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Genie S-3200 S-3800 Service Manual 226055 – PDF DOWNLOAD
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Genie S-3200 S-3800 Service Manual 226055 – PDF DOWNLOAD
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Description
Genie S-3200 S-3800 Service Manual 226055 – PDF DOWNLOAD
Language : English
Pages : 260
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-3200 S-3800 Service Manual 226055 – PDF DOWNLOAD
Cover........................................................................ 1
Introduction................................................................. 2
Serial Number Legend......................................................... 3
Safety Rules................................................................. 5
Table of Contents............................................................ 7
Specifications............................................................... 17
Machine Specifications
S-3200/S-3800........................ 17
Performance Specifications S-3800 .................................. 18
Performance Specifications S-3200 .................................. 19
Hydraulic Oil Specifications............................................. 20
Hydraulic Oil Components................................................. 21
Deutz Engine TD2011L04i.................................................. 22
Cummins Engine B3.3T C80................................................. 24
Machine Torque Specifications............................................ 25
Hydraulic Hose and Fitting Torque Specifications......................... 25
SAE and Metric Fastener Torque Chart..................................... 27
Scheduled Maintenance Procedures............................................. 28
Maintenance Inspection Report............................................ 32
Checklist A Procedure.................................................... 34
A-1 Inspect the Manuals and Decals................................... 34
A-2 Perform Pre-operation Inspection................................. 35
A-3 Perform Function Tests........................................... 35
A-4 Perform Engine Maintenance- Cummins Models....................... 36
A-5 Check the Hydraulic Filter Condition Indicators.................. 36
A-6 Perform 30 Day Service........................................... 38
A-7 Perform Engine Maintenance- Deutz Models......................... 38
A-8 Grease the Extendable Axles...................................... 39
A-9 Grease the Turntable Rotation Bearing and Rotate Gear............ 39
A-10 Replace the Drive Hub Oil....................................... 41
Checklist B Procedures................................................... 42
B-1 Inspect the Batteries............................................ 42
B-2 Inspect the Electrical Wiring.................................... 43
B-3 Check the Engine Oil Cooler and Cooling Fins- Deutz Models....... 45
B-4 Inspect the Engine Air Filter.................................... 45
B-5 Perform Hydraulic Oil Analysis................................... 46
B-6 Perform Engine Maintenance- Deutz Models......................... 47
B-7 Perform Engine Maintenance- Cummins Models....................... 47
B-8 Check the Exhaust System......................................... 48
B-9 Inspect the Tires, Wheels and Lug Nut Torque..................... 49
B-10 Check the Drive Hub Oil Level and Fastener Torque............... 49
B-11 Confirm the Proper Brake Configuration.......................... 50
B-12 Check and Adjust the Engine RPM................................. 51
B-13 Test the Key Switches........................................... 54
B-14 Test the Ground Control Override................................ 55
B-15 Test the Platform Self-leveling................................. 56
B-16 Test the Safety Envelope and Circuits........................... 57
B-17 Inspect the Fuel and Hydraulic Tank Cap Venting Systems......... 63
B-18 Test the Engine Idle Select Operation........................... 64
B-19 Test the Drive Brakes........................................... 65
B-20 Test the Drive Speed- Stowed Position........................... 65
B-21 Test the Drive Speed- Raised or Extended Position............... 66
B-22 Inspect the Boom Extend/Retract Cables.......................... 67
Checklist C Procedures................................................... 68
C-1 Perform Engine Maintenance- Deutz Models......................... 68
C-2 Perform Engine Maintenance- Cummins Models....................... 68
C-3 Replace the Engine Air Filter Element............................ 69
C-4 Grease the Platform Overload Mechanism (if equipped)............. 69
C-5 Test the Platform Overload System (if equipped).................. 70
Checklist D Procedures................................................... 72
D-1 Check the Boom Wear Pads......................................... 72
D-2 Check the Extendable Axle Wear Pads.............................. 73
D-3 Check the Free-wheel Configuration............................... 73
D-4 Check the Turntable Rotation Bearing Bolts....................... 75
D-5 Check the Turntable Rotation Gear Backlash....................... 76
D-6 Replace the Drive Hub Oil........................................ 77
D-7 Inspect for Turntable Bearing Wear............................... 79
D-8 Perform Engine Maintenance- Deutz Models......................... 80
D-9 Perform Engine Maintenance- Perkins Models....................... 81
D-10 Replace the Hydraulic Filter Elements........................... 81
Checklist E Procedures................................................... 83
E-1 Test or Replace the Hydraulic Oil................................ 83
E-2 Perform Engine Maintenance- Cummins Models....................... 85
E-3 Perform Engine Maintenance- Deutz Models......................... 85
E-4 Perform Engine Maintenance- Deutz Models......................... 86
E-5 Perform Engine Maintenance- Deutz Models......................... 86
E-6 Perform Engine Maintenance- Deutz Models......................... 87
E-7 Replace the Boom Extend/Retract Cables........................... 87
Repair Procedures............................................................ 88
Display Module........................................................... 89
Platform Controls........................................................ 93
1-1 Circuit Boards
.................................................. 94
1-2 Membrane Decal................................................... 95
1-3 Joysticks........................................................ 96
