September 2023 Maintenance Manual

Maintenance Procedures

Maintenance Schedule
Maintenanc e Schedul e

Programmed Example (under 1000 HRS):

The maintenance procedures have been divided
into subsections that include: Commissioning,
Quarterly, Annually and Programmed maintenance
intervals. The maintenance inspection report has
been divided into general areas of the machine
that include: Drive Chassis, Booms and Platform,
Functions and Controls, Engine and Turntable.
Programmed Example:
Failure to perform these procedures may result in
poor performance, component damage and unsafe
operating conditions. They are essential to safe
operation, machine performance and service life.
Commissioning: A series of required one time
maintenance procedures to be performed at Instructions Legend
50 and 150 hour intervals. Use the following detailed descriptions to identify
the intended use of the maintenance inspection
Quarterly and Annually: A series of maintenance reports.
procedures to be performed quarterly or annually.
Specific Interval: blank box is the interval to
Programmed: A series of maintenance
procedures to be performed during a Pre-Delivery be completed and the ∅ marks the interval
Preparation or based on machine operating hours. as not required.

The description of the procedure or

Maintenance Inspection Report checklist to be completed.
The maintenance inspection report contains
checklists for each type of scheduled inspection. The procedure number or checklist to be
completed.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed Check box to indicate status of inspection.
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements. Specific interval is not required for this
procedure.
Instruction Examples
General area of the machine to complete
Commissioning Example: the procedure.

If this box has a designated time interval:

this is the specific time interval to complete
the procedure or checklist.
Quarterly and Annually Example:
If this box is empty: the maintenance
checklist will include multiple time intervals,
use this box to write in the specific interval
for the inspection completed.

Part No. 1268489GT S® Booms • Z® Booms 37

Maintenance Manual September 2023

Pre-Delivery Preparation Report

Fundamentals Instructions
Pre-Deliv ery Prepar ati on Repor t

It is the responsibility of the owner or dealer to Use the operator’s manual on your machine.
perform the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the
each delivery. The inspection is designed to Maintenance items and the Function Tests.
discover if anything is apparently wrong with a
machine before it is put into service. Use this form to record the results. Place a check
in the appropriate box after each part is
A damaged or modified machine must never be completed. Follow the instructions in the operator’s
used. If damage or any variation from factory manual.
delivered condition is discovered, the machine
must be tagged and removed from service. If any inspection receives an N, remove the
machine from service, repair and re-inspect it.
Repairs to the machine may only be made by a After repair, place a check in the R box.
qualified service technician, according to the
manufacturer's specifications. Legend
Y = yes, acceptable
Scheduled maintenance inspections shall be N = no, remove from service
performed by qualified service technicians, R = repaired
according to the manufacturer's specifications and Comments
the requirements listed in the responsibilities
manual.

Pre-delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items completed
Function tests completed

Model

Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
 Scheduled - Quarterly September 2023

Maintenance Inspection Report – Booms

Schedul ed Mai ntenance Inspec tion R eport - Quarterly or Frequent

Model Hour meter Date

Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Inspection Type Legend Y = yes, N = no, remove from service Make copies of this report to use for each
Q = quarterly or frequent acceptable inspection.
inspections Select the appropriate procedures for the type of
R = repaired ∅ = not applicable inspection(s) to perform.
If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a "R" in the box.

Drive Chassis  Functions and Controls, continued 

Test the Drive Brakes Q-21

Inspect the Tires, Wheels and Lug Nut Torque Q-6
Check the Oscillate Valve Linkage (if equipped) Q-8 Test the Drive Speed – Stowed Position Q-22

Confirm the Proper Brake Configuration Q-20 Test the Drive Speed – Raised or Extended Position Q-23

Turntable Mechanicals and Hydraulics Test the Drive Speed – Raised and Extended Position - Q-24
ALC1000 Models
Visual Inspection of the Hydraulic Oil Q-9 Test the Turntable Level Sensor - Z-135/70, ZX-135/70, Q-25
SX-105XC, SX-125XC, SX-135XC, SX-150, SX-180
Inspect the Hydraulic Filters Q-10
Electrical Test the Secondary Boom Angle Sensor - Z-135/70, ZX- Q-26
135/70

