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Genie S-Booms Z-Booms Maintenance Manual 1268489 – PDF DOWNLOAD
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Description
Genie S-Booms Z-Booms Maintenance Manual 1268489 – PDF DOWNLOAD
Language : English
Pages : 184
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-Booms Z-Booms Maintenance Manual 1268489 – PDF DOWNLOAD
Front Cover..................................................................................................................... 1 Important Information........................................................................................................... 2 Models included in this manual.................................................................................................. 3 Identifying the Correct Procedure for your Model................................................................................ 5 Find additional Manuals for your Model.......................................................................................... 5 Revision History................................................................................................................ 6 General Safety Rules............................................................................................................ 8 Table of Contents............................................................................................................... 10 Specifications.................................................................................................................. 15 Performance Specifications.................................................................................................. 15 Function Speeds - S-100, S-105 and S-100HD.............................................................................. 15 Function Speeds - S-120, S-125 and S-120HD.............................................................................. 16 Function Speeds - All Other Models...................................................................................... 17 Drive Speeds............................................................................................................ 23 Torque Specifications....................................................................................................... 27 Tires and Wheels........................................................................................................ 27 TraX Torque Specifications.............................................................................................. 29 Engine Specifications....................................................................................................... 30 Engine Operator and Maintenance Manuals................................................................................. 30 Deutz Engine Models..................................................................................................... 31 Perkins Engine Models................................................................................................... 32 Ford Engine Models...................................................................................................... 34 Kubota Engine Models.................................................................................................... 35 GM Engine Models........................................................................................................ 36 Continental Engine Models............................................................................................... 36 Cummins Engine Models................................................................................................... 37 Hydraulic Specifications.................................................................................................... 38 Hydraulic Relief Valves................................................................................................. 38 Hydraulic and Drive Hub Fluid Capacities................................................................................ 41 Hydraulic Oil Specifications............................................................................................ 43 Hydraulic Hose and Fitting Torque Specifications........................................................................ 45 Torque Procedure........................................................................................................ 47 Maintenance Inspection Reports.................................................................................................. 51 Maintenance Schedule........................................................................................................ 51 Pre-Delivery Preparation Report............................................................................................. 52 Scheduled Maintenance Inspection Report - Quarterly or Frequent............................................................. 53 Scheduled Maintenance Inspection Report - Annual............................................................................ 54 Programmed Maintenance Inspection Report - Booms............................................................................ 55 Maintenance Procedures.......................................................................................................... 49 Introduction................................................................................................................ 49 Commissioning Procedures.................................................................................................... 56 C-1 Perform 50 Hour Service............................................................................................. 56 C-2 Perform Engine Maintenance – 50 Hours............................................................................... 56 C-3 Perform 150 Hour Service............................................................................................ 57 Quarterly Maintenance Procedures............................................................................................ 58 Q-1 Check for Open Bulletins and Owner Registration..................................................................... 58 Q-2 Battery inspection.................................................................................................. 59 Q-3 Inspect the Electrical Wiring....................................................................................... 61 Q-4 Inspect the Electrical Contactors - DC / Bi-Energy Models........................................................... 62 Q-5 Check the Exhaust System............................................................................................ 63 Q-6 Inspect the Tires, Wheels and Lug Nut Torque........................................................................ 64 Q-7 Check the Generator Belts and Pulleys, Bi-Energy Models............................................................. 64 Q-8 Check the Oscillate Directional Valve Linkage (if equipped)......................................................... 66 Q-9 Visual Inspection of the Hydraulic Oil.............................................................................. 66 Q-10 Inspect the Hydraulic Filters...................................................................................... 67 Q-11 Check and Adjust the Engine RPM.................................................................................... 68 Q-12 Test the Ground Control Override................................................................................... 74 Q-13 Test the Alarm Package (if equipped)............................................................................... 74 Q-14 Test the Emergency Power System.................................................................................... 75 Q-15 Test the Engine Idle Select - Engine Models........................................................................ 76 Q-16 Test the Fuel Select Operation - Gasoline/LPG Models............................................................... 77 Q-17 Inspect the Calibration Decal - ALC1000 Models..................................................................... 