Genie S-40 Service Manual 32222 – PDF DOWNLOAD

Description

Genie S-40 Service Manual 32222 – PDF DOWNLOAD

Language : English
Pages : 208
Downloadable : Yes
File Type : PDF

Table of Contents:

Genie S-40 Service Manual 32222 – PDF DOWNLOAD

Introduction
Important Information ii
Section One Safety Rules
General Safety Rules iii
Section Two Specifications
Machine Specifications 2 – 1
Performance Specifications 2 – 2
Hydraulic Specifications 2 – 3
Bolt Torque Specifications 2 – 4
Ford LSG 423 Engine Specifications 2 – 5
Deutz F3L Engine Specifications 2 – 7
Section Three Scheduled Maintenance Inspections
Introduction 3 – 1
Table A 3 – 2
Table B 3 – 3
Table C 3 – 5
Table D 3 – 6
Maintenance Inspection Report 3 – 7
Section Four Scheduled Maintenance Procedures
Introduction 4 – 1
A-1 Inspect the Manuals 4 – 2
A-2 Inspect the Decals and Placards 4 – 2
A-3 Inspect for Damage, Loose or Missing Parts 4 – 2
A-4 Check the Engine Oil Level 4 – 3
A-5 Check the Engine Coolant Level – Gasoline/LPG Models 4 – 3
A-6 Check for Fuel Leaks 4 – 3
A-7 Check the Hydraulic Oil Level 4 – 4
A-8 Check for Hydraulic Leaks 4 – 4
Section Four Scheduled Maintenance Procedures, continued
A-9 Check the Tire Pressure 4 – 5
A-10 Test the Platform and Ground Controls 4 – 5
A-11 Test the Auxiliary Power Operation 4 – 6
A-12 Test the Tilt Sensor 4 – 7
A-13 Test the Limit Switches 4 – 7
A-14 Test the Oscillate Axle 4 – 9
A-15 Replace the Engine Oil and Filter – Gasoline/LPG Models 4 – 10
A-16 Replace the Engine Air Filter 4 – 11
B-1 Check the Engine Belt(s) 4 – 12
B-2 Check the Radiator – Gasoline/LPG Models 4 – 12
B-3 Check the Oil Cooler and Cooling Fins – Deutz Diesel Models 4 – 12
B-4 Check the Exhaust System 4 – 13
B-5 Check the Battery 4 – 14
B-6 Check the Hydraulic Tank Filter Condition Indicator 4 – 14
B-7 Inspect the Electrical Wiring 4 – 15
B-8 Inspect the Tires and Wheels 4 – 15
B-9 Confirm the Proper Brake Configuration 4 – 16
B-10 Check the Oil Level in the Torque Hubs 4 – 16
B-11 Check and Adjust the Engine Idle Mixture – Gasoline/LPG Models 4 – 17
B-12 Check and Adjust the Engine RPM 4 – 17
B-13 Test the Key Switch 4 – 19
B-14 Test the Emergency Stop Buttons 4 – 20
B-15 Test the Ground Control Override 4 – 20
B-16 Check the Directional Valve Linkage 4 – 21
B-17 Test the Platform Self-leveling 4 – 21
B-18 Test the Service Horn 4 – 21
B-19 Test the Foot Switch 4 – 22
B-20 Test the Engine Idle Select 4 – 22
B-21 Test the Fuel Select Operation – Gasoline/LPG Models 4 – 23
Section Four Scheduled Maintenance Procedures, continued
B-22 Test the Drive Enable System 4 – 23
B-23 Test the Drive Brakes 4 – 24
B-24 Test the Drive Speed – Stowed Position 4 – 24
B-25 Test the Alarm Package – Optional Equipment 4 – 25
B-26 Perform Hydraulic Oil Analysis 4 – 25
B-27 Replace the Engine Oil and Filter – Deutz Diesel Models 4 – 26
C-1 Check the Boom Wear Pads 4 – 27
C-2 Check the Turntable Rotation Bearing Bolts 4 – 27
C-3 Check the Free-wheel Configuration 4 – 28
C-4 Grease the Turntable Rotation Bearing and Rotate Gear 4 – 29
C-5 Replace the Torque Hub Oil 4 – 29
