Genie S-40 TRAX Service And Repair Manual Download Page 2

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Service and Repair Manual

July 2019

Introduction

S-

40 XC • S

45 XC • S

40 TraX •

S-45 TraX

Part No. 1286829GT

Intr oducti on

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.
This manual provides troubleshooting and repair

procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.
Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Contact Us:

Internet: www.genielift.com

E-mail: [email protected]

Find a Manual for this Model

Go to

http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

First Edition, First Printing
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.

Summary of Contents for S-40 TRAX

Page 1: ...H 104 from S45XCH 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics S 45 XC S 40 TraX S 45 TraX For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1286829GT Rev A1 July 2019 ...

Page 2: ...esign Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvemen...

Page 3: ...ion History Revision Date Section Procedure Page Description A 2 2019 Initial Release A1 7 2019 Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

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

Page 5: ...erious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental reg...

Page 6: ... potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco aw...

Page 7: ...ine Specifications 7 Deutz D2011 L03i Engine Specifications 8 Deutz D 2 9 L4 Engine Specifications 9 Perkins 404F E22T Engine Specifications 10 Machine Torque Specifications 12 TRAX Torque Specifications 12 Hydraulic Hose and Fitting Torque Specifications 13 Torque Procedure 14 Section 3 Repair Procedures 16 Introduction 16 Control System 18 1 1 ALC 600 Platform Control Module 18 1 2 ALC 600 Servi...

Page 8: ...latform Overload Calibration 39 How to Replace the Platform Overload Load Cell 40 2 4 Platform 41 Jib Boom Components 41 3 1 Jib Boom 41 3 2 Jib Boom Lift Cylinder 43 Primary Boom Components 44 4 1 Cable Track 44 How to Remove the Cable Track 44 How to Repair the Cable Track 45 4 2 Boom 45 4 3 Boom Lift Cylinder 48 4 4 Boom Extension Cylinder 49 4 5 Platform Leveling Master Cylinder 50 4 6 Primary...

Page 9: ... 66 7 3 Jib Boom and Platform Rotate Manifold Components 67 7 5 Traction Manifold Components 4WD 68 7 6 Valve Adjustments Traction Manifold 70 7 7 How to Set Up the Oscillate Directional Valve 71 7 8 Valve Adjustment Oscillate Relief Valve 72 7 9 Generator Manifold Components 73 7 10 Valve Coils 74 Turntable Rotation Components 76 8 1 Turntable Rotation Assembly 76 How to Adjust the Turntable Rota...

Page 10: ...lt Codes 116 How to Retrieve Ford MSG 425 Engine Fault Codes 116 Section 5 Schematics 122 Introduction 122 Electrical Symbol Legend 123 Hydraulic Symbols Legend 124 Engine Relay Layout All engines 125 Engine Relay Layout Perkins 404F 22T 126 Circuit Connector Legend 127 3 kW Generator Receptacle Wiring 131 7 kW Generator Receptacle Wiring 132 12 kW Generator Receptacle Wiring 133 Electrical Schema...

Page 11: ...eel 38 psi 2 62 bar Wheel lugs 9 5 8 18 Lug nut torque dry 230 ft lbs 325 Nm Lug nut torque lubricated 170 ft lbs 244 Nm Track Components TRAX option Track material Rubber Weight assembly each 480 lbs 218 kg Fluid capacities LPG tank 33 5 pounds 15 2 kg Fuel tank 20 gallons 75 7 liters Fuel tank option 30 gallons 113 6 liters Hydraulic tank 45 gallons 170 liters Hydraulic system including tank 55 ...

Page 12: ...ls which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydrauli...

Page 13: ...ly above 120 F 49 C Hydraulic Fluid Temperature Range 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 Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash...

Page 14: ... heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180...

Page 15: ...pecifications Drive Pump Type bi directional variable displacement piston pump Flow rate 2500 rpm 0 28 gpm 0 122 6 L min Drive pressure maximum 3625 psi 250 bar Charge Pump Type gerotor Displacement per revolution 0 85 cu in 13 9 cc Flow rate 2500 rpm 9 gpm 34 L min Charge pressure 2500 rpm 310 psi 21 4 bar Function pump Type gear pressure balanced Displacement 1 04 cu in 17 cc Flow rate 2500 rpm ...

Page 16: ...ot oil relief pressure 280 psi 19 3 bar Two speed drive motors 2WD and 4WD models Displacement per revolution low speed 0 99 cu in 16 3 cc Displacement per revolution high speed 1 83 cu in 30 cc Hydraulic Filters Medium pressure filter Beta 3 ˆ 200 Medium pressure filter bypass pressure 51 psi 3 5 bar Hydraulic tank return filter 10 micron with 25 psi 1 7 bar bypass Manifold Component Specificatio...

Page 17: ...4 liters Oil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Oil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils 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 Fuel requirement For fuel requirements refer to the engin...