Platform Components......................................................103
2-1 Platform
........................................................103
2-2 Platform Leveling Cylinder.......................................103
2-3 Platform Rotator.................................................105
Platform Level Sensor................................................106
Platform Overload System.............................................107
Boom Components..........................................................110
4-1 Cable Track......................................................111
4-2 Boom.............................................................114
4-3 Boom Lift Cylinder...............................................125
4-4 Extension Cylinders..............................................127
4-5 Boom Extend/Retract Cables.......................................131
Engines..................................................................135
6-1 RPM Adjustment...................................................135
6-2 Flex Plate.......................................................135
6-3 Oil Pressure and Coolant Sending Units- Cummins Models ..........137
6-4 Oil Pressure and Coolant sending Units- Deutz Models.............137
Ground Controls..........................................................138
7-1 Circuit Boards...................................................138
7-2 Membrane Decal...................................................139
7-3 Control Relays...................................................140
Limit Switches...........................................................142
8-1 Limit Switches...................................................143
8-2 Limit Switch and Level Sensor Locations..........................146
8-3 Limit Switch Functions...........................................147
Hydraulic Pumps..........................................................150
9-1 Function Pumps...................................................150
9-2 Drive Pump.......................................................151
9-3 Auxiliary Pump...................................................154
Manifolds................................................................156
10-1 Function Manifold, S-3200 Models................................156
10-2 Valve Adjustments- Function Manifold, S-3200 ...................160
10-3 Proportional Valves- Function Manifold..........................161
10-4 Function Manifold, S-3800 Models................................162
10-5 Valve Adjustments- Function Manifold, S-3800....................166
10-6 Proportional Valves- Function Manifold..........................167
10-7 Platform Manifold Components....................................168
10-8 Proportional Valves- Platform Manifolds.........................170
10-9 Platform Rotate Counterbalance Valve Manifold...................170
10-10 Turntable Rotation Manifold Components.........................171
10-11 Steer and Axle Extend/Retract Manifold
........................172
10-12 Valve Adjustments - Steer and Axle Extend/Retract Manifold
....174
10-13 Traction Manifold, 2WD.........................................175
10-14 Valve Adjustments- Traction Manifold...........................177
10-15 Valve Coils....................................................177
Fuel and Hydraulic Tanks.................................................180
11-1 Fuel Tank.......................................................180
11-2 Hydraulic Tank..................................................181
Turntable Rotation Components............................................183
12-1 Turntable Rotation Hydraulic Motor and Drive Hub................183
Axle Components..........................................................186
13-1 Steer Sensors...................................................186
13-2 Yoke and Hub....................................................187
13-3 Drive Motor.....................................................189
13-4 Drive Hub.......................................................190
Steering Cylinders...................................................190
13-6 Hub and Bearings, 2WD Models....................................191
13-7 Extendable Axles................................................193
Fault Codes..................................................................197
Schematics...................................................................207
Wire Circuit Legend......................................................208
Limit Switches...........................................................214
Relay Layout.............................................................216
Drive Chassis Controller Pin Legend......................................217
Platform Controller Pin Legend...........................................218
Turntable Controller Pin Legend..........................................219
Electrical Symbols Legend................................................220
Hydraulic Symbols Legend.................................................221
Electrical Schematics, S-3200 Models.....................................224
S-3200 ES- View 1....................................................224
S-3200 ES- View 2....................................................225
S-3200 ES- View 3....................................................228
S-3200 ES- View 4 ...................................................229
S-3200 ES- View 5, Deutz Engine......................................232
S-3200 ES- View 6, Cummins Engine....................................233
S-3200 ES- View 7....................................................236
S-3200
Safety Circuit Schematic.....................................237
Electrical Schematics, S-3800 Models.....................................240
S-3800 ES- View 1....................................................240
S-3800 ES- View 2....................................................241
S-3800 ES- View 3....................................................244
S-3800 ES- View 4....................................................245
S-3800 ES- View 5, Deutz Engine......................................248
S-3800 ES- View 6, Cummins Engine....................................249
S-3800 ES- View 7....................................................252
S-3800 Safety Circuit Schematic......................................253
Hydraulic Schematics, S-3200 Models......................................256
Hydraulic Schematics, S-3800 Models......................................257
Back Cover...................................................................259S.S 05/24
