Genie S-40 Service Manual
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Genie S-40 Service Manual

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Service Manual
S-40
TM
S-45
TM
S-40 TRAX
TM
S-45 TRAX
TM
Serial Number Range
from S4012-17232
to S4015-20504
Part No. 826364
Rev C1
October 2014

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Summary of Contents for Genie S-40

  • Page 1 Service Manual Serial Number Range from S4012-17232 S-40 to S4015-20504 S-45 S-40 TRAX S-45 TRAX Part No. 826364 Rev C1 October 2014...

  • Page 2: Introduction

    "Genie" and "S" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Contact Us: Printed on recycled paper Printed in U.S.A. http://www.genielift.com e-mail: awp.techpub@terex.com S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 3: Table Of Contents

    3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...

  • Page 4: Reference Examples

    3-3_Section 3_Maintenance Procedure Page #. Click on any procedure or page number 4-48_Section 4_Repair Procedure Page #. highlighted in blue to view the update. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 5: Serial Number Legend

    This machine complies with: Terex South Dakota 500 Oak Wood Road PO Box 1150 Watertown, SD 57201 Serial Label Sequence Number (located under cover) (stamped on chassis) PN - 77055 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...

  • Page 6: Safety Rules

    Indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 7 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. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...
  • Page 8 Inspect the Decals and Manuals ..............3 - 7 Perform Pre-operation Inspection ..............3 - 8 Perform Function Tests ................3 - 8 Perform Engine Maintenance- Ford Models ..........3 - 9 viii S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 9 B-11 Test the Platform Self-leveling ..............3 - 24 B-12 Test the Engine Idle Select ................ 3 - 25 B-13 Test the Fuel Select Operation - Ford Models ..........3 - 26 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...
  • Page 10 Perform Engine Maintenance - Perkins Models .......... 3 - 53 Perform Engine Maintenance - Deutz Models ..........3 - 54 Perform Engine Maintenance - Deutz Models ..........3 - 54 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 11 Cable Track ....................4 - 16 Boom ......................4 - 18 Boom Lift Cylinder ..................4 - 21 Boom Extension Cylinder ................4 - 22 Platform Leveling Master Cylinder .............. 4 - 23 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...
  • Page 12 Axle Components Oscillate Axle Cylinders ................4 - 52 Track Components 10-1 Track Assembly - TRAX Option ..............4 - 53 Generators 10-1 Hydraulic Generator ..................4 - 55 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 13: Schematics

    Deutz D 2.9 L4 Models ................6 - 11 Engine Wire Harness Perkins 404F-22 Models ................6 - 14 Engine Wire Harness Ford MSG425 Models ................6 - 15 xiii Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...
  • Page 14 Deutz D2011L03i Models Perkins 404D-22 Models ................6 - 44 Platform Switch Panel Wiring Diagram - ANSI / CSA Deutz Deutz D2011L03i Models Perkins 404D-22 Models ................6 - 45 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 15 Platform Control Box Wiring Diagram - CE Ford MSG-425 EFI Models ................. 6 - 74 Platform Switch Panel Wiring Diagram - CE Ford MSG-425 EFI Models ................. 6 - 75 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX...
  • Page 16 12.5 kW Hydraulic Generator Electrical Schematic- Welder Option ..... 6 - 102 12.5 kW Hydraulic Generator Wiring Diagram- Welder Option ......6 - 103 Hydraulic Schematic, 2WD ................. 6 - 106 Hydraulic Schematic, 4WD ................. 6 - 107 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 17: Specifications

    230 Nm Lug nut, lubricated 130 ft-lbs 176 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 1...

  • Page 18: Hydraulic Oil Specifications

    3 to 4 ft 0.9 to 1.2 m Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 19 2.8 gallons per minute 10.6 liters per minute Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 3...
  • Page 20 Hot oil relief pressure 280 psi 19.3 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 21: Manifold Component Specifications

    Solenoid valve, 2 position 3 way, 12V DC (schematic items CE) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 5...

  • Page 22: Ford Msg-425 Efi Engine Specifications

    Oil switch pressure point 7-9 psi 0.48 to 0.62 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 23 Alternator Output 95A, 13.8V DC Battery Type 12V DC, Group 31 Quantity Cold cranking ampere @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 7...

  • Page 24: Deutz D2011L03I Engine Specifications

    0.3 mm Injection pump make Bosch Exhaust 0.020 in Injection pump pressure, maximum 15000 psi 0.5 mm 1034 bar Injector opening pressure 3046 psi 210 bar 2 - 8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 25 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Alternator output 60A @ 14V DC Fan belt deflection inch 9 to 12 mm Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 9...

  • Page 26: Deutz D 2.9 L4 Engine Specifications

    Injector opening pressure 3046 psi (including filter) 9 liters 210 bar Fuel requirement For fuel requirements, refer to the engine Operator's Manual on your machine. 2 - 10 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 27 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Alternator output 95A @ 14V DC Fan belt deflection inch 9 to 12 mm Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 11...

  • Page 28: Perkins 404D-22 Engine Specifications

    2.8 to 4.1 bar Fan belt deflection to ½ in Oil capacity 9.4 quarts to 11.2 quarts 9 to 12 mm (including filter) 8.9 liters to 10.6 liters 2 - 12 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 29: Perkins 404F-22 Engine Specifications

    10 mm Starter motor Current draw, normal load 140A - 200A Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 13...
  • Page 30 Reserve capacity @ 25A rate 200 minutes Engine coolant Capacity 7.7 quarts 7.3 liters Coolant temperature sending unit Temperature switch point 221° F 105° C 2 - 14 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 31: Machine Torque Specifications

    Drive motor mounting bolts, dry 49 ft-lbs 66.4 Nm Drive motor mounting bolts, lubricated 37 ft-lbs 50 Nm Turntable bearing Turntable bearing mounting bolts, lubricated 180 ft-lbs 244 Nm Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 15...