Page 18: ...synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 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 Oil temperature switch Temperature switch point 300 F 149 C Oil pressure switch Oil pressure switch point 22 psi 1 5 bar Fuel injection system Injection pump ma...

Page 19: ...ove 23 F 5 C 20W 50 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 Oil temperature switch Temperature switch point 257 F 125 C Oil pressure switch Oil pressure switch point 20 psi 1 4 bar Engine coolant Capacity 10 quarts 9 4 liters Fuel injection system Injection pump m...

Page 20: ... pressure 2000 rpm 40 to 60 psi 1 4 to 3 bar Oil capacity including filter 9 4 11 2 quarts 8 9 10 6 liters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil pressure s...

Page 21: ...0 XC S 45 XC S 40 TraX S 45 TraX 11 Perkins 404F 22 Engine continued Battery Type 12V DC Quantity 1 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 ...

Page 22: ...t lbs 217 Nm Drive motor brake mounting bolts dry use blue thread locking compound 49 ft lbs 66 4 Nm Drive motor brake mounting bolts lubricated 37 ft lbs 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 TraX Torque Specifications Hub adapter to drive hub fasteners Lug nut torque dry 230 ft lbs 312 Nm Lug nut torque lub...

Page 23: ...8 1 1 2 8 3 4 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 ...

Page 24: ...al is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube fl...

Page 25: ... the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the b...

Page 26: ...r s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parke...

Page 27: ... used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation whi...

Page 28: ...icator Module The joystick controllers at the platform controls utilize Hall Effect technology and require no calibration Automatic calibration of center voltage occurs on power up if the signal value is in the valid range Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion The remaining boom functions operate by on off toggle swi...

Page 29: ...ls select the ground control mode using the key switch 2 Push and hold buttons numbered 2 and 3 underneath the display screen 3 Pull out the red Emergency Stop button 4 You will be prompted for a password Enter 3 3 2 4 5 Press the Gear button to access the settings menu Note There will be a delay while the menu is being loaded on the display screen 6 The machine will now operate normally and allow...

Page 30: ...o allow the operator at the platform controls to exit the platform 1 Move the key switch to the Ground Control position 2 Pull out the red Emergency Stop button at the ground controls 3 While pressing the ground function enable button push and hold the recovery toggle switch in the recovery position Result The auxiliary power unit will turn on and the boom will begin the following recovery sequenc...

Page 31: ...oom Angle Sensor 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 1 5 Machine Functions How to Adj ust the Machine M axim um Speed Setti ng How to Adjust the Joystick Maximum Speed Setting The maximum speed of a joystick controlled machine function can be modified from the...

Page 32: ...m 8 10 5 sec Non stowed 40 ft 38 45 sec 12 2m 38 45 sec How to Adj ust the Joystick Ram p R ate Setting How to Adjust the Joystick Ramp Rate Setting The ramp rate setting is an adjustment that controls the way boom functions start and stop There are two types of ramp rates to adjust on separate menus Ramp Up Time the amount of time it takes to accelerate to speed Ramp Down Time the amount of time ...

Page 33: ...output at which a function proportional valve can open and allow the function to operate The boom function threshold current should be operating at near zero speed smoothly with no vibrations Note Perform this procedure with the boom in the stowed position 1 Enter the Service Mode 2 Press the SETTINGS button above the display screen 3 Select SPEEDS from the display screen 4 Navigate to the desired...

Page 34: ...x head screws securing the Display Controller DISCON door and remove the door to expose the USB port 1 Insert the flash drive into the USB port 2 Set keyswitch to ground and pull out the red ground ESTOP while holding buttons 1 and 4 3 The Display Controller will go into the bootloader mode 4 Browse and select the desired software Follow the on screen guidance to start the update procedure 5 When ...

Page 35: ...cific TRAX region specific select tires Region ANSI CSA AUS CE select region Screen or Menu Item Selections Default Options Footswitch Timeout 10 sec 2 min 30 min 2 min Note Some options may not be visible with earlier software revisions Drive Priority ON OFF OFF This cannot be turned off if CE region is selected Drive Cutout ON OFF OFF Platform Level ON PRIORITY CUTOUT ON Generator NO GENERATOR G...

Page 36: ...eeds XC and HF Forward Threshold 128 max 1 min 100 723 mA default Reverse Threshold 131 max 1 min 100 690 mA default Forward Max 150 max 74 min 100 1556 mA default Reverse Max 150 max 74 min 100 1129 mA default Forward Out of Stow Max 150 max 82 min 100 1140 mA default Reverse Out of Stow Max 150 max 81 min 100 1129 mA default Screen or Menu Item Default Drive Speeds TraX Forward Threshold 149 max...

