Genie S-40 S-45 Service Manual 72136 – PDF DOWNLOAD

Description

Genie S-40 S-45 Service Manual 72136 – PDF DOWNLOAD

Language : English
Pages : 304
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie S-40 S-45 Service Manual 72136 – PDF DOWNLOAD

Introduction
Important Information ii
Section 1 Safety Rules
General Safety Rules iii
Section 2 Rev Specifications
B Machine Specifications 2 – 1
Performance Specifications 2 – 3
Hydraulic Specifications 2 – 4
Hydraulic Oil Specifications 2 – 5
Ford LRG 425 EFI Engine Specifications 2 – 6
Deutz F3L 1011F Engine Specifications 2 – 7
Perkins 704-30 Engine Specifications 2 – 8
Machine Torque Specifications 2 – 9
Hydraulic Hose and Fitting Torque Specifications 2 – 10
SAE and Metric Fastener Torque 2 – 11
Section 3 Rev Theory of Operation
A Power Source 3 – 1
Hydraulic System 3 – 1
Electrical System 3 – 1
Limit Switches 3 – 2
Electrical System 3 – 2
Section 4 Rev Scheduled Maintenance Procedures
Introduction 4 – 1
Maintenance Inspection Report 4 – 3
B Checklist A Procedures
A-1 Inspect the Operator’s and Safety Manuals 4 – 5
A-2 Inspect the Decals and Placards 4 – 5
A-3 Inspect for Damage, Loose or Missing Parts 4 – 6
A-4 Check the Engine Oil Level 4 – 7
A-5 Check the Engine Coolant Level – Liquid Cooled Models 4 – 8
A-6 Check for Fuel Leaks 4 – 8
A-7 Check the Hydraulic Oil Level 4 – 9
A-8 Check for Hydraulic Leaks 4 – 10
A-9 Check the Tire Pressure 4 – 10
A-10 Test the Oscillate Axle (if equipped) 4 – 11
A-11 Test the Platform and Ground Controls 4 – 12
A-12 Test the Auxiliary Power Operation 4 – 13
A-13 Test the Tilt Sensor 4 – 14
A-14 Test the Limit Switches 4 – 14
A-15 Drain the Fuel Filter/Water Separator – Diesel Models 4 – 17
A-16 Perform 30 Day Service 4 – 19
A-17 Replace the Engine Oil and Filter – Gasoline/LPG Models 4 – 19
A-18 Check the Engine Belt – Gasoline/LPG and Perkins Models 4 – 21
A-19 Replace the Fuel Filter – Gasoline/LPG Models 4 – 22
Section 4 Rev Scheduled Maintenance Procedures, continued
B Checklist B Procedures
B-1 Check the Exhaust System 4 – 30
B-2 Inspect the Engine Air Filter 4 – 25
B-3 Inspect the Radiator – Liquid Cooled Models 4 – 26
B-4 Check the Battery 4 – 27
B-5 Inspect the Electrical Wiring 4 – 28
B-6 Check the Oil Cooler and Cooling Fins – Deutz Models 4 – 29
B-7 Check the Hydraulic Tank Return Filter Condition Indicator 4 – 30
B-8 Inspect the Tires, Wheels and Lug Nut Torque 4 – 31
B-9 Confirm the Proper Brake Configuration 4 – 32
B-10 Check the Oil Level in the Drive Hubs 4 – 33
B-11 Check and Adjust the Engine RPM 4 – 35
B-12 Test the Key Switch 4 – 36
B-13 Test the Emergency Stop Buttons 4 – 37
B-14 Test the Ground Control Override 4 – 37
B-15 Check the Directional Valve Linkage 4 – 38
B-16 Test the Platform Self-leveling 4 – 38
B-17 Test the Horn 4 – 39
B-18 Test the Foot Switch 4 – 39
B-19 Test the Engine Idle Select Operation 4 – 40
B-20 Test the Fuel Select Operation – Gasoline/LPG Models 4 – 41
B-21 Test the Drive Enable System 4 – 42
B-22 Test the Drive Brakes 4 – 43
B-23 Test the Drive Speed – Stowed Position 4 – 44
B-24 Test the Drive Speed – Raised or Extended Position 4 – 45
B-25 Test the Alarm Package (if equipped) 4 – 46
Section 4 Rev Scheduled Maintenance Procedures, continued
B-26 Perform Hydraulic Oil Analysis 4 – 46
B-27 Replace the Hydraulic Tank Return Filter 4 – 47
B-28 Replace the Engine Air Filter Element 4 – 48
B-29 Replace the Spark Plugs – Gasoline/LPG Models 4 – 49
A Checklist C Procedures
C-1 Check the Engine Belt – Deutz Models 4 – 51
C-2 Check the Engine Valve Clearances – Deutz Models 4 – 52
C-3 Replace the Fuel Filter/Water Separator Element – Perkins Models 4 – 53
