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Genie S-40 S-45 S-40 TRAX S-45 TRAX Service Manual 826364 – PDF
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Description
Genie S-40 S-45 S-40 TRAX S-45 TRAX Service Manual 826364 – PDF DOWNLOAD
Language : English
Pages : 296
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-40 S-45 S-40 TRAX S-45 TRAX Service Manual 826364 – PDF DOWNLOAD
Front cover.................................................................. 1
Introduction................................................................. 2
Serial Number Legend......................................................... 5
Safety Rules................................................................. 7
Table of Contents............................................................ 8
Section 2 Specifications.................................................... 17
Machine Specifications................................................... 17
Performance Specifications............................................... 18
Hydraulic Oil Specifications............................................. 18
Hydraulic Component Specifications....................................... 19
Manifold Component Specifications........................................ 21
Valve Coil Resistance Specifications..................................... 21
Ford MSG-425 EFI Engine Specifications................................... 22
Deutz D2011L03i Engine Specifications
................................... 24
Deutz D 2.9 L4 Engine Specifications
.................................... 26
Perkins 404D-22 Engine Specifications.................................... 28
Perkins 404F-22 Engine Specifications
................................... 29
Machine Torque Specifications............................................ 31
TRAX Torque Specifications............................................... 31
Hydraulic Hose and Fitting Torque Specifications......................... 32
SAE and Metric Fastener Torque Chart..................................... 34
Section 3 Scheduled Maintenance Procedures.................................. 35
Pre-Delivery Preparation................................................. 37
Maintenance Inspection Report............................................ 39
Checklist A Procedures................................................... 41
A-1 Inspect the Manuals and Decals.................................. 41
A-2 Perform Pre-operation Inspection................................ 42
A-3 Perform Function Tests.......................................... 42
A-4 Perform Engine Maintenance - Ford Models........................ 43
A-5 Perform Engine Maintenance - Perkins
Models .................... 43
A-6 Perform Engine Maintenance - Deutz Models
....................... 44
A-7
Inspect the Track Components, TRAX option...................... 44
A-8
Check the High Pressure Hydraulic Condition Indicator .......... 45
A-9
Test the Oscillate Axle (if equipped) .......................... 45
A-10
Perform 30 Day Service...................................... 46
A-11
Replace the Drive Hub Oil................................... 46
A-12
Perform Engine Maintenance- Ford Models..................... 47
A-13 Perform Engine Maintenance- Perkins
Models.................. 47
A-14 Perform Engine Maintenance- Ford Models
........................ 48
A-15
Grease the Turntable Rotation Bearing and Rotate Gear....... 48
A-16
Perform Engine Maintenance - Ford Models.................... 49
Checklist B Procedures................................................... 50
B-1 Inspect the Battery............................................. 50
B-2 Inspect the Electrical Wiring................................... 51
B-3
Check the Exhaust System........................................ 53
B-4
Perform Engine Maintenance - Perkins Models..................... 54
B-5
Check the Oil Cooler and Cooling Fins- Deutz Models............. 54
B-6
Inspect the Tires, Wheels and Lug Nut Torque.................... 56
B-7
Confirm the Proper Brake Configuration......................... 56
B-8
Check the Drive Hub Oil Level and Fastener Torque.............. 57
B-9
Test the Ground Control Override............................... 57
B-10
Check the Oscillate Directional Valve Linkage ................ 58
B-11
Test the Platform Self-leveling............................... 58
B-12
Test the Engine Idle Select.................................. 59
B-13
Test the Fuel Select Operation - Ford Models................. 60
B-14
Test the Drive Brakes......................................... 61
B-15
Test the Drive Speed- Stowed Position......................... 62
B-16
Test the Drive Speed- Raised or Extended Position............. 63
B-17
Test the Alarm Package (if equipped).......................... 64
B-18
Perform Hydraulic Oil Analysis................................ 65
B-19 Inspect the Fuel and Hydraulic Tank Cap Venting Systems........ 66
B-20
Check the Track Tension and Fastener Torque, TRAX option...... 67
B-21 Test the Emergency Power System ............................. 68
B-22
Perform Engine Maintenance- Ford Models...................... 69
