hub Oil Level 5 Check the torque of the drive hub mounting
and Fastener Torque fasteners. Refer to Torque Specifications,
Tires and Wheels.
6 Repeat this procedure for each drive hub.

performed annually.
Failure to maintain proper drive hub oil levels may
cause the machine to perform poorly and
continued use may cause component damage.
Models with tires:
1 Drive the machine to rotate the hub until the
plugs are located one on top and the other at
90 degrees.
1 drive hub plugs
2 Remove the plug located at 90 degrees and

check the oil level.
Result: The oil level should be even with the
bottom of the plug hole.
3 If necessary, remove the top plug and add oil
until the oil level is even with the bottom of the
side plug hole.

Models with TraX: 6 Attach a lifting strap from an overhead crane

(2000 lbs / 1000 kg) to the center-point of the
1 Select the drive hub to be serviced. Loosen track assembly, above the sprocket.
and remove as many sprocket retaining
fasteners as possible from the hub adapter.
7 Remove the remaining sprocket retaining

fasteners from the hub adapter.
8 Carefully remove the track assembly from the
1 sprocket retaining fasteners drive hub and set aside.
2 Drive the machine in either direction just Crushing hazard. The track
enough to access the remaining fasteners. Do assembly could become
not remove the the retaining fasteners. unbalanced and fall when
3 Chock the tracks at the opposite end of the removed from the machine if
machine to prevent the machine from rolling. not properly supported by the
overhead crane.
4 Center a lifting jack of ample capacity
(20,000 lbs / 10,000 kg) under the drive 9 Locate the hub disconnect pin in the center of
chassis between the tracks. the drive hub. Manually depress the pin and
5 Lift the machine until the tracks are off the rotate the drive hub until the plugs are one on
ground and place jack stands under the drive top and the other at 90 degrees.
chassis for support.
1 drive hub plugs

10 Remove the plug located at 90 degrees and Turntable rotate drive hub:
check the oil level.
1 Remove the plug located on the side of the
Result: The oil level should be even with the hub and check the oil level and check the oil
bottom of the plug hole. level.
11 If necessary, remove the top plug and add oil Result: The oil level should be even with the
until the oil level is even with the bottom of the bottom of the side hole.
side plug hole.
12 Install the plug(s) into the drive hub.
13 Check the torque of the drive hub mounting
fasteners. Refer to Torque Specifications,
Tires and Wheels.
14 Attach a lifting strap from an overhead crane
to the center-point of the track assembly,
above the sprocket.
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 1 fill plug
possible to the hub adapter and torque to 2 drain plug
specification. Refer to Torque Specifications, 3 mounting fasteners
TraX Torque Specifications.
2 If necessary, remove the fill plug and add oil
16 Raise the machine, remove the jack stands until the oil level is even with the bottom of the
lower the machine. drain plug.
17 Drive the machine in either direction just until 3 Apply pipe thread sealant to the plug (s), and
the remaining sprocket retaining fasteners install the plug (s) in the drive hub.
can be installed onto the drive hub adapter.
Turn the machine off. 4 Check the torque of the turntable drive hub
mounting fasteners.
18 Install the remaining sprocket retaining
fasteners to the drive hub adapter and torque
to specification. Refer to Torque
Specifications, TraX Torque Specifications.

Torque values are listed as dry. The retaining Model and Serial Range Torque
fasteners must be coated with a mineral based ft-lbs / Nm
lubricant when removed. If a retaining fastener is S-80, S-80HF, S-80X, S-80XC, S-85, S-85HF, S-85XC
removed, the torque value is reduced. Refer to the to S80/80X/85 H-14097 110 / 149
Service and Repair Manual that is appropriate for to S8016D-235
your machine. from S80/80X/85 H-14098 122 / 165
from S80XC/85XC H-101
Model and Serial Range Torque from S8016D-236
ft-lbs / Nm S-100, S-105, S-120, S-125, S-100HD, S-120HD
S-40, S-45, S-40XC, S-45XC from S100/105/120/125 15D-983 380 / 515
(includes TraX™ models) from S100HD/120HD 14D-200
to S4015-21540 210 / 285 SX-105XC, SX--125XC, SX-135XC
from S4015-21541 244 / 330 from SX105/125 D-101 122 / 165
from S40XC/45XC H-101 from SX135H-101
S-60, S-60HF, S-60J, S-60X, S-60XC, S-65, S-65HF, S-65XC SX-150, SX-180
(includes TraX™ models)
from SX15015H-101 106 / 144
to S60/60X/60XC/60TX/65TX 14A-29212 110 / 149 from SX18014-101
to S6014D-396
Z-33
from S60/60X/60XC/60TX/65TX 14A-29213 90 / 122
from S6014D-397 from Z331815M-101 108 / 147
from S60TXD-651 Z-40N, Z-40N RJ
from S60H-36400
from S60JH-101 to Z40N16N-3999 210 / 284
from S60M/65TX/65XC M-101 from Z40N16N-4000 180 / 244
from Z40NF-4916
Z-45BE, Z-45DC, Z-45FE, Z-45IC, Z-45XC
to Z4525A-55298 113 / 153
to Z4525B-5452
to Z452516M-6699
to Z452516N-56105
to Z4525D-1894
from Z45EM-101 106 / 143
from Z4525F-58605
from Z4525M-6700
from Z452516N-56106
from Z452516D-1895

Model and Serial Range Torque A-15

ft-lbs / Nm
Z-51
Test the Dual Capacity and
to Z513014B-1517 113 / 153 Platform Overload System - SX-
to Z5130M-2035 105XC, SX-125XC and SX-135XC
from Z5130M-2036 106 / 143
Models
Z-60DC, Z-60FE
from Z6016N-101 90 / 122
Z-62
from Z6215A-101 90 / 122 Genie specifications require that this procedure be
from Z6216D-101 performed annually OR when the machine fails to
from Z6216M-101
from Z62H-3000
Z-80 Testing the platform overload system regularly is
to Z80H-7147 124 / 168 essential to safe machine operation. Continued
from Z80H-7148 106 / 143 use of an improperly operating platform overload
Z-135
from Z13505-101 110 / 149 could be compromised resulting in the machine
ZX-135 tipping over.
to ZX13515-2584 110 / 149
from ZX13515-2585 122 / 165
1 Remove all weight, tools, accessories and
inaccurate test.

