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Service Manual - Genie Industries

1. L K G F E D C B A ye 7 PLATFORM ROTATE 1 aes BOOM A SLAVE UP DOWN PRIMARY EMT ME led E mae L oW o N os ee ES e Eu Pu _ pw d um T3 J 0 5 ig ami AL 2 Coe a l meg ill 0 035 0090 R1 gt S T tf c owl _ MI A 5 45 JIB SELECT MANIFOLD 0030 Llud l 1 BEFORE SERIAL 5593 JM NP 59 m7 SE p tL MASTER B _ B em MINE e pebre sosire LE quie com LEVEL j TURNTABLE BOOM 3 ay L __ 5152 __ __ __ PI Pe _ EXTEND _ __ _ _ morem ej 1 FUNCTION EU LU J tn 69 t 0 9 T PSI HIGH p uM 290 DE PSI lt gt PRESS OPTIONAL c qd o a FILTER GENERATOR a MM d elod Bo 50 NSF Pero gi al p 2400 PSI E
2. 1O N 1 BRN GROUND e 8 T m a BLU RED 3 a WHT 5 HO ST E WHT 1 RED 5 BLK 5 fe Tel g dg a r m ul a o ae BLU WHT 3 ES LO E B T Fe WHT BLK 1 WHT BLKiF31 E H yr ddr o y E o 9 9 WHT RED 1 E WHT RED 32 E H i lt f s 5 Qo TRAVEL ALARM n M OPTION BLU BLK 1 Eu BLU BLK 37 E H tel Ye STEER RIGHT BLU 1 BLU 36 E H t o 4 STEER LEFT ek 31 o Ed 8 El F PES gt tl 42 Loe Bee ome 4 Oc o 8 gt co t ORG 1 WHT 6 BRN 6 BOOM UP Vas LIMIT SWITCH oleo 1 WHEE EXTEND ow Hg ee A LIMIT SWITCH asic Z ooao Es m Fe WHT RED 3 QS i gt t o o im WHT BLK 3 WHT 3 E WHT 4 5 m TE TURNTABLE 1 ROTATE RIGHT ROTATE n LEFT WHT BLK 4 TURNTABLE EERE MEANE I rs E m 4 ROTATE LEFT
3. 1 GRIWT 4 GRN WHT 1 45 GENERATOR OPTION i 44 GR BK E H SPARE GRN R5i86 GRN 1 43 HORN o onamDcr ORGEK SE PULSE PIOKUP Vi e ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH SIGNAL BLU RED 1 39 BU RD S P L P G 1 BLU WHT E H BLU WHT 1 38 BU WT S P GLOW PLUG LED WHT RED 26A BU BK E H BLU BLK 1 37 BL BK D B STEER LEFT NL L BLU E H BLU 1 36 BLU D B STEER RIGHT GRN GROUND KS 1 BLK RED 1 35 BK RD R3430 BK RD S P RPM STACKED CONTACTS il ios N TE 4 En Fi mmm TE OPTION aet EU T WHT BLK 25A f WT RD E H WHT RED 1 32 WT RD D B BRAKE 2 jp Me EN WT BK E H WHT BLK 1 31 E D C yd 2 i RED 5 WHT 1 30 ED C KS1 WHT 23A CABLE RD WT E H RW 29 2WD 4WD 2 1 6 RD BK A H RED BLK 1 28 TILT ALARM i 34 i E EH 27 RED ISM amp 4 PH RED S P AUXILIARY POWER i NO NO amp HO H im 26 WT RD S P WATER TEMPERATURE SENDER olo NO NO 59 WT BK E H 25 WT BK S P OIL PRESSURE SENDER N PO NC GA Ae c i WHT ISM 10_ WHT E H 24 WARNING SENDER NO CABLE WHT E H WHT 2 23 WHT ISM 7 WHT S P KEY SWITCH POWER is
4. A TEREX COMPANY S 40 S 45 G Part No 72136 REVA N LO N BLK 22 a O S BLK 26 WHT 23 9 ad E a z 5 n t o a Lr tr IZ lt lt i9 2 202 BLK RED T t 35 orm BRN TO GRD o WHT 1 H P L WHT RED 32 GRN WHT 19 4 a e BLU BLK 37 BLU 36 4 RED 10 H P L st GEN OPTION 45 GRN WHT 1 WHT BLK 31 SPARE 44 GRN BLK 1 WHT 30 Go HORN 43 GRN 1 BLK 33 SPARE 42 ORG RED 1 PULSEPICKUP 41 LIMIT SWITCH 40 WHT 21 LP 39 BLU RED 1 4 GLOW PLUG LED 38 BLUWHT 1 o9 000 e SID STEER LEFT 37 BLU BLK 1 9 C STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 BL HT SS GLOW PLUG 34 BLK WHT 1 BOE START 33 BLK 1 BRAKE 32 WHT RED 1 Fy Fy E D C 31 WHT BLK 1 GG E D C 30 WHT 1 29 5 2WD 4WD amp RED WHT 1 ARERR AUX POWER 27 RED 1 GHNHES PWR TOES 26 BLK FS PWR START 25 RED FS o N PWR 24 WHT FS cc VA PWR FRM PLAT 23 WHT 2 E o PWR TO PLAT 22 BLK2 AN OPTION WIRE 21 WHT v
5. Section 6 Schematics Electrical Schematic Gasoline LPG Models March 2008 z iva mcr e e n BLK RED 1 i a HIGH RPM p m 3 1 ENGINE SPEED F FUNCTIONENABLE 20 89 E 1 HIGH RPM i o Ut m F GRN WHT 4 7 GENERATOR OPTION OFF GENERATOR LON GRN WHT 1 s o 91 WHT FLASHING BEACON m OPTION 9 OIL PRESSURE Y GAUGE SENDER WATER TEMPERATURE S u GAUGE SENDER a zx 8 VOLT METER 8 3 HOUR METER ui BLU WHT 1 o BLU WHT A NA m 24 BLU RED 1 o a FUEL 9 GAS T ul s a B3 z9 FUEL 52 GAS 2 1 5 25l TEST ato Ru RUN cr e SPER Gee boi to 5S v e S 4 ololololololololo E 3 E zs sig o BLK 1 EY PNK LGRN FEH 658 PIN 6 ro a ENGINE START 6 Ozi WHT PUR 209 PIN 18 2 815 2 Loi RED GRN FEH 16A PIN 1 ENGINE START YEL BLK 674 PIN 7 a TAN LBLU FEH 306 PIN 24 a e c a YEL FEH 37B PIN 8 Gz u YEL
6. TRACTION L K J F E 1 7 PLATFORM ROTATE A 3 E PLATFORM ROTATE UP DOWN PRIMARY 1 r 63 TURNTABLE upeol tt IA A Romare EM LL 2 a Ty omIP 3 Ho LRL y NE se ama 11 us el 7 25 x ae OL v2 TO PR2 S 45 JIB SELECT MANIFOLD 4 _ L BEFORE SERIAL 5593 d AL 2500 PSI before serial no 1865 D 0525 3500 PSI after serial 1864 3 E mm NS o S edle _ p F EEO j Function T PSI L MANIFOLD TE 290 Pst Y y GENERATOR 2200 o 1950 p FILTER A PSI Go PSI ve L om Hi ha i _ E 2400 Psi jai tpe pete e er 4 i m Gwy OERE 3500 o 4 E EN ENDE So RT dr OPTIONAL E amp 196 E eal GENERATOR GPM GP XH LL 1 10 GPM MANIFOLD 1 9 e Dem fp PRESS DRIVE PUMP AC 1 HEM i OO O 5 P oll 2000 i 1 25 ES SEC REG Oe ge 3 3 PSI PSI PSI ES gt 5 RESERVOIR AUX PUMP 6 7 TANK Note alpha callouts refer t
7. 4 5 A 3 Inspect for Damage Loose or Missing 4 6 A 4 Check the Engine 4 7 A 5 Check the Engine Coolant Level Liquid Cooled Models 4 8 A 6 Check for Fuel Leaks ssssssssssseseeeeeeeeenmeee enne enne 4 8 A 7 Check the Hydraulic Oil 4 9 A 8 Check for Hydraulic 4 10 A 9 Check the Tire Pressure 4 nene 4 10 A 10 Test the Oscillate Axle if 4 11 A 11 Test the Platform and Ground Controls 4 12 A 12 Test the Auxiliary Power Operation 4 13 A 13 Test the Tilt 4 14 A 14 Test the Limit Switches 220000 4 4 11 4 14 A 15 Drain the Fuel Filter Water Separator Diesel Models 4 17 A 16 Perform 30 Day Service 242 01 0 00000 4 19 A 17 Replace the Engine Oil and Filter Gasoline LPG Models 4 19 A 18 Check the Engine Belt Gasoline LPG and Perkins Models 4 21 A 19 Replace the Fuel Filter Gasoline LPG 4 22 Genie viii S 40 5 45 72136 20
8. 4 39 B 18 Test the Foot 4 39 B 19 Test the Engine Idle Select Operation 4 40 B 20 Test the Fuel Select Operation Gasoline LPG Models 4 41 B 21 Test the Drive Enable 4 42 B 22 Test the Drive 004 4 43 B 23 Test the Drive Speed Stowed Position 4 44 B 24 Test the Drive Speed Raised or Extended Position 4 45 B 25 Test the Alarm Package if equipped 4 46 S 40 5 45 March 2008 Section 4 Rev Scheduled Maintenance Procedures continued B 26 Perform Hydraulic Oil Analysis 4 46 B 27 Replace the Hydraulic Tank Return Filter 4 47 B 28 Replace the Engine Air Filter Element 4 48 B 29 Replace the Spark Plugs Gasoline LPG Models 4 49 A Checklist C Procedures C 1 Check the Engine Belt Deutz Models 4 51 C 2 Check the Engine Valve Clearances Deutz Models 4 52 C 3 Replace the Fuel Filter Water Separator Element Perkins Models 4 53 C 4 Replace the F
9. 25 30 ft Ibs 34 41 Nm 21 Flow regulator valve 0 6 2 3 L min U Platform level circuit 10 12 ft Ibs 14 16 Nm 22 Solenoid valve Poppet Mss Platform level down 25 30 ft lbs 34 41 Nm 23 Differential sensing valve W Pilot to close flow directional valve 10 12 ft Ibs 14 16 Nm 24 Relief valve 2600 psi 180 bar S 40 Xi System relief 35 40 ft lbs 47 54 Nm 24 Relief valve 2900 psi 200 bar S 45 System relief 35 40 ft lbs 47 54 Nm 25 Diagnostic nipple Yos Testing 26 Check valve Zu Differential sensing circuit Platform rotate 11 13 ft Ibs 15 18 Nm 27 242 Differential sensing circuit Platform rotate right 11 13 ft lbs 15 18 Nm 28 Priority flow regulator valve 10 12 ft Ibs 14 16 Nm 3 5 gpm 13 25 L min oscillate models 2 0 gpm 7 6 L min non oscillate models 29 Solenoid valve N O Poppet Platform rotate 25 30 ft lbs 34
10. 35 40 ft lbs 47 54 Nm 4 Pilot operated unloader valve 950 psi 65 Sequencing 10 12 ft lbs 14 16 Nm 5 Shuttle valve 2 position 3 way QQ 10 12 ft Ibs 14 16 Nm 6 Check valve RR Oscillate check right 35 40 ft lbs 47 54 Nm 7 jo Check valve circuit the piston is located between index numbers 3 and 6 8 Shuttle valve 2 position way SS 2 2 35 40 ft lbs 47 54 Nm 9 Diagnostic nipple Testing Plug Torque Specifications Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm 7 48 5 40 5 45 Part No 72136 2008 Section 7 e Repair Procedures REV B 11 5 Valve Adjustments Oscillate Manifold How to Adjust the Oscillate Seguencing Valve Pressure When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Connect a 1 2000 psi 0 to 138 bar pressure gauge to the diagnostic nipple index 9 loc
11. Limit switch 151 Limit switch normally open held closed 152 N C H O T Limit switch normally closed held open TB22 Key switch PR4 Power relay m 1HVIS 3NION3 Toggle switch SPDT A TEREX COMPANY z 18 31 1 1 Toggle switch DPDT Control relay contact normally open FS1 BLK Foot switch P3 H HORN Horn button normally open aie 0752 N O Oil temperature switch normally open wrst NO Water temperature Switch normally open OPS1 NC Oil pressure Switch normally closed Emergency Stop button normally closed Gauge sending unit Oil cooling fan Auxiliary pump Tilt sensor Auxiliary lift pump BPT 22 a oy 21 TAAR Boom Drive controller joystick Joystick 510 Resistor with Ohm value S 40 S 45 Part No 72136 2008 Section 6 Schematics Abbreviation Legend LABEL DESCRIPTION BAT auc Battery BP Boom proportional controller Capacitor C e wt Circuit breaker Control relay DP Drive proportional controller FB cee Flashing beacon mc e Foot switch Graces Gauge Horn or Alarm
12. 8 E Wl N 4 a 8 2 E 5 a 2 d 545 g 8g 5 Sag 29 29 99 ae 229 230 568 2522 FORD ENGINE CONTROL MODULE ECM us 59 29 a gt as 2 52 50m 9050 QUICK DISCONNECTS myd a SE 25 8 on oua NOON 25959 TO ECM SHOWN 95TW18 X1 IGNITION COIL 1 po Fi NOTUSED NOTES 3611918 Ki VPWR 5 37BY18 F2 KEEP ALIVE PWR AANE B 1 ON MACHINES MANUFACTURED BEFORE m NOT USED Dc FEBRUARY 1 2000 THE WIRE COLOR AT pte 349DB18 61 CRANKSHAET SENSOR RETURN i 3 PIN 7 FUEL SELECT IS BROWN WHITE 350GY18 H2 NKSHAFT SENSOR RETURN SE 282DB O18 J1 CAMSHAFT SENSOR FEED cafes 21 g 355GY W18 C1 THROTTLE POSITION SENSOR INPUT 238ADG Y18 FUEL PUMP MONITOR NOT USED FORD 42 PIN QUICK DISCONNECT _ Wa NOTUSED D 555718 53 FUEL INJECTOR 1 ENGINE HARNESS 12 556W18 52 FUEL INJECTOR 2 ELECTRICAL SCHEMATIC FORD EF I 557BR YIB S1 FUEL INJECTOR 3 558BR LB18 Ti FUEL INJECTOR 4 T YTACHLEAD 2 11T Y20 351BR W18 A2 VREF H R GN KEEP ALIVE PWR 1 16AR LG16 77DB Y18 lt R2 DRY FUEL MODULATOR D Y KEEP ALIVE PWR 8 37BY18 B3 NOT USED ib J 4 R W WATER TEMPERATURE SWITCH 16 39RW2
13. REX COMPANY Hold the function enable switch to either side and move the boom up down toggle switch in DOWN direction and check voltage at TB2 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom controller in the DOWN direction Check voltage at TB2 Press down the foot switch and move the boom controller in the DOWN direction and check voltage at TP2 ov Press down the foot switch and check voltage at terminal on the boom controller 12V or more 12V or more 12V or more 12V or more Re adjust boom controller see Repair Section OR replace boom controller OR consult Genie Industries Service Department 2008 REV Repair open in red blk 4 wire circuit from TB2 to boom directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot boom up down toggle switch OR repair open in red blk wire circuit from TS16 to TB2 OR consult Genie Industries Service Department Repair open in red blk 3 wire from TP2 to TB2 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from ground to the boom controller S 40 S 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV CHART 15 0 or Continued fr
14. a TANK TRACTION STEERING CYL i l S CN Fl Note alpha callouts refer to 8 components shown in the manifold illustrations Refer to the Repair Section A TEREX COMPANY Part No 72136 S 40 S 45 6 35 35 2008 Section 6 Schematics 5 40 45 2WD Hydraulic Schematic Oscillating Axle 36 REV A S 45 JIB BOOM S 45 JIB SELECT MANIFOLD AFTER SERIAL NO 5592 REAR RIGHT March 2008 Section 6 Schematics SSS SSS SS se 5 40 45 4WD Hydraulic Schematic Oscillating Axle
15. KS editos Keyswitch RY N LED ES osito net Limit switch Pitra Emergency Stop Button PE Power relay Resistor TE Terminal base location Terminal platform location Toggle switch A TEREX COMPANY Part No 72136 S 40 S 45 6 5 Section 6 Schematics March 2008 Hydraulic Symbols Legend 6 Pressure gauge lt gt Filter cooler 1 Pump prime mover engine or motor Fixed displacement pump e Bi directional motor Bi directional Pump Double acting cylinder n Check valve Filter with bypass valve ee Priority flow regulator Solenoid operated dump valve Solenoid valve normally closed poppet ws DKK Solenoid operated proportional valve Solenoid operated 2 position 3 way directional valve B LIIN Ww X Solenoid operated pos 4 way directional valve Flow divider combiner valve with pressure balancing orifice 3 jc ONI Deo IQ Counterbalance valve Differential sensing valve e 1 Relief valve a l 1 Pilot operated unloader valve m Shutoff valve
16. nee Un 7 9 1 4 Toggle Switches 7 10 Platform Components 271 eal 1109 900 Y 7 11 2 2 Platform Leveling Slave 7 11 2 3 Platform 7 13 Jib Boom Components 5 45 Models 3 1 lt JID BOOM uii Gu ete mide 7 15 3 2 Jib Boom Lift Cylinder 2 02 0 7 16 A Boom Components 4 1 Boom Cable 2 0 2220000000 RR LLYR n nn nnne 7 17 4 2 7 19 4 3 Boom Lift 2 0 7 22 4 4 Extension Cylinder fesis Y LEL 7 23 4 5 Platform Leveling Master 2 0 7 25 Turntable Covers 5 1 Turntable Covers trece teneret 7 26 Genio Xiv S 40 S 45 Part No 72136 2008 Section 7 Part No 72136 TABLE OF CONTENTS Rev Repair Procedures continued A Deutz Engine F3L 1011F 6 1 e d e e mee e deed 7 27 6 2 Flex Plate zis eh EP 7 27 6 3 Oil Temperature and Pressure Gauges 7 28 Perkins 704 30 Engine 7 1 7 29 452 3blex
17. 2008 Section 5 Troubleshooting Flow Charts REV B previous page Continued from the Disconnect wires to 0 or boom extend directional infinite valve coil item C and ohms test the resistance of the valve coil See Repair Section Replace boom extend directional valve coil 2 5 to 3 5 ohms function Hold the function enable operates switch to either side and move the boom extend retract toggle switch TS15 in the EXTEND direction Manually override the directional valve by pushing in on the end of the valve spool Replace faulty directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 345 bar pressure restrictions keeping the gauge at the quick boom from extending disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Hold the Genie Industries Service function enable switch to Department either side and move the boom extend retract toggle switch in the EXTEND direction Check the pressure less than 1950 PSI function operates Exchange boom extend flow regulator valve item G with boom up down flow regulator valve item H Check boom extend function Replace the faulty flow regulator valve function inoperative Repair the cylinder or cylinder counterbalance valve OR function manifold could have an
18. EH BLK 2 BLK 8 8 BLKARS EH GORN S au O WHT R17 E H 848 HYDRAULIC OIL gt Wr 4 TEMPERATURE o D eS SWITCH ria T o 9 si fix m 52 i En RED ORG R17 E H COOLING FAN a UE 1 option wr ma E cud Ut ORG BLK 1 m ORG BLK 41 E H f 4 mm H n i 9 a i Oo g g 8 iS Or W E z tel ie 2 1 o t EF 1 o N OC suf i 848 mag E x q RE C E 2 i o ie ttt LS jm E 3 gd E g RED pedi el zy m RED Fay RED 20 E H 4 n N N LO N Section 6 Schematics Electrical Schematic Perkins Diesel Models March 2008 LIFT DRIVE SELECT OPTION REV A
19. 14 E a 10 t p 1 4 WHT RED 4 n OE 1 7 Tel S 8 FLOW CONTROL 5 BED REDA PRIMARY t tod UP RED BLK BOOM UP is PRIMARY BOOM c TDOWN RED BLK 4 PRIMARY au D i FR d BOOM DOWN B DESCENT ALARM RED WHT 4 n OPTION PRIMARY BOOM a o FLOW CONTROL EE REB OW CONTRO RED BLK 3 o Fu n E RED WHT 3 amp BLK 3 EXTEND BOOM 5 RETRACT BLK WHT 3 B m Ey BLK 4 EL BOOM EXTEND ee a EXTEND BLK WHT 4 a 1 7 BOOM t BLK WHT 4 n uo 1 RETRACT BOOM RETRACT B 2 d 4 tn p BLK RED 4 T 5 EXTEND RETRACT g FLOW CONTROL BLK RED 3 ad amp E ORG 3 PLATFORM LEVEL m 1 DOWN ORG BLK 3 me f E x E ORGA PLATFORM D ej LEVEL UP p 4 UP ORG BLK PLATFORM LEVEL 1 DOWN m ORG BLK 4 PLATFORM iu LEVEL DOWN p up a 2 BLK 6 REDS E ORG RED 3 5 PLATFORM LEVEL DISABLE m CE OPTION E GRN 3 RIGHT 2 PLATFORM ROTATE 4 w L LEFT z GRN BLK 3 m GRN BLK o LT a Rae eS E RIGHT PLATFORM GRN GRNWHT ROTATE 1 PLATFORM ROTATE m O LEFT GRN 4 LEFT JIB UP tn JIB BOOM 1 DOWN m GRNWHT3 5 o m i c 71 10 RED JIB
20. DATA LINK CONNECTOR PIIR GN W OIL PRESSURE SWITCH 26 2 253DG W20 S26ALB O16 FUEL PUMP RELAY CONTROL b ai NOTE SHOWS USED WIRES M3 NOT USED Sd ore 359FGY R20 B2 SINGLE RETURN N3 SED 1 Pi NOT USED o aai kzal i 743GY20 C D1 INTAKE AIR TEMP SENSOR 358LG BK20 B1 MAP SENSOR INPUT 35410 818 D2 ECT SENSOR d SW T2 NO USAGE x 6 342LG P16 L3 STARTER LOCKOUT d ap 5 EI NOTUSED Y 264W LB18 R1 IDLE AIR CONTROL 225 20 DRY FUEL SENSOR i 253BDG W20 J3 OIL PRESSURE 4 57BK18 T3 GROUND 242DG18 P2 DRYFUEL LOCKOFF MATING FACE i 967 018 IGNITION COIL 2 SHOWN 74GY LB18 E2 25 SENSOR SIDE 1 it a 7 3 8292 3 as 959 ge ga RS 38 aS as ax 8982559 FORD WIRING HARNESS WIRE CODE ES 2 gt ou 395 oF OD Sz zu eU 55269 MATING FACE E ogan 9 i9 559 oo 23 A os os 551852 CODE COLOR CODE COLOR CODE COLOR 2 gt oo ioo Sa xo so ix ER xo 5 SHOWN as 2 49 RS SS 59 3 855 50 Pet GG 4 5 a S SSS 5 se SISN BL BLUE GY GREY P PURPLE LL Al BK BLACK LB LIGHT BLUE R RED 4 BR BROWN LG LIGHTGREEN TAN H one DIAGNOSTIC DB
21. PartNo 72136 Hold the function enable switch to either side and move the boom up down toggle switch in the AU DOWN direction and check voltage at TB3 With key switch turned 6 to 7V to platform controls and both Emergency Siop buttons pulled out to the ON position press down the foot switch and move the boom controller in DOWN direction Check voltage at TP3 ov Press down the foot switch and check voltage at terminal on the boom controller 12V or more Re adjust boom controller see Repair Section OR replace boom controller OR consult Genie Industries Service Department Chart 15 Repair open in red wht 4 wire circuit from TB3 to boom up down proportional valve coil OR repair open in brn ground wire circuit to valve coil Repair open in red wht 3 wire from TP3 to TB3 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from ground to boom controller Section 5 Troubleshooting Flow Charts CHART 15 Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the DOWN direction Check voltage on red blk 4 wire on boom directional valve coil item B 20V or more Continued on the next page
22. IIl He ds Ael llo eu ud l t U eet Jl 5 45 JIB SELECT MANIFOLD c Llud TOURS BEFORE SERIAL NO 5593 0 0 1 502 1 SS TO PRI ll _ Ll ll 2500 PSI bef ial no 1865 DS 0 025 3500 PSI after settal no 1864 PERDU LEVEL TURNTABLE BOOM 3 Si s2 P1 P2 EXTEND RETRACT Alo TUM eee zl m o ol L PRESS OPTIONAL PSI NA i GENERATOR ee 2200 1950 a FILTER amp i PSII Bo PSII JO og A 0 0 S 6 amp 2400 PSI J J NW Ont X 4 3500 ad MT qe Tren a iT WT HN LOL T 1 OPTIONAL l 5 FUNCTION GENERATOR OM 9 Ke of PUMP 6 e Mol J T0 GER MANIFOLD le Op pH PRESS i ee DRIVE PUMP ye He pem eem 2000 PSI qu arg ce aa s ccc 25 3 3 PSI PSI PSI cl M RESERVOIR AUC BUMP 6 REAR RIGHT 250 PSI 8 To
23. Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report Failure to perform each procedure AWARNING as presented and scheduled may cause death serious injury or substantial machine damage M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than three months must complete the quarterly inspection Unless otherwise specified perform each procedure with the machine in the following configuration Machine parked on a flat level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey
24. 2008 Section 6 e Schematics N Electrical Schematic Deutz Diesel Models Section 6 Schematics March 2008 REV A Electrical Schematic Deutz Diesel Models NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION ORG BLK 1 WHT RED a RED RED HIGH RPM SPEED TP35 TS4 BLK RED 1 BRN e 4 OFF 7 GENERATOR LON TP45 TS12 I FUNCTION ENABLE HIGH RPM BLK RED GRN WHT 1 TB35 TB45 CR3 N O CR4 N O GRN WHT 4 E H TS20 i IGN START MODULE TS2 ENGINE START TP34 ENGINE START 1 5 RELAY 2 TACHOMETER 3 START INPUT 4 AUX ON O 5 GROUND 6 BATTERY 7 KEY PWR TB33 BLK KEY BYPASS 9 IGN FUEL ON p 10 ENG FAULT WHT 25 WHT BLK E H WHT BLK o TB24 WHT 24 E H BLK WHT 1 WHT RED E H V WHT RED TB26 TS3 RED 25 BLK WHT WHT l aow PLUG TS11 GLOW 1 PLUG CR2 8
25. Checklist E Procedures REV E 1 2 Close the two hydraulic shutoff valves located at the hydraulic tank essential for good machine performance and i i service life Dirty oil and suction strainers may cause the machine to perform poorly and open closed continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more frequently Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is Component damage hazard The A CAUTION engine must not be started with The machine uses Dexron equivalent hydraulic oil Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the fuel tank See Repair Section 12 1 How to Remove the Fuel Tank Part No 72136 A TEREX COMPA the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the
26. GAUGE SENDER on 29 5 OIL PRESSURE 3 i SWITCH i BLK 1 26 fo a gt 5 5 i la HE 0O WATER TEMPERATURE 22 ENGINE z9 EO Sau o SWITCH START 565586528 E9 n t EF o Od xe x 9 iui z z E ENGINE oleleleleelelol START BLK 1 i qp WHTRED WHT RED E H WATER TEMPERATURE 9 GAUGE SENDER 8 a 5 4 FUEL RELAY N oz co e p WHT 21 E H t IN 4 WHT 21 RED J HoLp cor BLK FUEL SOLENOID zx WHT putt x lacte Fea y BLUME VV GLOW PLUG LED gt AN g BLU WHT 34 E H EZ 8 nm WHT BED a a GLOW PLUG M CONTROLLER E RED GLOW PLUG STARTER RELAY RE t BLK R1 E H 9 AUXILIARY g m AUXILIARY PUMP i m 9 5 PUMP N 1 Fl uk a STARTER MOTOR 1 E RED 1 ES C el Tz REDs27 E H AUXILIARY POWER j m gg RELAY a 8 i RED WHT RED BLK 1 OS 815 mx amp A 58 AUXILIARY PUMP WHT WHT 2 e to e eim tri e om i Ft ll ose we RED BLK 28 E H E Fe REM bod RED WHT 23 E H p PEVEISSENSOH o 4 1 e z o BR OH RN E y A Y I RN E M A GRN 1 a GRN 1 HORN RELAY 2 lt e 878 o iN T a TS Z 8 B
27. Scon Ju sul oo 0 uo ass OE gt sun dala r EE am aui Ozma sou eI 5 954409 ti 5 lt oraaa aSo o I a IIA FP 2008 Section 6 e Schematics pn Platform Control Box Wiring Diagram Perkins Diesel Models S 45 JIB BOOM 5 45 JIB SELECT MANIFOLD AFTER SERIAL NO 5592 REAR RIGHT March 2008 Section 6 Schematics SSS 5 40 45 2WD Hydraulic Schematic Non Oscillating Axle
28. 0 035 Orifice with size A TEREX COMPANY 6 6 S 40 S 45 Part No 72136 2008 Section 6 Schematics Ford LRG 425 EFI THROTTLE ACTUATOR POSITION SENSOR POWER FUEL PUMP STARTER 1 CR FA CR FB CR FC FUEL INJECTOR VALVES 6 665 yc 4 3 2 1 Sl Sl Sl l 8 l 8 8 mod md Om 1 WATER TEMP gt SWITCH NO D 1 i Bey alia
29. 5 Install the new sending unit Do not over tighten 6 Connectthe wires to the new sending unit Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Coolant temperature sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 13 16 inch Temperature switch point 230 F 112 C Oil pressure sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 11 16 inch Oil pressure switch point 8 psi 0 55 bar 7 32 S 40 5 45 Part No 72136 March 2008 Section 7 e Repair Procedures Ground Controls REV A 9 1 87 Control Relays Relays used for single function switching are single 87a L pole double throw SPDT relays 0 How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connect the leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 without resistor 85 to 950 terminal 85 to 86 with resistor 75 to 850 terminal 87 to 87a amp 30 no continuity infini
30. Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if it is not properly supported 7 Remove the four mounting fasteners from the When removing a hose assembly lift cylinder barrel end pivot pin mounting plate or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 8 With the lift cylinder being supported by the overhead crane pull the cylinder toward the platform to remove it from the machine Crushing hazard The lift cylinder AWARNING could become unbalanced and fall if it is not properly supported Component damage hazard The CAUTION cables and hydraulic hoses can be damaged if the lift cylinder is pulled across them Extend the boom until the extension cylinder rod end pivot pins are accessible in the extension tube Remove the master cylinder See 4 5 How to Remove the Platform Leveling Master Cylinder A TEREX COMPANY S 40 S 45 7 23 Part No 72136 Section 7 Repair Procedures March 2008 COMPONENTS REV Raise the boom to horizontal position 9 Support and slide the extension cylinder out of Remove the external snap rings from the LL extension cylinder rod end pins at the platform AWARNING Crushing hazard The extension end Use soft metal drift to remove the pins cylinder will fall when it i
31. Engine compartment hydraulic filters fittings hoses pumps and component tray All hydraulic cylinders REV B A 9 Check the Tire Pressure Genie specifications require that this procedure be performed daily This procedure does not need to be performed on machines equipped with the foam filled tire option Bodily injury hazard An over AWARNING inflated tire can explode and could cause death or serious injury Tip over hazard Do not use AWARNING temporary flat tire repair products To safeguard maximum stability achieve optimum machine handling and minimize tire wear it is essential to maintain proper pressure in all air filled tires 1 Check each tire with an air pressure gauge Add air as needed Tire specifications Tire size All hydraulic manifolds 515 a AWO TUR and rear tires ii UNES Primary and jib booms The underside of the turntable Pressure 2 a The underside of the drive chassis Ground area under the machine Genie A TEREX CON S 40 S 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV CHECKLIST PROCEDURES A 10 Test the Oscillate Axle if equipped Genie specifications require that this procedure be performed daily Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over 1
32. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system Part No 72136 2008 Section 7 Repair Procedures REV A 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to Remove the Platform Rotator CAUTION Component damage hazard Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal If a new rotator is installed or the rotator is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Remove the platform See 2 1 How to Remove the Platform Part No 72136 A TEREX COMPANY PLATFORM COMPONENTS S 40 Models 2 Tag disconnect and plug the hydraulic hoses from the platform rotator Cap the fittings on the rotator Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin
33. A TEREX COMPANY REV B Release the function enable toggle switch Result The engine RPM should change to low idle Turn the key switch to platform controls 5 At the platform controls move the engine idle select toggle switch to high idle rabbit symbol Do not press down the foot switch Result The engine RPM should change to high idle Move the engine idle select switch to low idle turtle symbol Result The engine RPM should change to low idle Move the engine idle select toggle switch to foot switch activated high idle rabbit and foot switch symbol Result The engine RPM should not change to high idle Press down the foot switch Result The engine RPM should change to high idle 4 40 S 40 5 45 PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 20 Test the Fuel Select Operation Gasoline LPG Models Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first The ability to select and switch between gasoline and LPG fuels as needed is essential to safe machine operation A fuel selection can be made while the engine is running or not Switching malfunctions and or the failure of the engine to start and run properly in both fuel modes and through all idle speeds can indicate fuel system problems that could develop into a hazardous situation Perform this test after checking the
34. Check for mechanical restrictions keeping jib boom up function from operating OR repair or replace jib boom cylinder OR replace See Note 2 counterbalance valve OR 0 030 orifice item AE may be plugged OR jib boom platform rotate select manifold has an internal fault OR consult Genie Industries Service Department function Exchange jib boom operates Replace faulty counterbalance valves counterbalance valve and activate jib boom up Note 1 function 5 40 2600 psi or more 5 45 2900 psi or more function inoperative Note 2 S 40 less than 2600 psi 5 45 less than 2900 psi Consult Genie Industries Service Department A TEREX COMPANY Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 27 Jib Boom Down Function Inoperative Be sure all other functions operate normally With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the position hold the function enable switch to either side and move the jib boom toggle switch TS19 in the DOWN direction Check voltage at the grn blk 4 wire on the jib boom down directional valve item DD With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the jib boom toggle switch TS24 in the DOWN direction Check voltage at TB18 12V Cont
