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Genie S-40 S-45 Service Manual 102521 – PDF DOWNLOAD
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Description
Genie S-40 S-45 Service Manual 102521 – PDF DOWNLOAD
Language : English
Pages : 325
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-40 S-45 Service Manual 102521 – PDF DOWNLOAD
Front cover................................................................................................................................ 1 Introduction............................................................................................................................... 2 Serial Number Legend....................................................................................................................... 5 Safety Rules............................................................................................................................... 7 Table of Contents.......................................................................................................................... 9 Section 2 Specifications.................................................................................................................. 19 Machine Specifications................................................................................................................. 19 Performance Specifications............................................................................................................. 20 Hydraulic Oil Specifications........................................................................................................... 20 Hydraulic Component Specifications..................................................................................................... 21 Manifold Component Specifications...................................................................................................... 23 Valve Coil Resistance Specifications................................................................................................... 23 Ford LRG-425 EFI Engine Specifications................................................................................................. 24 Ford DSG-423 EFI Engine Specifications................................................................................................. 25 Deutz F3L-1011F Engine Specifications.................................................................................................. 26 Deutz F3L-2011/Deutz D2011L03i......................................................................................................... 27 Perkins 704-30 Engine Specifications................................................................................................... 29 Perkins 404-22 Engine Specifications................................................................................................... 30 Machine Torque Specifications.......................................................................................................... 31 Hydraulic Hose and Fitting Torque Specifications....................................................................................... 32 SAE and Metric Fastener Torque Chart................................................................................................... 33 Section 3 Maintenance Procedures......................................................................................................... 34 Pre-Delivery Preparation............................................................................................................... 38 Maintenance Inspection Report.......................................................................................................... 40 Checklist A Procedures................................................................................................................. 42 A-1 Inspect the Manuals and Decals................................................................................................ 40 A-2 Perform Pre-operation Inspection.............................................................................................. 41 A-3 Perform Function Tests........................................................................................................ 41 A-4 Perform Engine Maintenance - All Models....................................................................................... 41 A-5 Inspect the Track Components, TRAX option...................................................................................... 42 A-6 Perform 30 Day Service....................................................................................................... 43 A-7 Perform Engine Maintenance- Deutz and Ford Models............................................................................. 43 A-8 Replace the Drive Hub Oil.................................................................................................... 44 A-9 Perform Engine Maintenance- Perkins Models.................................................................................. 45 A-10 Inspect the Fuel Filter/Water Separator- Deutz Models....................................................................... 45 A-11 Perform Engine Maintenance- Ford Models..................................................................................... 46 A-12 Grease the Turntable Rotation Bearing and Rotate Gear....................................................................... 47 A-13 Perform Engine Maintenance - Deutz 1011 F Models............................................................................ 47 A-14 Perform Engine Maintenance - Ford Models.................................................................................... 48 Checklist B Procedures................................................................................................................. 49 B-1 Inspect the Battery........................................................................................................... 49 B-2 Inspect the Electrical Wiring................................................................................................. 50 B-3 Inspect the Air Filter........................................................................................................ 51 B-4 Test the Key Switch........................................................................................................... 52 B-5 Perform Engine Maintenance - Deutz and Perkins Models.......................................................................... 52 B-6 Check the Exhaust System....................................................................................................... 53 B-7 Check the Oil Cooler and Cooling Fins- Deutz Models............................................................................ 53 B-8 Inspect the Tires, Wheels and Lug Nut Torque................................................................................... 54 B-9 Check the Drive Hub Oil Level and Fastener Torque............................................................................. 55 B-10 Confirm the Proper Brake Configuration....................................................................................... 