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1. Part 89721 October 2006 600 Platform Components 602 1 Platform Installation View 2 Rev Item Part Description Qty Asian and South American Railing Assembly with Decals 26 101375 4 Foot Platform Railing 1 101378 5 Foot Platform Railing 101381 6 Foot Platform Railing 101384 8 Foot Platform Railing 27 60160P 4 Foot Platform Flooring 1 54247P 5 Foot Platform Flooring 73477P 6 Foot Platform Flooring 73478P 8 Foot Platform Flooring 28 54274 Step Bolt 1 4 20 x 0 75 inch A TEREX COMPANY Part No 89721 5 40 5 45 600 e Platform Components October 2006 Figure Rev Description 603 1 B Platform Control Box View 1 A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 600 Platform Components 603 1 Platform Control Box View 1 Rev B Item PartNo Description Qty Description Qty 89844 Platform Control Box Assembly 11 13037 5 Toggle Switch before serial number 7181 boom extend retract 102147 Platform Control Box Assembly SPDT 3 position Momentary 1 afer senal number 7180 12 45383 Warble Tone Alarm 5 30V DC 27246 Rubber Boot includes mounting fasteners 1 54692 Nylo
2. A TEREX COMPANY S 40 5 45 Part 89721 October 2006 300 e Turntable Components 307 1 Ground Control Box View 2 Rev B Part Description Qty 1 89172 Terminal Rail Assembly includes item 3 1 74911 Terminal Block 33422 Mounting Rail 17 inches 74912 End Plate 74920 Number Marking Tags 1 10 74921 Number Marking Tags 11 20 74922 Number Marking Tags 21 30 74923 Number Marking Tags 31 40 74924 Number Marking Tags 41 50 2 56057 Start Ignition 006 1 3 74913 End STOD NEE 2 4 54365 Screw PHM 10 32 x 0 5 inch 5 6178 Nylock Nut 10 32 6 49743P Toggle Switch Mount Bracket 1 7 42730 S Toggle Switch run test Ford models SPDT 2 position Momentary 1 8 34052 SPDT Relay 12V DC Ford models before serial number 7597 4 34052 SPDT 12 DC Ford models after serial number 7596 5 34052 SPDT 12V Deutz models 6 34052 SPDT Relay 12V Perkins models 6 34053 SPDT Relay Socket as needed 34054 Relay Socket Terminal 10 12 Ga 34055 Relay Socket Terminal 14 16 Ga 34056 Relay Socket Terminal 18 20 9 54534 Relay Mount Bracket 1 88176 Nutsert 1 4 20 10 6090 Screw HHC
3. Part 89721 October 2006 600 Platform Components 602 1 Platform Installation View 2 Rev Description Qty Part No Description Qty 1 6888 Screw HHC 18 43956 Electrical Cord 14 Ga 14 20 x 1 inch GR 5 3 Conductor 5 40 828 inches 2 Lock Washer 1 5996 EE ER 8245 esee 888 inches i5 3 6638 Flat Washer 1 4 inch 19 4828 Nylock Nut 3 s 16 i i 1 4 887 Spring Clip Nut 1 4 20 20 57201 Hardened Flat Washer 5 73610 Platform Entry 5160 1 0 313 8 6 6019 Screw HHC 21 6550 U bolt 3 8 16 1 5 2 5 388 16 x 1 25 inches 5 1 2 uuu usu usus 2 7 6097 Flat Washer 3 8 inch 22 6175 Screw HHC 38 16 1 inch GR 5 482 Nylock Nut 3 8 1 m 8 828 De before serial number 7054 8 9 89334 Decal Plate 77692 Screw HHC before serial number 7182 1 3 8 16 x 1 inch GR 8 102145 Decal Plate with Word Decals after serial number 7053 USA Canada Australia from serial number 7182 to 9752 ES 8928 221 pu GR5 111275 Decal Plate with Word Decals USA Canada Australia 24 13775 Flat Washer after serial number 9752 1 063 x 2 x 0 134 inch 102146 Decal Plate with Symbol Decals Europe Asia South America 25 29764 Nylock Nut 1 8 after serial number 7181 USA and Canadian Railing Assembly with Decals 10 6090 Screw HHC bef
4. enie 5 40 5 45 G Part 89721 October 2006 800 Accessories 801 1 Alarm and Beacon Package Drive Light Option Rev D Part No Description Qty 46985 Alarm and Beacon Package Complete 89691 Drive Lights Option Complete includes item 3 Ref Alarm Package Harness refer to 311 1 72867 Label Drive Lights 1 45462 Chime Tone Alarm 5 25V DC descent 1 72326 Plastic Ring Nut 2 18963 Intermittent Tone Alarm 6 30V DC travel 1 72326 Plastic Ring Nut 3 35958 Housing Drive Light 2 35960 Drive Light 12V DC Ref Harness Drive Lights refer to 311 1 4 6147 Screw RHM 10 32 x 1 inch 5 6146 Flat Washer Plated 10 6 6178 Nylock Nut 10 32 7 122030 Strobe 12 72 V DC Amber 2 72282 Amber Lens 122019 Flashtube after serial number 11296 8 6096 Screw HHC 1 2 13 x 2 inches GR 5 9 33418 Plate Washer 5 8 2 25 x 0 15 inch A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 800 Accessories iption Platform Options Descripti Rev E Figure 802 1 09 2 09 Part 89721 5 40 5 45 October 2006 800 Accessories 802 1 Platform Opti
5. 1 44 89973 Exhaust Pipe Assembly 1 16 54862 Upper Radiator Hose 1 102134 Gasket 17 102977 Plastic Fitting 45 70419 Dipstick Tube 1 52566 Oil Level Dipstick 18 54598P Radiator Shroud 1 46 102779P Heat Shield Support Bracket 1 19 21019 Screw PHPM 10 24 x 0 5 inch 8255 Screw 3 8 16 3 4 inch 20 6146 Flat Washer 10 6021 Lock Washer 3 8 inch 6022 Hex Nut 3 8 16 21 102010 Fan Guard 1 47 102103 Air Cleaner Inlet Hose 1 22 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 48 110304 Radiatore etti 1 65473 Radiator 23 6638 Flat Washer 1 4 inch 49 89913P Radiator Baffle 1 245 6091 74 20 8255 Screw HHC 3 8 16 x 3 4 inch 25 52652 Charge Air 1 6021 Lock 3 8 inch 26 77170 Lower Radiator Hose 1 13014 Hose Clamp 2 25 inches 27 1702 Hose Coolant 5 8 inch 10 inches 28 102074 Fitting l u ceci 1 A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 fats Ford LRG 425 EFI Engine View 2 from serial number 7597 to 11066 Description Rev D 400 Engine Components Figure 417 1 GI be c
6. 4 31 88988 Outboard Engine Mount 1 1 2 9 88933 2 32 6198 Nylock Nut 1 2 13 33 39479 Screw HHC 1 454 Ue VeL 1 2 13 x 2 75 inches GR 5 11 4 ir Cleaner Outlet Hose 888537 Air Cleaner Mose 24 70452 Engine Vibration Isolator 4 12 88841 1 70385 Clamp 2 inches 35 80150 Flat Washer 1 2 inch 13 88991P Muffler Mount Gast Washer 14 111390 Exhaust Pipe 1 37 89929 Radiator 28116 1 88844 Exhaust Pipe Flange 38 89900P Intake Hose Support 1 94888 Exhaust Manifold 21019 Screw PHPM 72343 Exhaust Manifold Gasket 10 24 x 0 5 inch 72344 Stud M8 x 1 25 x 35 mm 6146 Flat Washer 10 62845 Flanged Nut M8 6607 Lock Washer 10 15 89596P Medium Pressure Filter 1 39 88846 Air Cleaner Inlet Hose 1 16 6019 Screw HHC 40 110304 Radiatore tee 1 3 8 16 x 1 25 inches GR 5 65473 Radiator Cap 17 5397 Flat Washer 5 16 inch 41 88989P Upper Radiator 18 4828 Nylock Nut 3 8 16 Support 1 19 77139 Medium Pressure Filter Assembly 1 60857 Filter Element 3 micron 20 Ref Engine Tray refer to 423 1 Part No 89721 S 40 S 45 October 2006 400 En
7. 1 62421 Filter Element 3 13022 Screw HHC 5 16 18 x 1 inch 25 72348 Fuel Lift PUMP 1 4 5397 Flat Washer 5 16 inch 65912 O ring 26 23057 Screw HHC 5 2 5 6002 Nut 5 16 18 8 1 25 20 GR 8 8 6 89953 Throttle Linkage 1 27 49408 Lock Washer M8 7 72350 Shut off Solenoid 28 6019 Screw HHC before serial number 9559 1 3 8 16 x 1 25 inches GR 5 111031 Shut off Solenoid after serial number 9558 29 6097 Flat Washer 3 8 inch 8 21130 Clevis 1 4 28 1 30 4828 Nylock Nut 5 8 16 9 21496 Nut 1 4 20 31 88992P Muffler Support Bracket 1 10 89759 Oil Dipstick cce 1 11 72337 Oil Pressure Switch before serial number 9559 1 111027 Oil Pressure Switch after serial number 9558 12 94762 Oil Filter ener 1 13 77402 Throttle Solenoid 1 14 8915 Screw HHC 1 4 20 x 1 25 inches GR 5 15 6638 Flat Washer 1 4 inch 16 6091 Nylock Nut 1 4 20 17 94378P Fuel Water Separator Bracket 1 18 75020 Fuel Water Separator 1 62433 Filter Element 19 54573 Bell Housing Kit 1 29749 Pump Coupler 15 Tooth 89771 Pump Mount Housing 89772 Coupler Flex Plate 89773 Hardware Kit 20 Ref Function Pump refer to 706 1 21 Ref Drive Pump refer to 706 1 Part No 89721 5 40 5
8. 3 Danger General Safety before serial number 9753 2 Danger General Safety after serial number 9752 Notice Tire Specifications 4 Danger Tilt Alarm 1 Notice Align Air Hoses 1 Label Patents 1 Label Lanyard Anchorage 3 Notice Function Enable before serial number 7181 1 Label Air Line to Platform 2 Notice Engine Specifications Ford LRG 425 EFI before serial number 7597 1 Notice Engine Specifications Ford LRG 425 EFI from serial number 7597 to 11066 Notice Engine Specifications Ford DSG 423 EFI after serial number 11066 Notice Max Side Force 90 Ibs 400 N Wind Speed 28 m sec Australia Models European models before serial number 9753 1 This list continues on the next page 100 Decals October 2006 Figure Rev Description 101 1 F Decals with Words 28171 82195 25994 82283 27564 77046 38149 28161 44981 31060 or 82581 28159 82588 0 82629 32719 82366 or 72847 Hoy 5 Ss 32700 or wa ei m I He 43663 t det SSS 28161 7 H7 1 97579 32719 or 82469 72847 lt Tan
9. iii Parts Stocking List ix How To Order Parts Xii Order Form uon dh e feret xiii Electronic Version Click on the figure description below to view the figure 100 e Decals 101 1 F Decals with Words 1021 F Decals with Symbols 200 Drive Chassis Components 201 1 B 2WD Steer Axle Linkage Oscillating Models 202 1 2WD Steer Axle Linkage Non oscillating Models 2031 B 2WD Steer Axle Wheels and Hubs 204 1 D 2WD Non steer Axle before serial number 7569 2042 B 2WD Non steer Axle after serial number 7568 2051 B 4WD Steer Axle Linkage 206 1 C 4WD Steer Axle Wheels and Hubs 207 1 E 4WD Non steer Axle before serial number 7569 Part No 89721 A TEREX COMPANY Table of Contents 200 e Drive Chassis Components Continued 207 2 208 1 B B 4WD Non steer Axle after serial number 7568 Oscillation Control Valve 300 Turntable Components 301 1 302 1 303 1 304 1 305 1 306 1 307 1 308 1 309 1 310 1 311 1 D Hydraulic and Fuel Tanks Gasoline LPG Hydraulic and Fuel Tanks Diesel Function Manifold Plug to Platform and Auxiliary Power Unit Turntable Rotator and Hydraulic Rotary Coupler Installation Turntable Rotation Drive Hub Ground Control Box View 1 Ground Control Box View 2 Turntable Covers View 1 Tank Side Turn
10. OO 5 aS Ww October 2006 500 Boom Components 504 1 Cable Track Installation Rev D Description Qty Part No Description Qty Ref Wire Harness Extend Retract 25 34954 Wear Pad Shim 16 Ga Limit Switch 1 5 x 3 5 inches as needed A 26 431910 Cable Track Attachment Plate 1 1 Ref Boom Assembly E refer to 502 1 or 503 1 27 25969 Spring Clip Nut 1 4 20 4 2 8914 Screw HHC 28 40653 Roller UHMW 1 1 4 20 x 0 625 inch GR 5 29 43128 Slide Block 1 3 6356 Lock Washer 1 4 inch 30 36204P Limit Switch Extension Bracket 1 4 6115 Screw HHC 31 8179 Screw HHC 1 4 20 x 3 5 inches GR 5 1 4 20 x 2 25 inches GR 5 5 6638 Flat Washer 1 4 inch 32 41031P Cable Track Guide Bracket 1 6 6889 Low Profile Nylock Nut 1 4 20 33 41029 Wear Pad 3x 2 x 0 5 inch 1 7 41750 Guide 00 1 34 41030 Wear Pad 2 5 x 2 25 x 0 5 inch 1 8 30671 S Cable Track Tube Assembly 1 5 22832 Screw HHC SCH 9 63433 Hose Clamp 1 16 x 6 inches GR 5 Die 10 63432 Bottom Hose Clamp 2201089 Nylook NUL S016 11 43852 S Track Support Cable Tube 1 37 36593 Cable Track Guide 1 12 73994 Cable Track 41 Links vB Du ur s 81007 Rep
11. 1 18 119170 Fuel Pressure Regulator 49498 Vibration Isolator 19 1116999 Regulator Mount 18503 Flange Nut 5 16 18 20 Ref Engine Tray refer to 423 1 46 113073 Upper Coolant Intake Hose 1 119053 Hose Clamp 1 5 inches 21 4266 Screw HHC 1 4 20 2 inches GR 5 22 112283 ECM Bracket 1 23 119169 Engine Control Module ECM 1 24 6145 Screw HHC 1 4 20 x 1 5 inches GR 5 25 56912 Spring Clip 1 4 20 26 6198 Nylock Nut 1 2 inch 27 39479 Screw HHC 1 2 13 x 2 75 inches GR 5 28 70452 Engine Vibration Isolator 2 A TEREX COMPANY Part No 89721 S 40 5 45 400 e Engine Components October 2006 Figure Rev Description 423 1 B Engine Tray Battery and Filter Installation lt au 1 Su 1 S COO A TEREX COMPANY S 40 5 45 89721 October 2006 400 Engine Components 423 1 Engine Tray Battery and Filter Installation Rev B Part No Description Qty Part No Description Qty 1 89596P Filter Mount 1 18 Ref Negative Battery Cable 2 6090 Screw HHC 14 20 0 75 5 19 57162 Terminal Cover Boot 2 3 6356 Lock Washer 1 4 inch 20 30144 Battery Hold 1 29883 Screw HHC
12. 5 40 5 45 89721 October 2006 200 e Drive Chassis Components 202 1 2WD Steer Axle Linkage Non oscillating Models Rev A Part Description Qty 1 6175 Screw HHC 38 16 x 1 inch GR5 2 6021 Lock Washer 3 8 inch 3 45226 Rod End 0 375 x 3 69 inches 1 4 30735 Pivot Pin 17 5 x 1 5 inches 1 5 89065 Steer Cylinder 2 89066 Seal Kit 6 25817 Bearing 1 x 1 25 x 1 inch 6 7 53081 Pivot Pin 4 63 x 1 5 inches 4 8 45071 Bearing 1 5 x 1 75 x 1 5 inches 6 9 65515 Yoke Assembly Left Side includes items 6 and 8 1 10 8220 Screw HHC 1 2 13 x 4 inches GR 5 11 6086 Nylock Nut 1 2 13 12 45074 Thrust Washer 1 51 x 3 5 x 0 187 inch 2 13 36603 Flat Washer 1 56 x 3 5 x 0 057 inch as needed 14 89804 Steer Axle Assembly Non oscillating includes items 6 and 8 1 15 65516 Yoke Assembly Right Side includes items 6 and 8 1 16 14815 Roll Pin 0 25 x 2 25 inches 2 17 49857 Screw HHC 3 8 16 x 0 875 inch GR 5 18 25284 Rod End 0 375 x 2 25 inches 2 19 30734 Pivot Pin 2 88 x 1 inch 2 20 19440 Clevis Pin 1 x 2 5 inches 2 21 63155 Tie RO iie 1 22 74389 Rue Ring 1 25 x 15 13 inches 4 A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Com
13. Manual Refer inside cover for additional serial number information Part No 89721 Rev D October 2006 S 40 S 45 from serial number 7001 4 Technical Publications Genie Industries 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 www genieindustries com e mail techsup genieind com A TEREX COMPANY October 2006 Serial Number Information Genie Industries offers the following Parts Manuals for these models Title Part No Genie S 40 Parts Manual before serial number 831 32223 Genie S 40 and S 45 Parts Manual from serial number 831 to 7000 52090 Copyright 2004 by Genie Industries 89721 Rev D October 2006 Third Edition Fourth Printing Genie and S are registered trademarks of Genie Industries in the USA and many other countries Printed on recycled paper Printed in U S A Part No 89721 October 6 How Read Your Serial Number Genie A TEREX COMPANY Model S 40 Serial number 54006 12345 Model year
14. 1 38 97815 Label Lower Mid rail 1 18 62075 5 45 19 62959 Cosmetic S 40 s 20 62960 45 E ded NE 21 82602 Danger Maximum Manual Force 150 Ibs 667 N USA Canada models 1 22 82604 Danger Maximum Manual Force 90 Ibs 400 N European models 1 23 82469 Platform Control Panel before serial number 7182 1 89836 Clear Protector 82242 Label Fuel Select Patch Ford models A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Figure Rev Description 201 1 B 2WD Steer Axle Linkage Oscillating Models 5 40 5 45 89721 October 2006 200 e Drive Chassis Components 201 2WD Steer Axle Linkage Oscillating Models Part No Description Qty Item Part No Description Qty 1 49857 Screw HHC 25 36603 Flat Washer 1 56 x 3 g 16 x 0 875 inch GR 5 3 5 x 0 057 inch as needed 2 6021 Lock Washer 3 s inch 26 89805 Steer Axle Assembly 3 25284 End 0 375 x 2 25 inches 8 7 1 5 27 65516 Yoke Assembly Right Side 4 30737 Pivot Pin x 1 25 inches
15. Part 89721 5 40 5 45 October 2006 700 e Hydraulic Components Part No 26 27 28 89309 62275 45912 84133 89307 62273 89311 19792 27807 110200 62255 62274 89855 89856 62276 110204 62256 110202 89678 74902 62256 110202 89307 62273 89311 19792 72047 27804 110201 27807 110200 48997 20224 48880 Description Solenoid Valve 2 position 3 way Coil 10V DC Coil Nut Seal Kit Solenoid Valve 3 position 4 way Coil 10V DC Dual Coil Spacer Coil Nut etree Seal Kit Proportional Valve 12V DC Coil 12V DC O ring O ring Lower sold separately Coil Nut Seal Kit Counterbalance Valve 3500 psi 242 bar Seal Kit Needle ValVe Kit Counterbalance Valve 3500 psi 242 bar Seal Kit Solenoid Valve 3 position 4 way Coil 10V DC Dual Coil Spacer Coil Nut Seal Kit Differential Sensing Valve 150 psi 10 3 bar Seal Kit Check Valve inse icc Seal Kit Diagnostic Nipple 4 SAE Female Quick Disconnect for Pressure Guage sold separately Diagnostic Nipple Cap Part No 89721 701 1 Function Manifold Rev F Function Boom down Turntable rotate left right Platform level down Turntable rotate left right Platform level up Platform
16. 1 23 37002 Pump Coupler ssseeeeeeeeeeeeeeen 1 24 33024 7 1 5 65495 Starter uoce 1 26 65487 Alternator 12V DC 65 A 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 EE Part 89721 5 40 5 45 400 Engine Components Perkins 704 30 Engine View 2 before serial number 7472 Description Rev A Figure 402 1 October 2006 400 Engine Components 402 1 Perkins 704 30 Engine View 2 before serial number 7472 Rev A Part Description Qty 1 49517 Engine Oil Drain Plug 1 2 62421 F el Filter arie 1 3 65500 Fuel Lift Pump 1 65501 Fitting Kit 53948 Fitting Adapter 4 65497 DIPSUCK iier 1 5 62422 Oil 1 6 65498 Oil Filler Cap 1 7 30810 Oil Pressure Sending Unit 1 8 53951 Female Adapter 3 4 16 1 9 53945 Hose Clamp 3 25 inches 5 10 34164 Elbow Hose 90 1 11 63463 Air Filter Housing 1 62420 Element Air Filter 12 53952 Air Filter Mount Bracket includes mounting fasteners 1 13 6584 Shoulder Bolt 1 4 x 0 625 inch 14 5365 Nylock Nut 10 24 15 21130 Clevis 1 4 28 1 16 21496 Nut 1 4 28 17 30785 1000 Threaded Rod 1 4 28 x 10 1068 1
17. 1 106275 Welder Leads Assembly 110276 1600 1 25 16 inches S 45 2 includes both cables 110276 2300 1 25 23 inches S 45 1 106183 0 6A 250V 110276 3200 1 25 32 inches 5 45 1 106141 Security Screw 110276 4700 1 25 47 inches 5 45 1 1 4 20 x 1 75 inches 110276 5000 1 25 50 inches S 45 1 mounting fasteners 28443 Cable Tie 11 5 inch 0 88406 Fire Extinguisher 14 18666 deg Cushioned Clamp 82862 Decal Fire Extinguisher 97579 Decal Danger Tip over 15 110220 Decal Warning Welder Safety 1 32728 Decal Generator 82264 warning 16 106204 Welder Leads Bracket 1 Welder Safety Instructions before serial number 7189 82265 Label Welder On Off 1 101547P Support 1 2 5397 Flat Washer 3 8 inch 3 4828 Nylock Nut 3 8 16 4 6550 U bolt 3 8 16 1 5 2 5 x 1 25 5 47363 Screw RHSM 8 32 0 5 inch 6 35461 Flat Washer 8 7 101731P Receptacle Bracket 1 4828 Nylock Nut 5 8 16 5397 Flat Washer 3 8 inch 6550 U bolt 38 16 x 1 5 2 5 1 25 inches 8 101732 Weatherproof Cover 1 9 106112 Plug 4 Wire 3 Phase 50A 1 10 106110 T Box 3 Phase includes item 11 1 106111 Locking Receptacle 3 Phase 50A 11 82237 Dec
18. 1 30 29616 ineunte 1 Part No 89721 5 40 5 45 Part No 7713 45454 22788 64079 89813 89811 37003 102136 6019 4828 24038 15086 48425 101121 33963 52078 33964 102794 33277 52580 65770 65454 13014 72358 33972 65456 418 1 Rev E Description Qty Nylock Nut 5 8 16 Rubber Cushioned Clamp 0 75 0 375 inch 1 Screw HHC 1 2 13 x 1 75 inches Bell Housing Kit 1 Coupler Flex Plate Pump Mount Housing Pump Coupler 15 Tooth Screw SHC 7 16 14 x 1 25 inches Screw HHC 3 8 16 x 1 25 inches GR 5 Nylock Nut 3 8 16 Lower Radiator Isolator 4 Fender Washer 3 8 x 1 5 x 0 125 inch Flange Lock Nut 3 8 16 Radiator Support Mount 1 Water Pump with Gasket 1 Water Pump Pulley Water Pump Gasket Screw HHC 8 x 1 25 x 40 GR 10 9 Flat Washer M8 Serpentine Belt 1 Timing Belt Flange Bolt M6 x 22 mm Clamp 2 25 inches 1 Water Inlet Tube 1 Coolant Temperature Sensor 1 Water Temperature Sending Unit 1 October 2006 14 Q9 G 5 40 5 45 Part 89721 400 Engine Components Ford 056 423 EFI Engine View 1 after serial numb
19. 1 19 88451 Throttle Body 1 88452 Body Gasket A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 400 e Engine Components lt lt o X PRP Ford DSG 423 EFI Engine View 2 after serial number 11066 y 7 2 YN 7 DV 2 c 4 Dee Be Z 8 Figure 420 1 Part 89721 A TEREX COMPANY G 5 40 5 45 October 2006 400 Engine Components 420 1 Ford DSG 423 EFI Engine View 2 after serial number 11066 Rev A Item Part No Description Qty 1 13000 Screw HHC 5he 18 x 1 25 inches GR 5 2 5397 Flat Washer 5 16 inch 3 18503 Flange Nut 5 16 18 4 119474 PEV VAVO nne 1 75631 Hose 3 8 inch 5 54071 Coolant Recovery Bottle 1 72327 Cap 21465 Hose Clamp 0 25 inch 6833 Rubber Cushioned Clamp 0 5 x 0 25 inch 6 6145 Screw HHC 1 4 20 x 1 5 inches GR 5 7 6638 Flat Washer 1 4 inch 8 56912 Spring Clip 1 4 20 9 119468 Water Pump with Pulley 1 10 32309 Screw HHC M8 1 25 x 60 mm GR 8 8 11 49408 Lock Washer M8 12 119153 Fam oip ege 1 13 119138 Sperpentine Belt 1 14 119470 Tensioner Pulley 1 15 119469 Tensioner 1 16 119496 Crank Position Sensor
20. 3 Injector Pump 1 Male 9 1 Hose Assembly Components Genie part numbers 48812 48819 48753 6 32 inches 1 eei eoe 1 Wear Pad 4 x 2 x 0 5 inch 4 Screw HHC 1 4 20 x 0 75 inch GR 5 Lock Washer 1 4 inch Screw HHC 5 8 11 x 1 75 inches GR 8 4 Lock Washer 5 8 inch Flat Washer 5 8 inch Ring GaP 1 Flexplate 1 Pump Coupler Pump Mount Plate Screw HHC 1 2 13 x 2 inches GR 5 Part No 89721 Part No 31 32 33 34 35 36 6033 83141 6175 6021 Ref 409 1 Rev B Description Qty Lock Washer 1 2 inch ONNI EE 1 Screw HHC 3 8 16 x 1 inch GR 5 Lock Washer 3 8 inch Function Pump refer to 706 1 Drive Pump refer to 706 1 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers 400 e Engine Components October 2006 Figure Rev Description 410 1 D Deutz F3L 1011F Engine View 3 before serial number 7544 6 G A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 400 Engine Components 1 a Im 10 11 12 13 14 15 16
21. 9 2 SV b EON w 2 iM gt Lei 6 5 40 5 45 89721 October 2006 200 e Drive Chassis Components 204 1 2WD Non steer Axle before serial number 7569 Rev Item Part Description Qty 22 73858 Screw SHC 1 2 13x 5 inches GR 5 23 13066 Flat Washer 1 2 inch 24 25969 Spring Clip Nut 1 4 20 8 25 30802P Non steer Axle Cover 2 26 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 27 6356 Lock Washer 4 inch 28 6638 Flat Washer 4 inch 29 30690 Axle Rotation Stop Bar oscillating models 2 30691 Axle Rotation Stop Bar non oscillating models 30 30808 Axle Rotation Stop Shim 9 5 x 1 5 x 0 108 inch as needed 31 30809 Axle Rotation Stop Shim 9 5 x 1 5 x 0 034 inch as needed 32 30735 Pivot Pin 17 5 x 1 5 inches 1 33 45226 Rod End 0 375 x 3 69 inches 1 34 6175 Screw HHC 38 16 x 1 inch GR 5 35 89803 Non steer End Cover with 26088 1 A TEREX COMPANY Part No 89721 S 40 5 45 sis Components October 2006 200 Drive Chas Es 5 KR E 2 c amp 2 lt D 9 2 5 2 Q an N ow oi Part 89721 5 40 5 45 October 2006 200 e Drive Chassis Components
22. Part No 10 11 12 13 14 14 6096 6021 73634 6146 77026 77027 73575 54156 89802 18396 36603 73196 54627 81489 73212 81008 81009 111449 111450 81492 81493 Description Screw HHC 1 2 13 2 inches GR 5 Lock Washer 3 8 inch Screw PHPM 10 24 x 0 5 Flat Washer 10 Bubble Level European models Spring 1 x 0 31 x 0 040 inch 3 Spring Clip Nut 10 24 Flanged Bearing 1 5 x 1 75 x EE Non steer Axle Assembly includes items 8 and 11 Bearing 1 5 x 1 75 x 1 inch Flat Washer Qty 14 inch 15 1 16 1 56 3 5 0 057 inch as needed Wheel 16 5 9 75 9 holes Lug Nut 5 8 18 90 Tire 12 16 5 8 Ply Tire 12 16 5 12 Ply Non marking Tire and Wheel Assembly Air filled Right Side Tire and Wheel Assembly Air filled Left Side Tire and Wheel Assembly Air filled with Sealant Right Side Tire and Wheel Assembly Air filled with Sealant Left Side Tire and Wheel Assembly Foam filled Right Side Tire and Wheel Assembly Foam filled Left Side 21 22 23 24 25 Part 73204 73205 111453 111454 102802 102803 73455 13064 101584 106119 106120 58320 106121 106122 106123 106124 106125 106126 106117 106118 101587 106098 88296 106134 25969 30802P 6090 204 2 2WD Non st
23. ene 1 7 3 27205 Arrow Yellow 1 8 4 27206 Triangle Blue 2 29 5 27207 Triangle Yellow 2 30 6 27564 Danger Electrocution Hazard 2 7 28158 Label 1 31 8 28159 1 32 9 28160 Label Liquid Petroleum Gas 2 10 28161 Warning Crushing Hazard 3 11 28163 Notice Max Side Force 150 Ibs 667 N before serial number 9753 1 97887 Notice Side Force 150 Ibs 667 N after serial number 9752 33 12 28164 Notice Hazardous Materials 1 13 28165 Notice Foot Switch 1 14 28171 Label No Smoking ssseseeseeeeen 1 Part No 89721 5 40 5 45 28174 28175 28176 28177 28181 28235 28236 30080 31060 32700 97890 32719 33952 35599 38149 40434 43663 44981 49741 97571 114169 44986 100 Decals 101 1 Decals with Words Rev F Description Qty Label Power to Platform 230V AC itch nese 2 Caution Compartment Access 1 Notice Missing Manuals 1 Warning Platform Rotate 2 Warning No Step or Ride 1 Label Power to Platform 15 aS OH 2 Warning Failure To Read 1 Notice Max Capacity 500 Ibs 227 kg 1 Danger Tip over Hazard Interlock
24. 94762 Serpentine Belt 119138 VEITH 89765 PCV Valve a a aI LL 119474 Deutz F3L 1011F Models before serial number 7544 Spark Plug 119467 Description part No Spark Plug pack of 4 119495 Air Filter Element a u u 62420 Fuel water Separator Filter 29560 Recommended Parts Engine Oil Filter 49924 Genie Gray Paint 12 Ounce 355ml Aerosol 1268 V Belt ined 32698 Genie Blue Paint 12 Ounce 355ml Aerosol 1484 Deutz F3L 2011 Models after serial number 7543 Genie Blue Paint 1 gallon 3 78 liters 32150 Description Part No Air Filter Element 2 62420 EE ze In line Fuel Strainer sess 70496 Parts Stocking List continues on the next page Fuel water Separator Filter 29560 Engine Oil Filter 49924 V ie 32698 Ford LRG 425 Models before serial number 7597 Description Part No Fuel Pre Filter qua as ses 52179 Fuel Pressure Regulator Filter 58967 Engine Oil Filter 28656 Air Filter Element 22 62420 Serpentine 52
25. 4 20 102066P Cast Washer sssssseseeeeeeeereneeernerene 2 3 33277 Flat Washer M8 31 110423 Lower Radiator 1086 1 119053 Hose Clamp 1 5 inches 4 25368 Nylock Nut M8 32 110416P Engine Mount Inboard 1 5 119185 LPG Regulator 1 9 119546 Fitting Kit 33 111339 Engine Mount Assembly with Decals Outboard 1 6 119232 LPG 1 te 34 110413 Fan Shroud 1 7 19363 E 1 35 110417 Radiator Support 1 8 110890P LPG Regulator Mount 1 36 48425 Flange Nut 3 8 16 9 67349 Screw HHC 3 M8 1 25 x 50 mm GR 8 8 37 15086 Fender Washer 1 5 0 125 inch 10 6638 Flat Washer 1 4 inch 38 24038 Shock Mount 4 11 6091 Nylock Nut 1 4 20 39 8516 Screw HHC 12 8255 Screw HHC 3 8 16 x 1 5 inches GR 5 38 16 0 75 inch GR 5 40 111632P Radiator 28116 1 13 49408 Lock Washer M8 41 110406 Radiator Get 1 14 70257 Rubber Cushioned Clamp 3 0 25 Inch u uuu dere 1 2 111341 Fan Guard Plate with 15 6175 Screw HHO Word Decals 1 122017P Fan Guard 38 16 1 inch GR 5 43 21019 Screw 10 24 0 5 inch 16 6097 Flat Washer 3 8 inch 44 6146 Flat Washer 10 17 4828 Nylock Nut 3 8 16 45 110419P Radiator
26. 72327 after serial number 7171 10 27142 Exhaust Gasket 1 E 11 77885 1 d 12 65460 Locking Flange Nut 4 38 13 88450 Oxygen Sensor 1 14 28717 Drain Valve 1 0 15 52565 Startet noeste e a 1 1 52593 Starter Solenoid 16 34619 Rubber 1 4e 17 6090 Screw HHC s 1 4 20 x 0 75 inch GR 5 18 63426 Male 9 1 e 19 63427 Low Pressure Hose 29 1 2 33 inches 6 20 53910 Oil Drain Gasket 1 47 21 77139 Medium Pressure 48 Filter Assembly DE 1 49 60857 3 Micron Filter Kit 22 89596P Filter Mount 11 23 6019 Screw HHC 3 8 16 1 25 inches GR 5 50 24 5397 Flat Washer 5 16 inch 25 4828 Nylock Nut 5 8 16 51 26 33024 1 52 27 6021 Lock Washer 3 8 inch 53 Part No 89721 S 40 S 45 37002 25571 Ref 89806 89807 Ref Ref 6175 81632 36208 52762 81635 81748 53832 81749 88757 81630 81634 48473P 25969 77295 77236 58247 102977 53124 6175 6097 7713 400 Engine Components 414 1 Rev B Description Qty Pump Coupler sseeeeeeeeeeeeeeeen 1 Pump Mount Plate 1 Function Pump refer to 706 1 Screw SHC 3 8 16 x 1 25 inche
