Genie S40 S45 Telescopic boom lift Service Repair Manual

S-40 • S-45 Part No. 102521 February 2012 ii Introduction Serial Number Information Genie offers the following Service Manuals for these models: Title Part No. S-40 and S-45 Service Manual (before serial number 3804) ................................ 32222 S-40 and S-45 Service Manual (from serial number 3804 to 4728) ....................... 52271 S-40 and S-45 Service Manual (from serial number 4729 to 7000) ....................... 72136 Copyright © 2011 by Terex Industries 102521 Rev C July 2007 Fourth Edition, Third Printing "Genie" and "S" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper Printed in U.S.A. Important Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine before attempting any maintenance or repair procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting fault codes 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.

Part No. 102521 S-40 • S-45 February 2012 Revision Date Section Procedure / Schematic Page / Description D 2/2012 2 - Spec. 2-1, 2-2, 2-13 3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54 4 - Repair 4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-60 6 - Schem. 6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138, 6-139, 6-150, 6-151, 6-153 D1 10/1012 2 - Spec. 2-1, 2-2 3 - Maint. 3-9, 3-33 to 3-34 4 - Repair 4-59 to 4-60 REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update. Revision History

S-40 • S-45 Part No. 102521 February 2012 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: 2-1_Section 2_Specifications Page #. 3-3_Section 3_Maintenance Procedure Page #. 4-48_Section 4_Repair Procedure Page #. Fault Codes_Section 5. 6-5_Section 6_Schematic Page #. Electronic Version Click on any procedure or page number highlighted in blue to view the update.

Part No. 102521 S-40 • S-45 February 2012 S40 06 - 12345 Model Model year Sequence number PN - 77055 Country of manufacture: USA This machine complies with: Genie Industries 18340 NE 76th Street Redmond, WA 98052 USA ANSI A92.5 CAN B.354.4 Model: S-40 Serial number: S4006-12345 Electrical schematic number: ES0274 Machine unladen weight: Rated work load (including occupants): 500 lb / 227 kg Maximum allowable inclination of the chassis: 0 deg Gradeability: N/A Maximum allowable side force : 150 lb / 670 N Maximum number of platfrm occupants: 2 Model year: Manufacture date: 01/05/06 2006 Maximum wind speed : 28 mph/ 12.5 m/s Maximum platform height : 60 ft 6 in/ 18.3 m Maximum platform reach : 34 ft 3 in/ 10.4 m Sequence number (stamped on chassis) Serial label (located under cover) iii Section 1 • Safety Rules Serial Number Legend

S-40 • S-45 Part No. 102521 July 2007 iv This page intentionally left blank. Section 1 • Safety Rules

Part No. 102521 S-40 • S-45 July 2007 Section 1 • Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual, and the Genie S-40 and S-45 Operator's Manual will result in death or serious 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 regulations You have the appropriate tools, lifting equipment and a suitable workshop. v

S-40 • S-45 Part No. 102521 July 2007 vi SAFETY RULES Personal 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. Read each procedure thoroughly. This manual and the decals on the machine use signal words to identify the following: Safety alert symbol—used to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. 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. Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. Section 1 • Safety Rules July 2007

Part No. 102521 S-40 • S-45 February 2012 Table of Contents Introduction Important Information ................................................................................................... ii Serial Number Legend ................................................................................................. iv Section 1 Safety Rules General Safety Rules .................................................................................................. v Section 2 Rev Specifications Machine Specifications .......................................................................................... 2 - 1 Hydraulic Oil Specifications ................................................................................... 2 - 2 Manifold Component Specifications ....................................................................... 2 - 5 Valve Coil Resistance Specifications ..................................................................... 2 - 5 Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6 Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7 Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8 Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9 Perkins 704-30 Engine Specifications .................................................................. 2 - 10 Perkins 404-22 Engine Specifications .................................................................. 2 - 11 Machine Torque Specifications ............................................................................ 2 - 12 Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13 SAE and Metric Fastener Torque Chart ............................................................... 2 - 14 Section 3 Rev Scheduled Maintenance Procedures Introduction ............................................................................................................ 3 - 1 Pre-Delivery Preparation ........................................................................................ 3 - 3 Maintenance Inspection Report .............................................................................. 3 - 5 Checklist A Procedures A-1 Inspect the Decals and Manuals .................................................................. 3 - 7 A-2 Perform Pre-operation Inspection ................................................................. 3 - 8 A-3 Perform Function Tests ................................................................................ 3 - 8 A-4 Perform Engine Maintenance ....................................................................... 3 - 9 vii

S-40 • S-45 Part No. 102521 February 2012 TABLE OF CONTENTS viii Section 3 Rev Scheduled Maintenance Procedures, continued A-5 Inspect the Track Components, TRAX option .............................................. 3 - 9 A-6 Perform 30 Day Service ............................................................................. 3 - 10 A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 10 A-8 Replace the Drive Hub Oil .......................................................................... 3 - 11 A-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12 A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12 A-11 Perform Engine Maintenance - Ford Models ............................................... 3 - 13 A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14 A-13 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14 A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 15 Checklist B Procedures B-1 Inspect the Battery ..................................................................................... 3 - 16 B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17 B-3 Inspect the Air Filter ................................................................................... 3 - 18 B-4 Test the Key Switch ................................................................................... 3 - 19 B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 19 B-6 Check the Exhaust System ....................................................................... 3 - 20 B-7 Check the Oil Cooler and Cooling Fins - Deutz Models ............................... 3 - 20 B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21 B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22 B-10 Confirm the Proper Brake Configuration ...................................................... 3 - 23 B-11 Check and Adjust the Engine RPM ............................................................ 3 - 24 B-12 Test the Engine Idle Select ........................................................................ 3 - 25 B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 26 B-14 Test the Ground Control Override ............................................................... 3 - 27 B-15 Check the Directional Valve Linkeage ........................................................ 3 - 27 B-16 Test the Platform Self-leveling ................................................................... 3 - 28

Genie S40 S45 Telescopic boom lift Service Repair Manual

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