Genie S-45 XC Service And Repair Manual
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Genie S-45 XC Service And Repair Manual

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Service and Repair Manual
S
-40 XC
®
S
-45 XC
®
S
-40 TraX
®
S
-45 TraX
®
Serial Number Range
™
™
™
™
from S40XCH-104
from S45XCH-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1286829GT
Rev A1
July 2019

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  • Page 1 Service and Repair Manual Serial Number Range -40 XC ® ™ This manual includes: from S40XCH-104 Repair procedures from S45XCH-101 -45 XC ® ™ Fault Codes Electrical and -40 TraX ® ™ Hydraulic Schematics -45 TraX ® ™ For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Introduction

    Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TraX" are trademarks of Terex South Dakota, Inc. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 3 Click on any content or procedure in the Table of Contents to view Section – Fault Codes, All charts the update. Section – Schematics, Legends and schematics Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 4: Serial Number Legend

    July 2019 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 5: Safety Rules

    • 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. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 6 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. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 7: Table Of Contents

    How to Adjust the Machine Maximum Speed Setting ........21 How to Adjust the Joystick Ramp Rate Setting ..........22 How to Adjust the Joystick Threshold Setting ..........23 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 8 5-3 Flex Plate......................53 5-4 Ford MSG-425 Engine Fault Codes ............... 57 5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models ..... 57 viii S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 9 How to Calibrate the Turntable Tilt Sensor ............. 78 Axle Components ....................80 9-1 Oscillating Axle Cylinders ................80 Track Components ..................... 81 10-1 Track Assembly .................... 81 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 10 Electrical Schematic- Deutz 2.9 Models ............. 139 Electrical Schematic- Perkins 404F-22T Models ..........144 Electrical Schematic- Ford MSG425 Models ............145 Hydraulic Schematic, 4WD Models ..............147 S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 11: Specifications

    Lug nut torque, 170 ft-lbs lubricated 244 Nm SAE 90 multipurpose hypoid gear oil API service classification GL5 For operational specifications, refer to the Operator's Manual. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 12: Performance Specifications

    If the hydraulic fluid temperature consistently exceeds 200°F / 90°C an optional oil cooler may be required. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 13 Rando HD Premium MV. Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 14 @ -13°F / -25°C 702.4 cSt @ -40°F / -40°C 2624 Flash point >100 Pour point -76°F / -60°C Maximum continuous operating 103°F / 75°C temperature S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 15: Hydraulic Component Specifications

    10.69 gpm 40.5 L/min Auxiliary Pump Type: fixed displacement gear pump Displacement per revolution 1.75 gpm 6.62 L/min Auxiliary pump relief pressure 3200 psi 220.6 bar Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 16: Manifold Component Specifications

    Beta 3 ˆ 200 Medium pressure filter bypass 51 psi pressure 3.5 bar Hydraulic tank return filter 10 micron with 25 psi / 1.7 bar bypass S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 17: Ford Msg-425 Efi Engine Specifications

    For oil requirements, refer to the Engine Operator Handbook on your machine. Electronic fuel pump Fuel pressure, static 60 psi 4.1 bar Fuel flow rate 0.58 gpm 2.2 L/min Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 18: Deutz D2011 L03I Engine Specifications

    Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 19: Deutz D 2.9 L4 Engine Specifications

    Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine. Oil temperature switch Temperature switch point 257°F 125°C Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 20: Perkins 404F-E22T Engine Specifications

    3/8 in 10 mm Starter motor Current draw, no load 140A - 200A Brush length, new 0.7480 in 19 mm Brush length, minimum 0.5 in 12.7 mm S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 21 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Engine coolant Capacity 7.7 quarts 7.3 liters Coolant temperature switch Temperature switch point 221° F 105° C Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 22: Machine Torque Specifications

    37 ft-lbs lubricated 50 Nm Drive motor and hubs Drive hub mounting bolts, dry 210 ft-lbs 284 Nm Drive hub mounting bolts, lubricated 160 ft-lbs 217 Nm S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    135 ft-lbs / 183 Nm (All types) 200 ft-lbs / 271,2 Nm (All types) 250 ft-lbs / 339 Nm (All types) 305 ft-lbs / 413,5 Nm Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 24: Torque Procedure