27. 8 8 25 56912 Spring Clip 1 4 20 This list continues the next page 26 111615 Exhaust Manifold Heat Shield 1 Genie A TEREX COMPANY Part No 89721 5 40 5 45 400 e Engine Components October 2006 Figure Rev Description 421 1 A Ford DSG 423 EFI Engine View 3 after serial number 11066 25 32 2 2999 6 6 9 A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 400 Engine Components 421 1 Ford DSG 423 EFI Engine View 3 after serial number 11066 Rev A Part Description Qty 53 22699 Flat Washer M10 54 22700 Lock Washer M10 55 102121 Muffler Clamp 1 875 inches 1 56 119051 Muffler Mount Band 2 1 111665 57 58 111697 Exhaust Tailpipe 1 Genie A TEREX COMPANY Part No 89721 5 40 5 45 400 e Engine Components October 2006 Figure Rev Description 422 1 A Ford DSG 423 EFI Engine View 4 after serial number 11066 S 40 S 45 Part No 89721 October 2006 400 Engine Components 422 1 Ford DSG 423 EFI Engine View 4 after serial number 11066 Rev A Item Part No Description Qty Part No Description Qty 1 110892 Regulator Support Bracket 1 29 6095 Flat Washer 2 inch 2 110919 Vibration Isolator
28. Backing Plate Tank Side SAO ee Backing Plate Tank Side S 45 Nylock Nut 1 4 20 Qty Carriage Bolt 1 4 20 x 0 75 inch Part No 89721 A TEREX COMPANY Item 18 19 20 21 22 23 24 25 Part No 73060P 73058P 73059P 6090 6638 6091 6888 34381 34389P 34388P Description Exhaust Cover Top Exhaust Cover Front Side Exhaust Cover Rear Side Screw HHC 1 4 20 x 0 75 inch GR 5 Flat Washer 1 4 inch Nylock Nut 1 2 20 Screw HHC 1 4 20 x 1 inch GR 5 Flap Swing Chassis Cover R bb er os reveren Flap Reinforcing Bar 23 Inches Flap Reinforcing Bar 37 5 Inches cited 819 1 Hostile Environment Package View 4 Rev B 800 Accessories October 2006 Figure Rev Description 820 1 B Hostile Environment Package View 5 S 40 S 45 Part No 89721 October 2006 800 Accessories 820 1 Hostile Environment Package View 5 Rev B Item Part Description Qty 1 49626 Cable Track Bolt Pad 2 2 49625 Cable Track Bolt Pad 3 3 53460 Cable Track Gasket Bracket 1 4 6889 Nylock Nut 1 4 20 5 6638 Flat Washer 1 4 inch 6 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 53459 Cable Track Gasket S 40 1 53626 Cable Track Gasket 5 45 8 53458 Cable Track Cover Brush 5 40 iis cete
29. 14 6090 Screw 1 4 20 0 75 inch 5 6091 Nylock Nut 1 4 20 6638 Flat Washer 1 4 inch 9 81368 Pipe Bracket 1 10 56525 Pipe Assembly 1 11 6550 U bolt 3 8 16 x 1 5 inches 4 12 4828 Nylock Nut 5 8 16 18 5397 Flat Washer 5 16 inch 14 55753 Plastic Plug 1 25 inches 2 Genie A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 806 1 B Air Line to Platform E A TEREX COMPANY 5 40 5 45 Part No 89721 October 2006 800 Accessories 806 1 Air Line to Platform Rev B Part Description Qty 30620 S Air Line to Platform Option 44981 Label Air Line to Platform 110 psi 7 58 bar 1 49177 71294 Hose Assembly Components Genie part numbers 49213 49213 and 39888 inches ed 1 7 Female Bulkhead Adapter 2 49212 2 Male Quick Disconnect Plug 1 49214 3 60886P Air Line Mount Plate mounts 4 with existing hardware 1 5 49215 Female Quick Disconnect 1 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker pa
30. Geh Jl JH JG 4 Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components Part No UE Je EB 10 11 12 13 14 15 16 17 18 19 20 88783 88784 28750 49612 33994 49613 94758 110194 52726 84135 27836 110194 27836 110194 27761 84134 101440 101446 94752 94757 94757 94754 94756 94751 94751 94751 94756 94757 94753 94752 94757 Traction Manifold after serial number 7568 Description 2WD Traction Manifold Complete AWD Traction Manifold Complete O ring Kit services SAE fittings Compact Controls and Sun valves O ring Kit services ORFS fittings Plug and Cap Kit for SAE ports Plug and Cap Kit for ORFS fittings Relief Valve 280 psi 19 3 bar s ssssssssesssenen Seal Kit Flow Divider Combiner Valve Seal Kit Check Valve 5 psi 0 34 bar Seal Kit Check Valve 5 psi 0 34 bar Seal Kit Shuttle Valve 3 position way Seal Kit Orifice Plug 0 070 inch 1 78 mm Relief Valve 260 psi 17 2 bar Flow Divider Combiner Valve eneen Check Valve psi 0 2 bar Check Valve psi 0 2 bar Flow Divider Combiner Valve seeen
31. before serial number 7190 1 platform level 21982 Key 1 key only SPDT 3 position Momentary 1 37947 Key package of 10 keys 66814 Push Button Base includes 2 each N O contacts 66816 N O Contact 16 16397 S Toggle Switch turntable rotate DPDT 3 position Momentary 1 17 16397 S Toggle Switch 2 96008 Key Switch 3 position with Base lat iai includes 1 pair of keys GC bs d M t 1 after serial number 7189 1 SES e 88827 Gasket 18 6090 Screw HHC 83093 Key includes boot 1 4 20 x 0 75 inch GR 5 Des 3 66812 Bed Push Button with 10 28995 Lock Washer EEN 73805 Push Button Base includes 20 6638 Flat Washer 1 4 inch 2 each N C contacts E 66818 N C Contact 21 73753 Receptacle Connector 24 way 1 4 19506 Hour Meter 10 80V DC ie 498205 Screw REM Sooo 12344 Nut 6 32 5 56298 Red Light LED 12 Ford models 1 23 25 50 Receptacle Connector 40 way 1 56848 Lock Washer LED 24 73803 Screw SHM 6 45384 Black Plastic Plug 0 5 inch 1 PEESNO 12 x inen 7 56457 S Toggle Switch 25 73736 Receptacle Connector 48 way 1 gasoline LPG Ford models 26 73717 Receptacle Connector 4 way SPDT 2 position Maintained 1 2 asta sasa 1 8 13037 5 Switch Me uu l glow plug diesel models 60928 2 Waya SPDT 3 position Momentar
32. 1 33962 Lower Radiator Hose 1 29 Ref Negative Battery Cable 2 13014 2 5 2 E 3 33965 Upper Radiator 1 30 57162 Terminal Cover Boot 1 4 45171 Clamp 1 75 inches 2 31 30144 Battery Hold Down ssssssseeeeesenee 1 5 27943 Radiator Cap 222 1 1200 pe Engine Mount Plate 6 33969 Radiator EE SUGAR Td ee 2 28717 Drain Valve 34 27034 Screw HHC 7 53425 5 Inboard Engine Mount Plate 1 N10 19 80 mm 8 8516 Screw HHC 35 22700 Lock Washer M10 3 8 16 1 5 inches GR 5 36 32339 Rubber Cushioned Clamp 9 6097 Flat Washer 3 inch 1 75 INCHES 2 10 4828 Nylock Nut 3 s 16 37 53290 Outboard Engine Mount 1 11 24038 Rubber Shock Mount grs 12 34929 Radiator Mount 1 39 6999 Flat Washer 1 2 inch 40 10598 Screw HHC 1 2 13 inches GR 5 41 73612 Screw PHPM 10 24 x 0 5 inch 42 73613 External Lock Washer 10 13 48425 Locking Flange Nut 3 8 16 14 60790 Carriage Bolt 38 16 x 1 5 inches GR 5 15 53909 Screw HHC 5 8 11 x 4 inches GR 8 4 43 34942P Outboard Radiator 16 6035 Flat Washer 5 8 inch Support Strut 2 17 6024 Nylock Nut 5 e 11 44 48498 Vibration Isolator 2 18 28076 Shock Mount 45 34927P Radia
33. 12 13 14 15 16 17 18 19 20 21 41252 106118 33432 32675 101586 106098 8177 88296 13066 106134 13004 29883 56911 13064 8255 6021 30889P 36858 36859 45454 206 1 AWD Steer Axle Wheels and Hubs Rev C Description Qty Part No Description Qty O ring 22 18505 Flange Screw before serial number 7569 2 5 16 18 x 2 25 inches O ring Viton 2 158 5 after serial number 7568 2 6902 Nut Ste 18 Drive Motor 24 106117 O ring Viton 2 010 2 before serial number 7569 25 60838 Rubber Cushioned Clamp includes item 10 2 amoris 2 Seal Kit Drive Motor 25cc after serial number 7568 includes items 10 and 24 Seal Kit Screw HHC 1 2 13 x 1 5 inches GR 5 before serial number 7569 Screw HHC 7 16 14 x 1 25 inches GR 5 after serial number 7568 Hardened Flat Washer 2 inch before serial number 7569 4 Hardened Flat Washer 7 16 inch after serial number 7568 Screw HHC 5 8 11 x 3 inches GR 8 before serial number 7569 12 Screw HHC 5 8 11 1 75 inches GR 8 after serial number 7568 Flat Washer 0 688 x 1 16 x 0 09 inch before serial number 7569 12 Hardened Flat Washer 5 8 inch after serial number 7568 Screw HHC 3 8 16 0 75 inch GR 5 Lock Washer 3 8 inch Hose Mount Bracket 2
34. 18 x 0 75 inch GR 5 26 8178 Screw HHC 7 5397 Flat Washer 5 16 inch 3 8 16 x 2 5 inches GR 5 8 6782 Nylock Nut 5 16 18 27 46999 Fuel Tank Assembly with Decals 30 gallons 113 6 liters 5 6886 Lock Washer Se inch before serial number 7401 1 10 60936P Return Filter Bracket 11 65611 5 Fuel Tank Assembly with Decals 20 gallons 75 7 liters 11 60508 Hydraulic Return Filter Assembly with Indicator 1 2490 61326 Return Filter Element 10 Micron 28 101726 Anti surge Vented Cap Green 1 816541 Return Filter Element 3 Micron 29 29137 Fitting 12 48922 Connector 1 4 inch x 1 4 inch 1 6 ORFS x 6 NPTF 1 30 30490 Fuel Line 1 4 inch 13 45161 Strainer Assembly Perkins 704 30 97 inches 1 5 inches 2 Deutz 1011 97 inches Deutz 2011 53 inches 14 48994 Ball Valve 16 MPT x 16 FPT 2 35418 Fuel Line 3 16 inch 15 89403 Elbow 45 16 MPT x 16 ORFS 2 Perkins 404 22 88 inches 16 81578 12 1 17 13002 Screw HHC 5 6 18 x 1 inch GR 5 18 6638 Flat Washer 1 4 inch 19 Ref Turntable Rotator refer to 305 1 20 4828 Nylock Nut 3 8 16 21 31507 Magnetic Square Head Plug Sa MES iiie tore 1 Part No 89721 5 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 303
35. 8 6 C5OLO S 8 6 F5OLO S 8 8 FLO S 8 FTX S 8 10 F5OLO S 8 12 C5OLO S 8 12 F5OLO S 8 16 F5OLO S 10 C5OLO S 10 CC5OLO S 10 F5OLO S 10 R5OLO S 10 S5OLO S 10 R6LO S 10 4 TRLO BL S 10 6 TRLO BL S 10 12 F5OLO S 12 C5OLO S 12 F5OLO S 12 R5OLO S 12 S5OLO S 12 V5OLO S 12 R6LO S 12 CLO S 12 FLO S 12 JLO S Rev Description Description BRANCH TEE STRAIGHT THREAD TO ORFS Hydraulic Hose and Fitting Cross reference Genie PN Parker PN 48968 12 WLO WLNL S ELBOW 45 STRAIGHT THREAD TO ORFS 48969 12 WJJLO WLNL S CONNECTOR MALE PIPE TO ORFS 48970 12 WELO WLNL S CONNECTOR MALE PIPE TO ORFS 48971 12 G5G5JG5 S PLUG STRAIGHT THREAD 48972 12 XHL6 S UNION 90 BULKHEAD ORFS 48973 12 1 2 F5OG S ELBOW 909 STRAIGHT THREAD TO ORFS 48974 12 10 C5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 48975 12 10 F5OLO S ELBOW 45 STRAIGHT THREAD TO ORFS 48976 12 16 C5OLO S ELBOW 909 STRAIGHT THREAD TO ORFS 48977 12 16 F50LO S CONNECTOR STRAIGHT THREAD TO ORFS 48978 12 16 V5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 48980 12 16 FLO S ELBOW 90 STRAIGHT THREAD TO ORFS 48983 16 C5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 48984 16 F5OLO S CONNECTOR LONG STRAIGHT THREAD TO ORFS 48985 16 V5OLO S RUN TEE STRAIGHT THREAD 48986 16 FLO S BRANCH TEE STRAIGHT THREAD TO ORFS 48988 16 CD45 S ELBOW 45 STRAIGHT THREAD TO ORFS 48989 12 58 RUN TEE SWIVEL NUT ORFS 48990 8 CD45 S BRANCH TEE SWIVEL NUT TO ORFS 48991 16 12 FLO S RUN TEE BULKHEAD ORFS 48992 16 12 V5OLO S REDUC
36. 94374 2380 Hydraulic Hoses and Fittings 4WD Drive and Steer System after serial number 7568 Description FRUN BEE Fitting EE Hose Assembly Components Genie part numbers 48812 48812 and 48753 19 5 inches u epe Hose Assembly Components Genie part numbers 48822 48826 and 48758 99 5 le elle BEE Hose Assembly Components Genie part numbers 48822 48826 and 48756 73 inches Hose Assembly Components Genie part numbers 48812 48816 and 48753 57 inches Fitting u su anu eth Hose Assembly Components Genie part numbers 48800 48802 and 48751 50 inches Hose Assembly Components Genie part numbers 48800 48802 and 48751 83 inches Hose Assembly Components Genie part numbers 48822 48827 and 48756 44 inches Fitting ess Fitting ui rece Hose Assembly Components Genie part numbers 48800 48802 and 48751 Q 74 5 inches Hose Assembly Components Genie part numbers 48841 48846 and 94358 20 5 Inches un ite annor Part No 89721 Item Part No 19 20 21 22 23 24 25 26 27 28 29 49149 2126 94374 2530 48907 48933 49143 4229 49109 4729 49109 4229 48904 48908 49117 5591 48911 700 e Hydraulic Components 708 2 Description Hose Assembly Componen
37. Components Genie part numbers 48841 7 49141 7818 Hose Assembly Components D Genie part numbers 48822 48841 and 94358 Q 31 inches 48826 and 48756 6 25 89871 3848 Hose Assembly Components ToS INCHES udi 2 Genie part numbers 48841 8 49128 5909 Hose Assembly Components EE Genie numbers 48812 26 89871 3948 Hose Assembly Components 48816 48753 57 inches 2 Genie part numbers 48841 9 48935 Fitting 1 ee 10 48920 Fitting 2 0 ERU a 11 49117 5191 Assembly Components SE SE Genie part numbers 48800 Sonia par numbers 25890 48802 and 48751 59 inches 48802 and 48751 50 inches 1 s 12 48904 Fitting pies 49999 13 49143 4629 Hose Assembly Components 30 49139 4368 Hose Assembly Components Genie part numbers 48830 Genie part numbers 48822 48827 and 48756 44 inches 1 Kees SE 4WD Drive Steer System 14 48905 tee Pate 1 15 48963 2 16 48960 Fiftingu siete eei 10 17 49117 7641 Hose Assembly Components Genie part numbers 48800 48802 48751 6 74 5 inches 1 18 94374 2380 Hose Assembly Components Genie part numbers 48841 48846 and 94358 20 5 inches Part No 89721 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers t
38. L 2007 Lade 7 or28235 Drive E H 28176 Chassis 28165 27207 1 27206 Lil D 30080 27208 28163 Platform or 44986 62073 or or 97887 62075 Shading indicates decal is hidden from 62959 62072 or view i e under covers or 62074 AA 97602 H 49741 5 al or 53037 82243 hm 97001 40434 T TRS or 97548 JL NS Engine 2 S or 114169 ng 8 x Side gt 2 0r 35599 114277 28181 28174 27564 32719 82588 114099 82588 32719 28161 28177 or 28235 28160 or 72847 or 82629 28164 or 82629 or 72847 28175 119589 Genie A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 Description Qty 89834 Decal Kit Safety Instructional 15 Gasoline LPG models includes items 2 7 9 10 16 12 14 16 19 21 26 29 30 44 47 51 and 57 17 before serial number 7182 18 89835 Decal Kit Safety Instructional Diesel models 19 includes items 2 6 8 10 12 14 16 19 21 30 44 47 20 51 and 57 before serial number 7182 21 102150 Decal Kit Safety Instructional includes items 1 5 7 10 2 12 14 16 19 21 30 36 43 49 51 23 from serial number 7182 to 9752 111322 Decal Kit Safety Instructional includes items 1 5 7 10 24 12 14 16 19 21 30 36 43 49 and 51 P after serial number 9752 1 25994 Caution Component Damage 25 Hydraulic Valves 1 6 2 2004 Arrow Blue
39. Nylock Nut 3 8 16 Medium Pressure Filter Assembly 1 Filter Element 3 micron Starter ceat et 1 Starter Solenoid 1 Screw HHC M14 2 x 40 mm GR 8 8 3 Lock Washer M14 Inboard Engine Mount 1 Engine Oil Cap 1 F el Lina nte 3 Fuel Injection Pump 1 Fuel Injector Oil Temperature Switch located under cover 1 Oil Pressure Switch 1 Screw HHC M6 1 x 20 mm GR 8 8 Lock Washer 4 inch Governor Actuator Lever 1 Dipstick 1 Fuel Shut Off Switch 1 Fuel Shut Off Solenoid Solenoid Cable Assembly Throttle Linkage 1 Nylock Nut 1 2 13 Screw HHC 1 2 13 x 2 75 inches GR 5 412 1 Deutz 2011 Engine View 2 after serial number 7543 Rev E Item Part No Description Qty 27 6175 Screw HHC 38 16 x 1 inch GR 5 28 70460P Outboard Engine Mount 1 29 21130 Clevis Yoke 1 4 28 1 30 21496 Hex Nut 4 20 31 77402 Throttle Actuator Solenoid 1 32 6888 Screw HHC 1 4 20 x 1 inch GR5 33 6638 Flat Washer 1 4 inch 34 6091 Nylock Nut 1 4 20 35 102067P Solenoid Mount Bracket 1 36 29560 Fuel Water Separator Filter 1 37 89259 Screw HHC M14 x 50 mm 38 49924 1 39 Ref Fun
40. Oscillate System Part Description Qty 1 49130 2432 Hose Assembly Components Genie part numbers 48812 48812 and 48753 22 5 In Chess u u aQ 4 2 48896 Fitting uy mu ee e 2 3 48916 RINO 6 4 49117 5191 Hose Assembly Components Genie part numbers 48800 48802 and 48751 6 50 inches 1 48904 EE 1 48937 Fitting EE 1 7 49143 4629 Hose Assembly Components Genie part numbers 48822 48827 and 48756 6 44 inches 1 8 48880 Diagnostic Nipple Dust 1 9 49207 Diagnostic Nipple 1 20224 Female Quick Disconnect 10 48891 1 11 48914 ce ers 1 12 48933 Fitting etr ces 1 13 49128 10809 Hose Assembly Components Genie part numbers 48812 48816 and 48753 Q 106 inches 2 length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 700 e Hydraulic Components October 2006 Figure 710 1 HYDRAULIC TANK LEGEND 16 16 Rev Description 0 Hydraulic Hoses and Fittings Turntable gt MEDIUM PRESSURE FILTER OUT ENGINE DRIVE PUMP du Aho fi FUNCTION PUMP GG BRAKE 2 SPD 207 Ma
41. Sending Unit Ford models 1 102326 5 Full Gauge Option Ford 33972 Sensor after serial number 7596 28607 Adapter 89405 S Full Gauge Option Deutz before serial number 7544 102324 5 Full Gauge Option Deutz after serial number 7543 89406 S Full Gauge Option Perkins before serial number 7472 102275 S Full Gauge Option Perkins after serial number 7471 1 37033 Oil Pressure Sending Unit Ford models before serial number 7597 Deutz models before serial number 7544 1 30810 Oil Pressure Sending Unit Ford models after serial number 7596 Deutz models after serial number 7543 2 75344 Oil Pressure Sending Unit Perkins models before serial number 7472 1 102348 Oil Pressure Sending Unit Perkins models after serial number 7471 53950 Adapter 3 53761 Voltage Gauge includes mounting bracket and fasteners 1 4 53758 Oil Pressure Gauge without sender includes mounting bracket and fasteners 1 5 53759 Water Temperature Gauge includes mounting bracket and fasteners Ford models 1 53760 Oil Temperature Gauge includes mounting bracket and fasteners Deutz models 6 34058 Water Temperature Sending Unit Perkins models 1 28607 Adapter A TEREX COMPANY Part No 89721 S 40 5 45 800 Access
42. 1 Hose Assembly Components Genie part numbers 48822 48827 and 48756 23 inches Deutz 1011F 1 2 2 RIIN ene enee 1 Hose Assembly Components Genie part numbers 48815 48819 and 48753 17 5 Inches u 1 Hose Assembly Components Genie part numbers 48812 48821 and 48753 28 inches before serial number 7569 Hose Assembly Components Genie part numbers 48800 48818 and 48751 28 inches after serial number 7568 Part No 89721 15 16 17 18 19 20 21 45161 89403 49159 3643 49159 4268 49159 4043 49159 4043 49159 4618 49159 4268 48912 48915 48904 49129 5425 49164 5643 710 1 Hydraulic Hoses and Fittings Turntable Rev C Description Qty Strainer Assembly 2 Fitting i ocean 2 Hose Assembly Components Genie part numbers 48854 48855 and 48764 Q 32 25 inches Ford models Perkins models Deutz 2011 1 Hose Assembly Components Genie part numbers 48854 48855 and 48764 Q 38 5 inches Deutz F3L 1011F Hose Assembly Components Genie part numbers 48854 48855 and 48764 Q 36 25 inches Deutz FAL 1011F Hose Assembly Components Genie part numbers 48854 48855 and 48764 Q 36 25 inches Ford models Perkins models Deutz 2011 1 Hose Assembly Componen
43. 1 17 119471 Tensioner Bracket 1 18 119544 Lower Idler Pulley 1 19 119473 pekt o 1 20 111744 Screw SHC M10 x 1 5 x 55 mm 8 8 21 22699 Flat Washer M10 22 13002 Screw HHC 5 16 18 x 1 inch GR 5 A TEREX COMPANY Part No 89721 S 40 5 45 400 e Engine Components October 2006 Figure Rev Description 421 1 A Ford DSG 423 EFI Engine View 3 after serial number 11066 S 40 S 45 Part No 89721 October 2006 400 Engine Components 421 1 Ford DSG 423 EFI Engine View 3 after serial number 11066 Rev A Part Description Qty Part No Description Qty 1 14033 Screw 27 119463 Exhaust Manifold 1 3 8 16 x 2 75 inches GR 5 119464 Exhaust Manifold Gasket 2 22692 Wave Washer 28 112285 Coolant 06 1 SEH 29 119588 blue 1 Ee 30 89813 Flex Plate 1 4 88450 Oxygen 1 31 55014 Screw SHC 5 106486 Catalytic Monitor Sensor 1 M8 x 1 25 x 25 mm GR 12 9 6 32064 Muffler Clamp 1 75 inches 3 32 33277 Flat Washer M8 7 111633 Muffler Pipe Heat Shield 33 37003 Pump Coupler sssseeeeeeeeeeeeeeeeen 1 8 111609 Relay Mounting Bracket 34 22788 Screw HHC 9 67537 Screw HHC M5 12 mm Henle pere MENER 10 49413 Flat
44. 1 D Function Manifold Plug to Platform and Auxiliary Power Unit S 40 S 45 Part No 89721 October 2006 300 e Turntable Components Function Manifold Plug to Platform Auxiliary Power Unit 303 1 Rev D Description Qty Screw HHC 388 16 x 1 25 inches GR 5 Auxiliary Power Unit Mount 1 Screw HHC 1 4 20 x 2 inches GR 5 Lock Washer 1 4 inch Auxiliary Power Unit 12V DC 1 Motor 12V DC Pump Seal Kit Solenoid Coupler Wire Harness Battery to APU Solenoid refer to 311 1 Item Part No Description Qty Part No 1 Ref Function Manifold 21 6019 refer to 701 1 2 89074P Function Manifold Mount 1 22 89439P 3 6935 Electric Locknut 1 2 inch 1 3 4266 4 43956 Electrical Cord 14 Ga 3 Conductor 24 6356 5 40 828 inches 25 89617 E WEE 888 inches 77069 5 7056 Squeeze Connector 62268 1 2 inch NPT ocer 1 37187 6 6595 North American Electrical Plug EE od 0 Ref 12153 British 3 Pin Electrical Plug 110 6666 European 2 Pin Electrical Plug 220V AC 25388 British 3 Pin Electrical Plug 220V AC 65737 Fuse 13A 7 29883 Screw HHC 5 8 11 x 1 75 inches GR 8 3 8 6036 Lock Washer 5 8 inch 9 13064 Hardened Flat Washer 5 8 inch 5 10 6024 Nylock Nut 5 8 11 11 6091 Nylock Nut 1 4 2
45. 10671 10 12 HOSE END FEMALE SWIVEL JIC 83112 1JC71 8 8 HOSE END FEMALE SWIVEL SEAL LOK 83113 1JS71 16 12 HOSE END FEMALE SWIVEL SEAL LOK 83114 1JS71 10 12 HOSE END FEMALE SWIVEL SEAL LOK 83115 1J971 8 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 83116 1J171 8 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 83117 1J771 8 8 HOSE END 45 FEMALE SWIVEL SEAL LOK 83127 8 HOSE END OO FEMALE SWIVEL JIC 83128 88 HOSE END FEMALE SWIVEL SEAL LOK 87033 12 6 TRLO S REDUCER TUBE END TO SWIVEL ORFS 87034 3J782 8 8 HOSE END 45 FEMALE SWIVEL SEAL LOK 87172 12 HP5ON S PLUG STRAIGHT THREAD 87185 8 WNLO WLNL S UNION BULKHEAD 45 ORFS 87246 4 6 5 ELBOW 90 SWIVEL NUT FLARE TUBE 87679 6 LHP S FLANGE SEAL FITTING MALE 87681 6PLS 0702 BONDED SEAL 88100 SR88100 ADAPTER OIL DRAIN GM 3 0L 88311 1JS43 20 20 HOSE END FEMALE SWIVEL SEAL LOK 88353 20 V5OLO S ELBOW 45 STRAIGHT THREAD TO ORFS 88474 10081 20 Crimp Shell 1 25 88475 1988 20 24 HOSE END 90 FLANGE HEAD 88476 JS88 24 24 HOSE END FEMALE SWIVEL SEAL LOK 88477 1JC88 20 20 HOSE END FEMALE SWIVEL SEAL LOK 88478 811 20 5 11 4 INCH ID 88936 20 16 F5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 88937 20 16 FLO S CONNECTOR MALE PIPE ORFS 88938 1JC88 16 16 HOSE END FEMALE SWIVEL SEAL LOK Genie A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 800 Accessories Rev Description Figure 801 1 Alarm and Beacon Package Drive Light Option 9 9 8
46. 11 48963 Eitting eee outs 2 12 48960 Fitting 12 18 94374 2380 Hose Assembly Components Genie part numbers 48841 48846 and 94358 6 20 5 inches 1 14 49149 2126 Hose Assembly Components Genie part numbers 48841 48845 and 48761 Q 18 inches 1 15 94374 2530 Hose Assembly Components Genie part numbers 48841 48846 and 94358 22 inches 1 16 49117 7641 Hose Assembly Components Genie part numbers 48800 48802 48751 6 74 5 inches 1 17 48933 u pupu eer 1 18 49172 4238 Hose Assembly Components Genie part numbers 48827 48828 and 48756 40 inches 0 0 89721 length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers 700 e Hydraulic Components October 2006 Figure Rev Description 707 2 B Hydraulic Hoses and Fittings 2WD Drive and Steer System after serial number 7568 ON O STEERING CYLINBER O CINDER O 1 1 2 2 5 FF 9 LEGEND FITTING To Oscillate Valve out option HOSE gt ASSEMBLY lt To Oscillate Valve in option 9
47. 12 Ply Non marking Tire 33 16LL 500 10 Ply Sand Tire High Flotation Tire 31 15 50 15 8 Ply Wide Tire and Wheel Assembly Air filled Right Side 1 Tire and Wheel Assembly Air filled Left Side Tire and Wheel Assembly Air filled with Sealant Right Side Tire and Wheel Assembly Air filled with Sealant Left Side Tire and Wheel Assembly Foam filled Right Side Tire and Wheel Assembly Foam filled Left Side Part No 89721 A TEREX CON 5 40 5 45 MPANY Item 14 14 14 15 16 4WD Non steer Axle before serial number 7569 Part No 73204 73205 111453 111454 102802 102803 73923 73490 73491 13004 56911 20451 21142 21149 21143 21147 37097 21148 21146 21144 21145 72283 58285 41252 207 1 Rev E Description Qty Tire and Wheel Assembly Air filled Non marking Right 5 1 Tire Wheel Assembly Air filled Non marking Left Side Tire and Wheel Assembly Air filled with Sealant Non marking Right Side Tire and Wheel Assembly Air filled with Sealant Non marking Left Side Tire and Wheel Assembly Non marking Foam filled Right Side Tire and Wheel Assembly Non marking Foam filled Left Side Tire and Wheel Assembly High flotation 2 Tire and Wheel Assembly Wide Foam filled Right Side 2 Tire and Whe
48. 2006 Manufacture date 01 05 06 Electrical schematic number 50274 Machine unladen weight Rated work load including occupants 500 Ib 227 kg Maximum number of platfrm occupants 2 Maximum allowable side force 150 Ib 670 Maximum allowable inclination of the chassis 0 deg S40 06 1 2345 Maximum wind speed 28 mph 12 5 m s Maximum platform height 60 ft 6 in 18 3 m i Model Sequence Maximum platform reach 34 ft 3 10 4 m number Gradeability N A Tm Country of manufacture USA ode year This machine complies with ANSI A92 5 CAN B 354 4 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Sequence number Serial label stamped on chassis located under cover PN 77055 A TEREX COMPANY Part No 89721 S 40 5 45 lii October 2006 This page intentionally left blank A TEREX COMPANY iv 5 40 5 45 Part 89721 October 2006 This manual is updated frequently Each parts figure listed below has a figure number and a revision letter If a figure is updated with new information the revision letter or Rev is updated example from Rev A to Rev Figure Rev Description 101 1 Decals If you have a printed manual you can keep it up to date by downloading new figures from the Genie website at www genieindustries com How To Read Your Serial Number
49. 27205 Arrow Yellow 1 6 82473 Caution Compartment Access 1 3 27206 Triangle Blue 2 27 82487 Label Read the Manual 2 4 27207 Triangle Yellow 2 8 82544 Danger Electrocution Hazard 3 5 28158 Label Unleaded 1 29 82545 Danger Maximum Load 6 28159 1 Diesel 1 SE secet 7 28160 Label Liquid Petroleum Gas 1 30 82548 Warning Platform Rotate 2 8 28171 Label No Smoking j s CC Se eer 9 28174 Label Power to Platform 82581 Ground Control Panel 230V 2 after serial number 7181 10 28235 Label Power to Platform 32 82586 Label Tire Pressure 4 TI VAO iniussu eer 2 33 82587 Label Tire Pressure 11 40434 Label Lanyard Anchorage 3 Hi Flotation 4 12 44981 Label Air Line to Platform 2 4 82588 Label Wheel Load 5 40 4 13 52966 Cosmetic 4 x 2 1 5 82629 Label Wheel Load 5 45 4 14 52967 Cosmetic 4 x 4 1 6 82646 Label Drive Enable Patch 1 15 62072 Cosmetic Genie 5 40 1 7 82924 Caution Component Damage 16 62073 Cosmetic S 40 s 1 EE 17 62074 Cosmetic Genie S 45
50. 45 from serial number 7001 Part 89721 Rev D G A TEREX COMPANY
