Terex Genie Lift Guard S-45 Bedienungsanleitung

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

included in this manual.

Original

Instructions

Part No. 1268489GT

Rev J2

June 2022

Maintenance Manual June 2022

Introduction

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

Intro ductio n Intro ductio n

Important

Read, understand and obey the safety rules

and operating instructions in the appropriate

Operator's Manual on your machine before

attempting any maintenance procedure.

This manual provides detailed scheduled

maintenance information for the machine

owner and user.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require

specialized skills, tools, lifting equipment and a

suitable workshop. In these instances, we

strongly recommend that maintenance be

performed at an authorized Genie dealer

service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection

and scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However,

continuous improvement of our products is a

Genie policy. Therefore, product specifications

are subject to change without notice.

Readers are encouraged to notify Genie of

errors and send in suggestions for

improvement. All communications will be

carefully considered for future printings of this

and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

1268489GT Rev J, May 2020

First Edition, Ninth Printing

Genie, "S" and "Z" are registered trademarks of Terex

South Dakota, Inc. in the U.S.A. and many other

countries.

"TraX" and "XC" are trademarks of Terex South Dakota,

Inc.

June 2022 Maintenance Manual

Introduction

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

Models included in this

manual

Use the following chart to identify the specific

serial number for models included in this

manual.

Models

Serial number

-40, S-45, S

40HF, S

45HF,

-40XC,

-45XC

from S4015-20505 to S4016H-23499

from S4515-20505 to S4516H-23499

from S40H-23500 from S45H-23500

from S40XCH-101

from S45XCH-101

-60, S-65, S

60HF, S

65HF, S

-60J,

-60X, S-

60XC, S

65XC

from S6013-26296 to S6016-31260

from S6016N-31261 to S6016N-35000

from S6016H-35001 to S6016H-36399

from S6014D-101 to S6016D-639

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

-80, S-85, S

80X, S

80XC,

-85XC, S-

80HF, S

85HF, S

-80J

from S80/85/80X15-12264 to16H-13999

from S80/85/80X15D-101 to 16D-339

from S80/85/80XH-14000

from S80/85/80XD-340

from S80/85XCH-101

from S80JH-101

-100, S-105 from S10015D-1001 to S10016D-1549

from S10515D-983 to S10516D-1549

from S100D-1550

from S105D-1550

-120, S-125 from S12015D-1012 to S12016D-1549

from S12515D-984 to S12516D-1549

from S120D-1550

from S125D-1550

-100HD,

-120HD

from S100HD14D-200 to S100HD16D-

229

from S120HD14D-201 to S120HD16D-

229

from S100/S120HDD-230

-105 XC from SX105D-101

-125 XC from SX125D-101

-135 XC from SX135H-101

-150 from SX15015-100 to SX15016H-499

from SX150H-500

-180 from SX18014-101 to SX18016H-599

from SX180H-600

Maintenance Manual June 2022

Introduction

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

-30/20N, Z-

30/20N RJ

from Z30N14-15222 to Z30N16F-18899

from Z30N16D-104 to Z30N16D-199

from Z30NF-18900

from Z30ND-200

-33/18 from Z331815M-101 to Z331816M-1299

from Z3318M-1300

-34/22 DC from Z3414-9686 to Z3416F-11999

from Z34F-12000

-34/22 N from Z34N14-10984 to Z34N16F-13999

from Z34N15D-102 to Z34N16D-279

from Z34NF-14000

from Z34ND-280

-34/22 IC from Z3406-4800 to Z3413-9460

from Z3413-9461 to Z3415-10688

from Z3416F-10689 to Z3416F-11999

from Z34F-12000

-34/22 BE from Z3414-9686 to Z3416F-11999

from Z34F-12000

-40/23N RJ from Z40N13-1902 to Z40N16N-4499

from Z40NN-4500

-45/25 DC,

-45/25J DC

from Z452513A-48153 to Z452516N-

57199

from Z452513B-3078 to Z452516M-6699

from Z452513D-101 to Z452516D-939

from Z4525D-940

from Z4525M-6700

from Z4525N-57200 to Z4525N-58604

from Z4525F-58605

-45/25 IC, Z-

45/25J IC, Z

45HF, Z

45XC

from Z452513A-47001 to Z452516N-

57199

from Z452514B-3301 to Z452516M-6699

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

-45/25(J) BE

from Z452513A-48153 to Z452516N-

57199

from Z4525N-57200 to Z4525N-58604

from Z4525F-58605

from Z4525M-6700

-45 DC, Z-

45 FE

from Z45EM-101

-51/30J from Z513014B-1201 to Z5130M-2000

from Z5130M-2000

-60/37 DC,

-60/37 FE

from Z6016N-101 to Z6016N-599

from Z60N-600 to Z60N-700

from Z60H-701

-62/40 from Z6215A-101 to Z6216N-2999

from Z6216D-101 to Z6216D-149

from Z6216M-101 to Z6216M-399

from Z62D-150

from Z62H-3000

from Z62M-400

-80/60 from Z8013-4592 to Z8016H-6399

from Z80H-6400

-135/70 from Z13505-101 to Z13513-2000

-135/70 from ZX13514-2533 to ZX13516H-3199

(includes 2463, 2469, 2531)

from ZX135H-3200

June 2022 Maintenance Manual

Introduction

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

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-80J, 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.