Page 37: ... D2 9 Anti Stall Threshold default 2375 rpm Drive Minimum default 50 Range default 125 rpm Hysteresis default 100 rpm Screen or Menu Item Default Deutz D2011 Anti Stall Threshold default 2500 rpm Drive Minimum default 60 Range default 700 rpm Hysteresis default 200 rpm Screen or Menu Item Default Perkins 404F Anti Stall Threshold default 2350 rpm Drive Minimum default 50 Range default 125 rpm Hyst...

Page 38: ... min 2500 ms default Extend Decelerating Rate 5000 ms max 250 ms min 1000 ms default Retract Accelerating Rate 5000 ms max 1000 ms min 2500 ms default Retract Decelerating Rate 5000 ms max 500 ms min 1000 ms default Up Accelerating Rate 5000 ms max 1000 ms min 3000 ms default Up Decelerating Rate 5000 ms max 500 ms min 3000 ms default Down Accelerating Rate 5000 ms max 1000 ms min 3000 ms default ...

Page 39: ...rm Rotate CCW Threshold max 113 min 1 default 561 mA 100 Jib Up Max Output max 150 min 86 default 776 mA 100 Jib Down Max Output max 150 min 85 default 741 mA 100 Platform Level Up Max Output max 150 min 81 default 700 mA 100 Platform Level Down Max Output max 150 min 86 default 637 mA 100 Platform Rotate CW Max Output max 150 min 91 default 671 mA 100 Platform Rotate CCW Max Output max 150 min 90...

Page 40: ...d washers Note the lanyard attachment point for reassembly 6 Remove the old DISCON gasket 2 from the ground box lid and clean the lid surface from any dirt oil or old adhesive residue Use a 99 solution of isopropyl alcohol to clean the surface Allow the surface to completely dry Note Both the ground box lid and new gasket must be 70 F 21 C or higher at the time of application Application of the ne...

Page 41: ...to the start battery and auxiliary batteries if equipped 1 9 How to Replace the Ground Box Control Overlay 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the negative terminal from the start battery and auxiliary battery if equipped 3 Open the ground box lid and remove the switch contacts from the function enable and E Stop buttons...

Page 42: ...witch are centered Apply the overlay to the ground box applying pressure evenly to eliminate any air bubbles Note Pay particular attention to the outside edges the LCD cutout edges and the area around the ribbon cables making sure there is complete contact between the overlay and the ground box Note It is not recommended peeling and reapplying the overlay so take time to align the overlay before m...

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 33 ...

Page 44: ... under the platform for support 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the jib boom on the blocks 4 Tag disconnect and cap the hydraulic hoses from the slave cylinder Plug the union hoses from the master cylinder together using a connector Bodily injury hazard Spraying hydraulic oil can penetrate an...

Page 45: ...m mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position Note When removing a hose assemb...

Page 46: ...platform mounting weldment off of the platform rotator Crushing hazard The platform mounting weldment may become unbalanced and fall if it is not properly supported 6 Support the platform rotator with an appropriate lifting device Do not apply any lifting pressure S 40 XC 7 Support the rod end of the platform leveling slave cylinder Protect the cylinder rod from damage 8 Remove the pivot pin retai...

Page 47: ...ctivate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw on the rotator but do not remove it Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen...

Page 48: ...Pl atform Overl oad System How to Calibrate the Platform Overload System Note Perform this procedure with the machine on a firm level surface Note The turntable level sensor must be calibrated before performing this procedure 1 Fully retract the boom Level the platform 2 Remove all material tools and equipment from the platform Remove the welder if equipped Tip over hazard Failure to remove all fa...

Page 49: ...Place the weight near the center entry point of the platform as far away from the operator controls as possible as shown in Illustration 1 Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls The engine should shut down Note There may be a 2 second del...

Page 50: ...utton above the display and navigate to the Sensor Calibrations menu 4 Navigate to the Load Sense calibration screen 5 Select and start the calibration procedure 6 Follow the on screen instructions to set the zero load 7 Continue to follow the prompts to accept the weight 8 The calibration is now complete Exit the Service Mode How to R eplace the Platform Overload Load C ell How to Replace the Loa...

Page 51: ...epair Procedure How to Calibrate the Platform Overload System 2 4 Platform How to Remove the Platform 1 Remove the cable clamp from the top of the platform mounting weldment 2 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side Do not disconnect the wiring 3 Remove the foot switch mounting fasteners 4 Remove the cover ...

Page 52: ...ing fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 6 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 7 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 8 Attach a lifting strap from an overhead crane to the jib boom 9 Support the barrel end of the jib boom lift cylinder with ...

Page 53: ...re to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin out enough to lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 S...

Page 54: ...power to plat cable from the AC outlet box 3 Remove the hose and cable clamps from the platform support 4 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the top of the primary boom Cap the bulkhead fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pre...