3 Using a suitable lifting device, place a test 7 Add an additional 320 lbs / 145 kg to the
weight of 550 lbs / 250 kg in the center of the platform.
platform. Secure the weight to the platform.
Result: There is an audible alarm. Platform
Note: The test weight may be within -0% / +5%. overload is displayed on the LCD screen at
the ground controls. Platform indicator light is
Result: The unrestricted range of motion flashing at the platform controls.
indicator light is on at ground controls.
Result: Engine does not start and run. Limited
Result: The restricted range of motion light is APU functionality. Primary boom up/extend
on at the ground controls. Calibrate the and jib extend does not operate.
overload system. Refer to Repair Procedure
in the appropriate Service and Repair Manual Result: There is no audible alarm. Platform
for your machine, How to Calibrate the overload is not displayed on the LCD screen
Platform Overload System. at the ground controls. Calibrate the overload
system. Refer to Repair Procedure in the
4 Start the engine and extend the jib. appropriate Service and Repair Manual for
Result: The jib should fully extend and retract. your machine, How to Calibrate the Platform
Overload System.
5 Add an additional 150 lbs / 68 kg to the
platform. 8 Using a suitable lifting device, remove all test
Result: The restricted range of motion
indicator light is on at the ground controls. Result: The platform overload indicator light is
off at platform controls, there is no error
Result: The unrestricted range of motion message displayed at the ground control LCD
indicator light is on. Calibrate the overload screen and the alarm does not sound.
appropriate Service and Repair Manual for Note: There may be an 2 second delay before the
your machine, How to Calibrate the Platform overload indicator lights and alarm turn off.
Overload System.
Note: There may be a 2 second delay before the functions from the ground controls.
sounds.
operate normally.
6 Extend the jib.
Result: The jib does not extend.

A-16 4 Start the engine and extend the primary

boom.
Platform Overload System - Result: The primary boom should fully extend
and retract.
Z-45XC Models
5 Add an additional 150 lbs / 68 kg to the
platform.
Result: The restricted range of motion
Genie specifications require that this procedure be indicator light is on at the ground controls.
lift the maximum rated load. Result: The unrestricted range of motion
indicator light is on. Calibrate the overload
Testing the platform overload system regularly is system. Refer to Repair Procedure in the
essential to safe machine operation. Continued appropriate Service and Repair Manual for
use of an improperly operating platform overload your machine, How to Calibrate the Platform
system could result in the system not sensing an Overload System.
tipping over.
sounds.
6 Extend the primary boom.
machine on a firm, level surface. Result: The primary boom does not extend.
1 Remove all weight, tools, accessories and 7 Add an additional 320 lbs / 145 kg to the
equipment from the platform. platform.
Note: Failure to remove all weight, tools and Result: There is an audible alarm. Platform
accessories from the platform will result in an overload indicator light is on at the ground
inaccurate test. controls.
2 Turn the key switch to ground control and pull Result: Engine does not start and run. Limited
out the red Emergency Stop button to the on APU functionality. Primary boom extend does
position at both ground and platform controls. not operate.
3 Using a suitable lifting device, place a test Result: There is no audible alarm. Platform
weight of 550 lbs / 250 kg in the center of the overload indicator light is not on at the ground
platform. Secure the weight to the platform. controls. Calibrate the overload system. Refer
to Repair Procedure in the appropriate
Note: The test weight may be within -0% / +5%. Service and Repair Manual for your machine,
How to Calibrate the Platform Overload
Result: The unrestricted range of motion System.
indicator light is on at ground controls.
Result: The restricted range of motion light is
on at the ground controls. Calibrate the
overload system. Refer to Repair Procedure
in the appropriate Service and Repair Manual
Platform Overload System.

8 Using a suitable lifting device, remove all test A-17

Result: There is no audible alarm. The Platform Overload System - S-
platform overload indicator light should turn
off at the ground controls. 40XC, S-45XC, S-60HF, S-65HF,
Note: There may be an 2 second delay before the S-60XC from S60XCH-45001, S-
overload indicator lights and alarm turn off. 65XC, S-80HF, S-85HF, S-80XC,
9 Start the engine and test all machine S-85XC.
functions from the ground controls.
operate normally. Genie specifications require that this procedure be
Testing the platform overload system regularly is
use of an improperly operating platform overload
tipping over.
Restricted Platform Overload

1 Remove all weight, tools, accessories and 5 Add additional weight to the platform.
S-80HF, S-85HF models: 370 lbs / 168 kg.
All other models: 320 lbs / 145 kg.
inaccurate test. Result: There is an audible alarm. Platform
overload icon is displayed on the LCD screen
2 Turn the key switch to ground control and pull at the ground controls. Platform indicator light
out the red Emergency Stop button to the on is flashing at the platform controls.
Result: Engine does not start and run. Limited
3 Using a suitable lifting device, place a test APU functionality. Primary boom up and
weight of 550 lbs / 250 kg in the center of the extend does not operate.
platform. Secure the weight to the platform.
Result: There is no audible alarm. Platform
Note: The test weight may be within -0% / +5%. overload icon is not displayed on the LCD
Result: Restricted range of motion icon is not screen at the ground controls. Calibrate the
displayed on the LCD screen at the ground overload system. Refer to Repair Procedure
controls. in the appropriate Service and Repair Manual
Result: Restricted range of motion icon is Platform Overload System.
displayed on the LCD screen at the ground
controls. Calibrate the overload system. Refer 6 Using a suitable lifting device, remove all test
to Repair Procedure in the appropriate weights from the platform.
Service and Repair Manual for your machine, Result: The platform overload indicator light is
How to Calibrate the Platform Overload off at platform controls, platform overload icon
System. is not displayed on the LCD screen at the
4 Add additional weight to the platform. ground controls and the alarm does not
sound.
S-80HF, S-85HF models: 100 lbs / 45 kg.
All other models: 150 lbs / 68 kg. functions from the ground controls.
Result: Restricted range of motion icon is Result: All ground control functions should
displayed on the LCD screen at the ground operate normally.
controls.
Result: Restricted range of motion icon is not
displayed on the LCD screen at the ground
controls. Calibrate the overload system. Refer
How to Calibrate the Platform Overload
System.

A-18 3 Using a suitable lifting device, place an

appropriate test weight equal to that of the
Test the Platform Overload maximum platform capacity at the center of
System - the platform floor.
S-40HF, S-45HF, S-60J, Z-45HF, Note: The test weight may be within -0% / +5%.
Z-45 DC/FE from Z45EM-101
S-40HF, S-45HF, Z-45HF 600 lbs / 272 kg
S-60J, Z-45 DC/FE 660 lbs / 300 kg
Genie specifications require that this procedure be operate.
lift the maximum rated load. Result: There is an audible alarm and the
Platform Overload indicator light is on at the
Testing the platform overload system regularly is ground controls. Calibrate the overload
essential to safe machine operation. Continued system. Refer to Repair Procedure in the
use of an improperly operating platform overload appropriate Service and Repair Manual for
system could result in the system not sensing an your machine, How to Calibrate the Platform
overloaded platform condition. Machine stability Overload System.
4 Add an additional 50 pounds / 22.7 kg to the
tipping over.
platform.
Note: Perform this procedure with the boom fully Result: There is an audible alarm and the
retracted and in the stowed position and with the Platform Overload indicator light is on at the
machine on a firm, level surface. ground controls.
1 Remove all weight, tools, accessories and Result: The machine does not drive and there
equipment from the platform. is limited APU functionality.
Note: Failure to remove all weight, tools and Result: There is no audible alarm and the
accessories from the platform will result in an Platform Overload indicator light is not on at
inaccurate test. the ground controls. Calibrate the overload
2 Turn the key switch to ground control and pull appropriate Service and Repair Manual for
out the red Emergency Stop button to the on your machine, How to Calibrate the Platform
Overload System.
sounds.
Result: There is no audible alarm and the
Platform Overload indicator light turns off at
the ground controls.
operate.
Note: There may be an 2 second delay before the
overload indicator lights and alarm turn off.