35. Repair open in brn ground wire circuit from terminal 3 on drive controller to ground Repair open in brn ground wire circuit from terminal 3 on drive controller to ground Part No 72136 A TEREX COMPANY Section 5 e Troubleshooting Flow Charts March 2008 lt ccm cm m k c _ Y CHART 30 REV Continued from the previous page Press down the foot switch and hold the drive controller in the full forward position and check voltage across the wht 12 wire and the wht blk 31 wire on EDC Troubleshoot drive forward and drive reverse functions separately OR replace pump OR consult Genie Industries Service Department Press down the foot switch and hold the drive controller in the full forward position Hold the drive enable toggle switch TS8 to either side and check the voltage across the wht 12 wire and the wht blk 31 on EDC Connect the positve lead from a voltmeter to terminal 5 on the drive controller and the negative lead from the voltmeter to the blu wht wire on TS8 Press down the foot switch and move the drive controller in the full forward position Hold the drive enable toggle switch to either side and check voltage Connect the positve lead from a voltmeter to terminal 5 on the drive controller and the negative lead of the voltmeter on the center terminal of the drive enable toggle switch Press down the foot switch and move the
36. S 40 S 45 G 6 10 Section 6 Schematics Electrical Schematic Gasoline LPG Models March 2008 LIFT DRIVE SELECT OPTION REV A lt N a 1 BRN 2 GROUND e o T m BLU RED 3 WHT 5 os 5 BRN5 S rn 2 DRIVE ENABLE E Bks LIMIT SWITCH dg amp R I ui a BLU WHT 3 5 5 WHT BLK 1 WHT BLK 31 E H G
37. Section 4 Scheduled Maintenance Procedures Checklist A Procedures REV B 1 Inspect the Manuals Genie specifications reguire that this procedure be performed daily Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition 1 Check to be sure that the storage container is present and in good condition 2 Check to make sure that the operator s responsibilities and safety manuals are present and complete in the storage container in the platform 3 Examine the pages of each manual to be sure that they are legible and in good condition 4 Always return the manuals to the storage container after use Contact your authorized Genie distributor or Genie Industries if replacementmanuals areneeded PartNo 72136 A TEREX S 40 S 45 4 5 MPANY A 2 Inspect the Decals and Placards Genie specifications require that this procedure be performed daily Maintaining all of the safety and instructional decals and placards in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance i
38. ge i ee e ge 5 2 I2 S A eg BLU RED 39 2 gt z ulum BLK RED 35 ora BRN GRD i o WHT 1 H P L m WHT RED 32 O p GRN WHT 19 O O a a O BLU BLK 37 BLU 36 4 RED 10 H P L GEN OPTION 45 GRNWHT 1 W T BLK 31 p SPARE 44 GRN BLK 1 WHT 30 HORN 43 GRN 1 SPARE 42 ORG RED 1 BLK 33 PULSEPICKUP 41 RED 25 LIMIT SWITCH 40 WHT 21 LP 39 BLU RED 1 o d OOO N CHECK ENGINE 38 BLU WHT 1 oll o STEER LEFT 37 BLU BLK 1 GRNWHT45 cy oM F STEER RIGHT 36 BLU 1 RPM 35 BLK RED 1 GLOW PLUG 34 BLK WHT 1 START 33 BLU WHT 12 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 E D C 30 WHT 1 N d N 2WD AWD 29 RED WHT 1 r F 28 BLU RED 13 AUX POWER 27 RED 1 PWR TO F S 26 BLK F S PWR START 25 RED F S o PWR 24 WHT F S cr PWR FRM PLAT 23 WHT 2 o PWR TOPLAT 22 BLK 2 OPTION WIRE 21 WHT uw GENERE RAS 20 e JIB VALVE 19 GRN WHT 3 RED 27 PLAT ROT R 18 GRN BLK 3 o P Om PLAT ROT L 17 GRN 3 obo PLAT LVL 16 ORG RED 3 5 BLK RED 9 PLAT LVL DN 15 ORG BLK 3 lt PLAT LVL UP 14 ORG 3 a p DRV ENA LT 13 BLU RED 3 BLK WHT 8 DRIVE ENABLE 12 BLU WHT 3 BLK 7 b SEC BOOMDN 11 GRN 17 E SEC BOOM UP 10 ar GRN 17 EXT RET F C 9 BLK RED 3 gw GRN BLK 18 RETRACT 8 BLK WHT 3 5 EXTEND 7 BLK 3 RED BLK 2 TURN ROT 6 WHT
39. 1 Remove the plug located on the side of the hub and check the oil level Result The oil level should be even with the bottom of the plug hole a drive hub b 4 34 A TEREX CON S 40 S 45 REV B 2 lf necessary add oil until the oil level is even with the bottom of the side plug hole 3 Apply pipe thread sealant to the plug and install the plug in the drive hub Turntable rotate drive hub oil 8 fluid ounces 0 24 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 11 Check and Adjust the Engine RPM Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Maintaining the engine rpm at the proper setting for both low and high idle is essential to good engine performance and service life The machine will not operate properly if the rpm is incorrect and continued use may cause component damage Gasoline LPG Models The engine rpm is controlled by the ECM and can only be adjusted by re programming the ECM If rpm adjustment or service is reguired please contact the Genie Industries Service Department your local Ford dealer Gasoline LPG models Low idle 1600 rpm High idle 2500 rpm Diesel models This procedure will reguire two people 1
40. 2 Inspect the oil cooler for leaks and physical damage a oilcooler b cylinder head cooling fins fan blower fins 3 Clean the oil cooler of debris and foreign material Cooling and Fan Blower Fins 4 Remove the air baffle retaining fasteners Remove the air baffle 5 Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the fan blower a engine pivot plate b pivot plate retaining bolts c air baffle Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES 6 Inspect the fan blower fins for physical damage 7 Clean the fan blower fins of debris and foreign material 8 Inspect the head cooling passages and fins for physical damage or foreign material using a flashlight 9 Clean the cylinder head cooling passages and fins of debris and foreign material 10 Install the engine side cover 11 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 12 Replace the air baffle and install the air baffle retaining fasteners A TEREX S 40 S 45 REV B B 7 Check the Hydraulic Tank Return Filter Condition Indicator Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the hydraulic tank return filter in good condition is essential to good system performance and safe mac
41. 7 34 A TEREX CON S 40 5 45 MEANY REV 9 4 Engine Fault Codes Gasoline LPG Models How to Retrieve Engine Fault Codes When a engine malfunction is detected by the Electronic Control Module ECM a fault code is recorded and the check engine light will turn on at the ground and platform controls Use the following procedure to retrieve the engine fault code to determine the engine malfunction Perform this procedure with the key switch in the off position 1 Open the ground controls side turntable cover 2 Open the ground control box and locate the run test toggle switch inside of the ground control box 3 Pull out the ground controls red Emergency Stop button to the on position 4 Hold the run test toggle switch to the test position and turn the key switch to the ground controls position Result The check engine light should turn on The check engine light should begin to blink Part No 72136 2008 Section 7 Repair Procedures REV A 5 Continue to hold the run test toggle switch in the test position and count the blinks Fault codes are two digits The check engine light will blink the first digit of a two digit code then will pause for 1 2 seconds and then blink the second digit For example the check engine light blinks 5 consecutive times then pauses for 1 2 seconds and then blinks 1 time That would indicate code 51 The ECM is able to store up to six individual
42. BLK 3 RED BLK 2 TURN ROT 6 WHT RED 3 1 TURN ROT R 5 WHT BLK 8 B TURN ROT L 4 WHT 3 Fa PRIMARY 3_ RED WHT 3 nr RED WHT 3 PRIMARY DN 2 RED BLK 3 5 PRIMARY UP 1 RED 3 ES R A WHT BLK 5 e m Qs WHT 4 TE MS oos X ra 1234567 10 S a m 5 a bri x 1 Ate cw E e m amp 5 WHT RED 6 5 T 8 m RED BLK 1 ORG 414 2 ORG BLK 15 T ORG RED 16 WHT CR14 GANAS REV A DESCRIPTION BOOM PROPORTIONAL JOYSTICK PLATFORM ROTATE SWITCH 545 SHOWN PRIMARY UP DOWN amp TURNTABLE ROTATE PLATFORM LEVEL SWITCH DELAY CAPACITOR BOOM EXTEND RETRACT SWITCH BOOM PROPORTIONAL JOYSTICK DRIVE ENABLE SWITCH STEER LEFT RIGHT TILT ALARM GENERATOR SWITCH OPTION JIB LOCKOUT RELAY PLATFORM ROTATOR RELAY DRIVE ENABLE LED EMERGENCY STOP BUTTON KEY SWITCH AUXILIARY SWITCH ENGINE START SWITCH GLOW PLUG SWITCH OPTION HIGH RPM SWITCH JIM BOOM SWITCH S45 ONLY LABEL BP1 C1 CR13 CR14 DP1 H1 L1 P2 P3 TS1 TS2 TS3 TS4 TS5 TS6 TS7 TS8 TS24 TS20 2008 Section 6 e Schematics Platform Control Box Wiring Diagram Deutz Diesel Models 25 2008 Section 6 Schematics E FSI Electrical Schematic Perkins Diesel Model
43. Genie Service Manual Refer to inside cover for additional serial number information Part No 72136 Rev B March 2008 5 40 5 45 from serial number 1790 7000 Introduction March 2008 Genie S 40 Genie S 45 Important Read understand and obey the safety rules and operating instructions in the Genie 5 40 5 45 Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting fault codes and repair procedures for gualified service professionals Basic mechanical hydraulic and electrical skills are reguired to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center 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 http Awww
44. NE BLU BLK 37B c RED BLK 2B 4 9 WHT RED 32B RED 1B 4 10 BRN GROUND BLK R1498 HE 1 START RELAY ORG BLK 4TB 2 TACHOMETER IGNITION START BLICSSD HE a START INPUT MODULE 8 2 BRN GROUND LC 5 GROUND ie lC BATTERY WHT23B HE 7 KEY POWER O KEY Bypass HE 9 IGN FUELON se 10 ENGINE FAULT RED 6 ISM WHT 9 ISM RED CB1 CR2 CR3 CR4 BLK 1 ISM BLK R1 E H BLK D B GRN 43D WHT 21D BLK RED 35B BEKARE H BLK RED R4 E H 1 BLK 22D enie A TEREX COMPANY S 40 S 45 Part No 72136 LABEL DESCRIPTION CB1 CIRCUIT BREAKER CONTROLS 15A CB2 CIRCUIT BREAKER ENGINE 15A CR1 IGNITION START RELAY CR2 IGNITION POWER RELAY CR3 HIGH IDLE RPM CUTOUT RELAY CR4 RPM RELAY CR5 HORN RELAY CR17 HYDRAULIC OIL COOLER OPTION RELAY CR18A CE PLATFORM LEVEL RELAY CR18B CE PLATFORM LEVEL RELAY DB DIODE BLOCK FC FLOW CONTROL G1 VOLT METER GAUGE G2 OIL PRESSURE GAUGE G3 WATER TEMPERATURE GAUGE HM HOUR METER ISM IGNITION START MODULE KS1 KEY SWITCH LS1 BOOM EXTEND LIMIT SWITCH LS2 BOOM UP LIMIT SWITCH LS3 DRIVE ENABLE LIMIT SWITCH Pi EMERGENCY STOP BUTTON PR1 AUXILIARY POWER RELAY PR2 GLOW PLUG POWER RELAY R2 RESISTOR 10 OHM BOOM FUNCTIONS
45. ground to brn wire at continuity terminal 5 on ignition start module 12V continuity Replace the ignition start module OR consult Genie Industries Service Department no continuity Check continuity from ground to terminal 85 Repair open in brn ground wire circuit to on CR2 CR2 good Crank engine and check voltage at org blk 41 wire on alternator Crank engine and check oy voltage at terminal 2 on ignition start module Repair open org blk 41 wire circuit from alternator to TB41 to terminal 2 on ignition start module Continued on the next page Genie REX COMPANY Repair open in blk wire from terminal 86 on CR2 to terminal 9 on the ignition start module Repair open in power supply wires to terminal 6 and 7 on ignition start module Repair open in brn ground wire circuit to terminal 5 on ignition start module Repair or replace alternator OR contact Genie Industries Service Department S 40 S 45 Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts m JU mr I REV B CHART 3 Continued from the previous page While cranking engine for 15 seconds check continuity to ground on terminal 10 on ignition start module Is continuity maintained no Check voltage at terminal 4 on ignition start module Replace ignition start module OR consult Genie Ind
46. id 5 BLK R5 30 BLK 2 22 BLK S P POWER TO PLATFORM TF WHT R2 87 WHT E H 21 WHT SP DB IGNITION POWER REDEA RED E H RED R17 30 20 WHT OIL SWITCH RED S P 12V BATTERY SUPPLY 3 GRNWHT 3__ 19 GR WT SP JIB VALVE 0 i GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLATFORM ROTATE RIGHT BLKWHT 8A i GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT BLK 7A BLK 6 ORG RED 3 16 OG RD D B OG RD S P PLATFORM LEVEL DISABLE BERIA i ORG BLK 3__ 15 OG BK D B OG BK S P PLATFORM LEVEL DOWN ORG CR18A 30 ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP HM RED BLK 2A WHT 5 BLU RED 3 13 DRIVE ENABLE LIGHT BEDAWHT 3A WHT EH BLUWHT3 12 BLK S DRIVE ENABLE gt sf 220 4 BLUBLK 3 11 BU BK D B BU BK S P SEC BOOM DOWN 1515 C E TS16 BLU 3 10 BLU D B BLU S P SEC BLK RED 4 BLK RED 3 9 BK RD S P BOOM EXT RET F C 9 BLK WHT 4 BLK WHT 3 8 BK WT DB BK WT S P BOOM RETRACT WHT BLK 5A i BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND a i W R 4 WHT RED 3 6 WT RD S P TURNTABLE ROTATE 4 TS 1 0 WHT BLK 4 WHT BLK 3 5 WT BK D B WT BK S P TURNTABLE ROTATE LEFT 519 M TS17 WHT 4 WHT 3 4_ WHT D B WHT S P TURNTABLE ROTATE RIGHT LABEL DESCRIPTION L3 R VU O O R W 4 RED WHT 3 3 RD WT S P PRIMARY i I 7 5 amp G HWHURED 6A RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRIMARY BOOM DOWN 1
47. n m e BLU RED 3 WHT 5 os BRN 5 g pa DRIVE ENABLE n n WHT 1 RED 5 BLK 5 LIMIT SWITCH fe Tel g dg a a I m y a o ae BLU WHT 3 LO ia WHT BLK 1 WHT BLK 31 E H DRIVE EDC g o H y y i 9 9 WHT RED 1 z WHT RED 32 E H i lt r iei BRAKE O s L TRAVEL ALARM o S 9 OPTION BLU BLK 1 Eu BLU BLK 37 E H tel Ye STEER RIGHT BLU 1 BLU 36 E H t e 4 STEER LEFT 1 14 41 e PN e 1 1 n lL 1 E i lt Qi EN Qu le gt tl o Loe Bee ome 4 ci 3 ag ORG 1 WHT6 Z BRN G BOOM UP e DU LIMIT SWITCH T N aooo E WHEE EXTEND Penn A LIMIT SWITCH x o o z ooeo a TE Fe WHT RED 3 QS i 4 cU o o im WHT BLK 3 fe WHT 3 WHT E m TE TURNTABLE 1 ROTATE RIGHT ROTATE i i ee n LEFT WHT BLK 4 ni TURNTABLE ener a I a ei 9 4 ROTATE LEFT EDDAU i E p 1 4 WHT RED 4 n OE 1 7 ol v 7x E FLOW CONTROL a 5 RED n REDA PRIMARY t tod UP RED BLK BOOM UP PRIMARY BOOM SERERE DOWN RED BLK 4 PRIMARY ral IR DN au 3 e BOOM DOWN E DESCENT ALARM RED WHT 4 n PRIMARY BOOM a o FLOW CONTROL EE REB OW CONTRO RED BLK 3
48. ov Press down the foot switch and check voltage at terminal on controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department CHART 18 Repair open in wht blk 4 wire circuit from 5 to turntable rotate left directional valve coil item A OR repair open in brn ground wire circuit to valve coil Troubleshoot turntable rotate toggle switch OR repair open in wht blk wire circuit from TS17 to TB5 OR consult Genie Industries Service Department Repair open in wht blk 3 wire from TP5 to TB5 Repair open in power supply circuit from TP24 to controller OR repair open in brn ground wire circuit from ground to controller Section 5 e Troubleshooting Flow Charts March 2008 EE E II 1 CHART 18 REV B Continued from the Disconnect wires to ininite previous page turntable rotate left directional valve coil Replace turntable rotate item A a n left directional valve coil resistance of the valve coil See Repair Section 2 5 to 3 5 ohms function Hold function enable Operates Replace faulty directional valve Switch to either side and move the turntable rotate toggle switch in the LEFT direction Manually override the directional valve by pushing in on the end of the valve spool function inoperative function operates Install a 0 to 5000 PSI Exchange boom rotate 345 bar pr
49. 7 52 S 40 5 45 72136 2008 Section 7 e Repair Procedures REV B 11 8 MANIFOLDS Steer Manifold Components Non oscillating Models The steer manifold is located underneath the function manifold Index Schematic No Description Item Function 1 position 4 way DOS valve TT uus Steer left right ne 30 35 in Ibs 3 4 Nm A TEREX COMPANY Part No 72136 S 40 S 45 Section 7 Repair Procedures March 2008 MANIFOLDS 11 9 2WD Drive Manifold Components The drive manifold is mounted inside the drive chassis at the non steer end REV B Index Schematic No Description Function Torgue 1 Relief valve 250 psi 17 bar XX Charge pressure circuit 10 12 ft lbs 14 16 Nm 2 Shuttle valve 3 position way VM e Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 0 1002 15 18 ft Ibs 20 24 Nm Orifice plug 0 070 in 1 8 mm AL ien Drive circuit 4 Flow divider combiner valve AB Controls flow to drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 5 Diagnostic nipple Testing o 72 3 e 0 2 Grp B amp D Plug Torque Specifi
50. 7 DRIVE EDC mm O H 3 4 9 o WHT RED 1 WHT RED 32 E H ort z isi BRAKE DON M M TRAVEL ALARM o S OPTION BLU BLK 1 Eu BLU BLK 37 E H tel Ye STEER RIGHT BLU 1 BLU 36 E H gt 4 STEER LEFT ek 31 o e Ed lL 1 E Qi EN af EN t i o J Nr 5 ag ORG 1 WHT 6 BRN 6 Boom uP LE Vas LIMIT SWITCH T oleo 1 P eo sro ko n o9 WHEE EXTEND Qu 5 4 LIMIT SWITCH o asic Z ooao Es Hx Fe WHT RED 3 QS i d cU lt a m Fe WHT BLK 3 WHT 3 4 WHT 5 m WHTA TURNTABLE 1 ROTATE RIGHT E RIGHT WHT BLK m TURNTABLE ROTATE n LEFT WHT BLK 4 ni TURNTABLE messed eec a 4 ROTATE LEFT 2 ED KL El P e 8 RE 10 0 t icum lo meo nas 1 tss 8 FLOW CONTROL i RED mi m B RED PRIMARY t TUP ARV HOU RED BLK 4 SERRE Y DOWN RED BLK 4 y PRIMARY au p s d BOOM DOWN DESCENT ALARM 1 Lt RED WHT 4 n OFTON PRIMARY BOOM a o FLOW CONTROL RED 3 RED BLK 3 o Fu E_E RED WHT 3 amp E BLK 3 EXTEND 2 BOOM t RETRACT BLK WHT 3 5 t lt BLK 7711 BEKA BOOM EXTEND es EXTEND BLK WHT in BOOM T U BLK WHT 4 D to 1 RETRACT
51. 8 Remove the pin retaining fasteners from the jib boom lift cylinder barrel end pivot pin Do not remove the pin 9 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 10 Use a soft metal drift to remove the jib boom lift cylinder rod end pivot pin 11 Use a soft metal drift to remove the jib boom lift cylinder barrel end pivot pin then remove the jib boom cylinder Crushing hazard The jib boom AWARNING lift cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane 12 Remove the pin retaining fasteners from the jib boom pivot pin Use a soft metal drift to remove the pin then remove the jib boom from the bellcrank Crushing hazard The jib boom AWARNING could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane Section 7 Repair Procedures March 2008 JIB BOOM COMPONENTS S 45 MODELS 3 2 Jib Boom Lift Cylinder S 45 Models How to Remove the Jib Boom Lift Cylinder Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the pla
52. Cable Track The boom cable track guides cables and hoses running up the boom It can be repaired link by link without removing the cables and hoses that run through it Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom How to Remove the Cable Track When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Open the platform control box and remove the platform control box mounting fasteners 2 Disconnect the foot switch wiring from the terminal strip inside the platform control box Remove the cable from the machine A TEREX Boom Components S 45 Models 3 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located near the platform rotator Cap the fittings on the manifold AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tag disconnect and plug the hydraulic hoses from the platform leveling cylinder at the union and connect the hoses from the cylinder together using a connector AWARNING Bodily injury hazard Spraying hydraulic oil can pen
53. Check for Fuel Leaks Genie specifications require that this procedure be performed daily Failure to detect and correct fuel leaks will result in an unsafe condition An explosion or fuel fire may cause death or serious injury Explosion and fire hazard Engine ADANGER 3 fuels are combustible Inspect the machine in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach 1 Open the shutoff valve on the liquid petroleum gas LPG tank by turning it counterclockwise if equipped 2 Perform a visual inspection around the following areas Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B Gasoline LPG models LPG tank hoses and fittings solenoid shutoff valve LPG regulator and throttle body An LPG detector may be necessary to locate LPG leaks Gasoline tank manual shutoff valve fuel pump fuel filters fuel rail and fuel injectors hoses and fittings and throttle body Diesel models Fuel tank shutoff valve hoses and fittings fuel pump fuel filter fuel injection pumps and fuel injectors atomizers ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Part No 72136 A TEREX S 40 S 45 4 9 MPANY CHECKLIS A PROC
54. GRN WHT 19 20 JIB VALVE 19 GRN WHT 3 RED 27 PLAT ROT R 18 GRN BLK 3 D PLAT ROT 1 17 GRN 3 PLAT LVL 16 ORG RED 3 a o BLK RED 9 PLAT LVL DN 15 ORG BLK 3 PLAT LVL UP 14 ORG 3 Vd p DRV ENABLE LT 13 BLU RED 3 BLK WHT 8 x DRIVE ENABLE 12 BLUWHT 3 BLK 47 e SEC BOOMDN 11 BLU BLK 3 GRN 17 E SEC BOOM UP 10 BLU 3 GRN BLK 18 EXT RET F C 9 BLK RED 3 RETRACT 8 BLK WHT 3 XS EXTEND 7 BLK 3 RED BLK 2 TURN F C 6 WHT RED 3 RED 1 9 TURN R 5 WHT BLK 3 N 8 TURN ROT L 4 WHT 3 FN 4 J E lu PRIMARY 3 RED WHT 3 z x RED WHT 3 PRIMARY DN 2 RED BLK 3 5 PRIMARY UP 1 RED 3 9 J R ve CQ um WHT BLK 5 n 2 ag m u mu Fed WHT 4 po E O 7 gt a oos 7 112131415617 10 a E o 3 X a a co WHT RED 6 a 3 n ORG 14 5 8 RED BLK 1 ET ORG BLK 15 ORG RED 16 WHT CR14 GRN 43 T 5 X Og 5 lal gt FE pis S 7 gt gt 5 I gt i o gt lt amp x o 2 3o esc 3 iu 5 r9 a Z3 Ez asa SS Es ES zrSPOt jzgiz SusxzrE PozpiguTrosggz al sion alul Sa 23 gt gaa ale 2 lt Q90 gt 5 256 ocs lt CS Ex SSE
55. Genie part number 33957 a engine pivot plate b pivot plate retaining bolts c air baffle Part No 72136 S 40 5 45 4 59 Section 4 Scheduled Maintenance Procedures March 2008 Checklist D Procedures D 1 D 2 Check the Boom Wear Pads Check the Free wheel Configuration Genie specifications require thatthis procedure be performed every 1000 hours or every 12 months whichever comes first Maintaining the boom wear pads in good condition is essential to safe machine operation Wear pads are placed on boom tube surfaces to provide a low friction replaceable wear pad between moving parts Improperly shimmed wear pads or continued use of extremely worn wear pads may result in component damage and unsafe operating conditions If the wear pads are still within specification see Repair Procedure 4 2 How to Shim the Boom 1 Start the engine from the ground controls 2 Raise the end of the boom to a comfortable working height chest high then extend the boom 1 foot 30 cm 3 Measure each wear pad Replace the wear pad if itis less than specification If the wear pad is still within specification shim as necessary to obtain zero clearance and zero drag 4 Extend and retract the boom through the entire range of motion to check for tight spots that may cause binding or scraping of the boom Always maintain squareness between the outer and inner boom tubes Wear pad specifications Upper and side wear p
56. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray S 45 Models 3 Tag disconnect the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator and connect them together using a connector Cap the fittings on the manifold 4 Supportthe platform leveling arms and platform mounting weldment with an appropriate lifting device but do not apply any lifting pressure All Models 5 Remove the six mounting bolts from the platform mounting weldment Remove the center bolt and slide the platform mounting weldment off of the platform rotator Crushing hazard The platform AWARNING mounting weldment could become unbalanced and fall if it is not properly supported 6 Supportthe platform rotator with an appropriate lifting device Do not apply any lifting pressure S 40 5 45 7 13 Section 7 Repair Procedures March 2008 PLATFORM COMPONENTS 7 Support the platform leveling slave cylinder Protect the cylinder rod from damage 8 Remove the pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 9 Use a soft metal drift to drive both pins out then remove the platform rotator from the machine Crushing hazard The platform AWARNING rotator could become unbalanced and fall if it is not properly supported How to Bleed the Platform
57. UN i BLK 33B C TS17 TURNTABLE ROTATE SWITCH l WHT m ae E SE TS19 JIB UP DOWN SWITCH 522 TS22 CHECK ENGINE SWITCH enie A TEREX COMPANY 6 14 S 40 S 45 Part No 72136 Section 6 Schematics Gasoline LPG Models Platform Control Box Wiring Diagram March 2008 6 15 A TEREX COMPANY S 40 S 45 G Part No 72136 REV A N LO BLK 22 a O a BLK 26 5 WHT 23
58. a machine with a damaged or leaking radiator may result in engine damage Also restricting air flow through the radiator i e dirt or debris will affect the performance of the cooling system A frequent check allows the inspector to identify changes in the condition of the radiator that might indicate cooling system problems AWARNING P dily injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Remove the air baffle retaining fasteners Remove the air baffle A TEREX Ct S 40 S 45 REV B 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the radiator a engine pivot plate b pivot plate retaining bolts c air baffle o Inspect the radiator for leaks and physical damage 4 Clean the radiator fins of debris and foreign materials Inspect all radiator hoses and connections o Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 7 Replace the air baffle and install the air baffle retaining fasteners PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 4 Inspect the Battery Genie specifications reguire that this procedure be performed
59. and or hose end must be replaced and then torqued to specification 7 Remove the pin retaining fastener from the rod during installation Refer to end pivot pin Section Two Hydraulic Hose and Use a soft metal drift to remove the pin Fitting Torque Specifications 9 Remove the master cylinder from the machine 1 Remove the turntable end cover to access the master cylinder Crushing hazard The master AWARNING cylinder could become unbalanced 2 Raise the boom until the master cylinder and fall if it is not properly attached rod end pivot pin is accessible to the overhead crane 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray A TEREX COMPANY Part No 72136 S 40 S 45 7 25 Section 7 Repair Procedures March 2008 Turntable Covers 5 1 Turntable Covers How to Remove a Turntable Cover 1 Raise the turntable cover Support and secure the open cover with an overhead crane or forklift Do not lift it ACAUTION CAUTION Crushing hazard Due to its heavy weight do not attempt to support the cover by hand Component damage hazard Protect the cover from damage by using carpet or padding on the crane or fork lift forks 2 Remo
60. note the pressure less than 2000 psi Check for a positive connection between good electric motor and the pump by removing the pump from the motor Leave all the hoses connected and visually check coupling connection motor does not operate bad Replace the auxiliary power unit bad With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position move the Test PR1 See Repair Procedure 8 5 good auxiliary pump toggle switch to either side and check the voltage on the red cable on the auxiliary power unit Move the auxiliary pump 12V or toggle switch to either more side and check voltage at TB27 ov Move the auxiliary pump toggle switch to either side and check the voltage at the center 12V terminal of TS9 REV B Reconnect pressure hose and check battery condition There may not be enough battery capacity to operate both auxiliary pump and directional valves Repair or replace pump OR replace relief valve Consult Genie Industries Service Department Replace PR1 Repair open from TB27 to PR1 OR repair open in brn ground wire circuit to PR1 OR replace PR1 Repair open in red power supply wire from key switch to auxiliary pump toggle switch 12V or more Repair open in red 27 wire from TS9 to TB27 OR replace TS9 Continued on the next page Genie REX COMPANY S 40 S
