Terex Genie S-40 User Manual (English)

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Maintenance Manual

- Booms

Booms

This manual includes detailed

procedures for each

maintenance inspection.

Booms

For Repair procedures, Fault

Codes,

Electrical and Hydraulic

Schematics, refer to the

appropriate Service and Repair

Manual for your machine.

Refer to the inside cover for a list of models

included in this manual.

Part No.

1268489GT

Rev

March 2022

Models Included in this Manual3
Identifying the Correct Procedure for Your Model5
Find Additional Manuals for Your Model5
Revision History6
Safety Rules8
Table of Contents10
Performance Specifications17
Function Speeds - S-100, S-105 and S-100HD17
Function Speeds - S-120, S-125 and S-120HD18
Function Speeds - All Other Models19
Drive Speeds25
Torque Specifications29
Tires and Wheels29
Trax Torque Specifications31
Engine Specifications32
Engine Operator and Maintenance Manuals32
Deutz Engine Models33
Perkins Engine Models34
Ford Engine Models36
Kubota Engine Models37
GM Engine Models38
Continental Engine Models38
Cummins Engine Models39
Hydraulic Specifications40
Hydraulic Relief Valves40
Hydraulic and Drive Hub Fluid Capacities43
Hydraulic Oil Specifications45
Hydraulic Hose and Fitting Torque Specifications48
Torque Procedure49
Maintenance Procedures51
Introduction51
Maintenance Schedule53
Pre-Delivery Preparation Report54
Scheduled Maintenance Inspection Report - Quarterly or Frequent55
Scheduled Maintenance Inspection Report - Annual56
Programmed Maintenance Inspection Report - Booms57
Commissioning Procedures58
Perform 50 Hour Service58
Perform Engine Maintenance - 50 Hours58
Perform 150 Hour Service59
Quarterly Maintenance Procedures60
Check for Open Bulletins and Owner Registration60
Battery Inspection61
Inspect the Electrical Wiring63
Inspect the Electrical Contactors - DC / Bi-Energy Models64
Check the Exhaust System65
Inspect the Tires, Wheels and Lug Nut Torque66
Check the Generator Belts and Pulleys, Bi-Energy Models66
Check the Oscillate Directional Valve Linkage (if Equipped)68
Visual Inspection of the Hydraulic Oil68
Inspect the Hydraulic Filters69
Check and Adjust the Engine RPM70
Test the Ground Control Override76
Test the Alarm Package (if Equipped)76
Test the Emergency Power System77
Test the Engine Idle Select - Engine Models78
Test the Fuel Select Operation - Gasoline/Lpg Models79
Inspect the Calibration Decal - ALC1000 Models81
Test the Recovery Mode System - ALC-1000 Models82
Test the Platform Self-Leveling83
Confirm the Proper Brake Configuration84
Test the Drive Brakes84
Test the Drive Speed - Stowed Position85
Test the Drive Speed - Raised or Extended Position85
Test the Drive Speed - Raised and Extended, ALC1000 Models86
Test the Turntable Level Sensor88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-18088
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/7090
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/7092
Test the Primary Boom Angle Sensor95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-18095
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70100
Test the Primary Boom Angle Sensor - Z-80/60104
Test the Safety Envelope and Circuits - Z-80/60105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000107
Test the Safety Envelope and Circuits109
And S-125109
Test the Aircraft Protection System (if Equipped)115
Test the Operator Protection Alarm (if Equipped)117
Inspect the Boom Extend/Retract Cables - All Models117
Test the Recovery Mode System - ALC600 Models119
Test the Turntable Level Sensor - ALC600 Models120
Test the Primary Boom Angle Sensor - ALC600 Models122
Annual Maintenance Procedures124
Grease the Turntable Rotation Bearing and Rotate Gear124
Check the Turntable Rotation Bearing Bolts125
Inspect for Turntable Bearing Wear127
Check the Extendable Axle - S-100, S-105, S-120 and S-125128
Perform Maintenance- Jib Rotate Bearing129
Test the Bypass/Recovery Key Switch - ALC1000 Models130
Grease the Platform Overload Mechanism (if Equipped)133
Test the Platform Overload System - (if Equipped)133
Test the Platform Overload System - ALC1000 Models135
Test the Platform Load Sense System - S-60 HC137
S-60/65, S-80/85 and S-80J Models138
Inspect the Boom Extend/Retract Cables and Sheaves139
Inspect the Boom Extend/Retract Cables and Sheaves141
S-100, S-105, S-120, S-125, SX-105XC and SX-125XC141
Inspect the Boom Extend and Retract Cables and Sheaves -143
Check the Drive Hub Oil Level and Fastener Torque146
Test the Dual Capacity and Platform Overload System - SX-105XC, SX-125XC and SX-135XC150
Test the Dual Capacity and Platform Overload System - Z-45XC Models152
Test the Dual Capacity and Platform Overload System - S-40XC, S-45XC, S-60HF, S-65HF, S-60XC from S60XCH-45001, S-65XC, S-80HF, S-85HF, S-80XC, S-85XC154
Test the Platform Overload System - S-40HF, S-45HF, S-60J156
S-80J, Z-45HF, Z-45 DC/FE from Z45EM-101156
Perform Engine Maintenance158
Programmed Maintenance Procedures159
P0-1 Check the Track Tension and Fastener Torque, Trax Models159
XC, S-65 XC, Z-62 Models159
P0-2 Check the Track Tension and Fastener Torque, Trax Models - S-40, S-45, S-40 XC, S-45 XC Models160
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125162
P0-4 Continental Engine Maintenance - under 1000 Hours163
P0-5 Cummins Engine Maintenance - under 1000 Hours164
P0-6 Deutz Engine Maintenance - under 1000 Hours165
P0-7 Ford Engine Maintenance - under 1000 Hours166
P0-8 Kubota Engine Maintenance - under 1000 Hours167
P0-9 Perkins Engine Maintenance - under 1000 Hours169
P0-10 GM .998L Engine Maintenance - under 1000 Hours170
P0-11 GM 3.0L Engine Maintenance - under 1000 Hours171
P1-1 Perform Engine Maintenance - 1000 Hours172
P1-2 Replace the Drive Hub Oil174
P1-3 Perform Engine Maintenance - 1500 Hours177
P2-1 Perform Engine Maintenance - 2000 Hours177
P2-2 Test or Replace the Hydraulic Oil179
P2-3 Replace the Hydraulic Filters180
P2-4 Check the Free-Wheel Configuration182
P2-5 Check the Boom Wear Pads184
P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD187
P2-7 Check the Turntable Rotation Gear Backlash187
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62188
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models190
DC/FE and Z-62190

Turntable Rotation	360° Continuous
Fuel Type	Diesel
Platform Capacity	227 kg
Drive Speed	4.8 km/h
Turning Radius (Outside)	4.57 m

Terex Genie S-40 Maintenance Manual

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