Checklist C Procedures................................................... 70
C-1 Grease the Platform Overload Mechanism (if equipped)
........... 70
C-2
Test the Platform Overload Mechanism (if equipped)............ 70
C-3
Replace the Engine Air Filter Element......................... 74
C-4
Perform Engine Maintenance - Perkins Models .................... 75
C-5
Perform Engine Maintenance - Perkins Models .................. 75
C-6 Perform Engine Maintenance- Deutz Models
........................ 76
C-7 Check and Adjust the Engine RPM
................................. 76
C-8
Perform Engine Maintenance- Ford Models......................... 78
Checklist D Procedures................................................... 80
D-1 Check the Boom Wear Pads
........................................ 80
D-2 Check the Turntable Rotation Bearing Bolts
...................... 81
D-3 Inspect for Turntable Bearing Wear
.............................. 82
D-4 Replace the Drive Hub Oil
....................................... 84
D-5
Check the Free-wheel Configuration ............................. 84
D-6 Replace the Hydraulic Filter Elements........................... 86
D-7 Perform Engine Maintenance - Perkins
Models................... 87
D-8 Perform Engine Maintenance - Deutz
Models ...................... 88
D-9 Perform Engine Maintenance- Deutz D2.9 Models
................... 88
Checklist E Procedures................................................... 89
E-1 Test or Replace the Hydraulic Oil............................... 89
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models................. 91
E-3 Perform Engine Maintenance -
Perkins Models.................... 92
E-4 Perform Engine Maintenance- Perkins
Models...................... 93
E-5 Perform Engine Maintenance- Perkins 404D-22
Models............. 93
E-6 Perform Engine Maintenance- Perkins 404F
Models................ 94
E-7 Perform Engine Maintenance- Deutz Models......................... 94
E-8 Perform Engine Maintenance- Deutz D2011
Models ................. 95
E-9 Perform Engine Maintenance- Deutz
Models........................ 95
Section 4 Repair Procedures.................................................. 97
Platform Controls........................................................ 98
1-1 ALC-500 Circuit Board............................................ 98
1-2 Joysticks........................................................ 99
Platform Components......................................................104
2-1 Platform Leveling Slave Cylinder.................................104
2-2 Platform Rotator.................................................105
2-3 Platform Overload System.........................................106
Jib Boom Components......................................................110
3-1 Jib Boom.........................................................110
3-2 Jib Boom Lift Cylinder...........................................111
Boom Components..........................................................112
4-1 Cable Track......................................................112
4-2 Boom.............................................................114
4-3 Boom Lift Cylinder...............................................117
4-4 Extension Cylinder...............................................118
4-5 Platform Leveling Master Cylinder................................119
Engines..................................................................120
5-1 RPM Adjustment- Deutz D2011
Models..............................120
5-2 RPM Adjustment- Perkins 404D
Models.............................120
5-3 Flex Plate.......................................................120
5-4 Ford MSG-425 Engine Fault Codes
.................................124
5-5 Deutz D 2.9 L4 and Perkins 404F-22 Engine Fault Codes
...........124
Hydraulic Pumps..........................................................125
6-1 Function Pump....................................................125
6-2 Drive Pump.......................................................126
Manifolds................................................................128
7-1 Function Manifold Components.....................................128
7-2 Valve Adjustments- Function Manifold.............................132
7-3 Jib Select, Platform Rotate and Generator Manifold Components....133
7-4 Brake Manifold Components
.......................................134
7-5
Oscillate Directional Valve Components..........................135
7-6
Valve Adjustments- Oscillate Relief Valve.......................137
7-7
Traction Manifold Components, 2WD...............................138
7-8
Valve Adjustments, 2WD Drive Manifold...........................139
7-9
Traction Manifold Components, 4WD...............................140
7-10
Valve Adjustments, 4WD Drive Manifold..........................142
7-11
Drive Oil Diverter Manifold Components (welder option)........143
7-12
Valve Coils....................................................144
Turntable Rotation Components............................................146
8-1 Turntable Rotation Assembly......................................148
Axle Components..........................................................148