56 B-11 Check and Adjust the Engine RPM.............................................................................................. 57 B-12 Test the Engine Idle Select.................................................................................................. 58 B-13 Test the Fuel Select Operation - Ford Models................................................................................. 59 B-14 Test the Ground Control Override.............................................................................................. 60 B-15 Check the Directional Valve Linkage........................................................................................... 60 B-16 Test the Platform Self-leveling............................................................................................... 61 B-17 Test the Drive Brakes......................................................................................................... 61 B-18 Test the Drive Speed- Stowed Position......................................................................................... 62 B-19 Test the Drive Speed- Raised or Extended Position............................................................................. 62 B-20 Perform Hydraulic Oil Analysis................................................................................................ 63 B-21 Test the Alarm Package (if equipped).......................................................................................... 64 B-22 Inspect the Fuel and Hydraulic Tank Cap Venting Systems....................................................................... 65 B-23 Check the Track Tension and Fastener Torque, TRAX option...................................................................... 66 B-23 Perform Engine Maintenance- Ford Models....................................................................................... 67 Checklist C Procedures................................................................................................................. 68 C-1 Perform Engine Maintenance - Deutz and Perkins Models......................................................................... 68 C-2 Grease the Platform Overload Mechanism (if equipped).......................................................................... 69 C-3 Test the Platform Overload Mechanism (if equipped)............................................................................ 69 C-4 Replace the Engine Air Filter Element- Deutz and Perkins Models............................................................... 72 C-5 Replace the In-line Fuel Strainer- Deutz Models............................................................................... 73 C-6 Perform Engine Maintenance- Ford Models........................................................................................ 73 Checklist D Procedures................................................................................................................. 74 D-1 Check the Boom Wear Pads...................................................................................................... 74 D-2 Check the Turntable Rotation Bearing Bolts.................................................................................... 75 D-3 Check the Free-wheel Configuration ............................................................................................ 76 D-4 Replace the Drive Hub Oil..................................................................................................... 78 D-5 Perform Engine Maintenance - Deutz and Perkins Models......................................................................... 79 D-6 Replace the Hydraulic Filter Elements......................................................................................... 80 D-7 Inspect for Turntable Bearing Wear............................................................................................ 81 Checklist E Procedures................................................................................................................. 83 E-1 Test or Replace the Hydraulic Oil............................................................................................. 83 E-2 Grease the Steer Axle Wheel Bearings, 2WD Models............................................................................... 85 E-3 Perform Engine Maintenance - Deutz and Perkins Models......................................................................... 86 E-4 Perform Engine Maintenance- Ford Models........................................................................................ 87 E-5 Perform Engine Maintenance- Deutz and Perkins Models........................................................................... 87 E-6 Perform Engine Maintenance- Deutz and Perkins Models........................................................................... 88 E-7 Perform Engine Maintenance- Deutz Models....................................................................................... 89 E-8 Perform Engine Maintenance- Deutz Models....................................................................................... 89 E-9 Perform Engine Maintenance- Ford Models........................................................................................ 90 Section 4 Repair Procedures................................................................................................................ 92 Platform Controls...................................................................................................................... 93 1-1 ALC-500 Circuit Board.......................................................................................................... 93 1-2 Joysticks...................................................................................................................... 94 Platform Components.................................................................................................................... 99 2-1 Platform Leveling Slave Cylinder............................................................................................... 99 2-2 Platform Rotator...............................................................................................................100 2-3 Platform Overload System.......................................................................................................102 Jib Boom Components....................................................................................................................105 3-1 Jib Boom.......................................................................................................................105 3-2 Jib Boom Lift Cylinder.........................................................................................................106 Boom Components........................................................................................................................107 4-1 Cable Track....................................................................................................................107 4-2 Boom...........................................................................................................................109 4-3 Boom Lift