61. o Fu n E RED WHT 3 N n BLK 3 EXTEND EE BOOM 5 1 RETRACT BLK WHT 3 BIK m Ey BLK 4 EL BOOM EXTEND ee a EXTEND BLK WHT 4 a 7 BOOM t BLK WHT 4 n uo 1 RETRACT BOOM RETRACT B 2 d 4 tn p BLK RED 4 T 5 EXTEND RETRACT g FLOW CONTROL BLK RED 3 ad n E ORG 3 1 PLATFORM LEVEL 2 DOWN lt ORG BLK 3 me m i 1 dq ORG 4 PLATFORM amp D 4 LEVEL UP E ol UP ORG BLK P PLATFORM LEVEL t Lo 1 DOWN m ORG BLK 4 PLATFORM iu LEVEL DOWN E m B 09 E BLk 6 RED 6 E ORG RED 3 5 PLATFORM LEVEL DISABLE m CE OPTION E GRN 3 RIGHT e PLATFORM ROTATE 4 w L LEFT z GRN BLK 3 m GRN BLK 0 PLATFORM ROTATE 3 RNCM RIGHT JIB DOWN Le SRIGHT PLATFORM GRN GRNWHT ROTATE PLATFORM ROTATE m LEFT GRN 4 LEFT JIB UP 99 P tn JIB BOOM 1 DOWN 3 3 o 2 2 ni m i c 71 10 j RED JIB BOOM 9 858 E 1 Je RED E VALVES n x 8 RED BLK z EDO D pe A Q WU m LIFT DRIVE i SELECTOR i9 10 iE e LE a a z tr E c ORG BLK 1 2008 Section 6 Schematics Electrical Schematic Deutz Diesel Mode
62. pushing in on the end of the valve spool function inoperative Install a 0 to 5000 PSI 845 bar pressure gauge at the quick disconnect coupling on the boom function function See operates Note 1 Replace faulty flow regulator valve manifold and start the engine Hold the function enable switch to either side and move the turntable rotate toggle switch in the RIGHT direction and check the pressure See Note 2 Continued on the next page valve item H Check turntable rotate right function function inoperative Repair turntable rotation motor OR function manifold may have an internal fault Consult Genie Industries Service Department Note 1 5 40 2600 psi or more 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts erd REV B CHART 19 Plumb a 0 to 5000 psi lessthan Function manifold could 345 bar pressure 250 psi have an internal fault gauge into the hose Consult Genie Industries from the function Service Department manifold to the turntable rotation brake Hold the function enable switch to either side and move the turntable rotate toggle switch in the RIGHT direction Continued from the previous page 250 psi or more Exchange turntable rotate right and left function counterbalance v
63. remove the blocks re AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage Steer wheels 4WD models 7 Chock the non steering wheels to prevent the machine from rolling 8 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the steer wheels 9 Lift the wheels off the ground and then place blocks under the drive chassis for support 10 Disengage the drive hubs by turning over the drive hub disconnect caps on each steer wheel hub a disengage position EN mf E arfi engage position Part No 72136 A TEREX CON S 40 S 45 4 61 MPANY CHECKLIST D PROCEDURES 11 Manually rotate each steer wheel Result Each steer wheel should rotate with minimum effort 12 Re engage the drive hubs by turning over the drive hub disconnect caps Rotate each wheel to check for engagement Lift the machine and remove the blocks llisi PI AWARNING Collision hazard Failure to re engage the drive hubs may cause death or serious injury and property damage All models 13 Be sure the free wheel valve on the drive pump is closed clockwise The free wheel valve is located on the drive pump and should always remain closed a drive pump b free wheel valve c liftpump d screwdriver Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES D 3 Che
64. valve coil Repair open in blk red 3 wire from TP9 to TB9 Repair open in power supply circuit from TP24 to TS7 Replace extend retract toggle switch S 40 S 45 Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts REV B 0 or infinite ohms Disconnect wires to boom extend directional valve coil item C and test the resistance of the valve coil See Repair Section Continued from the previous page Replace boom extend directional valve coil 2 5 to 3 5 ohms function Hold the function enable operates switch to either side and move the boom extend retract toggle switch in the EXTEND direction Manually override the directional valve by pushing in on the end of the valve spool Replace faulty directional valve function inoperative Install a 0 to 5000 PSI Check for mechanical 845 bar pressure restrictions keeping gauge at the quick boom from retracting disconnect coupling on OR repair cylinder or the boom function cylinder counterbalance manifold and start the valves OR consult engine Hold the Genie Industries Service function enable switch to Department either side and move the boom extend retract toggle switch in the RETRACT direction and check the pressure less than 1950 PSI function operates Exchange extend retract flow regulator valve item G with boom up down flow regulator valve item H Check
65. whichever comes first Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual Perkins part number TPD 1359E Genie part number 62424 PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV A C 8 Replace the PCV Valve Gasoline LPG Models Engine specifications reguire that this procedure be performed every 800 hours Yearly replacement of the PCV valve is essential to good engine performance A malfunctioning PCV valve can impair crankcase ventilation and may cause engine damage Perform this procedure with the engine off 1 Open the engine side turntable cover 2 Remove the air baffle retaining fasteners Remove the air baffle 3 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the PCV valve CHECKLIST C PROCEDURES 4 Locate the PCV valve on the engine under the intake manifold Detach the hose from the PCV valve a PCV valve b PCV valve hose Remove the valve from the valve cover Discard the valve 6 Thoroughly clean the inside and outside of the hose tubes and fittings 7 Install the new PCV valve and connect the hose 8 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts AT 3 47 9 Install the air baffle and the air baffle retaining FY V fasteners LI PCV Valve
66. 2 40 6 cm 41 9 cm Maximum horizontal reach 31 ft 8 in 31 ft 8 in 97 97 Wheel width 10 in 9 3 4 in 25 4 cm 24 8 cm Maximum turntable tailswing 34 in 34 in FN 86 4 86 4 Wheel lugs 80 5 8 18 90 5 8 18 x 7 Lug nut torque dry 170 ft lbs 230 Nm Wheelbase 7ft3in 7ft3in yg nut torque lubricated 130 ft lbs 176 Nm 2 2 2 2 Fluid capacities Minimum turning radius 15 ft 8 in 15 ft 8 in outside 4 8m 4 8m Fuel tank 30 gallons 114 liters Minimum turning radius 6 ft 8 in 6 ft 8 in LPG tank 33 5 pounds inside 2m 2m 15 2 kg Turntable rotation continuous continuous Hydraulic tank 45 gallons Platform rotation 160 160 EONS Hydraulic system 50 gallons Platform dimensions 6 ft Standard 6 ft Standard including tank 189 liters 8 ft Optional 8 ft Optional Drive hubs 17 fl oz Length x width 6 ft 72inx 30in 72inx 30in 0 5 liters 1 8m x 76 1 8m x 76 cm Length x width 8 ft 96inx36in 96inx36in Turntable rotation 8 fl oz Maximum capacity 500 Ibs 500 Ibs Continuous improvement of our products is a Genie 227 kg 227 kg policy Product specifications are subject to change without notice Part No 72136 S 40 S 45 2 1 Section 2 Specifications March 2008 SPECIFICATIONS REV B Machine Specifications 2WD RT 4WD RT S 45 Models Maximum allowable side force ANSI and CSA 150 Ibs 150 Ibs Stowed dimension
67. 22 Nm If necessary fit the pipe clamps 9 Clean and replace the sealing washers and fit the leak off line Tighten the banjo bolts to 7 ft lbs 9 Nm Part No 72136 A TEREX COMPANY Section 4 Scheduled Maintenance Procedures i CHECKLIST E PROCEDURES Bleed the system 10 Loosen the vent plug on the side of the fuel injection pump 11 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent point Tighten the vent plug 12 Clean up any fuel that may have spilled during this procedure 13 Operate the starter motor for intervals of 15 seconds until the engine starts Check for leaks ADANGER Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system S 40 S 45 4 81 Section 4 Scheduled Maintenance Procedures March 2008 M This page intentionally left blank A TEREX COMPANY 4 82 S 40 5 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts
68. 45 Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts E i REV B CHART 36 Check continuity from Replace negative cable negative terminal on from auxiliary pump auxiliary pump motor to motor to ground ground Continued from the previous page Replace auxiliary pump motor A TEREX COMPANY Part No 72136 S 40 S 45 5 73 Section 5 e Troubleshooting Flow Charts March 2008 __ This page intentionally left blank Genie 5 74 S 40 5 45 PartNo 72136 2008 Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie 5 40 and 5 45 Operator s Manual Be sure that all necessary tools and test eguipment are available and ready for use PartNo 72136 A TEREX S 40 S 45 6 1 MPANY Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING
69. 6 Replace the Drive Loop Hydraulic Filter Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Replacing the drive loop hydraulic filter is essential to good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of ACAUTION hot oil Contact with hot oil may cause severe burns Perform this procedure with the engine off 1 Locate the drive loop hydraulic filter mounted on the engine near the pump 2 Remove the filter housing by using a wrench on the nut provided on the bottom of the housing Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES Remove the filter element from the housing Inspect the housing seal and replace if necessary 5 Install the new filter and hand tighten the housing onto the filter head Clean up any oil that may have spilled during the installation procedure 6 Start the engine from the ground controls 7 Inspect the filter assembly to be sure that there are no leaks 8 Clean up any oil that may have spilled Drive loop hydraulic filter Genie part number 20880 A TEREX CON S 40 S 45 REV B D 7 Replace the Engine Oil and Filter Deutz Diesel Models Engine specifi
70. BLK 3 15 OG BK D B OG BK S P PLATFORM LEVEL DOWN ORG CR18A 30_ ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP HM WHT 5 BLURED a 13 DRIVE ENABLE LIGHT REDWHT 3A WHT E H BLUWHT 3 12 BLK 5 DRIVE ENABLE E 6 ed BLUBLK 3 11 BU BK S P SEC BOOM DOWN AU O 7515 7516 BLU 3 10 BLU S P BOOM o BLK RED 4 BLKRED3 9 BK RD SP BOOMEXT RET o BLK WHT 4 BLKWHT 3 8 BKWT D B BKWT S P BOOM RETRACT 4 a BOTSH WHT BLK 5A BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND an T W R 4 WHTRED 3 6 WT RD S P TURNTABLE ROTATE 1910 7519 ER yn WHT BLK 4 WHT BLK 3 5_ WT BK D B WT BK S P TURNTABLE ROTATE LEFT LABEL DESCRIPTION TS17 WHT 4 WHT 3 WHT D B WHT S P TURNTABLE ROTATE RIGHT m d O S R W 4 RED WHT 3 3 RD WT S P PRIMARY CIRCUIT BREAKER CONTROLS 15 o WHWRED GA RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRIMARY BOOM DOWN CB2 CIRCUIT BREAKER ENGINE 15A 1 RED D B 5 PRIMARY BOOM UP CRI IGNITION START RELAY a i GRN 17A HED 57 ORG REUHGD CR2 IGNITION POWER RELAY o N RESI 2 lw te PE CR3 HIGH IDLE RPM CUTOUT RELAY Gell HG a 3 GRNLK 188 CR4 HORN RELAY TS12 1 CB2 ey o ME 4 rf BURNS CR17 HYDRAULIC OIL COOLER OPTION RELAY 5 Y TS14 B S ae CR18A CE PLATFORM LEVEL RELAY OJ Tx E wnei CR18B CE PLATFORM LEVEL RELAY ORG RED 16A WHHBLCSB 244 2 BLU 3
71. BOOM 9 858 E 2 1 RED y I JIB VALVES n 18 ge BLK RED BLK 3 lo Ml 9 1 m LIFT DRIVE em SELECTOR 1 lm FEE ei 8 8 B 8 E c 2008 Section 6 Schematics Electrical Schematic Perkins Diesel Models 29 2008 Section 6 Schematics L Y Ground Control Box Wiring Diagram Perkins Diesel Models 2008 Section 6 Schematics REV A Ground Control Box Wiring Diagram Perkins Diesel Models A B D E F G H J K L M
72. BOOM FUNCTIONS CR18B F 1 SP SWITCH PANEL ORG BLK 4 AL TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH INLINE BLK amp RT EH JE T TS11 GLOW PLUG OPTION SWITCH C BLK D B TS12 FUNCTION ENABLE CR17 Li GRN 43D WHT 21D BLK RED 35B TS13 PLATFORM ROTATE SWITCH 8 5 BLK RED R4 E H TS14 PLATFORM LEVEL SWITCH CR5 515 BOOM EXTEND RETRACT SWITCH NU LEM C TS16 PRIMARY BOOM UP DOWN SWITCH Me A ES BLK 22D 441 T S17 TURNTABLE ROTATE SWITCH TS19 JIB UP DOWN SWITCH enie A TEREX COMPANY 6 30 5 40 5 45 Part No 72136 Section 6 Schematics Perkins Diesel Models Platform Control Box Wiring Diagram March 2008 6 31
73. G H J K L M N REV A 1 GRAWTA GRN WHT 1 GENERATOR OPTION GRN BLK EH GR BK 1 44 GR BK A H SPARE GRN R4486 GRN 1 43 HORN BLK 7 ORG REDA 42 SPARE O F OG BK E H ORG BLKi 4 ORG BK ISM 2 PULSE PICKUP a WHT 7 ORG 1 40 WHT 6 LIMIT SWITC
74. Genie REX COMPANY REV B Repair open in wht red 4 wire circuit from TB6 to turntable rotate proportional valve coil OR repair open in brn ground wire circuit to valve coil 4 to 6V__ Repair open in wht red wire from TP6 to TB6 Repair open in power supply circuit from TP24 to the controller OR repair open in brn ground wire circuit from ground to controller S 40 S 45 Part No 72136 2008 REV B Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the LEFT direction Check voltage on wht blk 4 wire on boom rotate directional valve coil item A 12V or more Continued on the next page PartNo 72136 Section 5 Troubleshooting Flow Charts m M Hold the function enable Switch to either side and move the turntable rotate toggle switch in the LEFT direction Check voltage at TB5 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the turntable rotate controller in the LEFT direction Check voltage at TB5 oV Press down the foot switch and move the turntable rotate controller in the LEFT direction Check voltage at TP5
75. Hose and Fitting Torque Specifications 1 Raise the boom until the boom is horizontal 2 Place support blocks across the turntable under the boom lift cylinder 3 Attach an overhead 5 ton 5 000 kg crane to the boom Do not lift the boom 4 Support the rod end of the boom lift cylinder with an appropriate lifting device Part No 72136 March 2008 Section 7 e Repair Procedures EE REV A BOOM COMPONENTS 5_ Tag disconnect and plug the boom lift cylinder 4 4 1 hoses Cap the fittings on the Extension Cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to sguirt or spray The extension cylinder extends and retracts the boom extension tube The extension cylinder is eguipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Extension Cylinder 6 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Lower the lift cylinder onto the blocks Protect the cylinder rod from damage This procedure reguires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could cause death or serious injury and significant component damage Dealer service is strongly recommended
76. Industries Service Department Check for poor terminal connections check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Isolate the ground and platform RPM toggle switches TS4 and TS12 check individually and replace faulty switch REV Refer to the fault code chart in this section for a description of the fault and recommended repairs S 40 S 45 Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts REV B Engine Stat engine move the solenoid Check high ae i select toggle 3 adjustment see High Idle switch TS12 to high idle PIS I Maintenance section Inoperative Diesel Models Be sure mechanical linkage is not binding or defective Be sure 2 speed solenoid grounding wires are free of corrosion and have full continuity to ground rabbit symbol and check if 2 speed solenoid pulls in solenoid does not pull in Check voltage at blk red wire on RPM select toggle switches TS4 and TS12 12V PartNo 72136 OR see Deutz OR Perkins workshop manual to troubleshoot fuel injection system Check voltage on red wire at center terminal of RPM select toggle switches Repair open in circuit supplying 12V to center terminal of toggle switch 12V Replace toggle switch Check voltage at TB35 2d Repair open in bl
77. OR replace the IAT sensor Faulty oil pressure Check engine oil level OR check for Low oil switch wires shorted to shorted wires or poor terminal connections pressure ground or not enough from the oil pressure switch to the ECM OR engine oil replace the oil pressure switch A TEREX COMPANY Part No 72136 S 40 S 45 5 5 Section 5 e Troubleshooting Flow Charts March 2008 FAULT CODE CHART REV Fault Code The CKP and CMP sensors work together if one is bad the other Crankshaft one won t work Position correctly and causes Check for shorted wires or poor terminal CKP sensor the ECM to detect a connections from the CKP and CMP senses extra fault ECM uses sensors to the ECM OR replace the CKP or or missing the signal pulses from CMP sensor pulses the CKP and CMP sensors to initiate seguential fuel injection The CMP and CKP sensors work together if one is bad the other Camshaft one won t work Position correctly and causes Check for shorted wires or poor terminal CMP sensor the ECM to detect a connections from the CKP and CMP senses fault The ECM uses sensors to the ECM OR replace the CKP or unknown the signal pulses from CMP sensor pattern the CKP and CMP sensors to initiate seguential fuel injection The ECM received an illegal instruction signal ECM Fault from one or more of the lllegal sensors has gone Replace the ECM Operation into a default program and
78. Phone 31 183 581 102 Fax 31 183 581 566
79. Plate sor ss e 7 29 7 3 Coolant Temperature and Pressure 7 30 Ford LRG 425 Engine 8 1 Timing 7 31 8 2 Blex Plate RUE 7 31 8 3 Coolant Temperature and Pressure 7 32 Ground Controls 9 1 Gontrol Relays nei To eei feeds 7 33 9 2 Toggle Switches See 1 4 Toggle 7 34 9 3 Wago Components 7 34 9 4 Engine Fault Codes Gasoline LPG Models 7 35 A Hydraulic Pumps 10 1 Lift Steer Pump 7 36 10 2 Drive PUMP csc e Y e Ret 7 37 S 40 5 45 XV 2008 Section 7 Rev Repair Procedures continued B Manifolds 11 1 Function Manifold 7 40 11 2 Valve Adjustments Function Manifold seeen 7 44 11 8 Turntable Rotation Manifold Components 7 46 11 4 Oscillate Manifold 7 48 11 5 Valve Adjustments Oscillate Manifold 7 49 11 6 Directional Valve Manifold Components 7 50 11 7 Steer Oscillate Manifold Components Oscillating Models 7 52 11 8 Ste
80. Rotator Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Connect a clear hose to the top bleed valve Place the other end of the hose in a container to collect any drainage Secure the container to the boom REV Move the platform rotate toggle switch to the left and then to the right through two platform rotation cycles continue holding the switch to the right until the platform is fully rotated to the right Open the top bleed valve but do not remove it Move the platform rotate toggle switch to the left until the platform is fully rotated to the left Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of 5 6 the platform during rotation Connect the clear hose to the bottom bleed valve Open the bottom bleed valve but do not remove it Hold the platform rotate toggle switch to the right until the platform is fully rotated to the right Continue holding the switch until air stops coming out of the bleed valve Close the bleed valve AWARNING Crushing hazard Keep clear of the platform during rotation 7 Remove the hose from the bleed valve and clean up any hydraulic oil that may have spilled 8 Rotate the platform full right then full left and inspect the bleed valves for leaks top bleed valve b bottom bleed valve c container d clear hose 7 14 S 40 5
81. S 45 perform the following procedure 3 Extend the boom until the wear pads are accessible 4 Loosen the wear pad mounting fasteners Install the new shims under the wear pad to obtain zero clearance and zero drag 6 Tighten the mounting fasteners 7 Extend and retract the boom through an entire cycle Check for tight spots that could cause binding or scraping Always maintain squareness between the outer and inner boom tubes COMPANY Part No 72136 S 40 S 45 7 19 Section 7 Repair Procedures BOOM COMPONENTS How to Remove the Boom 1 AWARNING Podily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform 2 Remove the platform rotator and leveling slave cylinder See 2 3 How to Remove the Platform Rotator S 45 Models 3 Remove the jib boom See 3 1 How to Remove the Jib Boom 4 Remove the cable track See
82. SP SWITCH PANEL TS9 AUXILIARY SWITCH TS10 ENGINE START SWITCH TS11 GLOW PLUG OPTION SWITCH TS12 FUNCTION ENABLE TS13 PLATFORM ROTATE SWITCH TS14 PLATFORM LEVEL SWITCH TS15 BOOM EXTEND RETRACT SWITCH TS16 PRIMARY BOOM UP DOWN SWITCH TS17 TURNTABLE ROTATE SWITCH 519 JIB UP DOWN SWITCH REVA Section 6 Schematics Deutz Diesel Models Platform Control Box Wiring Diagram March 2008 6 23 A TEREX COMPANY S 40 S 45 G Part No 72136 N LO BLK 22 O a
83. Troubleshooting Flow Charts March 2008 Chart 16 REV B Boom Extend With key switch turned Hold the function enable Repair open in blk red 3 Function to ground controls and switch to either side and wire circuit from TB9 to both Emergency Stop move the boom extend 9 to 10V boom extend retract 1 buttons pulled out to the toggle switch in the proportional valve coil Inoperative ON position hold the EXTEND direction Check OR repair open in brn function enable switch to voltage at TB9 ground wire circuit to Be sure all other either side and move the valve coil functions operate boom extend toggle switch TS15 in the EXTEND direction Check voltage on blk red 4 wire on boom extend retract proportional valve coil item G normally With key switch turned 9 to 10V Repair open in blk red 3 to platform controls and wire from TP9 to TB9 both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom extend retract toggle switch TS7 in the EXTEND direction Check voltage at TP9 oV Repair open in power circuit from TP24 to TS7 Press down the foot switch and check voltage at center terminal of TS7 12V or more 20V or more Test toggle switch TS7 bad EHO toggle switch see Repair Section good Repair open in blk red wire circuit from TS7 to TP9 Continued on the next page Genie REX COMPANY 5 34 S 40 5 45 PartNo 72136
84. adjust or replace linkage Adjust the seguence valve See Repair procedure 10 5 How to Adjust the Oscillate Seguencing Valve Pressure OR consult Genie Industries Service Department Section 5 Troubleshooting Flow Charts March 2008 Chart 26 Jib Boom Up Function Inoperative Be sure all other functions operate normally With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the position hold the function enable switch to either side and move the jib boom toggle switch TS19 in the uP direction Check voltage at the grn wire on the jib boom up directional valve item CC 12V With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on position press down the foot switch and move the jib boom toggle switch TS24 in the uP direction Check voltage at TB17 12V Continued on the next page Hold the function enable switch to either side and move the jib boom 12V toggle switch in the UP direction and check voltage at TB17 Repair open in red power wire circuit from key switch to TS19 OR replace TS19 Press down the foot 12V switch and move the jib boom toggle switch in the UP direction Check voltage at TP17 With the key switch 12V turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and check voltag
85. air cleaner canister Remove the air filter retaining fastener Remove the filter element Clean the inside of the canister and the gasket with a damp cloth Inspect the filter element If needed blow out from inside out using low pressure dry compressed air or tap out dust taking care not to damage the element Install the air filter element and install the mountingfastener Install the end cap onto the canister Install and tighten the retaining ring PartNo 72136 A TEREX S 40 S 45 MPANY a air filter b dustdischarge valve 4 Clean the inside of the canister and the canister end cap with a damp cloth 5 Inspect the filter element If needed blow out from inside out using low pressure dry compressed air or tap out dust taking care not to damage the element Install the filter element Install the end cap onto the canister Secure the retaining fasteners Air filters Genie part numbers Ford LRG 425 EFI Engine 27916 Deutz 1011F Engine 27916 Perkins 704 30 Engine 62420 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 3 Inspect the Radiator Liquid Cooled Models Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the radiator in good condition is essential for good engine performance Operating
86. all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the A DANGER presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Wheels chocked Part No 72136 S 40 S 45 4 1 Section 4 Scheduled Maintenance Procedures March 2008 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be reguired to perform this procedure Indicates that new parts will be reguired to perform this procedure Indicates that a cold engine will be
87. bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs 217 Nm Drive motor mounting bolts dry 110 ft lbs 149 Nm Drive motor mounting bolts lubricated 80 ft lbs 109 Nm How to Remove the Hub and Bearings 1 Loosen the wheel lug nuts Do not remove them Block the non steering wheels and place a lifting jack of ample capacity under the steering axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the lug nuts then remove the tire and wheel assembly Remove the dust cap cotter pin and slotted nut Always use a new cotter pin when installing a clevis pin Pull the hub off the spindle The washer and outer bearing should fall loose from the hub Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Section 7 Repair Procedures 2WD STEERING AXLE COMPONENTS How to Install the Hub and Bearings When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until it is flush 4 Slide the hub onto the yoke spindle Component damage Do not CAUTION apply excessive force or damage to the lip of the seal may occur Place the outer bearing into the hub Install the w
88. boom retract function Replace faulty flow regulator valve function inoperative Repair cylinder or cylinder counterbalance valve OR function manifold could have an internal fault Consult Genie Industries Service Department A TEREX COMPANY CHART 17 Part No 72136 S 40 5 45 Section 5 Troubleshooting Flow Charts March 2008 Chart 18 Turntable Rotate Left Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the LEFT direction Check voltage on wht red 4 wire on turntable rotate proportional valve coil item 12V or more Continued on the next page Hold the function enable switch to either side and move the turntable rotate toggle switch in 259 the LEFT direction and check voltage at TB6 ov With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move turntable rotate controller in the LEFT direction and check voltage at TP6 oV Press down the foot switch and check voltage at terminal on controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department
89. boom to the stowed position and turn the engine off 10 Inspect the following areas for burnt chafed corroded pinched and loose wires Cable track on the primary boom Cables on the primary and jib booms Jib rotate manifold Inside of the platform control box 11 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 12 Replace the air baffle and install the air baffle retaining fasteners Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B B 6 Check the Oil Cooler and Cooling Fins Deutz Diesel Models Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Maintaining the oil cooler in good condition is essential for good engine performance Operating a machine with a damaged oil cooler may result in engine damage Also restricting air flow through the oil cooler will affect the performance of the cooling system Bodily inj AWARNING injury hazard Do not inspect while the engine is running Remove the key to secure from operation Bodily injury hazard Beware of ACAUTION hot engine components Contact with hot engine components may cause severe burns Oil Cooler 1 Remove the engine side cover mounting fasteners Remove the engine side cover PartNo 72136 A TEREX S 40 S 45 MPANY CHECKLIST B PROCEDURES