  • Page 32: Hydraulic Hose And Fitting Torque Specifications

    135 ft-lbs / 183 Nm -16 (All types) 200 ft-lbs / 271.2 Nm -20 (All types) 250 ft-lbs / 339 Nm -24 (All types) 305 ft-lbs / 413.5 Nm 2 - 16 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 33 Refer to fitting. Figure 1. 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 2 - 17...
  • Page 34 Section 2 • Specifications February 2014 SPECIFICATIONS 10.9 12.9 2 - 18 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 35: Scheduled Maintenance Procedures

    • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 1...
  • Page 36 Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 37: Pre-Delivery Preparation

    Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Terex South Dakota, Inc USA Genie UK 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000...
  • Page 38 Section 3 • Scheduled Maintenance Procedures October 2014 This page intentionally left blank. 3 - 4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 39: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 5...
  • Page 40 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 41: Checklist A Procedures

    Note: Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 7...

  • Page 42: Perform Pre-Operation Inspection

    Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. 3 - 8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 43: Perform Engine Maintenance- Ford Models

    Ford MSG 425 EFI Operator Handbook Perkins 400 Series Operation Manual Genie part number 215322 Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 9...

  • Page 44: Perform Engine Maintenance - Deutz Models

    Deutz 2.9 L4 Series Operation Manual (Deutz part number 0312-3893) Deutz 2011 Series Operation Manual Genie part number 139320 Deutz 2.9 L4 Series Operation Manual Genie part number 1251561 3 - 10 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 45: Check The High Pressure Hydraulic Filter Condition Indicator

    Note: If the chassis does not remain level during test, refer to Repair Procedure 8-5, How to Set Up the Directional Valve Linkage. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 11...

  • Page 46: Perform 30 Day Service

    Refer to Section 2, Specifications. 5 Install the plugs into the drive hub. 6 Repeat this procedure for the other drive hub. 3 - 12 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 47: Perform Engine Maintenance - Ford Models

    Ford MSG 425 EFI Operator Handbook Perkins 400 Series Operation Manual Genie part number 215322 Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 13...

  • Page 48: Perform Engine Maintenance - Ford Models

    2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. 3 - 14 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 49: Perform Engine Maintenance - Ford Models

    2 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 15...

  • Page 50: Checklist B Procedures

    Note: Adding terminal protectors and a corrosion specific gravity of each battery cell with a preventative sealant will help eliminate corrosion on hydrometer. Note the results. the battery terminals and cables. 3 - 16 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 51: Inspect The Electrical Wiring

    Do not overfill. 12 Install the vent caps and neutralize any electrolyte that may have spilled. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 17...
  • Page 52 9 Remove the center turntable cover retaining fasteners. Remove the center turntable cover from the machine. 3 - 18 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 53: Check The Exhaust System

    1 Remove the safety pin from the engine pivot plate latch. Note: The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 19...

  • Page 54: Perform Engine Maintenance - Perkins Models

    1 Remove the safety pin from the engine pivot plate latch. Note: The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine. 3 - 20 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 55 12 Install the engine pivot plate safety pin. oil cooler cylinder head cooling fins fan blower fins 5 Clean the oil cooler of debris and foreign material. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 21...

  • Page 56: Inspect The Tires, Wheels And Lug Nut Torque

    3 Check each lug nut for proper torque. Refer to Section 2, Specifications . 4 Check the pressure in each air-filled tire. Refer to Section 2, Specifications . 3 - 22 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 57: Check The Drive Hub Oil Level And Fastener Torque

    4 Install the plug(s) into the drive hub. 5 Check the torque of the drive hub mounting bolts. Refer to Section 2, Specifications . 6 Repeat this procedure for each drive hub. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 23...

  • Page 58: Test The Platform Self-Leveling

    • Cotter pins are installed through clevis pins Result: The platform should remain level at • Linkage is properly attached to all times to within ±5 degrees. directional valve 3 - 24 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 59: Test The Engine Idle Select

    Result: The engine should change to high idle. 3 Release the function enable toggle switch. Result: The engine should return to low idle. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 25...

  • Page 60: Test The Fuel Select Operation - Ford Models

    (rabbit and foot switch symbol). 2 Start the engine from the platform controls and allow it to run at low idle. 3 - 26 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 61: Test The Drive Brakes

    3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol), then lower the boom into the stowed position. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 27...

  • Page 62: Test The Drive Speed - Stowed Position

    3 Move the engine idle control switch to foot switch activated high idle (rabbit and foot switch symbol), then lower the boom into the stowed position. 3 - 28 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 63: Test The Drive Speed - Raised Or Extended Position

    5 Choose a point on the machine; i.e., contact patch of a tire, as a visual reference for use when crossing the start and finish lines. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 29...
  • Page 64 Result: The descent alarm should sound when the switch is held down. 3 - 30 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 65: Perform Hydraulic Oil Analysis

    If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 31...

  • Page 66: Inspect The Fuel And Hydraulic Tank Cap Venting System

    1 Remove the cap from the fuel tank. venting system. Dry using low pressure compressed air. Repeat this procedure beginning with step 6. 8 Install the breather cap onto the hydraulic tank. 3 - 32 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 67: Check The Track Tension And Fastener Torque, Trax Option

    4 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 33...

  • Page 68: Test The Emergency Power System

    Result: All boom functions operate. 4 Close the emergency power switch cover and secure the cover with a security tie (if equipped). 3 - 34 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 69: Perform Engine Maintenance - Ford Models

    Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) Ford MSG-425 EFI Operator Handbook Genie part number 215322 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 35...

  • Page 70: Checklist C Procedures

    3 Remove all weight, tools and accessories from or equivalent the platform. Note: Failure to remove all weight, tools and accessories from the platform will result in an inaccurate test. 3 - 36 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 71 Refer to Repair overload indicator lights flash, the alarm sounds Procedure 2-4, How to Calibrate the Platform Overload System (if equipped). and the engine shuts off. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 37...
  • Page 72 Result: All ground control functions should Timer Relay operate normally. 15 Turn the key switch to platform control. Orange Wire Terminal 5 Illustration 2 3 - 38 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 73 Result: The Valve Power LED should illuminate. Result: The Valve Power LED is not illuminated. Remove the machine from service and contact the Genie Service Department . Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 39...
  • Page 74 5 Install the new filter element. 6 Install the end cap on the canister and re- connect the latches. Note: Be sure the evacuator valve is pointing down. 3 - 40 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 75: Perform Engine Maintenance - Perkins Models

    Genie part number 94890 Genie part number 94890 Perkins 404F Series Operation Manual Perkins 404F Series Operation Manual Genie part number 1251562 Genie part number 1251562 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 41...