A-19 A-20
Perform Engine Maintenance Perform Engine Maintenance
Engine specifications require that this procedure Engine specifications require that this procedure
be performed annually. be performed every two years.
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.
Kubota Models Kubota Models
D1803 D1803
• DPF piping - check • Intake air line - replace
• EGR piping - check • Fuel pipes and clamp bands - replace
• Exhaust manifold - check • Radiator hoses and clamp bands - replace
• Radiator coolant (L.L.C.) - replace
Replace all rubber related piping on the
following:
• Oil separator
• DPF
• Intake airline and suction air pressure
takeout
• Boost sensor pressure
• EGR cooler
• Water
• Lubricant

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

bogey wheels.
Check the Track Tension and
Fastener Torque, TraX Models - Result: There is less than 1 inch / 2,5 cm of
gap between the bogey wheels and the inside
S-60, S-65, S-60XC, S-65XC and surface of the track. Proceed to step 12.
Z-62 Models Result: There is 1 inch / 2,5 cm or more of
surface of the track. Proceed to step 6.
Manufacturer specifications require that this

procedure be performed every 50 hours.
Maintaining proper track tension and properly
torqued fasteners is essential to good machine
performance and service life. The machine will not
operate properly with a track that is incorrectly
tensioned. Continued use of a machine with
incorrectly tensioned tracks may cause component
damage.
1 Thoroughly clean the track assembly of any
dirt, rocks, clay, etc.
2 Chock the tracks at one end of the machine to
prevent the machine from rolling.
3 Center a lifting jack of ample capacity 1 bogey wheels
(20,000 lbs / 10,000 kg) under the drive
chassis between the tracks at the other end of 6 Locate the grease plug on the track tension
the machine. cylinder. Loosen the plug, but do not remove
4 Lift the machine until the tracks are off the it.
ground and then place jack stands under the
drive chassis for support.
1 grease zerk
2 grease plug

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

side 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 S-40, S-45, S-40XC, S-45XC
tighten the grease plug. Do not overtighten. Models
9 Continue to pump grease into the grease zerk
fitting just until the idler wheel moves. Check
the track tension.
10 If necessary, continue to pump grease into procedure be performed every 50 hours.
the cylinder until the track has proper tension.
Maintaining proper track tension and properly
Component damage hazard. torqued fasteners is essential to good machine
Do not over tighten the track. performance and service life. The machine will not
Over tightening the track will operate properly with a track that is incorrectly
cause the machine to lose tensioned. Continued use of a machine with
power during operation. incorrectly tensioned tracks may cause component
damage.
Note: If the track becomes too tight, loosen the
grease plug on the cylinder to remove grease and 1 Thoroughly clean the track assembly of any
loosen the track. dirt, rocks, clay, etc.
11 Clean up any grease that may have spilled. 2 Chock the tracks at one end of the machine to
prevent the machine from rolling.
12 Check the torque of the track assembly
fasteners. Refer to Specifications, TraX 3 Center a lifting jack of ample capacity
Torque Specifications. (20,000 lbs / 10,000 kg) under the drive
chassis between the tracks at the other end of
13 Raise the machine, remove the jack stands the machine.
and lower the machine.
4 Lift the machine until the tracks are off the
14 Repeat this procedure for each track ground and then place jack stands under the
assembly. drive chassis for support.
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 is less than 1 inch / 2,5 cm of
0.75 - 1 inch / 1,9 - 2,5 cm of gap between the
bogey wheels and the inside surface of the
surface of the track. Proceed to step 7.
track.
Result: There is 1 inch / 2,5 cm or more of
gap between the bogey wheels and the inside Component damage hazard.
surface of the track. Proceed to step 6. Do not over tighten the track.
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
Torque Specifications.
9 Raise the machine, remove the jack stands
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
Grease the Extendable Axles - S-
100, S-105, S-120, S-125, S100HD
and S-120HD

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
2 Thoroughly pump grease into each grease

fitting. When grease is pumped into each
fitting, a hose directs this lubrication to the top
or bottom wear pad.
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.

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:
D2011 L03i TD2011 L04i TD 2.2 L3 TCD 2.2 L3 D 2.9 L4 TD 2.9 L4 D436 L3i CN3
Deutz Engines Hour Intervals

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 - D436, D2011, TD2011 models  
Engine oil and filter – replace, TD2011, TD 2.2, TCD 2.2, TD 2.9 models  
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:
D-1105-E3B D1105-E4B D1803-CR-TIE4 WG972 Z482-E
Kubota Engines Hour Intervals

Procedure  = Not required Daily 50 75 100 150 200 400 500 800
Coolant level - check        

Oil level - check        
Fuel hoses and clamp bands - check        
Water separator - drain        
Engine oil - replace, Z482        
Fan belt tension and damage - check        
Battery electrolyte level - check        
Spark plug - check        
Air cleaner element - clean
(Replace the 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        
Engine oil - replace, D1803        
Oil filter cartridge - replace, D1803        
Fuel filter cartridge - replace        

Kubota Engines, continued Hour Intervals

Procedure  = Not required Daily       500 
Fuel/Water separator - replace, D1803        
Air cleaner element - replace        
Fan belt - replace        
Cleaning of water jacket (radiator interior)        
Removal of sediment in fuel tank        
Recharging battery        
Damage in electric wiring and loose connections - check        
Valve clearance - check, D1105, WG972, Z482        

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 404D-22T
Perkins 404F-22 Perkins 404F-22T Perkins 404F-E22T Perkins 404F-E22TA
Perkins 804D-33 Perkins 854F-34T Perkins 1104D-44T
Perkins Engine Hour Intervals

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  

P0-10
GM .998L Engine Maintenance – Under 1000 Hours
GM .998L Engine Hour Intervals