C-6 Replace the Hydraulic Tank Filter 4 – 31
C-7 Replace the Drive Loop Hydraulic Filter 4 – 31
C-8 Replace the Diesel Fuel Filter – Deutz Diesel Models 4 – 32
C-9 Replace the Gasoline Fuel Filter – Gasoline/LPG Models 4 – 32
C-10 Replace the PCV Valve – Gasoline/LPG Models 4 – 34
C-11 Clean or Replace the Distributor Cap and Rotor – Gasoline/LPG Models 4 – 34
C-12 Replace the Spark Plugs – Gasoline/LPG Models 4 – 35
C-13 Check and Adjust the Air/LPG Mixture – Gasoline/LPG Models 4 – 36
C-14 Check and Adjust the Ignition Timing – Gasoline/LPG Models 4 – 37
C-15 Check the Engine Valve Clearances – Deutz Diesel Models 4 – 37
D-1 Test or Replace the Hydraulic Oil 4 – 38
D-2 Change or Recondition the Engine Coolant – Gasoline/LPG Models 4 – 39
D-3 Change the Fuel Lines 4 – 41
D-4 Check the Engine Valve Clearance – Gasoline/LPG Models 4 – 42
D-5 Check the Engine Cylinder Compression – Gasoline/LPG Models 4 – 42
D-6 Clean the PCV Hoses and Fittings – Gasoline/LPG Models 4 – 43
D-7 Check the Fuel Injection Pumps and Injectors – Deutz Diesel Models 4 – 44
D-8 Check the Toothed Belt – Deutz Diesel Models 4 – 44
D-9 Replace the Timing Belt – Gasoline/LPG Models 4 – 44
Section Five Troubleshooting Flow Charts
Introduction 5 – 1
1 Engine Will Not Crank Over 5 – 3
2 Engine Cranks Over But Will Not Start – Gasoline/LPG Models 5 – 5
3 Engine Cranks Over But Will Not Start – Deutz Diesel Models 5 – 12
4 Engine Will Not Start On LPG, But Will Start On Gasoline
– Gasoline/LPG Models 5 – 15
5 Engine Will Not Start On Gasoline, But Will Start On LPG
– Gasoline/LPG Models 5 – 17
6 Engine High Idle Inoperative – Gasoline/LPG Models 5 – 19
7 Engine Low Idle Inoperative – Gasoline/LPG Models 5 – 21
8 Engine High Idle Inoperative – Deutz Diesel Models 5 – 22
9 Engine Low Idle Inoperative – Deutz Diesel Models 5 – 24
10 All Functions Inoperative, Engine Starts and Runs 5 – 25
11 All Lift and Steer Functions Inoperative, Drive Functions Operational 5 – 26
12 Ground Controls Inoperative, Platform Controls Operate Normally 5 – 27
13 Platform Controls Inoperative, Ground Controls Operate Normally 5 – 28
14 Boom Up Function Inoperative 5 – 29
15 Boom Down Function Inoperative 5 – 31
16 Boom Extend Function Inoperative 5 – 33
17 Boom Retract Function Inoperative 5 – 35
18 Turntable Rotate Function Inoperative 5 – 36
19 Turntable Rotate Left Function Inoperative 5 – 38
20 Turntable Rotate Right Function Inoperative 5 – 39
21 All Platform Leveling Functions Inoperative 5 – 40
22 Platform Level Up Function Inoperative 5 – 41
23 Platform Level Down Function Inoperative 5 – 42
Section Five Troubleshooting Flow Charts, continued
24 Platform Rotate Left Function Inoperative 5 – 43
25 Platform Rotate Right Function Inoperative 5 – 44
26 Oscillate Function Inoperative 5 – 45
27 Steer Left Function Inoperative 5 – 46
28 Steer Right Function Inoperative 5 – 47
29 All Drive Functions Inoperative, All Other Functions Operate Normally 5 – 48
30 Drive Forward Or Reverse Function Inoperative 5 – 51
31 Traction Function Inoperative 5 – 52