Page 55: ... pinched 7 Connect the ends of the replacement cable track section to the existing cable track using the pins and snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 2 Primary Boom How to Remove the Primary Boom Bodily injury hazard This procedure requires...

Page 56: ...and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Using an overhead supporting device attach a strap to the rod end of the primary boom lift cylinder 10 Remove the retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The boom lift...

Page 57: ...secondary boom tube on blocks for support Crushing hazard The secondary boom tube may become unbalanced and fall when removed if it is not properly supported when it is removed from the machine Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove and label the wear pads from the top side of the secondary boom tube at the platform end of the ...

Page 58: ...rrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 6 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spra...

Page 59: ...sition 4 At the pivot end of the boom remove the cover from the end of the 1 boom tube 5 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 6 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraul...

Page 60: ...m until both the rod end and barrel end pivot pins on the master cylinder are accessible 2 Use an overhead supporting device to support the platform Do not apply lifting pressure 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the ...

Page 61: ...splay and navigate to the Sensor Calibrations menu 4 Navigate to the Boom Angle Sensor calibration screen 5 Select and start the calibration procedure 6 Start the engine 7 When the display prompts the operator to lower the boom press and hold the function enable button and the boom down buttons until the display indicates that the lower calibration point has been obtained This may require holding ...

Page 62: ...de See Repair Procedure How to Enter Service Mode 3 Press the settings button above the display and navigate to Sensor Calibrations 4 Navigate to the Boom Length Sensor calibration screen 5 Select and start the calibration procedure 6 Start the engine 7 When the display prompts the operator to retract the boom press and hold the function enable and boom retract buttons until the display indicates ...

Page 63: ...lpipe bracket mounting fasteners from the engine bell housing 2 Support the drive pump assembly with an appropriate lifting device 3 Remove all of the engine bell housing fasteners 4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 5 Remove the flex plate mounting fasteners Re...

Page 64: ...ate lifting device 4 Remove all of the engine bell housing fasteners 5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 6 Remove the flex plate mounting fasteners 7 Remove the flex plate from the flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine f...

Page 65: ...unting bolts labeled C to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to...

Page 66: ...ervice and Repair Manual July 2019 Engines 56 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT Deutz Models D2011L03i Deutz Models D 2 9 L4 Ford Models Perkins Models 404D 22 Perkins Models 404F 22 ...

Page 67: ... 5 Engine Fault Codes Deutz D 2 9 L4 and Perkins 404F 22 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at ...

Page 68: ...tarted with the hydraulic tank shut off valves in the closed position or component damage will occur 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 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loos...

Page 69: ...equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves Component damage...

Page 70: ...he test port on the drive pump 2 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position Perkins 404D 22 models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Deutz D2011 L03i models Hold the manual fuel shutoff valve clockwise to the closed position 1 manual fuel shutoff valve 3 Have ...

Page 71: ...ector 33 37 ft lbs 45 50 Nm 8 Proportional solenoid valve W Boom variable speed control 20 25 ft lbs 27 34 Nm 9 Pressure compensator valve X Compensate for pressure variation 30 35 ft lbs 41 47 Nm 10 Check valve 65 psi 4 5 bar AA Isolate Platform level circuit 20 25 ft lbs 27 34 Nm 11 Proportional solenoid valve 3 position 4 way AE Select flow direction and speed for jib and rotate 26 30 ft lbs 35...

Page 72: ...Service and Repair Manual July 2019 Manifolds 62 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT ...

Page 73: ...t lbs 41 47 Nm 22 Sequence valve S Redundant pressure limit for oscillate circuit 50 55 ft lbs 68 75 Nm 23 Solenoid Valve spool type Y Primary boom up down selector 26 30 ft lbs 35 40 Nm 24 Solenoid Valve NO poppet P Boom extend selector 33 37 ft lbs 45 50 Nm 25 Solenoid Valve spool type V Turntable rotate left right selector 26 30 ft lbs 35 40 Nm 26 Check valve H Back flow preventer 8 10 ft lbs 1...

Page 74: ...Service and Repair Manual July 2019 Manifolds 64 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT ...

Page 75: ...er than specified 7 Repeat this procedure beginning with step 2 to confirm the relief valve pressure 8 Remove the pressure gauge How to Adj ust the Boom Dow n R elief Valve How to Adjust the Boom Down Relief Valve Note Perform this procedure with the machine in the stowed position Note Refer to the Function Manifold Component list to locate the Boom Down relief valve 1 Connect a 0 to 5000 psi 0 to...

Page 76: ... and hold the function enable button Activate and hold the primary boom extend switch with the boom fully extended 4 Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 5 Turn the engine off Use a wrench to hold the relief valve and remove the cap Refer to Repair Procedures Function Manifold Components item BG 6 Adjust the internal hex sock...