51. 6 09 16 12 12 12 4 2 2WD DRIVE MANIFOLD 1 12 CDL M3 M1 CDR 17 12 12 17 21 19 AN 20 6 20 21 G 79 2 23 23 A 10 18 BRK To A 2 SPD SC NON 12 RIGHT NON STEER gt gt NON STEER DRIVE MOTOR H M C AND BRAKE DRIVE MOTOR H2 AND BRAKE 12 8 Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 707 2 Hydraulic Hoses and Fittings 2WD Drive and Steer System after serial number 7568 Rev B Part Description Qty Part No Description Qty 1 48915 el Lu Le BEE 2 20 94374 3930 Hose Assembly Components 2 49919 Fitting iae 2 Genie pan 58521 48846 and 94358 36 inches 2 21 49143 4229 Hose Assembly Components Genie part numbers 48827 48822 and 48756 40 inches 2 3 49130 2132 Hose Assembly Components Genie part numbers 48812 48812 and 48753 19 5 incfies uineis 2 4 49128 5909 Hose Assembly Components 22 48908 sete Mona eee 2 Genie part numbers 48812 23 49117 5591 Hose Assembly Components 48816 48753 57 inches 2 Genie part numbers 48800 5 48920 Eng 2 4975105 IDEE RS ue e 6 49117 5191 Hose Assembly Components Genie part numbers 48800 48802 48751 Q 50 inches 1 7 48904 FRING ME 2 8 48937 Fittilig E 1 9 49143 4629 Hose Assembly Components Genie part numbers 48822 48827
52. 7 8516 Screw HHC 38 16 x 1 5 inches GR 5 8 4828 Nylock Nut 3 8 16 9 30219 Bearing 1 25 x 1 41 x 1 inch before serial number 8126 2 30370 Bearing 1 25 x 1 5 x 1 inch after serial number 8125 10 13852 Bleed Valve Assembly before serial number 8126 2 88516 Bleed Valve Assembly after serial number 8125 11 Ref Rotator Manifold refer to 704 1 12 6145 Screw HHC 1 4 20 x 1 5 inches GR 5 13 6638 Flat Washer 1 4 inch 14 94398 Platform Rotator includes items 9 and 10 1 62417 Kit before serial number 8126 94442 Seal Kit after serial number 8125 106421 Arctic Seal Kit before serial number 8126 75395 Bearing Kit before serial number 8126 15 30187 Pivot Pin 5 25 x 1 25 inches 1 16 59266 Bearing 1 25 1 5 x 0 75 inch 4 Part No 89721 5 40 5 45 505 1 Slave Cylinder and Platform Rotator 5 40 Rev D Description Qty Slave Cylinder includes item 16 1 Seal Kit Counterbalance Valve 3500 psi 242 bar before serial number 7358 Counterbalance Valve 3500 psi 242 bar after serial number 7357 October 2006 500 e Boom Components Part Description Qty 1 30217 External Snap Ring 22 1 25 lee uu uu tees 2 2 30255 Flat Washer pu 1 27 x 2 13 x 0 062 inch m 3 Ref Boom Assembly refer to 502 1 or 503 1 4 34267 Pivot Pin 8 25 x 1 30 inc
53. 8 CC5OLO S PLUG FLARE TUBE 75628 1JB43 4 4 UNION BULKHEAD ORFS 75631 801 6 UNION BULKHEAD ORFS 75654 20 F5OLO S CONNECTOR STRAIGHT THREAD TO 75655 1J943 20 20 ORFS SWIVEL 75656 881 20 O RING KIT 75971 8 5 UNION BULKHEAD FLARE TUBE 77307 1JB43 8 8 UNION BULKHEAD 90 FLARE TUBE 77309 8 WLNL S BULKHEAD LOCKNUT 77379 8M18C87OMX S CONNECTOR STRAIGHT THREAD TO FLARE TUBE RUN TEE STRAIGHT THREAD 77703 3J982 8 8 HOSE 3 4 INCH ID 77711 801 10 CLAMP TUBE 77758 12 WNLO WLNL S UNION CROSS ORFS 78091 6 C6X S CONNECTOR STRAIGHT THREAD TO FLARE TUBE 78684 30582 8 8B HOSE END 90 FEMALE SWIVEL JIC 78852 549 2 PLUG STRAIGHT THREAD 78855 10657 4 2 BRANCH TEE SWIVEL NUT TO ORFS 79138 PS B 37 CAP TUBE END 79476 1J843 6 8 VALVE CHECK 79847 12 3 4 AOEG S CONNECTOR MALE PIPE TO ORFS 80044 8 CLO S CLAMP HYDRAULIC HOSE 80502 8 5 CONNECTOR STRAIGHT THREAD 375 SWIVEL 80503 8 5 5 CAP TUBE END 81010 AS B 27 ADAPTER CONVERSION 83052 821 6 CONNECTOR STRAIGHT THREAD TO ORFS 83053 821 8 ELBOW 45 MALE TO FEMALE PIPE 83054 821 12 CAP TUBE END 83055 30682 6 6 SLEEVE COMPRESSION 83056 30682 12 12 Genie A TEREX COMPANY Description NUT COMPRESSION HOSE END PUSH LOK MALE ELBOW 90 MALE TO FEMALE PIPE ADAPTER FEMALE PIPE TO STRAIGHT THREAD CONNECTOR STRAIGHT THREAD TO ORFS CONNECTOR MALE BSPP TO ORFS CONNECTOR MALE BSPP TO ORFS CONNECTOR MALE PIPE TO ORFS PLUG PIPE THREAD PLUG PIPE THREAD UNION 90 BULKHEAD W NUT OR
54. Check Valve 2 5 psi 0 17 bar Orifice Plug 0 040 inch 1 02 mm Orifice Plug 0 040 inch 1 02 mm Orifice Plug 0 040 inch 1 02 mm Check Valve 2 5 psi 0 17 bar Check Valve 3 psi 0 2 bar Shuttle Valve 40 psi 2 8 bar Flow Divider Combiner Valve soseen Check Valve 3 psi 0 2 bar Part No 89721 Letter 702 2 Rev B Function Charge pressure circuit Controls flow to drive motors in forward and reverse Drive circuit Drive circuit Controls flow to drive motors in forward and reverse Equalizes flow across flow divider combiner valve 2 Charge pressure circuit Controls flow to non steer end drive motors in forward and reverse Steer end drive motor circuit Non steer end drive motor circuit Controls flow to flow divider combiner valves 8 and 19 Non steer end drive motor circuit Equalizes pressure on both sides of flow divider combiner valve 11 Equalizes pressure on both sides of flow divider combiner valve 8 Equalizes pressure on both sides of flow divider combiner valve 19 Steer end drive motor circuit Steer end drive motor circuit Charge pressure circuit that directs hot oil out of low pressure side of drive pump Controls flow to steer end drive motors in forward and reverse Non
55. Oil Diverter Manifold welder option 6 c 1 2 A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components Part No 705 1 Oil Diverter Manifold welder option Rev Description Letter Function 101516 Oil Diverter Manifold welder option 1 102746 Pilot Operated Directional 816 CU Diverter valve 2 106394 Orifice Disc 0 30 inch 0 76 mm CM E Delays shift to drive 3 94760 Solenoid Valve 10V OW Pilot valve to diverter 94765 Coil 12V DC 94759 Nut 4 101446 Relief Valve 250 psi 17 2 bar Charge pressure circuit 5 94757 Check Valve e e ERE uei CY isst Prevents oil flow to generator Genie Part No 89721 A TEREX COMPANY 700 e Hydraulic Components October 2006 Figure Rev Description 706 1 A Hydraulic Pumps Hydraulic Pump Assembly Non oscillate Models ees ee EE DEE EE s Sao eae EE Hydraulic Pump Assembly 4 Oscillate Models POPE A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 706 1 Hydraulic Pumps Rev A Part Description Qty 89591 Drive Pump Assembly N
56. Screw SHM PHP 12 x 3 4 inch 10 73736 Receptacle Connector 48 way 1 83130 Pin Terminal 16 18 Ga 54255 Receptical Lock 12 Way 14 18 Ga 11 42781 Plastic Plug 1 4 inch 1 A TEREX COMPANY Part No 89721 S 40 5 45 600 e Platform Components October 2006 Figure Rev Description 605 1 A Joystick Controllers O T 2 Single axis Multi axis one 2 Controller Controller with Steer Rocker Switch option 3 OO ORO ORG Part No 89721 October 2006 600 Platform Components 605 1 Joystick Controllers Rev A Part Description Qty 62390 Joystick Controller Multi axis drive steer boom up down and turntable rotate functions calibration required after replacement 75565 Joystick Controller Single axis with Steer Rocker Switch option drive steer functions calibration required after replacement 83098 Amp Terminal 22 24 Ga 1 62392 Joystick Knob 1 2 62393 Screw PHM 6 32 5 8 inch 3 62394 Joystick Rubber Boot 1 4 75143 Boot Guard 1 5 62395 Joystick Centering Spring 1 6 62396 Joystick Centering Collar 1 7 62397 Joystick Housing O ring 1 8 62398 Joystick H
57. Washer M5 35 6095 Flat Washer 1 2 inch 11 6090 Screw HHC 36 6198 Nylock Nut 1 2 13 1 4 20 x 0 75 inch GR 5 37 110415P Engine Support Plate 1 12 6638 Flat Washer 1 4 inch 38 110405 Bell Housing Kit 13 6091 Nylock Nut 1 4 20 E 5 31 and 34 1 14 94324 950 Inlet Tube Air Cleaner 119054 Pump Hardware Kit 45485 Hose Clamp 2 5 inehes 39 111611P Lower Muffler Mount Plate 1 15 45435 Hose Clamp 2 5 inches 2 40 6175 Screw HHC 16 111603 Inlet Hose Air Cleaner 1 3 8 16 x 1 inch GR 5 De 79449 eier 41 5397 Flat Washer 5 16 inch uj 222 eer 1 42 29868 Spring Clip 3 8 16 43 10597 Screw HHC b s Ee EE 1 1 2 13 x 1 25 inches GR 5 38922 Fitting Elbow 44 13066 Flat Washer 1 2 inch BO SBMPT Seinen Bath 45 6033 Lock Washer 1 2 inch P 5899 SE SE GR5 46 111604P Upper Muffler Mount Plate 1 20 119394 Rubber Cushioned Clamp 47 119484 Coolant Cap 0 75 inch 1 1 38 3 8 INCHES 3 48 46131 Hose Clamp 0 63 inch 1 21 111653P Lifting Eye Plate and 49 119485 Coolant Cap 0 313 inch 1 2 50 21465 Clamp 0 25 1 E See 51 110424 Coolant Return Hose 1 23 45171 Hose Clamp 1 75 inches 4 52 25548 Screw HHC 24 119140 1 M10 1 5 40 mm
58. Washer M8 12 65490 Fans duse nin attis 1 13 62423 V belt 1 14 102683 Fan Pulley eege e 1 15 65496 Crankshaft Pulley 1 16 65491 Water PUMP a 1 17 65492 Water Pump Gasket 1 Genie A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 400 Engine Components Perkins 704 30 Engine View 4 before serial number 7472 Description Rev A Figure 404 1 enie G 5 40 S 45 Part No 89721 October 2006 400 Engine Components 404 1 Perkins 704 30 Engine View 4 before serial number 7472 Rev A Description Qty Part Description Qty 1 53909 Screw HHC 28 28076 Vibration Isolator 4 Eesen 20 63419 Outboard Engine Mount 2 2 33418 Plate Washer 5 8 x 2 25 0 187 inch 3 6024 Nylock Nut 5 8 11 4 21465 Hose Clamp 0 5 inch 4 5 63413 Radiator Upper Hose 1 6 63418 Inboard Engine Mount 1 7 49384 Screw HHC M14 2 x 30 mm GR 8 8 37505 Lock Washer M14 9 63364P Fan Shroud 1 10 13002 Screw HHC 5 16 18 x 1 inch GR 5 11 5397 Flat Washer 5 16 inch 12 63362P Inboard Radiator Mount 1 13 6175 Screw HHC 38 16 x 1 inch GR 5 14 6638 Flat Washer 1 4 inch 15 7713 Nylo
59. from serial number 7597 to 11066 Description Qty 1 33965 Upper Radiator 1 31 2 22672 Clamp 1a gen e deeds 1132 3 33966 Thermostat 1 4 52575 Thermostat Gasket 1 SS 5 33970 Ignition Coil Assembly 1 34 6 49881 Oil Filler 1 7 52570 Spark Plug Wire Set 8 106490 Spark Plug pack of 4 1 9 89812 Oil Pressure Switch Assembly 1 10 28656 Oil Filter een 1 99 11 70423P Rear Engine Mount 1 36 12 33957 PCV Valve 37 13 6198 Nylock Nut 1 2 13 E 14 39479 Screw HHC 1 2 13 2 75 inches GR 5 15 70452 Engine Isolator 4 2 16 6095 Flat Washer 1 2 inch B 17 102066 Cast Washer E 18 25929 Screw HHC 40 8 1 25 30 8 8 19 49408 Lock Washer 8 41 20 1011180 Inboard Engine Mount 1 2 21 58321 Exhaust 102134 Gasket 43 22 28717 Drain Valve ad ettet bud 1 44 23 44064 Screw HHC 45 M10 1 5 x 30 mm GR 8 8 46 24 22700 Lock Washer M10 47 25 101119P Outboard Engine Mount 1 26 4828 Nylock Nut 3 8 16 27 6175 Screw HHC 38 16 x 1 inch GR 5 28 6097 Flat Washer 3 8 inch 29 27920 Starter Solenoid
60. level circuit Platform level down Platform rotate and jib boom up down S 45 Differential sensing circuit meters flow to functions Differential sensing circuit platform rotate left and jib boom up S 45 Testing A TEREX COMPANY 700 e Hydraulic Components October 2006 Figure Rev Description 702 1 B Traction Manifold before serial number 7569 E FE 5 HA OH HB 3 88 2288 HC 8 HD HE 10 5 40 5 45 89721 October 2006 700 e Hydraulic Components Part No 10 11 12 13 14 34448 34447 28750 49612 33994 49613 43597 52726 33520 27761 48997 20224 48880 52726 52726 33520 33520 27761 48997 20224 48880 33521 43597 29737 Description 2WD Drive Manifold Complete includes items 1 6 4WD Drive Manifold Complete includes items 7 14 O ring Kit services SAE fittings Compact Controls and Sun valves O ring Kit services ORFS fittings Plug and Cap Kit for SAE ports Plug and Cap Kit for ORFS fittings Relief Valve 210 psi 14 5 bar Flow Divider Combiner Valve Orifice Plug 0 070 Shuttle Valve 3 position way Diagnostic Nipple 4 SAE Female Quick Disconnect for Pressure Gauge Cap Diagnostic Nipple Flow Divider Comb
61. numbers 48822 48839 and 48756 68 inches 1 6 49203 Fitting 2 euet eec 1 7 48933 Fitting 3 8 49143 2979 Hose Assembly Components Genie part numbers 48822 48827 and 48756 6 27 5 inches uuu uu u pein 1 9 48937 Fitting i cie in m s 3 10 48905 masaqa ee 1 11 48960 Fitting nuusan s 1 12 65513 Hose Assembly Components Genie part numbers 48828 48827 and 48756 MERES neret 1 27 5 1 48935 13 1 48958 14 15 49101 7835 Hose Assembly Components Genie part numbers 48833 48840 and 48759 6 75 25 05 1 16 49101 5910 Assembly Components Genie part numbers 48833 48840 and 48759 6 dE 1 17 48954 Fitting 18 48934 Fitting 19 48916 Fitting The length listed in the component description is the length of the hose only 20 48917 Fitting Refer to 712 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 800 Accessories October 2006 Figure Rev Description 810 1 C Gauge Option Deutz Engine A TEREX COMPANY S 40 5 45 89721 October 2006 800 Accessories 810 1 Gauge Option Rev Part Description Qty Part Description Qty 89404 5 Full Gauge Option Ford 7 65456 Water Temperature before serial number 7597
62. steer end drive motor circuit A TEREX COMPANY 700 e Hydraulic Components October 2006 Figure Rev Description 703 1 B Two Speed Brake Manifold D 2 DB Part 89721 October 2006 700 e Hydraulic Components Part No 1 89572 20000 49612 33994 49613 2 89857 45912 3 3 74404 88785 A 94761 94764 94760 94765 94759 94760 94765 94759 W k Description Two Speed Brake Manifold before serial number 7569 O ring Kit services SAE fittings Compact Controls and Sun valves O ring Kit services ORFS Plug and Cap Kit for SAE ports Plug and Cap Kit for ORFS 703 1 Two Speed Brake Manifold Rev B Letter Function Solenoid Valve 2 position way DA x Brake release Coil Nut Coil 10V DC Orifice Plug 0 025 inch DB Turntable rotation brake release Two Speed Brake Manifold after serial number 7568 Check Valve 2 ERI o e Dem ADAMS ED us Brake release circuit Orifice Plug 0 025 inch EA cos Turntable rotaton brake release Solenoid Valve 2 position 3 way Brake release Coil 10V DC Coil Nut Solenoid Valve 2 position 3 way EG iss Two speed motor shift Coil 10V DC Coil Nut Part No 89721 A T
63. 0 SI MPT WEE 1 40 48994 Ball Valve 16 MPT x 16 FPT 2 23 7713 Nylock Nut 3 8 16 41 89403 Elbow 45 16 MPT x 16 ORFS 2 24 77219 Fuel Pump u rene 1 77181 Rubber Cushioned Clamp A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 302 1 E Hydraulic and Fuel Tanks Diesel S 40 S 45 Part No 89721 October 2006 300 e Turntable Components 302 1 Hydraulic and Fuel Tanks Diesel Rev E Item Part No Description Qty Part No Description Qty 1 31524 Tank Strap with Rubber 22 27089 Fuel Line 5 16 inch 66 INCHES ss 2 Perkins 704 30 and 31658 Rubber Strip 24 inches Deutz F3L 1011 96 inches 2 21141 Fluid Level Indicator includes Deutz E mounting fasteners 1 serial number 10833 81 inches Ee Deutz 2011 after 3 31506 Filler Neck Strainer 1 serial number 10832 97 inches 4 53527 Breather Filler Cap 3 Micron 1 RST SO 78 inches 5 89071 Hydraulic Tank Assembly 23 21465 Hose Clamp 1 2 inch 2 45 gallons 170 3 liters 24 53023 Fitting includes items 2 4 13 and 21 1 5 16 inch Barb x 1 4 inch 1 6 10107 Screw HHC 25 19487 Manual Fuel Shut off Valve 1 Bh 16
64. 0 12 6638 Flat Washer 1 4 inch 13 6888 Screw HHC 1 4 20 1 inch GR 5 14 30677 S Tank Tray peered raa 1 15 29868 Spring Clip Nut 3 8 16 16 6175 Screw HHC 3 8 16 1 inch GR 5 17 6021 Lock Washer 3 inch 18 6097 Flat Washer 3 8 inch 19 Ref Ground Controls refer to 305 1 and 306 1 20 94077 Level 1 Part No 89721 S 40 S 45 October 2006 Turntable Rotator and Hydraulic Rotary Coupler Installation Description Rev G 300 e Turntable Components Figure 304 1 4 enie G 5 40 5 45 Part 89721 October 2006 300 e Turntable Components Part No 1 2 3 4 5 10 11 12 13 14 15 16 17 18 19 20 21 22 22541 6607 6178 88356 11205 19491 27643 1505 6090 6356 6638 30783 6019 6021 89571 94937 45495 13064 8255 6097 89064 11637 32731 45031 34079 28476 Description Qty Harness Drive Enable Switch includes item 4 and 5 refer to 311 1 Screw RHM 10 32 x 1 5 inches Lock Washer Plated 10 Nylock Nut 10 32 Limit Switch with Roller Arm 1 Contact Roller Arm Electrical Cord 16 Ga 2 Conductor 40 inches Screw HHC 1 4 20 x 0 75 inch GR 5 Lock Washer 4 inch Flat Washer 4 inch Limit Switch
65. 0 4282 Hose Assembly Components Genie part numbers 48812 48812 and 48753 41 inches The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part 32 49151 4148 Hose Assembly Components Genie part numbers 48841 48841 and 48761 39 inches 1 l Dumbers to Parker part numbers Part No 89721 700 e Hydraulic Components October 2006 Figure 710 1 HYDRAULIC TANK LEGEND 16 16 Rev Description 0 Hydraulic Hoses and Fittings Turntable gt MEDIUM PRESSURE FILTER OUT ENGINE DRIVE PUMP du Aho fi FUNCTION PUMP GG BRAKE 2 SPD 207 Manifold 9 2SPD 21 43 k OSCILLATE PUMP 69 ASSEMBLY IN AUXILIARY POWER UNIT OUT 227 g PAS 4 8 HYDRAULIC ROTARY COUPLER 9 69 OIL COOLER option 69 To T1 option option 44 37 2 TANK A P TEST 6 37 LA ZA 8 AUX STi ST2 T2 FUNCTION MANIFOLD LS TEST PRESS 5 58 39 Genie A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 700 e Hydraulic Components 710 1 Hydraulic Hoses and Fittings Turntable Rev C Part Description Qty 3
66. 06115 89604 5 102689 106637 82237 106113 106274 110344 6782 5397 13002 10107 4828 6097 8516 9145 13066 6198 36294 6889 106658 102319 74006 Description Qty Wire Cable 8 ga 5 40 684 inches Wire Cable 8 ga E EE 744 inches Cooler Option refer to 815 1 before serial number 7995 Oil Cooler Option refer to 815 1 after serial number 7994 Time Delay Module Decal Danger High Voltage Harness Lincoln Welder refer to 311 1 Hydraulic Generator Assembly includes item 37 1 Generator 12 5 kW Brush Box Assembly Generator Oil Diverter Manifold refer to 705 1 Nylock Nut 5 16 18 Flat Washer 5 16 inch Screw HHC 5 16 18 x 1 inch GR 5 Screw HHC 5 16 18 x 0 75 inch GR 5 Nylock Nut 3 8 16 Flat Washer 3 inch Screw HHC 3 8 16 1 5 inches GR 5 Screw HHC 1 2 13 x 2 5 inches GR 5 Flat Washer 1 2 inch Nylock Nut 1 2 13 Screw HHC 1 4 20 2 75 inches GR 5 Nylock Nut 1 4 20 Welder Control Module Low Amperage 1 Enclosure Assembly includes items 13 16 18 26 29 35 1 Weatherproof Outlet Cover includes mounting hardware 1 Part No 89721 A TEREX COMPANY Welder Option Chassis Components View 1 Item 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
67. 1 53629 Cable Track Cover Brush 5 45 9 53143 Cable Track Gasket Bracket 1 10 53457 Cable Track Cover 5 40 1 53623 Cable Track Cover S 45 11 8914 Screw HHC 1 4 20 x 0 625 inch GR 5 12 6356 Lock Washer 4 inch A TEREX COMPANY Part No 89721 S 40 5 45 California Proposition 5 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Parts Manual S 40 amp S
68. 1 4 20 x 0 75 inch GR 5 A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 308 1 D Turntable Covers View 1 Tank Side S 40 S 45 Part No 89721 October 2006 308 1 Turntable Covers View 1 Tank Side Rev D Item PartNo Description Qty tem Part Description Qty 1 49816 Screw PHM 19 49189 4638 Bearing Lubrication Hose 10 32 x 0 75 inch Assembly 1 2 6146 Flat Washer Plated 10 20 13002 Screw HHC Bian 3 6178 Nylock Nut 2 4 53903 Turntable Cover Latch 52293 Key 22 6019 Screw HHC e 5 8915 Screw HHC 8 16 1 25 inches 5 1 4 20 1 25 5 23 6021 Lock Washer 5 8 inch 6 12906 Fender Washer 24 29868 Spring Clip Nut 3 8 16 6 1 25 89408 Tank Side Bulkhead Front 1 E 7 Eer 26 33555 Stud 5 16 A8 2 1 4 8 6991 PO Nuh ed 27 6002 LP Nylock Nut 5 16 18 9 65477 Turntable Cover Assembly 28 28301 Gas Strut with Tank aida Retaining Sprin 1 before serial number 7190 1 27377 Ge Se ke E 102137 Turntable Cover with Word 9 Spring Decals Tank Side 29 36388 Rubber Bumper with Stud from serial number 7190 to 9752 before serial number 10974 1 111327 Turntable Cover with Word 111663 Rubber Bumper with Stud Decals Tan
69. 1 425 556 8659 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All back ordered parts will be shipped when available via the same ship method as the original order unless Noted below O Ship complete order only No back orders O Ship all available parts and contact customer on disposition of back ordered parts O Other please specify For INpusrRIEs Use ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code October 2006 Parts Figures Genie Part No 89721 S 40 5 45 100 Decals October 2006 Figure Rev Description 101 1 F Decals with Words 28171 82195 25994 82283 27564 77046 38149 28161 44981 31060 or 82581 28159 SE Be 82588 or 82629 32719 82366 or 72847 Hoy 5 Ss 32700 or wa ei m I He 43663 t det SS 28161 7 H7 1 97579 32719 or 82469 72847 lt Tank 82767 82588 or Side 82283 p V Or 114099 reed 52966 or 32700 92967 or 97890 27204 y xe 27206 T
70. 1 75 inches GR 5 22 30582 Wear Pad 5 73 2 IDCh EE 1 23 111521 Extension Boom Tube Assembly with Decal includes item 24 USA Canada Australia 111544 Extension Boom Tube Assembly includes item 24 Europe Asia South America Part No 89721 S 40 5 45 Part 30220 30729 8255 63202 63342 89872 36188 502 1 Boom Assembly 5 40 Rev B Description Qty Bearing 1 25 x 1 5 x 0 68 inch 2 Pivot Pin 7 x 1 2 Screw HHC 3 8 16 x 0 75 inch GR 5 Extension Cylinder 1 Seal Kit Counterbalance Valve 3000 psi 206 8 bar Counterbalance Valve 2000 psi 137 9 bar 500 e Boom Components October 2006 Figure Rev Description 503 1 B Boom Assembly S 45 21 GOS 5 40 5 45 89721 October 2006 500 e Boom Components Part No Description Qty 1 10597 Screw HHC 24 1 2 13 x 1 25 inches GR 5 25 2 6033 Lock Washer 1 2 inch 26 3 30418 Rod End 0 5 x 4 inches 1 4 30731 Pivot Pin 16 x 1 5 inches 1 27 5 30738 Bearing 1 5 x 2 x 1 5 inches 2 6 53219 Pivot Pin 11 125 x 1 inch 1 7 30748 Flat Washer 1 01 x 1 63 x 0 062 inch 8 30742 External Snap Ring 1 inch 6 102144 Primary Boom Tube Assembly includes item 5 1 10 6175 Screw HHC 38 16 x 1 inch GR 5 11
71. 11 21496 Hex Nut 4 28 A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 301 1 D Hydraulic and Fuel Tanks Gasoline LPG S 40 S 45 Part No 89721 October 2006 300 Turntable Components 301 1 Hydraulic and Fuel Tanks Gasoline LPG RevD Description Qty Part No Description Qty 1 31524 Tank Strap Assembly 2 5 65892 6 2 7 391656 Rubber stip eaiinehes 26 27089 Fuel Line 5 16 inch 12 inches 2 21141 Fluid Level Indicator WC includes mounting fasteners 1 27 21465 Hose Clamp 1 2 inch 6 3 31506 Filer Neck Strainer 1 8 52179 Fuel Pre filter 1 4 53527 Breather Filler Cap 3 Micron 1 29 45455 Hose Clamp 2 75 inches 1 5 89071 Hydraulic Tank Assembly 30 19487 Manual Fuel Shut off Valve 1 45 gallons 170 3 liters 31 53023 Fitting includes items 2 4 13 and 22 1 5 16 inch Barb x 1 4 inch MPT 2 6 10107 Screw HHC 32 71909 Fuel Line 5 16 inch 5 16 18 x 0 75 inch GR 5 High Pressure 53 inches before serial number 7597 7 5 5397 Flat Washer 5 16 inch 0 71909 Fuel Line 5 t6 inch 8 6782 Nylock Nut 5 16 18 High Pressure 48 inches 9 6886 Lock W
72. 11348 Deluxe Hostile Environmental Package S 40 111349 Standard Hostile Environmental Package S 45 111350 Deluxe Environmental Package S 45 34956 Protective Cover Oscillate includes item 2 1 73842 Steer Cylinder Protective 2 2 30580 Oscillate Protective Bellow includes items 7 and 8 2 3 34505 Jib Cylinder Protective Bellow 5 45 includes items 7 and 8 1 4 30577 Master Slave Cylinder Protective Bellow S 40 includes items 7 and 8 1 34503 Master Slave Cylinder Protective Bellow S 45 includes items 7 and 8 5 34506 Boom Lift Cylinder Protective Bellow includes items 7 and 8 1 6 36208 Hose Clamp 1 25 inches 1 used on oscillate and master slave cylinder 45435 Hose Clamp 2 25 inches used on lift cylinder 19273 Hose Clamp 0 75 inches used on steer cylinder 7 30971 Hose Clamp 068 1 used on oscillate and master slave cylinder 45435 Hose Clamp 2 5 inches used on steer cylinder 34955 Hose Clamp 5 inches used lift cylinder A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 817 1 B Hostile Environment Package View 2 Perkins Engine Ford Engine Deutz Engine A TEREX COMPANY S 40 S 45 Part No 89721 October 2006 800 Accessories 817 1 Hostile Environment Package View 2 Re
73. 12 Non Marking Tire 13 45113 Spindle Nut 1 14 2 12 X 16 5 12 Ply 14 45114 Cotter Pin 0 219 x 1 75 inches 2 81489 Rough Terrain Tire 12 x 16 5 8 Ply 15 45112 Spindle Washer 2 11 73198 Tire and Wheel Assembly 16 45108 Outer Cone Bearing 2 Industrial shown 2147 4504 Hub A incl it 111448 Tire and Wheel Assembly SCH d e 2 Industrial Air filled with Sealant ER 40145 Large Race 73764 i and Wi SE 40146 Small Race 8 26 Wheel Stud 5 8 8 81490 Tire and Wheel Assembly 18 45107 Inner Cone Bearing 2 Rough Terrain Air filled Right Side 1 19 45110 Grease Seal 2 81491 Tire Wheel Assembly 45873 Hub Seal and Bearing Kit Rough Terrain Air filled includes items 9 13 15 16 Left Side and races EH ier Assembly 20 46958 Drive Chassis Weight 429 Ibs Rough Terrain 2WD S 40 1 EE E DE RENE 111452 Tire and Wheel Assembly 21 53415 Drive Chassis Weight 429 Ibs Rough Terrain 2WD S 45 1 Air filled with Sealant Left Side 81494 Tire and Wheel Assembly Rough Terrain Foam filled Right Side 81495 Tire and Wheel Assembly Rough Terrain Foam filled Left Side 22 34079 Screw HHC 1 8 x 8 5 inches GR 5 A TEREX COMPANY Part No
74. 126 Seal Kit after serial number 8182 Arctic Seal Kit before serial number 8126 Bearing Kit before serial number 8126 Bearing 1 25 x 1 375 x 0 69 inch 8 Jib Boom Cylinder includes item 23 1 Seal Kit Counterbalance Valve 3000 psi 207 bar Seal Kit Leveling Arm Pin 14 25 x 1 25 inches 2 Slave Cylinder includes of item 23 1 Seal Kit Counterbalance Valve 3500 psi 242 bar Pivot Pin 5 25 x 1 25 inches 1 Screw HHC 3 8 16 x 2 inches GR 5 Nylock Nut 3 8 16 Jib Boom Hose Guard 1 JID BOOM st teins sed 1 Screw HHC 1 4 20 x 1 5 inches GR 5 Flat Washer 1 4 inch Rotator Manifold refer to 704 1 600 e Platform Components October 2006 Figure Rev Description 601 1 D Platform Installation View 1 SE OCO N 2 ee Nils d N aN d DS N L N gt gt a Y Ws N e A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 600 Platform Components Part Description Qty Platform Assemblies with Word Decals before serial number 9753 USA and Canadian models 89742 4 Foot Platform Assembly 89743 5 Foot P
75. 17 18 19 20 21 22 23 24 25 26 27 28 29 34162 3150 53945 34164 62420 63463 6175 6097 7713 53952 30967 30769P 29557 65765 52352 32752 72255 102686 49923 49924 29560 23057 49408 33240P 22578 49407 6584 5365 21130 21496 30785 1000 410 1 Deutz 1011F Engine View before serial number 7544 Rev Description Qty Air Intake Hose 2 5 inches 1 Hose Clamp 3 inches 5 Rubber Elbow 90 1 Air Filter Element 1 Air Filter Assembly includes item 4 1 Screw HHC 3 8 16 x 1 inch GR 5 Flat Washer 3 8 inch Nylock Nut 3 8 16 Air Cleaner Bracket 1 Air Intake Hose 2 75 D x 2 25 inches 1 Air Cleaner Mount 1 Oil Filler 1 Oil Pressure Sending Unit 1 DipStlCk ET 1 Fuel Shut Off Solenoid 1 Connector Solenoid Switch Oil Temperature Sending Unit 1 Fuel Pump sess 1 Engine Oil Filter 1 Fuel Water Separator Filter 1 Screw HHC M8 1 25 x 20 mm GR 8 8 Lock Washer M8 Lever Actuator Bracket 1 Screw HHC M6 x 1 x 20 mm GR 8 8 Lock Washer M6 Shoulder Bolt 4 x 0 625 inch Nylock Nut 10 24 Clevis 1 4 28
76. 18 6888 Screw HHC 1 4 20 x 1 inch GR 5 19 6638 Flat Washer 1 4 inch 20 29073 2 Speed Solenoid 1 21 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 22 81199 Fuel Filter Water Separator 1 65853 Filter Element 23 63399P Air Filter Bracket 1 24 13002 Screw HHC 5 16 18 x 1 inch GR 5 25 5397 Flat Washer 5 16 inch 26 6782 Nylock Nut 5 16 18 27 34162 3150 Air Intake Hose 1 A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 400 Engine Components Perkins 704 30 Engine View 3 before serial number 7472 Description Rev A Figure 403 1 9 enie G 5 40 S 45 Part 89721 October 2006 400 Engine Components 403 1 Perkins 704 30 Engine View 3 before serial number 7472 Rev A Description Qty 1 65505 Thermostat Housing Gasket 1 2 65506 Hose Clamp 2 3 65507 Water 1 4 3 Thermostat 1 5 34058 Coolant Temperature Sending Unit 1 6 65488 Alternator Adjustment Bracket 1 7 49381 Screw HHC M12 1 75 x 30 mm GR 8 8 8 65355 Lock Washer M12 9 65494 Thermostat Housing 1 10 67349 Screw HHC M8 1 25 50 mm GR 8 8 11 49408 Lock