  • Page 76: Perform Engine Maintenance - Deutz Models

    1 Connect a tachometer to the engine. Start the Deutz 2.9 L4 Series Operation Manual engine from the ground controls. Refer to Genie part number 1251561 Section 2 , Specifications. 3 - 42 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 77 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 43...

  • Page 78: Perform Engine Maintenance Ford Models

    Required maintenance procedures and additional engine information are available in the Ford MSG-425 EFI Operator Handbook (Ford part number 1020010) Ford MSG-425 EFI Operator Handbook Genie part number 215322 3 - 44 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 79 October 2014 Section 3 • Scheduled Maintenance Procedures CHECKLIST C PROCEDURES This page intentionally left blank. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 45...

  • Page 80: Checklist D Procedures

    Note: The minimum shim clearance for primary boom wear pads is 0.070 inch / 1.8 mm and the maximum allowable shim clearance is 0.188 inch / 4.8 mm. 3 - 46 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 81: Check The Turntable Rotation Bearing Bolts

    Crushing hazard. Failure to secure the engine pivot plate from moving could result in death or serious injury. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 47...

  • Page 82: Inspect For Turntable Bearing Wear

    Rotation Bearing Bolts. 3 Start the machine from the ground controls and raise the primary and secondary booms to full height. Do not extend the primary boom. 3 - 48 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 83 12 Remove the dial indicator from the machine. 5 At the dial indicator, adjust it to "zero" the indicator. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 49...

  • Page 84: Replace The Drive Hub Oil

    6 Check the torque of the drive hub mounting (20,000 lbs / 10,000 kg) under the drive chassis bolts. Refer to Section 2, Specifications . between the non-steer tires. 3 - 50 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 85 Collision hazard. Failure to result in death or serious injury and re-engage the drive hubs could property damage. result in death or serious injury and property damage. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 51...

  • Page 86: Replace The Hydraulic Filters

    3 Lift the handle on the filter element and rotate the element counterclockwise to release the element from the housing. 4 Remove the filter element from the filter housing. 3 - 52 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 87: Perform Engine Maintenance - Perkins Models

    Perkins 404F Series Operation Manual (Perkins part number SEBU8609). Perkins 400 Series Operation Manual Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 53...

  • Page 88: D-8 Perform Engine Maintenance - Deutz Models

    Deutz 2.9 L4 Series Operation Manual (Deutz part number 3012-3893) Deutz 2011 Series Operation Manual Genie part number 139320 Deutz 2.9 L4 Series Operation Manual Genie part number 1251561 3 - 54 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 89: Checklist E Procedures

    Refer open closed to Section 2, Hydraulic Hose and Fitting Torque Specifications . Note: Perform this procedure with the boom in the stowed position. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 55...
  • Page 90 How to Prime the Pump. return filter housing from the hydraulic tank. Note: Always use pipe thread sealant when installing the suction hose fittings and the drain plug. 3 - 56 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 91: Grease The Steer Axle Wheel Bearings, 2Wd Models

    Result: There should be no side to side or up 15 Place the large inner bearing into the rear of the and down movement. hub. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 57...

  • Page 92: Perform Engine Maintenance - Perkins Models

    (Perkins part number SEBU8609). specification. Refer to Section 2, Specifications. Perkins 400 Series Operation Manual Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 3 - 58 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 93: Perform Engine Maintenance - Deutz Models

    139320 Genie part number 139320 Deutz 2.9 L4 Series Operation Manual Deutz 2.9 L4 Series Operation Manual Genie part number 1251561 Genie part number 1251561 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 59...

  • Page 94: Perform Engine Maintenance - Perkins Models

    Perkins 404F Series Operation Manual (Perkins part number SEBU8609). Perkins 400 Series Operation Manual Genie part number 94890 Perkins 404F Series Operation Manual Genie part number 1251562 3 - 60 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 95: Perform Engine Maintenance - Deutz Models

    Deutz 2011 Series Operation Manual (Deutz part number 0312-3547). Perkins 404F Series Operation Manual Genie part number 1251562 Deutz 2011 Series Operation Manual Genie part number 139320 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3 - 61...
  • Page 96 Section 3 • Scheduled Maintenance Procedures October 2014 This page intentionally left blank. 3 - 62 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 97: Repair Procedures

    • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 1...

  • Page 98: Platform Controls

    ALC-500 circuit board drive/steer joystick controller secondary boom up/down joystick controller primary boom up/down and turntable rotate left/right joystick controller 4 - 2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 99: Joysticks

    Note: The joystick must be calibrated before the threshold, max-out or ramping can be set. Note: Perform this procedure with the engine off. 1 Open the platform control box. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 3...
  • Page 100 6 When the alarm sounds, release the drive in 2% increments. enable toggle switch. 12 Repeat steps 9 through 11 for each joystick controlled machine function. 4 - 4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 101 11 Release the foot switch. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 5...
  • Page 102 Note: Do not operate any machine function during the 10 second waiting time. 15 Cycle the red Emergency Stop button off, then back on. 4 - 6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 103 Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode. Result: The alarm does not sound. Repeat steps 3 through 7. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 7...

  • Page 104: Platform Components

    2 Raise the primary boom slightly and place 8 Remove the pin retaining fastener from blocks under the platform for support. the slave cylinder rod-end pivot pin. Do not remove the pin. 4 - 8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 105: Platform Rotator

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Remove the platform and platform support. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 9...
  • Page 106 Crushing hazard. The platform rotator could become unbalanced and fall if it is not properly supported. 4 - 10 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 107: Platform Overload System

    Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 11...
  • Page 108 Note: There may be a 2 second delay before the platform overload indicator light and alarm responds. 4 - 12 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 109 15 Turn the key switch to platform control. 16 Test all machine functions from the platform controls. Result: All platform control functions should operate normally. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 13...

  • Page 110: Jib Boom Components

    4 - 14 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 111: Jib Boom Lift Cylinder

    Do not allow oil to the overhead crane. squirt or spray. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 15...