90. chassis at the non steer end Index No Description Function Torgue 1 elas GY y Y Breather 2 20 25 ft lbs 27 33Nm 2 Spool valV6 22 iren Yd Directional control A TEREX COMPANY 7 50 S 40 S 45 Part No 72136 2008 Section 7 e Repair Procedures REV B How to Set Up the Directional Valve Linkage Adjustment of the directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Failure to perform this procedure on a level floor will compromise the stability of the machine and could result in the machine tipping over 3 Check the tire pressure in all four tires and add air if needed to meet specification 4 Remove the drive chassis cover from the non steer end 5 Disconnect the linkage clevis yoke from the drive chassis if not already disconnected 6 Place a bubble type level across the drive chassis side plates at the non steer end Check to be sure the drive chassis is completely level 7 Tolevel the drive chassis start the engine and push up or pull down on the linkage adjustment rod until the machine is completely level 8 Verify that the ground and drive chassis are completely level Part No 72136 A TEREX S 40 5 45 MANY MANIFOLDS 9 Adjust the l
91. consult Genie Industries Service Department Replace faulty flow regulator valve Note 1 S 40 2600 psi or more S 45 2900 psi or more Note 2 S 40 less than 2600 psi S 45 less than 2900 psi Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Platform Rotate Right Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the platform rotate toggle switch TS13 in the RIGHT direction Check voltage at grn blk 4 wire on platform rotate right directional valve item DD Continued on the next page 12V or more With key switch turned to ground controls and both Emergency Siop buttons pulled out to the ON position hold the function enable switch to either side and move the platform rotate toggle switch in the RIGHT direction Check voltage at TB18 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the platform rotate toggle switch in the RIGHT direction Check voltage at TB18 Troubleshoot platform rotate toggle switch TS13 OR repair open in red power wire circuit to TS13 OR repair open in grn blk wire circuit from TS13to TB18 OR consult Genie Industries Service
92. engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION 20dily injury hazard Beware hot engine components Contact with hot engine components may cause severe burns 1 Remove the air baffle retaining fasteners CHECKLIST A PROCEDURES 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the front engine access cover mounting fasteners mall A a engine pivot plate b pivot plate retaining bolts c air baffle 3 Remove the front engine access cover mounting fasteners models 4 Inspect the engine belt for Cracking Remove the air baffle Glazing Separation Breaks Part No 72136 S 40 5 45 4 21 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES 5 Replace belt if any damage is found Ford LRG 425 EFI engines are equipped with a serpentine belt and incorporate a self adjusting belt tensioner No adjustment is required Perkins Diesel models 6 Check the engine belt for proper tension Perkins Diesel engine 7 Install the front engine access cover 8 Swing the engine pivot plate back to its original position and install t
93. engine oil temperature gauge is an electrical gauge The engine oil temperature sending unit has limit contacts that are factory set The contacts will close at approximately 300 F 149 When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine oil temperature will be indicated on the gauge when the key is on and the Emergency Stop Button is pulled out to the on position The engine oil pressure gauge is an electrical gauge The engine oil pressure sending unit has limit contacts that are factory set The contacts will close at approximately 7 psi 0 48 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on the gauge when the engine is running REV A How to Remove the Oil Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Remove the fasteners from the engine side cover remove the cover 2 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the engine block 3 Install the new sending unit Do not over tighten 4 Connect the wires to the new sending unit Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Oil temperature sending unit specifications Torgue 8 10 ft lbs 11 14
94. foam and aeration suppression properties Optional fluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Guintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Part No 72136 CAUTION Continued use of Chevron Aviation A hydraulic oil when ambient temperatures are consistently above 32 F 0 C may result in component damage Use Chevron Aviation A hydraulic oil when ambient temperatures are consistently below O F 18 C Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 2059F 96 Genie specifications reguire additional eguipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie T 5 40 5 45 Section 2 Specifications March 2008 SPECIFICATIONS Ford LRG 425 EFI Engine Displacement 153 cu in 2 5 liters Number of cylinders 4 3 78 x 3 4 inches 96 01 x 86 36 mm Bore amp stroke Horsepower gross intermittent 97 continuous 82 horsepower 2500 rpm 70 Firing order 1 3 4 2 Low idle 1600 rpm 396 8 Hz High idle 2500 rpm 620 Hz Compression ratio 9 4 1 Compression pressure approx Pressure psi of lowest cyli
95. frequently a engine pivot plate 3 Put on protective clothing and eye wear 4 Disconnect the coolant return hose at the radiator and drain the coolant return tank into a suitable container Bodily injury hazard Beware of ACAUTION hot engine parts and coolant Contact with hot engine parts and or coolant will cause severe 5 Slowly remove the radiator cap from the burns radiator Perform this procedure with the Bodily injury hazard Allow any ACAUTION engine off and cooled pressure to dissipate gradually 1 Remove the air baffle retaining fasteners Delors removing te tadiaton Remove the air baffle 6 Open the drain valve on the radiator and allow all the coolant to drain into a suitable container 7 After all the coolant has drained close the drain valve Connect the coolant return hose to the radiator A TEREX COMPANY Part No 72136 S 40 5 45 4 75 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST E PROCEDURES 8 Open the drain valve on the engine block and allow the coolant to drain into a container After the fluid is drained close the drain valve 9 Replace all coolant hoses and clamps 10 Fill the radiator with the proper coolant mixture coolant and water for your climate until it is full 11 Fill the coolant recovery tank to the NORMAL range 12 Clean up any coolant that may have spilled during this procedure 13 Start the engine from the ground c
96. function inoperative Check for mechanical restrictions keeping turntable rotate left from operating OR replace shuttle valve item I OR consult Genie Industries Service Department A TEREX COMPANY Part No 72136 S 40 5 45 18 Consult Genie Industries Replace faulty counterbalance valve 5 41 Section 5 Troubleshooting Flow Charts March 2008 Chart 19 Turntable Rotate Right Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the RIGHT direction Check voltage on wht red wire on turntable rotate proportional valve coil item 5 12V or more Continued on the next page REX COMPANY Hold the function enable switch to either side and move the turntable rotate toggle switch in the RIGHT direction Check at TB6 With key switch turned to platform controls and both Emergency Siop buttons pulled out to the ON position press down the foot switch and move turntable rotate controller in the RIGHT direction Check voltage at TP6 oV Press down the foot switch and check voltage at terminal on controller 4 to 6V REV B Repair open in wht red 4 wire circuit from TB6 to turntable rotate proportional v
97. gasket Install the filter and tighten it securely by hand 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter PartNo 72136 A TEREX S 40 S 45 PANY CHECKLIST D PROCEDURES 8 Fill the engine with new oil per specifications and install the oil filler cap 9 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 10 Check the oil filter and drain hose for leaks 11 Check the engine oil level dipstick Add oil if needed Deutz F3L 1011F Engine Oil capacity including filter 8 5 quarts 8 liters Oil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 C 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Oil filter Genie part number 49924 4 67 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES D 8 Clean the Fuel Pump Strainer Deutz Diesel Models Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Cleaning the fuel pump strainer is essential for good engine performance and service life A dirty or clogged strainer may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions or not operating the machine for ext
98. gasoline and LPG fuel levels and warming the engine to normal operating temperature 1 Move the fuel select toggle switch to gasoline and then move the engine idle select switch to foot switch activated high idle rabbit and foot switch symbol 2 Start the engine from the platform controls and allow it to run at low idle PartNo 72136 A TEREX COMPA CHECKLIST B PROCEDURES Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle Release the foot switch and shut the engine off by pushing the red Emergency Stop button in to the off position Move the fuel select switch to LPG Start the engine and allow it to run at low idle Press down the foot switch to allow the engine to run at high idle Result The engine should start promptly and operate smoothly in low and high idle The engine may hesitate momentarily and then continue to run on the selected fuel if the fuel source is switched while the engine is running S 40 S 45 4 41 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 21 Test the Drive Enable System Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive enable system operation is essential to safe machine operation When the boom is past the non steering wheels drive movement is st
99. head With the assembly in this position engage and tighten the setscrew Bleed the system 10 Loosen the vent plug on the side of the fuel injection pump 11 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent e point Tighten the vent plug 12 Clean up any fuel that may have spilled during this procedure 13 Operate the starter motor for intervals of 15 Setscrew upper seal O ring filter element lower seal bottom cover 4 Lower the bottom cover of the filter 5 Remove the element and dispose of properly 6 Clean the inside surfaces of the filter head and the cover 7 Lightly lubricate the upper seal and the O ring with clean fuel and install them into the filter head 8 Lightly lubricate the lower seal with clean fuel and install it into the bottom cover A TEREX COMPANY seconds until the engine starts It is important to allow the starter motor to cool for 30 seconds between each 15 second interval of operation If the engine runs correctly for a short time and then stops or runs roughly check for air in the fuel system If there is air in the fuel system there is probably a leak in the low pressure side of the system Part No 72136 S 40 5 45 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES C 5 Replace the Engine Oil and Filter Perkins Diesel
100. improperly operating Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation for groundand platform personnel As a safety feature selecting and operating the ground controls will override the platform controls including the platform Emergency Stop button 1 Start the engine from ground controls 2 Push down the red Emergency Stop button to the orr position Result The engine should shut off and no machine functions should operate Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds 3 Start the engine from platform controls Push down the red Emergency Stop button to the orr position Result The engine should shut off and no machine functions should operate The ground control Emergency Stop button will stop all machine operation even if the Key switch is switched to platform control PartNo 72136 A TEREX S 40 S 45 MPANY CHECKLIST B PROCEDURES B 14 Test the Ground Control Override Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning ground control override is essential to safe machine operation The ground control override function is intended to allow ground personnel to operate the machine from the ground controls whether or not the Emergency Stop button on the platform controls is
101. internal fault Consult Genie Industries Service Department A TEREX COMPANY CHART 16 Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 17 Boom Retract Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom extend retract toggle switch TS15 in the RETRACT direction Check voltage on blk red 4 wire on boom extend retract proportional valve coil item G 12V or more Continued on the next page Hold the function enable switch to either side and move the boom extend 9 to 10V retract toggle switch in the EXTEND direction Check voltage at TB9 With key switch turned 9 to 10V to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom extend retract toggle switch TS7 in the RETRACT direction Check voltage at TP9 ov Press down the foot switch and check voltage at center terminal of TS7 12V or more Test extend retract bad toggle switch see Repair Section good Repair open in blk red wire circuit from TS7 to TP9 REV Repair open in blk red 4 wire circuit from TB9 to boom extend retract proportional valve coil OR repair open in brn ground wire circuit to
102. is properly supported 14 Lower the rod end of the boom lift cylinder onto support blocks Protect the cylinder rod from damage 15 Remove the pin retaining fastener from the boom pivot pin 16 Remove the boom pivot pin with a soft metal drift Carefully remove the boom from the machine Crushing hazard If the overhead crane is not properly attached the boom may become unbalanced and fall when it is removed from the machine Part No 72136 A TEREX S 40 5 45 7 21 MPANY BOOM COMPONENTS How to Disassemble the Boom Complete disassembly of the boom is only necessary if the outer or inner boom tubes must be replaced The extension cylinder can be removed without completely disassembling the boom See 4 4 How to Hemove the Extension Cylinder 1 Remove the boom See 4 2 How to Hemove the Boom 2 Place blocks under the extension cylinder for support 3 Remove the pin retaining fastener from the extension cylinder barrel end pivot pin at the pivot end of the boom Use a soft metal drift to remove the pin 4 Remove and label the wear pads from the platform end of the boom Pay careful attention to the location and amount of shims used with each wear pad Section 7 Repair Procedures March 2008 BOOM COMPONENTS 5 Support and slide the extension tube and extension cylinder out of the boom tube Crushing hazard The extension AWARNING tube could become unbalanced and fall whe
103. kit Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings ORFS tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 15 ft lbs 20 3 4 18 ft lbs 24 4 Nm 6 35 ft lbs 47 5 Nm 6 30 ft Ibs 40 7 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 100 ft lbs 135 6 Nm 10 60 ft lbs 81 3 Nm 12 135 ft lbs 183 Nm 12 85 ft lbs 115 Nm 16 200 ft lbs 271 Nm 16 110 ft lbs 149 Nm 20 250 ft lbs 334 Nm 20 140 ft Ibs 190 Nm 24 305 ft lbs 414 Nm 24 180 ft lbs 244 Nm 2 10 S 40 S 45 Part No 72136 2008 Section 2 Specifications REV A SPECIFICATIONS SAE FASTENER TORGUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual THREAD Grade5 2 Grade 8 LUBED LUBED LUBED indbs_ Nm indbs Nm infbs Nm j Nm inlbs Nm vq 20 80 9 10 113 10 124 140 158 f 159 147 28 90 101
104. o A O 4 Setthe preliminary ramp rate Turn the ramp rate trimpot adjustment screw counterclockwise 15 turns or until you hear a repeated click 5 Connect the red lead from a volt meter to the A terminal on the controller printed circuit board Connect the black lead to ground 6 Set the threshold Press down the foot switch then slowly move the control handle off center until the moment a voltage reading appears Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Part No 72136 A TEREX COMPAR PLATFORM CONTROLS Set the max out Press down the foot switch then move the control handle all the way to the up position Adjust the voltage to 6 5V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Set the lo range Press down the foot switch then move the control handle all the way to the DOWN position Adjust the voltage to 4 8V DC Turn the lo range trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Start the engine and move the engine idle control switch to foot switch activated high idle rabbit and foot switch symbol Lower the boom to the stowed position Engine should be at normal operating temperature 10 Start a timer and record how long it takes for the
105. platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 19 3 Test the Engine Idle Select Operation Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first A properly operating engine idle select switch is essential to good engine performance and safe machine operation There are three settings 6 Low idle turtle symbol allows the operator to control individual boom functions only Drive o functions do not operate at low idle High idle rabbit symbol allows the operator 7 to control multiple boom and or drive functions simultaneously This setting maintains a consistent high idle and is usually selected only when the generator option is being used Foot switch activated high idle rabbit and foot switch symbols should be used for normal machine operation This selection activates high idle only when the foot switch is pressed down 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Start the engine from the ground controls Move and hold the function enable toggle switch in the high idle rabbit symbol position Result The engine RPM should change to high idle
106. pump disconnect the fuel hose to the fuel tank and drain the fuel tank into the container 5 Remove and replace all of the fuel hoses and clamps according to the following illustration Explosion and fire hazard Fuel Injection systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too quickly Loosen the fuel lines very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV CHECKLIST D PROCEDURES 6 p 5 p p p D 11 Check the Engine Valve Clearances Perkins Diesel Models Engine specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first la AU A a on S e ca Complete information to perform this procedure is available in the Perkins User s Handbook Perkins part number TPD 1359E Genie part number 62424 0 9 5 9 a hose from the injector to the fuel tank b hoses connecting injectors hose from the fuel shutoff valve to the fuel pump d hose from the fuel pump to the fuel filter e hose from the fuel filter to the injection pump hose from the injection pump to the injectors Part No 72136 S 40 5 45 Section 4 Scheduled M
107. relief valve specifications Pressure 2200 psi 152 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap index 6 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and check the relief valve pressure Part No 72136 2008 Section 7 e Repair Procedures REV B How to Adjust the Boom Extend Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 1 3000 psi 0 to 207 bar pressure gauge to the test port index 25 on the function manifold Start the engine from the ground controls 3 Hold the function enable switch to the high rpm rabbit symbol side and activate and hold the extend switch with the boom fully extended Observe the pressure reading on the pressure gauge Boom extend relief valve specifications Pressure 1950 psi 134 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap index 5 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Then install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than speci
108. the saw horses 5 Remove the platform mounting fasteners and remove the platform from the machine AWARNING Crushing hazard The platform could become unstable and fall if it is not properly supported Part No 72136 A TEREX 5 40 5 45 MPANY Platform Components 2 2 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the entire range of boom motion It operates in a closed circuit hydraulic loop with the master cylinder The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Slave Cylinder Before cylinder removal is considered to correct a malfunction bleed the slave cylinder to be sure there is no air in the closed loop hydraulic circuit When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Adjust the platform to a level position 2 Extend the boom until the slave cylinder barrel end pivot pin is accessible Section 7 Repair Procedures March 2008 PLATFORM COMPONENTS 3 Raise the boom slightly and place saw horses of ample capacity under the platform mounting weldment Lower the boom until the p
109. this procedure be performed daily Drive Limit Switches Detecting limit switch malfunctions is essential to safe machine operation The drive limit switches are used to restrict drive speed when the boom is raised or extended An improperly functioning drive limit switch will allow the machine to operate in an unsafe position 1 Remove the cover from the rear of the turntable to access the drive limit switch 2 Visually inspect the boom up drive limit switch mounted to the turntable riser at the pivot end of the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loose wiring a turntable riser b boom boom up drive limit switch LS2 PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV 3 Manually activate the boom up drive limit switch Result The boom up drive limit switch arm should move freely and spring return to center A distinct click should be felt and heard 4 Visually inspect the boom extend drive limit switch located at the end of the cable track on the boom Inspect for the following Broken or missing roller or arm Missing fasteners Loose wiring boom extend drive limit switch LS1 b cable track 5 Start the engine from the ground controls Extend the boom approximately 3 feet 0 9 m 7 Manually activate the boom extend drive limit switch Result The boom extend drive limit switch arm sho
110. thread sealant when installing the drain plug and strainers Use only Rykon MV equivalent hydraulic fluid Hydraulic system Hydraulic tank capacity 45 gallons 170 liters Hydraulic system 55 gallons capacity including tank 208 liters Hydraulic fluid Rykon MV equivalent Part No 72136 2008 Section 7 e Repair Procedures REV A How to Prime the Pump Component damage hazard Be CAUTION sure that the hydraulic tank shutoff valves are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component 4 damage will occur 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple on the drive pump 2 Gasoline LPG models Close the valve on the LPG tank then disconnect the hose from the 5 tank Move the fuel select toggle switch to the LPG position 6 Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the closed position Wyr a WU CHOED Ke Sof VP T NN 2 PAN manual fuel shutoff valve Genie A TEREX COMPANY FUEL AND HYDRAULIC TANKS Perkins Diesel models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 250 psi 17 2 bar Gasoli
111. to 60 seconds Ramp rate 3 to 4 seconds 7 4 A TEREX COMPANY S 40 5 45 REV Turntable Rotation Controller Adjustments Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Do not adjust the controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output 1 Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Do not start the engine 3 Open the platform control box lid and locate the turntable rotation controller Refer to the platform control box illustration page 7 2 Part No 72136 March 2008 Section 7 e Repair Procedures REV A PLATFORM CONTROLS 7 Set the max out Press down the foot switch fully retract the boom then move the control handle all the way to the left or right Adjust the voltage to 5 7V DC Turn the max out trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage Engine should be at normal operating temperature 8 Fully retract the boom then start a timer and record how long it takes the turntable to rotate a ramp rate trimpot through a compl
112. wheel bearings W Result If there is side to side or up and down movement continue to step 11 and replace the wheel bearings with new ones When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The washer and outer bearing should fall loose from the hub 13 Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing 14 Pack both bearings with clean fresh grease PartNo 72136 A TEREX S 40 S 45 MPANY CHECKLIST E PROCEDURES 15 Place the large inner bearing into the rear of the hub 16 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the hub 17 Slide the hub onto the yoke spindle CAUTION Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur 18 Place the outer bearing into the hub 19 Install the washer and castle nut 20 Tighten the slotted nut to 158 ft lbs 214 Nm to seat the bearings 21 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 Nm 22 Install a new cotter pin Bend the cotter pin to lock it in place Always replace the cotter pin with anew one when rem
113. wires for the hydraulic manifold valves are free of corrosion and have full continuity to ground Install a 0 to 5000 PSI 345 bar pressure gauge on the function manifold Start engine hold the function enable toggle switch to either side and move the boom retract toggle switch TS7 in the RETRACT direction Check the hydraulic pressure Adjust the function manifold system relief valve item X all the way in clockwise counting the number of turns Hold the function enable switch to either side and move the boom retract toggle switch in the RETRACT direction and check the hydraulic pressure See Note 2 Check steer functions Check the function pump see Repair section Replace the function pump A TEREX COMPANY Part No 72136 S 40 S 45 steering operates steering inoperative Chart 11 Troubleshoot each function individually or consult Genie Industries Service Department Hold the function enable switch to either side and move the boom retract toggle switch in the RETRACT direction and adjust the relief pressure to 2600 psi Repair or replace differential sensing valve item W OR repair or replace priority flow regulator valve item BB OR manifold has an internal fault consult Genie Industries Service Department Replace the relief valve item X OR manifold has an internal fault Consult the Genie Industries Service Department Note 1 S 40
114. with the engine off 1 Place a suitable container under the hydraulic tank return filter Part No 72136 S 40 5 45 4 47 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 28 Replace the Engine Air Filter Element Engine specifications requires that this procedure be performed every 400 hours or annually whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage Perform this procedure with the engine off Gasoline LPG and Deutz Diesel Models 1 Open the engine side cover and remove the retaining ring from the end cap of the air filter canister 2 Remove the end cap from the air cleaner canister 3 Remove the air filter retaining fastener Remove the filter element 4 Clean the inside of the canister and the gasket with a damp cloth 5 Install the new air filter element and install the mounting fastener A TEREX CON S 40 S 45 REV B 6 Install the end cap onto the canister Install tighten the retaining ring Perkins Diesel models 1 Open the engine side cover and disconnect the retaining fasteners from the end cap of the air filter canister Remove the end cap 2 Remove the filter element 3 Empty the dust discharge valve b