Page 77: ...onents The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way FC Platform rotate jib boom select 18 20 ft lbs 25 27 Nm 2 Counterbalance valve FA Platform rotate right 30 35 ft lbs 41 47 Nm 3 Counterbalance valve FB Platform rotate left 30 35 ft lbs 41 47 Nm ...

Page 78: ... high steer angles by allowing some bypass flow around the left flow divider 6 Relief valve 280 psi 19 3 bar DI Hot oil shuttle relief 35 40 ft lbs 14 16 Nm 7 Flow divider combiner valve 24 gpm 91 lpm DM Combines return flow from RF and RR motors 80 90 ft lbs 108 122 Nm 8 Flow divider combiner valve 24 gpm 91 lpm DB Combines return flow from LF and LR motors 80 90 ft lbs 108 122 Nm 9 Check valve D...

Page 79: ...July 2019 Service and Repair Manual Manifolds Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 69 ...

Page 80: ...rt the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turn the engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 2WD models Hold the charge pressure relief valve and remove the cap item GA 4WD models Hold the charge pr...

Page 81: ...res on some machines are foam filled and do not need air added to them 3 Remove the non steer end drive chassis cover and axle covers 4 Remove the ball joint retaining fastener from the bracket 5 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 6 Verify that the ground and drive chassis are completely level 7 Adjust the ...

Page 82: ...Refer to Specifications Hydraulic Specifications 4 With the engine running in high rpm manually activate the directional valve linkage in either direction Observe the pressure reading on the pressure gauge when the machine fully oscillates Refer to Specifications Hydraulic Specifications 5 Loosen the nut of the oscillate valve on the function manifold 6 Adjust the hex screw Turn it clockwise to in...

Page 83: ...chematic Item Function Torque 1 Relief valve GA Generator relief valve 50 ft lbs 67 Nm 2 Solenoid Valve GB Charge pressure circuit 60 65 ft lbs 81 88 Nm 3 Needle valve GD Charge pressure circuit 50 ft lbs 67 Nm 4 Differential sensing valve GC Pilot valve to diverter valve 50 ft lbs 67 Nm 5 Counterbalance valve CF Adds backpressure to generator circuit 6 Check valve GE Prevents oil to generator 24 ...

Page 84: ...ous injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance 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 Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient...

Page 85: ...terminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 ...

Page 86: ...nnections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach a suitable lifting device to the turntable rotator assembly 1 backlash pivot plate 2 adjustment bolt with locknut 3 backlash pivot plate mounting bolts 4 drive hub mounting bolts 4 Back off the locknut and loosen the adjustment bolt 5 Loosen the backlash pivot plate mounting fastener...

Page 87: ...pad 2 Loosen the backlash pivot plate mounting fasteners 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts 3 Push the backlash pivot plate towards the turntable as far as possible this will push the rotation gear into the turntable bearing ring gear 4 Loosen the lock nut on the adjustment bolt 5 Turn the adjustment bolt clockwise until it contacts the bac...

Page 88: ...s located to the left of the fuel tank Orient the level along the pitch axis of the machine 8 Enter the value as seen on the digital level into the ground control display If the digital level is showing a negative value enter it as a positive number Press OK when the value on the ground control display matches the value of the digital level excluding the plus minus sign 9 A graphic of the machine ...

Page 89: ...roll will now be shown on the display By pressing the UP and DOWN buttons the graphic will change to show whether the operator is on the uphill or downhill side of the machine Select the image that corresponds to the current roll of the machine and press OK Turntable Roll 1 uphill 2 downhill 14 The calibration is now complete 15 Exit the Service Mode ...

Page 90: ...ons Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires or tracks 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradu...

Page 91: ...e the sprocket 7 Remove the fasteners holding the TRAX mounting pin located underneath the axle Remove the pin supporting the TRAX assembly 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane How to Replace the Track 1 Remove the track...

Page 92: ...ck Note Be sure to align the split tooth in both of the sprocket halves 12 Insert a pin or rod through the wheel stud hole closest to the split tooth to hold the sprocket in place 13 Insert a pointed pry bar into the wheel stud hole near the top of the sprocket Insert another pointed pry bar into the wheel stud hole at the opposite side of the split tooth 14 Using the pry bars lift the sprocket ha...

Page 93: ... Wheels chocked All external AC power supply disconnected from the machine 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 Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that ...

Page 94: ...e fault will be reflected by the System Fault Indicator lights and the alarm Logged Faults The faults contained in the fault log have occurred in the past and may or may not still be in effect Both faults may be viewed by pressing the Fault Button above the ground display and navigating to either the Active Machine Faults screen or the Machine Fault Log screen The list of faults will by shown by f...

Page 95: ...depending on the engine option Check the engine fault codes with an engine diagnostic tool Note The control system shuts off the engine immediately upon receiving this fault from the engine 10 Ground Controls Engine Start Switch 27 Active at startup Engine start button held at startup Engine start is disabled Release engine start button check DISCON overlay and ribbon cable if issue persists 11 Pl...