    2 reference mark 3 body hex fitting Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 25 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 26: Repair Procedures

     Use only Genie approved replacement parts.  Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 27: About This Section

    Indicates that a specific result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 28: Control System

    1 ALC-600 platform control module 2 primary boom up/down and turntable rotate left/right joystick controller 3 LED indicator module 4 Drive/steer joystick controller S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 29: Service Mode

    5 Settings menu 6 (not implemented) 7 Faults menu 8 Fault LED Indicator 9 Engine hours 10 Maintenance LED indicator 11 Maintenance menu 12 Home menu Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 30: How To Use The Recovery Mode

    Move the key switch to the Ground Control position. Pull out the red Emergency Stop button at the ground controls. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 31: Full Machine Calibration

    • Primary boom length sensor. Refer to Repair Procedure, How to Calibrate the Primary Boom Length Sensor. • Select option configuration. Refer to Repair Section, Display Module, Options. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 32: How To Adjust The Joystick Ramp Rate Setting

    Scroll and press OK. The change is effective immediately. Start the engine from the ground controls. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 33: How To Adjust The Joystick Threshold Setting

    Using the joystick, verify that the function engages smoothly and without sudden movement or excessive joystick dead spots. 10 Adjust the parameter in the ground display to achieve a smooth function threshold. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 34: How To Enter Alc600 Software Update Mode

    Power up normally. As the display controller starts, operator shall verify on the start-up screen that the proper software and revision are displayed. Perform a function check. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 35: Display Module Menus

    Glowplug Preglow Time 1 sec - 100 sec 12 sec Lift Connect NOT INSTALLED / INSTALLED INSTALLED Alarm Setting OFF / TRAVEL / MOTION 4m Platform NOT INSTALLED / INSTALLED NOT INSTALLED Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 36 Forward Out of Stow Max 150% max, 76% min, 100% = 1455 mA (default) Reverse Out of Stow Max 150% max, 75% min, 100% = 1451 mA (default) S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 37 Screen or Menu Item Default Ford MSG425 Threshold default = 2375 rpm Anti-Stall Drive Minimum default = 85% Range default = 125 rpm Hysteresis default = 170 rpm Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 38 CW Out of Stow Max 150% max, 78% min, 100% = 1005 mA (default) CCW Out of Stow Max 150% max, 78% min, 100% = 1005 mA (default) S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 39 Disable Engine Start / Drive Speed Cripple / Lift Speed Cripple Reset to Defaults OK to reset Model Configuration and Options Software Update OK to enter Software Update Mode Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 40: How To Replace The Display Controller (Discon) Module

    2 DISCON gasket the DISCON's mounting stud. 3 DISCON 4 8/32 nylock nuts 5 #8 flat washers 6 ribbon cable 7 DISCON door 8 Torx head screws S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 41: How To Replace The Ground Control Overlay

    Unscrew the nut holding the buttons and key switch and remove the key switch and buttons. Note the orientation of the key switch so it can be reassembled in the same position. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 42 17 Close and fasten the ground box lid. 18 Reconnect the negative terminal to the start battery and auxiliary batteries, if equipped. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 43 July 2019 Service and Repair Manual Repair Procedures Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 44: Platform Components

    Note: Do not rest the entire weight of the jib boom on the blocks. Use a soft metal drift and drive the barrel-end pin out. 10 Carefully pull the cylinder out of the primary boom. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 45: Platform Rotator

    Note: If the load sense components are disassembled and/or removed from the platform support, the platform load sense system will need to be calibrated. Refer to Repair Procedure, Platform Load Sense System. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 46 Support the platform rotator with an appropriate lifting device. Do not apply any lifting pressure. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 47 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 48: Platform Overload System

    10 Place a 1,000 lb / 454 kg test weight on the platform floor using a suitable lifting device. Place the weight near the center entry point of S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 49 The engine should shut down. Note: There may be a 2 second delay before the overload indicator lights flash and the alarm sounds. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 50: How To Perform Zero Load Platform Overload Calibration

    The calibration is now complete. of the bottom of the sensor.The foot should not contact the flex plate when assembling Exit the Service Mode onto the platform support. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 51: Platform