Procedure  = Not required Daily 100 150 200 400 800
Coolant level - check     

Oil level - check     
Oil, fuel and coolant systems - check for leaks     
Fan belt tension and damage - check     
Radiator hoses and clamps - check     
Intake manifold - check for vacuum leaks     
LPG system - check for leaks     
Radiator – clean • Radiator hoses and clamps - check     
Engine oil and filter – replace     
LPG Vaporizer - drain/clean     
PCV valve - check     
Air cleaner element - clean/replace     
Timing belt - check     
Electrical wiring - check for chafing or damage     
Vacuum lines and fittings - check     
Fuel filter - replace     
Fuel lines and clamps - check for leaks     
Air intake system - inspect for leaks     
Cylinder head bolts - torque (40.5 ft-lbs / 55 Nm)     
Valve clearance - check/adjust     
PCV valve - replace     
Cooling system coolant - replace     
Spark plugs - replace     
Spark plug wires - check/replace     

P0-11
GM 3.0L Engine Maintenance – Under 1000 Hours
GM 3.0L Engine Hour Intervals

Procedure  = Not required Daily 100 150 200 250 400 800
Coolant level - check      

Oil level - check      
Oil, fuel and coolant systems - check for leaks      
Radiator – clean      
LPG Vaporizer - drain/clean      
Air cleaner element - clean/replace      
Engine oil and filter – replace      
Fuel filter - replace      
Air filter - replace      
Distributor cap - replace      
Spark plug wires - replace      

P1-1 Deutz Models

Perform Engine Maintenance – All Models:
1000 Hours • Fuel system primary filter (water separator)
element – replace
• Fuel system secondary filter – replace
Engine specifications require that this procedure • Hoses and clamps – inspect/replace
be performed every 1000 hours.
• By-pass oil filter - replace
Required maintenance procedures and additional
engine information are available in the • Engine mounts - inspect
manufacturer's manuals. Refer to Specifications, • Glow plugs - check
Engine Operator and Maintenance Manuals.
• V-belts - re-tension/renew
Continental TME27
• Cold starting device (if equipped) - check
• Spark plugs - replace
• Battery and cable connectors - check
• O2 sensors - replace
• Engine valve lash – inspect/adjust
Cummins Models
D436 L3i, D2011, D 2.9 L4
• Drive belt tension - measure
• Engine oil and filter – replace
• Drive belt - inspect D 2.9 L4, TD 2.9 L4
GM 3.0L
• Coolant (additive concentration) - check
• Fan belt - inspect/replace
• Radiator hoses and clamps - check
• PCV system - check

Perkins Models
All Models:
• Alternator and fan belts - replace
• Engine valve lash – inspect/adjust
• Engine crankcase breather - replace
403D-11, 404F-22
• Turbocharger - inspect
804D-33
• Alternator - inspect
• Starting motor - inspect
854F
• Water pump - inspect
• Engine crankcase breather - replace
Kubota Models
D1803
• Valve clearance - check
WG972
• Coolant and vacuum lock hose of LPG
vaporizer - replace
• Radiator coolant (L.L.C.) - replace
• Cleaning water jacket and radiator interior
• Valve clearance - check
• Cleaning cylinder head
• Valve seats - check
• Air cleaner element - replace
• Gasoline fuel hose and clamp bands -
replace
• Carburetor and fuel tank inside - clean
Z482-E, D-1105
• Fuel injection nozzle injection pressure -
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.
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
ground and place jack stands under the drive
chassis for support. 1 drive hub plug
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 Torque Specifications,
TraX Torque Specifications.

16 Raise the machine, remove the jack stands 4 Remove the drive hub mounting bolts from
lower the machine. the 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. Note: If equipped with two turntable rotation drive
Turn 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 Torque rotate drive hub assembly could
Specifications, TraX 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
turntable rotation lock pin. 5 Remove the plug from the side of the drive
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
How to Adjust the Turntable Rotation Gear
Backlash.

P1-3 P2-1
Perform Engine Maintenance – Perform Engine Maintenance –
1500 Hours 2000 Hours
be performed every 1500 hours. be performed every 2000 hours.
Required maintenance procedures and Required maintenance procedures and
additional engine information are available in the additional engine information are available in the
Kubota Models Cummins Models
D1803 • Cooling system - flush
• Fuel injection nozzle - check • Valve clearance - check/adjust
• EGR cooler - check GM .998L
• Oil separator element - change • Spark plug wires - replace
• Timing belt - replace
• Bolts, nuts and fasteners - check/tighten
GM 3.0L
• Electrical wiring - check for chafing or

damage
• Vacuum lines and fittings - check
• LPG fuel lock-off valve - check for leaks
• Fuel lines and clamps - check for leaks
• Air intake system - inspect for leaks
• Intake manifold - check for vacuum leaks
• Exhaust manifold - check for leaks
• Exhaust system – check for leaks
• HEGO sensor - check for damage
• Catalyst - Inspect

Deutz Models Kubota Models

All Models: Z482-E, D1105, WG972
• V-Belts - replace • Radiator coolant (L.L.C.) - replace
D436 L3i, D2011, TD2011 • Battery - replace
• Glow plugs - replace • Radiator hoses and clamp bands -
replace
TD 2.2 L3, TCD 2.2 L3, D 2.9 L4, TD 2.9 L4
• Fuel pipes and clamp bands - replace
• Cooling system coolant - replace
• Extended life coolant (ELC) - replace • Intake air line - replace
WG972
Perkins Models
• Fuel filter - replace
All Models:
• LPG fuel hose and clamp bands - replace
• Coolant and vacuum lock hose of LPG
• Engine mounts - inspect
vaporizer - replace
• Starting motor - inspect
Perkins 854F-34T
• Aftercooler core - inspect
Perkins 1104D-44T
• Aftercooler core - inspect
• Cooling system coolant - replace

P2-2 Testing the oil:

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

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.
Genie requires that this procedure be performed 8 Install the filter housing cap.
every 2000 hours.
9 Use a permanent ink marker to write the
Perform this procedure more often if dusty date and number of hours from the hour
conditions exist. meter on the oil filter housing.
Replacement of the hydraulic filters is essential 10 Inspect the filter housings and related
for good machine performance and service life. components to be sure that there are no
A dirty or clogged filter may cause the machine leaks.
to perform poorly and continued use may cause
External:
component damage. Extremely dirty conditions
may require that the filter be replaced more 1 Locate the hydraulic return filter.
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 3 Remove the filter with an oil filter wrench.
pressure filter and drive motor case drain filter. 4 Apply a thin layer of fresh oil to the gasket
The quantity and type of filter(s) may vary by of the new oil filter.
model.
5 Install the new hydraulic return filter element
Bodily injury hazard. Beware of and tighten it securely by hand.
hot oil. Contact with hot oil may 6 Clean up and properly dispose of any oil
cause severe burns. that may have spilled during the installation
procedure.
Note: Perform this procedure with the engine off.
7 Use a permanent ink marker to write the
Hydraulic return filter date and number of hours from the hour
Note: The return filter may be mounted in the top meter on the oil filter.
of the hydraulic tank (internally) or outside of the 8 Inspect the filter housings and related
tank (externally). 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 Note: The case drain filter is for the charge
charge pump and the high pressure filter is for pump.
all machine functions except the drive circuit and
oscillating axle circuit. 1 Open the engine side turntable cover and
locate the case drain filter mounted to the
1 Locate the medium and high pressure engine tray near the hydraulic pumps.
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
3 Remove the filter housings by using a using a wrench on the nut provided on the
wrench on the nut provided on the bottom bottom of the housing.
of the housings.
4 Remove the case drain element from the
4 Remove the filter elements from the housing.
housings.
5 Inspect the housing seal and replace it if
5 Inspect the housing seals and replace them necessary.
if necessary.
6 Install the new case drain filter element into
6 Install the new filter elements into the the housing. Install the filter housing onto
housings and tighten them securely. the filter head and tighten it securely.
7 Clean up and properly dispose of any oil 7 Clean up and properly dispose of any oil
that may have spilled during the installation that may have spilled during the installation
procedure. procedure.
8 Use a permanent ink marker to write the 8 Use a permanent ink marker to write the
date and number of hours from the hour date and number of hours from the hour
meter on the oil filter. meter on the oil filter.
9 Inspect the filter housings and related 9 Start the engine from the ground controls.
components to be sure that there are no
10 Inspect the all of the filter housings and
leaks.
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
Check the Free-wheel chassis for support.
Configuration
4 Disengage the drive hubs by turning over
the drive hub disconnect caps on each non-
steer / circle-end wheel hub.
Genie requires that this procedure be performed
every 2000 hours.
Proper use of the free-wheel configuration is
essential to safe machine operation. The free-
wheel configuration is used primarily for towing.
A machine configured to free-wheel without
operator knowledge may cause death or serious
injury and property damage.
2 brake engaged position
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
Result: Each non-steer / circle-end wheel
with Circle-end and Square-end wheels.
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 / 6 Re-engage the drive hubs by turning over
3.2 km/h. the hub disconnect caps. Rotate each
wheel or track to check for engagement. Lift
Non-steer or Circle-end wheels: the machine and remove the jack stands.
1 Chock the steer/square-end wheels to Collision hazard. Failure to re-

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

2 brake engaged position 1 drive pump
2 screwdriver
11 Manually rotate each steer / square-end 3 lift pump
wheel or track. 4 free-wheel valve
Result: Each steer / square-end wheel or
track should rotate with minimum effort. Note: The location of the free-wheel valve may
vary 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-40HF, S-45HF, S-40XC, S45XC,

S-60, S-65, S-60HF, S-65HF, S-60J, S-60X, S-
Check the Boom Wear Pads 60XC, S-65XC
Boom wear pad specifications Minimum

Top and side wear pads 0.50 inch
Genie requires that this procedure be performed (platform end of boom) 12,7 mm
every 2000 hours.
Bottom wear pads 0.625 inch
Maintaining the boom wear pads in good (platform end of boom) 15,9 mm
condition is essential to safe machine operation. Top and side wear pads 0.50 inch
Wear pads are placed on boom tube surfaces to (pivot end of boom) 12,7 mm
provide a low friction, replaceable wear pad Bottom wear pads 0.625 inch
between moving parts. Improperly shimmed (pivot end of boom) 15,9 mm
wear pads or continued use of extremely worn
wear pads may result in component damage and
S-80, S-85, S-80HF, S-85HF, S-80X, S-80XC,
unsafe operating conditions.
S-85XC
1 Measure each wear pad. Replace the wear
pad once it reaches the minimum allowable Boom wear pad specifications
thickness. If the wear pad is still within Boom number one Minimum
specification, shim as necessary to obtain Bottom wear pads 0.50 inch
minimum clearance with zero binding. (extension end of boom) 12,7 mm
2 Extend and retract the boom through the Top and side wear pads 0.625 inch
entire range of motion to check for tight (extension end of boom) 15,9 mm
spots that may cause binding or scraping of Boom number two
the boom. Top, bottom and side wear pads 0.50 inch
Note: Always maintain squareness between the (extension end of boom) 12,7 mm
outer and inner boom tubes. Bottom wear pads 0.50 inch
(pivot end of boom) 12,7 mm
Boom number three
Top, bottom and side wear pads 0.50 inch
S-100, S-105, S-120, S-125, S-100HD, S-

120HD
Boom wear pad specifications 0.50 inch

12,7 mm

SX-105XC, SX-125XC, SX-135XC, SX-150, SX- Z-33/18

180
Primary boom wear pad Minimum
Primary boom wear pad specifications Minimum specifications
Platform end Top wear pads 0.6875 inch
(platform end of boom) 17,46 mm
Bottom and side wear pads 0.63 in
16 mm Side wear pads 0.5625 inch
Top wear pads 0.35 in
(SX105XC, SX125XC, SX135XC #1 to 9 mm Bottom wear pads 0.625 inch
#2) (platform end of boom) 15,9 mm
(SX150, SX180 #1 to #2; #2 to #3) Top and side wear pads 0.69 inch
(SX125XC, SX180 #0 to #1) (pivot end of boom) 17,46 mm
Top wear pads 0.63 in Bottom wear pads 0.81 inch
(SX105XC, SX125XC, SX135XC #2 to 16 mm (pivot end of boom) 20,64 mm
#3)
Top wear pads 0.47 in
Z-34/22 IC, Z-34/22 Bi-Energy
(SX150, SX180 #3 to #4) 12 mm
Pivot end Primary boom wear pad specifications Minimum
Top wear pads 0.63 in Top, bottom and side wear pads 0.625 inch
16 mm (platform end of boom) 15,9 mm
Side wear pads 0.47 in Bottom wear pads 0.50 inch
12 mm (pivot end of boom) 12,7 mm
Top wear pads 0.625 inch
Z-30/20N (RJ), Z-34/22N, Z-34/22DC (pivot end of boom) 15,9 mm
Side wear pads 0.375 inch
Models without rotating jib boom (pivot end of boom) 9,5 mm
Primary boom wear pad Minimum
specifications Z-40/23N (RJ)
(extension end of boom) 15,9 mm Primary boom wear pad specifications Minimum
Bottom and side wear pads 0.625 inch Top and side wear pads 0.625 inch
(pivot end of boom) 15,9 mm (platform end of boom) 15,9 mm
Top wear pads 0.375 inch Bottom wear pads 0.375 inch
(pivot end of boom) 9,5 mm (platform end of boom) 9,5 mm
Models with rotating jib boom Top, bottom and side wear pads 0.375 inch
All wear pads 0.375 inch
9,5 mm

