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Z-45 XC
Genie Z-45 XC Maintenance Manual
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Maintenance Manual
-
Booms
S
®
Booms
This m
anual
inclu
des d
etai
led
procedures for e
ach
maintenance inspection.
Z
®
Booms
For Repair
procedures, Fault
Codes, Ele
ctrical and Hydrauli
c
Schemat
ics, r
efer to t
h
e
appropriate Service and Repair
Manual for your machine.
Refer to th
e insid
e cover f
or a list
of mode
ls
included in thi
s manual.
Part N
o. 1268489G
T
Rev F
1
April
201
8
2
Table of Contents
Table of Contents
9
Maintenance Procedures
42
Introduction
42
Maintenance Schedule
44
Pre-Delivery Preparation Report
45
Scheduled - Quarterly April 2018 Maintenance Inspection Report - Booms
46
Scheduled Maintenance Inspection Report - Quarterly or Frequent
46
Scheduled Maintenance Inspection Report - Annual
47
Programmed Maintenance Inspection Report - Booms
48
Commissioning Procedures
49
Perform 50 Hour Service
49
Perform Engine Maintenance - 50 Hours
49
Perform 150 Hour Service
50
Check for Open Bulletins and Owner Registration
51
Quarterly Maintenance Procedures
51
Battery Inspection
52
Inspect the Electrical Wiring
54
Inspect the Electrical Contactor - DC / Bi-Energy Models
55
Check the Exhaust System
56
Inspect the Tires, Wheels and Lug Nut Torque
56
Check the Generator Belts and Pulleys, Bi-Energy Models
57
Check the Oscillate Directional Valve Linkage (if Equipped)
58
Visual Inspection of the Hydraulic Oil
59
Inspect the Hydraulic Filters
60
Check and Adjust the Engine RPM
61
Test the Ground Control Override
66
Test the Alarm Package (if Equipped
67
Test the Alarm Package (if Equipped)
67
Test the Emergency Power System
68
Test the Engine Idle Select - Engine Models
68
Test the Engine Idle Select Operation
68
Test the Fuel Select Operation - Gasoline/Lpg Models
70
Inspect the Calibration Decal - ALC1000 Models
71
Test the Recovery Mode System - ALC-1000 Models
72
Test the Recovery System - ALC-1000 Models
72
Test the Platform Self-Leveling
73
Confirm the Proper Brake Configuration
74
Test the Drive Brakes
74
Test the Drive Speed - Raised or Extended Position
75
Test the Drive Speed - Stowed Position
75
Test the Drive Speed - Raised and Extended Position
76
Test the Drive Speed - Raised and Extended, ALC1000 Models
76
Test the Turntable Level Sensor
78
XC, SX-125 XC, SX-135 XC, SX-150 and SX-180
78
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
80
Test the Turntable Level Sensor
81
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
82
Test the Secondary Boom Angle Sensor
82
Test the Primary Boom Angle Sensor
85
XC, SX-125 XC, SX-135 XC, SX-150 and SX-180
85
Test the Safety Envelope Limit Switches
90
XC, SX-125 XC, SX-135 XC, SX-150 and SX-180
90
Test the Primary Boom Angle Sensor
94
Test the Primary Boom Angle Sensor - Z-80/60
94
Test the Safety Envelope and Circuits
95
Test the Safety Envelope and Circuits - Z-80/60
95
Check the Safety Envelope Limit Switches and Angle
97
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-60XC and S-80X
97
And S-125
99
Test the Safety Envelope and Circuits
99
Test the Aircraft Protection System (if Equipped
105
Test the Aircraft Protection System (if Equipped)
105
Inspect the Boom Extend/Retract Cables - All Models
107
Test the Operator Protection Alarm (if Equipped)
107
Test the Recovery Mode System - ALC-600 Models
108
Test the Turntable Level Sensor - S-80 XC and S-85 XC
109
Test the Primary Boom Angle Sensor - S-80 XC, S-85 XC
111
Annual Maintenance Procedures
113
Grease the Turntable Rotation Bearing and Rotate Gear
113
Check the Turntable Rotation Bearing Bolts
114
Inspect for Turntable Bearing Wear
115
Check the Extendable Axle - S-100, S-105, S-120 and S-125
116
Perform Maintenance- Jib Rotate Bearing
117
Test the Bypass/Recovery Key Switch - ALC1000 Models
118
Grease the Platform Overload Mechanism (if Equipped)
120
All Models, Except ALC1000 and S-60HC Models
121
Test the Platform Overload System
121
Test the Platform Overload System - ALC1000 Models
123
Test the Platform Load Sense System - S-60 HC
124
Inspect the Boom Extend/Retract Cables - S-60 and S-80 Models
125
Inspect the Boom Extend/Retract Cables - S-100, S-105, S-120, S-125, SX-105 XC and SX-125 XC
127
Inspect the Boom Extend and Retract Cables
129
XC, SX-150 and SX-180
129
Check the Drive Hub Oil Level and Fastener Torque
133
Test the Dual Capacity and Platform Overload System
135
Test the Dual Capacity and Platform Overload System - S-80 XC and SX-85 XC
135
XC, SX-125 XC and SX-135 XC
135
Z-45 XC Models
137
P0-1 Check the Track Tension and Fastener Torque, TRAX Models
140
Programmed Maintenance Procedures
140
S-60, S-65 and Z-62 Models
140
P0-2 Check the Track Tension and Fastener Torque, TRAX Models
141
S-40 and S-45 Models
141
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125
143
P0-4 Continental Engine Maintenance - under 1000 Hours
144
P0-5 Cummins Engine Maintenance - under 1000 Hours
145
P0-6 Deutz Engine Maintenance - under 1000 Hours
146
P0-7 Ford Engine Maintenance - under 1000 Hours
147
P0-8 Kubota Engine Maintenance - under 1000 Hours
148
P0-9 Perkins Engine Maintenance - under 1000 Hours
149
P0-10 GM .998L Engine Maintenance - under 1000 Hours
150
P0-11 GM 3.0L Engine Maintenance - under 1000 Hours
151
P1-1 Perform Engine Maintenance - 1000 Hours
152
P1-2 Replace the Drive Hub Oil
153
P2-1 Perform Engine Maintenance - 2000 Hours
156
P2-2 Test or Replace the Hydraulic Oil
158
P2-3 Replace the Hydraulic Filters
159
P2-4 Check the Free-Wheel Configuration
161
P2-5 Check the Boom Wear Pads
163
P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD
166
P2-7 Check the Turntable Rotation Gear Backlash
166
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62
167
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models - S-60, S-65, Z-60 DC/FE and Z-62
169
P3-1 Perform Engine Maintenance - 3000 Hours
170
P4-1 Perform Engine Maintenance - 4000 Hours
171
P5-1 Perform Engine Maintenance - 5000 Hours
172
P6-1 Perform Engine Maintenance - 6000 Hours
172
P12-1 Perform Engine Maintenance - 12000 Hours
173
P12-2 Remove and Inspect the Boom Extend/Retract Cables
173
Cable Replacement Criteria
176
Other manuals for Genie Z-45 XC
Service Manual
440 pages
Operating Manual
61 pages
Operator's Manual Supplement
7 pages
4
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Genie Z-45 XC Specifications
General
Weight
15, 400 lb (7, 000 kg)
Gradeability - 4WD
45%
Power Source
Diesel
Ground Clearance
12 in
Platform Dimensions
72 in x 30 in
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