  • Page 112: Boom Components

    11 Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom. Do not disconnect the wiring. 4 - 16 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 113 8 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 17...

  • Page 114: Boom

    Note: Always replace the cotter pin with a new one when removing a clevis pin. 11 Remove the fasteners from the side panel on the cable track to access the cable track mounting fasteners. 4 - 18 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 115 Do not allow oil to squirt or spray. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 19...
  • Page 116 Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. 4 - 20 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 117: Boom Lift Cylinder

    Turn the machine off. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 21...
  • Page 118 4 Remove the external snap rings from the installation. extension cylinder rod-end pins (at the platform end). Use a soft metal drift to remove the pins. 5 Remove the turntable end cover. 4 - 22 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 119: Platform Leveling Master Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 23...

  • Page 120: Rpm Adjustment - Perkins Models

    4 Support the drive pump with an appropriate lifting device. Then remove all of the bell housing to engine mounting bolts. Leave the pump connected to the bell housing. 4 - 24 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 121 Do not remove the oxygen sensor. 7 Support the muffler and bracket assembly with a suitable lifting device. 8 Remove the exhaust pipe fasteners at the muffler. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 25...
  • Page 122 (Genie part number 128025) to the splines of the pump shaft and flex plate. Grease Specification ® Shell Alvania Grease CG, NLGI 0/1 or equivalent. Deutz models Perkins models 4 - 26 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 123 Deutz models Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. Perkins models Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 27...

  • Page 124: Ford Msg-425 Engine Fault Codes

    Refer to Section 5, How to Retrieve Engine Fault Codes for your specific model of engine. Use the Fault Code Chart within Section 5 to aid in identifying the fault. 4 - 28 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 125: Hydraulic Pumps

    If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 29...

  • Page 126: Drive Pump

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 30 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 127 3 Open the engine pivot plate latch and swing the valve. engine pivot plate out and away from the machine. 7 Start the engine from the ground controls and check for hydraulic leaks. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 31...

  • Page 128: Function Manifold Components

    Flow regulator valve ......BP ..Bleeds off differential sensing valves to tank ........30-35 ft-lbs / 41-47 Nm This list continues. Please turn the page 4 - 32 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 129 February 2014 Section 4 • Repair Procedures MANIFOLDS Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 33...
  • Page 130 2900 psi / 200 bar ......BR ..System relief (S-45) ......30-35 ft-lbs / 41-47 Nm Relief valve, 2600 psi / 179 bar ......BR ..System relief (S-40) ......30-35 ft-lbs / 41-47 Nm Check valve ........BS ..Blocks flow from auxiliary pump...
  • Page 131 February 2014 Section 4 • Repair Procedures MANIFOLDS Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 35...

  • Page 132: Valve Adjustments - Function Manifold

    Tip-over hazard. Do not adjust the relief valve higher than specified. 7 Repeat steps 2 through 5 and recheck relief valve pressure. 8 Remove the pressure gauge. 4 - 36 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 133 Solenoid valve, 2 position 3 way ..CC ..Platform rotate/jib boom select ..18-20 ft-lbs / 25-27 Nm Jib Select Manifold Platform Rotate Manifold Generator Manifold Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 37...
  • Page 134 Solenoid valve, 2 position 3 way ... EC ... Two-speed motor shift ..... 20-25 ft-lbs / 27-34 Nm Check valve ........ED ... Brake release circuit ......20-25 ft-lbs / 27-34 Nm 4 - 38 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 135: Oscillate Directional Valve Components

    The oscillate directional valve is mounted inside the drive chassis at the non-steer end. Index Description Function Torque Cap ..............Breather ..........20-25 ft-lbs / 27-33 Nm Spool valve ............Directional control Relief valve ............Pressure adjustment Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 39...
  • Page 136 7 To level the drive chassis, start the engine, select high idle and push up or pull down on the Service Department. threaded rod until the machine is completely level. 4 - 40 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 137: Valve Adjustments, Oscillate Relief Valve

    5 With the engine running at high idle, manually activate the valve and observe the pressure reading on the pressure gauge. Oscillate relief valve specification Pressure 950 psi 65.5 bar Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 41...

  • Page 138: Traction Manifold Components, 2Wd

    ......50-55 ft-lbs / 68-75 Nm Orifice, 0.070 inch / 1.78 mm .... GF ..Equalizes flow across flow divider/combiner valve (item GB) 4 - 42 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 139 3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 43...

  • Page 140: Traction Manifold Components, 4Wd

    1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 4 - 44 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 141 February 2014 Section 4 • Repair Procedures MANIFOLDS Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 45...
  • Page 142 3 Turn the engine off and connect a 0 to 600 psi / 0 to 41 bar pressure gauge to the diagnostic nipple located on the drive manifold. 4 - 46 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 143: Drive Oil Diverter Manifold Components (Welder Option)

    Relief valve ........CX ... Charge pressure circuit ....35-40 ft-lbs / 47-54 Nm Check valve ........CU ... Prevents oil to generator ....35-40 ft-lbs / 47-54 Nm Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 47...

  • Page 144: Valve Coils

    (Ω). Refer to the Valve Coil Resistance Specification table. Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil. 4 - 48 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 145 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 49...

  • Page 146: Turntable Rotation Components

    1 Secure the turntable from rotating with the turntable rotation lock pin. Unlocked position brake assembly drive hub backlash plate mounting bolts backlash plate manifold motor Locked position 4 - 50 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 147 When installing the drive hub assembly: ® 6 Install the drive hub. Apply Loctite removable thread sealant and torque the backlash plate mounting fasteners to 160 ft-lbs / 217 Nm. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 51...

  • Page 148: Axle Components

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Rotate the turntable until the boom is between the steer tires. 4 - 52 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 149: Track Components

    Crushing hazard. The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 53...
  • Page 150 10 Continue rotating the half sprocket until it is fully engaging the track. 4 - 54 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 151: Hydraulic Generator

    The generator is ready for use. Result: The generator output voltage is outside the ±10% voltage range. Repeat the procedure beginning with step 2. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 4 - 55...
  • Page 152 February 2014 Section 4 • Repair Procedures GENERATORS This page intentionally left blank. 4 - 56 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 153: Fault Codes

    • Key switch in the off position with the key removed • Wheels chocked • All external AC power disconnected from the machine Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 1...

