Genie S-40 TRAX Manuale utente

Service Manual

Part No. 102521

Rev A

January 2005

Refer to inside cover for serial number information

Genie S-40 and S-45 Part No. 102521

January 2005

Introduction

Important

Read, understand and obey the safety rules and

operating instructions in the

Genie S-40 and S-45

Operator's Manual

before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner

and user. It also provides troubleshooting fault

codes and repair procedures for qualified service

professionals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Technical Publications

Genie Industries has endeavored to deliver the

highest degree of accuracy possible. However,

continuous improvement of our products is a Genie

policy. Therefore, product specifications are

subject to change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genielift.com

e-mail:[email protected]

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

S-40 and S-45 Service Manual

(before serial no. 7001)......................................... 72136

102521 Rev A January 2005

First Edition, First Printing

"Genie" and "S" are registered trademarks of

Genie Industries in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Part No. 102521 Genie S-40 and S-45

January 2005

iii

Safety Rules

Section 1 • Safety Rules

Danger

Failure to obey the instructions and safety rules in

this manual, and the

Genie S-40 and S-45

Operator's Manual

will result in death or serious

injury.

Many of the hazards identified in the operator's

manual are also safety hazards when maintenance

and repair procedures are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Genie S-40 and S-45 Part No. 102521

January 2005

SAFETY RULES

Section 1 • Safety Rules

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine

use signal words to identify the following:

Safety alert symbol—used to alert

personnel to potential personal

injury hazards. Obey all safety

messages that follow this symbol

to avoid possible injury or death.

Red—used to indicate the

presence of an imminently

hazardous situation which, if not

avoided, will result in death or

serious injury.

Orange—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, could result in death or

serious injury.

Yellow with safety alert symbol—

used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Yellow without safety alert

symbol—used to indicate the

presence of a potentially

hazardous situation which, if not

avoided, may result in property

damage.

Green—used to indicate operation

or maintenance information.

Workplace Safety

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

Be sure to keep sparks, flames and

lighted tobacco away from flammable

and combustible materials like battery

gases and engine fuels. Always have an approved

fire extinguisher within easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free

of debris that could get into machine components

and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components

may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

Part No. 102521 Genie S-40 and S-45

January 2005

Table of Contents

Introduction

ImportantInformation ..................................................................................................

Section 1 Safety Rules

General Safety Rules .................................................................................................

iii

Section 2 Rev Specifications

A Machine Specifications.......................................................................................... 2 - 1

A Hydraulic Specifications ........................................................................................ 2 - 2

A Manifold Component Specifications ...................................................................... 2 - 4

A Machine Torque Specifications.............................................................................. 2 - 4

A Ford LRG-425 EFI Engine Specifications.............................................................. 2 - 5

A Deutz F3L-1011F Engine Specifications................................................................ 2 - 6

A Deutz F4L-1011F Engine Specifications................................................................ 2 - 7

A Deutz F3L-2011 Engine Specifications.................................................................. 2 - 8

A Perkins 704-30 Engine Specifications ................................................................... 2 - 9

A Perkins 404-22 Engine Specifications ................................................................. 2 - 10

A Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 12

Section 3 Rev Scheduled Maintenance Procedures

Introduction ........................................................................................................... 3 - 1

Pre-Delivery Preparation ....................................................................................... 3 - 3

Maintenance Inspection Report ............................................................................. 3 - 5

AChecklist A Procedures

A-1 Perform Pre-operation Inspection ................................................................ 3 - 7

A-2 Perform Function Tests ............................................................................... 3 - 7

A-3 Perform Engine Maintenance - Deutz Models.............................................. 3 - 8

A-4 Perform Engine Maintenance - Ford Models................................................ 3 - 8

A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9

A-6 Drain the Fuel Filter/Water Separator - Diesel Models................................. 3 - 9

Genie S-40 and S-45 Part No. 102521

January 2005

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures, continued

A-7 Check for Fuel Leaks................................................................................. 3 - 10

A-8 Check the High Pressure Hydraulic Filter Condition Indicator.................... 3 - 11

A-9 Test the Oscillate Axle (if equipped) .......................................................... 3 - 11

A-10 Perform 30 Day Service............................................................................. 3 - 12