77. 2 includes items 14 and 17 1 3 999 0 LEE Loo eege 2 28 30734 Pivot Pin 2 88 x 1 inch 2 6 EE CS 29 1 includes item 7 2 89100 Seal Kit 31106 Counterbalance Valve 3000 psi 206 bar 7 59266 Bearing 1 25 x 1 5 x 0 75 inch 4 8 6175 Screw HHC 3 8 16 x 1 inch GR 5 9 45226 Rod End 0 375 x 3 69 inches 3 10 30735 Pivot Pin 17 5 x 1 5 inches 1 11 19440 Clevis Pin 1 x 2 5 inches 4 12 74389 Rue Ring 1 25 x 15 13 inches 4 18 89065 Steer Cylinder 2 89066 Seal Kit 14 25817 Bearing 1 x 1 25 x 1 inch 6 15 14815 Roll Pin 0 25 x 2 25 inches 4 16 53081 Pivot Pin 4 63 x 1 5 inches 4 17 45071 Bearing 1 5 x 1 75 x 1 5 inches 6 18 65515 Yoke Assembly Left Side includes items 14 and 17 1 19 8220 Screw HHC 1 2 13 4 inches GR 5 20 6086 Low Profile Nylock Nut 1 2 13 21 30190 Pivot Pin 7 25 x 1 25 inches 2 22 6708 Screw HHC 3 8 16 2 25 inches GR 5 23 4828 Nylock Nut 3 8 16 24 45074 Thrust Washer 1 51 x 3 5 x 0 187 2 Genie A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Figure Rev Description 202 1 A 2WD Steer Axle Linkage Non oscillating Models
78. 2 25 inches 8 EE ems 1 26 89805 Yoke Assembly Right Side 4 30737 Pivot Pin x 1 25 inches 2 includes items 13 and 16 1 8 99386 EE 2 27 30734 PivotPin 2 88 1 inch 2 9 30370 pearing TNN 5 28 19440 Clevis Pin 1 x 2 5 inches 2 7 890997 Cylinder 29 6355 Tie Rod oeenn 1 includes item 8 2 89100 Seal Kit 30 74389 Rue Ring 1 25 x 15 13 inches 4 31106 Counterbalance Valve 3000 psi 206 8 bar 8 59266 Bearing 1 25 x 1 5 x 0 75 inch 4 9 6175 Screw HHC 3 8 16 x 1 inch GR 5 10 45226 Rod End 0 375 x 3 69 inches 3 11 30735 Pivot Pin 17 5 x 1 5 inches 1 12 89065 Steer 2 89066 Seal Kit 13 25817 Bearing 1 x 1 25 x 1 inch 6 14 14815 Roll Pin 0 25 x 2 25 inches 4 15 53081 Pivot Pin 4 63 x 1 5 inches 4 16 45071 Bearing 1 5 x 1 75 x 1 5 inches 6 17 89804 Yoke Assembly Left Side includes items 13 16 1 18 8220 Screw HHC 1 2 13 x 4 inches GR 5 19 6086 Nylock Nut 1 2 13 20 30190 Pivot Pin 7 25 x 1 25 inches 2 21 6708 Screw HHC 3 8 16 2 25 inches GR 5 22 4828 Nylock Nut 3 8 16 23 45074 Thrust Washer 1 51 x 3 5 x 0 187 2 Genie A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Fi
79. 21 8170 Wing Nut 14 20 2 Je 11 x 1 75 inches GR 8 1 22 6638 Flat Washer 1 4 inch EL 8 6936 23 45708 Threaded Rod 10 inches 2 6 13064 Flat Washer 5 s inch 7 77139 Medium Pressure Filter Assembly 1 60857 Filter Kit 3 Micron 8 6019 Screw HHC 3 8 16 x 1 25 inches GR 5 9 5397 Flat Washer 5 16 inch 10 4828 Nylock Nut 3 8 16 11 6356 Lock Washer 1 4 inch 12 89597 Engine Tray Perkins models before serial number 7472 Deutz models before serial number 7544 Ford models before serial number 7597 1 102062P Engine Tray shown Perkins models after serial number 7471 Deutz models after serial number 7543 Ford models after serial number 7596 13 45209 Wear Pad 2 x 4 x 0 5 inch 4 81851 Shim 2 4 0 06 inch 14 21175 Screw SHC 5 8 11 x 4 inches 15 33418 Plate Washer 5 8 x 2 25 x 0 187 inches 16 30143 Battery 12V DC 1000 1 49869 Corrosion Inhibitor Grease 17 Ref Positive Battery Cable refer to 311 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 500 e Boom Components October 2006 Figure Rev Description 501 1 E Boom Lift and Master Leveling Cylinder Installation 9 A TEREX COMPANY 5 40 5 45 89721 October 2006 500 e Bo
80. 24 88448 Ford OEM Harness before serial number 7597 1 106605 Ford OEM Harness after serial number 7596 A TEREX COMPANY Part No 89721 S 40 5 45 400 e Engine Components October 2006 Figure Rev Description 401 1 C Perkins 704 30 Engine View 1 before serial number 7472 S 40 S 45 Part No 89721 October 2006 400 Engine Components 401 1 Perkins 704 30 Engine View 1 before serial number 7472 Rev C Part Description Qty Ref Engine Harness Assembly refer to 311 1 1 65499 Oil Filter 1 2 65503 Muffler Gasket 1 3 65504 Flange Nut M10 1 4 63313 7 1 5 16584 U bolt 5 16 18 x 2 5 inches 1 6 63326P Exhaust Bracket 1 7 6037 Nut 5 16 18 8 6886 Lock Washer 5 16 inch 9 5397 Flat Washer 5 16 inch 10 23057 Screw HHC M8 1 25 20 mm GR 8 8 11 6638 Flat Washer 1 4 inch 12 44064 Screw HHC M10 1 5 x 30 mm GR 8 8 13 22700 Lock Washer M10 14 45454 Rubber Cushioned Clamp nete eee 1 15 Ref Drive Pump refer to 706 1 16 Ref Function Pump refer to 706 1 17 6175 Screw HHC 3 8 16 x 1 inch GR 5 18 6097 Flat Washer 3 8 inch 19 83141 seeded 1 20 8177 Screw HHC 1 2 13 x 1 5 inches GR 5 21 6033 Lock Washer 1 2 inch 22 63464P Pump Mount
81. 26 Part No 89721 5 40 5 45 206 1 4WD Steer Axle Wheels and Hubs Rev C Description Tire and Wheel Assembly Non marking Air filled Right 5 1 Tire Wheel Assembly Non marking Air filled Left Side Tire and Wheel Assembly Non marking Air filled with Sealant Right Side Tire and Wheel Assembly Non marking Air filled with Sealant Left Side Tire and Wheel Assembly Non marking Foam filled Right Side Tire and Wheel Assembly Non marking Foam filled Left Side Tire and Wheel Assembly Wide Foam filled Right Side 2 Tire and Wheel Assembly Wide Foam filled Left Side Tire and Wheel Assembly High flotation 2 Drive Hub 18 1 before serial number 7569 2 Seal Kit Wheel Stud Bearing and Race Kit End Cover O ring included in seal kit part number 21142 Thrust Washer Cap Cover End Cover domed Disconnect Rod Actuator Disconnect Rod Drive Hub 57 1 after serial number 7568 2 Gearbox Seal Kit Wheel Stud Disconnect Rod Disengage Cap End Cover O ring Brake Lining Kit Brake Seal Kit Bearing Kit This list continues on the next page October 2006 200 e Drive Chassis Components 4WD Steer Axle Wheels and Hubs Rev Description 0 Figure 206 1 Part 89721 5 40 5 45 October 2006 10 11
82. 34 35 Part No 106140 101995 80543 106477 106073 33607 33608 102314 6090 106077 18665 106104 7056 6935 56237 20776 102340 106184 800 e Accessories 812 1 Rev B Description Qty Potentiometer Bracket 1 Potentiometer Resistor Tk 2 1 GFCI Outlet 110V AC 1 GFl Circuit Breaker Assembly 1 Circuit Breaker 20A Single Phase 1 Relay 12V DC DPDT 1 Relay Socket 1 Enclosure Panel 1 Screw HHC 1 4 20 x 0 75 inch GR 5 Squeeze Connector 0 75 inch 1 Electric Locknut 1 inch NPT 2 O ring 1 inch NPT oseese 2 Squeeze Connector 0 5 inch 1 Electric Locknut 1 2 inch 1 1 Squeeze Connector 0 75 inch 1 Generator Support Bracket 1 Hydraulic Motor 2100 1 800 Accessories October 2006 Figure Rev Description 813 1 D Welder Option Platform Components View 2 Dee 7 NL Part No 89721 October 2006 800 Accessories 813 1 Welder Option Platform Components View 2 Rev D Item PartNo Description Qty Part No Description Qty Protective Sleeve Fire Resistant 13 101525 Welder Invertec 1 110276 2200 1 25 22 inches 5 40
83. 45 October 2006 400 Engine Components 9 600 6 6 D OG TTS 8 is EI Z 5 I N gt 5 Ao N 1 SS YN A d S DA 72 SA A Perkins 404 22 Engine View 2 after serial number 7471 Description Rev B Figure 406 1 Part No 89721 5 40 5 45 October 2006 400 Engine Components 406 1 Perkins 404 22 Engine View 2 after serial number 7471 Rev B Item Part No Description Qty Part No Description Qty 1 54071 Coolant Return Tank with Hose 1 21 13014 Clamp 2 25 inches 3 we EH 22 54578 Upper Radiator 1 2 EE Ee 1 23 889900 Radiator Fan Shroud 1 3 6888 14 20 x 1 inch GR 5 24 544877 Fan Guard 1 d 25 21019 Screw PHPM 1 4 6638 Flat Washer 1 4 inch 10 24 x 0 5 inch 1 4 2 pu 6 6146 Flat Washer 10 6 63463 Air Filter Assembly 1 0 62420 Air Filter Element 27 54579 Lower Radiator Hose 1 6782 Nylock Nut 5 16 18 28 54687 Screw HHC 5397 Flat Washer 5 16 inch M14 1 5 x 40 mm GR 8 8 6888 Screw HHC 1 4 20 x 1 inch GR 5 29 37505 Lock Washer M14 7 53959 Air Cleaner Bracket j 990b lat WasheriM14 8 89901 Exhaust
84. 48810 and 48751 Q 90 inches FITTING s Sosa eite Hose Assembly Components Genie part numbers 48812 48815 and 48753 6 110 Assembly Components Genie part numbers 48812 48816 48753 103 inches 89721 2 16 49117 1191 17 18 49130 1982 19 length listed the component description is the length of the hose only Refer to 713 1 to cross reference Genie part 48915 48913 Hose Assembly Components Genie part numbers 48800 48802 and 48751 10 inches Hose Assembly Components Genie part numbers 48812 48812 and 48753 18 inches Fitting s Rouen numbers to Parker part numbers 700 e Hydraulic Components October 2006 Figure 713 1 Genie PN Parker PN 12342 13757 19685 22664 27431 28678 39871 39872 39873 39874 39875 39876 39877 39878 39879 39880 39881 39882 39883 39885 39886 39887 39888 39889 39890 39891 39892 39894 39895 42286 42756 42757 42758 42759 42760 42761 42762 42768 42776 42777 42786 42787 42788 42789 42790 42791 42792 42793 6 4 F5OX S 4 R6X S 12 10 C5OX S 12 10 050 8 12 F5OX S AS B 33 6 WETX WLN S 4 R5OX S 6 C50X S 8 6 C5OX S 4 6 C5OX S 6 8 C5OX S 4 F5OX S 6 F5OX S 4 8 F5OX S 6 10 F5OX S 4 6 F5OX S 4 HP5ON S 8 8 5 269HB 12 12 431 6 540N 2 801 8
85. 5 16 18 Part No 89721 A TEREX Part 22 23 24 25 26 27 28 29 30 31 MPANY 6019 6021 Ref 33987 6033 102091P 85053 22700 61109 16584 34162 475 89912P 411 1 Rev F Description Qty Screw HHC 38 16 1 25 inches GR 5 Lock Washer 3 8 inch Battery refer to 423 1 Screw HHC 1 2 13 x 1 inch GR 5 Lock Washer 1 2 inch Exhaust Pipe Mount 1 Screw HHC M10 1 5 x 70 mm GR 8 8 Lock Washer M10 Rubber Cushioned Clamp 1 25 0 438 inch 2 Clamp ze tede decas 2 Air Intake Hose 2 1 2 1 0 1 Engine Baffle 1 400 e Engine Components October 2006 Figure Rev Description 412 1 E Deutz F3L 2011 Engine View 2 after serial number 7543 S 40 S 45 Part No 89721 October 2006 400 Engine Components 1 2 o N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 89596P 6019 5397 4828 77139 60857 89777 89778 22558 37505 70461P 89779 89780 89791 89792 111445 65765 22578 6356 50787P 89781 32752 89793 58256 94485 6198 39479 70452 80150 102066P Description Qty Medium Pressure Filter Bracket 1 Screw HHC 3 8 16 1 25 inches GR 5 Flat Washer 5 16 inch
86. 580 PCV 33957 Spark Plug i uires 28647 Genie A TEREX COMPANY Part No 89721 S 40 5 45 ix October 2006 Parts Stocking List Manuals Genie Industries offers the following support documents for these models Title Part No Genie S 40 S 45 Operator s Manual before serial number 7190 43645 Genie S 40 S 45 Operators Manual from serial number 7190 to 9752 82500 Genie S 40 S 45 Operators Manual after serial number 9752 1000056 Genie S 40 Service Manual before serial number 3804 32222 Genie S 40 Service Manual from serial number 3804 to 4728 52271 Genie S 40 S 45 Service Manual from serial number 4728 to 7000 72136 Genie S 40 S 45 Service Manual from serial number 7001 102521 EMI Safety Manual 27581 Manual of Responsibilities ANSI A925 tiet edere merito E de 31779 Genie A TEREX COMPANY x S 40 5 45 Part No 89721 October 6 Genie Part No 89721 This page intentionally left blank 5 40 5 45 October 2006 How Order Parts Please be prepared with the following information when ordering replacement parts for your Genie product Machine model number Machine serial number Genie part number Part descrip
87. 6 3 s gt 26 oc o 2 sls c 2 gt ES as N I N 19 Oe A Si MATES A e e 6 Part 89721 5 40 5 45 October 2006 700 e Hydraulic Components Item Part No Description Letter 13 27807 Check Valve 4 isset ie tdt ent 110200 Kit 14 30968 Flow Regulator Valve 2 7 6 L min AN 110202 Seal Kit 15 89851 Check Valve 2 AQ 110205 Seal Kit 16 49207 Diagnostic Nipple Female Swivel 4 ORFS AP us 20224 Female Quick Disconnect for Pressure Gauge 48880 Diagnostic Nipple Cap not shown sold separately 17 48907 Fitting 45 Elbow 4 ORFS x 4 SAE SAE 520320 18 102616 Relief Valve 2900 psi 200 bar 5 45 AQ 102617 Relief Valve 2600 psi 179 bar 5 40 AQ uus 110194 Seal Kit 19 27764 Flow Regulator Valve 4 5 17 03 L min AB 110194 Seal Kit 20 27836 Check ValV6 z uibs eee 5255 110194 Seal Kit 21 111703 Solenoid Valve 3 position 4 way E 89861 Coil 10V DC for solenoid part number 62260 111778 Coil 10V DC for solenoid part number 111703 89854 Dual Coil Spacer for solenoid part number 62260 19792 Coil Nu
88. 6021 Lock Washer 3 8 inch 12 6097 Flat Washer 3 8 inch 13 38620 Wear Pad Shim 1 5 5 0 075 inch as needed 14 30138 Wear Pad 5 x 1 5 x 0 63 inch 8 15 29080 Wear Pad Shim 5 1 5 0 064 inch as needed 16 34124 Wear Pad 5 x 3 x 0 68 inch 4 17 38621 Wear Pad Shim 3 x 5 x 0 0747 inch as needed 18 34344 Wear Pad Shim 3 x 5 x 0 0635 inch as needed 19 53197 Wear Pad 6 5 x 2 75 1 inch 2 20 6091 Nylock Nut 1 4 20 21 12906 Washer 1 4 1 25 inches 22 6637 Screw HHC 1 4 20 1 75 inches GR 5 23 52882 Extension Boom Tube Assembly with Decal includes item 24 USA Canada Australia 1 111408 Extension Boom Tube Assembly includes item 24 Europe Asia South America Part No 89721 S 40 5 45 30220 53200 53354 8255 63202 63342 89872 36188 503 1 Boom Assembly S 45 Rev B Description Qty Bearing 1 25 x 1 5 x 0 68 inch 2 Pivot Pin 8 71 x 1 inch 2 Screw HHC 3 8 16 1 25 inches GR 5 Screw HHC 3 8 16 x 0 75 inch GR 5 Extension Cylinder 1 Seal Kit Counterbalance Valve 3000 psi 206 8 bar Counterbalance Valve 2000 psi 137 9 bar October 2006 enie G 5 40 S 45 89721 500 Boom Components o 5 5 5 gr
89. 8 67906 69316 69333 69503 69775 71038 71196 71383 72270 73436 4 CC5OLO S 20 12 TRLO BL 12 C6LO S 20 F5OHAO S 6 10 C5OLO S 6 WNLO WLNL S 4 WNLO WLNL S 4 WLO WLNL S 12 AOEL6 482TC 16 6 JLO S 782 12 881 24 11943 20 24 33782 8 8 12 FF5OLO S 1 8 X 1 5 FFF 8 PNTX S 4 WLO WLNL S 6 WLO WLNL S 8 F65OL S 6001012 6 WTX WLNS 6 WETX S 6 WLN S 6 8 F5OX S 6 R5OX S 811 12 H3174PP 4 KLO S 10 6 F5OX S 13943 8 6 10 HP5ON S 12 S6LO S 4 FNL S DC 370 F0F0 5 8 FLO S H3174PP 4 F650X S 8 FNL S 1 4X1 4F3HG S 12 8 6 14 58 12FNL S 60C 4 Rev Description A Hydraulic Hose and Fitting Cross reference Description Genie PN Parker PN ELBOW 90 LONG STRAIGHT THREAD TO ORFS 73437 61C 4 REDUCER TUBE END TO SWIVEL ORFS 73438 33482 4 4B ELBOW 90 SWIVEL NUT ORFS 73767 1CD S UNION STRAIGHT THREAD 73768 20 16 F5OG5 S ELBOW 90 STRAIGHT THREAD TO ORFS 73769 16 20 F5OLO S UNION BULKHEAD 45 ORFS 74660 6 8 F42EDMLO S UNION BULKHEAD 45 ORFS 74661 8 8 F42EDMLO S UNION BULKHEAD ORFS 75007 4 FLO S ELBOW 90 STRAIGHT THREAD TO ORFS SWIVEL 75008 1 8 HP S HOSE 1 INCH ID 75014 1 2 HP S UNION TEE ORFS 75042 8 WELO WLNL S HOSE 3 4 INCH ID 75043 3 4 FF S HOSE 11 2 INCH ID 75254 24 F5OHAO S HOSE END 90 FLANGE HEAD 75255 12 F5OHAO S RUN BULKHEAD ORFS 75256 XV5O6P 24 UNION BULKHEAD 45 ORFS 75574 4 WLNL S HOSE END 45 FEMALE SWIVEL JIC 75612 8 WJLO WLNL S CONNECTOR LONG STRAIGHT THREAD TO ORFS 75613 12 8 F5OG5 S NIPPLE PIPE 75614
90. 80 Turntable Rotation Brake Assembly before serial number 7154 1 06 Turntable Rotation Brake Assembly after serial number 7153 12 102682 Torque Hub Swing Assembly 1 A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 300 e Turntable Components OUG EE GG GEI d 8 E e See 2 5 5 wy 6 8 6 gt m E 8 zu 9 9 96996 GO Part 89721 5 40 5 45 October 2006 300 e Turntable Components 306 1 Ground Controls 1 Rev B Description Qty Part No Description Qty 89680 5 Ground Control Box Assy 5 40 11 24018 Circuit Breaker 15A 89861 5 Ground Control Box Assy 5 45 engine 1 110656 Retained Key Option 83131 Key Switch Retained Key Option 12 41999 Cir Breaker 20A ES 27246 Rubber Boot oil cooler option 1 54692 Nylon Spacer 13 24018 Circuit Breaker 15A 0 718 x 0 526 x 0 219 inch ContrOlS is ac dete 1 1 81900 Nylon Plug Black Domed 14 13037 S Toggle Switch 2 093 inches 3 jib boom up down 2 66811 Key Switch 3 position with Base SEDIS postion Momentary sace includes 1 pair of keys 15 13037 S Toggle Switch
91. 801 12 10643 6 6 13943 6 6 13743 6 6 30682 8 8 30682 10 12 8 8 5 8 12 CLO S 8 12 FLO S 4 JLO S 4 4 FLO S 6 8 FLO S 1J143 6 4 1J743 6 4 1J043 4 4 601 8 1J743 16 16 16 CLO S 16 68 16 8 TRLO BL S 6 6 CLO S 8 10 V5OLO S 3 4 CD S 3 4 X 1 2 PTR S 1 2 CR S Rev Description A Hydraulic Hose and Fitting Cross reference Description Genie PN Parker PN CONNECTOR STRAIGHT THREAD TO FLARE TUBE 42794 1 CR S RUN TEE SWIVEL NUT ORFS 42795 BV 0839 ELBOW 90 STRAIGHT THREAD TO FLARE TUBE 42796 BV 0838 ELBOW 90 STRAIGHT THREAD TO FLARE TUBE 42874 6 8 CLO S CONNECTOR STRAIGHT THREAD TO FLARE TUBE 42912 13943 6 4 SLEEVE NYLON 1 81 ID 42920 BV 0840 UNION 90 BULKHEAD W NUT FLARE TUBE 42932 AS B 17 RUN TEE STRAIGHT THREAD 42936 10243 2 4 ELBOW 90 STRAIGHT THREAD FLARE TUBE 42953 1 2 DD S ELBOW 90 STRAIGHT THREAD FLARE TUBE 42956 6 WELO WLNL S ELBOW 90 STRAIGHT THREAD FLARE TUBE 45349 8 V50X S ELBOW 90 STRAIGHT THREAD FLARE TUBE 45351 4 V50X S CONNECTOR STRAIGHT THREAD TO FLARE TUBE 47223 10343 6 6 CONNECTOR STRAIGHT THREAD TO FLARE TUBE 47419 PS690503 6 6 CONNECTOR STRAIGHT THREAD TO FLARE TUBE 48750 421 4 CONNECTOR STRAIGHT THREAD TO FLARE TUBE 48751 481TC 4 CONNECTOR STRAIGHT THREAD TO FLARE TUBE 48752 482TC 4 PLUG STRAIGHT THREAD 48753 451TC 6 CONNECTOR MALE PIPE TO FLARE TUBE 48754 482TC 6 ELBOW 90 BEADED HOSE BARB TO MALE PIPE 48755 381 6 HOSE 3 8 INCH ID 48756 451TC 8 HOSE 1 8 INCH ID 4
92. 82 Ref 102992 12443 12446P 20973 21121 73610 94745P Ref 44743 24514 79138 28443 4828 5397 6019 Ref 56424 601 1 Platform Installation View 1 Rev D Description Qty Foot Switch Guard USA Canada Australia 1 Foot Switch Guard Europe Asia South America Screw PHM 10 24 x 0 75 Lock Washer 10 Spring Clip Nut 10 24 Foot Switch Wire Assembly with Conpector 1 Squeeze Connector 1 2 inch Foot Switch Microswitch Decal Plate refer to 602 1 Sliding Mid rail Assembly With 1 Sliding Mid rail Guide Sliding Mid rail Tube Wire Loom 3 8 inch Black Cable Tie 4 inches Platform Entry Step 1 European Platform Entry 1 Platform Flooring refer to 602 1 Manual Storage Box with Decals USA Canada Australia 1 Manual Storage Box with Decals Europe Asia South America Nylon Sleeve 72 inches Cable Tie 11 5 inches 02 3 Nylock Nut 3 8 16 Flat Washer 5 16 inch Screw HHC 3 8 16 1 25 inches GR 5 Platform Control Box Assembly refer to 603 1 and 604 1 Rubber Cushioned Clamp 1 25 x 0 5 INCA u 1 600 e Platform Components October 2006 Figure Rev Description 602 1 E Platform Installation View 2
93. 8757 482TC 8 HOSE 1 2 INCH ID 48758 381 8 HOSE 3 4 INCH ID 48759 381 10 HOSE END FEMALE SWIVEL JIC 48760 451TC 10 HOSE END 90 FEMALE SWIVEL JIC 48761 482TC 12 HOSE END 45 FEMALE SWIVEL JIC 48762 451TC 12 HOSE END FEMALE SWIVEL JIC 48763 772 12 HOSE END FEMALE SWIVEL JIC 48764 881 16 ELBOW 90 MALE PIPE TO FLARE TUBE 48765 772 16 ELBOW 90 MALE PIPE TO ORFS 48766 AS B 15 CONNECTOR MALE PIPE TO ORFS 48767 AS B 22 UNION TEE ORFS 48770 881 8 CONNECTOR MALE PIPE TO ORFS 48771 881 10 CONNECTOR MALE PIPE TO ORFS 48772 381 4 HOSE END 90 FEMALE SWIVEL SEAL LOK 48773 AS B 13 HOSE END 45 FEMALE SWIVEL SEAL LOK 48800 4 HOSE END MALE GEAL LOK 48801 4 HOSE 1 2 INCH ID 48802 1J943 4 4 HOSE END 45 FEMALE SWIVEL SEAL LOK 48804 1JM43 4 4 ELBOW 90 MALE PIPE ORFS 48805 10643 4 4 RUN TEE SWIVEL NUT ORFS 48806 13943 4 4 REDUCER TUBE END TO SWIVEL ORFS 48807 1JS43 4 4 ELBOW 90 MALE PIPE ORFS 48808 3JC82 8 8 ELBOW 45 STRAIGHT THREAD TO ORFS 48809 3JC82 12 12 ELBOW 90 MALE TO FEMALE PIPE 48810 1JC43 6 4 REDUCER MALE TO FEMALE PIPE 48811 1J943 6 4 ELBOW 90 MALE PIPE 48812 6 Genie 5 40 5 45 A TEREX COMPANY Description LBOW 90 MALE PIPE ALL VALVE BALL VALVE ELBOW 90 MALE PIPE TO ORFS HOSE END 90 FEMALE SWIVEL JIC BALL VALVE 90 E B SLEEVE NYLON 1 22 ID HOSE END FEMALE PIPE ELBOW 90 FEMALE PIPE UNION 90 BULKHEAD W NUT ORFS ELBOW 45 STRAIGHT THREAD TO FLARE TUBE ELBOW 45 STRAIGHT THREAD TO F
94. 8878 16 12 05010 6 ELBOW 90 STRAIGHT THREAD TO ORFS 48817 8 HOSE END FEMALE SWIVEL SEAL LOK 48879 8 C6LO S ELBOW 90 SWIVEL NUT ORFS 48818 1 943 8 4 HOSE END 90 FEMALE SWIVEL SEAL LOK 48880 PD6 285 CAP DIAGNOSTIC NIPPLE 48819 1JC43 8 6 HOSE END FEMALE SWIVEL SEAL LOK 48881 6 HLO S UNION ORFS 48820 6 HOSE END 45 FEMALE SWIVEL SEAL LOK 4882 PD34BTL DIAGNOSTIC NIPPLE SEAL LOK SWIVEL 48821 1J943 8 6 HOSE END 90 FEMALE SWIVEL SEAL LOK 48883 8P5ON S PLUG STRAIGHT THREAD 48822 1JC43 8 8 HOSE END FEMALE SWIVEL SEAL LOK 48884 8M18F870MLO S CONNECTOR METRIC STRAIGHT THREAD 48823 1JS43 8 8 HOSE END FEMALE SWIVEL SEAL LOK TO ORFS 48824 1 143 8 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 48885 4 WGTX WLN S CONNECTOR BULKHEAD FEMALE PIPE TO 48825 1J543 8 8 HOSE END 90 FEMALE SWIVEL SEAL LOK FLARE TUBE 48826 1J743 8 8 HOSE END 45 FEMALE SWIVEL SEAL LOK 488864 F5OLO SW 2MM OFF CONNECTOR MACHINED STRAIGHT THREAD 48827 8 HOSE END 90 FEMALE SWIVEL SEAL LOK ORFS 48828 8 HOSE END FEMALE SWIVEL SEAL LOK 48887 4 8 ELBOW 90 MALE PIPE TO FLARE TUBE iaga Tote HOSE END FEMALE SWIVEL SEAL LOK 48888 10 12 V5OLO S ELBOW 45 STRAIGHT THREAD TO ORFS Po Cee HOSE 45 FEMALE SWIVEL SEAL LOK 48890 A 68 BRANCH TEE STRAIGHT THREAD TO ORFS 48831 1J943 10 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 48891 45610 8 BRANCH TEE SWIVEL NUT TO ORFS 48833 1JC43 10 10 HOSE END FEMALE SWIVEL SEAL LOK 48892 6 C6LO S ELBOW 90 SWIVEL NUT ORFS 48834 5 0 HOSE END 90 FE
95. 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Figure Rev Description 204 1 D 2WD Non steer Axle before serial number 7569 6 9 2 SV b EON w 2 iM gt Lei 6 5 40 5 45 89721 October 2006 200 e Drive Chassis Components Part No 10 11 12 13 14 14 6096 6021 73634 6146 77026 77027 73575 54156 89802 18396 36603 73196 54627 81489 73212 81008 81009 111449 111450 81492 81493 Description Screw HHC 1 2 13 2 inches GR 5 Lock Washer 3 8 inch Screw PHPM 10 24 x 0 5 Flat Washer 10 Bubble Level European models Flanged Bearing 1 5 1 75 x 1 inch Non steer Axle Assembly includes items 8 and 11 Bearing 1 5 x 1 75 x 1 inch Flat Washer 1 56 x Qty Item 14 inch 15 1 16 3 5 x 0 057 inch as needed Wheel 16 5 x 9 75 9 holes Lug Nut 5 8 18 90 Tire 12 16 5 8 Ply Tire 12 16 5 12 Ply Non marking Tire and Wheel Assembly Air filled Right Side Tire and Wheel Assembly Air filled Left Side Tire and Wheel Assembly Air filled with Sealant Right Side Tire and Wheel Assembly Air filled with Sealant Left Side Tire and Wheel Assembly Foam filled Right Side Tire and Wheel A
96. 9 48997 Diagnostic Nipple 1 40 48907 1 41 49119 4778 Hose Assembly Components Genie part numbers 48800 48800 48751 46 inches after serial number 7568 1 42 48905 est ees 1 43 48916 Fitting before serial number 7569 1 48905 Fitting after serial number 7568 44 49207 Diagnostic Nipple 1 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 700 e Hydraulic Components October 2006 Figure Rev Description 711 1 B Hydraulic Hoses and Fittings Boom Components S 40 LEGEND FITTING HOSE ASSEMBLY S 40 NZ 3 ay g 3 4 L x 5 4 6 6 E 3 8 SLAVE MASTER CYLINDER CYLINDER E Z 9 fo n BOOM EXTENSION O E CYLINDER 0 ga BOOM LIFT 12 Q E CYLINDER TURNTABLE 18 MOTOR gt sw2 Ge 17 13 EXTEND P1 PL1 PR1 13 17 10 RETRACT P2 P
97. 99 Part No 89721 a A TEREX COMPANY 5 40 S 45 G 69 CIN October 2006 400 Engine Components Ford LRG 425 EFI Engine View 2 from serial number 7597 to 11066 Se Part Description Qty Part No Description Qty 1 89921 Coolant Bottle Mount 1 30 6097 Flat Washer 3 8 inch 2 67537 Screw HHC M5 x 12 mm 31 4828 Nylock Nut 3 8 16 3 49413 Lock Washer M5 32 6096 Screw HHC 4 106485 Air Valve Mixer 1 UE MISSED 5 85434 2 inches s GE GE 6 102117 Air Intake Hose 34 Ref Drive Pump refer to 706 1 21 0 x2 inches 1 5 Ref Function Pump refer to 706 1 7 102128 Vac Hose 3 16 inch 1 36 106487 Engine Performance Module 1 8 102129 LP Hose ete 1 37 6091 Nylock Nut 4 20 9 102065P Harness Connector Bar Mount 1 38 6638 Flat Washer 4 inch 10 65892 Connector Assembly 1 39 6145 Screw HHC 11 71909 High Pressure Vesey Le ichas dH Fuel Line 18 inches 40 25969 Spring Clip Nut 1 4 20 2 12 65453 Pressure Regulator Mount 1 41 6356 Lock Washer 1 4 inch 13 58967 Gas Pressure Regulator 1 42 6090 Screw HHC 14 49898 1 Ke 15 49817 Screw PHPM 43 101127P Inboard Muffl
98. AND BRAKE 8 A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 707 1 Hydraulic Hoses and Fittings 2WD Drive and Steer System before serial number 7569 Rev B Item Part No Description Qty Part No Description Qty 1 48915 FIRING ico ee 2 19 89871 3348 Hose Assembly Components Ms Genie part numbers 48841 2 48919 e ul Le RE 2 48841 and 94358 31 inches Ee Hose Assembly Components 20 89871 3848 Hose Assembly Components Genie part numbers 48812 Geni 48812 and 48753 enie part numbers 48841 48841 and 94358 36 inches 19 5 inches 2 4 49128 5909 Hose Assembly Components 21 89871 3943 Fose Assembly Components Genie part numbers 48841 Genie pany number 48841 and 94358 37 inches 48816 48753 57 inches 2 1 5 48920 2 22 48906 6 49117 5191 Hose Assembly Components SS EE oso Genie part numbers 48800 Geer 48802 and 48751 6 59 inches 48802 48751 6 50 inches 1 dd 7 48904 EI 2 24 48953 Fitting 25 49139 4368 Hose Assembly Components 8 48937 el ln e ose ctore trees 1 Genie part numbers 48822 9 49143 46629 Hose Assembly Components 48830 48756 41 inches Genie part numbers 48822 r 48827 and 48756 6 44 inches 1 26 48946 10 48905 Fitting time 1
99. Cosmetic Genie 5 45 1 Ford models 1 38 62072 Cosmetic Genie 5 40 1 3 119589 Caution 12V Electrical Ford 056 423 models 39 62073 Cosmetic 5 40 1 after serial number 11066 1 40 62075 Cosmetic S 45 1 54 114099 Label Transport Diagram 2 41 62959 Cosmetic S 40 1 55 82862 Label Fire Extinguisher 42 62960 Cosmetic S 45 1 welder option 1 43 63461 Notice Engine Specifications 56 97579 Danger Tip over Hazard Perkins 704 30 welder option 1 before serial number 1 57 72847 Notice Tire Specifications 82644 Notice Engine Specifications High Flotation 4 Perkins 404 22 gh Flotation after serial number 7471 44 82243 Label Fault Codes 1 45 82317 Notice Operating Instructions before serial number 7182 2 82283 Notice Operating Instructions from serial number 7182 to 9752 1000057 Notice Operating Instructions from serial number 9753 46 82366 Label Chevron Rykon 1 47 82195 Ground Control Panel before serial number 7182 1 82581 Ground Control Panel after serial number 7181 48 82588 Label Wheel Load 5 40 4 49 82629 Label Wheel Load 5 45 4 50 77046 Labe