9-1 Oscillate Cylinders..............................................148
Track Components
........................................................149
10-1 Track Assembly - TRAX option....................................149
Generators
..............................................................151
11-1 Hydraulic Generator
............................................151
Section 5 Fault Codes........................................................153
Fault Code Chart- Control System.........................................154
Fault Code Display- Deutz D2.9 L4 and Perkins 404F-22 Models
............158
Fault Code Display- Flashing and Solid LED's
............................159
Fault Code Display- Soft Key Functions and Icons
........................160
Fault Code Display- Main Menu Structure
.................................161
Deutz D 2.9 L4 Engine Fault Codes .......................................162
Perkins 404F-22 Engine Fault Codes
......................................177
Ford MSG-425 EFI Engine Fault Codes
.....................................180
Section 6 Schematics.........................................................187
Electrical Symbols Legend................................................188
Hydraulic Symbols Legend.................................................189
Electrical Abbreviations Legend
.........................................190
Ford MSG-425
Engine Relay Layout .......................................193
Deutz D2.9 L4 and Perkins 404F-22 Engine Relay Layout
...................194
Connector Pin Legend.....................................................196
Deutz D 2.9 L4 Schematics ...............................................237
Engine Wire Harness .................................................197
ANSI Electrical Schematic
...........................................204
ANSI Ground Control Box Wiring Diagram
..............................208
ANSI Platform Control Box Wiring Diagram
............................210
ANSI Platform Switch Panel Wiring Diagram
...........................211
Perkins 404F Schematics
................................................247
Engine Wire Harness ................................................200
ANSI Electrical Schematic
...........................................214
ANSI Ground Control Box Wiring Diagram
..............................218
ANSI Platform Control Box Wiring Diagram
............................220
ANSI Platform Switch Panel Wiring Diagram
...........................221
Deutz D2011L03i and
Perkins 404D-22 Schematics ........................257
ANSI/CSA Electrical Schematic
.......................................224
ANSI/CSA Ground Control Box Wiring Diagram
.........................228
ANSI/CSA Platform Control Box Wiring Diagram
........................230
ANSI/CSA Platform Switch Panel Wiring Diagram
.......................231
CE
Electrical Schematic ............................................277
CE
Ground Control Box Wiring Diagram ...............................281
CE
Platform Control Box Wiring Diagram .............................283
CE
Platform Switch Panel Wiring Diagram ............................284
AUS Electrical Schematic
............................................264
AUS Ground Control Box Wiring Diagram
...............................268
AUS Platform Control Box Wiring Diagram
.............................270
AUS Platform Switch Panel Wiring Diagram
............................271
Ford MSG-425 Schematics .................................................267
Ford MSG-425 Engine Wire Harness
....................................201
ANSI/CSA Electrical Schematic
.......................................234
ANSI/CSA Ground Control Box Wiring Diagram
..........................238
ANSI/CSA Platform Control Box Wiring Diagram
........................240
ANSI/CSA Platform Switch Panel Wiring Diagram
.......................241
CE
Electrical Schematic ............................................255
CE
Ground Control Box Wiring Diagram ...............................258
CE
Platform Control Box Wiring Diagram .............................260
CE
Platform Switch Panel Wiring Diagram ............................261
AUS Electrical Schematic
............................................274
AUS Ground Control Box Wiring Diagram
...............................278
AUS Platform Control Box Wiring Diagram
.............................280
AUS Platform Switch Panel Wiring Diagram
............................281
CTE Option Wiring Diagram
...............................................284
MTE Hydraulic Generator Option Wiring Diagram
...........................285
MTE
Generator Hydraulic Schematic ......................................292
12.5 kW Welder Generator Electrical Schematic
.........................288
12.5 kW
Welder Generator Electrical Wiring Diagram......................289
12.5 kW Generator Hydraulic Schematic
...................................292
2WD Hydraulic Schematic
.................................................292
4WD Hydraulic Schematic
.................................................293
Back cover...................................................................295S.S 05/24