  • Page 154: Fault Codes - Control System

    OR use a grounded wrist strap. 5 - 2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 155 Boom 2 directional Valve is operating Cycle power off, valves outside of operational then on and Fault limits. Alarm sounds problem should be indicating fault. corrected. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 3...
  • Page 156 Drive enable Drive enable function Cycle power off, toggle switch is inoperative. then on and Fault problem should be corrected. 5 - 4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 157 Steer directional Valve is operating Cycle power off, valves outside of operational then on and Fault limits. Alarm sounds problem should be indicating fault. corrected. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 5...

  • Page 158: Fault Code Display - Deutz D 2.9 L4 And Perkins 404F-22 Models

    These faults will not be erased when Fault Log Previous Faults Device List corrective action has been completed. Quick Data Currently Active Faults SPN: FMI: 5 - 6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 159: Fault Code Display - Flashing And Solid Led's

    6 Right red LED: Flashing, engine fault detected. Contact service. Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact service. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 7...

  • Page 160: Fault Code Display - Soft Key Functions And Icons

    Exit / Back Scroll Scroll Select One Screen Down Main Hour Coolant Menu Meter Pressure Temp. Soot Engine Soot Level Voltage Pin # Percent (%) Protected 5 - 8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 161: Fault Code Display - Main Menu Structure

    System Setup Language Fault Log Screen Setup Reset Defaults Parameters Number of Screens Units Device List Display Select Screen PIN Setup Trip Reset Quick Data Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 9...

  • Page 162: Fault Codes - Deutz D 2.9 L4 Engine

    1014 Actuator error EGR-Valve; signal range check high Sensor error water in fuel; signal range check low 1157 Water in fuel level prefilter; maximum value exceeded 5 - 10 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 163 Sesnor error rail pressure; check high signal range check high Sensor error charged air Sensor error rail pressure; temperature; signal range signal range check low check low Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 11...
  • Page 164 Sensor error intake air; signal Sensor camshaft speed; range check high disturbed signal Sensor error intake air sensor; signal range check low 5 - 12 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 165 Injector 1 (in firing order); pressure Venturiunit (EGR); short circuit signal range check low High side to low side short circuit in the injector 1 (in firing order) Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 13...
  • Page 166 Sensor supply voltage monitor 1 error (ECU) Cold start aid relay error. 1080 Sensor supply voltage monitor Cold start aid relay open load 2 error (ECU) 5 - 14 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 167 1231 CAN-Bus 1 "BusOff-Status" 1180 1461 Turbocharger Wastegate CAN 1235 CAN-Bus 2 "BusOff-Status" feedback; shut off threshold exceeded Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 15...
  • Page 168 1039 Physical range check high for measurement cyl. Bank 0 exhaust gas temperature upstream (DOC) 4765 1042 Physical range check low for exhaust gas temperature upstream (DOC) 5 - 16 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 169 Controller mode switch; short 523470 2 Pressure Relief Valve (PRV) circuit to ground forced to open; performed by 523008 1 Manipulation control was pressure shock triggered Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 17...
  • Page 170 Internal software error ECU; detection reported error injection cut off 523612 12 Internal ECU monitoring 523612 12 Internal ECU monitoring detection reported error detection reported error 5 - 18 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 171 Timeout Error of CAN-Receive- 523615 3 Metering unit (Fuel-System); Frame Active TSC1AE short circuit to battery highside 523767 9 Timeout Error of CAN-Receive- Frame Passive TSC1AE Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 19...
  • Page 172 523920 2 1379 Sensor exhaust gas back pressure burner; 523896 13 check of missing injector plausibility error adjustment value programming (IMA) injector 2 (in firing order) 5 - 20 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 173 523960 0 1011 Physical range check high for EGR cooler downstream temp. 523935 12 Timeout Error of CAN-Transmit- Frame EEC3VOL1; Engine send messages Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 21...
  • Page 174 524034 5 1436 Disc Separator; open load 524014 1 1254 Air pressure glow plug flush 524034 12 1437 Disc Separator; line; below limit powerstage over temperature 5 - 22 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 175 1672 Timeout error of CAN- Receive-Frame Receive-Frame ComRxCM1 ComRxEGRMsFlw1 524119 9 1673 Timeout error of CAN- 524107 9 1678 Timeout error of CAN- Receive-Frame Receive-Frame ComRxCustSCR3 ComRxEGRMsFlw2 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 23...
  • Page 176 1685 Timeout error of CAN- Receive-Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN- Receive-Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN- Receive-Frame ComTxTrbChActr 5 - 24 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 177 Voltage Above Normal Engine Rack Position Sensor: Battery Potential/ Power Input 1: Voltage Above Normal Voltage Below Normal Engine Rack Position Sensor: Voltage Below Normal Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 25...
  • Page 178 "Particulate Trap Intake Gas Temp: Voltage Above “Normal" 3610 DieselParticulate Filter Outlet Pressure Sensor 1: 3242 "Particulate Trap Intake Gas Temp: Voltage Below Normal Voltage Below “Normal" 5 - 26 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 179 Abnormal Rate of Change 4765 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Low-most severe (3) 4765 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Above Normal Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 27...

  • Page 180: Fault Codes - Ford Msg-425 Engine

    The check engine light should begin to blink. could result in death or serious injury. Remove all rings, watches and other jewelry. 3 Connect the negative battery cable to the battery. 5 - 28 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 181 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 29...
  • Page 182 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 5 - 30 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 183 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 31...
  • Page 184 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 5 - 32 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 185 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5 - 33...
  • Page 186 Ford MSG-425/ Ford DSG-423 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425/DSG-423 EFI Diagnostic Manual Genie part number 162067 5 - 34 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 187 Be sure that all necessary tools and test symptoms discovered equipment are available and ready for use. problem still exists Inspect Perform Return to and test repair service problem solved Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 1...

  • Page 188: Electrical Symbols Legend

    Key switch Coil with suppresion Fuse with amperage N.O. Circuit breaker with amperage Control relay contact DiodeStarting aid: normally open (NO) glow plug or flame ignitor 6 - 2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 189: Hydraulic Symbols Legend

    Pump, prime mover Differential sensing valve (engine or motor) Pilot operated 2 position, Double acting cylinder 2 way, directional valve Solenoid operated proportional valve Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 3...