    Crushing hazard. The platform could become unstable and fall when it is removed from the machine if not properly supported. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 52 Crushing hazard. The jib boom remove the pin. may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 53: Jib Boom Lift Cylinder

    Do not allow oil to squirt or spray. Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 54: Primary Boom Components

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 55: How To Repair The Cable Track

    Install the rollers onto the new section of cable track. Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 56 11 Place a support block across the turntable and lower the lift cylinder on it. 12 Remove the retaining fasteners from the primary boom pivot pin. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 57 Note: During removal, the overhead crane strap will need to be carefully adjusted for proper balancing. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 58: Boom Lift Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 59: Boom Extension Cylinder

    At the pivot end of the boom, remove the retaining fasteners and blocks securing the extend cylinder to the #2 boom tube through the access holes in the #1 boom tube. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 60: 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. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 61: Primary Boom Angle Sensor Calibration

    This may require holding the buttons for several seconds after the boom has touched the rest pad. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 62: Boom Length Sensor

    This may require holding the buttons for several seconds after the boom has fully retracted. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 63: Engines

    Support the muffler and bracket assembly with a suitable lifting device. Remove the muffler bracket mounting fasteners from the bell housing. Carefully remove the muffler and bracket assembly from the engine. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 64 Component damage hazard. Hoses can be damaged if they are kinked or pinched. Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 65 Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged. Perkins Models Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 66 Service and Repair Manual July 2019 Engines Deutz Models D2011L03i Perkins Models 404D-22 Deutz Models D 2.9 L4 Perkins Models 404F-22 Ford Models S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 67: Ford Msg-425 Engine Fault Codes

    Refer to Fault Code Section, How to Retrieve Active Engine Fault Codes for your specific engine model. Use the Fault Code Chart to aid in identifying the fault. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 68: 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. open closed S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 69: Drive Pump

    Do not allow oil to drive pump. squirt or spray. Support the pump with a lifting devic and remove the pump mounting fasteners. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 70 Deutz D2011 L03i models: Release the manual fuel shutoff valve. Start the engine from the ground controls and check for hydraulic leaks. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 71: Manifolds

    20-25 ft-lbs / 27-34 Piston Pilot open check valve for level adjust Relief valve, 3200 psi / 221 bar Limit auxiliary pump pressure 20-25 ft-lbs / 27-34 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 72 Service and Repair Manual July 2019 Manifolds S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 73 26-30 ft-lbs / 35-40 Orifice Plug, 0.6mm Brake set delay 5-7 ft-lbs / 7-9.5 Nm Solenoid Valve, 2 position 3 way Motor displacement control 26-30 ft-lbs / 35-40 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 74 Service and Repair Manual July 2019 Manifolds S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 75: Valve Adjustments - Function Manifold

    Remove the pressure gauge. Repeat this procedure beginning with step 2 to confirm the relief valve pressure. Remove the pressure gauge. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 76: How To Adjust The Boom Extend Relief Valve

    Tip-over hazard. Do not adjust the relief valve higher than specified. Repeat this procedure beginning with step 2 to confirm the relief valve pressure. Remove the pressure gauge. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 77: Jib Boom And Platform Rotate Manifold Components

    Platform rotate/jib boom select 18-20 ft-lbs / 25-27 Nm Counterbalance valve Platform rotate right 30-35 ft-lbs / 41-47 Nm Counterbalance valve Platform rotate left 30-35 ft-lbs / 41-47 Nm Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 78: Traction Manifold Components, 4Wd

    80-90 ft-lbs / 108-122 relief valve Orifice, 0.40 inch / 1 mm Prevents scrub at high steer angles by allowing some bypass flow around the left flow divider S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 79 July 2019 Service and Repair Manual Manifolds Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 80: Valve Adjustments, Traction Manifold

    Turn the engine off. Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 81: How To Set Up The Oscillate Directional Valve

    To level the drive chassis, start the engine and push up or pull down on the threaded rod until the machine is completely level. Verify that the ground and drive chassis are completely level. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 82: Valve Adjustment - Oscillate Relief Valve

