First Edition • Third Printing Operator's ManualControlsPart No. 217555 S-40 TRAX • S-45 TRAX 21ControlsThe S-40 and S-45 machineswill have one of these two stylesof ground control panel.The descriptions in this section andthe instructions in the Function Testand Operating Instructions apply toboth panels, unless specifically noted.

Introduction

Symbol and Hazard Pictorials Definitions

General Safety

Personal Safety

Work Area Safety

Legend

Controls

Inspections

Operating Instructions

emergency stop

Transport and Lifting Instructions

Maintenance

Specifications

Genie S-40 Trax Operator's Manual

safety rules

personal safety

April

performance specifications

engine specifications

hydraulic specifications

about this section

maintenance inspection report

Z-30/20N (RJ

Z-51/30J

Z-34/22 BE

S-40 TRAX

Safety Rules

electrocution hazards

Pre-operation Inspection

Function Tests

Workplace Inspection

fall protection

Decals

Machine Specifications

Hydraulic Oil Specifications

Manifold Component Specifications

Machine Torque Specifications

Hydraulic Hose and Fitting Torque Specifications

Pre-Delivery Preparation

Maintenance Inspection Report

A-2 Perform Pre-operation Inspection

A-4 Perform Engine Maintenance- Ford Models

A-6 Perform Engine Maintenance - Deutz Models

A-8 Check the High Pressure Hydraulic Filter Condition Indicator

A-10 Perform 30 Day Service

A-12 Perform Engine Maintenance - Ford Models

A-14 Perform Engine Maintenance - Ford Models

A-16 Perform Engine Maintenance - Ford Models

B-1 Inspect the Battery

B-2 Inspect the Electrical Wiring

B-3 Check the Exhaust System

B-4 Perform Engine Maintenance - Perkins Models

B-6 Inspect the Tires, Wheels and Lug Nut Torque

B-8 Check the Drive Hub Oil Level and Fastener Torque

B-11 Test the Platform Self-leveling

B-12 Test the Engine Idle Select

B-13 Test the Fuel Select Operation - Ford Models

B-14 Test the Drive Brakes

B-15 Test the Drive Speed - Stowed Position

B-16 Test the Drive Speed - Raised or Extended Position

B-18 Perform Hydraulic Oil Analysis

B-19 Inspect the Fuel and Hydraulic Tank Cap Venting System

B-20 Check the Track Tension and Fastener Torque - TRAX Option

B-21 Test the Emergency Power System

B-22 Perform Engine Maintenance - Ford Models

C-1 Grease the Platform Overload Mechanism (if equipped)

C-4 Perform Engine Maintenance - Perkins Models

C-6 Perform Engine Maintenance - Deutz Models

C-8 Perform Engine Maintenance Ford Models

D-1 Check the Boom Wear Pads

D-2 Check the Turntable Rotation Bearing Bolts

D-3 Inspect for Turntable Bearing Wear

D-4 Replace the Drive Hub Oil

D-6 Replace the Hydraulic Filters

D-7 Perform Engine Maintenance - Perkins Models

D-8 Perform Engine Maintenance - Deutz Models

E-1 Test or Replace the Hydraulic Oil

E-2 Grease the Steer Axle Wheel Bearings, 2WD Models

E-3 Perform Engine Maintenance - Perkins Models

E-4 Perform Engine Maintenance - Deutz Models

E-6 Perform Engine Maintenance - Perkins Models

E-8 Perform Engine Maintenance - Deutz Models

repair procedures

ALC-500 Circuit Board

Joysticks

Platform Leveling Slave Cylinder

Platform Rotator

Platform Overload System

Jib Boom

Jib Boom Lift Cylinder

Cable Track

Boom

Boom Lift Cylinder

Platform Leveling Master Cylinder

Flex Plate

Ford MSG-425 Engine Fault Codes

Function Pump

Drive Pump

Function Manifold Components

Valve Adjustments - Function Manifold

oscillate directional valve components

Valve Adjustments, Oscillate Relief Valve

Traction Manifold Components, 2WD

Traction Manifold Components, 4WD

Drive Oil Diverter Manifold Components (welder option)