32 Machine Will Not Drive At Full Speed 5 – 53
33 Machine Drives At Full Speed With Platform Raised or Extended 5 – 54
34 Drive Enable System Is Malfunctioning 5 – 55
35 Auxiliary Functions Inoperative 5 – 56
Section Six Schematics
Introduction 6-1
Electrical Symbols Legend 6-2
Electrical Schematic – Gasoline/LPG Models 6-3
Ground Control Box Legend – Gasoline/LPG Models 6-5
Relay Panel Legend – Gasoline/LPG Models 6-6
Platform Control Box Legend – Gasoline/LPG Models 6-7
Electrical Schematic – Diesel Models 6-8
Ground Control Box Legend – Diesel Models 6-10
Platform Control Box Legend – Diesel Models 6-11
Hydraulic Symbols Legend 6-12
2WD Hydraulic Schematic – Non-Oscillating Axle 6-13
2WD Hydraulic Schematic – Oscillating Axle 6-14
4WD Hydraulic Schematic 6-15
Introduction 7 – 1
Platform Controls
1-1 Joystick Controllers 7 – 2
1-2 Horsepower Limiter Board 7 – 5
1-3 Foot Switch 7 – 7
1-4 Resistors 7 – 7
1-5 Toggle Switches 7 – 8
Platform Components
2-1 Platform 7 – 9
2-2 Platform Leveling Slave Cylinder 7 – 9
2-3 Platform Rotator 7 – 10
Boom Components
3-1 Plastic Cable Track 7 – 12
3-2 Boom 7 – 12
3-3 Boom Lift Cylinder 7 – 14
3-4 Extension Cylinder 7 – 15
3-5 Platform Leveling Master Cylinder 7 – 16
Turntable Covers
4-1 Turntable Covers 7 – 17
Deutz Engine F3L 1011
5-1 RPM Adjustment 7 – 18
5-2 Flex Plate 7 – 18
5-3 Oil Temperature and Oil Pressure Gauges 7 – 18
Ford LSG-423 Engine
6-1 Governor Actuator 7 – 19
6-2 Choke Adjustments 7 – 20
6-3 Timing Adjustment 7 – 21
6-4 Carburetor Adjustment 7 – 21
6-5 RPM Adjustment 7 – 21
6-6 Flex Plate 7 – 21
Section Seven Repair Procedures, Ford LSG-423 Engine, continued
6-7 Water Temperature and Oil Pressure Gauges 7 – 22
6-8 Vacuum Switch 7 – 22
Ground Controls
7-1 Control Relays 7 – 23
7-2 Toggle Switches, See 1-5, Toggle Switches 7 – 8
7-3 Wago® Components 7 – 25
7-4 Resistor 7 – 26
7-5 Power Relay 7 – 26
Hydraulic Pumps
8-1 Lift/Steer Pump 7 – 27
8-2 Drive Hydraulic Pump 7 – 28
Function Manifold
9-1 Function Manifold Components 7 – 30
9-2 Valve Adjustments – Function Manifold 7 – 32
Fuel and Hydraulic Tanks
10-1 Hydraulic Tank 7 – 35
10-2 Fuel Tank 7 – 36
Turntable Rotation Components
11-1 Rotation Hydraulic Motor 7 – 37
11-2 Turntable Rotation Manifold Components 7 – 38
2WD Steering Axle Components
12-1 Yoke and Hub 7 – 39
12-2 Steering Cylinders 7 – 40
12-3 Tie Rod 7 – 41
4WD Steering Axle Components
13-1 Yoke and Hub 7 – 42
13-2 Steering Cylinders 7 – 43
13-3 Tie Rod 7 – 43
Section Seven Repair Procedures, continued
Oscillating Axle Components
14-1 Oscillating Axle Cylinders 7 – 44
Steer and Oscillate Manifolds
15-1 Oscillate Manifold Components 7 – 45
15-2 Valve Adjustments 7 – 46
15-3 Directional Valve Manifold Components 7 – 47
15-4 Steer Manifold Components 7 – 49
Non-steering Axle Components
16-1 Drive Motor 7 – 50
16-2 Torque Hub 7 – 50
2WD Drive Manifold
17-1 2WD Drive Manifold Components 7 – 52
17-2 Valve Adjustments 7 – 54
4WD Drive Manifold
18-1 4WD Drive Manifold Components 7 – 56
18-2 Valve Adjustments 7 – 58

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