78 Q-18 Test the Recovery Mode System - ALC-1000 Models.................................................................... 79 Q-19 Test the Platform Self-leveling.................................................................................... 81 Q-20 Confirm the Proper Brake Configuration............................................................................. 81 Q-21 Test the Drive Brakes.............................................................................................. 82 Q-22 Test the Drive Speed – Stowed Position............................................................................. 82 Q-23 Test the Drive Speed - Raised or Extended Position................................................................. 83 Q-24 Test the Drive Speed – Raised and Extended, ALC1000 Models......................................................... 84 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.... 85 Q-26 Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70...................................................... 88 Q-27 Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70........................................................ 90 Q-28 Test the Primary Boom Angle Sensor - SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180............................... 92 Q-29 Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70, SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180..... 97 Q-30 Test the Primary Boom Angle Sensor - Z-80/60.......................................................................101 Q-31 Test the Safety Envelope and Circuits - Z-80/60....................................................................102 Q-32 Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000................104 Q-33 Test the Safety Envelope and Circuits - S-100, S-105, S-120, S-125, S-100HD and S--120HD...........................107 Q-34 Test the Aircraft Protection System (if equipped)..................................................................113 Q-35 Test the Operator Protection Alarm (if equipped)...................................................................115 Q-36 Inspect the Boom Extend/Retract Cables - All Models................................................................115 Q-37 Test the Recovery Mode System - ALC600 Models......................................................................116 Q-38 Test the Turntable Level Sensor - ALC600 Models....................................................................117 Q-39 Test the Primary Boom Angle Sensor - ALC600 Models.................................................................120 Annual Maintenance Procedures...............................................................................................122 A-1 Grease the Turntable Rotation Bearing and Rotate Gear...............................................................122 A-2 Check the Turntable Rotation Bearing Bolts..........................................................................123 A-3 Inspect for Turntable Bearing Wear..................................................................................125 A-4 Perform Maintenance - Jib Rotate Bearing............................................................................126 A-5 Test the Bypass/Recovery Key Switch - ALC1000 Models................................................................128 A-6 Grease the Platform Overload Mechanism (if equipped)................................................................130 A-7 Inspect the Boom Extend/Retract Cables and Sheaves - S-60/65, S-80/85 and S-80J Models..............................130 A-8 Inspect the Boom Extend/Retract Cables and Sheaves - S-100, S-105, S-120, S-125, SX-105XC and SX-125XC..............132 A-9 Inspect the Boom Extend and Retract Cables and Sheaves - SX-135XC, SX-150 and SX-180................................134 A-10 Check the Drive Hub Oil Level......................................................................................138 A-11 Check the Drive Hub Mounting Fastener Torque.......................................................................142 A-12 Perform Engine Maintenance.........................................................................................143 A-13 Perform Engine Maintenance.........................................................................................144 Programmed Maintenance Procedures...........................................................................................145 P0-1 Check the Track Tension and Fastener Torque, TraX Models - S-60, S-65, S-60 XC, S-65 XC, Z-62 Models...............145 P0-2 Check the Track Tension and Fastener Torque, TraX Models - S-40, S-45, S-40 XC, S-45 XC Models.....................146 P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125........................................................148 P0-4 Continental Engine Maintenance – Under 1000 Hours..................................................................149 P0-5 Cummins Engine Maintenance – Under 1000 Hours......................................................................150 P0-6 Deutz Engine Maintenance – Under 1000 Hours........................................................................151 P0-7 Ford Engine Maintenance – Under 1000 Hours.........................................................................152 P0-8 Kubota Engine Maintenance – Under 1000 Hours.......................................................................153 P0-9 Perkins Engine Maintenance – Under 1000 Hours......................................................................155 P0-10 GM .998L Engine Maintenance – Under 1000 Hours....................................................................156 P0-11 GM 3.0L Engine Maintenance – Under 1000 Hours.....................................................................157 P1-1 Perform Engine Maintenance – 1000 Hours............................................................................158 P1-2 Replace the Drive Hub Oil..........................................................................................160 P1-3 Perform Engine Maintenance – 1500 Hours............................................................................163 P2-1 Perform Engine Maintenance – 2000 Hours............................................................................163 P2-2 Test or Replace the Hydraulic Oil..................................................................................165 P2-3 Replace the Hydraulic Filters......................................................................................166 P2-4 Check the Free-wheel Configuration.................................................................................168 P2-5 Check the Boom Wear Pads...........................................................................................170 P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD..............................173 P2-7 Check the Turntable Rotation Gear Backlash.........................................................................173 P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62.......................174 P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models - S-60, S-65, Z-60 DC/FE and Z-62.................................176 P3-1 Perform Engine Maintenance – 3000 Hours............................................................................177 P4-1 Perform Engine Maintenance – 4000 Hours............................................................................179 P5-1 Perform Engine Maintenance – 5000 Hours............................................................................179 P6-1 Perform Engine Maintenance – 6000 Hours............................................................................180 P12-1 Perform Engine Maintenance – 12000 Hours..........................................................................180 P12-2 Remove and Inspect the Boom Extend/Retract Cables.................................................................181 Cable Replacement Criteria..........................................................................................183 Back Cover......................................................................................................................184
S.S 04/24
