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Genie Z6215A-101
Terex Genie Z6215A-101 Maintenance Manual
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Maintenan
ce M
anu
al
-
Boo
ms
S
®
Booms
This m
anua
l includes d
etailed
procedur
es f
or each
maintenance inspection.
Z
®
Booms
For Re
pair procedures, Faul
t
Codes,
Electr
ical and Hy
drau
lic
Schematics, r
efer to the
appr
opriate S
ervice and
Repair
Manual for your machine.
Refer to the inside cover for a list of models
included in th
is manual.
Par
t N
o.
1268489GT
Rev
J1
March
202
2
2
Table of Contents
Models Included in this Manual
3
Identifying the Correct Procedure for Your Model
5
Find Additional Manuals for Your Model
5
Revision History
6
Safety Rules
8
Table of Contents
10
Performance Specifications
17
Function Speeds - S-100, S-105 and S-100HD
17
Function Speeds - S-120, S-125 and S-120HD
18
Function Speeds - All Other Models
19
Drive Speeds
25
Torque Specifications
29
Tires and Wheels
29
Trax Torque Specifications
31
Engine Specifications
32
Engine Operator and Maintenance Manuals
32
Deutz Engine Models
33
Perkins Engine Models
34
Ford Engine Models
36
Kubota Engine Models
37
GM Engine Models
38
Continental Engine Models
38
Cummins Engine Models
39
Hydraulic Specifications
40
Hydraulic Relief Valves
40
Hydraulic and Drive Hub Fluid Capacities
43
Hydraulic Oil Specifications
45
Hydraulic Hose and Fitting Torque Specifications
48
Torque Procedure
49
Maintenance Procedures
51
Introduction
51
Maintenance Schedule
53
Pre-Delivery Preparation Report
54
Scheduled Maintenance Inspection Report - Quarterly or Frequent
55
Scheduled Maintenance Inspection Report - Annual
56
Programmed Maintenance Inspection Report - Booms
57
Commissioning Procedures
58
Perform 50 Hour Service
58
Perform Engine Maintenance - 50 Hours
58
Perform 150 Hour Service
59
Quarterly Maintenance Procedures
60
Check for Open Bulletins and Owner Registration
60
Battery Inspection
61
Inspect the Electrical Wiring
63
Inspect the Electrical Contactors - DC / Bi-Energy Models
64
Check the Exhaust System
65
Inspect the Tires, Wheels and Lug Nut Torque
66
Check the Generator Belts and Pulleys, Bi-Energy Models
66
Check the Oscillate Directional Valve Linkage (if Equipped)
68
Visual Inspection of the Hydraulic Oil
68
Inspect the Hydraulic Filters
69
Check and Adjust the Engine RPM
70
Test the Ground Control Override
76
Test the Alarm Package (if Equipped)
76
Test the Emergency Power System
77
Test the Engine Idle Select - Engine Models
78
Test the Fuel Select Operation - Gasoline/Lpg Models
79
Inspect the Calibration Decal - ALC1000 Models
81
Test the Recovery Mode System - ALC-1000 Models
82
Test the Platform Self-Leveling
83
Confirm the Proper Brake Configuration
84
Test the Drive Brakes
84
Test the Drive Speed - Stowed Position
85
Test the Drive Speed - Raised or Extended Position
85
Test the Drive Speed - Raised and Extended, ALC1000 Models
86
Test the Turntable Level Sensor
88
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
88
Test the Secondary Boom Angle Sensor - Z-135/70 and ZX-135/70
90
Test the Primary Boom Angle Sensor - Z-135/70 and ZX-135/70
92
Test the Primary Boom Angle Sensor
95
SX-105XC, SX-125XC, SX-135XC, SX-150 and SX-180
95
Test the Safety Envelope Limit Switches - Z-135/70, ZX-135/70
100
Test the Primary Boom Angle Sensor - Z-80/60
104
Test the Safety Envelope and Circuits - Z-80/60
105
