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S-45 TRAX
Genie S-45 TRAX Service And Repair Manual
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July 2019
Service a
nd Repa
ir Manua
l
Introduc
tion
Part No. 1
286829GT
S-
40 XC •
S
-
45 XC
• S
-
40 T
raX •
S-
45 T
raX
iii
Revis
ion Histor
y
Revision
Date
Section
Procedure / P
age / D
escripti
on
A
2/2019
Ini
tia
l Rel
eas
e
A1
7/2019
Reference
Examples:
Electronic V
ersion
Click on any content or procedure in the Table of Contents to view
the update.
Section
–
Repa
ir Pro
cedure, 4
-2
Section
–
Fau
lt Codes, A
ll chart
s
Section
–
Sch
ematics, L
egends an
d schemat
ics
2
4
Table of Contents
Table of Contents
7
Introduction
2
Find a Manual for this Model
2
Read, Understand and Obey the Safety Rules and Operating Instructions in the Appropriate Operator's Manual on Your Machine
2
Serial Number Legend
4
Safety Rules
5
Table of Contents
7
Specifications
11
Machine Specifications
11
Performance Specifications
12
Hydraulic Oil Specifications
12
Hydraulic Component Specifications
15
Manifold Component Specifications
16
Ford MSG-425 EFI Engine Specifications
17
Deutz D2011 L03I Engine Specifications
18
Deutz D 2.9 L4 Engine Specifications
19
Perkins 404F-E22T Engine Specifications
20
Machine Torque Specifications
22
TRAX Torque Specifications
22
Hydraulic Hose and Fitting Torque Specifications
23
Torque Procedure
24
Repair Procedures
26
Introduction
26
Immediately Tag and Remove from Service a
26
Observe and Obey
26
About this Section
27
Control System
28
1 ALC-600 Platform Control Module
28
Service Mode
29
How to Use the Recovery Mode
30
Full Machine Calibration
31
Machine Functions
31
How to Adjust the Machine Maximum Speed Setting
31
How to Adjust the Joystick Ramp Rate Setting
32
How to Adjust the Joystick Threshold Setting
33
How to Enter ALC600 Software Update Mode
34
Display Module Menus
35
How to Replace the Display Controller (DISCON) Module
40
How to Replace the Ground Control Overlay
41
Platform Components
44
Platform Leveling Slave Cylinder
44
Bodily Injury Hazard. Spraying
44
Connections very Slowly to Allow
44
Gradually. Do Not Allow Oil to
44
Hydraulic Oil Can Penetrate and Burn Skin. Loosen Hydraulic
44
Squirt or Spray
44
The Oil Pressure to Dissipate
44
Platform Rotator
45
Platform Overload System
48
How to Calibrate the Platform Overload System
48
How to Perform Zero Load Platform Overload Calibration
50
How to Replace the Platform Overload Load Cell
50
Platform
51
Jib Boom Components
51
Jib Boom
51
Jib Boom Lift Cylinder
53
Primary Boom Components
54
Cable Track
54
How to Remove the Cable Track
54
How to Repair the Cable Track
55
Boom
55
Boom Lift Cylinder
58
Boom Extension Cylinder
59
Platform Leveling Master Cylinder
60
Primary Boom Angle Sensor Calibration
61
Boom Length Sensor
62
Engines
63
RPM Adjustment - Deutz Models
63
RPM Adjustment - Perkins Models
63
Flex Plate
63
Ford MSG-425 Engine Fault Codes
67
Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models
67
Hydraulic Pumps
68
Function Pump
68
Drive Pump
69
Manifolds
71
Function Manifold Components
71
Valve Adjustments - Function Manifold
75
How to Adjust the Boom down Relief Valve
75
How to Adjust the System Relief Valve
75
How to Adjust the Boom Extend Relief Valve
76
Jib Boom and Platform Rotate Manifold Components
77
Traction Manifold Components, 4WD
78
Valve Adjustments, Traction Manifold
80
How to Set up the Oscillate Directional Valve
81
Valve Adjustment - Oscillate Relief Valve
82
Generator Manifold Components
83
Valve Coils
84
Turntable Rotation Components
86
Turntable Rotation Assembly
86
How to Adjust the Turntable Rotation Gear Backlash
87
How to Calibrate the Turntable Tilt Sensor
88
Axle Components
90
Oscillating Axle Cylinders
90
Track Components
91
Track Assembly
91
Fault Codes
93
Introduction
93
Be Sure that All Necessary Tools and Test Equipment Are Available and Ready for Use
93
Before Troubleshooting
93
Damaged or Malfunctioning Machine
93
Repair any Machine Damage or Malfunction before Operating the Machine
93
Troubleshooting and Repair Procedures Shall be Completed by a Person Trained and Qualified on the Repair of this Machine
93
Control System Fault Codes
94
How to Retrieve Control System Fault Codes
94
Control System Fault Codes (Software Version H and Up)
95
Engine Fault Codes
112
Deutz D 2.9 L4 Engine Fault Codes
113
Perkins 404F-22 Engine Fault Codes
124
Ford MSG-425 Engine Fault Codes
126
How to Retrieve Ford MSG-425 Engine Fault Codes
126
Electrocution/Burn Hazard
126
Schematics
132
Introduction
132
Electrical Symbol Legend
133
Hydraulic Symbols Legend
134
Engine Relay Layout - All Engines
135
Engine Relay Layout - Perkins 404F-22T
136
Circuit Connector Legend
137
Kw Generator Receptacle Wiring
141
Kw Generator Receptacle Wiring
142
12 Kw Generator Receptacle Wiring
143
Electrical Schematic- TCON
145
Electrical Schematic- Deutz 2.9 Models
149
Electrical Schematic- Perkins 404F-22T Models
154
Electrical Schematic- Ford MSG425 Models
155
Electrical Schematics
156
Hydraulic Schematic, 4WD Models
157
Other manuals for Genie S-45 TRAX
Operator's Manual
66 pages
Service Manual
296 pages
5
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Genie S-45 TRAX Specifications
General
Brand
Genie
Model
S-45 TRAX
Category
Boom Lifts
Language
English
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