C-4 Replace the Fuel Filter Element – Perkins Models 4 – 54
C-5 Replace the Engine Oil and Filter – Perkins Models 4 – 56
C-6 Check the Specific Gravity of Engine Coolant – Liquid Cooled Models 4 – 57
C-7 Check the Glow Plugs – Perkins Models 4 – 58
C-8 Replace the PCV Valve – Gasoline/LPG Models 4 – 59
B Checklist D Procedures
D-1 Check the Boom Wear Pads 4 – 60
D-2 Check the Free-wheel Configuration 4 – 60
D-3 Check the Turntable Rotation Bearing Bolts 4 – 62
D-4 Grease the Turntable Rotation Bearing and Rotate Gear 4 – 63
D-5 Replace the Drive Hub Oil 4 – 63
D-6 Replace the Drive Loop Hydraulic Filter 4 – 65
D-7 Replace the Engine Oil and Filter – Deutz Models 4 – 66
D-8 Clean the Fuel Pump Strainer – Deutz Models 4 – 68
D-9 Replace the Diesel Fuel Filter/Water Separator – Deutz Models 4 – 69
D-10 Change the Fuel Hoses – Deutz Models 4 – 70
D-11 Check the Engine Valve Clearances – Perkins Models 4 – 71
D-12 Clean the Engine Breather Assembly – Perkins Models 4 – 72
Section 4 Rev Scheduled Maintenance Procedures, continued
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil 4 – 73
E-2 Change or Recondition the Engine Coolant – Liquid Cooled Models 4 – 75
E-3 Change the Fuel Hoses – Gasoline/LPG Models 4 – 76
E-4 Replace the Engine Breather – Perkins Models 4 – 78
E-5 Grease the Steer Axle Wheel Bearings, 2WD Models 4 – 78
E-6 Check the Fuel Injectors – Perkins Models 4 – 80
Section 5 Rev Troubleshooting Flow Charts
B Introduction 5 – 1
Fault Codes 5 – 3
1 Engine Will Not Crank Over 5 – 8
2 Engine Cranks Over But Will Not Start – Gasoline/LPG Models 5 – 10
2A Engine Runs While Cranking then Dies- Gasoline/LPG Models 5 – 12
3 Engine Cranks Over But Will Not Start – Diesel Models 5 – 13
4 Engine Will Not Start On LPG, But Will Start On Gasoline
– Gasoline/LPG Models 5 – 16
5 Engine Will Not Start On Gasoline, But Will Start On LPG
– Gasoline/LPG Models 5 – 18
6 Engine High Idle Inoperative – Gasoline/LPG Models 5 – 19
7 Engine Low Idle Inoperative – Gasoline/LPG Models 5 – 20
8 Engine High Idle Inoperative – Diesel Models 5 – 21
9 Engine Low Idle Inoperative – Diesel Models 5 – 23
10 All Functions Inoperative, Engine Starts and Runs 5 – 24
11 All Lift and Steer Functions Inoperative, Drive Functions Operational 5 – 25
Section 5 Rev Troubleshooting Flow Charts, continued
12 Ground Controls Inoperative, Platform Controls Operate Normally 5 – 26
13 Platform Controls Inoperative, Ground Controls Operate Normally 5 – 27
14 Boom Up Function Inoperative 5 – 28
15 Boom Down Function Inoperative 5 – 31
16 Boom Extend Function Inoperative 5 – 34
17 Boom Retract Function Inoperative 5 – 36
18 Turntable Rotate Left Function Inoperative 5 – 38
19 Turntable Rotate Right Function Inoperative 5 – 42
20 All Platform Leveling Functions Inoperative 5 – 46
21 Platform Level Up Function Inoperative 5 – 47
22 Platform Level Down Function Inoperative 5 – 49
23 Platform Rotate Left Function Inoperative 5 – 51
24 Platform Rotate Right Function Inoperative 5 – 53
25 Oscillate Function Inoperative 5 – 55
26 Jib Boom Up Function Inoperative 5 – 56
27 Jib Boom Down Function Inoperative 5 – 58
28 Steer Left Function Inoperative 5 – 60
29 Steer Right Function Inoperative 5 – 62
30 All Drive Functions Inoperative, All Other Functions Operate Normally 5 – 64
31 Drive Forward Or Reverse Function Inoperative 5 – 67
32 Traction Function Inoperative 5 – 68
33 Machine Will Not Drive At Full Speed 5 – 69
34 Machine Drives At Full Speed With Platform Raised or Extended 5 – 70
35 Drive Enable System Is Malfunctioning 5 – 71
36 Auxiliary Functions Inoperative 5 – 72
Section 6 Rev Schematics
Introduction 6 – 1