Maintenance Manual June 2022

Introduction

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

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 the update.

Section – Maintenance, (procedure)

June 2022 Maintenance Manual

Introduction

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

Revision History (continued)

Revision Date Section Procedure / Description

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

J1 3/2022 All Sections Add S80J model

Annual A-8, A-9, A-15, A-16, A-17, A-18

J2 6/2022 Annual Remove A-4, A-8, A-9, A-10, A-15, A-16, A-17, A-18

Reference Examples:

Section – Specifications Electronic Version

Click on any content or procedure in the Table of Contents to view the update.

Section – Maintenance, (procedure)

Maintenance Manual June 2022

Safety Rules

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

Sec ti 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 modify or alter a MEWP without prior

written permission from the manufacturer.

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.

June 2022 Maintenance Manual

Safety Rules

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

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to

identify the following:

Safety alert symbol

—used to

alert personnel to potential

personal injury hazards. Obey all

safety messages that follow this

symbol to avoid possible injury or

death.

Indicates a imminently hazardous

situation which, if not avo

ided,

will result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or

moderate

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

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.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extingu

isher within easy

reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins an

d self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work

area

is properly ventilated and well lit.

June 2022

Table of Contents

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

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

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Terex Hubarbeitsbühne Handbücher

Terex

Terex S-60 J Installations- und Betriebsanleitung

Terex

Terex Gyro 4020 Bedienungsanleitung

Terex

Terex Genie Z-60 DC Bedienungsanleitung

Terex

Terex Z-33 Bedienungsanleitung

Terex

Terex SX15015-101 Bedienungsanleitung

Terex

Terex Genie Z-34 IC Installations- und Betriebsanleitung

Terex

Terex Genie GR-26J Bedienungsanleitung

Terex

Terex Genie Z-51/30J Bedienungsanleitung

Terex

Terex Genie Z-51/30 J Bedienungsanleitung

Terex

Terex Z-30/20N Bedienungsanleitung

Terex

Terex Genie Z4525XCM-2501 Bedienungsanleitung

Terex

Terex Genie Z-45 Bedienungsanleitung

Terex

Terex Genie Z-34/22 Installations- und Betriebsanleitung

Terex

Terex Genie ZX13515-2559 Bedienungsanleitung

Terex

Terex S8016D-236 Bedienungsanleitung

Terex

Terex Genie Z-80 Installations- und Betriebsanleitung

Terex

Terex Genie S-45XC Bedienungsanleitung

Terex

Terex Genie GS-3384 Bedienungsanleitung

Terex

Terex Genie Z-40/23N Installations- und Betriebsanleitung

Terex

Terex Genie Z-34/22N Bedienungsanleitung

Terex

Terex Genie GS-1930 Bedienungsanleitung

Terex

Terex Genie S-80 SC Bedienungsanleitung

Terex

Terex Genie ZX-135/70 Bedienungsanleitung

Terex

Terex Genie S-40XC Bedienungsanleitung

Beliebte Hubarbeitsbühne Handbücher anderer Marken

Genie

Genie Z-80 Bedienungsanleitung

Genie

Genie Z-45/25 Bedienungsanleitung

JLG

JLG Skytrak 6036 Gebrauchs- und Pflegehandbuch

LGMG

LGMG T65JE Bedienungsanleitung

Genie

Genie Z-135/70 Bedienungsanleitung

Oshkosh Corporation

Oshkosh Corporation JLG H800AJ Gebrauchs- und Pflegehandbuch

Oshkosh

Oshkosh JLG 1500SJ Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ30AJE Bedienungsanleitung

Oshkosh

Oshkosh JLG 800A Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ 46AJ Bedienungsanleitung

Molift

Molift Quick Raiser 205 Bedienungsanleitung

Snorkel

Snorkel SL26RTE Kurzanleitung

Oshkosh Corporation

Oshkosh Corporation JLG E300A Bedienungsanleitung

Skyjack

Skyjack SJ45 T+ Bedienungsanleitung

Genie

Genie S-105 Bedienungsanleitung

nifty

nifty 170SD series Montageanleitung

JLG

JLG 15MVL Series Bedienungsanleitung

Genie

Genie Z-45 XC Bedienungsanleitung