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Genie S-40 XC S-40 HF S-40 TraX S-45 XC S-45 HF S-45 TraX Service & Repair Manual – PDF
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Genie S-40 XC S-40 HF S-40 TraX S-45 XC S-45 HF S-45 TraX Service & Repair Manual 1322629 – PDF DOWNLOAD
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Description
Genie S-40 XC S-40 HF S-40 TraX S-45 XC S-45 HF S-45 TraX Service & Repair Manual 1322629 – PDF DOWNLOAD
Language : English
Pages : 179
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-40 XC S-40 HF S-40 TraX S-45 XC S-45 HF S-45 TraX Service & Repair Manual 1322629 – PDF DOWNLOAD
Front Cover.............................................................. 1 Important Information.................................................... 2 Find a Manual for this Model............................................. 2 Revision History......................................................... 3 Serial Number Legend..................................................... 4 General Safety Rules..................................................... 5 Table of Contents........................................................ 7 Specifications........................................................... 13 Machine Specifications............................................... 13 Performance Specifications........................................... 14 Hydraulic Oil Specifications......................................... 14 Hydraulic Component Specifications................................... 17 Manifold Component Specifications.................................... 18 Ford MSG-425 EFI Engine Specifications............................... 19 Deutz D2011 L03i Engine Specifications............................... 20 Deutz D 2.9 L4 Tier IV Engine Specifications......................... 21 Deutz D 2.9 L4 Stage IV Engine Specifications........................ 22 Deutz TD 2.2 L3 Engine Specifications................................ 23 Perkins 404F-E22T Engine Specifications.............................. 24 Machine Torque Specifications........................................ 25 Machine Component Weights............................................ 25 TRAX Torque Specifications........................................... 26 Hydraulic Hose and Fitting Torque Specifications..................... 27 Torque Procedure..................................................... 28 Repair Procedures........................................................ 30 Introduction......................................................... 30 Control System....................................................... 32 1-1 ALC-600 Platform Control Module.............................. 32 1-2 ALC-600 Service Mode......................................... 32 1-3 Full Machine Calibration..................................... 33 1-4 Machine Functions............................................ 34 How to Adjust the Machine Maximum Speed Setting.............. 34 How to Adjust the Joystick Ramp Rate Setting................. 35 How to Adjust the Joystick Threshold Setting................. 36 1-5 How to Enter ALC600 Software Update Mode..................... 37 1-6 Display Module Menus......................................... 38 1-7 How to Replace the Display Controller (DISCON) Module........ 44 1-8 How to Replace the Ground Control Overlay.................... 45 Platform Components.................................................. 48 2-1 Platform Leveling Cylinder................................... 48 How to Remove the Platform Leveling Cylinder................. 48 How to Bleed the Platform Leveling Cylinder.................. 48 2-2 Platform Rotator............................................. 49 2-3 Platform Overload System..................................... 52 How to Perform a Zero Load Platform Calibration.............. 52 How to Perform a Full Load Platform Calibration.............. 53 How to Replace the Platform Overload Load Cell............... 55 2-4 Platform..................................................... 56 2-5 Platform Level Sensor........................................ 57 Jib Boom Components.................................................. 58 3-1 Jib Boom..................................................... 58 3-2 Jib Boom Lift Cylinder....................................... 59 Primary Boom Components.............................................. 60 4-1 Cable Track.................................................. 60 How to Remove the Cable Track................................ 60 How to Repair the Cable Track................................ 61 4-2 Boom......................................................... 61 4-3 Boom Lift Cylinder........................................... 63 4-4 Boom Extension Cylinder...................................... 64 4-5 Primary Boom Angle Sensor Calibration........................ 65 4-6 Boom Length Sensor........................................... 66 Engines.............................................................. 67 5-1 RPM adjustment - Deutz Models................................ 67 5-2 RPM adjustment - Perkins Models.............................. 67 5-3 Flex Plate................................................... 67 How to install the Pump and Bell Housing Assembly............ 70 5-4 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3........ 71 Hydraulic Pump....................................................... 72 6-1 Function Pump................................................ 72 6-2 Drive Pump................................................... 73 Manifolds............................................................ 75 7-1 Function Manifold Components................................. 75 7-2 Valve Adjustments - Function Manifold........................ 79 How to Adjust the System Relief Valve........................ 79 How to Adjust the Boom Extend Relief Valve................... 79 7-3 Traction Manifold Components................................. 80 7-4 Valve Adjustments, Traction Manifold......................... 82 7-5 Valve Adjustment - Oscillate Relief Valve.................... 83 How to Set Up the Oscillate Directional Valve................ 83 7-6 Platform Manifold Components, S-40 XC, S-40 HF, S-40 TraX.... 85 7-7 Platform Manifold Components, S-45 XC, S-45 HF, S-45 TraX.... 86 7-8 Platform Rotate Manifold Components.......................... 87 7-9 Generator Manifold Components................................ 88 7-10 Valve Coils................................................. 89 How to Test a Coil Diode..................................... 90 Turntable Rotation Components........................................ 91 8-1 Turntable Rotation Assembly.................................. 91 How to Adjust the Turntable Rotation Gear Backlash........... 92 How to Calibrate the Turntable Tilt Sensor................... 93 Axle Components...................................................... 95 9-1 Oscillating Axle Cylinders................................... 95 Track Components..................................................... 96 10-1 Track Assembly.............................................. 96 Fault Codes.............................................................. 98 Introduction......................................................... 98 Control System Fault Codes........................................... 99 How to Retrieve Control System Fault Codes....................... 99 Control System Fault Codes.......................................100 Engine Fault Codes...................................................115 Deutz D 2.9 L4 Tier IV Engine Fault Codes............................116 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes.............127 Perkins 404F-E22T Engine Fault Codes.................................137 Ford MSG-425 Engine Fault Codes......................................139 Schematics...............................................................144 Introduction.........................................................144 Electrical Symbol Legend.............................................145 Hydraulic Symbols Legend.............................................146 Limit Switch Location Legend.........................................147 Engine Relay Layout - All engines except Perkins 404F................148 Engine Relay Layout - Perkins 404F-22T...............................149 3 kW Generator Receptacle Wiring.....................................150 7 kW Generator Receptacle Wiring.....................................151 12 kW Generator Receptacle Wiring....................................152 Connector Pin Legend.................................................153 Electrical Schematics................................................155 Electrical Schematic, Turntable Controller.......................156 Electrical Schematic, Platform Controller........................157 Electrical Schematic, Deutz TD 2.2 L3 Engine.....................160 Electrical Schematic, Deutz D 2.9 L4 Stage IV Engine.............164 Electrical Schematic, Deutz D2011L03i Engine.....................168 Electrical Schematic, Deutz D 2.9 L4 Tier IV Engine..............169 Electrical Schematic, Perkins 404F-E22T..........................172 Electrical Schematic, Ford MSG-425 EFI Engine....................173 Hydraulic Schematics.................................................175 Hydraulic Schematic, S-40XC / HF / TraX..........................176 Hydraulic Schematic, S-45XC / HF / TraX..........................177 Back Cover...............................................................179
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