Genie S-40 TRAX Manuale utente

Service Manual

Part No. 102521

Rev E

October 2013

Serial Number Range

from S40-7001 to

S4012-17231

S-40

S-45

Property of American Airlines

S-40 • S-45 Part No.102521

October 2013

Introduction

Serial Number Information

Genie offers the following Service Manuals for

these models:

Title Part No.

S-40 and S-45 Service Manual

(before serial number 3804) ................................ 32222

S-40 and S-45 Service Manual

(from serial number 3804 to 4728) .......................52271

S-40 and S-45 Service Manual

(from serial number 4729 to 7000) .......................72136

102521 Rev E October 2013

Fourth Edition, Fifth Printing

"Genie" and "S" are registered trademarks of

Terex South Dakota, Inc. in the USA and many

other countries.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate operator's

manual on your machine 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.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie 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]

Property of American Airlines

Part No.102521 S-40 • S-45

October 2013

Revision Date Section Procedure / Schematic Page / Description

D 2/2012 2 - Spec. 2-1, 2-2, 2-13

3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54

4 - Repair 4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-60

6 - Schem. 6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138,

6-139, 6-150, 6-151, 6-153

D1 10/1012 2 - Spec. 2-1, 2-2

3 - Maint. 3-9, 3-33 to 3-34

4 - Repair 4-59 to 4-60

D2 10/2013 4- Repair 4-3

6 - Schem. 6-19, 6-29, 6-33, 6-93

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.

3-3_Section 3_Maintenance Procedure Page #.

4-48_Section 4_Repair Procedure Page #.

Fault Codes_Section 5.

6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Revision History

Property of American Airlines

S-40 • S-45 Part No.102521

October 2013

REVISION HISTORY, CONTINUED

Revision Date Section Procedure / Schematic Page / Description

REFERENCE EXAMPLES:

2-1_Section 2_Specifications Page #.

3-3_Section 3_Maintenance Procedure Page #.

4-48_Section 4_Repair Procedure Page #.

Fault Codes_Section 5.

6-5_Section 6_Schematic Page #.

Electronic Version

Click on any procedure or page number

highlighted in blue to view the update.

Property of American Airlines

Part No.102521 S-40 • S-45

October 2013

S40 06 - 12345

Model

Model year

Sequence

number

PN - 77055

Country of manufacture: USA

This machine complies with:

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

ANSI A92.5

CAN B.354.4

Model: S-40

Serial number: S4006-12345

Electrical schematic number: ES0274

Machine unladen weight:

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

0deg

Gradeability: N/A

Maximum allowable side force : 150lb/670N

Maximum number of platfrm occupants: 2

Model year: Manufacture date: 01/05/06

2006

Maximum wind speed : 28 mph/ 12.5 m/s

Maximum platform height : 60 ft 6 in/ 18.3 m

Maximum platform reach : 34 ft 3 in/ 10.4 m

Sequence number

(stamped on chassis)

Serial label

(located under cover)

iii

Section 1 • Safety Rules

Serial Number Legend

Property of American Airlines

S-40 • S-45 Part No.102521

July 2007

This page intentionally left blank.

Section 1 • Safety Rules

Property of American Airlines

Part No.102521 S-40 • S-45

July 2007 Section 1 • Safety Rules

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.

Property of American Airlines

S-40 • S-45 Part No.102521

July 2007

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.

Used to indicate the presence of

an imminently hazardous situation

which, if not avoided, will result in

death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, could result

in death or serious injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

minor or moderate injury.

Used to indicate the presence of a

potentially hazardous situation

which, if not avoided, may result in

property damage.

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.

Workplace Safety

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.

Section 1 • Safety Rules July 2007

Property of American Airlines

Part No.102521 S-40 • S-45

October 2013

Table of Contents

Introduction

Important Information ...................................................................................................

Serial Number Legend .................................................................................................

Section 1 Safety Rules

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

Section 2 Rev Specifications

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

Hydraulic Oil Specifications ................................................................................... 2 - 2

Manifold Component Specifications ....................................................................... 2 - 5

Valve Coil Resistance Specifications ..................................................................... 2 - 5

Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6

Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7

Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8

Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9

Perkins 704-30 Engine Specifications .................................................................. 2 - 10

Perkins 404-22 Engine Specifications .................................................................. 2 - 11

Machine Torque Specifications ............................................................................ 2 - 12

Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13

SAE and Metric Fastener Torque Chart ............................................................... 2 - 14

Section 3 Rev Scheduled Maintenance Procedures

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

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

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

Checklist A Procedures

A-1 Inspect the Decals and Manuals .................................................................. 3 - 7

A-2 Perform Pre-operation Inspection ................................................................. 3 - 8

A-3 Perform Function Tests ................................................................................ 3 - 8

A-4 Perform Engine Maintenance ....................................................................... 3 - 9

vii

Property of American Airlines

S-40 • S-45 Part No.102521

October 2013

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

A-5 Inspect the Track Components, TRAX option .............................................. 3 - 9

A-6 Perform 30 Day Service ............................................................................. 3 - 10

A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 10

A-8 Replace the Drive Hub Oil .......................................................................... 3 - 11

A-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12

A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12

A-11 Perform Engine Maintenance - Ford Models ............................................... 3 - 13

A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14

A-13 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14

A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 15

Checklist B Procedures

B-1 Inspect the Battery ..................................................................................... 3 - 16

B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17

B-3 Inspect the Air Filter ................................................................................... 3 - 18

B-4 Test the Key Switch ................................................................................... 3 - 19

B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 19

B-6 Check the Exhaust System ....................................................................... 3 - 20

B-7 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 20

B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21

B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22

B-10 Confirm the Proper Brake Configuration...................................................... 3 - 23

B-11 Check and Adjust the Engine RPM ............................................................ 3 - 24

B-12 Test the Engine Idle Select ........................................................................ 3 - 25

B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 26

B-14 Test the Ground Control Override ............................................................... 3 - 27

B-15 Check the Directional Valve Linkeage ........................................................ 3 - 27

B-16 Test the Platform Self-leveling ................................................................... 3 - 28

Property of American Airlines

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