Z-45/25 (J) IC, BE, DC, Z-45 DC/FE, Z-45XC, Z- Z-135/70, ZX-135/70
51/30J
Note: The minimum shim clearance for the
Primary boom wear pad specifications Minimum secondary boom wear pads is 0.070 inch /
Top, bottom and side wear pads
1,8 mm and the maximum allowable shim
0.625 inch
(platform end of boom) 15,9 mm clearance is 0.25 inch / 6,4 mm.
Bottom and side wear pads 0.50 inch Note: The minimum shim clearance for the jib
(pivot end of boom) 12,7 mm boom and primary boom wear pads is 0.070 inch
Top wear pads 0.625 inch / 1,8 mm and the maximum allowable shim
(pivot end of boom) 15,9 mm clearance is 0.188 inch / 4,8 mm.
Primary boom wear pad specifications Minimum

Z-60 DC/FE, Z-62
Primary boom wear pad specifications Minimum (platform end of boom) 15,9 mm
Top and side wear pads 0.486 inch Top and side wear pads 0.50 inch
12,3 mm (pivot end of boom) 12,7 mm
Side wear pads 0.519 inch Side wear pads 0.375 inch
13,2 mm (pivot end of boom) 9,5 mm
Secondary boom wear Minimum
pad specifications
Z-80/60
Boom wear pad specifications Minimum (extension end of boom) 9,5 mm
Primary Boom Side wear pads 0.50 inch
(extension end of boom) 12,7 mm
15,9 mm Bottom wear pads 7/8 inch
(extension end of boom) 22 mm
Primary and secondary extension boom
Top and bottom wear pads 0.625 inch
Top wear pads 0.625 inch (pivot end of boom) 15,9 mm
15,9 mm
Side wear pads 0.50 inch
Side wear pads 0.50 inch (pivot end of boom) 12,7 mm
12,7 mm
Jib boom wear pad specifications Minimum
Secondary Boom
Bottom and side wear pads 0.625 inch
Top wear pads 0.50 inch (platform end of boom) 15,9 mm
12,7 mm
Bottom and side wear pads 0.875 inch (platform end of boom) 12,7 mm
22,22 mm
Bottom wear pads 0.625 inch

P2-6 P2-7
Check the Extendable Axle Check the Turntable Rotation
Wear Pads - S-100, S-105, S-120, Gear Backlash - ALC1000
S-125, S-100HD and S-120HD Models
Genie requires that this procedure be performed
every 2000 hours.
Genie requires that this procedure be performed Properly adjusted turntable rotation gear
every 2000 hours. backlash is essential for good machine
performance and service life. Improperly
Maintaining the axle wear pads in good condition adjusted turntable rotation gear backlash will
is essential to safe machine operation. Wear cause the machine to perform poorly and
pads are placed on axle tube surfaces to provide continued use will cause component damage.
a low friction, replaceable wear pad between The turntable rotation drive hubs are mounted
moving parts. Improperly shimmed wear pads or on an adjustable plate on the swing chassis
continued use of worn out wear pads may result behind the fixed side cover at the ground
in component damage and unsafe operating controls side of the machine.
conditions.
Note: Be sure that the axles are fully extended This procedure does not apply to the Z-
before attempting this procedure. 60/80 models.
1 Measure each wear pad. Note: Perform this procedure with the machine
fully stowed and the counterweight at the square
Wear pad specifications Minimum end of the machine.
Top, side and bottom wear 0.437 inch
Note: Perform this procedure with the machine
pads 1,12 mm
on a firm, level surface that is free of
2 Replace any wear pad if it is less than obstructions.
specification. If a wear pad is not less than
specification, shim as necessary to obtain 1 Rotate the turntable until the boom is
minimum clearance and no drag. centered between the circle end wheels.
Note: If the wear pads are still within 2 Apply approximately 20 lbs / 89 N of side
specification. Refer to Repair Procedure in the force to the platform, moving the platform to
appropriate Service and Repair Manual for your one side as far as it will go.
machine, How to Shim the Extendable Axles. 3 Using a feeler gauge, measure the gap
Note: If any wear pads are replaced, refer to between the swing hub pinion gear and the
Repair Procedure in the appropriate Service and turntable rotation bearing at the center tooth
Repair Manual for your machine, Grease the on one of the drive hubs. The gap should
Extendable Axles. be measured on one side of the pinion gear
on the center tooth.
3 Extend and retract the axles through the Note: The pinion gear can be accessed on the
entire range of motion to check for tight outside of the chassis under the pinion gear
spots that may cause binding or scraping of guard.
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 S-60, S-65, Z-60 DC/FE
Result: The gap is less than 0.010 inch /
and Z-62)
0,254 mm or more than 0.022 inch /
0,559 mm. The backlash needs to be
adjusted. Refer to Repair Procedure in the
appropriate Service and Repair Manual for Genie requires that this procedure be performed
your machine, How to Adjust the Turntable every 2000 hours.
Rotation Gear Backlash. Perform this procedure more often if dusty
SX-150 and SX-180 conditions exist.
Result: The gap is between 0.016 inch / Maintaining the steer axle wheel bearings is
0,406 mm and 0.024 inch / 0,62 mm. The essential for safe machine operation and service
backlash is within tolerance. life. Operating the machine with loose or worn
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 component damage. Extremely wet or dirty
/ ,.62 mm. The backlash needs to be conditions or regular steam cleaning and
adjusted. Refer to Repair Procedure in the pressure washing of the machine may require
appropriate Service and Repair Manual for that this procedure be performed more often.
your machine, How to Adjust the Turntable
Rotation Gear Backlash. 1 Loosen the wheel lug nuts. Do not remove
them.
SX-105 XC, SX-125 XC, SX-135XC, Z-
135/70 and ZX-135/70 2 Block the non-steer wheels, then center a
lifting jack under the steer axle.
Result: The gap is between 0.013 inch /
0,33 mm and 0.023 inch / 0,58 mm. The 3 Raise the machine 6 inches / 15 cm and
backlash is within tolerance. place blocks under the drive chassis for
support.
Result: The gap is less than 0.013 inch /
0,33 mm or more than 0.023 inch / 4 Remove the lug nuts. Remove the tire and
0,58 mm. The backlash needs to be wheel assembly.
adjusted. Refer to Repair Procedure in the
5 Check for wheel bearing wear by attempting
to move the wheel hub side to side, then up
your machine, How to Adjust the Turntable
and down.
Rotation Gear Backlash.
Result: There should be no side to side or
4 Repeat the procedure for the other turntable up and down movement.
rotation hub.
Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. 15 Place the large inner bearing into the rear of
Remove the cotter pin from the castle nut. the hub.
7 Tighten the castle nut to specification, to 16 Install a new bearing grease seal into the
seat the bearings. hub by pressing it evenly into the hub until it
is flush.
S-40, S-45, Z-45/25 IC, Z-30/20N, Z- 35 ft-lbs
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- 158 ft lbs
45/25 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, Z- 8 ft-lbs
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- 35 ft lbs
19 Install the washer and castle nut.
45/25 BE 47 Nm
9 Check for wheel bearing wear by attempting 20 Tighten the slotted nut to specification, to
to move the wheel hub side to side, then up seat the bearings.
and down. S-40, S-45, Z-45/25 IC, Z-30/20N, Z- 35 ft-lbs
34/22N, Z-33/18, Z-34/22 IC 47 Nm
Result: If there is no side to side or up and
down movement, continue with step 11 and Z-34/22 BE, Z-40/23, Z-45/25 DC, Z- 158 ft lbs
45/25 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 specification.
down movement, continue to step 11 and
replace the wheel bearings with new ones. S-40, S-45, Z-45/25 IC, Z-30/20N, Z- 8 ft-lbs
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- 35 ft lbs
inner and outer bearings, including the pressed- 45/25 BE 47 Nm
in races, must be replaced.
22 Install a new cotter pin. Bend the cotter pin
10 Remove the dust cap from the hub. to lock it in.
Remove the cotter pin from the castle nut.
Note: Always replace the cotter pin with a new
11 Remove the castle nut. one when removing the castle nut or when
checking the torque of the castle nut.
12 Pull the hub off of the spindle. The washer
and outer bearing should fall loose from the 23 Install the dust cap, then the tire and wheel
hub. assembly. Torque the wheel lug nuts to
13 Place the hub on a flat surface and gently specification. Refer to Specifications, Tires
pry the bearing seal out of the hub. Remove and Wheels Specifications.
the 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
Grease the Steer Axle Wheel and down.
Bearings, 2WD Models -
Result: If there is no side to side or up and
S-60, S-65, Z-60 DC/FE and Z-62 down movement, continue with step 10 and
grease the wheel bearings.
Result: If there is side to side or up and
Genie requires that this procedure be performed down movement, continue to step 10 and
every 2000 hours. replace the wheel bearings with new ones.
Note: When replacing a wheel bearing, both the
Perform this procedure more often if dusty
inner and outer bearings, including the pressed-
conditions exist. in races, must be replaced.
Maintaining the steer axle wheel bearings is
6 Remove the cover from the hub.
essential for safe machine operation and service
life. Operating the machine with loose or worn
wheel bearings may cause an unsafe operating
condition and continued use may result in
component damage. Extremely wet or dirty
conditions or regular steam cleaning and
pressure washing of the machine may require
that this procedure be performed more often.
1 Loosen the wheel lug nuts. Do not remove
them.
2 Block the non-steer wheels, then center a
lifting jack under the steer axle.
3 Raise the machine 6 inches / 15 cm and 1 retaining fastener
place blocks under the drive chassis for
2 washer
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.
Engine specifications require that this procedure
Remove the inner bearing.
be performed every 3000 hours.
11 Pack both bearings with clean, fresh
grease. Required maintenance procedures and
additional engine information are available in the
12 Place the large inner bearing into the rear of manufacturer's manuals. Refer to Specifications,
the hub. Engine Operator and Maintenance Manuals.
13 Install a new inner oil seal into the hub by Deutz Models
pressing it evenly into the hub until it is
flush. D 2011, TD 2011
14 Slide the hub onto the spindle. • Toothed belt - replace
Component damage hazard. • Injection valve- replace
Do not apply excessive force or
• Charge air cooler - clean
damage to the lip of the seal
may occur. • Turbocharger compressor outlet- clean
15 Place the outer bearing into the hub. • V-belt and tensioning pulley - replace
16 Install the outer ring. TD 2.2 L3, TCD 2.2 L3, D 2.9 L4, TD 2.9 L4
17 Install the shims. • V-belt and tensioning pulley - replace
18 Install the cover and torque the retaining Ford Models