100. Dual Hose Clamp pair 2 Top Plate Clamp 2 Rubber Cushioned Clamp 2 Genie Part No 89721 200 e Drive Chassis Components A TEREX COMPANY 5 40 5 45 October 2006 4WD Non steer Axle before serial number 7569 Description 200 Drive Chassis Components Rev E Figure 207 1 Part 89721 5 40 5 45 October 2006 200 e Drive Chassis Components Part No 1 10 11 6096 6021 73634 6146 77026 77027 73575 54156 89802 18396 36603 73196 73492 73924 54627 81489 73212 73925 73493 81008 81009 111449 111450 81492 81493 Description Qty Screw HHC 1 2 13 2 inches GR 5 Lock Washer 3 8 inch Screw PHPM 10 24 x 0 5 inch 3 Flat Washer 0 Bubble Level European models 1 Spring sia ei ete 3 Spring Clip Nut 10 24 3 Flanged Bearing 1 5 1 75 x 1 inch 1 Non steer Axle Assembly includes items 10 and 36 1 Bearing 1 5 x 1 75 x 1 inch 1 Flat Shim Washer 1 56 x 3 5 x 0 057 inch as needed Wheel 16 5 x 9 75 9 hole 2 Wheel 15 x 13 9 hole Wheel 19 5 x 14 9 hole Lug Nut 5 8 18 90 18 Tire 12 16 5 8 2 Tire 12 16 5
101. EF REX COMPANY 700 e Hydraulic Components October 2006 Figure Rev Description 704 1 B Jib Select Platform Rotate and Generator Manifolds aye Jib Manifold GER Platform Rotate OQ 2 Manifold 0 98 8 Generator Manifold A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 704 1 Jib Select Platform Rotate and Generator Manifolds Rev B Item Part No Description Letter Function 1 62506 Counterbalance Valve 3300 psi 228 bar CA ue Platform rotate right 43018 Kit 2 73807 Platform Rotate Dual Counterbalance Valve Manifold 62507 O ring 3 62506 Counterbalance Valve 3300 psi 228 bar CB Platform rotate left 43018 4 31529 Relief Valve 2400 psi 165 5 bar CD Generator overload relief 5 53976 Generator Manifold 6 19969 Solenoid Valve 2 position way 12V DC Controls generator on off 27535 Coil 12V DC 45782 Diode 6A 45914 O ring a 33568 Coil Nut 110198 Seal Kit 7 88786 Jib Select Manifold 8 89862 Solenoid Valve 2 position 3 way CC Platform rotate jib boom select 89864 104759 Coil 10V DC 44174 Coil Nut Part No 89721 S 40 5 45 700 e Hydraulic Components October 2006 Figure Rev Description 705 1 A
102. ER TUBE END TO SWIVEL ORFS 48993 XV501 12 ELBOW 90 STRAIGHT THREAD TO ORFS 48994 XV501 16 CONNECTOR STRAIGHT THREAD TO ORFS 48995 XV510P 12 CONNECTOR MALE PIPE TO ORFS 48996 XV510P 16 CONNECTOR MALE PIPE TO FLARE TUBE 48997 PD341 CONNECTOR STRAIGHT THREAD TO ORFS 48998 PD 361 ELBOW 90 STRAIGHT THREAD TO ORFS 48999 DT 500 MOMS 5 CONNECTOR STRAIGHT THREAD TO ORFS 49201 10 V5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 49202 0 ELBOW 90 STRAIGHT THREAD TO ORFS 49203 10 8 V5OLO S ELBOW 90 LONG STRAIGHT THREAD TO ORFS 49205 6 F5OHAO S CONNECTOR STRAIGHT THREAD TO ORFS 49207 PD34BTL RUN TEE STRAIGHT THREAD 49209 8 18 870 5 BRANCH TEE STRAIGHT THREAD TO ORFS RUN TEE SWIVEL NUT ORFS 49212 8 WGTX WLN S REDUCER TUBE END TO SWIVEL ORFS REDUCER TUBE END TO SWIVEL ORFS 49213 30682 8 8 CONNECTOR STRAIGHT THREAD TO ORFS 49216 831 8 ELBOW 902 STRAIGHT THREAD TO ORFS 49217 33982 8 8 CONNECTOR STRAIGHT THREAD TO ORFS 49219 PS B 35 RUN TEE STRAIGHT THREAD 49418 4 6 58 BRANCH TEE STRAIGHT THREAD TO ORFS 49511 DT370 MOMS 5 ELBOW 45 STRAIGHT THREAD TO ORFS 49512 1DD S RUN TEE SWIVEL NUT ORFS 49513 1 FF S ELBOW 902 MALE PIPE TO ORFS 49514 10 HP5ON S CONNECTOR MALE PIPE TO ORFS 49515 12 16 CLO S UNION TEE ORFS 49517 6 HP5ON S Genie A TEREX COMPANY Description UNION BULKHEAD ORFS RUN TEE BULKHEAD ORFS UNION 90 BULKHEAD W NUT ORFS TEE FEMALE STRAIGHT THREAD ADAPTER 37 MALE TO SWIVEL ORFS ADAPTER FEMALE PIPE TO STRAIGHT THREAD ELBOW 90 S
103. FS 83063 13743 4 4 HOSE END 45 FEMALE SWIVEL JIC 89403 16 VLO S ELBOW 45 MALE PIPE TO ORFS 83064 13743 8 8 HOSE END 45 FEMALE SWIVEL JIC 89449 6 WJJLO WLNL S RUN TEE BULKHEAD ORFS 83065 7 12 HOSE END 45 FEMALE SWIVEL JIC 89489 4 WJMLO S BRANCH TEE BULKHEAD ORFS 83066 13943 8 8 HOSE END 90 FEMALE SWIVEL JIC 89551 1JB43 6 6 HOSE END BULKHEAD SEAL LOK 83067 14143 6 6 HOSE END 90 FEMALE SWIVEL JIC 89552 1JB43 8 8 HOSE END BULKHEAD SEAL LOK 83068 14143 8 8 HOSE END 90 FEMALE SWIVEL JIC 89593 20 C5OLO S ELBOW 90 STRAIGHT THREAD TO ORFS 83069 14143 12 12 HOSE END 90 FEMALE SWIVEL JIC 94161 8 8 CLO S ELBOW 90 MALE PIPE TO ORFS 83070 772 8 HOSE 1 2 INCH ID 94358 351TC 12 HOSE 3 4 INCH ID 83071 10671 8 8 HOSE END FEMALE SWIVEL JIC 94418 20 FLO S CONNECTOR MALE PIPE TO ORFS 83072 10671 12 12 HOSE END FEMALE SWIVEL JIC 96358 12 TX S SLEEVE FLARE TUBE 83073 13771 8 8 HOSE END 45 FEMALE SWIVEL JIC 96359 12 BTX S NUT FLARE TUBE 83074 13771 12 12 HOSE END 45 FEMALE SWIVEL JIC 96397 8 5 CONNECTOR STRAIGHT THREAD FLARE TUBE 83075 13971 8 8 HOSE END 90 FEMALE SWIVEL JIC 96398 12 8 F5OX S CONNECTOR STRAIGHT THREAD TO FLARE TUBE 83076 13971 12 12 HOSE END 90 FEMALE SWIVEL JIC 96402 10343 6 6 HOSE END MALE JIC 83077 14171 8 8 HOSE END 90 FEMALE SWIVEL JIC 96407 30382 6 6B HOSE END MALE JIC 83078 14171 12 12 HOSE END 90 FEMALE SWIVEL JIC 83080 13943 16 16 HOSE END 90 FEMALE SWIVEL JIC 83103 10671 16 12 HOSE END FEMALE SWIVEL JIC 83104
104. FS NIPPLE PIPE UNION STRAIGHT THREAD UNION STRAIGHT THREAD BALL VALVE BULKHEAD LOCKNUT RUN TEE BULKHEAD ORFS ADAPTER FEMALE PIPE TO STRAIGHT THREAD ELBOW 90 LONG STRAIGHT THREAD TO ORFS HOSE END BULKHEAD SEAL LOK HOSE 3 8 INCH ID CONNECTOR STRAIGHT THREAD TO ORFS HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE 1 1 4 INCH ID UNION STRAIGHT THREAD HOSE END BULKHEAD SEAL LOK BULKHEAD LOCKNUT ELBOW 90 METRIC STRAIGHT THREAD TO FLARE TUBE HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE 5 8 INCH ID UNION BULKHEAD 45 ORFS ELBOW 90 SWIVEL NUT TO FLARE TUBE HOSE END PUSH LOK MALE HOSE 1 8 INCH ID HOSE END FEMALE SWIVEL JIC SLEEVE NYLON 2 38 ID HOSE END FEMALE SWIVEL SEAL LOK ELBOW 90 STRAIGHT THREAD TO FEMALE PIPE ELBOW 90 MALE PIPE TO ORFS CONNECTOR STRAIGHT THREAD TO FLARE TUBE ELBOW 90 STRAIGHT THREAD TO FLARE TUBE SLEEVE NYLON 1 63 ID HOSE 3 8 INCH ID HOSE 1 2 INCH ID HOSE 3 4 INCH ID HOSE END FEMALE SWIVEL JIC HOSE END FEMALE SWIVEL JIC 5 40 5 45 Part 89721 October 2006 700 e Hydraulic Components 713 1 Hydraulic Hose and Fitting Cross reference Rev A Genie PN Parker PN Description Genie PN Parker PN Description 83057 33782 6 6 HOSE END 45 FEMALE SWIVEL JIC 88939 16 HOSE END OO FEMALE SWIVEL ORFS 83058 33982 6 6 HOSE END 90 FEMALE SWIVEL JIC 88940 811 16 HOSE 1 INCH ID 83060 33982 12 12 HOSE END 90 FEMALE SWIVEL JIC 88944 1J988 20 20 HOSE END 90 FEMALE SWIVEL OR
105. I Engine View 2 from serial number 7597 to 11066 Ford LRG 425 EFI Engine View 3 from serial number 7597 to 11066 Ford DSG 423 EFI Engine View 1 after serial number 11066 Ford DSG 423 EFI Engine View 2 after serial number 11066 Ford DSG 423 EFI Engine View 3 after serial number 11066 Ford DSG 423 EFI Engine View 4 after serial number 11066 Engine Tray Battery and Filter Installation 500 Boom Components 501 1 502 1 503 1 504 1 505 1 506 1 E Boom Lift and Master Leveling Cylinder Installation Boom Assembly S 40 Boom Assembly S 45 Cable Track Installation Slave Cylinder and Platform Rotator S 40 Jib Boom and Platform Rotator S 45 vi A TEREX COMPANY 600 Platform Components 601 1 D Platform Installation View 1 602 1 E Platform Installation View 2 603 1 B Platform Control Box View 1 604 1 F Platform Control Box View 2 605 1 A Joystick Controllers 700 e Hydraulic Components 701 1 F Function Manifold 702 1 B Traction Manifold before serial number 7569 702 2 B Traction Manifold after serial number 7568 703 1 B Two Speed Brake Manifold 704 1 B Jib Select Platform Rotate and Generator Manifolds 705 1 A Oil Diverter Manifold welder option 706 1 A Hydraulic Pumps 707 1 B Hydraulic Hoses and Fittings 2WD Drive and Steer System before serial number 7569 707 2 B Hydraulic Hoses and Fittings 2WD Drive and Steer System after
106. KT02586 O RING KIT ORFS FITTINGS 55190 49613 PKT06276 PLUG AND CAP KIT SERVICE ORFS 55448 49728 10143 12 12 HOSE END MALE PIPE 55839 49729 16 1 F50G S ADAPTER FEMALE PIPE TO STRAIGHT THREAD 55968 49814 12 8 FLO S CONNECTOR MALE PIPE TO ORFS 56003 49829 DT 500 MOMF 5 VALVE CHECK 56166 49831 881 12 HOSE 3 4 INCH ID 56188 49834 16 JLO S UNION TEE ORFS 56233 49838 12 8 TRLO BL S REDUCER TUBE END TO SWIVEL ORFS 56234 49840 8 JLO S UNION TEE ORFS 56235 49844 10 8 TRLO BL S REDUCER TUBE END TO SWIVEL ORFS 56236 49854 8 5 PLUG STRAIGHT THREAD 56237 49855 12 HOSE END FEMALE SWIVEL SEAL LOK 56238 49859 4 P5ON S PLUG STRAIGHT THREAD 56352 49861 4 FF50LO S CONNECTOR LONG STRAIGHT THREAD TO ORFS 56353 49867 12 3 4 F50G S ADAPTER FEMALE PIPE TO STRAIGHT THREAD 56354 51152 6 R6X S RUN TEE SWIVEL NUT ORFS 56604 51153 6 4 TRTX S REDUCER TUBE END TO SWIVEL ORFS 56639 51154 4 4 GTX CONNECTOR FEMALE PIPE TO FLARE TUBE 56640 51264 881 12 HOSE 3 4 INCH ID 56655 51265 8 JLO S UNION TEE ORFS 56676 51508 6 BTX S NUT FLARE TUBE 56776 51580 12 8 TRLO BL S TUBE END REDUCER ORFS 56777 51628 6 R6X S RUN TEE SWIVEL NUT ORFS 56789 51735 3 8 HHP PLUG PIPE THREAD 57884 51803 1J943 6 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 59335 53023 125HBL 5 4 FITTING HOSE BARB TO MALE PIPE 59342 53497 02585 O RING KIT 59371 53499 1JC71 16 16 HOSE END FEMALE SWIVEL SEAL LOK 60653 53500 3 904 O RING STRAIGHT THREAD 4 60806 53501 3 906 O RING STRAIGHT THREAD 6 61064 53502 3 908
107. L2 PR2 6 FUNCTION MANIFOLD Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 711 1 Hydraulic Hoses and Fittings Boom Components 5 40 Rev B Description Qty PartNo Description Qty 1 49119 58678 Hose Assembly Components 16 49130 1982 Hose Assembly Components Genie part numbers 48800 Genie part numbers 48812 48800 and 48751 48812 and 48753 18 inches 2 2 17 289080 Fiting 2 2 48907 etes 2 3 49120 49781 Hose Assembly Components Genie part numbers 48800 48810 and 48751 496 inches 1 4 49121 4313 Hose Assembly Components Genie part numbers 42768 48800 and 48751 41 25 inches 2 5 49120 50781 Hose Assembly Components Genie part numbers 48800 48810 48751 506 inches 1 6 48919 i iue usb 2 7 48912 Fitting AUREUS EAS 2 8 49181 10440 Hose Assembly Components Genie part numbers 48801 48810 and 48751 6 102 inches 1 9 49181 9240 Hose Assembly Components Genie part numbers 48801 48810 and 48751 90 inches 1 10 48916 Fitting teme 10 11 49126 11233 Hose Assembly Components Genie part numbers 48812 48815 and 48753 6 110 inches emen 2 12 49128 10509 Hose Assembly Compo
108. LARE TUBE HOSE END MALE JIC SWIVEL 90 STRAIGHT THREAD TO 37 FLARE HOSE 1 4 INCH ID HOSE 1 4 INCH ID 1 4 INCH ID HOSE 3 8 INCH ID HOSE 3 8 INCH ID HOSE 3 8 INCH ID 1 2 INCH ID 1 2 INCH ID D D D D D D HOSE 1 2 INCH I HOSE 5 8 INCH HOSE 5 8 INCH HOSE 3 4 INCH HOSE 3 4 INCH HOSE 3 4 INCH HOSE 1 INCH ID HOSE 1 INCH ID SLEEVE NYLON 1 06 ID SLEEVE NYLON 1 42 ID HOSE 1 2 INCH ID HOSE 5 8 INCH ID HOSE 1 4 INCH ID SLEEVE NYLON 86 ID HOSE END FEMALE SWIVEL SEAL LOK HOSE END 45 FEMALE SWIVEL SEAL LOK HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE END MALE SEAL LOK NO O RING HOSE END FEMALE SWIVEL JIC HOSE END 90 FEMALE SWIVEL JIC HOSE END FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK Part No 89721 October 2006 700 e Hydraulic Components 713 1 Hydraulic Hose and Fitting Cross reference Rev A Genie PN Parker PN Description Genie PN Parker PN Description 48813 114366 HOSE END 90 FEMALE SWIVEL SEAL LOK 48875 6 R6LO S RUN TEE SWIVEL NUT ORFS 48814 1 543 6 6 HOSE END 90 FEMALE SWIVEL SEAL LOK 488774 F50LO SW 0250RI CONNECTOR STRAIGHT THREAD TO ORFS 48815 1 743 6 6 HOSE END 45 FEMALE SWIVEL SEAL LOK W 025 ORI 48816 1J943 6 6 HOSE END 90 FEMALE SWIVEL SEAL LOK 4
109. LOK 48911 4 6 C5OLO S ELBOW 90 STRAIGHT THREAD ORFS 48854 6 HOSE END FEMALE SWIVEL SEAL LOK 48912 4 6 68 CONNECTOR STRAIGHT THREAD TO ORFS 48855 46 HOSE END 90 FEMALE SWIVEL SEAL LOK 489134 6 F50LO SW 0300R CONNECTOR STRAIGHT THREAD TO ORFS 48856 1171 16 16 HOSE END 90 FEMALE SWIVEL SEAL LOK W 030 ORI 48857 1971 16 16 HOSE END 90 FEMALE SWIVEL SEAL LOK 48914 4 8 F5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 48859 1JS43 8 4 HOSE END FEMALE SWIVEL SEAL LOK 48915 6 68 ELBOW 90 STRAIGHT THREAD ORFS 48867 PD36BTL DIAGNOSTIC NIPPLE SEAL LOK SWIVEL 48916 68 CONNECTOR STRAIGHT THREAD TO ORFS 48873 6 PNLO S PLUG TUBE END ORFS 48917 68 CONNECTOR LONG STRAIGHT THREAD TO ORFS 48874 6PNTX S PLUG FLARE TUBE 48918 6RS5OLO S RUN TEE STRAIGHT THREAD Part No 89721 5 40 5 700 e Hydraulic Components October 2006 Figure 713 1 Genie PN Parker PN 48919 48920 48921 48922 48923 48925 48926 48927 48928 48929 48930 48931 48932 48933 48934 48935 48936 48937 48938 48939 48940 48941 48942 48943 48944 48945 48946 48947 48948 48949 48950 48951 48952 48953 48954 48955 48956 48957 48958 48959 48960 48961 48962 48963 48964 48965 48966 48967 6 S5OLO S 6 V5OLO S 6 FLO S 6 6 FLO S 6 P5ON S 6 WELO S 6 4 65 6 4 65 6 4 V5OLO S 6 8 C5OLO S 6 8 F5OLO S 6 10 F5OLO S 8 C5OLO S 8 F5OLO S 8 FF5OLO S 8 68 8 S5OLO S 8 V5OLO S 8 R6LO S 8 S6LO S 8 WJJLO WLNL S 8 4 TRLO S
110. MALE SWIVEL SEAL LOK 48893 6 FSOHAO S UNION STRAIGHT THREAD 48835 2 HOSE END FEMALE SWIVEL SEAL LOK 48894 8WLO WLNL S UNION BULKHEAD ORFS 48836 8 HOSE END FEMALE SWIVEL SEAL LOK 48895 DT 370 MSMO 5 VALVE CHECK 48837 8 HOSE END FEMALE SWIVEL SEAL LOK 48896 6 JLO S UNION TEE ORFS 48838 8 HOSE END 45 FEMALE SWIVEL SEAL LOK 48897 DT 50 MSMS 5 VALVE CHECK 48839 1J943 12 8 HOSE END 90 FEMALE SWIVEL SEAL LOK 48898 DT 750 MOMS 5 VALVE CHECK 48840 0 HOSE END 90 FEMALE SWIVEL SEAL LOK 48899 DT 620 MOMS 5 VALVE CHECK HOSE END FEMALE SWIVEL SEAL LOK 489004 6 F5OLO SW 0350RI CONNECTOR STRAIGHT THREAD TO ORFS 48842 12 HOSE END MALE SEAL LOK W 035 ORI 48843 1143 12 12 HOSE END 90 FEMALE SWIVEL SEAL LOK 48902 16 1 AOEAG S ELBOW 90 LONG FEMALE PIPE TO 48844 1543 12 12 HOSE END 90 FEMALE SWIVEL SEAL LOK STRAIGHT TAREAD 48845 12 HOSE END 45 FEMALE SWIVEL SEAL LOK 22905 LEES NIFPLEPIPE 48846 1J943 12 12 HOSE END 90 FEMALE SWIVEL SEAL LOK 8901 AA 0 48905 68 CONNECTOR STRAIGHT THREAD ORFS 48848 10543 12 12 HOSE END MALE STRAIGHT THREAD 48909 RUN TEE STRAIGHT THREAD 48849 2 HOSE END FEMALE SWIVEL SEAL LOK 48907 Ee ELBOW 42 STRAIGHT RUSS EE 48850 2 HOSE END FEMALE SWIVEL SEAL LOK dodge ee RUN TEE SWIVEL NUT ORFS 48851 1171 12 12 HOSE END 90 FEMALE SWIVEL SEAL LOK KE Ee LOK 489104 GTX S W 0300RIFIC CONNECTOR FEMALE PIPE TO FLARE TUBE 48853 1971 12 12 HOSE END 90 FEMALE SWIVEL SEAL
111. Mount Bracket 1 Screw HHC 3 8 16 1 25 inches GR 5 Lock Washer 3 8 inch Hydraulic Rotary Coupler 1 Seal Kit Screw SHC 5 8 11 x inches 38 20 Hardened Flat Washer 5 8 inch 44 Screw HHC 3 8 16 x 0 75 inch GR 5 Flat Washer 3 8 inch Pin Retainer Plate 1 Pin Retainer with Lanyard 1 Turntable Rotation Pin Assembly includes items 11 and 15 18 1 Turntable Rotation Bearing 1 Screw HHC 1 8 x 8 5 inches Flat Washer 1 25 x 3 x 0 188 inch Part No 89721 23 24 25 26 27 28 29 30 31 32 53141 33265 29605 21175 81137 28646 49189 4638 48887 81110 Ref 304 1 Turntable Rotator and Hydraulic Rotary Coupler Installation Rev G Description Qty Drive Chassis Weight 1047 Ibs 5 45 2 Jam Nut 1 8 Lock Washer 1 inch Screw SHC 5 8 11 x 4 inches GR 8 20 Swivel Stop Bracket 2 1 Hose Assembly Components Genie part numbers 48805 48805 and 48751 44 inches Fitting EE 1 Screw HHC 5 8 11 2 inches GR 8 4 Turntable Rotation Drive Hub Motor and Brake Assembly refer to 305 1 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part num
112. O RING STRAIGHT THREAD 8 61079 53503 3 910 O RING STRAIGHT THREAD 10 61080 53535 3 912 O RING STRAIGHT THREAD 12 61083 53536 4 PNLO S PLUG TUBE END ORFS 61086 53537 6 PNLO S PLUG TUBE END ORFS 61090 53538 8 PNLO S PLUG TUBE END ORFS 61091 53539 10 PNLO S PLUG TUBE END ORFS 61093 53540 12 PNLO S PLUG TUBE END ORFS 61095 53946 129HB 5 4 FITTING 90 HOSE BARB TO MALE PIPE 61100 53951 8 1 4F50G S ADAPTER FEMALE PIPE TO STRAIGHT THREAD 61130 53980 6 S6LO S BRANCH TEE SWIVEL NUT TO ORFS 61131 54132 4 C6LO S ELBOW 90 SWIVEL NUT ORFS 61132 54135 11343 16 16 HOSE END MALE SWIVEL PIPE 61152 54283 8 10 C5OLO S ELBOW 90 STRAIGHT THREAD TO ORFS 61251 Part No 89721 S 40 5 45 713 1 Hydraulic Hose and Fitting Cross reference Rev A Genie PN Parker PN 54428 8M18C87OMLO S FS F 16 10 10143 2 4 3 8 HP S 8 HLO S 6 F650X S 10 C50X S 6 CC5OLO S BV 0837 10143 8 6 2 011 2 012 2 014 2 016 2 018 2 021 6 WLNL S 8J782 12 12 3982 12 12 10 8 68 3JC82 10 10 3J982 10 10 3JC82 8 10 10 8 C5OLO S 471TC 6 471TC 8 811 16 3 8 FF 6 FNL S 4 FNL S 8 HP5ON S BV 0751 125HB 3 4 5 1 4 F5OG S 4 WELO WLNL S 6 WLO WLNL S 24 F5OLO S 20 R5OLO S 24 20 F5OLO S 1J943 24 24 1J978 12 12 1JS43 20 16 811 24 1JS43 24 24 1JS78 12 12 1J778 12 12 139HB 6 4 BV 0750 Description ELBOW 90 METRIC STRAIGHT THREAD TO ORFS SLEEVE FIRE 96 ID HOSE END MALE PIPE PLUG PIPE THREAD UNION ORFS CONNECTOR STRAIGHT THREAD TO 37 SWIVEL ELBOW 90 ST
113. OUSING 1 9 75449 Joystick Knob 1 10 75448 Sensor 1 11 75447 Switch Shield 1 12 75446 Centering Spring 1 13 75445 Rocker Switch Assembly 1 14 75444 Rocker Switch Retainer 1 15 75443 Rocker Switch Boot 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 D s 5 o gt RS oc o 5 s 6 lt 2 5 EJ o 55 N N 19 gt lt Oe Z Part 89721 S 40 5 45 October 2006 700 e Hydraulic Components Part No 89814 89073 28750 49612 33994 49613 Ref 1 52598 74902 31100 74902 2 27807 110200 3 62263 62273 19792 72043 27807 110200 62263 62273 19792 72043 27807 AB 27802 110196 27802 110196 102615 74902 32975 ks sak 74902 27807 110200 102614 74902 Description Function Manifold S 40 complete includes items 1 15 and 17 34 Function Manifold S 45 complete includes items 1 15 and 17 34 O ring Kit services SAE fittings Compact Controls and Sun Valves O
114. Perkins models from serial number 7472 to serial number 9558 Engine Harness Assembly Perkins models after serial number 9558 Engine Harness Assembly Deutz models before serial number 7544 1 Engine Harness Assembly Deutz models after serial number 7543 Part No 89721 A TERI 300 e Turntable Components 311 1 Wire Harness and Power Cable Assemblies Rev A Item 10 11 12 13 14 15 16 17 18 19 20 21 22 Part No 89662 102107 102316 102304 89674 89665 89664 89663 73479 89657 89654 89658 89655 89659 89656 89692 89925 Description Engine Harness Assembly Ford models before serial number 7597 1 Engine Harness Assembly Ford models after serial number 7596 Lincoln Welder Harness Assembly Pigtail option 1 Welder Harness Assembly option 1 Function Manifold Harness Assembly 1 Drive Enable Limit Switch Harness Assembly 1 Boom Angle Limit Switch Harness Assembly 1 Boom Extend Retract Limit Switch Harness Assembly 1 Alarm Package Harness Assembly option 1 12V to Platform Harness Assembly 5 40 1 12V to Platform Harness Assembly S 45 Boom Cable 1 Harness Assembly 5 40 1 Boom Cable 1 Harness Assem
115. Platform 16 6638 Flat Washer 1 4 inch Tri Entry Assembly 111303 8 Foot Platform This list continues on the next page Tri Entry Assembly European models 102439 8 Foot Platform Tri Entry Assembly Australian models before serial number 9753 102434 6 Foot Platform Tri Entry Assembly 102438 8 Foot Platform Tri Entry Assembly after serial number 9752 111304 6 Foot Platform Tri Entry Assembly 111305 8 Foot Platform Tri Entry Assembly Asia and South American models 102436 6 Foot Platform Tri Entry Assembly 102443 8 Foot Platform Tri Entry Assembly Genie A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 800 Accessories iption Platform Options Descripti Rev E Figure 802 1 09 2 09 Part 89721 5 40 5 45 October 2006 800 Accessories 802 1 Platform Options Rev E Part Description Qty USA and Canada models before serial number 9753 17 107704 6 Foot Platform Tri Entry Railing Assembly with Decals 107705 8 Foot Platform Tri Entry Railing Assembly with Decals after serial number 9752 17 111319 6 Foot Platform Tri Entry Railing Assembly with Decals mE 111320 8 Foot Platform Tri Entry Railing Assembly with Decals European models 17 107706 8 Foot Platform Tri Entry Railing Asse
116. R 3 ND gt 2 lt 2 5 N 5 8 d 1 FITTING To Oscillate 2 Valve out HYDRAULIC option HosE ROTARY 2B ASSEMBLY To Oscillate 6 Valve option 2 s 21 21 16 21 21 M4 M2 TANK M6 16 A B 16 4WD DRIVE MANIFOLD 7 5 1 22 16 16 16 16 d 23 24 25 25 26 Se V BRK BRK LEFT NON STEER N RIGHT DRIVE MOTOR EN 4 NON STEER AND BRAKE DRIVE MOTOR 16 5 40 5 45 89721 October 2006 700 e Hydraulic Components 708 1 Rev A Hydraulic Hoses and Fittings 4WD Drive and Steer System before serial number 7569 Item Part No Description Qty Part No Description 1 48915 ei Le RE 2 19 49149 2126 Hose Assembly Components Ka Genie part numbers 48841 2 48919 FRIDO 2 48845 and 48761 6 18 inches 275421200152 hose Assembly Components 20 49374 2530 Hose Assembly Components Genie part numbers 48812 Geni 48812 and 48753 enie part numbers 48841 48846 and 94358 22 inches 19 5 inches 2 4 48946 EE 000397 5 49107 10213 Hose Assembly Components 22 48933 Fitting E Genie part numbers 48822 23 49172 4238 Hose Assembly Components 48826 and 48758 Genie part numbers 48827 99 5 inches 4 48828 and 48756 Q 40 inches 6 48937 Fitting inco es 3 24 89871 3348 Hose Assembly
117. R 5 A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 819 1 B Hostile Environment Package View 4 S 40 S 45 Part No 89721 October 2006 800 Accessories Item 15 16 17 Part 6019 6021 5397 63145 63135 63145 63177 63146 63174 63146 63136 63163P 63168P 63163P 63175P 81905P 63137P 81904P 63176P 63142 63138 63142 63138 63164P 63167P 63164P 63167P 6889 6878 Description Screw HHC 3 8 16 1 25 inches GR 5 Lock Washer 3 8 inch Flat Washer 5 16 inch Wiper Bracket S 40 Wiper Bracket Top S 45 Wiper Bracket Bottom S 40 Wiper Bracket Bottom S 45 Wiper S 40 Wiper Top S 45 Wiper Bottom S 40 Wiper Bottom S 45 Backing Plate Top 5 40 Backing Plate Top S 45 Backing Plate Bottom SAO eee tee Backing Plate Bottom S 45 Wiper Bracket Engine Side Wiper Bracket Engine Side 5 45 Wiper Bracket Tank Side GAD deeg Wiper Bracket Tank Side S 45 Wiper Engine Side S 40 Wiper Engine Side S 45 Wiper Tank Side 5 40 Wiper Tank Side S 45 Backing Plate Engine Side ecu cu Backing Plate Engine Side S 45
118. RAIGHT THREAD TO FLARE TUBE ELBOW 902 LONG STRAIGHT THREAD TO ORFS BALL VALVE 90 HOSE END MALE PIPE O RING ORFS 4 O RING ORFS 6 O RING ORFS 8 O RING ORFS 10 O RING ORFS 12 O RING ORFS 16 LOCKNUT BULKHEAD HOSE END 45 FEMALE SWIVEL SEAL LOK HOSE END 90 FEMALE SWIVEL SEAL LOK CONNECTOR STRAIGHT THREAD TO ORFS HOSE END FEMALE SWIVEL SEAL LOK HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK ELBOW 902 STRAIGHT THREAD TO ORFS HOSE 3 8 INCH ID HOSE 1 2 INCH ID HOSE 1 INCH ID NIPPLE PIPE CAP TUBE END CAP TUBE END PLUG STRAIGHT THREAD BALL VALVE FITTING HOSE BARB TO MALE PIPE ADAPTER FEMALE PIPE TO STRAIGHT THREAD UNION 90 BULKHEAD W NUT ORFS UNION BULKHEAD ORFS CONNECTOR STRAIGHT THREAD TO ORFS RUN TEE STRAIGHT THREAD CONNECTOR STRAIGHT THREAD TO ORFS HOSE END 90 FEMALE SWIVEL SEAL LOK HOSE END 90 FEMALE SWIVEL JIC HOSE END FEMALE SWIVEL SEAL LOK HOSE 11 2 INCH ID HOSE END FEMALE SWIVEL SEAL LOK HOSE END FEMALE SWIVEL SEAL LOK HOSE END 45 FEMALE SWIVEL JIC ELBOW 45 BARB TO MALE PIPE BALL VALVE 700 e Hydraulic Components October 2006 Figure 713 1 Genie PN Parker PN 61259 61260 61262 61263 61264 61265 61268 61269 61272 61316 61321 61327 61328 61336 61345 12 WJJLO WLNL S 61346 8 WNLO WLNL S 4 61569 61610 61742 63426 64271 64272 65776 65880 66154 66155 66156 66389 66392 66396 66829 67217 67339 67357 67358 67371 6749
119. ROTATION MOTOR sw2 13 13 13 2 4 EXTEND P1 PL1 PR1 swi 13 118 13 13 2 4 P2 PL2 PR2 A TEREX COMPANY S 40 S 45 Part No 89721 October 2006 700 e Hydraulic Components 21 Hydraulic 10565 Fittings Boom Components 5 45 Rev B Description Qty Part Description Qty 1 10 11 12 13 14 15 49117 5791 48905 49119 3278 48904 49119 68278 49120 49781 49184 3001 48919 49120 50781 48912 49181 10440 49181 9240 48916 49126 11233 49128 10509 Hose Assembly Components Genie part numbers 48800 48802 and 48751 56 inches Fittiric Sea saan sha Hose Assembly Components Genie part numbers 48800 48800 48751 31 inches Fitting ai c Hose Assembly Components Genie part numbers 48800 48800 and 48751 Q 681 inches nnnnnneesoonnannnennnnnn Hose Assembly Components Genie part numbers 48800 48810 and 48751 496 inches Hose Assembly Components Genie part numbers 42768 48802 and 48751 Q 28 inches nice Hose Assembly Components Genie part numbers 48800 48810 and 48751 6 506 Hose Assembly Components Genie part numbers 48801 48810 and 48751 102 inches aee Hose Assembly Components Genie part numbers 48801
120. Rotation Stop Bar non oscillating models 30 30808 Axle Rotation Stop Shim 9 5 1 5 0 108 inch as needed 31 30809 Axle Rotation Stop Shim 9 5 x 1 5 x 0 034 inch as needed 32 30735 Axle Pivot Pin 17 5 x 1 5 inches 1 33 45226 Rod End 0 375 3 69 inches 1 34 6175 Screw HHC 38 16 x 1 inch GR 5 35 6021 Lock Washer 3 8 inch 36 89803 Non steer End Cover with 26088 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 200 e Drive Chassis Components after serial number 7568 Descriptio B 4WD Non steer Axle Rev Figure 207 2 Part No 89721 S 40 5 45 October 2006 200 e Drive Chassis Components Part Description Qty 1 6096 Screw HHC 14 1 2 13 x 2 inches GR5 2 6021 Lock Washer 3 8 inch 9 73634 Screw 10 24 0 5 14 4 6146 Flat Washer 10 5 77026 Bubble Level x European models Ets 007 Spring EE 3 7 73575 Spring Clip Nut 10 24 8 54156 Flanged Bearing 1 5 1 75 1 inch 1 9 89802 Non steer Axle Assembly includes items 8 and 17 1 10 18396 Bearing 1 5 x 1 75 x 1 inch 1 11 36603 Flat Washer 1 56 x 14 3 5 x 0 057 inch as needed 12 73196 Wheel 16 5 x 9 75 9 hole 2 E
121. S 73492 Wheel 15 13 9 hole 73924 Wheel 19 5 14 9 hole 13 54627 Lug Nut 5 8 18 90 18 14 14 Part No 89721 S 40 5 45 4WD Non steer Axle after serial number 7568 Part No 81489 73212 73925 81008 81009 111449 111450 81492 81493 73204 73205 111453 111454 102802 102803 73923 73490 73491 207 2 Rev B Description Qty Tire 12 16 5 8 2 Tire 12 16 5 12 Ply Non marking Tire 33 16LL 500 10 Ply Sand Tire High Flotation Tire and Wheel Assembly Air filled Right 566 1 Tire and Wheel Assembly Air filled Left Side Tire and Wheel Assembly Air filled with Sealant Right Side Tire and Wheel Assembly Air filled with Sealant Left Side Tire and Wheel Assembly Foam filled Right Side Tire and Wheel Assembly Foam filled Left Side Tire and Wheel Assembly Air filled Non marking 1 Tire Wheel Assembly Air filled Non marking Left Side Tire and Wheel Assembly Air filled with Sealant Non marking Right Side Tire and Wheel Assembly Air filled with Sealant Non marking Left Side Tire and Wheel Assembly Non marking Foam filled Right Side Tire and Wheel Assembly Non marking Foam filled Left Side Tire and Wheel Assembly High flotation 2 Tire and Wheel Assembly Wide Foam filled Right Side 1 Tire and Wheel Assembly W