115. 0 C2 USED i Y VPWR 9 37Y12 570BK W18 H X2 POWER GROUND PK BK FUEL PUMP OUTPUT 5 767PK BK16 570ABK W18 GROUND VREF 3172 351DBR W20 570BBK W18 lt Wi POWER GROUND 1 28 BK W BATTERY 34 570 12 e i e 570 18 t W2 POWER GROUND BK W BATTERY 42 9 570EBK W12 C3 NOT USED P DATALINK 22 107P20 NOTUSED DB BK DRIVE BY WIRE SIGNAL INPUT 14 151LB BK20 G2 NOT USED GN O AUXILARY INPUT 37 198DG O20 G3 NOT USED W P SELF TESTINPUT 18 209W P20 107P20 1 LINK ff 31 2 3 5 T LB GOVERNOR SPEED CONTROL 241 306T LB20 151LB BK20 A1 DRIVE BY WIRE GOVERNOR SPEED CONTROL 25 9 307BK Y20 198DG O20 L1 AUXILLARY INPUT lal L A PK LG FAULTLIGHT 6 9 658PK LG20 209W P20 SELF TEST INPUT Y BK FUEL SELECT 7 2 674Y BK20 306T LB20 J2 GOVERNOR SELECT 1 M T O DATA LINK CONNECTOR 11 914 20 307 2 K2 GOVERNOR SELECT 2 i D 5 PK LB DATA LINK CONNECTOR 3 915PK LB20 658PK LG20 R3 MALFUNCTION INDICATOR LAMP N i BL STARTER INPUT 15 2 32ADKBL16 674BR W20 FUEL SELECT 1 GY R DRIVE BY WIRE SIGNAL RETURN 33 359LGY Y20 914 20 2 DATALINK CONNECTOR R LB STARTER OUTPUT 131 32R LB16 915PK LB20
116. 008 Section 5 Troubleshooting Flow Charts Fault Code Chart REV 011 Noma operation Throttle Faulty TP sensor OR Position TP sensor wires shorted to sensor low ground OR poor voltage terminal connection Check for poor terminal connections OR shorted wires from the TP sencor to the ECM OR replace the TP sensor Manifold Absolute Faulty MAU SOS Check for poor terminal connections OR sensor wires shorted to Pressure wires shorted to ground OR replace MAP MAP sensor ground OR poor sensor low voltage terminal connection Engine speed cr Check for obstructions in the throttle body Obsrtruction in throttle exceeded bodv OR faultv ECM that could cause binding of the throttle 4000 RPM y y assembly OR replace ECM The ECM senses a signal from the TP sensor that is greater than 4 9V DC OR the Check for poor terminal connections OR TP sensor wiring is shorted wires from the TP sensor to the shorted to ground OR ECM OR replace the TP sensor there is a poor terminal connection OR the TP sensor is faulty Throttle Position TP sensor high voltage Manifold Absolute Faulty MAP sensor OR Pressure sensor wires shorted to shorted wires from the MAP sensor to the Check for poor terminal connections OR ground OR poor MAP sensor terminal connection high voltage ECM to ground OR replace MAP sensor A TEREX COMPANY PartNo 72136 5 40 5 45 5 3 Sectio
117. 08 Section 4 Part No 72136 TABLE OF CONTENTS Rev Scheduled Maintenance Procedures continued B Checklist B Procedures B 1 Check the Exhaust System 4 30 B 2 Inspect the Engine Air 4 25 B 3 Inspect the Radiator Liquid Cooled 4 26 B 4 Check the 4 27 B 5 Inspect the Electrical 4 28 B 6 Check the Oil Cooler and Cooling Fins Deutz Models 4 29 B 7 Check the Hydraulic Tank Return Filter Condition Indicator 4 30 B 8 Inspect the Tires Wheels and Lug Nut Torque 4 31 B 9 Confirm the Proper Brake Configuration 4 32 B 10 Check the Level in the Drive 4 33 B 11 Check and Adjust the Engine 044 447 001 4 35 B 12 Test the Key 0 12222 enne 4 36 B 13 Test the Emergency Stop 4 37 B 14 Test the Ground Control Override 4 37 B 15 Check the Directional Valve 4 38 B 16 Test the Platform Self leveling 4 38 B 17
118. 1 1 LS1 2 3 Contact Limit switch O un ed GG 19491 Telemecanique XESP2151 3 Level sensor Level sensor 4 5 44586 Power Comp of Midwest L836 04 5L 1 501 1 P1 P2 Contact 128499 Laughlin ZBBATA 4 Contact 45081 Telemecanique 2 2 101 1 PR1 Relay 12V DC continuous 27155 Stancor 70 902 1 This list continues on the next page A TEREX COMPANY 2 S 40 5 45 PartNo 72136 2008 Section 6 Schematics mu A er ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number FD med Resistor 100 25 watt 27287 825F10R 1 TS1 TS9 Toggle switch DPST 2 position momentary 13480 Microswitch Control Inc 2 1 8 2 52 5 8 10 121 Toggle switch SPDT position momentary 13037 Microswitch Control Inc WNT lt f iiie 6 TS20
119. 11F rated at 36 horsepower 3000 rpm anda Perkins 704 30 rated at 63 horsepower 2600 rpm Hydraulic System All machine functions are performed by the hydraulic system The hydraulic system can be divided into two groups Boom Steer functions and Drive functions Boom Steer functions are powered by a single section gear pump rated at 10 gpm 37 9 L min When the engine is running this pump supplies hydraulic fluid under pressure to the function manifold where the directional and flow control valves are located To protect from over pressurization of the Boom Steer system the pump is provided with a pressure relief valve set at 2900 psi 200 bar for the S 45 and 2600 psi 180 bar for the S 40 Drive functions are powered by a bi directional variable output piston pump rated at 0 to 31 6 0 to 119 6 L min 2500 rpm Two internal 3500 psi 241 bar relief valves are used to prevent over pressurization of the closed loop drive system The boom lift cylinder boom extend cylinder platform leveling slave cylinder platform rotator and jib boom cylinder S 45 only incorporate counterbalance valves to prevent movement in the event of a hydraulic line failure Part No 72136 A TEREX CON S 40 S 45 3 1 MPANY Theory Of Operation Electrical System Boom Steer functions are accomplished by moving a toggle switch or a controller which sends voltage to the appropriate directional control valve Thes
120. 120 135 120 135 160 18 140 158 a LUBED DRY LUBED DRY LUBED ftibs Nm ftibs Nm ftibs Nm ftibs ftibs Nm 516 18 13 6 17 23 18 24 25 339 121 284 2 4 a9 149 257 20 271 27 366 325 745 60 81 3 90 1084 62 921 1016 80 1084 110 149 93 16 90 80 90 110 38 16 24 716 L14 20 115 108 4 149 162 13 1 20 916 2 18 01 10 203 18 10 16 9 14 230 366 515 406 569 583 827 637 908 8 867 1233 12 962 990 1342 7 12 7 1071 1206 1518 12 930 1260 1240 1681 6 212 1 1 1 1 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 2 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067 METRIC FASTENER TOROUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Size Class 4 6 Class 8 8 Class 10 9 Class 12 9 LUBED LUBED LUBED Nm in Ibs Nm in bs Nm in tbs in lbs Nm in bs Nm in tbs Nm 24 41 463 54 618 58 663 78 884 f 68 775 91 103 407 69 7 87 93 105 100 113 132 15 16 132 155 17 6 Nm ftibs Nm ftlbs Nm ftibs Nm ftibs ftibs Nm ftibs Nm 175 278 1 1055 682 925 909 1233 mm JR U m di olo ol Ala ajojo N aj 1
121. 1950 psi 134 bar Oscillate axle 950 psi 66 bar Steer regulator 2WD non oscillating models 2 gallons per minute 7 6 liters per minute 2WD oscillating models and 4WD models 1 5 gallons per minute 5 7 liters per minute Auxiliary pump Front drive motors 4WD models Type fixed displacement gear pump Displacement Displacement static 0 152 cu in per revolution 1 52 cu in 25 cc 2 5 cc Non steer end drive motors Displacement 1 4 gallons per minute 5 3 liters per minute Displacement per revolution 2 13 cu in 35cc Auxiliary pump 2000 psi relief pressure 138 bar Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 5 40 5 45 Part No 72136 2008 Section 2 Specifications REV B Hydraulic Oil Specifications Hydraulic Oil Specifications Hydraulic oil type Viscosity grade Chevron Rykon MV eguivalent Multi viscosity Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron lll oils Genie specifications reguire hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and
122. 2600 psi or more S 45 2900 psi or more Note 2 S 40 less than 2600 psi S 45 less than 2900 psi Section 5 Troubleshooting Flow Charts March 2008 Chart 12 Does the engine start yes from ground controls Ground Controls Inoperative Platform Controls Operate Normally Be sure all other functions operate normally including the platform controls no With both Emergency Stop buttons pulled out to the ON position check voltage at red wire on the input side of the ground controls contact of the key switch the red wire checked should originate at the Emergency Stop button With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the position check voltage at red wire on the output side of the ground controls contact on the key switch Repair open in red wire circuit from key switch to function enable toggle switch to each function toggle switch Genie Start the engine from ground controls Hold the function enable toggle switch to either side and check the voltage on both center terminals of the platform rotate toggle switch 13 12V Troubleshoot each function individually Repair open in red wire circuit from Emergency Stop button to key switch Check if key switch internal cam is activating ground contact no Replace key switch REV Repair open in red wire circuit from key
123. 3 1 How to Remove the Boom Cable Track 5 Raise the boom to a horizontal position A TEREX COMPAN 5 40 5 45 2008 REV Remove the turntable end cover Remove the retaining fastener from the master cylinder rod end pivot pin Use a soft metal drift to remove the pin Pull the cylinder back and secure it out of the way CAUTION Component damage hazard When pulling the master cylinder back be sure not to damage the master cylinder hoses or fittings Remove the fasteners from the drive speed limit switch mounted to the turntable riser at the pivot end of the boom Do not disconnect the wiring Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Attach an overhead 5 ton 5 000 kg crane to the center point of the boom 11 Attach a similar lifting device to the boom lift cylinder 12 Place support blocks across the turntable under the lift cylinder Part No 72136 2008 Section 7 Repair Procedures REV A 13 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The boom lift AWARNING cylinder will fall unless it
124. 30 seconds Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications March 2008 SPECIFICATIONS Hydraulic Specifications Drive pump Type bi directional variable displacement piston pump Displacement 2500 rpm O to 31 6 gallons per minute 0 to 119 6 liters per minute Maximum drive pressure 3500 psi 241 3 bar Charge pressure neutral position 290 psi 20 bar drive position 250 psi 17 bar Medium pressure filter 3 micron Medium pressure filter 50 psi bypass pressure 3 4 bar Drive manifold Brake relief pressure 250 psi 17 2 bar Steer end drive motors 4WD models 4WD front motor flow regulators 2 5 to 8 gallons per minute 9 4 to 30 2 liters per minute 4WD rear motor flow regulators 5 to 15 gallons per minute 18 9 to 56 7 liters per minute 2WD rear motor flow regulators 8 to 22 gallons per minute 30 2 to 83 2 liters per minute REV B Function pump Type pressure balanced gear Displacement static 1 03 cu in 17 Displacement 2500 rpm O to 12 3 gallons per minute 0 to 46 6 liters per minute Hydraulic tank circuit return line filter 10 micron with 25 psi 1 7 bar bypass Function manifold Function relief valve pressure S 40 2600 psi 179 bar 5 45 2900 200 Boom down 2200 psi relief valve pressure 152 bar Boom extend
125. 37 PIN 9 3 y x PNK BLK FEH 787 PIN 5 m BLK WHT 570 34 4 BLK WHT 570 PIN 42 D CAEN ONES J FUEL PUMP Ug a 8 3 LPG LOCKOUT SOLENOID arti i cei RED FEH 36IN aua LT m DGRN FEH24 592 958 ux eco Wn ay OF 88 HIGH IDLE CUTOUT RELAY a STARTER RELAY e cc alt 1 c s s M j oi STARTER MOTOR S a AUXILIARY _ AUXILIARY 3 3 PUMP M 1 PUMP RED F RED 27 E H 858 AUXILIARY POWER amp amp t RELAY xl 1 E RED 1 toH amp le a gt gt AUXILIARY PUMP E a5 _ 8 RED RED RED BLK 1 pr RED BLK 28 E H 1 1 RED WHT 23 E H x 9 m e lu LEVEL SENSOR g g L SSE 1 gt i x a 2 ato e9 arn GRN 1 GRN el alts HORN RELAY 3 x 5 7 A a 4 BLK 2 B BLK O78 BLKER5 EH Ed Lt HORN Y r Ez O WHTHRIZ EH HYDRAULIC OIL 2 t SS sits TEMPERATURE a5 SM SWITCH cA roi Tied TZ a LE 1 u RED 8 15 17 zu COOLING FAN OPTION r 0 WHT 21 E H ET 2 RED E H ORG BLK 1 ORG BLK 41 E H A Q a t 5 a ml uw 3g ads mig 27 5 Ot O1 Q RED REDH20 E H I Part No 72136 A TEREX COMPANY
126. 41 Nm 30 Solenoid valve Poppet DD Platform rotate right 25 30 ft lbs 34 41 Nm 31 Flow regulator valve 0 6 2 27 l min EE Platform rotate 10 12 ft Ibs 14 16 Nm 32 Counterbalance FF Platform level 35 40 ft lbs 47 54 Nm 33 Counterbalance GG Platform level down 35 40 ft lbs 47 54 Nm 34 Check valve seen Boom extend retract circuit 11 13 ft Ibs 15 18 Nm Plug Torque Specifications Description Hex size Torque Valve Coil Resistance Specifications SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft Ibs 18 Nm Proportional solenoid valve 12V 4 7 to 6 50 schematic items 5 SAE No 6 1 4 18 ft lbs 24 Normally open poppet valve 4to7O SAE No 8 5 16 50 ft lbs 68 Nm schematic item T V CC and DD Genie 7 42 S 40 5 45 72136 March 2008 Section 7 e Repair Procedures REV B MANIFOLDS ORGS C r F a Gar H 27 ES D 9 66 MAG Part No 72136 S 40 S 45 7 43 Section 7 Repair Procedures March 2008 MANIFOLDS 11 2 Valve Adjustments Function Manifold How to Adjust the Syste
127. 45 Part No 72136 2008 Section 7 e Repair Procedures REV A 3 1 Jib Boom How to Remove the Jib Boom Jib Boom Components S 45 Models 6 Remove the hose cover hoses and cables from the side of the jib boom and set them aside Component damage hazard CAUTION Hoses and cables can be damaged if they are kinked or Begin this procedure with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform Remove the platform mounting weldment and the platform rotator See 2 3 How to Remove the Platform Rotator From the ground controls raise the jib boom to a horizontal position Support the jib boom with a strap from an overhead crane Tag disconnect and plug the hydraulic hoses from the jib boom lift cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Part No 72136 A TEREX S 40 S 45 7 15 MANY pinched 7 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin
128. 5 7 L min Boom extend retract circuit prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 8 Flow regulator valve 1 5 5 7 L min H Boom up down circuit prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 9 Flow regulator valve 1 5 5 7 L min Turntable rotate left right prevents overflowing the proportional valve 10 12 ft Ibs 14 16 Nm 10 Flow regulator valve 0 1 0 4 L min J Bleeds off differential sensing valve to tank 10 12 ft Ibs 14 16 Nm 11 Check valve des Kuss Differential sensing circuit boom extend retract 11 13 ft Ibs 15 18 Nm 12 Orifice Plug 0 140 inch 3 6 mm Ius Boom extend retract circuit 13 Solenoid valve N C Poppet M Boom extend retract 25 30 ft Ibs 34 41 Nm 14 Check val ete Differential sensing circuit boom up down 11 13 ft lbs 15 18 Nm This list continues Please turn the page Plug Torgue Specifications Description Hex size Torgue Valve Coil Resistance Specifications SAE No 2 1 8 50 in lbs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm 3 position 4 way directional valve 10V 21050 schematic items SAE No 6 1 4 18 ft lbs 24 Nm Proportional solenoid valve 10
129. 6 87 8 WHT 21 E H E TB21 BLK WHT 34 E H AUXILIARY PUMP TP27 59 RED 1 gt t AUXILIARY PUMP TB34 CR1 85 87 BLK R1 E H 27 RED h RED 27 E H H1 TP28 RED WHT RED BLK 1 TB28 T PR1 Lao N O g 87 187 RED BLK 28 E H WHT WHT 2 RED WHT 23 E H TP23 P3 TP43 GRN GRN 1 TB23 GRN TP22 d HORN TB22 BLK 2 TB43 CR5 307786 87 85 BLK R5 E H PLAT E GRND KS1 RED ORG BLK 1 B41 WHT R17 E H H2 D E3 O RED g ORG BLK 41 E H RED CB2 om P1 a gt 15 RED RED CB1 20 15 RED FUSE o 2 o 3k 2 fr I FLASHING BEACON OPTION HIGH IDLE RELAY HIGH IDLE CUTOUT RELAY RPM SOLENOID GENERATOR OPTION HOUR METER VOLT METER OIL PRESSURE GAUGE SENDER OIL PRESSURE SWITCH OIL TEMPERATURE SWITCH OIL TEMPERATURE GAUGE SENDER FUEL RELAY FUEL SOLENOID GLOW PLUG OPTION STARTER RELAY STARTER MOTOR AUXILIARY POWER RELAY AU
130. 68 DB DIODE BLOCK WHT 4B 3 8 BLU BLK 37B BLU RED 39A 20 RED BLK 2B 4 5228 WHT RED 32B EU FLOW CONTROL RED 24A RED 1B 5 10 BRN GROUND G1 VOLT METER GAUGE RED R1 30 G2 OIL PRESSURE GAUGE ee lecum FO 1 smara G3 WATER TEMPERATURE GAUGE BEUMHT 8A ORGBEKSIE 2 tachometer IGNITION START HM HOUR METER 6 FC s smermeur MODULE ISM IGNITION START MODULE R2 b enr TO xor KS1 KEY SWITCH GROUND S AN L3 CHECK ENGINE i3 161 BOOM EXTEND LIMIT SWITCH 5 EN LS2 BOOM UP LIMIT SWITCH CR18B wenas FETS ven cue on 153 DRIVE ENABLE LIMIT SWITCH cens PEL CABLE ware A qo ENONEFAUT P1 EMERGENCY STOP BUTTON PLATFORM LEVEL DISABLE amp 2 EES ISM PRI AUXILIARY POWER RELAY HYDRAULIC OIL COOLER WHT 9 ISM CR2 CR3 CR4 PR2 GLOW PLUG POWER RELAY 7 OPTION RELAYS CR1 R2 RESISTOR 10 OHM BOOM FUNCTIONS ORGBLETBIS mS rl 5 SWITCH PANEL RED 6 TS9 AUXILIARY SWITCH CR18A E BLKFR1 EH TT E TS10 ENGINE START SWITCH wem BKDB waa TS11 GLOW PLUG SWITCH RED CB1 WHT TS22 4 RED EH BLK REE 512 FUNCTION ENABLE INLINE BLK 22D TS13 PLATFORM ROTATE SWITCH RED TB20C FE me j CHECK ENGINE TOGGLE SWITCH GRN 43D TS14 PLATFORM LEVEL SWITCH 8 CR17 WHTJSMET DGRN FEH TS15 BOOM EXTEND RETRACT SWITCH WHTRILEH E BRN R1 97 WHT 23B BRN LP SOLENOID TS16 PRIMARY BOOM UP DOWN SWITCH OIL TEMP SWITCH C nmi
131. 72136 2008 Section 5 e Troubleshooting Flow Charts REV Drive Enable System Is Malfunctioning Be sure the boom is in the stowed position With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the non steer tires press down the foot switch and move drive controller in the forward direction Does machine drive yes With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the boom rotated between the steer tires press down the foot switch and move the drive controller in forward direction Does the machine drive yes Check for continuity continuity from TB30 to TB12 no continuity Repair open from TB30 through red 5 wire to LS3 then from 53 through blk 5 wire to 12 A TEREX COMPANY Part No 72136 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the drive controller in forward direction Check voltage at terminal 2 on drive controller 12V or more Repair open from terminal 4 on drive controller to center terminal on TS8 OR refer to Chart 28 OR consult Genie Industries Service Department Hold the drive enable toggle switch TS8 to either side and press down the foot switch Move the drive controller in the forward d
132. 72136 Repair open in blk 2 wire circuit from TB22 22 Repair open in blk wire from TP22 to Emergency Stop button Check if Emergency yes Replace contact on Stop button internal cam Emergency Stop button is activating the contact no Repair open in wht wire with diode from Replace the platform Emergency Stop button Emergency Stop button to TP23 Section 5 Troubleshooting Flow Charts March 2008 Chart 14 Boom Up Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the UP direction Check voltage on red wht wire on boom up down proportional valve coil item P 20V or more Continued on the next page Hold the function enable switch to either side and move the boom up down toggle switch in the UP direction and check voltage at TB3 With the key switch 8 to 9V turned to platform controls and both Emergency Stop buttons pulled out to the position press down the foot switch and move the boom controller in the uP direction Check voltage at TP3 oV Press down the foot switch and check voltage at terminal on boom controller 12V or more Re adjust controller see Repair Section OR replace contro
133. 8 Section 4 Scheduled Maintenance Procedures REV B 2 sure the free wheel valve is closed clockwise CHECKLIST PROCEDURES B 10 Check the Oil Level in The free wheel valve is located on the Drive Hubs the drive pump Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first a drive pump b free wheel valve liftpump d screwdriver The free wheel valve should always remain closed Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Drive the machine to rotate the hub until the plugs are located one on top and the other at 90 degrees 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the plug hole A TEREX COMPANY Part No 72136 S 40 S 45 4 33 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES 3 If necessary remove the top plug and add oil until the oil level is even with the bottom of the side plug hole 4 Apply pipe thread sealant to the plug s and then install the plug s in the drive hub 5 Repeat this procedure for each drive hub Drive hub oil 17 fl oz 0 5 liters Capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Drive Hub
134. ANY REV B 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Loosen the wheel lug nuts Do not remove them 4 Block the non steering wheels and center lifting jack of ample capacity under the steering axle 5 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 6 Remove the lug nuts then remove the tire and wheel assembly 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the drive hub and then remove the drive motor from the machine 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins 11 Support and secure the yoke drive hub assembly to a lifting jack 12 Use a slide hammer to remove the upper yoke pivot pin then use a soft metal drift to drive the lower yoke pivot pin down and out Crushing hazard The yoke hub ACAUTION assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly secured and supported by the lifting jack Part No 72136 2008 Section 7 Repair Procedures REV B 13 Place the
135. BLK 26 WHT 23 Lo E 8 T2 5 a F O ta gt EE t I2 59 20z 2 eel z BLK RED 35 BRN GRD o WHT 1 T WHT RED 32 GRN WHT 19 3 Neu BLU BLK 437 BLU 436 RED 10 H PL 2 bon GEN OPTION 45 GRN WHT 1 WHT BLK 31 0 19 SPARE 44 GRN BLK 1 WHT 30 GO HORN 43 GRN 1 BLK 33 SPARE 42 ORG RED 1 GRN 425 PULSEPICKUP 41 LIMIT SWITCH 40 WHT 21 L P 39 BLU RED 1 m GAS 38 BLU WHT 1 200 g STEER LEFT 37 BLU BLK 1 oooo E STEER RIGHT 36 BLU 1 a E RPM 35 BLK RED 1 BLK WHTE34 34 GLOW PLUG OPT BLK WHT 1 BLU WHT 12 START 33 BLK 1 BRAKE 32 WHT RED 1 E D C 31 WHT BLK 1 a B E D C 30 WHT 1 hu 29 d 2WD AWD 29 RED WHT 1 AUX POWER 27 RED 1 ME PWR TOFS 26 BLK F S PWR START 25 RED FS o PWR CONT 24 WHT F S or PWR FRM PLAT 23 WHT 2 2 PWR TO PLAT 22 BLK 2 OPTION WIRE 21 WHT u j GRNAWHT 20 _ 19 4 JIB VALVE GRN WHT 3 RED 27 PLAT 18 GRN BLK 3 PLAT ROT L 17 GRN 3 osol PLAT LVL F C 16 ORG RED 3 D BLK RED 49 PLAT LVL DN 15 ORG BLK 3 E PLAT LVL UP 14 ORG 3 0 DRV LT 13 BLU RED 3 BLK WHT 8 DRIVE ENABLE 12 BLUWHT 3 BLK 7 9 SEC BOOMDN 11 BLU BLK 3 GRN 17 E SEC BOOM UP 10 BLU 3 GRN BLK 18 EXT RET 9 BLK RED 3 8 BLK WHT 3 XS EXTEND 7
136. C CR17 WHT R17 E H OIL TEMP SWITCI ORG R17 E H FAN seem zz GR WT 4 GRN WHTA 45 GENERATOR OPTION 44 GR BK A H SPARE i GRN R5486 GRN 1 43 HORN xd BLK 7 ORG REDJ 42 SPARE OG BK E H ORG BLK 41 ORG BK ISM 2 PULSE PICKUP ORG 1 40 WHT 7 WHT 6 LIMIT SWITCH SIGNAL i BLU RED 1 39 BU RD S P LP BLU WHT 1 38 BU WT S P GAS BU BK E H BLU BLK 1 37 BUBK D B STEER LEFT BLU E H BLU 1 36 BLU D B STEER RIGHT BLK RED 1 35 BK RD R3 30 BK RD S P RPM BKWT E H BLKWHT 54 BKWT S P GLOW PLUG OPTION BLK ISM 3 BLK 1 33 BLK S P START WT RD E H WHT RED 1 32 WT RD D B BRAKE WT BK E H WHT BLK 1 31 E D C RED 5 WHT 1 30 E D C RD WT E H 29 2WD 4WD RD BK A H RED BLK 1 28 TILT ALARM RED E H RED 1 27 45 44 RED S P AUXILIARY POWER WT RD E H 26 WT RD S P OIL TEMPERATURE SENDER WT BK E H 25 WT BK S P OIL PRESSURE SENDER WHT ISMF10 24 WARNING SENDER WHT E H WHT 2 23 WHT ISM 7 WHT S P KEY
137. CIRCUIT BREAKER CONTROLS 15 GAN I7A D C UB 4 CB2 CIRCUIT BREAKER ENGINE 15A em a lt Aa ORG 14B 2 06 GRN 17B CR2 Ho H H Te D M O GRNIBLICTOA 1 GRN BLK 188 CR3 HIGH IDLE RPM CUTOUT RELAY 513 DENM BLK R1487 CR4 RPM RELAY 5 TS12 CB1 2 7514 H GRN WHT 19A BLK WHT 8B 5 4 10 BRN GROUND CR5 HORN RELAY i 7 DEM BLK 7B ei WHT2IA C CR17 HYDRAULIC OIL COOLER OPTION RELAY 14 i OARD EN WHUBHESB 2 1 BLU 388 CR18A CE PLATFORM LEVEL RELAY RED R1 30 m SB YTT Odo d CR18B CE PLATFORM LEVEL RELAY erm RED 1B BRN GROUND DIODE BLOCK FLOW CONTROL BLK RED 35A H BLU WHT 38A SEEMS G1 VOLT METER GAUGE Re HC 1 STARTRELAY ONITIONSTART G2 OIL PRESSURE GAUGE 2 TACHOMETER MODULE WATER TEMPERATURE GAUGE 6 BUD HE START INPUT HM HOUR METER RED 27B nem FO 4 aux ON 15 IGNITION START MODULE ORG 4 BRN GROUND GROUND KS1 KEY SWITCH RED R2 30 O 6 BATTERY CR18A ES 161 BOOM EXTEND LIMIT SWITCH oes 1 1 5 7 152 BOOM UP LIMIT SWITCH PLATFORM LEVEL DISABLE amp 5 ON 153 DRIVE ENABLE LIMIT SWITCH 9 HYDRAULIC OIL COOLER wrai Ec P1 EMERGENCY STOP BUTTON OPTION RELAYS 1 AUXILIARY POWER RELAY 7 ORG BLICTBISD pue PR2 GLOW PLUG POWER RELAY RED 6 REDCB CR2 CRS3 CR4 R2 RESISTOR 10 OHM
138. Connect a tachometer to the engine Start the engine from the ground controls Result Low idle should be 1500 rpm for Deutz models 1600 rpm for Perkins models PartNo 72136 A TEREX COMI S 40 S 45 CHECKLIST B PROCEDURES Skip to step 4 if the low idle rpm is correct 2 Loosen the low idle lock nut and turn the low idle adjustment screw clockwise to increase the rpm or counterclockwise to decrease the rpm Tighten the low idle lock nut and confirm the rpm solenoid boot high idle adjustment nut yoke lock nut yoke low idle adjustment screw low idle lock nut 09 3 Move the function enable toggle switch to the high idle rabbit symbol position Result High idle should be 2500 rpm for Deutz models 2200 rpm for Perkins models Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES If high idle rpm is correct disregard adjustment step 4 4 Loosen the yoke lock nut then turn the high idle adjustment nut and solenoid boot counterclockwise to increase the rpm or clockwise to decrease the rpm Tighten the yoke lock nut and recheck the rpm Be sure the solenoid fully retracts when activating high idle Deutz Diesel models Low idle 1500 rpm High idle 2300 rpm Perkins Diesel models Low idle 1600 rpm High idle 2200 rpm G 4 36 A TEREX CON S 40 S 45 REV B B 12 Test the Key Switch Genie specifications require t
139. DARK BLUE NATURAL W WHITE Cl ZN lt LOCATED INSIDE THE CONNECTOR 8 3 4 j B 119 GROUND CONTROL BOX Z DG DARK GREEN ORANGE YELLOW OIL PRESSURE L SWITCH NC ENGINE d GN GREEN PK PINK o op HEATED COOLANT A WY AIR 5 c OXYGEN TEMPERATURE TEMPERATURE SENSOR Smos COIL SENSOR MANIFOLD SENSOR 1 WIRES ARE LABELLED WITH FORD CIRCUIT NUMBER COLOR AND WIRE GUAGE HO2S 3832 o5 ECT ABSOLUTE qth J S630 A EXAMPLE 29 2 PRESSURE bX 5 29g 74GY LB18 MEANS CIRCUIT 74 GREY WIRE WITH LIGHT BLUE STRIPE 18 GUAGE WIRE 5 ma SENSOR 35649 59 LPG LOCKOUT RELAY AND VALVE oz 1 2 2 INTERNAL SPLICES ARE NOT SHOWN a Part No 72136 S 40 S 45 6 7 2008 Section 6 Schematics _ Ford LRG 425 Engine Wire Harness 2008 Section 6 e Schematics A Electrical Schematic Gasoline LPG Models REV A ORG BLK 1 NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION
140. Department 12V or more Chart 24 Repair open in grn blk 4 wire from TB18 to platform rotate right directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot platform rotate toggle switches TS13 and TS5 OR repair open in red power wire circuit to TS13 and TS5 OR repair open in grn blk wire circuit from 1513 and TS5 to TB18 OR consult Genie Industries Service Department Part No 72136 Section 5 Troubleshooting Flow Charts n CHART 24 Continued from the previous page Disconnect the wires at from the platform rotate AU 9 right directional valve BUS coil item DD and test the resistance of the valve coil 6 to 7 ohms function operates Exchange platform rotate right and left directional valves items DD and CC and activate the platform rotate right function function inoperative function Exchange platform operates rotate right and left counterbalance valves at the counterbalance valve manifold and activate the platform rotate right function function inoperative Install a 0 to 3000 207 bar pressure gauge at the guick disconnect ae coupling on the function manifold and activate the plaiform rotate right function See Note 2 function operates Exchange platform rotate flow regulator valve item EE with platform level flow regulator valv
141. Descent alarm Flashing beacon Alarms and a beacon are installed to alert operators and ground personnel of machine proximity and motion The alarm package is installed on the turntable covers The alarms and beacon will operate with the engine running or not running 1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Result The flashing beacon should be on and flashing 2 Hold the function enable switch to either side and activate the boom toggle switch in the down position hold for a moment and then release it Result The descent alarm should sound when the toggle switch is held down A TEREX CON S 40 S 45 REV B 3 Turn the key switch to platform controls Result The flashing beacon should be and flashing 4 Move the lift drive selector switch to the lift position if equipped 5 Press down the foot switch Move the boom controller to the down position hold for a moment and then release it Result The descent alarm should sound when the control handle is held down 6 Move the lift drive selector switch to the drive position if equipped 7 Press down the foot switch Move the drive controller off center hold for a moment and then release it Move the drive controller off center in the opposite direction hold for a moment and then release it Result The travel alarm should sou