fastener to 383 ft-lbs / 519 Nm.
• Coolant filler cap - clean/replace
19 Install the tire and wheel assembly. Torque
the wheel lug nuts to specification. Refer to
Specifications, Machine Specifications.

Perkins Models Kubota Models

403D-11, 403F-11, 404D-22, 404F-22, Z482-E, D1105
404F-22T, 804D, 1104D-44T
• Injection pump - check
• Fuel Injector - test/change
• Fuel injection timing - check
• Cooling system coolant (Heavy Duty) -
D1803
change
403F-11 • Turbocharger - inspect
• Coolant temperature regulator - replace • DPF - clean
404F-22, 404F-22T • EGR system - check
• Coolant temperature regulator - replace

• Diesel particulate filter - clean
• Glow plugs (ARD combustion) - replace
• Radiator cap - inspect/replace
404F-E22T, 404F-E22TA
• Coolant temperature regulator - replace
• Exhaust gas recirculation valve - clean
• Cooling system coolant (Heavy Duty) -
change
854F-34T
• Alternator and fan belts - replace
• Diesel particulate filter - clean
• Radiator cap - inspect/replace

P4-1 P5-1
be performed every 4000 hours. be performed every 6,000 hours.
Perkins Models GM 3.0L
404F-E22T, 404F-E22TA, 854F-34T, • Cooling system coolant - replace
1104D-44T
• Aftercooler core - clean/test

P6-1 P12-1
be performed every 6,000 hours. be performed every 12000 hours.
Perkins models Perkins Models
404F-E22T, 404F-E22TA, 1104D-44T • Cooling system coolant (ELC) - change
• Cooling system coolant extender (ELC) -
add

P12-2 1 Remove the boom extend and retract

cables. Refer to the appropriate Service and
Remove and Inspect the Boom Repair Manual for repair procedure, How to
Extend/Retract Cables Replace the Boom Extend/Retract Cables.
2 Inspect the sheaves for the following:
• Broken or damaged sheaves
Genie specifications require that this procedure
be performed after 12 years. • Unusual or excessive wear
• All fasteners in place and secure
Manufacturers specifications require that this
procedure be performed by personnel that are • Bearings are secure
competent in cable / wire rope inspection.
• Bearings, excessive wear
Note: If the cables pass inspection and are
Note: A groove gauge should be used to check
not replaced, the cables must be removed
the condition of the sheaves.
and inspected every 3 years until all boom
cables have been replaced. Note: If one or more sheaves require
Note: Additional or more frequent replacement, the sheaves must be replaced as a
inspections may be required due to the set.
following:
• exposed to hostile or corrosive
The boom extend and retract cables are
responsible for the extension and retraction of
the boom tubes. Inspection and replacement of
the boom extend and retract cables, when 1 good condition
required, is essential to good machine 2 too tight - replace
performance and safe machine operation. The 3 too loose - replace
boom extend and retract functions should
operate smoothly and be free of hesitation,
jerking and unusual noise.