  • Page 190: Electrical Abbreviations Legend

    Load sense aux recovery (AS models) LS18 CE limit switch CR51 Aircraft package (option) Gauge Battery Charge Indicator Engine oil pressure Engine coolant temp. Engine oil temp. Hour meter 6 - 4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 191 Primary boom up/down toggle switch TS62 Turntable rotate toggle switch TS63 Primary boom extend/retract toggle switch TS64 Run/test toggle switch (Ford) TS74 Run/test toggle switch (Deutz) Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 5...
  • Page 192 ALC500 input/out connectors WH/RD ........White/Red X107 ALC500 input/out connectors WH/YL ........White/Yellow X108 ALC500 input/out connectors YL/BK ........Yellow/Black X109 ALC500 input/out connectors X1-4 Circuit splice 6 - 6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 193: Ford Engine Relay Layout

    F1 Battery voltage to EPR F2 Ignition voltage to GCP and relays F3 Battery voltage to GCP F4 Fuel pump F5 Battery voltage out of Power Relay F6 Alternator Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 7...
  • Page 194 Fuel pump, Alternator Ext. CR15A Glow plug 1 CR15B Glow plug 2 CR15C ARD Glow plug CR15D Burner air pump Diode 6A, Alternator Ext. C1 (BLACK) C2 (GREY) 6 - 8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 195: Connector Pin Legend

    Section 6 • Schematics October 2014 Connector Pin Legend 6 - 10 6 - 9...
  • Page 196 BK 12GA C4P-5 C17JU C4P-6 C18JD GR/BK C4P-7 C19JSV GR/WH C4P-9 C4P-10 DRV_LT C4P-11 C4P-12 DRV_LT PIN# CKT# COLOR C7-1 P22BAT C7-2 P23BAT C7-3 BATGND C7-4 6 - 10 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 197: Engine Wire Harness

    IND. D105CAN+ BK/RD DIAG-H D82CAN+ YL DIAG-M NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 11...

  • Page 198: Engine Wire Harness

    October 2014 Section 6 • Schematics Engine Wire Harness Deutz D 2.9 L4 Models 6 - 11 6 - 12...
  • Page 199 Section 6 • Schematics October 2014 Engine Wire Harness Perkins 404F Models 6 - 14 6 - 13...
  • Page 200 October 2014 Section 6 • Schematics Engine Wire Harness Perkins 404F Models 6 - 14 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 201 October 2014 Section 6 • Schematics Engine Wire Harness Ford MSG-425 EFI Models Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 15...
  • Page 202 October 2014 Section 6 • Schematics Engine Wire Harness Ford MSG-425 EFI Models 6 - 15 6 - 16...
  • Page 203 Section 6 • Schematics October 2014 Electrical Schematic - ANSI Deutz D 2.9 L4 Models 6 - 18 6 - 17...

  • Page 204: Deutz D 2.9 L4 Models

    Deutz D 2.9 L4 Models C32 CONN. PLUG NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 18 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 205 Electrical Schematic - ANSI Deutz D 2.9 L4 Models NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 19...
  • Page 206 October 2014 Section 6 • Schematics Electrical Schematic - ANSI Deutz D 2.9 L4 Models 6 - 19 6 - 20...
  • Page 207 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - ANSI Deutz D 2.9 L4 Models 6 - 22 6 - 21...

  • Page 208: Ground Control Box Wiring Diagram - Ansi Deutz D 2.9 L4 Models

    86 86 86 86 86 86 YL C5-16 GR C5-15 87 87 87 87 87 87 RD/WH C5-8 BR GND WH 23A RD TS63 RD TS62 RD TS61 6 - 22 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 209 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - ANSI Deutz D 2.9 L4 Models 6 - 24 6 - 23...

  • Page 210: Platform Control Box Wiring Diagram - Ansi Deutz D 2.9 L4 Models

    October 2014 Section 6 • Schematics Platform Control Box Wiring Diagram - ANSI Deutz D 2.9 L4 Models CR14 C28TTA RD/BK C1P-2 6 - 24 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 211 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI Deutz D 2.9 L4 Models CR13 DETAIL A: LIFT/DRIVE OPTION HORN AUXILIARY PUMP CE SEE DETAIL A Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 25...

  • Page 212: Platform Switch Panel Wiring Diagram - Ansi Deutz D 2.9 L4 Models

    October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI Deutz D 2.9 L4 Models 6 - 25 6 - 26...

  • Page 213: Perkins 404F-22 Models

    Section 6 • Schematics October 2014 Electrical Schematic - ANSI Perkins 404F-22 Models 6 - 28 6 - 27...

  • Page 214: Electrical Schematic - Ansi Perkins 404F-22 Models

    Electrical Schematic - ANSI Perkins 404F-22 Models C32 CONN. PLUG NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 28 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 215 Electrical Schematic - ANSI Perkins 404F-22 Models NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 29...
  • Page 216 October 2014 Section 6 • Schematics Electrical Schematic - ANSI Perkins 404F-22 Models 6 - 29 6 - 30...
  • Page 217 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - ANSI Perkins 404F-22 Models 6 - 32 6 - 31...

  • Page 218: Ground Control Box Wiring Diagram - Ansi Perkins 404F-22 Models

    YL C5-16 CR61B GR C5-15 CR4A CR4B BR GND WH 23A BK 33B OR/RD 34D BK/RD 35D RD TS63 BK/WH C5-13 BK.RD C5-14 RD TS62 RD TS61 6 - 32 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 219 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - ANSI Perkins 404F-22 Models 6 - 34 6 - 33...

  • Page 220: Platform Control Box Wiring Diagram - Ansi Perkins 404F-22 Models

    October 2014 Section 6 • Schematics Platform Control Box Wiring Diagram - ANSI Perkins 404F-22 Models CR14 C28TTA RD/BK C1P-2 6 - 34 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 221 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI Perkins 404F-22 Models CR13 DETAIL A: LIFT/DRIVE OPTION HORN AUXILIARY PUMP CE SEE DETAIL A Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 35...