122. TRAIGHT THREAD TO ORFS CONNECTOR STRAIGHT THREAD TO ORFS ELBOW 90 STRAIGHT THREAD TO ORFS CONNECTOR STRAIGHT THREAD TO ORFS ELBOW 45 STRAIGHT THREAD TO ORFS CONNECTOR MALE PIPE TO ORFS ELBOW 90 STRAIGHT THREAD TO ORFS 0 5 0 5 5 5 0 5 ONNECTOR STRAIGHT THREAD TO ORFS LBOW 45 STRAIGHT THREAD TO ORFS ONNECTOR MALE PIPE TO ORFS LBOW 45 MALE TO FEMALE PIPE LBOW 45 MALE TO FEMALE PIPE LBOW 45 MALE TO FEMALE PIPE ONNECTOR MALE PIPE TO ORFS LBOW 45 STRAIGHT THREAD TO ORFS BALL VALVE BALL VALVE BALL VALVE BALL VALVE DIAGNOSTIC NIPPLE STRAIGHT THREAD DIAGNOSTIC NIPPLE STRAIGHT THREAD VALVE CHECK ELBOW 45 STRAIGHT THREAD TO ORFS HOSE END FEMALE SWIVEL SEAL LOK ELBOW 45 STRAIGHT THREAD TO ORFS UNION STRAIGHT THREAD DIAGNOSTIC NIPPLE SEAL LOK SWIVEL CONNECTOR METRIC STRAIGHT THREAD TO FLARE TUBE CONNECTOR BULKHEAD FEMALE PIPE TO FLARE TUBE HOSE END FEMALE SWIVEL JIC HOSE 1 2 INCH ID HOSE END 90 FEMALE SWIVEL JIC SLEEVE NYLON 2 19 ID ELBOW 45 STRAIGHT THREAD TO ORFS VALVE CHECK ELBOW 90 FEMALE PIPE NIPPLE PIPE PLUG STRAIGHT THREAD ELBOW 90 MALE PIPE TO ORFS PLUG STRAIGHT THREAD 5 40 5 45 Part 89721 October 2006 700 e Hydraulic Components Genie PN Parker Description 49519 16 12 F5OLO S CONNECTOR STRAIGHT THREAD TO ORFS 49520 4 VTX S ELBOW 45 MALE PIPE FLARE TUBE 54803 49530 16 C6LO S ELBOW 90 SWIVEL NUT ORFS 54954 49612 P
123. X COMPANY Part No 89721 S 40 5 45 vli October 2006 Notes A TEREX COMPANY viii S 40 S 45 Part No 89721 October 2006 Parts Stocking List Required Parts to 11066 following parts required to perform Description Part No maintenance procedures as outlined in the Fuel Pre Filter 52179 Genie S 40 and S 45 Service Manual Fuel Pressure Regulator Filter 58967 Perkins 704 30 Models before serial number 7472 Engine Oil Filter 28656 Description Part No Air Filter Element AAA 77295 Air Filter Element 0 ee 62420 Serpentine Belt see 52580 Fuel Filter Element 62421 POV diet dies 33957 Fuel water Separator Eiter 65853 Spark Plug pack of 4 106490 Engine 0 62422 Ford 050 423 EFI Models m a 62423 1 number 11965 PN Perkins 404 22 Models after serial number 7471 F elPre Filter onera ess 52761 Description Part No ne Fuel Pressure Regulator Filter 119491 Air Filter Element 4 1 62420 Fuel Filter Element 62421 Se 149139 Fuel water Separator Element 62433 Air Filter Element 222 4 440422 2 77295 Engine Oil Filter
124. aiies 1 Nut 4 28 Threaded Rod 1 4 28 x 10 inches 1 G Part No 89721 A TEREX Part 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 MPANY 6090 6638 6889 60521 73993 29073 52537 33241P 77139 61326 89596P 44064 22700 6019 5397 4828 Ref 6097 Description Qty Screw HHC 1 4 20 x 0 75 inch GR 5 Flat Washer 1 4 inch Low Profile Nylock Nut 1 4 20 Relay 30 40 1 Harness RPM Solenoid Relay 2 Speed Solenoid 1 Boot Mount Bracket 1 Medium Pressure Filter Assembly 1 Fiberglass Element 10 Micron Medium Pressure Filter Bracket 1 Screw HHC M10 1 5 x 30 mm GR 8 8 Lock Washer M10 Screw HHC 3 g 16 x 1 25 inches GR 5 Flat Washer 5 16 inch Nylock Nut 3 8 16 Battery refer to 423 1 Flat Washer 3 8 inch October 2006 400 Engine Components Om T TSE 0 SCH Sek Je AWA US x i 7 6 0 j 0 Ke eg ANN Ws XA Y ees Deutz 2011 Engine View 1 after serial number 7543 Description Rev F Figure 411 1 CRA 2 Part 89721 5 40 5 45 G October 2006 400 Engine Componen
125. air Link Set 4 Links 13 6091 Nylock Nut 1 4 20 39 25072 6 Lower Cable Track Hose 1 14 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 15 8255 Screw HHC 38 16 0 75 inch GR 5 16 6021 Lock Washer 3 8 inch 17 6097 Flat Washer 3 8 inch 18 44081 S Track Tray Cable Cover 1 19 88356 11165 Limit Switch with Roller Arm 1 19491 Contact 27643 Roller Arm 20 6179 Screw RHSM 10 32 x 1 25 inches 21 6607 Lock Washer 10 22 1505 Electrical Cord 16 Ga 2 Conductor 236 inches 23 52653 Cable Track Tray with Trim 1 24 31411 Wear Pad 3 63 x 2 75 x 0 75 inch 2 A TEREX COMPANY Part No 89721 S 40 5 45 500 e Boom Components October 2006 Figure Rev Description 505 1 D Slave Cylinder and Platform Rotator S 40 0 00000 A TEREX COMPANY 5 40 5 45 Part No 89721 October 2006 500 e Boom Components Part Description Qty Part 1 30217 External Snap Ring 17 81693 25 2 75469 2 30255 Flat Washer 1 27 2 13 x 0 062 59267 3 Ref Boom Assembly refer to 502 1 4 30728 Pivot Pin m PONE 7 13 x 1 25 inches 1 5 34239 Pivot Pin 7 88 x 1 25 inches 1 6 30418 Rod End 0 5 x 3 75 inches 2
126. al Danger High Voltage 2 12 102408P Welder Mount 1 102409 Welder Mount Support 106044 U bolt 3 8 16 x 4 inches 4828 Nylock Nut 3 8 16 5397 Flat Washer 3 8 inch 106043 Security Screw 5 16 18 x 1 inch 6782 Nylock Nut 5 16 18 Genie A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 814 1 B Hoses and Fittings Welder FUNCTION MANIFOLD ft ets WELDER MANIFOLD PMPB CLR PMPA LEGEND gt gt lt CONNECTOR HYDRAULIC ROTARY COUPLER 12 5 KW GENERATOR Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 800 Accessories 814 1 Hoses and Fittings Welder Rev B Part No Description Qty 1 102313 2726 Hose Assembly Components Genie part numbers 48841 48845 and 94358 Q 24 inches 1 2 48977 2 67371 Fitting EE 1 4 61070 3750 Hose Assembly Components Genie part numbers 48827 48836 48756 6 35 inches 1 5 102313 2926 Hose Assembly Components Genie part numbers 48841 48845 94358 26 inches 1 w 6 48959 Fitting 2 7 48933 Deet EE 1 8 48963 2 9 48960 e EE 4 10 102312 2088 Assembly Components Genie part numbers 48841 102311 and 94358 18 inches 1 11 94374 5030 H
127. and 48756 Q 44 inches 1 10 48905 FIRING AE 4 11 48963 Fittihg noce ane 2 12 48960 Fitting BE 12 13 94374 2380 Hose Assembly Components Genie part numbers 48841 48846 and 94358 6 20 5 inches 1 14 49149 2126 Hose Assembly Components Genie part numbers 48841 48845 and 48761 Q 18 inches 1 15 94374 2530 Hose Assembly Components Genie part numbers 48841 48846 and 94358 Q 22 inches 1 16 49117 7641 Hose Assembly Components Genie part numbers 48800 48802 and 48751 6 74 5 2 17 48933 FRING 4 18 48911 Fitting 19 94374 4230 Assembly Components length listed the component description Genie part numbers 48841 is the length of the hose only 48846 and 94358 39 inches Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 700 e Hydraulic Components October 2006 Figure Rev Description 708 1 A Hydraulic Hoses and Fittings 4WD Drive and Steer System before serial number 7569 LEFT RIGHT C STEERING CYLINDER 6 e STEERING CYLINDER e 1 2 2 1 LEFT RIGHT STEER AXLE 5 DRIVE MOTOR DRIVE MOTO
128. art 89721 5 40 5 45 October 2006 200 e Drive Chassis Components 204 2 2WD Non steer Axle after serial number 7568 Rev B Item Part Description Qty 26 6356 Lock Washer 4 inch 27 6638 Flat Washer 1 4 inch 28 30690 Axle Rotation Stop Bar oscillating models 2 30691 Axle Rotation Stop Bar non oscillating models 29 30808 Axle Rotation Stop Shim 9 5 x 1 5 x 0 108 inch as needed 30 30809 Axle Rotation Stop Shim 9 5 x 1 5 x 0 034 inch as needed 31 30735 Pivot Pin 17 5 x 1 5 inches 1 32 45226 Rod End 0 375 3 69 inches 1 33 6175 Screw HHC 3 8 16 x 1 inch GR 5 34 89803 Non steer End Cover with A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Figure Rev Description 205 1 B 4WD Steer Axle Linkage ch S db cs Zi 2 AQ 52 Part 89721 October 2006 200 e Drive Chassis Components 205 1 4WD Steer Axle Linkage Rev B Description Qty Part Description Qty 1 49857 Screw HHC 24 36603 Flat Washer 38 16 x 0 88 inch GR 5 1 56 x 3 5 x 0 057 inch as needed 2 6021 Lock Washer 3 s inch 25 5 Steer Axle Assembly 3 25284 End 0 375 x
129. asher 5 16 inch 33 8178 Screw HHC 10 60936 Return Filter Bracket 1 38 16 x 2 5 inches GR 5 E EE 34 46999 Fuel Tank Assembly with Decals Assembly with Indicator 1 30 gallons 113 6 liters before serial number 7401 1 65610 5 Fuel Tank Assembly with Decals 61326 Return Filter Element 10 Micron 816541 Return Filter Element 3 Micron 12 48922 Connector 20 gallons 75 7 liters 6 ORFS x 6 NPTF 1 after serial number 7400 13 45161 Strainer Assembly 35 101727 Red Anti surge Vented Cap 1 1 5 inches 2 36 27089 Fuel Line 5 inch 80 inches 14 81578 Horn 12V DC 1 before serial number 7597 27089 Fuel Line 5 16 inch 57 inches 15 13002 Screw HHC 2 5 16 18 1 inch GR 5 after serial number 7596 37 6019 Screw HHC 1 4 i 16 6638 Flat Washer 1 4 inch 3 s 16 x 1 25 inches GR 5 17 Ref Turntable Rotator refer to 304 1 38 53120 S LPG Tank Mount 18 4828 Nylock Nut 3 8 16 before serial number 7401 1 102342 LPG Tank Mount 5 16 19 6002 Nylock Nut 5 16 18 refer to 808 1 20 6097 Flat Washer 3 8 inch after serial number 7400 21 13002 Screw HHC 39 25967 LPG Hose Assembly 5 16 18 1 inch GR 5 before serial number 7401 1 30275 LPG Hose Assembly 22 31507 Magnetic Square Head Plug after serial number 740
130. atform Control Box Cover after serial number 7121 Aluminium Rivet 3 16 inch Platform Controls Hinge 28 inches Platform Controls Cover before serial number 7080 Draw Latch before serial number 7080 Platform Controls Cover lid before serial number 7080 Rubber Bumper before serial number 7080 Rubber Bumper Platform Controls Cover Lid from serial number 7080 to 7121 Platform Controls Cover Lid after serial number 7121 Platform Controls Cover Lid Assembly after serial number 7121 Platform Controls Cover Engine Side Nylock Nut 4 20 Flat Washer 4 inch Screw HHC 1 4 20 x 0 75 inch GR 5 Door Latch Aluminium Rivet 0 25 x 0 375 inch Base Control Box Cover Assembly with Decals includes items 13 14 and 16 1 Qty Part No 17 88607P 18 102786P 19 8914 20 6356 E 15 poene 1 xu 1 2 Sous 1 2 zm 2 1 1 NU 1 7 E 3 Genie Part No 89721 803 1 Ground and Platform Control Box Covers Options Rev C Description Qty Platform Controls Cover Tank Side iets ii 1 Control Box Lid Latch 2 Screw HHC 1 4 20 x 0 625 inch GR 5 Lock Washer 1 4 inch A TEREX COMPANY 800 Accessories October 2006 Figure Rev Description 804 1 C Pl
131. atform Overload European Models S 40 S 45 Part No 89721 October 2006 800 Accessories 804 1 Platform Overload European Models Rev Part Description Qty Part Description Qty 102069 Platform Overload Upgrade Kit 22 21604 Screw HHC before serial number 7182 3 8 16 x 3 25 inches 5 7 Sense 23 111091 Platform Overload Module 1 refer to 311 1 89922 Platform Overload Option 24 45383 Alarm Warble Tone after serial number 7181 5 30V DG icem eh 1 1 61997 Platform Support 1 25 72326 Retainer Nut 1 2 6833 Rubber Cushioned Clamp 0 5 x 0 25 1 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 6091 Nylock Nut 1 4 20 3 6888 Screw HHC 1 4 20 1 inch GR 5 4 45748 Rod End 0 25 x 2 75 inches 4 5 6091 Nylock Nut 1 2 20 6 61726 Pivot Pin 0 75 x 5 75 inches 4 x 94643 Zerk Fitting 7 61804 Rotator Mount 1 8 94175 Flanged Bearings 0 75 x 0 875 x 0 5 inch 8 9 51063 Screw PHPM 10 32 x 1 5 inches 10 6146 Flat Washer 10 11 4828 Nylock Nut 3 8 16 12 6097 Flat Washer 3 8 inch 13 61975 Spring Retainer 1 21 x 0 375 inch 1 14 61974 Compression Spring 232 in Ibs 1 15 89755 Load Supp
132. ator option 13 2 Position Maintained 1 54692 Nylon Spacer 0 718 x 0 526 x 0 219 inch 14 27246 Rubber Boot 32728 Generator Decal 15 5 32735 Flow Regulator Valve 16 4 3 gpm 16 3 L min for use with 2500W generator 1 65841 Flow Regulator Valve m 6 5 gpm 24 6 L min for use with 3000W generator 17 6 13918 Screw HHC 18 3 8 16 x 1 75 inches 8 19 7 5397 Flat Washer 5 16 inch 8 4828 Nylock Nut 3 8 16 Part 89721 5 40 5 45 Part 36928 32732 32733 89719 52086 111381 32732 32733 52000 52001 894340 4266 6638 Ref 6019 7713 53120 S 102342 49000 53605 25967 30275 808 1 Generator and Second LPG Tank Options Rev G Description Hydraulic Generator 2500W 220V AC 50Hz includes item 2 1 Rectifier Assembly Bridge 35A Full Wave Brush Endbell Assembly Hydraulic Motor Hydraulic Generator 3000W 110V AC 60Hz includes item 2 1 Rectifier Assembly Bridge 35 Full Wave Brush Holder Assembly with Brush Hydraulic Motor Generator Mount 1 Screw HHC 1 4 20 2 inches GR 5 Flat Washer 1 4 inch Flow Control Manifold Refer to 704 1 Screw HHC 3 8 16 x 1 25 inches GR 5 Nylock Nut 5 8 16 LPG Tank Mount before serial number 7401 1 LPG Tank Mount after serial number 7400 LP Tank Latc
133. bers to Parker part numbers 300 e Turntable Components October 2006 Figure Rev Description 305 1 C Turntable Rotation Drive Hub CHE A TEREX COMPANY S 40 5 45 89721 October 2006 300 e Turntable Components 305 1 Turntable Rotation Drive Hub Rev Part Description Qty 81108 Turntable Rotation Drive Hub Motor and Brake Assembly before serial number 7154 89885 Turntable Rotation Drive Hub Motor and Brake Assembly after serial number 7153 1 75677 Pinion Integral Shaft 1 2 75678 Reducer Seal Kit 1 3 75681 Bearing Kit 1 4 75682 DISC KI 1 5 75683 Spring NEE 1 6 62466 Brake Seal Kit 1 7 111092 Screw SHC M12 x 30mm GR 12 9 2 8 75684 Swing Drive Motor 1 75685 Seal Kit 9 102680 Turntable Rotation Manifold includes item 36648 before serial number 7154 1 75117 Turntable Rotation Manifold includes item 75118 after serial number 7153 36648 Counterbalance Valve 2500 psi 172 4 bar before serial number 7154 75118 Counterbalance Valve 3000 psi 206 8 bar after serial number 7153 75119 Seal Kit 10 41489 Screw SHC 5 16 18 x 2 inches after serial number 7153 11 1026
134. bly S 45 Boom Cable 2 Harness Assembly 5 40 1 Boom Cable 2 Harness Assembly S 45 Drive Light Harness Assembly option 1 Platform Overload Harness Assembly option 1 This list continues on the next page EX COMPANY 300 e Turntable Components October 2006 Figure Rev Description 311 1 A Wire Harness and Power Cable Assemblies PLATFORM CONTROL BOX 5 JIB KIT J1 ALC500 Jal FUNCTION TRACTION MANIFOLDS 2 Ap AN MANIFOLD BOOM NY WORK EXT RET 16 2 SWITCH eed ANGLE 20 19 18 SWITCH DRIVE ENABLE 4 gt _ GROUND DRIVE CONTROL LIGHTS BE O x PLATFORM A 239 Ge ALARM HYDRAULIC 8 UI PACKAGE GENERATOR 1 12 WELDER 10 24 AUX A 7 POWER UNIT BATTERY A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 300 e Turntable Components 311 1 Wire Harness and Power Cable Assemblies Rev A Item Part No Description Qty 23 89927 Platform Overlaod Harness Assembly option before serial number 7182 1 111152 Platform Overload Harness Assembly option after serial number 7182
135. ck Nut 3 8 16 16 65473 Radiator Cap 1 17 63462 Radiator _ an nasaq ass 1 18 Ref Engine Tray refer to 423 1 19 63363P Outboard Radiator Mount 1 20 54071 Coolant Return Tank with Hose 1 72327 Return Tank Cap 21 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 22 6889 Low Profile Nylock Nut 4 20 23 6888 Screw HHC 1 4 20 x 1 inch GR 5 24 6091 Nylock Nut 1 4 20 25 63457P Air Intake Bracket 1 26 45455 Rubber Cushioned Clamp 27S NENES vg deen 1 27 63414 Lower Radiator Hose 1 A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 400 e Engine Components Perkins 404 22 Engine View 1 after serial number 7471 Description D Figure 405 1 KL 0 6 0 f lt 69 enie G 5 40 5 45 Part No 89721 October 2006 400 Engine Components 405 1 Perkins 404 22 Engine View 1 after serial number 7471 Rev Item Part No Description Qty Part No Description Qty 77736 Glow Plug 22 6096 Screw HHC 94890 Engine Operator s Manual 1 2 13 x 2 inches GR 5 Ref Engine Harness refer to 311 1 23 6033 Lock Washer 1 2 inch 1 89758 Oil acte aaa 1 24 94889 Fuel Filter Assembly 1 2 60585 Isolator M8
136. ction Pump refer to 706 1 40 Ref Drive Pump refer to 706 1 41 6096 Screw HHC 1 2 13 x 2 inches GR 5 42 6033 Lock Washer 1 2 inch 43 70381 Pump Mount Plate 1 37003 Pump Coupler 33024 Flexplate 44064 Screw HHC M10 1 5 x 30 mm GR 8 8 22700 Lock Washer M10 89785 Ring Gear 44 61110 Screw SHC M10 1 5 30 mm 45 22700 Lock Washer M10 46 6888 Screw HHC 1 4 20 x 1 inch GR 5 47 6638 Flat Washer 1 4 inch 48 6091 Nylock Nut 1 4 20 49 70375 Air Cleaner Hose 1 30971 Clamp 3 inches Engine Isolator 4 Flat Washer 2 inch Cast Washer Part No 89721 A TERI This list continues on the next page EX COMPANY 400 e Engine Components October 2006 Figure Rev Description 412 1 E Deutz F3L 2011 Engine View 2 after serial number 7543 S 40 S 45 Part No 89721 October 2006 400 Engine Components 412 1 Deutz 2011 Engine View 2 after serial number 7543 Rev E Part Description Qty 50 70351P Air Cleaner Mount 1 51 10107 Screw HHC 5 16 18 x 0 75 inch GR 5 52 5397 Flat Washer 5 16 inch 53 6782 Nylock Nut 5 16 18 54 53952 Air Cleaner Bracket 1 55 63463 Air Filter Assembly 62420 Air Filter Element 56 89786 Engine P
137. e 1 6833 Coolant Return Clamp 19358 itting 2 88847 Air Cleaner Outlet Hose 1 32 102098 FRING 2r oes 1 3 45435 Clamp 2 5 3 33 102073 Fitting EE 1 102072 Fitting 4 77236 Air Filter Assembly 1 us 77295 Air Filter Element 34 81778 Hose Coolant 3 4 inch 1 58247 Air Filter Cap 35 102118 Heat Shield includes item 47 102977 Plastic Hose Fitting sold separately 1 5 77296 Air Cleaner Mount Band j 4020722 Heat Shield Support 6 33361 Rubber Elbow 45 2 36 32064 Clamp 1 25 inches 2 7 10107 Screw HHC 37 30144 Battery Hold Down 1 5 16 18 x 0 75 inch GR 5 38 Ref Battery refer to 423 1 8 6782 Nylock Nut 5 16 18 39 77139 Medium Pressure Filter 9 102121 Clamp 1 875 inches 2 Assembly 4 222 2 1 60857 Filter Element 3 micron 10 102109P Muffler Support Bracket 1 40 6019 Screw HHC 11 102009 Exhaust Pipe 1 3 8 16 1 25 inches 12 106486 Cat Monitor Air Sensor 1 44 5397 Flat Washer 5 16 inch 13 106178 Muffler 1 42 4828 Nylock Nut 3 8 16 14 Ref Engine Tray refer to 423 1 43 89596 Medium Pressure Filter Bracket 1 15 102104 Air Intake Hose
138. e 09 15 SWITCH DRIVE ENABLE 14 gt GROUND DRIVE CONTROL LIGHTS e 0 x PLATFORM A i overvony 29 ALARM HYDRAULIC T 7 PACKAGE GENERATOR 11 12 WELDER Kat c ENGINE Q9 Goen AUX A 7 POWER UNIT BATTERY A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 10 10 Part 73480 102033 89673 89067 89666 89677 89983 89651 89650 30892 89631 89661 89942 111026 89660 89999 Description Qty Work Light Harness Assembly option 1 Jib Manifold Harness Assembly 5 45 1 Platform Control Box Harness Assembly 1 Platform Joystick Harness Assembly 1 Jib Kit Harness Assembly 4 1 Ground Control Box Harness Assembly 1 Positive Battery Cable Assembly Battery to APU 1 Positive Battery Cable Assembly Diesel models 1 Positive Battery Cable Assembly Ford models Negative Battery Cable Assembly Diesel models and Ford models before serial number 7597 1 Negative Battery Cable Assembly Ford models after serial number 7596 Engine Harness Assembly Perkins models before serial number 7472 1 Engine Harness Assembly
139. eer Axle after serial number 7568 Rev B Description Qty Tire and Wheel Assembly Non marking Right Side 1 Tire and Wheel Assembly Non marking Left Side Tire and Wheel Assembly Non marking with Sealant Right Side Tire and Wheel Assembly Non marking with Sealant Left Side Tire and Wheel Assembly Non marking Foam filled Right Side Tire and Wheel Assembly Non marking Foam filled Left Side Screw HHC 5 8 11 x 2 25 inches GR 8 12 Hardened Flat Washer 5 8 12 Drive Hub 57 1 2 Gearbox Seal Kit Wheel Stud Drive Hub Cover Disconnect Rod Disengage Cap End Cover O ring Brake Lining Kit Brake Seal Kit Bearing Kit O ring Viton 2 010 2 O ring Viton 2 158 2 Drive Motor brake includes items 18 19 2 Seal Kit Screw HHC 7 16 14 1 25 inches GR 5 Hardened Flat Washer DAT EE A Spring Clip Nut 1 4 20 8 Non steer Axle Cover 2 Screw HHC 1 4 20 x 0 75 inch GR 5 This list continues on the next page Part No 89721 A TEREX COMPANY 5 40 5 45 sis Components October 2006 200 Drive Chas Es 5 KR E 2 c amp 2 lt D 9 2 5 2 Q an N ow oi P
140. el Assembly Wide Foam filled Left Side Screw HHC 5 8 11 x inches GR 8 12 Flat Washer 0 688 x 1 16 x 0 09 inch Drive Hub 35 1 2 Seal Kit Wheel Stud 5 8 18 Bearing and Race Kit End Cover Drive Hub End Cover O ring included in seal kit part number 21142 Washer Cap Cover Disconnect Rod Actuator Disconnect Rod End Cover Domed Spindle Torque Hub October 2006 4WD Non steer Axle before serial number 7569 Description 200 Drive Chassis Components Rev E Figure 207 1 Part 89721 5 40 5 45 October 2006 200 e Drive Chassis Components 207 1 4WD Non steer Axle before serial number 7569 Rev E Part Description Qty 19 73897 Ausco Brake includes item 18 2 77240 Seal Kit 77239 Lining Kit 65608 Bearing Kit 20 22811 2 21 41398 Drive Motor includes item 19 2 E 32680 Seal Kit 22 73858 Screw SHC 1 2 13 x 5 inches GR 5 23 13066 Hardened Flat Washer Me 4 24 25969 Spring Clip Nut 1 4 20 8 25 30802 S Non steer Axle Cover 2 26 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 27 6356 Lock Washer 4 inch 28 6638 Flat Washer 1 4 inch 29 30690 Axle Rotation Stop Bar oscillating models 2 30691 Axle
141. er 11066 Description Rev A Figure 419 1 October 2006 400 Engine Components 419 1 Ford DSG 423 EFI Engine View 1 after serial number 11066 Rev A Part Description Qty 119472 Engine Harness with Relay Block 1 119135 LPG Mixer saaan 1 119500 Mixer Gasket 119547 O ring Smoothed 119548 O ring Ribbed 2 119142 Mixer Throttle Body Adapter 1 119466 Adapter Gasket 3 119498 Knock Sensor 1 4 119551 Thermostat Housing 1 5 119476 Upper Idler Pulley 1 119477 Idler Pulley Bracket 6 119479 Fuel 8010 4 7 119478 Ignition Coil 4 8 119467 Spark Plug 4 119495 Spark Plugs pack of four 9 119480 Cylinder Head Temperature i o d 1 10 119497 Cam Position Sensor 1 11 119461 Coolant Housing 1 12 119482 Coolant Bypass Hose 1 13 119465 Flywheel Assembly with Ring 1 14 119481 Oil Pressure Switch 1 15 119139 Oil Filter uet 1 16 119137 Starter uu t ease 1 17 119545 Intake Manifold 1 119585 Vacuum Cap 5 16 inch High Temp 119586 Vacuum Cap 5 8 inch High Temp 119568 Spring Clamp 1 2 inch 18 119475 Map Sensor
142. er Mount nsee 1 10 32 x 1 25 inches 44 6019 Screw HHC 16 6146 Flat Washer 10 E inches CRUS 17 5365 Nylock Nut 10 24 09 6888 TA EE ene Sien SE 46 102068 Megajector Mount 1 19 49408 Lock Washer M8 UM n SE Gate 20 53821P Map Sensor Bracket 1 48 49407 Lock Washer M6 2 a SE E 1 49 70527 FuelMegajector 1 106491 Megajector Jumper Harness 22 89917P Air Cleaner Mount Plate 1 50 102013P Radiator Support Mount 1 St rem Serew HHC i 8 1 25 x 70mm GR 8 8 24 6782 Nylock Nut 5 16 18 52 49408 Lock Washer M8 59 EE EE SAMD 1 53 4898 Air Filter Isolator v v 1 1 111111111 2 e EE Munt 1 54 E 1 27 25548 Screw HHC 70489 Fan Spacer 55 1011280 Inboard Muffler Clamp 1 SX SE ER 56 6833 Clamp 1 See SE aa 57 19872 Lock Washer 5 Part No 89721 5 40 5 45 October 2006 400 Engine Components Ford LRG 425 EFI Engine View 3 from serial number 7597 to 11066 Description Rev E Figure 418 1 AN 3 gt P 48 gt 6 Ee 4 CJ OCO GGG 96 999 262729 278228131 5 40 5 45 G Part No 89721 October 2006 400 Engine Components Ford LRG 425 EFI Engine View 3
143. g 1 x 1 25 x 1 inch LE A RE 1 Bearing 1 25 1 5 1 inch 5 45 500 e Boom Components October 2006 Figure Rev Description 502 1 B Boom Assembly S 40 BO QOS 5 40 5 45 89721 October 2006 500 e Boom Components Part No Description Qty 1 10597 Screw HHC 24 1 2 13 1 25 inches GR 5 25 2 6033 Lock Washer 1 2 inch 26 3 30418 Rod End 0 5 x 4 inches 1 4 30731 Pivot Pin 16 x 1 5 inches 1 27 5 30738 Bearing 1 5 x 2 x 1 5 inches 2 6 30730 Pivot Pin 9 54 x 1 inch 1 7 30748 Flat Washer 7 1 01 0 062 1 63 8 44662 External Snap Ring 1 inch 6 102143 Primary Boom Tube Assembly includes item 5 1 25817 Bearing 1 x 1 25 x 1 inch 10 6175 Screw HHC 3 8 16 x 1 inch GR 5 11 6021 Lock Washer 3 8 inch 12 6097 Flat Washer 3 8 inch 13 29080 Wear Pad Shim 5 1 5 0 0635 inch as needed 14 30138 Wear Pad 5 x 1 5 x 0 63 inch 12 15 38620 Wear Pad Shim 1 5 5 0 075 inch as needed 16 30741 Wear Pad 6 5 x 5 0 75 inch 2 17 30472 Wear Pad Shim 6 5 x 5 x 0 059 inch as needed 18 30581 Wear Pad 3975X 1 19 6091 Nut 1 4 20 20 6638 Flat Washer 1 4 inch 21 6637 Screw HHC 1 4 20
144. gine Components DO 9 9 E d 4 Vu E y 27 AG C V M eS e Perkins 404 22 Engine View 3 after serial number 7471 Description Rev E Figure 407 1 24 Part No 89721 5 40 5 45 G October 2006 400 Engine Components 407 1 Perkins 404 22 Engine View 3 after serial number 7471 Rev E Description Qty 1 77476 Thermostat Housing 1 2 Ref Battery refer to 423 1 3 8170 Wing Nut 1 4 20 2 6638 Flat Washer 1 4 inch 45704 Threaded Rod 10 inches 4 30144 Battery Hold Down 1 5 72335 Starter ae 1 9 Starter Solenoid 6 89762 Alternator Bracket 1 7 54687 Screw HHC M14 1 5 x 40 mm GR 8 8 8 37505 Lock Washer M14 9 49411 Flat Washer M14 10 88987P Inboard Engine Mount 1 11 72342 Alternator 13 8V DC 55 A before serial number 9559 1 111029 Alternator 13 8V DC 65 A after serial number 9558 12 89763 Water PUMP 1 77482 Water Pump Pulley 13 89764 Water Pump Hose 1 14 6198 Nylock Nut 1 2 13 15 39479 Screw HHC 1 2 13 x 2 75 inches GR 5 16 70452 Engine Vibration Isolator 4 17 80150 Flat Washer 1 2 inch 18 102066P Cast Washer 19 6097 Flat Washer 3 8 i
145. gine Tray refer to 423 1 15 89527 Inboard Engine Mount 1 16 89528 Outboard Engine Mount 1 A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 400 Engine Components Deutz 1011F Engine View 2 before serial number 7544 Description B Figure 409 1 8 6 9 enie G 5 40 5 45 Part No 89721 October 2006 400 Engine Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 34551 44064 22700 6097 6037 6886 5397 16584 30674 5 30438 32695 29559 52353 49919 49921 49929 49517 49135 3389 5 48884 45209 6090 6356 29883 6036 13064 49917 33024 37003 30806 6096 Deutz 1011 Engine View 2 before serial number 7544 Description Qty Exhaust Pipe 1 Screw M10 1 5 x 30 mm 8 8 Lock Washer M10 Flat Washer 3 8 inch Nut 5 16 18 Lock Washer 5 16 inch Flat Washer 5 16 inch U bolt 5 16 18 x 2 5 inches 1 Exhaust Pipe Support Bracket 1 Muffler Clamp 2 125 inches 1 1 Exhaust Gasket 3 Engine Side Cover 1 Fuel 8010 1 Injector Fuel Line
146. gure Rev Description 206 1 0 AWD Steer Axle Wheels and Hubs S 40 S 45 Part No 89721 October 2006 200 e Drive Chassis Components Part No Description Qty 1 6090 Screw HHC 8 73204 1 4 20 x 0 75 inch GR 5 2 6356 Lock Washer 1 4 inch 73205 3 6638 Flat Washer 1 4 inch 4 102278 Steer End Cover 1 111452 5 25969 Spring Clip Nut 1 4 20 6 73196 Wheel 16 5 x 9 75 9 hole 2 111454 73492 Wheel 15 13 9 hole 004 Wheel 19 5 14 9 hole 7 54627 Lug Nut 5 8 18 90 18 102802 8 81489 Tire 12 16 5 8 2 73212 Tire 12 16 5 12 Ply E 102803 Non marking 73925 Tire 33 16LL 500 10 Ply Sand Tire High Flotation 73493 Tire 31 15 50 15 8Ply Wide 8 73490 8 81008 Tire Wheel Assembly 73491 Air filled Right 566 1 81009 Tire and Wheel Assembly Air filled Left Side 8 73923 111449 Tire Wheel Assembly Air filled with Sealant 9 45553 Right Side 111450 Tire Wheel Assembly 21142 Air filled with Sealant 0 21149 Side 21143 81492 Tire Wheel Assembly 21147 Foam filled Right Side gt 37097 81493 Tire and Wheel Assembly Foam filled Left Side E 21148 21146 72283 21144 21145 101584 106119 106120 106121 106122 106123 106124 106125 1061