3 Inspect the cables for the following: correct incorrect

Cable Diameter Specifications
• Frayed or broken wire strands
Model Nominal Minimum
• Kinks or crushed cables Diameter Diameter
• Corrosion S-60, S-65, S-60HF, S-65HF, S-60X, S-60XC, S-
65XC, S-80, S-85 and S-80X (includes TraX™
• Paint or foreign materials on the cable models)
• Split or cracked cable ends Extend .438 inches .416 inches
11.13 mm 10.5 mm
Number of broken wires in one rope lay- Replace Retract .438 inches .416 inches
11.13 mm 10.5 mm
All strands of one rope lay 6
S-80HF, S-85HF, S-80XC and S-85XC
One strand in one rope lay 3
Extend .50 inches .475 inches
12.7 mm 12 mm
Retract .438 inches .416 inches
11.13 mm 10.5 mm
S-100 / 105 / 120 / 125 and SX-125 XC
Extend .625 inches .594 inches
15.875 mm 15 mm
Retract .375 inches .357 inches
9.5 mm 9 mm
1 wire
SX-135 XC
2 strand
3 one rope lay Extend .625 inches .594 inches
15.875 mm 15 mm
Note: Refer to Cable Replacement Criteria. Retract .50 inches .475 inches
12.7 mm 12 mm
Result: The cables are not damaged or
show excessive wear. Install the cables and SX-150 and SX-180
continue use. Extend - Boom 3 .625 inches .594 inches
15.875 mm 15 mm
Result: The cables are damaged or show
Retract - Boom 3 .625 inches .594 inches
excessive wear, the cables must be
15.875 mm 15 mm
replaced as a set.
Extend - Boom 4 .50 inches .475 inches
4 Inspect the cable diameter. Measure the 12.7 mm 12 mm
diameter in multiple locations along the
Retract - Boom 4 .50 inches .475 inches
cable. 12.7 mm 12 mm
Note: Calipers will be required to perform this Note: If any section of the cable is below the
procedure. minimum diameter, the cables must be replaced
as a set.

Cable Re place men t Crit eria
Cable Replacement Criteria

Note: The cables must be replaced if any
condition shown below is observed other than
normal wear.
Note The cables must be replaced as a set.
normal wear
abrasion
broken wires
rust
birdcaging
S® Booms • Z® Booms Part No. 126 848 9GT Maint enan ce M anu al May 2 020 Maint enan ce In specti on Re por t – Bo oms

Maintenance Manual - Booms

Uploaded by

Maintenance Manual - Booms

Uploaded by

Maintenance Manual - Booms

S® Booms This manual includes detailed

Z® Booms For Repair procedures, Fault

Important Technical Publications

ii S® Booms • Z® Booms Part No. 1268489GT

SX-105 XC from SX105D-101

Part No. 1268489GT S® Booms • Z® Booms iii

Z-30/20N, Z- from Z30N14-15222 to Z30N16F-18899 Z-45/25(J) BE from Z452513A-48153 to Z452516N-57199

iv S® Booms • Z® Booms Part No. 1268489GT

Identifying the Correct Procedure

Find additional Manuals for your

Part No. 1268489GT S® Booms • Z® Booms v

vi S® Booms • Z® Booms Part No. 1268489GT

Revision History (continued)

Part No. 1268489GT S® Booms • Z® Booms vii

Do Not Perform Maintenance

viii S® Booms • Z® Booms Part No. 1268489GT

Personal Safety Workplace Safety

Be aware of potential crushing hazards

Part No. 1268489GT S® Booms • Z® Booms ix

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

Section 1 Safety Rules .................................................................................................. viii

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

Torque Specifications .................................................................................... 12

Engine Specifications .................................................................................... 15

x S® Booms • Z® Booms Part No. 1268489GT

Section 3 Maintenance Procedures ............................................................................... 34

Commissioning Procedures .......................................................................... 41

Part No. 1268489GT S® Booms • Z® Booms xi

Quarterly Maintenance Procedures............................................................... 43

xii S® Booms • Z® Booms Part No. 1268489GT

Q-17 Inspect the Calibration Decal - ALC1000 Models...................................... 63

Part No. 1268489GT S® Booms • Z® Booms xiii

Annual Maintenance Procedures ................................................................ 105

xiv S® Booms • Z® Booms Part No. 1268489GT

Programmed Maintenance Procedures ....................................................... 137

Part No. 1268489GT S® Booms • Z® Booms xv

P3-1 Perform Engine Maintenance – 3000 Hours ........................................... 169

xvi S® Booms • Z® Booms Part No. 1268489GT

Function Speeds - S-100, S-

Part No. 1268489GT S® Booms • Z® Booms 1

Function Speeds - S-120, S-

2 S® Booms • Z® Booms Part No. 1268489GT

Function Speeds - All Other Models

Part No. 1268489GT S® Booms • Z® Booms 3

4 S® Booms • Z® Booms Part No. 1268489GT

Function Z-45 Z-51 Z-60 Z-62 Z-80

Part No. 1268489GT S® Booms • Z® Booms 5

6 S® Booms • Z® Booms Part No. 1268489GT

Part No. 1268489GT S® Booms • Z® Booms 7

8 S® Booms • Z® Booms Part No. 1268489GT

4WD models, 5.2 - 5.9 8 - 10.5 sec 8 - 10.5 sec 8 - 10.5 9 - 11

Part No. 1268489GT S® Booms • Z® Booms 9

Note: Drive speeds are shown in seconds.

10 S® Booms • Z® Booms Part No. 1268489GT

Note: Drive speeds are shown in seconds.

Function Z-34 IC Z-40N, Z-40N RJ Z-45/25, Z-45/25J Z-45/25 IC, Z-45/25J

Function Z-60 Z-62 Z-80 Z-135, ZX-135

Part No. 1268489GT S® Booms • Z® Booms 11

Tires and Wheels

12 S® Booms • Z® Booms Part No. 1268489GT

Tires and Wheels, continued

Part No. 1268489GT S® Booms • Z® Booms 13

TraX™ Torque Specifications

14 S® Booms • Z® Booms Part No. 1268489GT

Engine Operator and Ford DSG-423

Part No. 1268489GT S® Booms • Z® Booms 15

Deutz Engine Models TD 2.2 L3

16 S® Booms • Z® Booms Part No. 1268489GT

D 2.9 L4 Perkins Engine Models

Part No. 1268489GT S® Booms • Z® Booms 17

18 S® Booms • Z® Booms Part No. 1268489GT

854F-E34T Ford Engine Models

Part No. 1268489GT S® Booms • Z® Booms 19

Kubota Engine Models WG-972

20 S® Booms • Z® Booms Part No. 1268489GT