Cylinder.............................................................................................................112 4-4 Extension Cylinder.............................................................................................................113 4-5 Platform Leveling Master Cylinder..............................................................................................114 Engines................................................................................................................................115 5-1 RPM Adjustment- Deutz Models...................................................................................................115 5-2 RPM Adjustment- Perkins Models.................................................................................................115 5-3 Flex Plate.....................................................................................................................115 5-4 Engine Fault Codes- Ford Models................................................................................................119 Hydraulic Pumps........................................................................................................................120 6-1 Function Pump..................................................................................................................120 6-2 Drive Pump.....................................................................................................................121 Manifolds..............................................................................................................................123 7-1 Function Manifold Components...................................................................................................123 7-2 Valve Adjustments- Function Manifold...........................................................................................127 7-3 Jib Select, Platform Rotate and Generator Manifold Components..................................................................128 7-4 Brake Manifold Components (before serial no. 7569).............................................................................129 7-5 Brake/Two-Speed Manifold Components (after serial number 7568).................................................................130 7-6 Oscillate Directional Valve Components.........................................................................................131 7-7 Valve Adjustments- Oscillate Relief Valve......................................................................................133 7-8 Traction Manifold Components, 2WD (before serial no. 7569).....................................................................134 7-9 Traction Manifold Components, 2WD (after serial no. 7568) .....................................................................135 7-10 Valve Adjustments, 2WD Drive Manifold.........................................................................................136 7-11 Traction Manifold Components, 4WD (before serial no. 7569)....................................................................137 7-12 Traction Manifold Components, 4WD (from 7568 to 15822)........................................................................139 7-13 Traction Manifold Components, 4WD (from serial number 15823)..................................................................141 7-14 Valve Adjustments, 4WD Drive Manifold.........................................................................................143 7-15 Valve Coils...................................................................................................................144 7-16 Drive Oil Diverter Manifold Components (welder option).......................................................................146 Turntable Rotation Components..........................................................................................................147 8-1 Turntable Rotation Assembly....................................................................................................147 Axle Components........................................................................................................................149 9-1 Oscillate Cylinders............................................................................................................149 Track Components ......................................................................................................................150 10-1 Track Assembly - TRAX option..................................................................................................150 Generators.............................................................................................................................152 Hydraulic Generator................................................................................................................152 Section 5 Fault Codes......................................................................................................................154 Fault Code Chart- Control System.......................................................................................................155 Ford LRG-425 EFI Engine................................................................................................................159 Ford DSG-423 EFI Engine................................................................................................................165 Section 6 Schematics.......................................................................................................................170 Electrical Symbols Legend..............................................................................................................171 Hydraulic Symbols Legend...............................................................................................................172 Ford DSG-423 Engine Relay Layout.......................................................................................................173 Connector Pin Legend...................................................................................................................174 Electrical Schematic, Deutz F3L 1011 (before serial number 7544).......................................................................177 Ground Box Wiring Diagram, Deutz F3L 1011..............................................................................................180 Platform Control Box Wiring Diagram, Deutz F3L 1011....................................................................................183 Platform Control Box Switch Panel Wiring Diagram, Deutz F3L 1011F Models...............................................................184 Electrical Schematic, Perkins 704-30 Models (before serial no. 7472)...................................................................187 Ground Box Wiring Diagram, Perkins 704-30..............................................................................................190 Platform Control Box Wiring Diagram, Perkins 704-30....................................................................................193 Platform Control Box Switch Panel Wiring Diagram, Perkins 704-30 Models................................................................194 