    Observe the pressure reading on the pressure gauge when the machine fully oscillates. Refer to Specifications, Hydraulic Specifications. Loosen the nut of the oscillate valve on the function manifold. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 83: Generator Manifold Components

    Pilot valve to diverter valve 50 ft-lbs / 67 Nm Counterbalance valve Adds backpressure to generator circuit Check valve Prevents oil to generator 24-26 ft-lbs / 32.5-35.3 Nm Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 84: Valve Coils

    Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 85 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. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 86: Turntable Rotation Components

    When installing the drive hub assembly: Install the turntable rotator assembly. Apply removable thread locking compound to fastener threads.Torque the backlash pivot plate mounting fasteners to 160 ft-lbs / 217 S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 87: How To Adjust The Turntable Rotation Gear Backlash

    Check for tight spots that could cause binding. Readjust if necessary. 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 88: How To Calibrate The Turntable Tilt Sensor

    Press OK when the value on the ground control display matches the value of the digital level (excluding the plus/minus sign). S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 89 OK. Turntable Roll 1 uphill 2 downhill 14 The calibration is now complete. 15 Exit the Service Mode. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 90: Axle Components

    Do not allow oil to squirt or spray. Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to remove the pin. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 91: 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. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 92 0.75-1.0 inch / 19-25 mm of droop between the inside of the rubber track and the bottom surface of the bogey wheels. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 93: Fault Codes

    • Boom in the stowed position • Turntable secured with the turntable rotation lock • Welder disconnected from the machine (if equipped with the weld cable to platform option) Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 94: Control System Fault Codes

    The fault lists can be browsed. To learn more about a fault entry, select it and press OK. A screen will be shown that describes the fault in more detail. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 95: Control System Fault Codes (Software Version H And Up)

    55 and 65 ohms. *D81CAN+ (YL, TCON J5-3) should be between 1V and 5V. *D81CAN- (GR, TCON J5-4) should be between 1V and 5V. *Remove short(s) and cycle power. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 96 PCON J18-4) is at 2. 5V +/- 0.2 V at startup and does not go above 4.5 V or below 0.5 V when fully stroked in each direction. * Replace joystick if voltage check fails. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 97 * Verify wiring for C2PBD (RD/BK, TCON J4-9) and check for open or short circuits. * Verify resistance between Recovery Module pins J37-2 and J37-11 is zero ohms. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 98 * Verify LSB2S (C59CNK, BL/WH, TCON J7-5) operates properly. Signal should normally by 12 V. If cable tension is loose, signal should be 0 V. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 99 5 - 60 ohms. Replace Y69 if or GND. resistance is outside of those values. * Verify wiring for V44JD (BL/BK, PCON J12-9) and check for open or short circuits. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 100 0 V with the switch OFF and 12 V with the switch held in the ON position. *Cycle power to allow the machine to re-test the fault. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 101 * Replace joystick if voltage check fails. 27 Active at Circuit C160DRV startup voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 102 M7 telematics Information only Cycle power. If fault persists, check Device detected device not telematics ready connector wiring. If detected. there are no wiring issues replace S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 103 Verify the ribbon cables are properly seated and dry. * Re-seat and/or replace ribbon cables if necessary. * Replace ground control overlay. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 104 * If engine uses an analog oil pressure sensor, verify it is sending an analog voltage on C25PSR (WH/BK, TCON J6-9). S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 105 * Check that the load sensor is sensor out of mounted correctly and all fasteners calibration are tightened to spec. * Calibrate load sensor. * Replace sensor if issue persists. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 106 * Replace DISCON if required. 29 Software DISCON software Machine limited to Download latest software from version is out of date. recovery functions firmware site and update machine. mismatch S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 107 65 ohms. Check CAN wiring if resistance check fails. * Replace sensor if required. 17 Not Tilt sensor not Machine limited to Calibrate tilt sensor. calibrated calibrated recovery functions Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 108 5 - 60 ohms. Replace Y13 if or GND. resistance is outside of those values. * Verify wiring for C6TRF (WH/RD, TCON J4-1) and check for open or short circuits. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 109 * Verify wiring for C9PEF (BK/RD, TCON J4-5) and check for open or short circuits. * Verify resistance between Recovery Module pins J37-6 and J37-7 is zero ohms. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 110 * Verify wiring for C3PBF (RD/WH, TCON J4-4) and check for open or short circuits. * Verify resistance between Recovery Module pins J37-3 and J37-10 is zero ohms. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 111 12 and cathode at pin 11. If test fails, replace the PCON. * Check P23RET (BK) for shorts to ground or power. Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 112: Engine Fault Codes