  • Page 222: Platform Switch Panel Wiring Diagram - Ansi Perkins 404F-22 Models

    October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI Perkins 404F-22 Models 6 - 35 6 - 36...
  • Page 223 Section 6 • Schematics October 2014 Electrical Schematic - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models 6 - 38 6 - 37...
  • Page 224 GLOW ENGINE PLUG START CONN. PLUG REGULATOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 38 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 225 Electrical Schematic - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 39...
  • Page 226 October 2014 Section 6 • Schematics Electrical Schematic - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models 6 - 39 6 - 40...
  • Page 227 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models 6 - 42 6 - 41...
  • Page 228 October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models KEY SWITCH EDC RET. CR17 6 - 42 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 229 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models 6 - 44 6 - 43...
  • Page 230 GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALALRM 6 - 44 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 231 PLATFORM START HIGH/LOW HORN GLOW PLUG PLATFORM ROTATE AUXILIARY PUMP LEVEL GENERATOR GR/BK (OPTION) CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 45...
  • Page 232 October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI / CSA Deutz D2011L03i and Perkins 404D-22 Models 6 - 45 6 - 46...
  • Page 233 Section 6 • Schematics October 2014 Electrical Schematic - ANSI / CSA Ford MSG-425 EFI Models 6 - 48 6 - 47...

  • Page 234: Ford Msg-425 Efi Models

    PUMP SELECT AUXILIARY PUMP FUEL SELECT CONN. PLUG NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 48 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 235 Electrical Schematic - ANSI / CSA Ford MSG-425 EFI Models NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 49...
  • Page 236 October 2014 Section 6 • Schematics Electrical Schematic - ANSI / CSA Ford MSG-425 EFI Models 6 - 49 6 - 50...
  • Page 237 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - ANSI / CSA Ford MSG-425 EFI Models 6 - 52 6 - 51...

  • Page 238: Ground Control Box Wiring Diagram - Ansi / Csa Ford Msg-425 Efi Models

    October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - ANSI / CSA Ford MSG-425 EFI Models KEY SWITCH EDC_RET 6 - 52 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 239 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - ANSI / CSA Ford MSG-425 EFI Models 6 - 54 6 - 53...

  • Page 240: Platform Control Box Wiring Diagram - Ansi / Csa Ford Msg-425 Efi Models

    GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALALRM 6 - 54 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 241 TS47 TS14 HIGH/LOW GENERATOR DRIVE START HORN (OPTION) PLATFORM SPEED PLATFORM AUXILIARY EMERGENCY STOP ROTATE HIGH/LOW LEVEL PUMP FUEL SELECT GR/BK CE SEE DETAIL A Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 55...

  • Page 242: Platform Switch Panel Wiring Diagram - Ansi / Csa Ford Msg-425 Efi Models

    October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - ANSI / CSA Ford MSG-425 EFI Models 6 - 55 6 - 56...
  • Page 243 Section 6 • Schematics October 2014 Electrical Schematic - CE Deutz D2011L03i and Perkins 404D-22 Models 6 - 58 6 - 57...
  • Page 244 SENSE GLOW MODULE ENGINE PLUG START REGULATOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 58 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 245 Electrical Schematic - CE Deutz D2011L03i and Perkins 404D-22 Models NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 59...
  • Page 246 October 2014 Section 6 • Schematics Electrical Schematic - CE Deutz D2011L03i and Perkins 404D-22 Models 6 - 59 6 - 60...
  • Page 247 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - CE Deutz D2011L03i and Perkins 404D-22 Models 6 - 62 6 - 61...
  • Page 248 October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - CE Deutz D2011L03i and Perkins 404D-22 Models KEY SWITCH EDC RET. CR17 6 - 62 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 249 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - CE Deutz D2011L03i and Perkins 404D-22 Models 6 - 64 6 - 63...
  • Page 250 GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALALRM 6 - 64 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 251 PLATFORM START HIGH/LOW HORN GLOW PLUG PLATFORM ROTATE AUXILIARY PUMP LEVEL GENERATOR GR/BK (OPTION) CE SEE DETAIL A NOTE: 1) DASHED LINES INDICATE OPTION WIRES. Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 65...
  • Page 252 October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - CE Deutz D2011L03i and Perkins 404D-22 Models 6 - 65 6 - 66...
  • Page 253 Section 6 • Schematics October 2014 Electrical Schematic - CE Ford MSG-425 EFI Models 6 - 68 6 - 67...

  • Page 254: Electrical Schematic - Ce Ford Msg-425 Efi Models

    PUMP AUXILIARY FUEL LOAD PUMP SELECT SENSE MODUL NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 68 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 255 Electrical Schematic - CE Ford MSG-425 EFI Models NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 69...
  • Page 256 October 2014 Section 6 • Schematics Electrical Schematic - CE Ford MSG-425 EFI Models 6 - 69 6 - 70...
  • Page 257 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - CE Ford MSG-425 EFI Models 6 - 72 6 - 71...

  • Page 258: Ground Control Box Wiring Diagram - Ce Ford Msg-425 Efi Models

    October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - CE Ford MSG-425 EFI Models KEY SWITCH EDC_RET 6 - 72 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 259 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - CE Ford MSG-425 EFI Models 6 - 74 6 - 73...

  • Page 260: Platform Control Box Wiring Diagram - Ce Ford Msg-425 Efi Models

    GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 RD LS18 CABLE TILT ALARM 6 - 74 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 261: Platform Switch Panel Wiring Diagram - Ce Ford Msg-425 Efi Models

    TS47 TS14 HIGH/LOW GENERATOR DRIVE START HORN (OPTION) PLATFORM SPEED PLATFORM AUXILIARY EMERGENCY STOP ROTATE HIGH/LOW LEVEL PUMP FUEL SELECT GR/BK CE SEE DETAIL A Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 75...
  • Page 262 October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - CE Ford MSG-425 EFI Models 6 - 75 6 - 76...
  • Page 263 Section 6 • Schematics October 2014 Electrical Schematic - AUS Deutz D2011L03i and Perkins 404D-22 Models 6 - 78 6 - 77...