Inspect Electrical Contactors - DC / Bi-Energy Models Q-4 Test the Primary Boom Angle Sensor - Z-135/70 and ZX- Q-27
135/70

Battery Inspection Q-2 Test the Primary Boom Angle Sensor - Q-28
SX-105XC, SX-125XC, SX-135XC, SX-150, SX-180
Inspect the Electrical Wiring Q-3
Test the Safety Envelope Limit Switches - Z-135/70, ZX- Q-29
Engine 135/70, SX-105XC, SX-125XC, SX-135XC, SX-150, SX-
180
Check the Exhaust System Q-5
Test the Primary Boom Angle Sensor - Z-80/60 Q-30
Check Generator Belts/Pulleys - Bi-Energy Models Q-7

Check and Adjust the Engine RPM Q-11 Test the Safety Envelope and Circuits - Z-80/60 Q-31

Boom(s) and Platform Check the Safety Envelope Limit Switches and Angle Q-32
Inspect and Adjust Boom Cables - All Models Q-36 Sensor - S-60X, S-80X, to S60XCH-45000
(for first 12 months of ownership)
Test the Safety Envelope and Circuits - S-100, S-105, S- Q-33
Functions and Controls  120, S-125

Test the Aircraft Protection System (if equipped) Q-34

Check for Open Bulletins and Owner Registration Q-1
Test the Ground Control Override Q-12 Test the Operator Protection Alarm (if equipped) Q-35

Test the Alarm Package (if equipped) Q-13 Test the Recovery System - ALC600 Models Q-37

Test the Emergency Power System Q-14 Test the Turntable Level Sensor - ALC600 Models Q-38
Test the Engine Idle Select Operation Q-15 Test the Primary Boom Angle Sensor - ALC600 Models Q-39
Test Fuel Select Operation - Gas/LPG Models Q-16
Inspect the Calibration Decal - ALC1000 Models Q-17
Test the Recovery System - ALC-1000 Models Q-18
Test the Platform Self-leveling Q-19

Part No. 1268489GT S® Booms • Z® Booms Maintenance Manual 39

 Scheduled - Annual September 2023

Maintenance Inspection Report – Booms

Schedul ed Mai ntenance Inspec tion R eport - Annual

Model Hour meter Date

Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Inspection Type Legend Y = yes, acceptable N = no, remove from service Make copies of this report to use for each inspection.
A = annual inspections Select the appropriate procedures for the type of
R = repaired ∅ = not applicable inspection(s) to perform.

If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a "R" in the box.

Confirm all applicable quarterly maintenance Confirm all applicable quarterly and annual
procedures have been included and completed with maintenance procedures have been included and
the annual inspection. completed with the 2 year inspection.
Drive Chassis  Perform Every 2 Years
Check the Drive Hub Oil Level A-10 Engines 
Check the Drive Hub Mounting Fastener Torque A-11 Perform Engine Maintenance - Kubota D1803 A-13

Turntable Mechanicals and Hydraulics

Grease the Turntable Rotation Bearing A-1
Check Turntable Bearing Bolts A-2
Inspect for Turntable Bearing Wear A-3

Boom(s) and Platform

Jib Rotate Bearing (if equipped) A-4
Grease the Platform Overload Mechanism A-6

Inspect Boom Cables - All S-60, S-80 Models A-7

Inspect Boom Cables - S-100 to S-125, S-100HD, S- A-8
120HD, SX-105XC, SX-125XC
Inspect Boom Cables - SX-135XC, SX-150, SX-180 A-9