142. EDURES A 7 Check the Hydraulic Oil Level Genie specifications require that this procedure be performed daily Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stowed position then visually inspect the sight gauge located on the side of the hydraulic oil tank Add oil as needed Result The hydraulic oil level should be within the top 2 inches 5 cm of the sight gauge Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES A 8 Check for Hydraulic Leaks Genie specifications require that this procedure be performed daily Detecting hydraulic fluid leaks is essential to operational safety and good machine performance Undiscovered leaks can develop into hazardous situations impair machine functions and damage machine components Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 1 Inspect for hydraulic oil puddles dripping or residue on or around the following areas Hydraulic tank filter fittings hoses auxiliary power unit filters and component tray
143. EREX COMPANY S 40 S 45 REVA C 4 Replace the Fuel Filter Element Perkins Diesel Models Engine specifications require that this procedure be performed every 500 hours or 12 months whichever comes first Replacing the diesel fuel filter element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may required that the filter be replaced more often Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Open the engine side cover and locate the fuel filter 2 Thoroughly clean the outside surfaces of the fuel filter assembly Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV A CHECKLIST C PROCEDURES 3 Hold the bottom cover of the filter element and 9 Putthe bottom cover under the new element and release the setscrew which is fitted through the hold the element sguarely to the filter head filter head above the center of the element Ensure that the element is fitted in the center Ore against the O ring in the filter
144. Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Perform service problem repair solved Section 6 Schematics March 2008 TT Qn Electrical Components Item Description Genie Part Manufacturer Manufacturer Qty Part Number Part Number Battery 1000 CCA 12V DC 30143 sd i deste tenes ee 2 22 1 BP1 42 n Joystick controller Dual axis 53073 OEM Controls EJS5M1197 1 CB1 CB2 Circuit breaker 24018 ET Gi 45 700 IG1 P10 2 CR1through CH7 17 18 19 Relay SPDT 12V DC 34052 Potter Brumfield VF4 15F11 CO5 10 Diode Diode 6 amp 200 PIV 45782 Motorola MOTMR752 36 DP Joystick controller Drive 20424 OEM Contr
145. Filter Water Separator Deutz Diesel Models Engine specifications reguire that this procedure be performed every 1000 hours or every 12 months whichever comes first Replacing the diesel fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may reguire that the filter be replaced more often Explosion and fire hazard Engine A DANGER at 4 fuels are combustible Replace the fuel filter water separator in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Turn the manual fuel shutoff valve located at the fuel tank to the closed position Part No 72136 A TEREX CON S 40 S 45 MPANY CHECKLIST D PROCEDURES 2 Remove the fuel filter water separator with a filter wrench a olilfilter b fuel filter water separator 3 Fill the new filter with clean diesel fuel and apply a thin layer of clean diesel fuel to the new fuel filter gasket 4 Install the new filter and tighten it securely by hand Clean up any diesel fuel that might have spilled during the procedure 5 Turn the manual fuel shutoff valve located at the fuel tank to the open position 6 Startthe engine from the ground controls and inspect the fuel f
146. H SIGNAL YEUBLK EH _ BLURED 39 BU RD S P L P PINK GRN EH BLUWHT i 58 BUWT S P CHECK ENGINE WHT RED 26A BU BK E H BLU BLK i 37 BUBK D B STEER LEFT AL GRN GROUND BLU EH BLU 1 36 BLU D B STEER RIGHT KS1 TANLBLU EH BLK RED 35 BK RD S P RPM BLKWHT 1 34 BKWT S P GLOW PLUG 2 STACKED CONTACTS WHT 21A BLK ISM 3 BLK 1 5224 H BLK S P START DW WHT BLK 25A WT RD E H WHT RED 1 32 WT RD D B BRAKE P 2 PP WT BK E H WHT BLK 1 31 EDC 2 A RED 5 WHT 1 30 ED C X KS1 WHT 23A RD WT E H RW 1 29 2WD AWD opo 1 n gt RD BK A H RED BLKA 28 TILT ALARM i 27 PE i E RED EH RED 1 RED ISM 4 RED S P AUXILIARY POWER LONC b oo TS9 WT RD E H 26 WT RD S P WATER TEMPERATURE SENDER olo NO NO O O WT BK E H 25 WT BK S P OIL PRESSURE SENDER x NCC A DO YEL E H YEL E H 24 RED CR2 RED S P WARNING SENDER S y Le ordd J gt RED WHT 23 E H WHT 2 23 WHT TS22 5_ WHT S P KEY SWITCH POWER NL zi BLK R4 30 BLK 2 22 BLK S P POWER TO PLATFORM Wy WHT R2487 WHT EH 21 WHT S P WHT SP DB IGNITION POWER 3 BEDA RED AH RED R17 30 20 RED S P RED S P 12V BATTERY SUPPLY pus GRNWHT 3 19 GRNWT S P VALVE FM GRN BLK 4 GRNBLKs 18 GWBK D B GR BK SP PLATFORM ROTATE RIGHT GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT BLK 7A BLK 6 ORG RED 3 16 OG RD D B OG RD S P PLATFORM LEVEL DISABLE PET ORG BLK CR188 30 ORG
147. Harness 6 7 Electrical Schematic 6 10 Ground Control Box Wiring Diagram Gasoline LPG 6 14 A Platform Control Box Wiring Diagram Gasoline LPG 6 15 Electrical Schematic Deutz 6 18 A Ground Control Box Wiring Diagram Deutz 6 22 A Platform Control Box Wiring Diagram Deutz 6 23 A Electrical Schematic Perkins Diesel 6 26 A Ground Control Box Wiring Diagram Perkins 6 30 Platform Control Box Wiring Diagram Perkins 6 31 A 5 40 45 2WD Hydraulic Schematic Non oscillating axle 6 33 A 5 40 45 2WD Hydraulic Schematic Oscillating axle 6 35 A 5 40 45 4WD Hydraulic Schematic Oscillating axle 6 37 S 40 S 45 xiii March 2008 EEE LL LLLLLIL L S L l i d u ie i L L Oe eIO TABLE OF CONTENTS Section 7 Rev Repair Procedures 9 7 1 Platform Controls 1 1 Joystick Controllers 2 0 202 7 2 1 2 Horsepower Limiter 7 6 1 3 FOOL SWItCh
148. Models Engine specifications require that this procedure be performed every 500 hours or 12 months whichever comes first Perform this procedure more often if dusty conditions exist Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 500 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap located next to the dipstick 2 Pull the end of the engine oil drain hose out from under the engine A TEREX CON S 40 S 45 REV A 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications Do not remove the drain plug located on the side of the oil pan 4 Install and tighten the plug in the drain hose Use an oil filter wrench and remove the oil filter located below the fuel filter Clean inside the filter head 6 Apply a thin layer of fresh oil to the new filter gasket Install the fi
149. NY CHECKLIST B PROCEDURES 7 Install the new spark plugs then connect the wires Be sure that each spark plug wire is attached to the correct spark plug 8 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 9 Install the air baffle and the air baffle retaining fasteners Ford LRG 425 EFI Engine Spark plug specifications Spark plug type Motorcraft AWSF 52C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap 5 10 ft lbs 7 14Nm Spark plug torgue Section 4 Scheduled Maintenance Procedures March 2008 M This page intentionally left blank A TEREX COMPANY 4 50 S 40 5 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures Checklist C Procedures REV A C 1 Check the Engine Belt Deutz Diesel Models Engine specifications reguire that this procedure be performed every 500 hours Maintaining the engine belt is essential to good engine performance and service life The machine will not operate properly with a loose or defective belt and continued use may cause component damage AWARNING Bodily injury hazard Do not inspect while the engine is running Remove the key to secure from operation ACAUTION 20dily injury hazard Beware of hot engine components Contact with hot engine components may cause severe burns 1 Remove the air baffle retaining fasteners Remove the air b
150. Nm Hex size 13 16 inch Temperature switch point 300 F 1499 Oil pressure sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 11 16 inch Oil pressure switch point 7 psi 0 48 bar 7 28 S 40 S 45 Part No 72136 2008 Section 7 Repair Procedures REV A 7 1 RPM Adjustment Refer to Maintenance Procedures B 11 Check and Adjust the Engine RPM 7 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump pump pump shaft coupler flex plate with raised spline flywheel 1 4 inch 6 4 mm gap Perkins 704 30 Engine How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Ins
151. Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked Part No 72136 S 40 S 45 5 1 Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the appropriate Genie S 40 amp Genie S 45 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropiate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watche
152. P ES _f E 3 ogy Onpas Gwm CAKE 4 3500 i o c sz 1 t 1 rad 4 4 IH ce 711 2 PRESSURE B ri ME mer I OPTIONAL peer 5 044 sede poro mE E We Sod ii 1 PUMP MANIFOLD WM Ed bed vh ye ye sel up EYN INI CERCA C Ti TANK 5 MC OPTIONAL PSI SEHE ER 25 SEC REG OIL 3 3 PSI m COOLER PSI 2 RESERVOIR AUC BUR ____ _ 1 me 6 GPM L Hi STEER MANIFOLD z1 E 7 4 V E Llu nm L peces TANK AVALVE la en oe e BOE Note alpha callouts refer to Y a E mE components shown in the 8 manifold illustrations TRACTION STEERING Refer to the Repair Section Part No 72136 A TEREX COMPANY S 40 S 45 37 March 2008 Section 6 Schematics 5 40 45 4WD Hydraulic Schematic Oscillating Axle 38 2008 Section 7 Repair Procedures REV A Observe and Obey Repair procedures shall be completed by a person trained and gualified on the repair of this machine Immediately tag and remove from
153. Part No 72136 March 2008 Section 7 e Repair Procedures EE REV A TURNTABLE ROTATION COMPONENTS How to Remove the Turntable 3 Remove the drive hub mounting bolts and then use an appropriate lifting device to remove the Rotation Brake or Drive Hub drive hub from ihe machine 1 Secure the turntable from rotating with the Crushing hazard The turntable turntable rotation lock pin AWARNING rotate torque hub could become unbalanced and fall when it is removed from the machine if it is not properly supported 4 Install the drive hub Torque the drive hub mounting bolts to 180 ft lbs 244 Nm 5 Install the brake then motor onto the drive hub Torque the brake motor mounting bolts to 75 ft lbs 102 Nm unlocked locked Turntable rotate drive hub 2 Remove the motor See 13 1 How to Remove Capacity 8 fluid ounces the Rotation Hydraulic Motor 0 24 liters CAUTION Component damage hazard Type SAE 90 multipurpose hypoid gear oil API Hoses can be damaged if they are service classification GL5 kinked or pinched a motor brake mounting bolts b motor brake d drive hub mounting bolts e drive hub A TEREX COMPANY Part No 72136 S 40 5 45 7 67 Section 7 Repair Procedures March 2008 2WD Steering Axle Components REV B 14 1 2 Loosen the wheel lug nuts Do not Yoke and Hub remove them _ _ __ 3 Block the non steering wheels and center a How to Remove the Yoke
154. Pil B p BLK RED 4 n EXTEND RETRACT FLOW CONTROL z BLK RED 3 Y amp E 5 ORG 3 PLATFORM LEVEL x LDOWN a ORG BLK 3 E ORG amp x R ORG 4 PLATFORM Ey l LEVEL UP po lup ORG BLK PLATFORM LEVEL 1 DOWN m ORG BLK 4 PLATFORM ia LEVEL DOWN a m Ng po o gt 2 BLK 6 Im RED 6 ORG RED 3 5 PLATFORM o E LEVEL DISABLE E m CE OPTION E GRN 3 RIGHT PLATFORM ROTATE LLEFT GRN BLK 3 T GRN BLK gt m 0 PLATFORM ROTATE Eg z GRN BLK 4 RIGHT JIB DOWN 1 PLATFORM GRN 4 GRNWHT CE ROTATE PLATFORM ROTATE eo LEFT GRN 4 LEFT JIB UP 99 m up i JIB BOOM 1 DOWN m GRNWHT 3 o m i c q 10 RED JIB BOOM 2 88 n a 1 2 RED E y E zz JIB VALVES o a 8 2 BLK 3 Td amp 1 m LIFT DRIVE Qoi SELECTOR oim 8218 ol deed E 2008 Section 6 Schematics Electrical Schematic Gasoline LPG Models 2008 Section 6 Schematics EE Ground Control Box Wiring Diagram Gasoline LPG Models 2008 Section 6 Schematics EE LL II I I Ground Control Box Wiring Diagram Gasoline LPG Models A B
155. RED 3 BEDS b TURN ROT R 5 WHT BLK 3 P TURN ROT L WHT 3 E PRIMARY F C 3 RED WHT 3 u s RED WHT 3 PRIMARY DN 2 RED BLK 3 5 PRIMARY UP 1 RED 3 cy R b H fu NU WHT BLK 5 a lu m y 2 WHT 4 2 cst NS oos las a V 11231451617 10 a o am 22 E du 4 V 7 Dearie ja 9 tr 0 WHT RED 6 o 3 5 a 5 8 RED BLK 1 N ORG BLK 15 ORG RED 16 WHT CR14 GRN 43 2 E i 2 2 8 x ul x 2 x Om o z Ss gt Xx z z 5 853 oc 19 BlSl amp EIS gt iu E atc c a 5 x zE z Z xz 515 cz m S F eion o 2615 FEIO 2 al l ckS BREES 5 Selge el Sue uo ms oee SIZIS dail uolos O lt gt SE ziziE x Ou gt 2 gt ele x lt 2 gt gt cc Son si olo cu un olo nul o 5 gt cu See de c ir sun ao gt Ou 2 5 22 Of oe lag 5005215 09 SS o ciw a 5 lt a cs E ii ex oco a mwovOdSog 00000 2008 Section 6 e Schematics pn Emi Platform Control Box Wiring Diagram Gasoline LPG Models
156. Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the brake and remove the drive motor from the machine Torque specifications recommended Drive motor mounting bolts dry 75 ft lbs 102 Nm When removing a hose assembly or fitting the O ring on the fitting Drive motor mounting bolts lubricated 56 ft lbs and or hose end must be replaced 76 Nm and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the fasteners from the cover on the non steer axle Remove the cover Part No 72136 S 40 5 45 7 75 Section 7 Repair Procedures March 2008 NON STEERING AXLE COMPONENTS 17 2 Drive Hub How to Remove a Drive Hub REV B 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack Remove the drive hub mounting bolts that attach the drive hub to the chassis Remove the drive hub When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications Remove the drive motor See 17 1 How to Remove a Drive Motor Tag disconnect and plug the hydraulic hose from the brake Loosen the wheel lug nuts Do not remove them Block the steering wheels and center a lifting jack of ample capacity
157. Rotate Left Function Inoperative 5 51 Platform Rotate Right Function Inoperative 5 53 Oscillate Function Inoperative 40400000 5 55 Jib Boom Up Function Inoperative 2 5 56 Jib Boom Down Function Inoperative 5 58 Steer Left Function Inoperative 5 60 Steer Right Function Inoperative 5 62 All Drive Functions Inoperative All Other Functions Operate Normally 5 64 Drive Forward Or Reverse Function 5 67 Traction Function INOperative 5 68 Machine Will Not Drive At Full 5 69 Machine Drives At Full Speed With Platform Raised or Extended 5 70 Drive Enable System Is Malfunctioning 2 5 71 Auxiliary Functions INOperative 2 5 72 Xii S 40 5 45 Part No 72136 2008 Section 6 Part No 72136 TABLE OF CONTENTS Rev Schematics INtPODUCHION 6 1 Electrical Components iti te er Ee e e HR be ER a 6 2 A Electrical Symbols Legend 6 4 A Abbreviation Legend seeria tete de ch a c LESER RR HERE 6 5 A Hydraulic Symbols 6 6 Engine Wire
158. SWITCH POWER BLK R5 30 BLK 2 22 BLK S P POWER TO PLATFORM WHT R2 87 WHT EH 21 WHT SP DB IGNITION POWER RED A H RED R17430 20 WHT OIL SWITCH RED S P 12V BATTERY SUPPLY GRNWHT 3__ 19 GR WTS VALVE GRN BLK 4 GRN BLK 3 18 GR BK D B GR BK S P PLATFORM ROTATE RIGHT GRN 4 GRN 3 17 GRN D B GRN S P PLATFORM ROTATE LEFT BLK 6 ORG RED 3__ 16 OG RD D B OG RD S P PLATFORM LEVEL DISABLE ORG CR18B 30_ 8 15 OG BK D B OG BK S P PLATFORM LEVEL DOWN ORG CR18A 30_ ORG 3 14 ORG D B ORG S P PLATFORM LEVEL UP WHT 5 BLU RED 3___ 13 DRIVE ENABLE LIGHT WHT EH BLUWHTS3 12 BLK 5 DRIVE ENABLE BLU BLK 3 11 BU BK D B BU BK S P SEC BOOM DOWN BLU 3 10 BLU D B BLU S P SEC BOOM UP BLK RED 4 BLK RED 3 9 BK RD S P BOOM EXT RET BLK WHT 4 BLK WHT 3 8 BKWT D B BKWT S P BOOM RETRACT BLK 4 BLK 3 7 BLK D B BLK S P BOOM EXTEND W R 4 WHT RED S 6 WT RD S P TURNTABLE ROTATE WHT BLK 4 WHT BLK 3 5_ WT BK D B WT BK S P TURNTABLE ROTATE LEFT WHT 4 WHT 3 4_ WHT D B WHT S P TURNTABLE ROTATE RIGHT R W 4 REDWHT3 3 RD WT S P PRIMARY BOOM RED BLK 4 RED BLK 3 2 RD BK D B RD BK S P PRIMARY BOOM DOWN RED 4 RED 3 1 RED DB RED S P PRIMARY BOOM ORG BLK 15B ORG RED 16B ORG 14B 2 4 GRN 17B 1 NE GRN BLK 18B 4 BLK R1 87 BLK WHT 8B 10 BRN GROUND a BLK 7B gt WHT 21A O f WHT BLK 5B O24 Na BLU 36B i WHT 4B
159. Start the engine from the platform controls 2 Drive the right steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 3 Drive the left steer tire up onto a 6 inch 15 cm block or curb Result The three remaining tires should stay in firm contact with the ground and the chassis should remain level at all times 4 Drive both steer tires up onto a 6 inch 15 cm block or curb Result The non steer tires should stay in firm contact with the ground If the chassis does not remain level during test see Repair Procedure 11 6 How to Set Up the Directional Valve Linkage OR see Repair Procedure 11 5 Howto Adjust the Oscillate Sequencing Valve Pressure A TEREX COMPANY Part No 72136 S 40 5 45 4 11 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES A 11 Test the Platform and Ground Controls Genie specifications reguire that this procedure be performed daily Testing the machine functions and the red Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions and shut off the engine Each function should activate operate smoothly and be free of hesitation jerking and unusual
160. T N P Er c A T A co un ojo zu A Az Ao o AJN jN N AJNIS o E io o g co os D o ER p co gt N m P o A e 9 D A a o A o a Az N c ag A E ES alo alojn s z gt colo o 2 m o ENS V E f AR Api co a a c o TE B B a 0 m um m N 8 g pet a AR A 3 co 72136 S 40 5 45 2 11 Section 2 Specifications March 2008 EE c This page intentionally left blank A TEREX COMPANY 2 12 S 40 5 45 Part No 72136 2008 Section Theory of Operation REV A Power Source The Genie 5 40 and Genie 5 45 are powered by either a gasoline LPG engine or one of two diesel engines The gasoline LPG option uses a Ford LRG 425 EFI rated at 70 horsepower 2500 rpm The diesel options include a Deutz F3L 10
161. TION Perform this procedure with the engine off and cooled 1 Remove the air baffle retaining fasteners Remove the air baffle Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the fuel hoses a engine pivot plate b pivot plate retaining bolts c air baffle 3 Place a suitable container under the engine pivot plate See capacity specifications 4 Locate the fuel pressure regulator filter and the fuel pump on the engine pivot plate behind the engine 5 Atthe fuel pressure regulator filter disconnect the fuel hose to the fuel tank Drain the fuel tank into a suitable container Explosion and fire hazard A DANGER eis Electronic Fuel Injection EFI systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too guickly Loosen the fuel hoses very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them Part No 72136 A TEREX S 40 S 45 MPANY CHECKLIST E PROCEDURES 6 Remove and replace all of the fuel hoses and clamps according to the following hose routing diagram From tank Fuel Pump Pre Filter Pressure To engine Regulator filter Return to tank a high pressure hose from fuel pum
162. Toggle switch DPDT 2 position maintained 27378 Microswitch Control Inc 2NT1 9 nhe 1 TSA aiios Toggle switch DPDT position maintained 13038 Microswitch Control Inc utes 1 TS6 7 14 15 16 17 Toggle switch DPDT position momentary 16397 Microswitch Control Inc 2NT1 Z m 6 TS3 TS11 Gas LPG Toggle switch DPDT 2 position maintained 27378 Microswitch Control Inc 2NT 159 oett 2 TS3 TS11 Diesel Toggle switch SPDT position momentary 13037 Microswitch Control Inc TNT 1 7 iie 2 Genie A TEREX COMPANY Part No 72136 S 40 5 45 3 Section 6 Schematics March 2008 Electrical Symbols Legend 118 980 Wire color with cable number TB20 Terminal Quick disconnect terminal 21 WHT 21 T circuits connect at terminal T T circuits connect Connection no terminal Circuits crossing no connection Diode Battery 15 Circuit breaker with amperage Coil solenoid or relay H1 Horn Hour meter L3 LED Fuse with amperage 25 Glow plugs or starting aid 17 Ground supression circuit o Ls3
163. V 7 5 to 10 50 SAE No 8 5 16 50 ft lbs 68 Nm schematic item M Genie A TEREX COMPANY 7 40 S 40 5 45 Part No 72136 March 2008 Section 7 e Repair Procedures REV B MANIFOLDS G 6 o EUR 9 Qa 8 G8 A Ale ps ee Ur O 9 Q 5 p Dap 9 D A 99 49 8 7 A TEREX COMPANY Part No 72136 S 40 5 45 7 41 Section 7 Repair Procedures March 2008 MANIFOLDS REV B Function Manifold Components continued Index Schematic No Description Function Torgue 15 N T NY TW Fu Differential sensing circuit turntable rotate left right 11 13 ft lbs 15 18 Nm 16 Proportional solenoid valve Boom up down 10 12 ft lbs 14 16 Nm 17 Check valve 2 uvm RR Qu Differential sensing circuit platform level up 11 13 ft Ibs 15 18 Nm 18 CHECK valve asin Pin Differential sensing circuit platform level down 11 13 ft lbs 15 18 Nm 19 Proportional solenoid valve Os Turntable rotate left right 10 12 ft Ibs 14 16 Nm 20 Solenoid valve Poppet Ts Platform level up
164. XILIARY PUMP LEVEL SENSOR HORN RELAY HORN Part No 72136 HYDRAULIC OIL TEMPERATURE SWITCH COOLING FAN OPTION 25 ro RED 20 E H G S 40 S 45 6 18 Section 6 Schematics March 2008 REV A Electrical Schematic Deutz Diesel Models LIFT DRIVE SELECT OPTION e eo LO co o bd 1 GROUND e T
165. ace engine C 4 Fuel filter breather Perkins Models Daily or 8 hour Inspection A Perkins Models C 5 Replace engine oil and filter Perkins Models E 5 Wheel bearings Perform every 3000 hours Quarterly or 250 hour Inspection E 6 Fuel injectors C 6 Check the coolant Perkins Models Six Month or 500 hour Ford Perkins Models Inspection ASE SC C 7 Glow plugs Perkins Annual or 1000 hours C 8 PCV valve Ford Models Inspection A B C D 2 Year or 2000 hour ChecklistD RevB after each inspection procedure is D 3 Turntable bearing bolts completed D 4 Grease rotation bearing Use the step by step procedures in D 5 Drive hub oil section 4 to learn how to perform these inspections D 6 Drive loop hydraulic filter D 7 Replace engine oil and filter Deutz Models D 8 Fuel strainer Deutz If any inspection receives an tag and remove the machine from service repair and re inspect it After repair place a check in the R box D 9 Fuel filter water separator Deutz Models D 10 Change fuel lines Duetz D 11 Valves Deutz Models D 12Clean engine breather Perkins Models Legend Y yes acceptable N z no remove from service R repaired Inspection A B C D E D 1 Boom wear pads Place a check in the appropriate box D 2 Free wheel configuration Comments A TEREX COMPANY 4 4 S 40 5 45 PartNo 72136 2008
166. acity 25A rate 200 minutes Fan belt deflection 3 8 to 1 2 inch 9to12mm Part No 72136 A TEREX COMPANY Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Section 2 Specifications March 2008 SPECIFICATIONS Perkins 704 30 Engine Displacement 183 cu in 2 9 liters Number of cylinders 4 Bore and stroke 3 82 x 3 94 inches 97 x 100 mm Horsepower 63 amp 2600 rpm Firing order 1 3 4 2 Compression ratio 17 5 1 Compression pressure 300to 500 psi REV A Oil viscosity reguirements below 68 F 20 synthetic 5W 20 5 F to 1049F 15 C to 40 10W 30 above 14 F 10 C 15W 40 Engine oil should have properties of API classification CC SE API classification CD SE or CCMC D4 can be used but is not recommended during the first 50 hours nor for light load applications Injection system 20 7 to 34 5 bar Injection pump make Zexel PFR KX Pressure psi of lowest cylinder must be within Iniecti f 2 jection pump pressure 50 psi 3 45 bar of highest cylinder stage one 2755 psi 190 bar Low idle 1600 rpm stage two 3336 psi 230 bar Frequency 246 7 Hz Injector opening pressure 3626 psi 250 bar High idle 2200 rpm F uel requirement diesel ber 2 D Frequency 339 2 Hz 3 Engine coolant Governor centrifugal mechanical 3 Capacit 111 2 quarts Valve cleara
167. ads 9 16 inch 14 3 mm Bottom wear pads S 40 11 16 inch 17 5 mm Bottom wear pads S 45 9 16 inch 14 3 mm G A TEREX CON S 40 S 45 Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator Knowledge may cause death or serious injury and property damage Collision hazard Select a work site AWARNING that is firm and level Component damage hazard If the machine must be towed do not exceed 2 mph 3 2 km h CAUTION Non steering wheels All models 1 Chock the steer wheels to prevent the machine from rolling 2 Center a lifting jack of ample capacity 20 000 Ibs 10 000 kg under the drive chassis between the non steer wheels 3 Lift the wheels off the ground and then place blocks under the drive chassis for support 4 Disengage the drive hubs by turning over the drive hub disconnect caps on each non steering wheel hub PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 5 Manually rotate each non steering wheel Result Each non steering wheel should rotate with minimum effort 6 Re engage the drive hubs by turning over the hub disconnect caps Rotate each wheel to check for engagement Lift the machine and
168. affle Part No 72136 A TEREX CON S 40 S 45 MPANY 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the engine belt a engine pivot plate b pivot plate retaining bolts c air baffle 3 Remove the front engine access cover mounting fasteners 4 Inspect the engine belt for Cracking Glazing Separation Breaks 5 Replace belt if any damage is found 4 51 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES REVA 6 Check the engine belt for proper tension Adjust C 2 Check the Engine Valve Clearances Deutz Diesel Models Engine specifications reguire that this procedure be performed initially at 500 hours at 1000 Deutz Diesel engine hours and every 1000 hours thereafter 7 Install the front engine access cover Complete information to perform this procedure is available in the Deutz F3L 1011F Operation Manual Deutz part number 0297 7343 Genie part 8 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts number 52883 9 Replace the air baffle and install the air baffle retaining fasteners Belt deflection 3 8 inch to 1 2 inch Deutz Diesel models 9 mm to 12 mm Deutz Diesel models Engine Belt Genie part number 32698 Genie A TEREX COMPANY 4 52 S 40 5 45 PartNo 72136 2008 Sect
169. aintenance Procedures March 2008 CHECKLIST PROCEDURES D 12 Clean the Engine Breather Assembly Perkins Diesel Models Engine specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Cleaning the engine breather assembly is essential for good engine performance and service life A dirty or clogged breather may cause the engine to perform poorly and continued use may cause component damage 1 Remove the rocker cover from the engine 2 Release the four retaining fasteners securing the breather cover to the rocker cover 3 Remove the diaphragm and location ring assembly Remove the spring 4 Release the clips that retain the breather pipe and remove the breather pipe 5 Using a mild solvent clean the breather cavity in the rocker cover the passage through the rocker cover the breather pipe and the vent hole A TEREX Ct S 40 S 45 REV B 6 Install the spring into the breather cavity in the rocker cover 7 Install the location ring onto the diaphragm Install this assembly onto the spring Be sure that the location ring is on the spring 8 Install the breather cover Install and secure the breather cover retaining fasteners 9 Install the breather pipe and secure the retaining clips 10 Install the rocker cover and tighten the cap nuts to 8 ft lbs 11 Nm PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures
170. ak off line Do not allow dirt to enter the fuel system Before a connection is disconnected thoroughly clean the area around the connection After a component has been disconnected fit a suitable cover to all open connections Remove the union nuts of the high pressure line from the injector and from the fuel injection pump If necessary remove the pipe clamps CAUTION Component damage hazard Use a seperate wrench to prevent movement of the outlets of the fuel injection pump when the high pressure pipes are released or tightened Do not bend the fuel line Remove the setscrew of the injector clamp and remove the clamp the spacer the injector and its seat washer a clamp b O ring C Seat washer d spacer e setscrew Genie 4 80 S 40 5 45 PartNo 72136 2008 REV 5 Put the injector in position together with a new seat washer and a new O ring 6 Install the injector into the cyliner head with a new clamp the spacer and engage the setscrew CAUTION Component damage hazard When an injector is installed into the cylinder head ensure that any sharp edges on the cylinder head do not damage the O ring A new clamp must be used every time an injector is fitted to the engine Be sure the injector is not tilted when it is fitted to the cylinder head 7 Tighten the setscrew to 16 ft lbs 22 Nm 8 Fit the high pressure fuel pipe and tighten the union nuts to 16 ft lbs
171. alve coil OR repair open in brn ground wire circuit to valve coil 4 to 6V Repair open in wht red 3 wire from TP6 to TB6 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department Repair open in power supply circuit from TP24 to controller OR repair open in brn ground wire circuit from ground to controller S 40 S 45 Part No 72136 2008 REV B Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the RIGHT direction Check voltage on wht 4 wire on turntable rotate right directional valve coil item A 12V or more Continued on the next page Part No 72136 Section 5 Troubleshooting Flow Charts T Hold the function enable switch to either side and move the turntable rotate left right toggle switch in the RIGHT direction Check voltage at TB4 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the turntable rotate controller in the RIGHT direction Check voltage at TB4 0V Press down the foot switch and move the turntable rotate controller in the RIGHT direction Check voltage
172. alves operates Replace faulty items JJ and counterbalance valve Activate turntable rotate right function function inoperative Check for mechanical restrictions keeping turntable rotate right function from operating OR replace shuttle valve item Il OR consult Genie Industries Service Department A TEREX COMPANY Part No 72136 S 40 5 45 5 45 Section 5 e Troubleshooting Flow Charts March 2008 Chart 20 All Platform Leveling Functions Inoperative Be sure all other functions operate normally Remove both hydraulic hoses from the manifold ports PL1 amp PL2 Plug the hoses and cap the manifold fittings Activate the boom up function Check to see if platform levels Plumb a 0 to 5000 psi 345 bar pressure gauge into master cylinder rod end hydraulic hose hose connected to port PL2 using a tee fitting Activate boom up function and check the pressure Install a 0 to 5000 psi 345 bar pressure gauge into the barrel end hydraulic hose from the master cylinder and raise the boom one inch 2 5 cm ata time Continually monitor the pees gauge during oom up Do not allow the pressure to exceed 2600 2900 PSI Repair or replace the slave cylinder See Note 2 REV B Replace the platform level counterbalance valves items FF amp GG Check for mechanical restrictions OR replace the slave cylinder counterbalance valves Repair or replace t
173. and connect the fuel hoses to the filter 6 Clean up any fuel that may have spilled during the installation procedure 7 Remove the air baffle retaining fasteners Remove the air baffle 8 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the fuel pressure regulator filter 9 Locate the fuel pressure regulator filter installed on the engine mounting leg 10 Disconnect and plug the hoses from the fuel pressure regulator filter Explosion and fire hazard 4 Electronic Fuel Injection EFI systems operate at a very high pressure Fuel may be expelled under pressure if the hoses are removed too guickly Loosen the fuel hoses very slowly to allow the fuel pressure to dissipate gradually Wrap a cloth around fuel hoses to absorb leaking fuel before disconnecting them 11 Remove the fuel pressure regulator filter mounting fasteners Then remove the regulator filter from the engine mounting leg Part No 72136 A TEREX S 40 S 45 MPANY CHECKLIST A PROCEDURES 12 Install the new fuel pressure regulator filter Genie part number 58967 onto the engine mounting leg and connect the hoses to the regulator filter CAUTION Component damage hazard sure the correct regulator filter is installed or component damage may occur 13 Turn the manual shutoff valve located at the fuel tank to the open position 14 Start the machin
174. asher and slotted nut 7 Tighten the slotted nut to 158 ft lbs 214 Nm to seat the bearing 8 Loosen the slotted nut then re tighten to 35 ft lbs 47 Nm 9 Install a new cotter pin Bend the cotter pin to lock it Always use a new cotter pin when installing a clevis pin 10 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts Torque specifications Lug nut torque dry 170 ft lbs Always install a new bearing seal 230 Nm when removing a hub Lug nut torque lubricated 130 ft Ibs 176 Nm Genie Part No 72136 A TEREX COMPANY S 40 S 45 7 69 Section 7 Repair Procedures March 2008 2WD STEERING AXLE COMPONENTS 14 2 Steering Cylinders How to Remove a Steering Cylinder There are two identical steering cylinders that work in parallel They are part of the same hydraulic circuit but move in opposite directions The tie rod maintains egual movement of the tires When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Tag disconnect and plug the hydraulic hoses from the steering cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipa
175. at TP4 oV Press down the foot switch and check voltage at terminal on controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 19 Repair open in wht 4 wire circuit from TB4 to turntable rotate right directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot turntable rotate controller OR repair open in wht 3 wire circuit from boom controller to TB4 OR consult Genie Industries Service Department Repair open in wht 3 wire from TP4 to TB4 Repair open in power supply circuit from TP24 to controller OR repair open in brn ground wire circuit from ground to controller Section 5 e Troubleshooting Flow Charts March 2008 EE E II 1 CHART 19 REV B 0 or infinite ohms Replace turntable rotate Disconnect wires on turntable rotate right directional valve coil Continued from the previous page right directional valve coil Exchange flow regulator valve item 1 with boom up down flow regulator item A and test the resistance of the valve coil See Repair Section 2 5 to 3 5 ohms function Hold function enable operates Replace faulty switch to either side and directional valve move the turntable rotate toggle switch in the RIGHT direction Manually override the directional valve by
176. ated on the oscillate manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to sguirt or spray 2 Remove the chassis cover from the non steer end of the drive chassis 3 Disconnect the directional valve linkage by removing the clevis yoke from the drive chassis A TEREX COMPANY MANIFOLDS 4 Start the engine from the platform controls 5 With the engine running manually activate the valve and observe the pressure reading on the pressure gauge Sequencing valve specifications Pressure 950 psi 65 bar 6 Turn the engine off Hold the unloader valve with a wrench and remove the cap index 4 7 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap Tip over hazard Do not adjust the AWARNING relief valve higher than specified 8 Repeat steps 3 through 6 and manually activate the valve to confirm the valve pressure 9 Turn the engine off remove the pressure gauge and assemble the directional valve linkage 10 Install the cover on the non steer end of the drive chassis Part No 72136 S 40 S 45 7 49 Section 7 Repair Procedures March 2008 MANIFOLDS REV B 11 6 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive
177. ated tire can explode and may cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products 1 Check all tire treads and sidewalls for cuts cracks punctures and unusual wear 2 Checkeach wheelfor damage bends and cracked welds 4 31 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES Check each lug nut for proper torque 4 Check the pressure in each air filled tire Add air as necessary REV B B 9 Confirm the Proper Brake Configuration Tires and wheels 2WD Front 2WD Rear 4WD Front and Rear E Genie specifications require that Tire size 12 5 16 SL 12 16 5 NHS this procedure be performed every 45 psi 45 psi 250 hours or quarterly whichever 3 1 bar 3 1 bar comes first Tie 12 8 Proper brake configuration is essential to safe operation and good machine performance Wheel lugs 8 5 8 18 9 5 8 18 Hydrostatic brakes and hydraulically released Lug nut torque dry 170 ft lbs 170 ft lbs spring applied individual wheel brakes can appear 230 Nm 230 to operate normally when they are actually not fully operational Lug nut torque lubricated 130 ft lbs 130 ft lbs 176 Nm 176 Nm 1 Check each drive hub disconnect cap to be sure it is in the engaged position brake disengage position a org arfi brake engage position Genie 4 32 S 40 5 45 PartNo 72136 200
178. ation and workplace safety The drive enable limit switch stops the drive function when the boom is rotated past a non steer tire and alerts the operator that the machine may drive in the opposite direction that the drive and steer control handle is moved 1 Start the engine from the platform controls and rotate the turntable to the left until the boom is past the left non steer wheel Turn the engine off 2 Visually inspect the drive enable limit switch for the following Broken or missing roller or arm Missing fasteners Loose wiring turntable b drive enable limit switch LS3 c turntable rotation bearing 4 16 S 40 S 45 REV B Manually activate the drive enable limit switch Result The drive enable limit switch arm should move freely and spring return to center A distinct click should be felt and heard Start the engine from the platform controls and press down the foot switch Result The drive enable indicator light should be on Rotate the turntable so the boom is between the non steer tires Result The drive enable indicator light should be off and drive function should operate Rotate the turntable to the left until the boom is past the left non steer wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override toggle switch is activated Rotate the turntable to the right until the boom is past the right non stee
179. boom to fully raise Adjust the max out trimpot to achieve a 40 to 44 second cycle time Turn the max out trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed 11 Start a timer and record how long it takes for the boom to fully lower Adjust the lo range trimpot to achieve an 50 to 60 second cycle time Turn the lo range trimpot adjustment screw clockwise to increase the speed or counterclockwise to decrease the speed If the function cycle time is not achievable check the relief valve pressure See 11 2 Valve Adjustments Function Manifold S 40 S 45 7 3 Section 7 Repair Procedures March 2008 PLATFORM CONTROLS 12 Turn the engine off 13 Pull out the red Emergency Stop button to the on position 14 Press down the foot switch and then move the control handle all the way to the up position Record the maximum voltage reading 15 Start the engine 16 Start a timer and simultaneously move the control handle all the way to the up position Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 17 Set the ramp rate turn the ramp rate trimpot to obtain a 3 to 4 second ramp speed Turn the trimpot clockwise to increase the time or counterclockwise to decrease the time Boom up down specifications Threshold 3 5V DC Boom up Max out Cycle time 40 to 44 seconds Boom down Lo range Cycle time 50
180. btract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 8 Perform an equalizing charge OR fully charge the batteries and allow the batteries to rest at least 6 hours 9 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 10 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C O Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 217 Replace the battery 1 Check the battery acid level If needed replenish with distilled water to inch mm below the bottom of the battery fill tube Do not overfill 12 Install the vent caps and neutralize any electrolyte that may have spilled with baking soda Section 4 Scheduled Maintenan
181. cations o Description Hex size Torque SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm A TEREX COMPANY 7 54 5 40 5 45 Part No 72136 2008 Section 7 Repair Procedures tt REV B MANIFOLDS 11 10 Valve Adjustments 2WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connecta 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple index 5 located on the drive manifold 2 Startthe engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 bar 4 Turn the engine off Hold the charge pressure relief valve with a wrench and remove the cap index 1 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 6 Startthe engine from the platform controls Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off Remove the pressure gauge A TEREX COMPANY Part No 72136 S 40 5 45 7 55 Section 7 Repair Procedures March 2008 MANIFOLDS 11 11 4WD Drive Manifold Components REV B The drive manifold is mounted inside the drive chassis at the non steer end Index Sc
182. cations require that this procedure be performed every 1000 hours Perform this procedure more often if dusty conditions exist Periodic replacement of the engine oil and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A frequent check of elapsed machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 1000 hour interval Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns Perform this procedure after warming the engine to normal operating temperature 1 Remove the oil filler cap located next to the dipstick Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV 2 Pull the end of the engine oil drain hose out from under the engine 3 Remove the plug from the end of the drain hose and allow all of the oil from the engine to drain into a suitable container See capacity specifications Do not remove the drain plug located on the side of the oil pan 4 Install and tighten the plug in the drain hose Use an oil filter wrench and remove the oil filter Deutz Diesel engine a engine oil level dipstick b fuelfilter oil filter 6 Apply a thin layer of fresh oil to the new filter
183. ce Procedures March 2008 CHECKLIST PROCEDURES B 5 Inspect the Electrical Wiring Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Open the engine side turntable cover 2 Remove the air baffle retaining fasteners Remove the air baffle 3 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the wiring a engine pivot plate b pivot plate retaining bolts c air baffle A TEREX CON S 40 S 45 REV B 4 Inspect the following areas for burnt chafed corroded and loose wires Engine wiring harness Hydraulic manifold wiring 5 Open the ground controls side turntable cover 6 Inspect the following areas for burnt chafed corroded and loose wires Inside of the ground control box Hydraulic manifold wiring 7 Start the engine from the ground controls and raise the boom above the turntable covers 8 Inspect the turntable area for burnt chafed and pinched cables 9 Lower the
184. ck the Turntable Rotation Bearing Bolts Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Maintaining proper torque on the turntable bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Raise the boom and place a safety chock on the lift cylinder rod Carefully lower the boom onto the lift cylinder safety chock Crushing hazard Keep hands AWARNING away from cylinder and all moving parts when lowering the boom The lift cylinder safety chock is available through Genie part number 33484 4 62 A TEREX COMPANY S 40 S 45 REV B 2 Be sure that each turntable mounting bolt is torqued in sequence to 180 ft lbs 244 Nm Bolt torque sequence Lower the boom to the stowed position 4 Check to ensure that each bearing mounting bolt under the drive chassis is torqued in sequence to 180 ft lbs 244 Nm Bolt torque sequence Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV CHECKLIST PROCEDURES D 4 D 5 Grease the Turntable Rotation Bearing and Rotate Gear Yearly application of lubrication to the turntable bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased bearing and gear will result in component damage 1 Locate the grease f
185. ction Output 95A 14 5V Genie 2 6 S 40 S 45 Part No 72136 2008 REV A Deutz F3L 1011F Engine Displacement Number of cylinders Bore and stroke Horsepower Firing order Compression ratio Compression pressure Low idle Freguency High idle Freguency Governor Valve clearance cold 125 cu in 2 05 liters 3 3 58 x 4 13 inches 91 x 105 mm 36 amp 3000 rpm 1 2 3 18 5 1 362 to 435 psi 25 to 30 bar 1500 rpm 313 Hz 2500 rpm 521 7 Hz centrifugal mechanical Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 26 to 87 psi 1 8 to 6 0 bar Oil capacity 8 5 quarts including filter 8 liters Oil viscosity reguirements Temperature below 60 F 15 59C synthetic 5W 30 10 F to 90 F 23 C to 32 10W 40 Temperature above 4 F 34 C 15W 40 Engine oil should have properties of API classification SG CC or CD SG grades Section 2 Specifications Injection system SPECIFICATIONS Injection pump make OMAP Injection pump pressure 4351 psi 300 bar Injector opening pressure 3626 psi 250 bar Fuel reguirement diesel number 2 D Alternator output 55A 14V Starter motor Current draw no load 90A Brush length new 0 7480 in 19 mm Brush length minimum 0 5 in 12 7 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve cap
186. d endanger platform and ground personnel The engine should not start if the foot switch is pressed down 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 3 Do not press down the foot switch and attempt to start the engine Result The engine should start 4 Do not press down the foot switch and operate the machine functions Result The machine functions should not operate 5 Press down the foot switch and operate the machine functions Result The machine functions should operate Part No 72136 A TEREX CON S 40 S 45 MPANY CHECKLIST B PROCEDURES B 18 Test the Horn Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first A functional horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the
187. drive controller in the full forward position Hold the drive enable switch to either side and check voltage 2V Replace drive enable toggle switch TS8 Repair open in wht wire from terminal 4 on drive controller to TS8 to TP30 to TB30 through drive enable limit switch LS3 to TB12 to wht 12 wire on EDC quick disconnect plug Repair open in blu wht wire from TS9 to TP12 to TB12 Repair open in wire from terminal 4 from drive controller to drive enable toggle switch OR replace drive controller OR consult Genie Industries Service Department Genie REX COMPANY 5 66 S 40 5 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Drive Forword or Reverse Function Inoperative Be sure all other functions operate normally including drive in opposite direction of manfunction Chart 31 Repair or replace the drive controller Disconnect the EDC voltage readings different wire connector from the drive pump start the engine move the drive controller to full forward position and note the voltage across the wht 12 and the wht blk 31 wire terminals on the EDC Reverse the volt meter leads and move the drive controller to full reverse position and note the voltage voltage readings the same 0 infinite ohms Check the resistance of the EDC Replace the EDC 20 to 24 ohms Adjust the drive pum
188. e With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage on blu blk 37 wire on steer right directional valve coil item TT on steer manifold Disconnect wires to steer right directional valve coil on steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page 12V or more With key switch turned to platform controls and both Emergency Siop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage at the controller terminal with the blu blk wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu blk 37 wire circuit that runs from TB37 to steer right directional valve coil on steer manifold repair open in brn ground wire circuit to steer right valve coil Replace steer right directional valve coil OR repair open in brn ground wire circuit to steer right valve coil REV B Repair open in blu blk wire circuit from drive controller to TP37 then blu blk 1 to TB37 Genie A TEREX COMPANY 5 62 S 40 S 45 Part No 72136 2008 REV B Continued fr
189. e item U and activate the platform rotate right function function inoperative Consult Genie Industries Service Department A TEREX COMPANY March 2008 REV B Replace the platform rotate right directional valve coil item DD Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restrictions keeping platform rotate right function from operating OR repair or replace platform rotator OR replace platform rotator counterbalance valve manifold OR consult Genie Industries Service Department Replace faulty flow regulator valve Note 1 S 40 2600 psi or more S 45 2900 psi or more Note 2 S 40 less than 2600 psi S 45 less than 2900 psi Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV B Oscillate Function Inoperative Be sure all other function operate normally Remove the chassis cover at the non steer end Check the linkage for damage or improper linkage adjustment See Repair section 10 6 How to Set Up the Directional Valve Linkage Install a 0 to 2000 psi 138 bar pressure gauge at the guick disconnect coupling on the oscillate manifold Disconnect the oscillate linkage from non steer axle Start the engine and manually activate the directional valve Check the pressure Consult Genie Industries Service Department PartNo 72136 Chart 25 Re
190. e Components 16 1 Oscillating Axle Lock out Cylinders 7 74 B Non steering Axle Components 17 1 Drive nete Gom ees 7 75 17 2 Drive Hub ueu iae terere o eee FY AER 7 76 17 83 Wheel Brake tt ite D not ee 7 77 A TEREX COMPANY Part No 72136 S 40 S 45 xvii March 2008 EEE L LL L Ll I d IL Lu L uuhu I AI This page intentionally left blank Genie xviii S 40 S 45 Part No 72136 2008 Section 2 Specifications REV B Specifications Machine Specifications 2WD RT 4WD RT S 40 Models Maximum allowable side force ANSI and CSA 150 Ibs 150 Ibs Stowed dimensions 2WD RT 4WD RT 667 667 7 90 Ibs 90 Ibs Length 23 ft 11 in 23 ft 11 in 400 N 400 N 7 3 m 7 3 m wheels 2WD Rear Width 7ft6in 7ft6in 2WD Front 4WD Front 2 3 m 2 3m Tires Only and Rear Height 8 ft 2 in 8ft2in Tire size 12 5L 16SL 12 16 5 NHS 2 5 m 2 5m Tire ply rating 12 8 Weight 2 H PC Tire contact area 88 sq in 57 sq 9 9 568 sq cm 368 sq cm Ground clearance 12 Ve in 12 2in Overalltire diameter 33 7 in 33 2 in Operational dimensions Tire pressure 45 psi 45 psi 3 1 bar 3 1 bar Maximum platform height 40 ft 40 ft 12 2 m 12 2m Wheel diameter 16 in 161
191. e Specifications 2 2 1 Performance Specifications 1 2 3 Hydraulic Specifications 0 24400 0 2 4 Hydraulic 2 5 Ford LRG 425 EFI Engine 2 6 Deutz 1011F Engine Specifications 2 2 7 Perkins 704 30 Engine 2 8 Machine Torque 2 9 Hydraulic Hose and Fitting Torque Specifications 2 10 SAE and Metric Fastener Torque 2 11 Theory of Operation Part No 72136 POoWer SourC6 ir etti dese te rue e HAE raa bee e qve deis 3 1 Hydraulic Syste Ms sesini dauuria a a p aa aei ai nnne nnns 3 1 Electrical System tee C a a AER iD 3 1 Irc e i FON i 3 2 Electrical System ts ome te tette e rede ce e eA 3 2 S 40 5 45 vii March 2008 TABLE OF CONTENTS Section 4 Rev Scheduled Maintenance Procedures gy dae ae Ee Y e ee 4 1 Maintenance Inspection 4 3 B Checklist A Procedures A 1 Inspect the Operator s and Safety 4 5 2 Inspect the Decals and
192. e directional valves determine which direction the hydraulic fluid will travel The amount of hydraulic fluid volume is determined by a proportional valve or flow regulator valve A proportional valve receives a variable voltage signal and delivers more hydraulic fluid as the voltage increases A flow regulator valve is a mechanical valve and delivers a predetermined amount of hydraulic fluid Drive forward or reverse is accomplished by pressing down the foot switch in the platform and moving the drive controller joystick in the appropriate direction When activated the drive controller completes a circuit to the electronic displacement controller EDC The EDC regulates drive pump displacement in direct relation to the drive controller position A horsepower limiter printed circuit board located in the platform control box is provided to maintain engine RPM as drive system loads become greater This is done by sensing engine RPM via an AC tap on the alternator and limiting the amount of current supplied to the drive controller EDC which destrokes the pump reducing pump output Section Theory of Operation March 2008 THEORY OF OPERATION Limit switches There are two types of limit switches which are found in various locations on the machine drive speed limit switches and a drive enable limit switch The function of a drive speed limit switch is to limit the raised or extended drive speed to 0 6 miles per hour 1
193. e from the ground controls then inspect the fuel filters and hoses for leaks Explosion and fire hazard If a fuel ADANGER leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 15 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 16 Install the air baffle and the air baffle retaining fasteners Section 4 Scheduled Maintenance Procedures March 2008 Checklist B Procedures REV B 1 Check the Exhaust System Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first EL 2 a engine pivot plate Maintaining the exhaust system is essential to b pivot plate retaining bolts good engine performance and service life Running c air baffle the engine with a damaged or leaking exhaust system can cause component damage and unsafe 3 All models Be sure that all nuts and bolts are operating conditions tight Bodily injury h i Inspect all welds for cracks odily injury hazard Do no AWARNING inspect while the engine 5 Inspect for exhaust leaks i e carbon buildup is running Remove the key to around seams and joints Secure from operation 6 Diesel models Swing the engine pivot plate ACAUTION Bodily injury hazard Beware of back to its original position and install the two hot engine components Contact engi
194. e new oil filter Install the filter and tighten it securely by hand A TEREX Ct S 40 S 45 REV 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 11 Fill the engine with new oil per specifications and install the filler cap See capacity specifications 12 Start the engine from the ground controls Allow the engine to run for 30 seconds then turn the engine off 13 Check the oil filter oil pan drain hose and drain valve for leaks 14 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 15 Install the air baffle and the air baffle retaining fasteners 16 Check the engine oil level dipstick Add oil if needed 17 Clean up any oil that may have spilled Properly dispose of the oil and filter Ford LRG 425 EFI Engine 5 quarts Oil capacity including filter 4 7 liters Oil viscosity requirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade Oil filter Genie part number 52581 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B A 18 Check the Engine Belt Gasoline LPG and Perkins Diesel Models Engine specifications reguire that this procedure be performed every 200 hours Maintaining the