    Service and Repair Manual July 2019 Control System Fault Codes Engine F ault C odes Engine Fault Codes Some engine options have their own Electronic Control Module that contains more detailed fault information that is specific to the engine. This system can be accessed by using the engine's dedicated service tool.

  • Page 113: Deutz D 2.9 L4 Engine Fault Codes

    Overload by short-circuit Charged air pressure above shut off threshold 1016 Actuator position for EGR-Valve not plausible Sensor error charged air press.; signal range check low Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 114 Sesnor error rail pressure; signal range check high Physical range check low for oil temperature Sensor error rail pressure; signal range check low S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 115 Physical range check low for EGR differential pressure Injector 3 (in firing order); interruption of electric connection Sensor error differential pressure Venturiunit (EGR); signal range check low Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 116 Sensor supply voltage monitor 1 error error (ECU) 1188 2 1414 Wastegate; status message from 1080 13 Sensor supply voltage monitor 2 ECU missing error (ECU) S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 117 1523 Exhaust gas recirculation AGS exhaust gas temperature sensor; plausibility error upstream (DOC) 4765 1 1042 Physical range check low for exhaust gas temperature upstream (DOC) Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 118 Sensor supply voltage monitor 3 opening count error (ECU) 523009 Pressure relief valve (PRV) 523603 Timeout Error of reached maximun allowed open CAN-Receive-Frame AMB; time Ambient Temperature Sensor S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 119 523619 Physical range check high for 523612 Internal ECU monitoring exhaust gas temperature detection reported error upstrem (SCR-CAT) 523698 Shut off request from supervisory monitoring function Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 120 Passive Timeout Error of over temperature CAN-Receive-Frame TSC1TR 523919 1378 Sensor air pump airpressure; plausibility error 523920 1379 Sensor exhaust gas back pressure burner; plausibility error S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 121 EEC3VOL2; Engine send 523982 Powerstage diagnosis disabled; messages low battery voltage 523946 1158 Zero fuel calibration injector 1 (in firing order); maximum value exceeded Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 122 524029 1432 Timeout Error of CAN-Transmit-Frame CAN-Receive-Frame ComDPFTstMon ComEGRActr - exhaust gas recirculation positioner 524030 1440 EGR actuator; internal error 524031 1441 EGR actuator; calibration error S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 123 1687 Timeout error of 524111 9 1680 Timeout error of CAN-Receive-Frame CAN-Receive-Frame ComTxTrbChActr ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN-Receive-Frame ComRxITVActr Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 124: Perkins 404F-22 Engine Fault Codes

    High - least severe(1)" Voltage Below Normal 3242 Particulate Trap Intake Gas Temp: Engine Fuel Rack Actuator: Current High-moderate severity (2) Above Normal J1939 Network#1: Special Instruction S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 125 Particulate Trap #1 Soot Load Percent: High-moderate severity (2) 4016 High Current Auxiliary Power Relay 1: Current Above Normal 4201 Engine Speed Sensor #1: Voltage Above Normal Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 126: Ford Msg-425 Engine Fault Codes

    Connect the negative battery cable to the battery. Code Description Never crank synced at start FP low voltage FP high voltage MAP Low Voltage MAP High Pressure IAT higher than expected 1 S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 127 For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 128 FPump motor high-side shorted to power EFI Diagnostic Manual (EDI part number Fpump relay coil short to power 1080030). Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 129 AUX analog PUD1 low 1080030). 1543 AUX analog PUD2 high Ford MSG-425 EFI Diagnostic Manual 1544 AUX analog PUD2 low Genie part number 162067 1545 AUX analog PUD3 high Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 130 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 131 For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030). Ford MSG-425 EFI Diagnostic Manual Genie part number 162067 Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 132: Schematics