A-11 Perform Engine Maintenance - Deutz Models............................................ 3 - 12

A-12 Perform Engine Maintenance - Ford and Perkins Models.......................... 3 - 13

A-13 Inspect the Fuel Filter/Water Separator - Diesel Models............................ 3 - 13

A-14 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 15

A-15 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 16

A-16 Perform Engine Maintenance - Deutz 1011F Models................................. 3 - 17

A-17 Perform Engine Maintenance - Ford Models.............................................. 3 - 17

AChecklist B Procedures

B-1 Inspect the Battery..................................................................................... 3 - 18

B-2 Inspect the Electrical Wiring....................................................................... 3 - 19

B-3 Perform Engine Maintenance - Deutz 1011F Models................................. 3 - 20

B-4 Check the Exhaust System........................................................................ 3 - 20

B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21

B-6 Inspect the Tire and Wheels (including lug nut torque) .............................. 3 - 22

B-7 Confirm the Proper Brake Configuration .................................................... 3 - 22

B-8 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23

B-9 Check and Adjust the Engine RPM - Deutz Models................................... 3 - 23

B-10 Test the Engine Idle Select ........................................................................ 3 - 24

B-11 Test the Fuel Select Operation - Ford Models ........................................... 3 - 25

B-12 Test the Drive Brakes ................................................................................ 3 - 26

B-13 Test the Drive Speed - Stowed Position .................................................... 3 - 27

B-14 Test the Drive Speed - Raised or Extended Position ................................. 3 - 27

B-15 Perform Hydraulic Oil Analysis .................................................................. 3 - 28

B-16 Replace Hydraulic Filters ........................................................................... 3 - 28

Part No. 102521 Genie S-40 and S-45

January 2005

TABLE OF CONTENTS

vii

Section 3 Rev Scheduled Maintenance Procedures, continued

B-17 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 30

B-18 Test the Alarm Package (if equipped)........................................................ 3 - 32

B-19 Perform Engine Maintenance - Deutz Models............................................ 3 - 33

B-20 Perform Engine Maintenance - Ford Models.............................................. 3 - 33

B-21 Perform Engine Maintenance - Perkins Models ......................................... 3 - 34

AChecklist C Procedures

C-1 Perform Engine Maintenance - Deutz Models............................................ 3 - 35

C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 35

C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 36

C-4 Perform Engine Maintenance - Perkins Models ......................................... 3 - 38

C-5 Perform Engine Maintenance Ford Models................................................ 3 - 38

AChecklist D Procedures

D-1 Check the Boom Wear Pads ..................................................................... 3 - 39

D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 39

D-3 Check the Free-wheel Configuration.......................................................... 3 - 41

D-4 Replace the Drive Hub Oil ......................................................................... 3 - 42

D-5 Check and Adjust the Air/LPG Mixture - Ford Models................................ 3 - 43

D-6 Perform Engine Maintenance - Deutz Models............................................ 3 - 44

D-7 Calibrate the Platform Overload System (if equipped) ............................... 3 - 44

D-8 Replace the Hydraulic Filters ..................................................................... 3 - 46

AChecklist E Procedures

E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 47

E-2 Perform Engine Maintenance - Deutz Models............................................ 3 - 49

E-3 Perform Engine Maintenance - Deutz Models............................................ 3 - 49

Genie S-40 and S-45 Part No. 102521

January 2005

Section 4 Rev Repair Procedures

Introduction ........................................................................................................... 4 - 1

APlatform Controls

1-1 ALC-500 Circuit Board................................................................................. 4 - 2

1-2 Joysticks...................................................................................................... 4 - 3

APlatform Components

2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7

2-2 Platform Rotator........................................................................................... 4 - 8

AJib Boom Components

3-1 Jib Boom.................................................................................................... 4 - 10

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11

ABoom Components

4-1 Cable Track ............................................................................................... 4 - 12

4-2 Boom ......................................................................................................... 4 - 14

4-3 Boom Lift Cylinder ..................................................................................... 4 - 15

4-4 Boom Extension Cylinder .......................................................................... 4 - 16

4-5 Platform Leveling Master Cylinder ............................................................. 4 - 17

AEngines

5-1 RPM Adjustment - Deutz Models............................................................... 4 - 18

5-2 RPM Adjustment - Perkins Models ............................................................ 4 - 18