147. h 1 LPG Tank 33 5 Ibs 1 LPG Hose Assembly before serial number 7401 1 LPG Hose Assembly after serial number 7400 800 Accessories October 2006 Figure Rev Description 809 1 B Hydraulic Hoses and Fittings Generator LEGEND FITTING HOSE ASSEMBLY O Firer N37 H gt HYDRAULIC X TANK 1 GENERATOR 6 8 GENERATOR E P SELECT MANIFOLD f VALVE een Mel 13 H TO Gs gt LIFT Ad AN 2 x PRESS K47 4 EXTEND P1 51 PL1 PR1 V 9 9 19 19 39 RETRACT P2 52 2 2 FUNCTION MANIFOLD SEC 22 23 Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 800 Accessories 809 1 Hydraulic Hoses and Fittings Generator Rev B Part Description Qty Part No Description Qty 49613 Plug and Cap Kit 21 48912 el le BEE 1 for ORFS fittings 49612 O ring Kit 22 48930 Fitting WEE 1 services ORFS fittings 23 49117 3391 Hose Assembly Components T Genie part numbers 48802 1 48986 Fitting I 8900 SE 48800 and 48751 32 inches 1 2 49512 EE 1 3 49515 ostentum 2 4 48964 n san AE 2 5 49142 7062 Hose Assembly Components Genie part
148. h erh 1 28 52580 Serpentine Belt 1 3 81631 Non conducting Low Pressure 29 52078 Water Pump Pulley 1 LPG Hose 5 8 inch I D 31 inches 30 52077 Fan 1 4 30966 0150 Air Intake LPG Hose 2 25 x 1 5 1 1 1 52076 1 5 30966 0575 Air Intake Hose 32 32309 Screw HHC 2 25 x 5 75 inches 1 M8 1 25 x 60 mm GR 8 8 6 45435 Clamp 2 5 4 33 49408 Lock Washer 8 7 27211 0250 Air Intake Hose 34 33963 Water Pump 1 2 625 x 2 5 inches 1 35 33964 Water Pump Gasket 1 8 88455 Throttle Actuator Adapter 1 36 33960 Alternator 13 8V DC 95 A 1 9 88451 Electronic Throttle Position 37 65454 Flange Bolt M6 x 22 mm 2 Sensor Governor 1 88452 Actuator Throttle Gasket 38 52573 Thermostat Housing 1 10 88453 Adapter Plate Gasket 1 39 36208 Clamp 1 25 inches 1 11 23057 Screw HHC 40 52762 Water Inlet Hose 1 M8 1 25 x 20 mm GR 8 8 41 22672 Clamp 1 75 1 12 49408 Lock Washer M8 42 33965 Upper Radiator Hose 1 13 49817 Screw 43 33972 Coolant Tem
149. hes di WW 5 45226 Rod End 0 375 x 3 25 inches 9 6 8516 Screw HHC 23 3 8 16 1 5 inches GR 5 7 4828 Nylock Nut 3 8 16 24 8 34266 Pivot Pin 9 5 x 1 25 inches 9 89801 Bellcrank Assembly with Bearings includes item 10 1 10 35675 Flange Bearing m 1 25 x 1 5 x 1 25 inches 6 25 11 6021 Lock Washer 5 8 inch 26 12 34239 Pivot Pin 7 88 x 1 25 inches 2 13 34241 Pivot Pin 7 x 1 25 inches 1 14 61306 Leveling Arm Tank Side ue 15 60789 Leveling Arm Engine Side 1 27 16 89642P Hose 1 28 17 6326 Screw HHC 3 8 16 x 3 inches GR 5 29 18 5397 Flat Washer 5 16 inch 30 19 32339 Rubber Cushioned Clamp 1 34 20 30219 Bearing 1 25 x 1 41 x 1 inch 32 before serial number 8183 4 30370 Bearing 1 25 1 5 1 inch after serial number 8182 ER 21 13852 Bleed Valve Assembly 34 before serial number 8183 2 88516 Bleed Valve Assembly after serial number 8182 Part No 89721 5 40 5 45 506 1 Jib Boom Platform Rotator 5 45 Rev Part 94397 62417 94442 106421 75395 25683 63213 63353 33428 43018 81175 63210 63350 77303 30187 5224 3 75016 60933 6145 6638 Ref Description Platform Rotator includes items 20 and 21 1 Seal Kit before serial number 8
150. ide Foam filled Left Side This list continues on the next page October 2006 200 e Drive Chassis Components after serial number 7568 Descriptio B 4WD Non steer Axle Rev Figure 207 2 Part No 89721 S 40 5 45 October 2006 200 e Drive Chassis Components 207 2 4WD Non steer Axle after serial number 7568 Rev B Item Part No Description Qty Part No Description Qty 15 73455 Screw HHC 34 6021 Lock Washer 3 8 inch B Je 11 x 2 25 inches GR 8 12 35 89803 Cover 16 13064 Hardened Flat Washer with Decals 1 5 8 EE 12 17 101584 Drive Hub 57 1 2 106119 Gearbox Seal Kit 106120 Wheel Stud 106121 Disconnect Rod 106122 Disengage Cap 106123 End Cover O ring 106124 Brake Lining Kit 106125 Brake Seal Kit 106126 Bearing Kit 18 106117 O ring Viton 2 010 2 19 106118 O ring Viton 2 158 2 20 101587 Drive Motor LC30cc includes items 18 and 19 2 106098 Seal Kit 21 88296 Screw HHC 7 16 14x 1 25 inches GR 5 22 106134 Hardened Flat Washer 4 23 25969 Spring Clip 1 4 20 8 24 30802 Non steer Axle Cover 2 25 6090 Screw HHC 1 4 20 0 75 inch GR 5 26 6356 Lock Washer 4 inch 27 6638 Flat Washer 1 4 inch 28 30690 Axle R
151. ine Side Rev Description Qty Shroud Support Gasoline LPG models 1 Screw HHC 1 4 20 x 1 75 inches GR 5 Gas Strut with Retaining Spring 1 Retaining Spring Nylock Nut 5 16 18 Ball Stud 5 16 18 2 Engine Side Bulkhead Front 1 Engine Side Bulkhead Rear 1 Screw HHC 3 8 16 1 25 inches GR 5 Lock Washer 3 8 inch Flat Washer 3 8 inch Spring Clip Nut 3 8 16 6 Latch Plate before serial number 10974 1 Latch Plate after serial number 10973 Screw HHC 5 16 18 1 inch GR 5 Flat Washer 5 16 inch Nylock Nut 5 16 18 Rubber Bumper with Stud before serial number 10974 1 Rubber Bumper with Stud after serial number 10973 Rubber Bumper with Stud before serial number 10974 1 Rubber Bumper with Stud after serial number 10973 Hinge Mount Bracket 2 Screw HHC 1 4 20 x 1 inch GR 5 Lock Washer 1 4 inch Turntable Cover Hinge 2 Screw HHC 3 8 16 x 0 75 inch GR 5 300 e Turntable Components October 2006 Figure Rev Description 310 1 D Turntable Covers View 3 20000 2 QOC A TEREX COMPANY S 40 5 45 89721 October 2006 300 e Turntable Components 310 1 Turntable Covers View 3 Rev D Item Part No Description Q
152. iner Valve Flow Divider Combiner Valve Orifice Plug 0 070 inch Orifice Plug 0 070 Shuttle Valve 3 position way Diagnostic Nipple 4 SAE Female Quick Disconnect for Pressure Gauge Cap Diagnostic Nipple Flow Divider Combiner Valve Relief Valve 210 psi 14 5 bar Orifice Plug 0 052 Part No 89721 Letter 702 1 Traction Manifold before serial number 7569 Rev B Function Charge pressure circuit Controls flow to drive motors in forward and reverse Equalizes flow across flow divider combiner valve FB Charge pressure hot oil shuttle Testing Controls flow to steer end drive motors in forward and reverse Controls flow to non steer end drive motors in forward and reverse Rear drive motor circuit Equalizes pressure on both sides of flow divider combiner valve 12 HG Charge pressure hot oil shuttle Testing Controls flow to flow divider combiner valves 6 and 7 HA and HB Charge pressure circuit Front drive motor circuit A TEREX COMPANY 700 e Hydraulic Components October 2006 Figure Rev Description 702 2 B Traction Manifold after serial number 7568 lt 20 19 JM 18 JL JK 17
153. k 82767 82588 or Side 82283 p V Or 114099 reed 52966 or 32700 92967 or 97890 27204 y xe 27206 T L 2007 Lade 7 or28235 Drive E H 28176 27207 5 28165 27206 LEI 30080 44981 Platform or 62073 0 97887 62075 Shading indicates is hidden from 62959 62072 or view i e under covers or 62960 62074 31060 7 97602 H 49741 5 al or 53037 82243 hm or BG 40434 H EC or 97548 L Cen ES or 87571 Engine 7 EN or 114169 35599 Side gt d or 35599 114277 28181 98174 27564 32719 82588 114099 82588 32719 28161 28177 or 28235 28160 72847 or 82629 28164 or 82629 72847 28175 119589 Genie A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 100 Decals 101 1 Decals with Words Rev Item Part No Description Qty Part No Description Qty 34 52966 Cosmetic 4 x 2 1 1 82469 Platform Control Panel before serial number 7182 1 35 52967 Cosmetic 4 x 4 1 89836 Clear Protector 36 53037 Notice Engine Specifications 82242 Label Fuel Select Patch Deutz F3L 1011 Ford models before serial number 7544 1 82767 Platform Control Panel 97548 Notice Engine Specifications after serial number 7181 Deutz 2011 89836 Clear Protector after serial number 7549 52 114277 Label Belt Routing 37 62074
154. k Side after serial number 10973 after serial number 9752 E 102138 Turntable Cover with 30 74496P Hinge Mount Bracket 2 Symbol Decals Tank Side 31 6356 Lock Washer 1 4 inch after serial number 7189 10 6888 Screw HHC 14 20 1 inch GR 5 1 75073 Turntable Cover Hinge s a 2 12 49532 S Turntable Cover Support Tank Side KENNEN dee 1 13 49535P Latch Plate before serial number 10974 1 mE 111583 Latch Plate after serial number 10973 14 30973 Rubber Bumper with Stud before serial number 10974 1 111580 Rubber Bumper with Stud after serial number 10973 15 5397 Flat Washer 5 16 inch 16 6782 Nylock Nut 5 16 18 17 28646 Fitting BE 1 18 48885 1 Part 89721 5 40 5 45 300 Turntable Components October 2006 Turntable Covers View 2 Engine Side Description Rev D 300 Turntable Components Figure 309 1 Part 89721 October 2006 300 e Turntable Components 10 10 11 12 53078P 63400P 53079P 89913P 89929P 89912P 53903 52293 8915 12906 6638 6091 49816 6146 6178 65478 65479 102139 102140 53882 102740 49537P Description Qty Air Baffle Plate Ford models before serial number 7597 Air Baffle Plate Perkins models befo
155. l Serial Number 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 100 Decals October 2006 Figure Rev Description 102 1 F Decals with Symbols 82195or 82924 82487 82544 Serial 82472 28174 44981 82581 Plate 82247 or 28235 28171 82588 28158 or 82629 28159 82586 5 or 82587 40434 82472 i 1 Ge Sr ES Dm 114099 Ge 82767 52966 or or 82469 52967 27204 E 27206 82487 27207 T 28174 A 28235 Drive 97815 27207 Chassis 27206 RG 82545 27205 x r 44981 Platform 82602 62073 or or 82604 62075 Shading indicates decal is hidden from view i e under covers 62959 7 or 62960 40434 82544 E E I E ngine at 114277 Side 82473 82586 or 82588 or 28160 82587 62072 or 28174 or 82548 62074 28235 82629 82544 114099 82588 82586 or or 82629 82587 2 A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 100 Decals 102 1 Decals with Symbols Rev Item Part No Description Qty Part No Description Qty 102149 Decal Kit Safety Instructional 24 82767 Platform Control Panel includes items 1 11 24 30 32 after serial number 7181 1 and 34 37 89836 Clear Protector 1 27204 Arrow Blue sues 1 25 82472 Warning Crushing Hazard 3 2
156. latform Assembly 89335 6 Foot Platform Assembly 89337 8 Foot Platform Assembly Australian models 89746 4 Foot Platform Assembly mE 89747 5 Foot Platform Assembly 89748 6 Foot Platform Assembly 89749 8 Foot Platform Assembly after serial number 9752 USA and Canadian models 111234 4 Foot Platform Assembly 111235 5 Foot Platform Assembly 111236 6 Foot Platform Assembly 111237 8 Foot Platform Assembly Australian models 111238 4 Foot Platform Assembly 111239 5 Foot Platform Assembly 111240 6 Foot Platform Assembly 111241 8 Foot Platform Assembly Platform Assemblies with Symbol Decals European models 89744 4 Foot Platform Assembly 89745 5 Foot Platform Assembly 89336 6 Foot Platform Assembly 89338 8 Foot Platform Assembly Asian and South American models 89750 4 Foot Platform Assembly 89751 5 Foot Platform Assembly 89752 6 Foot Platform Assembly 89753 8 Foot Platform Assembly 1 6090 Screw HHC 1 4 20 0 75 inch GR 5 2 6638 Flat Washer 1 4 inch 6091 Nylock Nut 1 4 20 4 53517 Rubber Grommet 0 5 x 014 2 5 8915 Screw HHC 1 4 20 1 25 inches GR 5 6 6356 Lock Washer 1 4 inch A TEREX Part No 89721 S 40 5 45 Part 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 MPANY 73931 63766 73587 6607 73575 73233 7056 134
157. mbly with Decals Australian models 17 107707 6 Foot Platform Tri Entry Railing Assembly with Decals 107708 8 Foot Platform Tri Entry Railing Assembly with Decals Asia and South American models 17 107709 6 Foot Platform Tri Entry Railing Assembly with Decals 107710 8 Foot Platform Railing Assembly with Decals 18 88904 Work Light 110V AC 150W Halogen includes items 21 23 2 19 35958 Housing Work Light 2 35960 Work Light 12V DC 20 6036 Lock Washer 5 8 inch 21 35956 Work Light Mount Bracket 2 22 6145 Screw HHC 1 4 20 x 1 5 inches 23 6356 Lock Washer 4 inch A TEREX COMPANY Part No 89721 S 40 5 45 800 Accessories October 2006 Figure Rev Description 803 1 C Ground and Platform Control Box Covers Options S 40 S 45 Part No 89721 October 2006 800 Accessories Item 10 11 12 13 14 15 16 Part No 88603 S 81702 5 88609 5 102854 54486 111526 60467 5 61625 60468 5 43392 34619 88608 102785 102676 88606 6889 6638 6090 49534 53189 102148 30468 Description Base and Platform Covers Option Complete Platform Control Box Cover before serial number 7080 Platform Control Box Cover from serial number 7080 to 7121 Pl
158. n 44 37 2 TANK A P TEST 6 37 LA ZA 8 AUX STi ST2 T2 FUNCTION MANIFOLD LS TEST PRESS 5 58 39 Genie A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 700 e Hydraulic Components 710 1 Hydraulic Hoses and Fittings Turntable Rev C Part Description Qty Part No Description Qty 22 48916 el le u a uuu ayuy 5 3 48963 Fitting 23 49130 4282 Assembly Components eet 48959 Fitting Genie part numbers 48812 after serial number 7994 48812 and 48753 41 inches T before serial number 7569 1 34 49152 6369 Hose Assembly Components 49119 4378 Genie part numbers 48800 Genie part numbers 48841 48800 and 48751 Q 42 inches 48842 and 48761 61 inches after serial number 7568 before serial number 7995 1 49152 4869 Hose Assembly Components Genie part numbers 48841 48842 and 48761 6 46 inches after serial number 7994 24 49117 4891 Hose Assembly Components Genie part numbers 48800 48802 and 48751 47 inches 1 25 48904 Fitting BEE 1 35 49151 7748 Hose Assembly Components 26 94374 5530 Hose Assembly Components Genie part numbers 48841 Genie part numbers 48841 48841 and 48761 75 inches 48846 and 94358 52 inches before serial number 7995 1 Ford models Perkins 704 30 49151 9248 Hose Assembly Components Deutz FAL 1011F 1 Genie pa
159. n Spacer u 72326 Bina Nut 0 718 x 0 526 x 0 219 inch 9 Ref Toggle Switch 13 8914 Screw HHC generator option 1 4 20 x 0 63 inch KEE 14 63566 Lock Washer 1 4 inch 1 56298 Red LED Light 12V DC 1 K drive indicator 15 6638 Flat Washer 1 4 inch 56848 Lock Retainer Washer 16 Ref Joystick Controller Multi axis 2 13037 5 Toggle Switch boom up down and engine start turntable left right SPDT 3 position Momentary 1 refer to 605 1 3 56457 S Toggle Switch 17 pde d D s Ge EE 1 engine idle slow fast m inclu dos MO Conc PDT 2 ition Maintained 1 Sekt REIS Metales 66816 Contact 4 56457 5 Toggle Switch 2 gasoline LPG 18 13037 S ee PDT 2 ition Maintained 1 5 SPDT 3 position Momentary 1 5 66812 Red Push Button with Base Mushroom Head 1 19 16397 5 on 212 94506 Push Button Base GC 9 Sei M t 1 includes contacts 66818 Contact 20 13037 5 Toggle Switch 96 jib boom up down 6 Ref Joystick Controller Multi axis ji bg drive steer refer to 605 1 SPDT 3 position Momentary 1 Ref Joystick Controller Single axis 21 42730 S Toggle Switch with Steer Rocker Switch auxiliary power option refer to 605 1 SPDT 2 position Momentary 1 7 45384 Black Plastic Plug 0 5 inch 22 56457 S Toggle Switch 56298 Red LED Light 12V DC drive speed select tilt alarm SPDT 2 p
160. nch 20 4828 Nylock Nut 5 8 16 21 24038 Vibration Isolator 4 22 6653 Clamp 1 88 inches 1 23 89765 V belt ite 1 24 77483 et 1 94886 Fan Spacer 25 72339 Water Temperature Switch before serial number 9559 1 111028 Water Temperature Switch after serial number 9558 A TEREX COMPANY Part No 89721 S 40 5 45 400 e Engine Components October 2006 Figure Rev Description 408 1 C Deutz F3L 1011F Engine View 1 before serial number 7544 S 40 S 45 Part No 89721 October 2006 400 Engine Components 408 1 Deutz 1011F Engine View 1 before serial number 7544 Rev Part Description Qty L Ref Engine Harness refer to 311 1 1 111343 Fan Guard Assembly with Word Decals 1 35498 Fan Guard Assembly 2 29555 Engine Pulley Cover 1 3 32698 0 1 4 35586 Alternator eese 1 5 37950 Sela E 1 6 49915 Starter Solenoid 1 7 89259 Screw HHC M14 x 2 x 55 mm GR 8 8 8 37505 Lock Washer M14 9 89529 Engine Mount 1 10 53909 Screw HHC 5 8 11 x 4 inches GR 8 4 11 33418 Plate Washer 5 8 x 2 25 x 0 187 inch 12 6024 Nylock Nut 5 8 11 13 28076 Shock Mount Red amp White 8 14 Ref En
161. nents Genie part numbers 48812 48816 and 48753 6 103 inches 2 13 48904 E esce 4 14 49117 1191 Hose Assembly Components Genie part numbers 48800 48802 and 48751 Q 10 inches 1 15 48915 Fitting The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 700 e Hydraulic Components October 2006 Figure Rev Description 712 1 B Hydraulic Hoses and Fittings Boom Components S 45 LEGEND FITTING 1 JIB BOOM Ale CYLINDER D ser 9 Bu ASSEMBLY Platform Rotator S 45 FUNCTION MANIFOLD Genie Coo 3 PR1 2 3 2 J1 3 LL 2 J2 Y Cox PR2 4 3 ill vi JIB r5 2 v2 BOOM O MANIFOLD 6 7 x r1 9 7 8 8 L 5 0 11 SLAVE MASTER CYLINDER CYLINDER 19 12 R BOOM EXTENSION el CYLINDER 4 14 15 g R BOOM LIFT 15 1 3 5 CYLINDER 52 16 TURNTABLE
162. nie part numbers 48841 48842 and 48761 61 inches before serial number 7995 1 49152 4869 Hose Assembly Components Genie part numbers 48841 48842 and 48761 46 inches after serial number 7994 7 49151 7748 Hose Assembly Components Genie part numbers 48841 48841 and 48761 75 inches before serial number 7995 1 49151 9248 Hose Assembly Components Genie part numbers 48841 48841 and 48761 90 inches after serial number 7994 8 48959 nieto estes 1 9 48960 Fitting Ee 1 10 89533 Mounting Plate Cooler 1 11 71259 Oil Cooler with Fan 12V DC 1 4 Fan Cooler 75855 Thermostat The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 800 Accessories October 2006 Figure Rev Description 816 1 B Hostile Environment Package View 1 Typical Bellows Installation A TEREX COMPANY S 40 5 45 89721 October 2006 800 Accessories 816 1 Hostile Environment Package View 1 Rev B Part Description Qty 111347 Standard Hostile Environmental Package S 40 1
163. nifold 9 2SPD 21 43 k OSCILLATE PUMP 69 ASSEMBLY IN AUXILIARY POWER UNIT OUT 227 g PAS 4 8 HYDRAULIC ROTARY COUPLER 9 69 OIL COOLER option 69 To T1 option option 44 37 2 TANK A P TEST 6 37 LA ZA 8 AUX STi ST2 T2 FUNCTION MANIFOLD LS TEST PRESS 5 58 39 Genie A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 700 e Hydraulic Components Part No 10 11 12 13 14 61263 89593 88441 1090 48935 48933 49143 2029 49143 2229 48946 48960 49143 2229 49143 2529 48977 48984 48922 49133 1990 49129 3025 49164 3043 Description FRUN BEE 1 Fitting suc dac 2 Hose Assembly Components Genie part numbers 88477 88474 and 88478 Q 7 5 NENES eius 1 een 2 el ul Le BE 3 Hose Assembly Components Genie part numbers 48822 48827 and 48756 18 inches Ford models Perkins 704 30 Deutz FAL 1011F 1 Hose Assembly Components Genie part numbers 48822 48827 and 48756 20 inches Deutz F3L 1011F 2 el ul Le BE 5 Hose Assembly Components Genie part numbers 48822 48827 and 48756 20 inches Ford models Perkins 704 30 Deutz F4L 1011F Deutz 2011
164. o Parker part numbers 700 e Hydraulic Components October 2006 Figure Rev Description 708 2 A Hydraulic Hoses and Fittings 4WD Drive and Steer System after serial number 7568 LEFT UN Ce RIGHT f O STEERING CYLINDER C E O STEERING CYLINDER O 1 2 2 T 2 x e LEFT 4 5 MS 4 A RIGHT STEER AXLE STEER AXLE DRMEMOTOR 6 7 7 DRIVE MOTOR ege 2800 MU N SNE SRK BRK ai 5 29 4 A i2 1 12 42 To Oscillate To Oscillate Valve in Valve out option option 1 33 FITTING gt HOSE ASSEMBLY 17 2 2 17 20 19 18 22 22 16 22 22 2 4 M6 fe A 16 4WD DRIVE MANIFOLD CDL M3 M1 M7 M5 CDR 22 22 22 22 22 22 24 2 a 2 28 LN 28 57 14 14 BRK 29 BRK 2SPD r 2 SPD LEFT RIGHT NON STEER 22 NON STEER DRIVE MOTOR DRIVE MOTOR 4 B A TEREX COMPANY io S 40 5 45 Part No 89721 October 2006 Part No 10 11 12 13 14 15 16 17 18 48915 48919 49130 2132 48948 49107 10213 48937 49141 7563 49128 5909 48935 48920 49117 5191 49117 8491 49143 4629 48905 48963 48960 49117 7641
165. om Components 501 1 Boom Lift and Master Leveling Cylinder Installation Rev E Description Qty Part No Ref Harness Angle Limit Switch 20 25817 refer to 311 1 1 Ref Primary Boom Tube Assembly 30370 refer to 502 1 or 503 1 30732 Pivot Pin 6 38 x 1 5 inches 1 3 6708 Screw HHC 3 8 16 x 2 25 inches GR5 4 6097 Flat Washer 3 8 inch 5 45226 Rod End 0 375 x 3 69 inches 4 6 45072 Bearing 1 5 x 1 65 x 1 5 inches 4 7 63206 Boom Lift Cylinder includes item 6 1 63346 Seal Kit 73806 Counterbalance Valve 3000 psi 206 8 bar 8 30662 S Lift Cylinder Mount 1 9 13004 Screw HHC 5 8 11 x inches GR 8 4 10 13064 Flat Washer 5 8 inch 11 6024 Nylock Nut 5 8 11 12 30733 Pivot Pin 7 75 x 1 5 inches 1 13 1505 Electrical Cord 16 Ga 2 Conductor 108 inches 14 88356 146R5 Limit Switch with Roller Head 1 19491 Contact 89757 Roller Arm 15 22541 Screw RHSM 10 32 x 1 5 inches 16 6607 Lock Washer 10 17 30734 Pivot Pin 2 88 x 1 inch 8740 ees eite eed 2 34276 Pivot Pin 3 25 x 1 25 inches S 45 18 8255 Screw HHC 38 16 0 75 inch GR 5 2 19 81692 Master Cylinder 5 40 1 75468 Kit 19 81694 Boom Master Cylinder 5 45 1 75470 Seal Kit Part No 89721 S 40 5 45 Description Bearin
166. on oscillate models before serial number 7319 89933 Drive Pump Assembly Non oscillate models after serial number 7318 89592 Drive Pump Assembly Oscillate models before serial number 7319 89932 Drive Pump Assembly Oscillate models after serial number 7318 1 53961 Function Pump Non oscillate 1 65912 Seal Kit 2 29436 O ring before serial number 7319 1 83141 O ring after serial number 7318 3 88048 Drive Pump before serial number 7319 1 29739 Seal Kit 49897 Gasket 3 89934 Drive Pump after serial number 7318 1 29739 Seal Kit 4 89858 Function Pump Oscillate 1 89859 Seal Kit A TEREX COMPANY Part No 89721 S 40 5 45 700 e Hydraulic Components October 2006 Figure Rev Description 707 1 B Hydraulic Hoses and Fittings 2WD Drive and Steer System before serial number 7569 LEFT E RIGHT e STEERING CYLINDER STEERING CYLINDER 1 1 2 2 4 4 LEGEND FITTING HOSE ASSEMBLY To Oscillate Valve in option To Oscillate Valve out option 12 12 12 Mi 2WD DRIVE MANIFOLD A B 12 T1 2 17 17 17 LEFT lt RIGHT p gt NON STEER DRIVE MOTOR 25 2 DRE MOTOR AND BRAKE
167. ons Rev E Part No Description Qty PartNo Description Qty 53808 5 Pinch Guard Option 6 Foot 1 9599 S Tool Tray 1 Platform Complete 53807 S Pinch Guard Option 8 Foot 2 P ii gl 6 DE E 1 Platform Complete 52661 inch Guard 8 foot 73433 S Swing Gate Option Complete 3 53803 Pinch Guard Support 34321 8 Work Light Option 1 25 inch tubing 10 12V DC Complete includes item 19 4 4266 Soe es Ref Work Light Wire Harness 4 20 x 2 inches refer to 311 1 5 6091 Nylock Nut 1 4 20 89540 Halogen Work Light Option 110 150W 6 55753 Cap Plug 1 187 inches 2 102720 European 10600810 Tri Entry 7 7265 Steel Rivet 0 25 x 0 375 inch 14 Option 8 Foot includes items 5 13 16 8 36870 S Swing Gate 1 The following is a list of complete Tri Entry platform 9 43392 Rubber Bumper Gate Stop 1 assemblies by region and then by size 10 1487 Gate Latch 1 USA and Canada models 11 33674 Snap Pinu 1 before serial number 9753 us 102433 6 Foot Platform 12 1488 Railing Catch Casting 1 Tri Entry Assembly 13 102721P Toeboard Tri Entry 8 foot 2 102437 8 Foot Platform Tri Entry Assembly 14 94745P Toeboard Tri Entry 8 foot 1 1 4 after serial number 9752 6090 z be 111302 6 Foot
168. ore serial number 7544 Freeze Plug Heater 110V 60Hz Perkins models before serial number 7472 1 Freeze Plug Heater 110V 60Hz Perkins models after serial number 7471 Freeze Plug Heater 110V 60Hz Gasoline LPG models 1 Spring Clip Nut 1 4 20 Deutz models before serial number 7544 2 Part No 89721 Item Part No 800 Accessories 807 1 Cold Start Package Rev B Description Qty Solenoid 12V Continuous Deutz models before serial number 7544 1 A TEREX COMPANY 800 Accessories October 2006 Figure Rev Description 808 1 G Generator and Second LPG Tank Options S 40 S 45 Part No 89721 October 2006 800 Accessories Description Qty Item 89606 2500W Generator Option 9 220V AC 50Hz 89605 3000W Generator Option 110V AC 60Hz 73963 LPG Tank Option 89628 Second LPG Carrier Option includes item 20 m before serial number 7401 9 102347 Second LPG Carrier Option includes item 20 after serial number 7400 1 89531 5 Second LP Tank Carrier Mount before serial number 7401 1 60143 5 Second LP Tank Carrier Mount after serial number 7400 2 8255 10 38 16 0 75 inch GR 5 11 3 6021 Lock Washer 3 8 inch 27378 S Toggle Switch 12 gener
169. ore serial number 9753 1 4 20 0 75 inch GR 5 26 77838 4 Foot Platform Railing 1 77840 5 Foot Platform Railing 11 75067 Screw PHPM 73975 6 Foot Platform Railing 6 32 x 0 875 inch 73976 8 Foot Platform Railing 12 74006 GFCI Weatherproof Cover after serial number 9752 includes mounting fasteners 1 6 111250 4 Foot Platform Railing 1 111251 5 Foot Platform Railing 13 SE EEN 111252 6 Foot Platform Railing 6 foot or 8 foot platform 1 0 EM 102679 Platform Mount 111253 8 Foot Platform Railing 4 foot or 5 foot platform European Railing Assembly with Decals 14 Ref Platform Rotator 26 101373 4 Foot Platform Railing 1 101376 5 Foot Platform Railing 101379 6 Foot Platform Railing 15 13585 Receptacle 110V AC 1 101382 8 Foot Platform Railing 33629 UK Power to Platform Plate 33724 Gasket Kit 0 26 101374 4 Foot Platform Railing 1 97906 SE 101377 5 Foot Platform Railing 16 10775 2 75 x 4 5 x 2 inches 1 101380 6 Foot Platform Railing 101383 8 Foot Platform Railing Australian Railing Assembly with Decals 17 7056 Squeeze Connector V2 inch NPT 1 This list continues on the next page A TEREX COMPANY Part No 89721 S 40 5 45 600 e Platform Components October 2006 Figure Rev Description 602 1 E Platform Installation View 2
170. ories October 2006 Figure Rev Description 811 1 D Panel Cradle A TEREX COMPANY S 40 5 45 89721 October 2006 800 Accessories 811 1 Panel Cradle Rev Description Qty 77683 S Panel Cradle 88377 1400 Foam Padding 3 5 x 1 25 x 14 inches 2 2 77664 Strap Assembly 1 3 7718 Low Profile Nylock Nut 3 8 16 4 5397 Flat Washer 5 16 inch 5 77576P Hook Secondary Support uitia euet 2 6 89724 Cradle Base Assembly with 1 7 56934 Rubber Bumper 4 8 6550 U bolt 3 8 16 1 5 x 2 5 x 1 25 inches 2 9 73463 1175 Aluminum Tube 1 25 x 0 083 x 11 75 inches 2 10 8914 Screw HHC 1 4 20 x 0 63 inch GR 5 11 6638 Flat Washer 1 4 inch 12 6889 Low Profile Nylock Nut 4 20 13 56424 Rubber Cushioned Clamp 1 25 x 0 5 inch Genie A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 812 1 B Welder Option Chassis Components View 1 5 40 5 45 Part 89721 October 2006 10 11 12 13 14 15 16 17 Part 106115 1
171. ort with Bearings includes item 8 2 16 94549 Limit Switch 1 17 4266 Screw HHC 1 4 20 2 inches GR 5 18 6638 Flat Washer 1 4 inch 19 61972 Limit Switch Mount 1 20 34619 Rubber Bumper 2 21 80605 Flat Washer 0 375 x 1 5 x 0 125 inch Genie A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 800 Accessories Rev Description Figure 805 1 Platform Half Mesh and Pipe Cradle 0 2 TIMI enie G A TEREX COMPANY 5 40 5 45 Part 89721 October 2006 800 Accessories 805 1 Platform Half Mesh and Pipe Cradle Rev Item Part No Description Qty 85300 Pipe Cradle Option with Decal 72875 Decal Warning Pipe Cradle 73956 5 6 foot Half mesh Complete 73958 5 8 foot Half mesh Complete Swing Gate Option Complete refer to 802 1 1 56570 Pipe Cradle Strap 1 2 6884 Screw HHC 1 4 20 x 2 5 inches GR 5 3 6638 Flat Washer 1 4 inch 4 6889 Low Profile Nylock Nut 1 4 20 5 73500 Half mesh Right Side 8 Foot 1 54465 Half mesh Right Side 6 Foot 6 54457 Half mesh Swing Gate 1 7 73501 Half mesh Left Side 8 Foot 1 54458 Half mesh Left Side 6 Foot 8 56424 Clamp 1 25 x 0 5