Functions and Controls

Test the Bypass/Recovery Key Switch A-5

Engines
Perform Engine Maintenance - Kubota D1803 A-12

40 S® Booms • Z® Booms Maintenance Manual Part No. 1268489GT

 Programmed September 2023

Maintenance Inspection Report – Booms

Programm ed M ai ntenance Inspecti on Report - Booms

Model Hour meter Date

Serial number Inspector company Machine owner
Inspected by (print) Inspector signature
Programmed maintenance will be completed based on machine Legend Make copies of this report to use for each
hours. This program includes the onetime or commissioning Y = yes, acceptable inspection.
procedures for new products. N = no, remove from Select the appropriate procedures for the type
The onetime procedures will be completed at 50 or 150 hours. service of inspection(s) to perform.
R = repaired
∅ = not applicable
If any inspection receives an "N," tag and remove the machine from service, repair and re-inspect it. After repair, place a "R" in the box.

Commissioning 50 150 Programmed Maintenance Hours are in thousands

50 Hour Service - all models C-1 ∅

All models Perform every: 1 2 3 4 5 6 12
Engines - Ford, Kubota, Perkins Models C-2 ∅
Engines - all models, 1000 Hours P1-1 ∅ ∅ ∅ ∅ ∅ ∅
Perform 150 Hour Service C-3 ∅
Replace the Drive Hub Oil P1-2 ∅ ∅ ∅ ∅ ∅ ∅
Programmed Maintenance - Under 1000 HRS Status Enter
Hours
Engines - Kubota D1803, 1500 P1-3 ∅ ∅ ∅ ∅ ∅ ∅
Check the Track Tension and Fastener Torque P0-1 50 Hours
- S-60, S-65 and Z-62 Models Engines - all models, 2000 Hours P2-1 ∅ ∅ ∅ ∅ ∅ ∅
Check the Track Tension and Fastener Torque P0-2 50
Test or Replace the Hydraulic Oil P2-2 ∅ ∅ ∅ ∅ ∅ ∅
- S-40 and S-45 Models
Grease the Extendable Axles - (if equipped) P0-3 50 Replace the Hydraulic Filters P2-3 ∅ ∅ ∅ ∅ ∅ ∅

Engines - Continental Under 1000 HRS P0-4 Check the Free-wheel P2-4 ∅ ∅ ∅ ∅ ∅ ∅
Configuration
Engines - Cummins Under 1000 HRS P0-5
Check the Boom Wear Pads P2-5 ∅ ∅ ∅ ∅ ∅ ∅
Engines - Deutz Under 1000 HRS P0-6
Check the Extendable Axle Wear P2-6 ∅ ∅ ∅ ∅ ∅ ∅
Engines - Ford Under 1000 HRS P0-7 Pads

Engines - Kubota Under 1000 HRS P0-8 Check Turntable Gear Backlash - P2-7 ∅ ∅ ∅ ∅ ∅ ∅
ALC1000 Models
Engines - Perkins Under 1000 HRS P0-9
Grease the Steer Axle Wheel P2-8 ∅ ∅ ∅ ∅ ∅ ∅
Engines - GM .998L Under 1000 HRS P0- Bearings, 2WD Models (except Z-
10 62, S-60, S-65)
Engines - GM 3.0L Under 1000 HRS P0- Grease the Steer Axle Wheel P2-9 ∅ ∅ ∅ ∅ ∅ ∅
11 Bearings, 2WD Models - Z-62, S-
60, S-65
Engines - all models, 3000 Hours P3-1 ∅ ∅ ∅ ∅ ∅ ∅
Engines - Perkins models, 4000 P4-1 ∅ ∅ ∅ ∅ ∅ ∅
Hours
Engines - GM models, 5000 Hours P5-1 ∅ ∅ ∅ ∅ ∅ ∅
Engines - Perkins models, 6000 P6-1 ∅ ∅ ∅ ∅ ∅ ∅
Hours
Engines - Perkins models, 12000 P12-1 ∅ ∅ ∅ ∅ ∅ ∅
Hours
Remove and Inspect Boom cables P12-2 every 12 years
or
every 3 years after
first 12 years if not
replaced

Part No. 1268489GT S® Booms • Z® Booms Maintenance Manual 41