     Be sure that all necessary tools and test equipment are available and ready for use. S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 133: Electrical Symbol Legend

    Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow normally open switch - normally open normally closed normally open plug or flame ignitor Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 134: Hydraulic Symbols Legend

    Solenoid operated 3 Counterbalance valve with Solenoid valve, 2 position 2 position 4 way directional position, 4 way proportional pressure and pilot ratio valve directional valve S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 135: Engine Relay Layout - All Engines

    Engine glow plug A CR15B / CR7 Engine glow plug B / LPG solenoid CR17 Hydraulic oil cooler (option) CR23 Drive light CR39 Aux shut down Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 136: Engine Relay Layout - Perkins 404F-22T

    CR12A Engine ECU 1 CR12B Engine ECU 2 CR15C Glow plug 1 CR15D Glow plug 2 CR17B / Hyd fan / Start CR1A CR40 Fuel pump S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 137: Circuit Connector Legend

    GBOX service port PBOX service port 404D speed sensor 404D fuel solenoid Work lights VEC - black - 8 pin VEC - gray - 8 pin Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 138 Engine ECG Engine ECG Platform recirculation valve Telematics VEC2-black- 8 pin VEC2-black- 8 pin VEC2-blue- 8 pin VEC2-green- 8 pin VEC2-gray- 8 pin VEC2-black- 8 pin S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 139 PCON functions PCON logic PCON toggles PCON toggles PCON joysticks PCON unused Boom angle sensor operational- not used Boom angle sensor safety- not used Fuel level sensor Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 140 D2.9 ECU 1 D2.9 ECU 2 D2.9 engine interface Chassis tilt sensor operational Chassis tilt sensor safety D2011 engine interface LED PCB Recovery module power Recovery module I/O S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 141: Kw Generator Receptacle Wiring

    July 2019 Service and Repair Manual 3 kW Generator Receptacle Wiring Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 142: Kw Generator Receptacle Wiring

    Service and Repair Manual July 2019 7 kW Generator Receptacle Wiring S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 143: 12 Kw Generator Receptacle Wiring

    July 2019 Service and Repair Manual 12 kW Generator Receptacle Wiring Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 144 Service and Repair Manual July 2019 Electrical Schematic - TCON...

  • Page 145: Electrical Schematic- Tcon

    July 2019 Service and Repair Manual Electrical Schematic- TCON Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 146 Service and Repair Manual July 2019 Electrical Schematic- PCON S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 147 July 2019 Service and Repair Manual Electrical Schematic - PCON...
  • Page 148 Service and Repair Manual July 2019 Electrical Schematic- Deutz 2.9 Models...

  • Page 149: Electrical Schematic- Deutz 2.9 Models

    July 2019 Service and Repair Manual Electrical Schematic- Deutz 2.9 Models Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 150 Service and Repair Manual July 2019 S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...
  • Page 151 July 2019 Service and Repair Manual Electrical Schematic- Deutz 2011 Models Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 152 Service and Repair Manual July 2019 Electrical Schematic- Deutz 2011 Models...
  • Page 153 July 2019 Service and Repair Manual Electrical Schematic- Perkins 404F Models...

  • Page 154: Electrical Schematic- Perkins 404F-22T Models

    Service and Repair Manual July 2019 Electrical Schematic- Perkins 404F Models S-40 XC • S-45 XC • S-40 TraX • S-45 TraX Part No. 1286829GT...

  • Page 155: Electrical Schematic- Ford Msg425 Models

    July 2019 Service and Repair Manual Electrical Schematic- Ford MSG425 Models Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...

  • Page 156: Electrical Schematics

    Service and Repair Manual July 2019 Electrical Schematics- Ford MSG425 Models...

  • Page 157: Hydraulic Schematic, 4Wd Models

    July 2019 Service and Repair Manual Hydraulic Schematic, 4WD Part No. 1286829GT S-40 XC • S-45 XC • S-40 TraX • S-45 TraX...
  • Page 158 Service and Repair Manual July 2019 Hydraulic Schematic, 4WD S-40 XC • S-45 XC • S-40 Tr aX • S- 45 TraX Part No. 1286829GT Servic e and R epair M anual July 2019...

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