Check the Safety Envelope Limit Switches and Angle Sensor - S-60X, S-80X, and S-60XC to S60XC-45000
107
Test the Safety Envelope and Circuits
109
And S-125
109
Test the Aircraft Protection System (if Equipped)
115
Test the Operator Protection Alarm (if Equipped)
117
Inspect the Boom Extend/Retract Cables - All Models
117
Test the Recovery Mode System - ALC600 Models
119
Test the Turntable Level Sensor - ALC600 Models
120
Test the Primary Boom Angle Sensor - ALC600 Models
122
Annual Maintenance Procedures
124
Grease the Turntable Rotation Bearing and Rotate Gear
124
Check the Turntable Rotation Bearing Bolts
125
Inspect for Turntable Bearing Wear
127
Check the Extendable Axle - S-100, S-105, S-120 and S-125
128
Perform Maintenance- Jib Rotate Bearing
129
Test the Bypass/Recovery Key Switch - ALC1000 Models
130
Grease the Platform Overload Mechanism (if Equipped)
133
Test the Platform Overload System - (if Equipped)
133
Test the Platform Overload System - ALC1000 Models
135
Test the Platform Load Sense System - S-60 HC
137
S-60/65, S-80/85 and S-80J Models
138
Inspect the Boom Extend/Retract Cables and Sheaves
139
Inspect the Boom Extend/Retract Cables and Sheaves
141
S-100, S-105, S-120, S-125, SX-105XC and SX-125XC
141
Inspect the Boom Extend and Retract Cables and Sheaves -
143
Check the Drive Hub Oil Level and Fastener Torque
146
Test the Dual Capacity and Platform Overload System - SX-105XC, SX-125XC and SX-135XC
150
Test the Dual Capacity and Platform Overload System - Z-45XC Models
152
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-85XC
154
Test the Platform Overload System - S-40HF, S-45HF, S-60J
156
S-80J, Z-45HF, Z-45 DC/FE from Z45EM-101
156
Perform Engine Maintenance
158
Programmed Maintenance Procedures
159
P0-1 Check the Track Tension and Fastener Torque, Trax Models
159
XC, S-65 XC, Z-62 Models
159
P0-2 Check the Track Tension and Fastener Torque, Trax Models - S-40, S-45, S-40 XC, S-45 XC Models
160
P0-3 Grease the Extendable Axles - S-100, S-105, S-120 and S-125
162
P0-4 Continental Engine Maintenance - under 1000 Hours
163
P0-5 Cummins Engine Maintenance - under 1000 Hours
164
P0-6 Deutz Engine Maintenance - under 1000 Hours
165
P0-7 Ford Engine Maintenance - under 1000 Hours
166
P0-8 Kubota Engine Maintenance - under 1000 Hours
167
P0-9 Perkins Engine Maintenance - under 1000 Hours
169
P0-10 GM .998L Engine Maintenance - under 1000 Hours
170
P0-11 GM 3.0L Engine Maintenance - under 1000 Hours
171
P1-1 Perform Engine Maintenance - 1000 Hours
172
P1-2 Replace the Drive Hub Oil
174
P1-3 Perform Engine Maintenance - 1500 Hours
177
P2-1 Perform Engine Maintenance - 2000 Hours
177
P2-2 Test or Replace the Hydraulic Oil
179
P2-3 Replace the Hydraulic Filters
180
P2-4 Check the Free-Wheel Configuration
182
P2-5 Check the Boom Wear Pads
184
P2-6 Check the Extendable Axle Wear Pads - S-100, S-105, S-120, S-125, S-100HD and S-120HD
187
P2-7 Check the Turntable Rotation Gear Backlash
187
P2-8 Grease the Steer Axle Wheel Bearings, All 2WD Models, Except S-60, S-65, Z-60 DC/FE and Z-62
188
P2-9 Grease the Steer Axle Wheel Bearings, 2WD Models
190
DC/FE and Z-62
190
Other manuals for Terex Genie Z6215A-101
Operator's Manual
79 pages
Manual
12 pages
4
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Terex Genie Z6215A-101 Specifications
General
Brand
Terex
Model
Genie Z6215A-101
Category
Boom Lifts
Language
English
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