172. ose Assembly Components Genie part numbers 48841 48846 and 94358 48 inches 2 12 102312 2388 Hose Assembly Components Genie part numbers 48841 102311 and 94358 2 ien E 1 13 49143 7529 Hose Assembly Components Genie part numbers 48822 48827 and 48756 6 73 inches 1 14 48938 1 15 48948 uite tret mco 1 16 48958 Fitting ono ce 2 The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers Part No 89721 800 Accessories October 2006 Figure Rev Description 815 1 B Hydraulic Oil Cooler Option LEGEND A ADAPTER gt HOSE ASSEMBLY m 2 o rier 6 m x OIL COOLER FUNCTION MANIFOLD A TEREX COMPANY S 40 5 45 89721 October 2006 800 Accessories 815 1 Hydraulic Oil Cooler Option Rev B Part Description Qty 89604 S Oil Cooler Option before serial number 7995 111351 Oil Cooler Option after serial number 7994 1 6175 Screw HHC 3 8 16 x 1 inch GR 5 2 6021 Lock Washer 3 8 inch 3 6097 Flat Washer 3 8 inch 4 4828 Nylock Nut 3 8 16 5 48963 Fitting before serial number 7995 2 48959 Fitting after serial number 7994 6 49152 6369 Hose Assembly Components Ge
173. ose Hump inches to 4 inches 1 14 34955 Hose Clamp 5 inches 15 88493 Air Intake Precleaner 1 16 101639 Rubber Cushioned Clamp 5 38 x 0 375 inch 17 4828 Nylock Nut 3 8 16 18 6097 Flat Washer 3 8 inch 19 6175 Screw HHC 388 16 x 1 inch GR 5 Genie A TEREX COMPANY Part No 89721 5 40 5 45 800 Accessories October 2006 Figure Rev Description 818 1 D Hostile Environment Package View 3 S 40 S 45 Part No 89721 October 2006 800 Accessories 818 1 Hostile Environment Package View 3 Rev D Part Description Qty 1 34949 Ring Gear Bracket 1 2 81062 Ring Guard Angle 4 3 6888 Screw HHC 1 4 20 x 1 inch GR 5 4 6638 Flat Washer 1 4 inch 5 6889 Nylock Nut 1 4 20 6 34952 Ring Gear Wiper 1 7 34855 Ring Guard Bracket 1 8 89647 Louver Panel Engine Side Rear nce eis 1 89646P Louver Panel Engine Side Front Ford models 89992P Louver Panel Engine Side Front Deutz models 102747 Louver Panel Engine Side Front Perkins models 102784P Louver Panel Engine Side Rear Perkins models 89645 Louver Panel Tank Side Rear 89644 Louver Panel Tank Side Front 9 56912 Spring Clip Nut 1 4 20 10 6090 Screw HHC 1 4 20 x 0 75 inch G
174. osition Maintained 1 8 45384 Black Plastic Plug 0 5 inch 1 3 13037 S Toggle Switch 56298 Red LED Light 12V DC glow plug option platform overload SPDT 3 position Momentary 1 9 13037 5 Toggle Switch drive enable SPDT 3 position Momentary 1 10 45384 Black Plastic Plug 0 5 inch 1 27378 5 Toggle Switch work drive light option DPDT 2 Position Maintained 1 Part No 89721 S 40 S 45 600 e Platform Components October 2006 Figure Rev Description 604 1 F Platform Control Box View 2 A TEREX COMPANY 5 40 5 45 Part No 89721 October 2006 600 Platform Components 604 1 Platform Control Box View 2 Rev Part Description Qty 1 81551 Screw PHM 6 32 x 0 375 inch 2 81550 Standoff 6 32 x 0 75 x 0 25 10 3 94771 Printed Circuit Board before serial number 7569 1 102259 Printed Circuit Board after serial number 7568 Ref Wire Harness and Power Cable Assemblies refer to 311 1 4 45385 Nylon Plug Black Domed 1 12 inches nes 2 7056 Squeeze Connector 1 2 inch NPT 6935 Electric Locknut 1 2 inch 5 60443 Receptacle Lock 4 Way 14 18 1 73723 Receptacle Connector 6 49820 Screw PHM 6 32 x 0 5 inch 7 12344 Nylock Nut 6 32 8 73717 Receptacle Connector 4 way 12 14 Q8 1 73711 Terminal 12 14 60526 Receptacle Lock 4 way 12 14 Ga 9 73803
175. otation Stop Bar oscillating models 2 30691 Axle Rotation Stop Bar non oscillating models 29 30808 Axle Rotation Stop Shim 9 5 x 1 5 x 0 108 inch as needed 30 30809 Axle Rotation Stop Shim 9 5 x 1 5 x 0 034 inch as needed 31 30735 Pivot Pin 17 5 x 1 5 inches 1 32 45226 Rod End 0 375 x 3 69 inches 1 33 6175 Screw HHC 38 16 x 1 inch GR 5 A TEREX COMPANY Part No 89721 S 40 5 45 200 e Drive Chassis Components October 2006 Figure 208 1 Rev B Description Oscillation Control Valve 2000 5 OO 1 e A TEREX COMPANY 5 40 5 45 89721 October 2006 200 e Drive Chassis Components 208 1 Oscillation Control Valve Rev 8 Part No Description Qty 49613 Plug and Cap Kit for ORFS fittings 49612 O ring Kit for ORFS fittings 1 4266 Screw HHC 1 4 20 x 2 inches 2 6091 Nylock Nut 1 4 20 3 81552 Manual Control Valve 950 psi 65 5 bar 1 32681 Seal Kit 4 30884 Oscillate Valve Linkage 2 5 21130 Clevis Yoke 1 4 28 includes clevis pin and cotter pin 1 6584 Shoulder Bolt 1 4 x 0 625 inch 7 81691 Linkage Rod 1 4 28 1 8 20980 Nylon Flat Washer 0 257 x 0 437 x 0 047 inch 9 6178 Nylock Nut 10 32 10 30785 275 Threaded Rod 1 4 28 x 2 75 inches 1
176. perature Sensor 1 10 32 x 1 25 inches 44 65456 Temperature Sending Unit 1 14 6178 Nylock Nut 10 32 45 33966 1 15 49898 Map Sensor 1 46 52575 Thermostat Housing Gasket 1 16 53821P Map Sensor Mount Bracket 1 47 49881 Oil Filler Cap 1 17 52570 Spark Plug Wire Set 1 48 33970 Ignition Coil 1 18 28647 Spark Plug ese 1 separately 19 52566 Dipstick a Rene 1 Genie A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 400 Engine Components 09 09 23 69 a e 69 Ford LRG 425 EFI Engine View 2 before serial number 7597 Description Rev B Figure 414 1 G A TEREX COMPANY Part No 89721 5 40 5 45 October 2006 Ford LRG 425 EFI Engine View 2 before serial number 7597 Item Part Description Qty 1 77296 Air Cleaner Bracket 1 8 2 88457 Engine Performance Module 1 29 3 6888 Screw HHC 1 4 20 x 1 inch 30 4 6356 Lock Washer 1 4 inch 31 5 6638 Flat Washer 1 4 inch 6 25969 Spring Clip Nut 1 4 20 32 7 8915 Screw HHC 1 4 20 x 1 25 inches GR 5 33 8 6091 Nylock Nut 1 4 20 34 9 54071 Coolant Return Tank with Hose 1 35 65864 before serial number 7172
177. ponents October 2006 Figure Rev Description 203 1 B 2WD Steer Axle Wheels and Hubs COO 5 40 5 45 89721 October 2006 200 e Drive Chassis Components 203 1 2WD Steer Axle Wheels and Hubs Rev B Item Part Description Qty Part No Description Qty 1 6090 Screw HHC 11 102088 Tire and Wheel Assembly 1 4 20 x 0 75 inch GR 5 Rough Terrain Non marking d Air filled Right Side 1 1 2 95258 Focke Vasto 102089 Tire Wheel Assembly 3 6638 Flat Washer 1 4 inch Rough Terrain Non marking Air filled Left Side 111455 Tire Wheel Assembly Rough Terrain Non marking 25969 Spring Clip Nut 1 4 20 Air filled with Sealant 102278 Steer End Cover Assembly with 7 1 Right Side us 111456 Tire and Wheel Assembly 1 8 x 6 inches GR 5 Rough Terrain Non marking 7 38859 Flat Washer 1 x 2 5 x 0 14 inch Air filled with Sealant Left Side 29104 Nylock Nut 1 8 102804 Tire and Wheel Assembly 9 73199 Wheel 16 x 10 inches 8 hole 2 Rough Terrain Non marking 73268 Wheel 16 5 x 9 75 inches Foam filled Right Side 8 hole 102805 Tire Wheel Assembly 2 Rough Terrain Non marking 10 54627 Lug Nut 5 8 18 90 16 Foam filled Left Side 11 73201 Industrial Tire 12 45111 Dust Cap EE 2 12 5 16SL 14 Ply 2 732
178. re serial number 7472 Air Baffle Plate Deutz models before serial number 7544 Air Baffle Plate Ford models after serial number 7596 Air Baffle Plate Perkins models after serial number 7471 Air Baffle Plate Deutz models after serial number 7543 Turntable Cover Latch 1 Latch Key Screw HHC 1 4 20 x 1 25 inches GR 5 Fender Washer 1 4 x 1 25 x 0 062 inch Flat Washer 4 inch Nylock Nut 4 20 Screw PHM 10 32 x 0 75 inch Flat Washer Plated 0 Nylock Nut 10 32 Turntable Cover with Word Decals Engine Side Gasoline LPG models 1 Turntable Cover with Word Decals Engine Side Diesel models Turntable Cover with Symbol Decals Engine Side Gasoline LPG models 1 Turntable Cover with Symbol Decals Engine Side Diesel models Turntable Cover Support Engine Side before serial number 1048 1 Turntable Cover Support Engine Side after serial number 1047 Air Baffle Gasoline LPG models 1 Part No 89721 A TEREX Part 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 MPANY 30894P 6637 28301 27377 6002 33555 89412 89415 6019 6021 6097 29868 49535P 111583 13002 5397 6782 30973 111580 36388 111663 74496P 6888 6356 75073 8255 309 1 Turntable Covers View 2 Eng
179. ring Kit services ORFS fittings Plug and Cap Kit for SAE ports Plug and Cap Kit for ORFS fittings Letter Harness Gearbox Function Manifold refer to 311 1 Flow Regulator Valve 0 8 gpm 3 03 L min COL YA ell aa Seal Kit Flow Regulator Valve 0 6 gpm 2 27 L min EE Kit Check Valve Seal Kit Solenoid Valve 2 position 3 way Coil 10V DC Coil Nut Seal Kit Check Valve Seal Kit Solenoid Valve 2 position 3 way Coil 10V DC Coil Nut Seal Kit Check Valve Differential Sensing Valve 150 psi 10 3 bar Seal Kit Differential Sensing Valve 150 psi 10 3 bar Seal Kit Relief Valve 2200 psi 152 bar Seal Kit Flow Regulator Valve 0 1 0 38 L min Seal kit Check Valve Seal Kit Relief Valve 1950 psi 134 bar Seal Kit This list continues on the next page Part No 89721 701 1 Function Manifold Rev F Function Platform rotate and jib boom Platform rotate Differential sensing circuit Platform rotate right and jib boom down S 45 Platform level up down Differential sensing circuit Platform level up Platform level up down Differential sensing circuit Boom up down Turntable rotate circuit Boom up down circuit System relief Bleeds off differential sensing valves to tank Differential sensing circuit Boom up down System relief A TEREX COMPANY October 200
180. rt numbers Part No 89721 October 2006 800 Accessories Description Rev Figure 807 1 Cold Start Package B Deutz Diesel Engine Perkins Diesel Engine Ww 6 Ford Gasoline LPG Engine 2 enie G 5 40 5 45 Part 89721 October 6 Part No 53156 53982 70361 53159 S 70360 1 28853 2 31408 3 27246 4 32726 5 13037 54692 6 70552 77382 6 35610 7 25969 Description Qty Cold Start Package 110V 60Hz 8 Ford models includes items 1 and 6 Cold Start Package 110V 60Hz Perkins 704 30 models includes items 1 and 6 before serial number 7472 Cold Start Package 110V 60Hz Perkins 404 22 models includes items 1 and 6 after serial number 7471 Cold Start Package 110V 60Hz Deutz 1011F models includes items 1 5 7 and 8 before serial number 7544 Cold Start Package 110V 60Hz Deutz 2011 models includes item 1 after serial number 7543 Battery Blanket 110V 6072 3 27155 Glow Plug Deutz models before serial number 7544 1 Rubber Boot Deutz models before serial number 7544 1 Glow Plug Decal Deutz models before serial number 7544 1 Toggle Switch SPDT 3 Position Momentary includes mounting fasteners Deutz models before serial number 7544 1 Nylon Spacer 0 718 x 0 526 x 0 219 inch bef
181. rt numbers 48841 94374 5930 Hose Assembly Components 48841 and 48761 90 inches Genie part numbers 48841 after serial number 7994 48846 and 94358 56 inches Deutz 1011F 27 48926 Fitting 36 48959 ae 1 37 49150 5230 Hose Assembly Components Genie part numbers 48841 deco serial number 7569 1 48846 and 48761 49 inches itting i after serial number 7568 2 Ford models Perkins 70430 Deutz F4L 1011F 28 94374 5230 Hose Assembly Components Deutz 2011 1 Genie part numbers 48841 49150 5630 Hose Assembly Components 48846 and 94358 49 inches Genie part numbers 48841 Ford models Perkins 704 30 48846 and 48761 53 inches Deutz FAL 1011F 1 Deutz F3L 1011F 94374 5530 Hose Assembly Components Genie part numbers 48841 48846 and 94358 52 inches Deutz F3L 1011F 38 49109 4129 Hose Assembly Components Genie part numbers 48822 48827 and 48758 39 inches Ford LRG 425 Perkins 704 30 29 49124 2228 Hose Assembly Components Deutz FAL 1011F Genie part numbers 48812 Deutz 2011 1 48813 and 48753 6 20 inches 1 49109 4929 Hose Assembly Components Genie part numbers 48822 48827 and 48758 Q 47 inches Deutz F3L 1011F 30 49130 4482 Hose Assembly Components Genie part numbers 48812 48812 and 48753 Q 43 inches 1 This list continues on the next page 31 4913
182. s after serial number 7318 Flat Washer 3 8 inch after serial number 7318 O ring refer to 706 1 Drive Pump refer to 706 1 Screw HHC 3 8 16 1 inch GR 5 2 Clamp 1 25 Imnches ssssssesnneeeneenn 2 Water Inlet Hose 1 FRING ceni ater etta 1 Fitting 1 Fire Resistant Hose 5 8 inch I D 30 inches Fitting o etae 1 LPG Shut off Solenoid Valve with Filter 12V DC 1 Nolff LPG Regulator 1 Fitting eae 1 Air Filter Bracket 1 Spring Clip Nut 1 4 20 2 Air Filter Element 1 Air Filter Assembly includes items 1 and 48 1 Air Filter Cap Plastic Hose Fitting Air Intake Hose 2 5 x 12 inches 1 Screw HHC 3 8 16 x 1 inch GR 5 Flat Washer 3 8 inch Nylock Nut 3 8 16 October 2006 400 Engine Components Ford LRG 425 EFI Engine View 3 before serial number 7597 Description Rev C Figure 415 1 enie G 5 40 S 45 89721 October 2006 400 Engine Components 415 1 Ford LRG 425 EFI Engine View 3 before serial number 7597 Rev C Description Qty Part No Description Qty
183. serial number 7568 708 1 A Hydraulic Hoses and Fittings 4WD Drive and Steer System before serial number 7569 708 2 A Hydraulic Hoses and Fittings 4WD Drive and Steer System after serial number 7568 709 1 A Hydraulic Hoses and Fittings Oscillate System 710 1 C Hydraulic Hoses and Fittings Turntable 711 1 B Hydraulic Hoses and Fittings Boom Components S 40 712 1 B Hydraulic Hoses and Fittings Boom Components S 45 713 1 A Hydraulic Hose and Fitting Cross reference S 40 5 45 Part 89721 October 2006 Table of Contents 800 e Accessories 801 1 D Alarm and Beacon Package Drive Light Option 8021 E Platform Options 8031 Ground Platform Control Box Covers Options 8041 C Platform Overload European Models 805 1 C Platform Half Mesh and Pipe Cradle 806 1 8 Line to Platform 8071 Cold Start Package 8081 Generator and Second LPG Tank Options 8091 Hydraulic Fittings Generator 8101 Option 811 1 D Panel Cradle 812 1 B Welder Option Chassis Components View 1 8131 D Welder Option Platform Components View 2 8141 B Hoses and Fittings Welder 8151 Hydraulic Oil Cooler Option 8161 B Hostile Environment Package View 1 817 1 B Hostile Environment Package View 2 818 1 D Hostile Environment Package View 3 819 1 B Hostile Environment Package View 4 8201 B Hostile Environment Package View 5 A TERE
184. ssembly Foam filled Left Side Part No 73204 73205 111453 111454 102802 102803 13004 56911 20193 21142 21149 21143 58328 37097 21148 21146 21144 21145 72283 41252 41912 77240 77239 65608 22811 41398 32680 204 1 2WD Non steer Axle before serial number 7569 Rev D Description Qty Tire and Wheel Assembly Non marking Right Side 1 Tire and Wheel Assembly Non marking Left Side Tire and Wheel Assembly Non marking with Sealant Right Side Tire and Wheel Assembly Non marking with Sealant Left Side Tire and Wheel Assembly Non marking Foam filled Right Side Tire and Wheel Assembly Non marking Foam filled Left Side Screw HHC 5 8 11 x 3 inches GR 8 12 Flat Washer 5 8 inch Drive Hub 35 1 2 Seal Kit Wheel Stud 5 8 18 Bearing and Race Kit Drive Hub End Cover O ring included in Seal Kit Thrust Washer Cap Cover Actuator Disconnect Rod End Cover Ausco Brake includes item 18 2 Seal Kit Lining Kit Bearing Kit Drive Motor Non steer Axle includes item 20 2 Seal Kit This list continues on the next page Part No 89721 A TEREX COMPANY 5 40 5 45 200 e Drive Chassis Components October 2006 Figure Rev Description 204 1 D 2WD Non steer Axle before serial number 7569 6
185. t 110196 Kit for solenoid part number 62260 111779 Kit for solenoid number 111703 22 89309 Solenoid Valve 2 position way 62275 Col 10 0 45912 Coil Nut 84133 Kit 23 89309 Solenoid Valve 2 position 3 way AM 224 62275 Coil 10V DC 45912 Coil Nut 84133 Kit 24 62255 Proportional Valve 12V 00 AW 62274 Coil 12V DC 89855 O ring Upper 89856 O ring Lower sold separately 62276 Coil Nut 110204 Seal Kit 25 89309 Solenoid Valve 2 position 3 way 62275 Col 10 0 45912 Coil Nut 84133 Kit This list continues the next page 701 1 Function Manifold Rev F Function Differential sensing circuit boom extend retract Steer left right circuit Platform level up Testing System relief System relief Bleeds off differential sensing valves to tank Blocks flow from auxiliary pump to function pump Steer left right Boom extend Boom retract Boom up down circuit A TEREX COMPANY Part No 89721 October 2006 3 s gt 26 oc o 2 sls c 2 gt ES as N I N 19 Oe A Si MATES A e e 6
186. table Covers View 2 Engine Side Turntable Covers View 3 Wire Harness and Power Cable Assemblies 400 Engine Components 401 1 402 1 403 1 404 1 405 1 406 1 407 1 408 1 0 A 0 Perkins 704 30 Engine View 1 before serial number 7472 Perkins 704 30 Engine View 2 before serial number 7472 Perkins 704 30 Engine View 3 before serial number 7472 Perkins 704 30 Engine View 4 before serial number 7472 Perkins 404 22 Engine View 1 after serial number 7471 Perkins 404 22 Engine View 2 after serial number 7471 Perkins 404 22 Engine View 3 after serial number 7471 Deutz F3L 1011F Engine View 1 before serial number 7544 Table of Contents continues on the next page October 2006 Table of Contents 409 1 410 1 411 1 412 1 413 1 414 1 415 1 416 1 417 1 418 1 419 1 420 1 421 1 422 1 423 1 A B Deutz F3L 1011F Engine View 2 before serial number 7544 Deutz F3L 1011F Engine View 3 before serial number 7544 Deutz F3L 2011 Engine View 1 after serial number 7543 Deutz F3L 2011 Engine View 2 after serial number 7543 Ford LRG 425 EFI Engine View 1 before serial number 7597 Ford LRG 425 EFI Engine View 2 before serial number 7597 Ford LRG 425 EFI Engine View 3 before serial number 7597 Ford LRG 425 EFI Engine View 1 from serial number 7597 to 11066 Ford LRG 425 EF
187. tion and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized Genie Distributor in your area 8 8 8 ER Use the Service Parts Fax Order Form the next page and fax your order to our Parts Department Machine Information Model Serial Number Date of Purchase Authorized Genie Distributor Phone Number A TEREX Xii 5 40 5 45 Genie North America Telephone 425 556 6551 Toll Free 877 367 5606 in U S A and Canada Fax 425 556 8659 Genie UK Parts Telephone 44 0 1476 584352 Parts Fax 44 0 1476 584340 Genie Australia Parts Telephone 617 03375 1660 Parts Fax 617 03375 1002 Genie France Parts Telephone 33 0 237 26 09 99 Parts Fax 33 0 237 31 50 10 Genie Germany Parts Telephone 49 0 4202 885223 Parts Fax 49 0 4202 885225 Genie Scandinavia Parts Telephone 46 31 3409612 Parts Fax 46 31 3409613 Genie Iberica Parts Telephone 34 93 5795042 Genie Brazil Parts Telephone 55 114 1665755 Parts Fax 55 114 1665754 Genie Japan Parts Telephone 81 33 4536082 Parts Fax 81 33 4536083 Genie China Parts Telephone 86 215 3852570 Parts Fax 86 215 3852569 Part No 89721 remove this page make copies remove this page and make copies ie Service Parts Fax Order Form Fax to 425 556 8659 or Toll Free 888 274 6192 A TEREX COMPANY International
188. tor Shroud 1 Red amp White pair 3 46 34943P Inboard Radiator Support Strut 1 19 29883 Screw HHC 5 8 11 x 1 75 inches GR 8 3 20 6036 Lock Washer 5 8 inch 21 13064 Flat Washer Bis inch 22 6090 Screw HHC 1 4 20 x 0 75 inch GR 5 23 6356 Lock Washer 4 inch 24 6638 Flat Washer 1 4 inch 25 Ref Engine Tray refer to 423 1 26 45209 Wear Pad 2 x 4 x 0 5 inch 4 27 Ref Battery refer to 423 1 28 Ref Positive Battery Cable refer to 311 1 Genio A TEREX COMPANY Part No 89721 S 40 5 45 October 2006 0 N y US 2 8 9 6 gt N O ZN gt ADTA Gg 34 AN AAW 69 Ford LRG 425 EFI Engine View 1 from serial number 7597 to 11066 Description 0 5 G 400 Engine Components Figure 416 1 p 6 Part 89721 5 40 5 45 October 2006 400 Engine Components 416 1 Ford LRG 425 EFI Engine View 1 from serial number 7597 to 11066 Rev G Description Qty Part Description Qty Ref Engine Wire Harness 29 19363 DEE 1 refer to 311 1 30 70525 LP Regulator 1 1 54071 Coolant Return Tank with Hose 1 S i 72327 Coolant Return 31 88757 zi Lockout Valv
189. ts Item 10 11 12 13 14 15 16 17 18 19 20 21 Part No Ref 31408 70496 119344 102092 89774 89775 Ref 70459P 6198 39479 70452 6095 102066P 4828 6175 5397 89911P 33239 31523 111334 50579P 89776 102497 111668 111402 70460P 22558 37505 6782 Deutz F3L 2011 Engine View 1 after serial number 7543 Description Qty Engine Harness refer to 311 1 Glow Plug Inline Fuel Strainer before serial number 10833 Primer Bulb Kit before serial number 10833 Exhaust Pipe 1 Muffler i u lu 1 Clamp et ciet emet 1 Engine Tray refer to 423 1 Rear Engine Mount 1 Nylock Nut 1 2 13 Screw HHC 1 2 13 x 2 75 inches GR 5 Engine Isolator 4 Flat Washer 2 inch Cast Washer Nylock Nut 3 8 16 Screw HHC 3 8 16 x 1 inch GR 5 Flat Washer 5 16 inch Cold Air Intake 1 Air Intake Rubber 1 Clamp i i tr credet 1 Air Intake Tube with Word Decals sse 1 Air Intake Tube Engine Cover includes mounting fasteners 1 Fuel Lift Pump before serial number 10833 1 Fuel Lift Pump with hand priming pump after serial number 10832 O ring Fuel Lift Pump Outboard Engine Mount 1 Screw HHC M14 x 40 mm GR 8 8 Lock Washer M14 Nylock Nut
190. ts Genie part numbers 48841 48845 and 48761 18 inches Hose Assembly Components Genie part numbers 48841 48846 and 94358 22 inches Fittings p Fitting dee eene Hose Assembly Components Genie part numbers 48827 48822 and 48756 Q 40 inches Hose Assembly Components Genie part numbers 48822 48827 and 48758 Q 45 inches Hose Assembly Components Genie part numbers 48822 48827 and 48758 Q 40 inches Fitting EE Hose Assembly Components Genie part numbers 48800 48802 and 48751 Q 54 inches FIN Aeneid Rev A Qty The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers 700 e Hydraulic Components October 2006 Figure Rev Description 709 1 A Hydraulic Hoses and Fittings Oscillate System 2 EXT 3 E 3 RET SCH rae 7 2 RETIS LEFT RIGHT OSCILLATION CYLINDER 1 1 OSCILLATION CYLINDER P S 2 HYDRAULIC 4 5 7 ROTARY 2B COUPLER LEGEND FITTING HOSE ASSEMBLY CONTROL VALVE e Genie A TEREX COMPANY 5 40 5 45 89721 October 2006 700 e Hydraulic Components 709 1 Hydraulic Hoses and Fittings
191. ts Genie part numbers 48854 48855 and 48764 Q 42 inches Deutz F3L 1011F Hose Assembly Components Genie part numbers 48854 48855 and 48764 Q 38 5 inches Deutz FAL 1011F Fitting uii nu 1 Fitting before serial number 7569 2 Fitting after serial number 7568 Hose Assembly Components Genie part numbers 48812 48821 and 48753 52 inches before serial number 7569 1 Hose Assembly Components Genie part numbers 48818 48800 and 48751 54 inches after serial number 7568 This list continues on the next page The length listed in the component description is the length of the hose only Refer to 713 1 to cross reference Genie part numbers to Parker part numbers 700 e Hydraulic Components October 2006 Figure 710 1 HYDRAULIC TANK LEGEND 16 16 Rev Description 0 Hydraulic Hoses and Fittings Turntable gt MEDIUM PRESSURE FILTER OUT ENGINE DRIVE PUMP du Aho fi FUNCTION PUMP GG BRAKE 2 SPD 207 Manifold 9 2SPD 21 43 k OSCILLATE PUMP 69 ASSEMBLY IN AUXILIARY POWER UNIT OUT 227 g PAS 4 8 HYDRAULIC ROTARY COUPLER 9 69 OIL COOLER option 69 To T1 option optio
192. ty 1 34358P Turntable Boom Storage Cover 1 2 17712 Screw FHS 3 g 16 x 1 75 inches 3 5397 Flat Washer 5 16 inch before serial number 11635 4 4828 Nylock Nut 3 8 16 before serial number 11635 5 34370 Wear Pad x 8 x 0 5 inch 1 6 29868 Spring Clip after serial number 11634 2 7 33265 Jam Nut 1 8 8 29605 Lock Washer 1 inch 9 38859 Flat Washer 1 x 2 5 x 0 14 inch 10 53553 Counterweight 227 Ibs S 45 1 11 30798 Screw HHC 1 8 4 5 inches GR 5 12 46769 Counterweight 405 Ibs Tank Sid eue 1 13 6175 Screw HHC 3 8 16 x 1 inch GR 5 14 6021 Lock Washer 3 8 inch 15 6097 Flat Washer 3 8 inch 16 102141 Turntable Front Cover with Decals S 40 1 102142 Turntable Front Cover with Decals S 45 17 34079 Screw HHC 1 8 x 8 5 inches 18 46768 Counterweight 405 Ibs Engine Side 1 A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 311 1 A Wire Harness and Power Cable Assemblies PLATFORM CONTROL BOX 5 JIB KIT J1 ALC500 J2 FUNCTION TRACTION MANIFOLDS 2 Ap AN MANIFOLD BOOM Den NY WORK EXT RET 16 LIGHTS SWITCH 69 o
193. ulley Cover 1 89787 Screw 8 20 8 8 inches 89788 Flat Washer 9 57 32698 S eoa 1 58 35586 Alternator 14V DC 60 A 1 Genie A TEREX COMPANY Part No 89721 5 40 5 45 400 e Engine Components October 2006 Figure Rev Description 413 1 D Ford LRG 425 EFI Engine View 1 before serial number 7597 A TEREX COMPANY S 40 5 45 Part No 89721 October 2006 400 Engine Components 413 1 Ford LRG 425 EFI Engine View 1 before serial number 7597 Description Qty Part No Description Qty 52695 Ford LRG 425 EFI Workshop 20 52652 Air Temperature Sensor 1 Manual 21 28656 Engine Eiter 1 88761 Nolff LPG Kit Complete 94922 EFI Update Kit 22 33957 POV Valve 1 484730 Air Filter Bracket f E Viri asa 23 25929 Screw HHC EFI te Ki Update Kit 8 1 25 x 30 mm GR 8 8 Ref Engine Wire Harness refer to 311 1 24 65453 Fuel Filter Bracket 1 1 88763 Air Valve Mixer 1 25 58967 Fuel Filter Pressure Regulator 1 mE 75471 Diaphram Repair Kit Air Valve Mixer 26 58900 Camshaft Position Sensor 1 83082 27 33968 Crankshaft Position Sensor 1 2 46131 Clamp 5 8 inc
194. v B Part Description Qty Part No Description Qty 53949 Perkins Engine Air Precleaner 20 34162 350 Air Intake Hose 2 5 inches 1 before serial number 7472 102007 Perkins Engine Air Precleaner 21 89985P Air Intake Tube 1 after serial number 7471 22 34959 Air Intake Precleaner 1 102375 Ford Engine Air Precleaner after serial number 7596 23 102374P Air Intake Mount 1 34957 Deutz Engine Air Precleaner 24 33361 Rubber Elbow 45 1 before serial number 7544 e t 89991 Deutz Engine Air Precleaner 25 94342 1400 Aluminized Tube 2 5 inches 1 after serial number 7543 26 102005 Air Intake Hose Mount 1 102003P Baffle Plate Perkins and Ford models 102003P Baffle Plate Ford models 89989P Baffle Plate Deutz models 1 34163 Rubber Elbow 90 1 2 45435 Hose Clamp 2 5 inches 3 94324 950 Aluminized Tube 2 5 inches 1 4 50941 Air Intake Hose 90 1 5 71911 Muffler Clamp 2 5 inches 6 102372 Air Intake Tube 1 7 102373P Air Intake Tube Mount 1 8 6888 Screw HHC 1 4 20 x 1 inch GR 5 9 6638 Flat Washer 1 4 inch 10 6091 Nylock Nut 1 4 20 11 30971 Hose Clamp 3 inches 12 101640 Rubber Reducer inches to 2 5 inches 1 13 88492 H
195. y 1 12 14 Ga 27 16397 S Toggle Switch boom up down 1 DPDT 3 position Momentary 1 28 56298 Red Light LED 12V 1 10 13037 S Toggle Switch 1 start 56848 Lock Washer LED SPDT 3 position Momentary 1 This list continues on the next page 9 13037 S Toggle Switch function enable SPDT 3 position Momentary A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 306 1 B Ground Control Box View 1 GDU G OO 9 S 40 5 45 89721 October 2006 300 e Turntable Components 306 1 Ground Controls View 1 Rev Item Part No Description Qty 29 7056 Squeeze Connector 1 2 INCH 1 6935 Electric Locknut 1 2 inch 30 13037 S Toggle Switch boom extend retract SPDT 3 position Momentary 1 31 13480 S Toggle Switch auxiliary power DPST 2 position Momentary 1 32 89838 Ground Control Box Assembly with 060818 1 30782 Gasket 88176 Nutsert 1 4 20 30997 Corrosion Inhibitor A TEREX COMPANY Part No 89721 S 40 5 45 300 e Turntable Components October 2006 Figure Rev Description 307 1 B Ground Control Box View 2 0 D 6 ee 0 9

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