Page 96: ...S WH PCON J12 2 is LOW when foot switch is released and 12 V when held down 28 Timeout Foot switch depressed too long without action Machine will not be functional 17 Aux Pump Coil 11 Shorted to supply voltage TCON detected that C27AUX circuit is shorted to 12V Machine will not be functional Check C27AUX RD TCON J3 3 wiring With a voltmeter verify that C27AUX RD TCON J3 3 is 0 V when the Auxiliary...

Page 97: ... range of 2 5 V 0 2 V 22 Pri Boom Up coil 11 Shorted to supply voltage TCON detected that C1PBU circuit is shorted to 12 V Boom Up function will not operate Boom Down will also not operate if short is to 12 V With a voltmeter measure Y22 Proper resistance should be between 5 60 ohms Replace Y22 if resistance is outside of those values Verify wiring for C1PBU RD TCON J4 10 and check for open or sho...

Page 98: ... LST3S limit switch arm Verify that with the boom above 12 degrees C68LS BL TCON J7 3 is 0V and that the boom is not making contact with the LST3S limit switch arm Check LST3S limit switch for physical damage 17 Not calibrated Sensor has been replaced and requires calibration or calibration in memory has been erased Run the boom angle calibration process and verify fault is no longer active 19 Val...

Page 99: ...round Control Button 27 Active at startup Buttons were held at system start or are shorted on the ground control panel The function associated with the stuck button will not operate Release the ground control buttons and cycle power If problem persists open ground control box and open the Display Controller access door being careful to keep water out Verify the ribbon cables are properly seated an...

Page 100: ...2 5 V 0 2 V 42 Turntable Rotate CW Coil 11 Shorted to supply voltage TCON detected that C4TRL circuit is shorted to 12 V or GND Turntable Rotate functions will not operate With a voltmeter measure Y24 Proper resistance should be between 5 60 ohms Replace Y24 if resistance is outside of those values Verify wiring for C4TRL WH TCON J3 12 and check for open or short circuits 43 Turntable Rotate CCW C...

Page 101: ... not operate With a voltmeter measure Y70 Proper resistance should be between 5 60 ohms Replace Y70 if resistance is outside of those values Verify wiring for V17PRL GR PCON J12 5 and check for open or short circuits 47 Platform Rotate CCW Coil 11 Shorted to supply voltage PCON detected that V18PRR circuit is shorted to 12 V or GND Platform Rotate CCW function will not operate With a voltmeter mea...

Page 102: ...f resistance is outside of those values Verify wiring for C31REV WH BK TCON J2 7 and check for open or short circuits 54 Brake Release Coil 11 Shorted to supply voltage TCON detected that C32BRK circuit is shorted to 12 V or GND Machine will not be functional With a voltmeter measure Y2 Proper resistance should be between 5 60 ohms Replace Y2 if resistance is outside of those values Verify wiring ...

Page 103: ...ange of 2 5 V 0 2 V 62 Prox Override Togggle Switch 27 Active at startup Toggle switch input was detected as HIGH at start up The Jib Up or Down functions will not operate Verify with a voltmeter that the Jib Up Down Toggle Switch TS8 is operating properly C43JU BL PCON J17 6 should be 0 V with the switch OFF and 12 V with the switch held in the UP position C44JD BL BK PCON J17 8 should be 0 V wit...

Page 104: ...ys the opposite of C247CA OR PCON J12 11 Check wiring for open or short circuits Verify SW30 is receiving power and ground by verifying 12 V across C31 pins 1 and 3 Replace SW30 if necessary 21 Fault 73 Engine Oil Pressure 12 Sensor value too high Engine oil pressure sender is shorted to 12V Engine will not operate With a voltmeter check that C25PSR WH BK TCON J6P9 is not shorted to 12V and voltag...

Page 105: ...Up Extend and Turntable Rotate functions will not operate Verify sensor power P26PWR BK PCON J13 9 is at 12 V while the system is running Verify 12 V across pins on C27 2 and C27 3 on the harness connector Measure resistance across C27 pins 4 and 5 on the harness connector If resistance is not between 55 and 65 ohms check CAN wire harnesses Replace sensor if necessary 14 Cross check failed TCON ha...

Page 106: ...oftware is out of date Machine limited to recovery functions Download latest software from firmware site and update machine 79 Display Controller DISCON 13 Not detected TCON has not detected the DISCON on the communications bus Controls from the ground will not operate Verify DISCON is operating by checking that the display on the front is operating properly If there is no display try to power up ...

Page 107: ... This is a flag that indicates that the platform was overloaded and that auxiliary function enable was used while overloaded Advisory condition Machine is fully functional Power up the machine in service mode and clear the flag in the service menu on the ground control display 83 Disabled 21 By owner The telematics module has locked out machine operation Machine will not be functional or have limi...