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i 404-22 Models (from serial number 7544 to 12509)..................................197 Electrical Schematic, Perkins 404-22 Models (from serial number 7472 to 12509).........................................................197 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510 to 14831).....................201 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832 to 15662 )....................205 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models- ANSI / CSA / AS (from serial number 15663 to 16419)....209 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models- CE (from serial number 15663 to 16419).................213 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models- ANSI / CSA / AS (from serial number 16420).............217 Electrical Schematic, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models- CE (from serial number 16420)..........................221 Ground Control Box Wiring Diagram, Deutz F3L-2011 and Perkins 404-22 Models (before serial number 14832) ..............................225 Ground Control Box Wiring Diagram, Deutz F3L-2011 and Perkins 404-22 Models (from serial number 14832) ................................226 Platform Control Box Wiring Diagram, Deutz F3L-2011/Deutz D2011L03i and Perkins 404-22 Models (before serial number 14832).............229 Platform Control Box Wiring Diagram, Deutz D2011L03i and Perkins 404-22 Models (from serial number 14832)..............................230 Platform Control Box Switch Panel Wiring Diagram, Deutz F3L-2011/Deutz D2011L03i (from serial number 7544 to 12509)....................233 Platform Control Box Switch Panel Wiring Diagram, Perkins 404-22 Models (from serial number 7472 to 12509).............................233 Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i and Perkins 404-22 Models (from serial number 12510).................234 Electrical Schematic, Ford LRG-425 Models (before serial number 7597)..................................................................237 Ground Control Box Wiring Diagram, Ford LRG-425 EFI Models (before serial number 7597).................................................240 Platform Control Box Wiring Diagram, Ford LRG-425 EFI Models (before serial number 7597)...............................................243 Platform Control Box Switch Panel Wiring Diagram, Ford LRG-425 EFI Models (before serial number 7597)..................................244 Electrical Schematic, Ford LRG-425 EFI Models (from serial number 7597 to 11066).......................................................247 Ground Control Box Wiring Diagra, Ford LRG-425 EFI Models (from serial number 7597 to 11066)...........................................250 Platform Control Box Wiring Diagram, Ford LRG-425 EFI Models (from serial number 7597 to 11066)........................................253 Platform Control Box Switch Panel Wiring Diagram, Ford LRG-425 EFI Models (from serial number 7597 to 11066)...........................254 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 11067 to 12509)......................................................257 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 12510 to 14831)......................................................261 Electrical Schematic, Ford DSG-423 EFI Models (from serial number 14832 to 15662)......................................................265 Electrical Schematic, Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 15663 to 16419).....................................269 Electrical Schematic, Ford DSG-423 EFI Models- CE (from serial number 15663 to 16419).................................................273 Electrical Schematic, Ford DSG-423 EFI Models- ANSI / CSA / AS (from serial number 16420)..............................................277 Electrical Schematic, Ford DSG-423 EFI Models- CE (from serial number 16420)...........................................................281 Ground Control Box Wiring Diagram, Ford DSG-423 EFI Models (before serial number 14832)................................................285 Ground Control Box Wiring Diagram, Ford DSG-423 EFI Models (from serial number 14832)..................................................286 Platform Control Box Wiring Diagram, Ford DSG-423 EFI Models (before serial number 14832) .............................................301 Platform Control Box Wiring Diagram, Ford DSG-423 EFI Models (from serial number 14832) ..............................................290 Platform Control Box Switch Panel Wiring Diagram, Ford DSG-423 EFI Models (from serial number 11067 to 12509)..........................293 Platform Control Box Switch Panel Wiring Diagram, Ford DSG-423 EFI Models (from serial number 12510)...................................294 Engine Wire Harness, Ford LRG-425 EFI Models (before serial number 11067)..............................................................297 Engine Wire Harness, Ford DSG-423 EFI Models (from serial number 11067 to 11784).......................................................298 Engine Wire Harness, Ford DSG-423 EFI Models (after serial number 11784)...............................................................301 Joystick Connector Diagram.............................................................................................................302 CTE Option Wiring Diagram..............................................................................................................305 MTE Hydraulic Generator Option Wiring Diagram .........................................................................................307 Hydraulic Generator Wiring Diagram- Welder Option......................................................................................308 Hydraulic Schematic, 2WD Non-oscillating S-40 Models (before serial no. 7569)..........................................................311 Hydraulic Schematic, 2WD Non-oscillating S-45 Models (before serial no. 7569...........................................................312 Hydraulic Schematic, 4WD Oscillating S-40 Models (before serial no. 7569)..............................................................315 Hydraulic Schematic, 4WD Oscillating S-45 Models (before serial no. 7569)..............................................................316 Hydraulic Schematics, 2WD (from serial no. 7569).......................................................................................319 Hydraulic Schematics, 4WD (from serial no. 7569)......................................................................................320 Generator Hydraulic Schematic- Welder Option...........................................................................................322 Back cover.............................................................................................................................324 Back cover ................................................................................................................................324 spine......................................................................................................................................325
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