A Electrical Components 6 – 2
A Electrical Symbols Legend 6 – 4
A Abbreviation Legend 6 – 5
A Hydraulic Symbols Legend 6 – 6
A Engine Wire Harness – Gasoline/LPG 6 – 7
A Electrical Schematic – Gasoline/LPG 6 – 10
A Ground Control Box Wiring Diagram – Gasoline/LPG 6 – 14
A Platform Control Box Wiring Diagram – Gasoline/LPG 6 – 15
A Electrical Schematic – Deutz Diesel 6 – 18
A Ground Control Box Wiring Diagram – Deutz Diesel 6 – 22
A Platform Control Box Wiring Diagram – Deutz Diesel 6 – 23
A Electrical Schematic – Perkins Diesel 6 – 26
A Ground Control Box Wiring Diagram – Perkins Diesel 6 – 30
A Platform Control Box Wiring Diagram – Perkins Diesel 6 – 31
A S-40/45 2WD Hydraulic Schematic – Non-oscillating axle 6 – 33
A S-40/45 2WD Hydraulic Schematic – Oscillating axle 6 – 35
A S-40/45 4WD Hydraulic Schematic – Oscillating axle 6 – 37
Section 7 Rev Repair Procedures
Introduction 7 – 1
A Platform Controls
1-1 Joystick Controllers 7 – 2
1-2 Horsepower Limiter Board 7 – 6
1-3 Foot Switch 7 – 9
1-4 Toggle Switches 7 – 10
A Platform Components
2-1 Platform 7 – 11
2-2 Platform Leveling Slave Cylinder 7 – 11
2-3 Platform Rotator 7 – 13
A Jib Boom Components, S-45 Models
3-1 Jib Boom 7 – 15
3-2 Jib Boom Lift Cylinder 7 – 16
A Boom Components
4-1 Boom Cable Track 7 – 17
4-2 Boom 7 – 19
4-3 Boom Lift Cylinder 7 – 22
4-4 Extension Cylinder 7 – 23
4-5 Platform Leveling Master Cylinder 7 – 25
A Turntable Covers
5-1 Turntable Covers 7 – 26
Section 7 Rev Repair Procedures, continued
A Deutz Engine F3L 1011F
6-1 RPM Adjustment 7 – 27
6-2 Flex Plate 7 – 27
6-3 Oil Temperature and Oil Pressure Gauges 7 – 28
A Perkins 704-30 Engine
7-1 RPM Adjustment 7 – 29
7-2 Flex Plate 7 – 29
7-3 Coolant Temperature and Oil Pressure Gauges 7 – 30
A Ford LRG-425 EFI Engine
8-1 Timing Adjustment 7 – 31
8-2 Flex Plate 7 – 31
8-3 Coolant Temperature and Oil Pressure Gauges 7 – 32
A Ground Controls
9-1 Control Relays 7 – 33
9-2 Toggle Switches, See 1-4, Toggle Switches 7 – 34
9-3 Wago® Components 7 – 34
9-4 Engine Fault Codes – Gasoline/LPG Models 7 – 35
A Hydraulic Pumps
10-1 Lift/Steer Pump 7 – 36
10-2 Drive Pump 7 – 37
Section 7 Rev Repair Procedures, continued
B Manifolds
11-1 Function Manifold Components 7 – 40
11-2 Valve Adjustments – Function Manifold 7 – 44
11-3 Turntable Rotation Manifold Components 7 – 46
11-4 Oscillate Manifold Components 7 – 48
11-5 Valve Adjustments – Oscillate Manifold 7 – 49
11-6 Directional Valve Manifold Components 7 – 50
11-7 Steer/Oscillate Manifold Components, Oscillating Models 7 – 52
11-8 Steer Manifold Components, Non-oscillating Models 7 – 53
11-9 2WD Drive Manifold Components 7 – 54
11-10 Valve Adjustments, 2WD Drive Manifold 7 – 55
11-11 4WD Drive Manifold Components 7 – 56
11-12 Valve Adjustments, 4WD Drive Manifold 7 – 58
11-13 Jib Boom/Platform Rotate Manifold Components, S-45 Models
(before serial number 5593) 7 – 59
11-14 Jib Boom/Platform Rotate Manifold Components, S-45 Models
(after serial number 5592) 7 – 60
A Fuel and Hydraulic Tanks
12-1 Fuel Tank 7 – 62
12-2 Hydraulic Tank 7 – 63
A Turntable Rotation Components
13-1 Rotation Hydraulic Motor 7 – 66
Section 7 Rev Repair Procedures, continued
B 2WD Steering Axle Components
14-1 Yoke and Hub 7 – 68
14-2 Steering Cylinders 7 – 70
14-3 Tie Rod 7 – 71
B 4WD Steering Axle Components
15-1 Yoke and Hub 7 – 72
15-2 Steering Cylinders, See 14-2, Steering Cylinders 7 – 73
15-3 Tie Rod, See 14-3, Tie Rod 7 – 73
A Oscillating Axle Components
16-1 Oscillating Axle Lock-out Cylinders 7 – 74
B Non-steering Axle Components
17-1 Drive Motor 7 – 75
17-2 Drive Hub 7 – 76
17-3 Wheel Brake 7 – 77

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