Page 108: ...CE OR RD TCON J2 5 and check for open or short circuits 89 Fuel Level Sensor 12 Value to high Fuel sensor shorted to B Information only With a voltmeter check voltage on C65FLI BL WH TCON J7 11 The voltage should be between 1V and 5V Check for shorts to B 15 Value to low Fuel sensor shorted to GND With a voltmeter check voltage on C65FLI BL WH TCON J7 11 The voltage should be between 1V and 5V Che...

Page 109: ...the boom angle sensor cord is hooked up to the bracket on the boom and that the cord extends and retracts smoothly Calibrate boom length sensor Replace sensor if necessary 17 Not calibrated Boom length sensor not calibrated Calibrate boom length sensor 19 Valut out of expected range Min or max length out of expected range Verify that with the boom retracted C24LS OR RD TCON J7 4 is 12V and that th...

Page 110: ...ly C17PRL GR PCON J16 4 and C18PRR GR BK PCON J17 5 should be 12 V when the switch is pressed in their respective directions Cycle power to allow the machine to re test the fault 116 Model Configuration 31 Setup invalid Machine is not fully configured or set to wrong model Machine will not operate Navigate to Settings Model Configuration and ensure model engine tires and region are set and correct...

Page 111: ...rce 11 Shorted to supply voltage TCON detected that ESTOP 1 is at 12 V but ESTOP 3 is at 0 V ESTOP circuit cannot complete preventing machine functions Using a voltmeter and with the system turned OFF check the resistance between TCON J5 pins 9 and 10 Replace TCON if resistance is more than 5 ohms Check P79PWR BK TCON J5 9 and P23PWR RD TCON J5 10 for open or short circuits 186 ESTOP Return 11 Sho...

Page 112: ...l This service tool may be connected to the Engine Service Connector located to the right of the battery tray The ground controls display and fault menu will show basic engine faults such as low oil pressure and high coolant temperature It will also show faults for engine warning and engine stop which correspond to the engine warning lamp and engine stop lamp indicators that the engine may require...

Page 113: ...tor error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressure warning threshol...

Page 114: ...low sensor load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low batt...

Page 115: ...check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR S...

Page 116: ...898 9 305 Timeout Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal ra...

Page 117: ...low 2659 1 1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measuremen...

Page 118: ...n control 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Functi...

Page 119: ...nitoring detection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail...

Page 120: ...TR SPN FMI KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustmen...

Page 121: ...messages 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calibra...

Page 122: ...nt to actual value downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator due ...

Page 123: ... 9 1670 Timeout error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame SCR...

Page 124: ...al 558 4 Accelerator Pedal1 Low Idle Switch Voltage Below Normal 638 6 Engine Fuel Rack Actuator Current Above Normal 639 14 J1939 Network 1 Special Instruction SPN FMI Description 723 3 Engine Speed Sensor 2 Voltage Above Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period 723 10 Engine Speed Sensor 2 Abnormal Rate of Change...

Page 125: ...Due to System Timeout 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 3719 16 Particulate Trap 1 Soot Load Percent High moderate severity 2 4016 6 High Current Auxiliary Power Relay 1 Current Above Normal 4201 3 Engine Speed Sensor 1 Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor 1 Voltage Below Normal 4201 8 Engine Speed Sensor 1 Abnormal Frequency Pulse Nidth ...

Page 126: ... the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1 6 5 4 three times After the fault codes the check engine light will blink a code 1 6 5 4 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a three digit code three times for each code stored in memory It will blin...

Page 127: ...ge 236 TIP Active Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side short to Ground 268 Injector Coil Shorted 270 Injector Loop Open or Low side short to Ground 271 Injector Coil Shorted 273 Injector Loo...

Page 128: ... Fpump relay coil open 628 FPump motor loop open or high side shorted to ground 628 Fpump relay control ground short 629 FPump motor high side shorted to power 629 Fpump relay coil short to power Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 Fu...

Page 129: ...1 CHT higher than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high Code Description 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog PD2 high 1562 AUX analo...

Page 130: ...P1 invalid voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 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 Code Description 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1 2 simultaneous voltages out of range 2139 FPP1 lower tha...

Page 131: ... 2315 Primary Loop Open or Low side Short to Ground 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2618 Tach output ground short 2619 Tach output short to power For further engine fault code troubleshooting and diagnostic information refer to the Ford MSG 425 EFI Dia...

Page 132: ...and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove al...

Page 133: ...ction no terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch...

Page 134: ...alve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot rati...

Page 135: ...er CB2 15A System control logic power CB8A 30A Glow plug 1 CB8B 30A Glow plug 2 CB9 30A Engine run options acc CB10 20A System control driver power Diode D1 6A Alternator Ext Relays CR1 Engine start CR2 Engine run CR3 CR6 low RPM Fuel pump CR4 CR39 High RPM Aux shut down CR5 Horn C15A Engine glow plug A CR15B CR7 Engine glow plug B LPG solenoid CR17 Hydraulic oil cooler option CR23 Drive light CR3...