5-3 Flex Plate................................................................................................... 4 - 18

5-4 Engine Fault Codes - Ford Models ............................................................ 4 - 20

AHydraulic Pumps

6-1 Function Pump .......................................................................................... 4 - 21

6-2 Drive Pump................................................................................................ 4 - 22

viii

TABLE OF CONTENTS

Part No. 102521 Genie S-40 and S-45

January 2005

Section 4 Rev Repair Procedures, continued

AManifolds

7-1 Function Manifold Components ................................................................. 4 - 24

7-2 Valve Adjustments - Function Manifold...................................................... 4 - 28

7-3 Jib Select and Platform Rotate Manifold Components ............................... 4 - 29

7-4 Brake Manifold Components

(before serial no. 7569).............................................................................. 4 - 30

7-5 Brake/Two-Speed Manifold Components

(after serial no. 7568)................................................................................. 4 - 31

7-6 Oscillate Directional Valve Manifold Components...................................... 4 - 32

7-7 Valve Adjustments, Oscillate Relief Valve ................................................. 4 - 34

7-8 Traction Manifold Components, 2WD (before serial no. 7569)................... 4 - 35

7-9 Traction Manifold Components, 2WD (after serial no. 7568)...................... 4 - 36

7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 37

7-11 Traction Manifold Components, 4WD (before serial no. 7569)................... 4 - 38

7-12 Traction Manifold Components, 4WD (after serial no. 7568)...................... 4 - 40

7-13 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 42

7-14 Valve Coils................................................................................................. 4 - 43

ATurntable Rotation Components

8-1 Turntable Rotation Assembly..................................................................... 4 - 45

AAxle Components

9-1 Oscillate Axle Cylinders ............................................................................. 4 - 47

TABLE OF CONTENTS

Genie S-40 and S-45 Part No. 102521

January 2005

TABLE OF CONTENTS

Section 5 Rev Fault Codes

Introduction ........................................................................................................... 5 - 1

A Fault Codes - Control System ............................................................................... 5 - 2

A Fault Codes - Ford Engine .................................................................................... 5 - 6

Section 6 Rev Schematics

Introduction ........................................................................................................... 6 - 1

A Electrical Symbols Legend .................................................................................... 6 - 2

A Electrical Schematic, Deutz F3L 1011 Models (before serial no. 7544)................. 6 - 4

A Ground Control Box Wiring Diagram,

Deutz F3L 1011 Models (before serial no. 7544) ......................................... 6 - 6

A Platform Control Box Wiring Diagram,

Deutz F3L 1011 Models (before serial no. 7544) ......................................... 6 - 7

A Electrical Schematic, Perkins 704-30 Models (before serial no. 7472) .................. 6 - 9

A Ground Control Box Wiring Diagram,

Perkins 704-30 Models (before serial no. 7472) ........................................ 6 - 11

A Platform Control Box Wiring Diagram,

Perkins 704-30 Models (before serial no. 7472) ........................................ 6 - 12

A Electrical Schematic, Ford LRG-425 EFI Models (before serial no. 7597 ).......... 6 - 14

A Ground Control Box Wiring Diagram,

Ford LRG-425 EFI Models (before serial no. 7597 ) .................................. 6 - 16

A Platform Control Box Wiring Diagram,

Ford LRG-425 EFI Models (before serial no. 7597 ) .................................. 6 - 17

A Hydraulic Schematic, 2WD Non-oscillating S-40 Models

(before serial no. 7569).............................................................................. 6 - 19

A Hydraulic Schematic, 2WD Non-oscillating S-45 Models

(before serial no. 7569).............................................................................. 6 - 20

A Hydraulic Schematic, 2WD Oscillating S-40 Models (before serial no. 7569)...... 6 - 21

A Hydraulic Schematic, 2WD Oscillating S-45 Models (before serial no. 7569)...... 6 - 22

A Electrical Schematic, Deutz F3L 2011 Models (after serial no. 7543).................. 6 - 23

A Ground Control Box Wiring Diagram,

Deutz F3L 2011 Models (after serial no. 7543) .......................................... 6 - 25

A Platform Control Box Wiring Diagram,

Deutz F3L 2011 Models (after serial no. 7543) .......................................... 6 - 26

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