Valve Coils

Turntable Rotation Assembly

axle components

Track Assembly - TRAX Option

Hydraulic Generator

fault codes

Fault Codes - Control System

Fault Code Display - Deutz D 2.9 L4 and Perkins 404F-22 Models

Fault Code Display - Flashing and Solid LED's

Fault Code Display - Soft Key Functions and Icons

Fault Code Display - Main Menu Structure

Fault Codes - Deutz D 2.9 L4 Engine

Fault Codes - Ford MSG-425 Engine

Electrical Symbols Legend

Hydraulic Symbols Legend

electrical abbreviations legend

ford engine relay layout

A Machine Specifications

A-1 Perform Pre-operation Inspection

A-3 Perform Engine Maintenance - Deutz Models

A-5 Perform Engine Maintenance - Perkins Models

A-7 Check for Fuel Leaks

A-12 Perform Engine Maintenance - Ford and Perkins Models

A-14 Check and Adjust the Engine RPM - Perkins Models

A-15 Grease the Turntable Rotation Bearing and Rotate Gear

A-17 Perform Engine Maintenance - Ford Models

B-3 Perform Engine Maintenance - Deutz 1011F Models

B-5 Check the Oil Cooler and Cooling Fins - Deutz Models

B-6 Inspect the Tire and Wheels (including lug nut torque)

B-8 Check the Oil Level in the Drive Hubs

B-10 Test the Engine Idle Select

B-12 Test the Drive Brakes

B-13 Test the Drive Speed - Stowed Position

B-15 Perform Hydraulic Oil Analysis

B-17 Replace the Fuel Filter/Water Separator Element - Perkins Models

B-18 Test the Alarm Package (if equipped)

B-19 Perform Engine Maintenance - Deutz Models

B-21 Perform Engine Maintenance - Perkins Models

C-1 Perform Engine Maintenance - Deutz Models

D-3 Check the Free-wheel Configuration

D-5 Check and Adjust the Air/LPG Mixture - Ford Models

D-6 Perform Engine Maintenance - Deutz Models

D-8 Replace the Hydraulic Filters

E-2 Perform Engine Maintenance - Deutz Models

RPM Adjustment - Deutz Models

Engine Fault Codes - Ford Models

Jib Select and Platform Rotate Manifold Components

Traction Manifold Components, 2WD (before serial no. 7569)

Traction Manifold Components, 2WD (after serial no. 7568)

Traction Manifold Components, 4WD (before serial no. 7569)

Traction Manifold Components, 4WD (after serial no. 7568)

A Fault Codes - Ford Engine

A-5 Inspect the Track Components, TRAX option

A-6 Perform 30 Day Service

A-8 Replace the Drive Hub Oil

A-9 Perform Engine Maintenance - Perkins Models

A-11 Perform Engine Maintenance - Ford Models

A-12 Grease the Turntable Rotation Bearing and Rotate Gear

B-3 Inspect the Air Filter

B-4 Test the Key Switch

B-6 Check the Exhaust System

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

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

B-10 Confirm the Proper Brake Configuration

B-11 Check and Adjust the Engine RPM

B-14 Test the Ground Control Override

B-16 Test the Platform Self-leveling

B-18 Test the Drive Speed - Stowed Position

B-20 Perform Hydraulic Oil Analysis

B-21 Test the Alarm Package (if equipped) and the Descent Alarm

B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System

B-23 Check the Track Tension and Fastener Torque - TRAX Option

B-24 Perform Engine Maintenance - Ford Models

C-1 Perform Engine Maintenance - Deutz and Perkins Models

C-2 Grease the Platform Overload Mechanism (if equipped)

C-6 Perform Engine Maintenance Ford Models

D-7 Inspect for Turntable Bearing Wear

E-3 Perform Engine Maintenance - Deutz and Perkins Models

E-4 Perform Engine Maintenance - Ford Models

E-6 Perform Engine Maintenance - Deutz and Perkins Models

E-7 Perform Engine Maintenance - Deutz Models

E-9 Perform Engine Maintenance - Ford Models

Part No. 102521 S-40 •

Traction Manifold Components, 2WD (before serial number 7569)

Traction Manifold Components, 2WD (after serial number 7568)

Traction Manifold Components, 4WD (before serial number 7569)

Ford DSG-423 Engine Relay Layout

Connector Pin Legend

Ground Control Box Wiring Diagram Deutz F3L-1011F Models

Platform Control Box Wiring Diagram Deutz F3L-1011F Models

Ground Control Box Wiring Diagram Perkins 704-30 Models

Platform Control Box Wiring Diagram Perkins 704-30 Models

Platform Control Box Switch Panel Wiring Diagram Perkins 704-30 Models

Perkins 404-22 Models (before serial number 14832)


Contents Table Of Contents Introduction Symbol and Hazard Pictorials Definitions General Safety Personal Safety Work Area Safety Legend Controls Inspections Operating Instructions emergency stop Transport and Lifting Instructions Maintenance Specifications	First Edition • Third Printing Operator's ManualControlsPart No. 217555 S-40 TRAX • S-45 TRAX 21ControlsThe S-40 and S-45 machineswill have one of these two stylesof ground control panel.The descriptions in this section andthe instructions in the Function Testand Operating Instructions apply toboth panels, unless specifically noted. Previous Next / 66