Page 136: ...lay box Fuses F2 25A Hyd Start F3 1A Relay power F4 5A Eng ECU power F5 1A Spare F21 10A Fuel Alt exct F32 15A Heater Circuit Breakers CB8C 30A Glow plug 1 CB8D 30A Glow plug 2 CB31A 20A Eng ECU 1 CB32B 20A Eng ECU 2 Diode D1 6A Alternator Ext Relays CR12A Engine ECU 1 CR12B Engine ECU 2 CR15C Glow plug 1 CR15D Glow plug 2 CR17B CR1A Hyd fan Start CR40 Fuel pump ...

Page 137: ... Hydraulic oil cooler C15 Flashing beacons C16 Engine diagnostic port C17 Boom cable platform power C18 D2 9 engine connector C19 LST3S C20 LST1O C21 LSB1RS C22 LSB2S C23 Generator from engine harness C24 Welder encloser C25 GM3 0 vehicle interface conn 1 C26 GM3 0 vehicle interface conn 2 C27 Load sense C28 Boom angle sensor C29 Boom extension string pot C30 Canbus terminating resistor C31 Crew a...

Page 138: ... C44 VEC green 8 pin C45 VEC gray 2 pin C46 VEC black 2 pin C47 Function enable C48 Brake C49 Motor stroke C50 Drive pump C51 Engine ECG C52 Engine ECG C53 Platform recirculation valve C56 Telematics C57 ACP C61 VEC2 black 8 pin C62 VEC2 black 8 pin C63 VEC2 blue 8 pin C64 VEC2 green 8 pin C65 VEC2 gray 8 pin C66 VEC2 black 8 pin C72 ECU ...

Page 139: ... functions J4 TCON functions J5 TCON logic J6 TCON limit switches J7 TCON limit switches J8 TCON unused J9 TCON communication J10 DISCON J12 PCON power J13 PCON functions J14 PCON functions J15 PCON logic J16 PCON toggles J17 PCON toggles J18 PCON joysticks J19 PCON unused J20 Boom angle sensor operational not used J21 Boom angle sensor safety not used J22 Fuel level sensor ...

Page 140: ...l not used J24 Platform level sensor safety not used J25 Boom function joystick J26 Drive function joystick J27 404D ECG black J28 404D ECG gray J29 D2 9 ECU 1 J30 D2 9 ECU 2 J31 D2 9 engine interface J32 Chassis tilt sensor operational J33 Chassis tilt sensor safety J34 D2011 engine interface J35 LED PCB J36 Recovery module power J37 Recovery module I O ...

Page 141: ...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 131 ...

Page 142: ...Service and Repair Manual July 2019 7 kW Generator Receptacle Wiring 132 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT ...

Page 143: ...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 133 ...

Page 144: ...Service and Repair Manual July 2019 134 Electrical Schematic TCON ...

Page 145: ...July 2019 Service and Repair Manual Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 135 Electrical Schematic TCON ...

Page 146: ...Service and Repair Manual July 2019 136 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT Electrical Schematic PCON ...

Page 147: ...July 2019 Service and Repair Manual 137 Electrical Schematic PCON ...

Page 148: ...Service and Repair Manual July 2019 138 Electrical Schematic Deutz 2 9 Models ...

Page 149: ...July 2019 Service and Repair Manual Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 139 Electrical Schematic Deutz 2 9 Models ...

Page 150: ...Service and Repair Manual July 2019 140 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT ...

Page 151: ...July 2019 Service and Repair Manual Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 141 Electrical Schematic Deutz 2011 Models ...

Page 152: ...Service and Repair Manual July 2019 142 Electrical Schematic Deutz 2011 Models ...

Page 153: ...July 2019 Service and Repair Manual 143 Electrical Schematic Perkins 404F Models ...

Page 154: ...Service and Repair Manual July 2019 144 S 40 XC S 45 XC S 40 TraX S 45 TraX Part No 1286829GT Electrical Schematic Perkins 404F Models ...

Page 155: ...July 2019 Service and Repair Manual Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 145 Electrical Schematic Ford MSG425 Models ...

Page 156: ...Service and Repair Manual July 2019 146 Electrical Schematics Ford MSG425 Models ...

Page 157: ...July 2019 Service and Repair Manual Part No 1286829GT S 40 XC S 45 XC S 40 TraX S 45 TraX 147 Hydraulic Schematic 4WD ...

Page 158: ...Service and Repair Manual July 2019 148 Hydraulic Schematic 4WD S 40 XC S 45 XC S 40 Tr aX S 45 TraX Part No 1286829GT Service and R epair M anual July 2019 ...

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