  • Page 264: Perkins 404D-22 Models

    LOAD SENSE MODULE ENGINE START REGULATOR NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM ES0422X IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 78 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 265 Electrical Schematic - AUS Deutz D2011L03i and Perkins 404D-22 Models NOTE: 1. ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 79...
  • Page 266 October 2014 Section 6 • Schematics Electrical Schematic - AUS Deutz D2011L03i and Perkins 404D-22 Models 6 - 79 6 - 80...
  • Page 267 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - AUS Deutz D2011L03i and Perkins 404D-22 Models 6 - 82 6 - 81...
  • Page 268 October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - AUS Deutz D2011L03i and Perkins 404D-22 Models KEY SWITCH EDC RET. CR17 6 - 82 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 269 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - AUS Deutz D2011L03i and Perkins 404D-22 Models 6 - 84 6 - 83...
  • Page 270 PUMP AUXILIARY FUEL LOAD PUMP SELECT SENSE MODUL NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 84 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 271 Platform Switch Panel Wiring Diagram - AUS Deutz D2011L03i and Perkins 404D-22 Models NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 85...

  • Page 272: Platform Switch Panel Wiring Diagram - Aus

    October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - AUS Deutz D2011L03i and Perkins 404D-22 Models 6 - 85 6 - 86...
  • Page 273 Section 6 • Schematics October 2014 Electrical Schematic - AUS Ford MSG-425 EFI Models 6 - 88 6 - 87...

  • Page 274: Electrical Schematic - Aus Ford Msg-425 Efi Models

    PUMP AUXILIARY FUEL LOAD PUMP SELECT SENSE MODUL NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". 6 - 88 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 275 Electrical Schematic - AUS Ford MSG-425 EFI Models NOTE: ALL SWITCHES AND CONTACTS ARE SHOWN WITH THE BOOM IN THE STOWED POSITION AND KEYSWITCH "OFF". Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 89...

  • Page 276: Ford Msg-425 Efi Models

    October 2014 Section 6 • Schematics Electrical Schematic - AUS Ford MSG-425 EFI Models 6 - 89 6 - 90...
  • Page 277 Section 6 • Schematics October 2014 Ground Control Box Wiring Diagram - AUS Ford MSG-425 EFI Models 6 - 92 6 - 91...

  • Page 278: Ground Control Box Wiring Diagram - Aus Ford Msg-425 Efi Models

    October 2014 Section 6 • Schematics Ground Control Box Wiring Diagram - AUS Ford MSG-425 EFI Models KEY SWITCH EDC_RET 6 - 92 S-40 • S-45 • S-40 TRAX • S-45 TRAX 826364...
  • Page 279 Section 6 • Schematics October 2014 Platform Control Box Wiring Diagram - AUS Ford MSG-425 EFI Models 6 - 94 6 - 93...

  • Page 280: Platform Control Box Wiring Diagram - Aus Ford Msg-425 Efi Models

    CR76 CR14 GR/WH GR/WH + RD OUTPUT BR - C28TTA RD/BK C1P-2 GR/BK C4P-4 GR/WH BATGND C7P-3 C132PLI1 BK C1P-12 C132PLI2 BK C3P-10 TILT ALALRM 6 - 94 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 281: Platform Switch Panel Wiring Diagram - Aus Ford Msg-425 Efi Models

    TS47 TS14 HIGH/LOW GENERATOR DRIVE START HORN (OPTION) PLATFORM SPEED PLATFORM AUXILIARY ROTATE HIGH/LOW LEVEL FUEL SELECT PUMP GR/BK EMERGENCY STOP CE SEE DETAIL A Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 95...
  • Page 282 October 2014 Section 6 • Schematics Platform Switch Panel Wiring Diagram - AUS Ford MSG-425 EFI Models 6 - 95 6 - 96...

  • Page 283: Cte Option Wiring Diagram

    Section 6 • Schematics October 2014 CTE Option Wiring Diagram 6 - 98 6 - 97...
  • Page 284 October 2014 Section 6 • Schematics CTE Option Wiring Diagram 6 - 98 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 285: Hydraulic Generator Option Wiring Diagram- Mte

    October 2014 Section 6 • Schematics Hydraulic Generator Option Wiring Diagram- MTE Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 99...
  • Page 286 October 2014 Section 6 • Schematics Hydraulic Generator Option Wiring Diagram- MTE 6 - 99 6 - 100...

  • Page 287: 12.5 Kw Hydraulic Generator Electrical Schematic- Welder Option

    Section 6 • Schematics October 2014 12.5 kW Hydraulic Generator Electrical Schematic- Welder Option 6 - 102 6 - 101...
  • Page 288 F1 DIG IN 0 F2 DIG IN 1 GENERATOR ON N.O. F3 DIG IN 2 SX Controller Y75-2 PILOT PRESSURE SIGNAL FROM GENERATOR MANIFOLD BR-2 (16-2) DIVERTER MANIFOLD 6 - 102 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...

  • Page 289: 12.5 Kw Hydraulic Generator Wiring Diagram- Welder Option

    8 GA 5 CONDUCTOR BRASS 120 VAC GFI GREEN 12GA 12 GA 3 CONDUCTOR ENCLOSURE SILVER BRASS WHITE 110 VAC GREEN GREEN BLACK ES0506B 12 GA 3 CONDUCTOR Part No. 826364 S-40 • S-45 • S-40 TRAX • S-45 TRAX 6 - 103...
  • Page 290 October 2014 Section 6 • Schematics 12.5 kW Hydraulic Generator Wiring Diagram- Welder Option 6 - 103 6 - 104...
  • Page 291 Section 6 • Schematics October 2014 2WD Hydraulic Schematic 6 - 106 6 - 105...
  • Page 292 SET @ 2700 PSI AJ AK NO PRESS SW 200 PSI Note: 'alpha' callouts refer to HS0165J components shown in the manifold illustrations. Refer to the Repair Section. 6 - 106 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 826364...
  • Page 293 RELIEF VALVE SET @ 2700 PSI AJ AK NO PRESS SW 200 PSI Note: 'alpha' callouts refer to components shown in the manifold illustrations. Refer to the Repair Section. HS0165J Part No. 102521 S-40 • S-45 6 - 107...
  • Page 294 October 2014 Section 6 • Schematics 4WD Hydraulic Schematic 6 - 107 6 - 108...
  • Page 296 Part No. 826364 Rev C...

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