195. e on the center terminal of the jib boom toggle switch Check voltage at 0V terminal 30 on CR13 o 12V Check the voltage at terminal 87 on CR13 o lt 12V Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department REV Repair open grn 4 wire from TB17 to jib boom up directional valve OR repair open in brn ground wire circuit to directional valve Repair open grn 3 wire from TP17 to TB17 Repair open in grn wire from TS24 to TP17 OR replace TS24 Repair open in red wire from boom controller to CR13 OR repair open in brn ground wire circuit to CR13 Replace CR13 Genie REX COMPANY 5 56 S 40 5 45 PartNo 72136 2008 Section 5 Troubleshooting Flow Charts REV B previous page Continued from the CHART 26 Press down the foot switch and move the jib boom toggle switch in the UP direction Check voltage on the red and black wires at the jib boom platform rotate directional valves items Replace CR13 Install a 0 to 5000 psi Exchange jib function 845 bar pressure boom platform rotate operates gauge at the quick directional valves item disconnect coupling on AC Press down the the function manifold foot switch and activate and activate the jib the jib boom up function boom up function Replace faulty valve function inoperative
196. el models Connect the engine wiring harness to the fuel solenoid Deutz Diesel Models Release the manual fuel shut off valve Start the engine from the ground controls and check for hydraulic leaks 7 38 S 40 S 45 Part No 72136 March 2008 Section 7 e Repair Procedures This page intentionally left blank A TEREX COMPANY Part No 72136 S 40 5 45 7 39 Section 7 Repair Procedures March 2008 Manifolds REV B 11 1 Function Manifold Components The function manifold is located on the tank side tray behind the ground control box Index Schematic No Description Function Torgue 1 position 4 way valve yN Turntable rotate left right 30 35 in Ibs 3 4 Nm 2 position 4 way DOS valve B Boom up down 30 35 in Ibs 3 4 Nm 3 position 4 way DOS valve Qus Boom extend retract 30 35 in Ibs 3 4 Nm 4 Check valve pilot operated D Boom extend retract circuit 11 13 ft lbs 15 18 Nm 5 Relief valve 1950 psi 134 bar E uu Boom 25 30 ft lbs 34 41 Nm 6 Relief valve 2200 psi 152 bar Ex Boom down 25 30 ft lbs 34 41 Nm 7 Flow regulator valve 1 5
197. ended periods of time may required that the strainer be cleaned more often ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that may have spilled during this procedure 1 Open the engine side cover and locate the fuel pump located next to the engine oil dip stick 2 Close the fuel shut off valve REV B 3 Remove the fuel pump cover retaining fastener Remove the cover 4 Gently clean the fuel strainer with diesel fuel or a mild solvent 5 Install the fuel strainer pump cover onto the fuel pump Install and tighten the fuel pump cover retaining fastener 6 Turn the manual fuel shutoff valve located at the fuel tank to the open position 7 Start the engine from the ground controls and inspect the fuel filter for leaks ADANGER Genie A TEREX COMPANY Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Be sure the fuel filter is full of fuel before attempting to start the engine S 40 S 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV D 9 Replace the Diesel Fuel
198. ength of the rod by turning the clevis yoke until the clevis yoke can be pinned to the drive chassis 10 Install the clevis yoke pin then the cotter pin Be sure to bend the cotter pin 11 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis If the distance is not egual and the adjustment to the linkage was completed with the ground and drive chassis level consult Genie Industries Service Department S Section 7 Repair Procedures March 2008 MANIFOLDS REV B 11 7 Steer Manifold Components Oscillating Models The steer manifold is mounted underneath the function manifold Index Schematic No Description Function Torgue 1 Solenoid valve 3 position 4 way TET Steer 30 35 in Ibs 3 4 Nm 2 Check valve UU Priority flow regulator circuit 10 12 ft Ibs 14 16 Nm 3 Orifice plug 0 025 inch 0 64 mm VV Priority flow regulator circuit 4 Priority flow regulator valve 2 7 6 WW Regulates flow to oscillate manifold 10 12 ft Ibs 14 16 Nm C 49 Valve Coil Resistance Specifications Description Measurement Solenoid valve 3 position 4 way 10V 4 5 to 7 50 schematic item A TEREX COMPANY
199. epair open in wht wire circuit from CR2 to TB21 to CR3 to CR4 Replace CR4 relay OR repair open in blk red wire circuit from terminal 87 on CR4 to 2 speed solenoid Repair open in brn ground wire circuit from 2 speed solenoid to ground Check linkage or replace solenoid Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Engine Low Idle inoperative Diesel Models Check if mechanical linkage from 2 speed solenoid to fuel injection system is binding or defective At the platform controls start the engine and move the RPM select toggle switch TS4 to maintained low idle turtle symbol Check voltage at blk red wire on RPM select toggle switch Check voltage at the blk red wire on the 2 speed solenoid Check if 2 speed solenoid moves in and out freely Check adjustment of linkage and fuel injection system low idle See Maintenance section See Deutz OR Perkins workshop manual to troubleshoot fuel injection system OR consult Genie Industries Service Department moves freely Part No 72136 Isolate the platform and ground RPM select toggle switches TS4 and TS12 check individually and replace faulty toggle switch Replace CR4 relay Check linkage or replace solenoid Chart 9 S 40 S 45 Section 5 e Troubleshooting Flow Charts March 2008 Chart 10 REV All Functions inoperative Engine Star
200. er flex plate with raised spline flywheel 3 ainch 9 5 mm gap 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it from moving Component damage hazard CAUTION Hoses can be damaged if they are kinked or pinched 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine flywheel How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump Torque the flex plate mounting bolts to 34 ft lbs 46 Nm 2 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave a 3 8 inch 9 5 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump coupler set screw Torque the set screw to 45 ft lbs 61 Nm 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged A TEREX COMPANY Part No 72136 S 40 5 45 7 27 Section 7 Repair Procedures March 2008 DEUTZ F3L 1011F ENGINE 6 3 Oil Temperature and Oil Pressure Gauges The
201. er Manifold Components Non oscillating Models 7 53 11 9 2WD Drive Manifold Components 7 54 11 10 Valve Adjustments 2WD Drive Manifold 7 55 11 11 4WD Drive Manifold Components 7 56 11 12 Valve Adjustments 4WD Drive Manifold 7 58 11 13 Jib Boom Platform Rotate Manifold Components 5 45 Models before serial number 5593 7 59 11 14 Jib Boom Platform Rotate Manifold Components S 45 Models after serial number 5592 0000 0 7 60 Fuel and Hydraulic Tanks 12 1 Fuel Tank cien eee cree roa nie 7 62 12 2 Hydraulic Tanks iet eet 7 63 Turntable Rotation Components 13 1 Rotation Hydraulic 7 66 Genie Xvi S 40 5 45 72136 2008 Section 7 TABLE OF CONTENTS Rev Repair Procedures continued B 2WD Steering Axle Components 14 1 Yoke and AUD ciini tero eid eee tas 7 68 14 2 Steering Cylinders 20 4 1 1 0 0 7 70 14 3 Tie ROG iui or tet rp P REA 7 71 4WD Steering Axle Components 15 1 Yoke and El b ciere e eee e eee ns 7 72 15 2 Steering Cylinders See 14 2 Steering Cylinders 7 73 15 3 Tie Rod See 14 3 Tie Rod 7 73 A Oscillating Axl
202. erminals 5 Do not press down the foot switch Connect the NO NC leads from an ohmmeter or continuity tester to 2 2 each wire combination listed below and check i for continuity uS Sae brown Y guest Test Desired result red to black continuity zero red to white no continuity infinite black to white no continuity infinite Part No 72136 5 40 5 45 7 9 Section 7 Repair Procedures March 2008 PLATFORM CONTROLS 1 4 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches Dual function switching reguires a double pole double throw DPDT switch How to Test a Toggle Switch Continuity is the eguivalent of O to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the off position Tag and disconnect all wiring from the toggle switch to be tested 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed to on right to check for continuity Left Center Right cyr s 0 SPDT Double pole double throw DPDT A TEREX COMPANY Test Left position REV A Desired result terminal 1 to 2 3 4 5 amp 6 no continuity infinite O terminal 2 to 3 continuity zero termina
203. es sj Be aware of potential crushing hazards 3l Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure Hie fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe sure that your workshop or work area is properly ventilated and well lit 25 Part No 72136 2008 Introduction Section 1 Section 2 Section 3 Rev Rev Table of Contents Important Information EEE li Safety Rules General Safety 4 42 1 1 00 6 enne nennen nennen nnne enn iii Specifications Machin
204. es can be damaged if they are kinked or pinched 6 Remove the upper rollers from the replacement section of cable track 7 Lift up the hoses and cables and carefully insert the new 4 link section of cable track Component damage hazard CAUTION Hoses and cables can be damaged if they are kinked or pinched 8 Connect the ends of the replacement cable track section to the existing cable track using the fasteners provided in the kit Do not overtighten the fasteners Component damage hazard CAUTION Over tightening the fasteners will result in the cable track not rotating and it may bind during operation Be sure that the fasteners are installed from the inside out so the nuts are on the outside of the cable track 9 Install the black rollers onto the new section of cable track 10 Install cable track onto the machine and operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track ATER BOOM COMPONENTS 4 2 Boom How to Shim the Boom 1 Measure each upper and side wear pad Replace the pad if it is less than 9 16 inch 14 3 mm thick If the pad is more than 9 16 inch 14 3 mm thick perform the following procedure 2 Measure the bottom wear pad Replace the pad if it is less than 11 16 inch 17 5 mm thick 5 40 or 9 16 inch 14 3 mm thick S 45 If the pad is more than 11 16 inch 17 5 mm thick 5 40 or 9 16 inch 14 3 mm thick
205. es that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Section 7 Repair Procedures March 2008 Platform Controls 1 1 Joystick Controllers Maintaining joystick controllers at the proper settings is essential to safe machine operation Every joystick controller should operate smoothly and provide proportional speed control over its entire range of motion Platform control box horsepower limiter board terminals drive controller extend retract controller boom controller turntable rotate controller 7 2 5 40 5 45 REV Boom Up Down Controller Adjustments AWARNING Electrocutio
206. essure See flow regulator valve RE DAW UM gauge at the guick Note 1 item I with boom g disconnect coupling on up down flow regulator the boom function valve item H Check manifold and start the turntable rotate left engine Hold the function function enable switch to either side and move the turntable rotate toggle switch in the LEFT direction and check the pressure function inoperative Repair turntable rotation motor OR function manifold may have an internal fault Consult Genie Industries Service Department See Note 2 Note 1 5 40 2600 psi or more 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi Continued on the next page Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts srt REV B Plumb a 0 to 5000 psi lessthan Function manifold could 0 10 345 bar pressure 250 psi have an internal fault gauge into the hose from the function Service Department manifold to the turntable rotation brake Hold the function enable switch to either side and move the turntable rotate toggle switch TS17 in the LEFT direction Check the pressure Continued from the previous page 250 psi or more Exchange turntable rotate left and right function counterbalance valves operates items JJ and KK Activate turntable rotate left function
207. ete circle Adjust the max out b lo range trimpot trimpot to achieve a 78 to 83 second cycle time c terminal R activates max out range Turn the max out trimpot adjustment screw PT lockwise to increase the speed or terminal X not used COC RWISS O f terminal ground counterclockwise to decrease the speed g terminal positive h terminal A proportional output If the function cycle time 2 not i _ threshold trimpot achievable check the relief valve j hi range trimpot pressure See 11 2 Valve 4 Set the preliminary ramp rate Turn the ramp Adjustments Function Manifold rate trimpot adjustment screw counterclockwise 9 Turn the engine off 15 turns or until you hear a repeated click 10 Pull out the Emergency Stop button to 5 Connect the red lead from a volt meter to the the on position A terminal on the controller printed circuit board Connect the black lead to ground 11 Press down the foot switch and then move the control handle all the way to the left or right 6 Setthe threshold Press down the foot Switch Record the maximum voltage reading then slowly move the control handle off center until the moment a voltage reading appears 12 Start the engine Adjust the voltage to 3 5V DC Turn the threshold trimpot adjustment screw clockwise to increase the voltage or counterclockwise to decrease the voltage A TEREX COMPANY Part No 72136 S 40 5 45 7 5 Section 7 Repair Procedure
208. etrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Raise the boom to a horizontal position Remove the fasteners from the drive speed limit switch mounted on the side of the cable track at the pivot end of the boom Do not disconnect the wiring Remove the fasteners from the side panel on the lower cable track then remove the panel Pull all of the cables out of the channel Part No 72136 S 40 S 45 7 17 Section 7 Repair Procedures March 2008 BOOM COMPONENTS 8 Remove the cable cover on the side of the boom 9 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and AWARNING lower cable tracks are not properly secured together the cable track could become unbalanced and fall when it is removed from the machine 10 Remove the hose and cable clamp at the platform end of the cable track 11 Attach a lifting strap from an overhead crane to the cable track 12 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 13 Remove the cable track mounting fasteners that attach the lower cable track to the boom 14 Remove the cable track from the machine and place it on a structure capable of supporting it Crushing hazard The cable track AWARNING could become unbalanced and fall
209. every 250 hours or guarterly whichever comes first Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Put on protective clothing and eye wear 2 sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 3 Be sure that the battery hold downs and cable connections are tight 4 sure that the battery separator wire connections are tight 5 Fully charge the batteries and allow the batteries to rest at least 6 hours 6 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Part No 72136 A TEREX CON S 40 S 45 MPANY CHECKLIST B PROCEDURES 7 Checkthe ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Su
210. fault codes There will be a 2 4 second pause between codes 6 Refer to the Troubleshooting Section for definition of engine fault codes Once a fault code has been retrieved and the repair has been completed the ECM memory must be reset to clear the fault code from the ECM See 9 4 How to Clear Engine Fault Codes A TEREX COMPANY GROUND CONTROLS How to Clear Engine Fault Codes from the ECM Perform this procedure with the engine off and the key switch in the off position 1 Open the engine side turntable cover and locate the battery 2 Disconnect the negative battery cable from the battery for a minimum of 20 minutes Electrocution hazard Contact with AWARNING electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Connect the negative battery cable to the battery Part No 72136 S 40 S 45 7 35 Section 7 Repair Procedures March 2008 Hydraulic Pumps 10 1 Lift Steer Pump How to Remove the Lift Steer Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Close the two hydraulic tank valves located at the hydraulic tank open closed Component damage hazard The CAUTION engine must not be started with the hydraulic tank shutoff valves in
211. fied 6 Repeat steps 2 through 5 to confirm relief valve pressure Part No 72136 A TEREX 5 40 5 45 MANY MANIFOLDS How to Override Valve A hydraulic valve may need to be manually overridden to troubleshoot a malfunction The proportional boom functions boom up down extend retract and turntable rotate use a variable position proportional valve and a three position directional valve Example one position for boom up one position for neutral and one position for boom down The platform rotate function uses a three position valve The platform level uses a three position and a two position valve The three position valves and the proportional valves can be manually overridden To identify the manifold valves see 11 1 Function Manifold in this section 1 Push the button on the end of the valve in inch 6 mm 2 Hold the function enable switch to either side and move the ground control function switch for the function being overridden to operate function AWARNING Collision hazard Impact with moving boom components could result in death or serious injury Use extreme caution when overriding a machine function Identify the direction of machine movement before overriding a valve Section 7 Repair Procedures March 2008 MANIFOLDS 11 3 Turntable Rotation Manifold Components REV B The turntable rotation manifold is mounted to the turntable rotation motor on the tank side of the t
212. form controls Result No function should operate the engine should stop As a safety feature selecting and operating the ground controls will override the platform controls including the red Emergency Stop switch Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV 12 Test the Auxiliary Power Operation Genie specifications reguire that this procedure be performed daily Detection of auxiliary power system malfunctions is essential for safe machine operation An unsafe working condition exists if the auxiliary powered functions do not operate in the event of a main power loss When operating the machine on engine power selecting auxiliary power will stop the engine immediately Auxiliary power is designed for short term use only and excessive use will result in battery drain and component damage 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 2 Lift the red auxiliary power toggle switch cover 3 Simultaneously hold the auxiliary power toggle switch on and activate each boom function toggle switch Result All boom functions should operate To conserve battery power test each function through a partial cycle 4 Turn the key switch to platform control 5 Pull out the red Emergency Stop butto
213. genieindustries com e mail techsup genieind com A TEREX ct ii S 40 S 45 Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No S 40 and S 45 Service Manual before serial number 832 32222 S 40 and S 45 Service Manual from serial number 832 to 1789 52271 5 40 and 5 45 Service Manual from serial number 1790 to 7000 72136 Genie Industries Copyright 1998 by Genie Industries 72136 Rev B December 2007 Third Edition Second Printing Genie and 5 are Registered Trademarks of Genie Industries in the USA and many other countries Ts Printed on recycled paper Printed in U S A Part No 72136 2008 Section 1 Safety Rules f INTRODUCTION Serial Number Legend Genie A TEREX COMPANY Model S 40 Serial number 54006 12345 Model year 2006 Manufacture date 01 05 06 Electrical schematic number ES0274 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 N Maximum allowable inclination of the chassis 0 deg S40 06 1 2345 Maximum wind speed 28 12 5 m s Maximum platform height 60 ft 6 in 18 3 m tt Model Sequence Maximum platform reach 34 ft 3 in 10 4 m number Gradeability N A Count
214. hat this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to ground control start the engine and then turn the key switch to platform control 3 Check any machine function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Check any machine function from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position O Result The engine should stop and no functions should operate Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 13 Test the Emergency Stop Buttons Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Properly functioning Emergency Stop buttons are essential for safe machine operation An
215. he master cylinder Note 1 5 40 2600 psi or more 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi Note 3 5 40 2600 psi 5 45 2900 psi A TEREX COMPANY Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Platform Level Up Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the platform level toggle switch TS14 in the uP direction Check voltage at org 4 wire on platform level up directional valve item Continued on the next page 12V or more With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the platform level toggle switch in the direction Check voltage at TB14 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the platform level toggle switch in the UP direction Check voltage at TB14 Troubleshoot platform level toggle switch TS14 OR repair open in red power wire circuit to TS14 OR repair open in org 4 wire circuit from TS14 to TB14 OR consult Genie Industries Service Department 12V or mo
216. he drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from the machine Component damage hazard CAUTION Be sure to open the two hydraulic tank valves and prime the pump after installing the pump Before installing the pump verify proper pump coupler spacing Refer to the appropriate flex plate installation instructions for your engine How to Prime the Pump Component damage hazard Be ACAUTION sure that the hydraulic tank shutoff valves are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the cLosEp position or component damage will occur 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Gasoline LPG models Close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select toggle switch to the LPG position Deutz Diesel models Hold the manual fuel shutoff valve clockwise to the closed position A TEREX COMPAN REV A a manual fuel shutoff valve Perkins Diesel models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 250 psi 17 2 bar Gasoline LPG models Connect the LPG hose to the LPG tank and open the valve on the tank Perkins Dies
217. he gauge when the engine is running A TEREX Gt S 40 5 45 SOMPANY REVA How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the engine block 2 Install the new sending unit Do not over tighten 3 Connect the wires to the new sending unit Burn hazard Contact with hot ACAUTION engine fluids or components may cause severe burns Always use pipe thread sealant when installing a sending unit Coolant temperature sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 7 8 inch Temperature switch point 221 F 105 Oil pressure sending unit specifications Torque 8 10 ft lbs 11 14 Nm Hex size 7 8 inch Oil pressure switch point 4 2 psi 0 3 bar Part No 72136 March 2008 Section 7 e Repair Procedures Ford LRG 425 EFI Engine REV A 8 1 Flex Plate Removal Timing Adjustment 1 Disconnect the wiring plug at the electronic EE SS LLL LEO displacement controller EDC located on The ignition timing is controlled by the drive pump the ECM and can only be adjusted re programming the If 2 Support the drive pump with an appropriate timing adjustment or service is lifting device Then remove all of the pump reguired please contact Genie mounting plate to engine bell housing bolts Industries Se
218. he two engine pivot plate retaining bolts 9 Replace the air baffle and install the air baffle retaining fasteners 3 8 inch to 1 2 inch 9 mm to 12 mm Belt deflection Diesel models Engine belts Genie part numbers REV B A 19 Replace the Gasoline Fuel Filter Gasoline LPG Models Replacing the gasoline fuel filter is essential to good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may reguire that the filter be replaced more often Explosion and fire hazard Engine ADANGER ras fuels are combustible Replace the fuel filter in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Locate the fuel pre filter to the left of the ground control box 2 Turn the manual shutoff valve located at the fuel tank to the closed position 3 Atthe pre filter disconnect the fuel hose that goes to the fuel tank 4 Disconnect and plug the fuel hose from the fuel Gasoline LPG models 52580 fi Perkins Diesel models 62423 AU to the fuel pump then remove the pre Genie TEREX COMPANY S 40 S 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 5 Install the new fuel pre filter Genie part number 52179
219. hematic No Description Function Torgue 1 Flow divider combiner valve AC un Controls flow to flow divider combiner valves 4 and 5 25 30 ft lbs 34 41 Nm 2 Relief valve 250 psi 17 bar AD Charge pressure circuit 10 12 ft Ibs 14 16 Nm Orifice plug 0 052 inch 1 32 mm Front drive motor circuit 4 Flow divider combiner valve Controls flow to steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 5 Flow divider combiner valve AG Controls flow to non steer end drive motors in forward and reverse 25 30 ft lbs 34 41 Nm 6 Orifice plug 0 070 in 1 8 mm Rear drive motor circuit Orifice plug 0 070 in 1 8 mm Egualizes pressure both sides of flow divider combiner valve Index no 1 8 Shuttle valve 3 position way Ad uua Charge pressure circuit that gets hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 9 Diagnostic Testing Plug Torgue Specifications Description Hex size Torgue SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm SAE No 8 5 16 50 ft lbs 68 Nm Genie 7 56 S 40 S 45 Par
220. hine operation The filter condition indicator will show when the hydraulic flow is bypassing a clogged filter If the filter is not frequently checked and replaced impurities will remain in the hydraulic system and cause component damage Perform this procedure with the engine running 1 Start the engine from the platform controls 2 Move the engine idle speed select switch to high idle rabbit symbol Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 3 Inspect the filter condition indicator filter condition indicator b filter c hydraulic tank O Result The filter should be operating with the plunger in the green area If the display shows the plunger in the red area this indicates that the hydraulic filter is being bypassed and the filter should be replaced See B 27 Replace the Hyaraulic Tank Return Filter Part No 72136 A TEREX CON S 40 S 45 MPANY CHECKLIST B PROCEDURES B 8 Inspect the Tires Wheels and Lug Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Bodily injury hazard An over AWARNING infl
221. ieve Fault Codes Is there a fault code stored in the ECM memory Turn OFF the valve on the LPG tank then disconnect LPG supply line from LPG tank and peed pressure from ine With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select toggle switch TS11 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at TB39 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at terminal 85 on CR3 Continued on the next page Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Check the voltage at the center terminal of the fuel select toggle switch Replace fuel select toggle switch Repair open in blu red wire circuit from fuel select toggle switch to TB39 Repair open in red wire circuit from ECM to terminal 485 on CR3 OR replace ECM Genie REX COMPANY REV B Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to fuel select toggle switch S 40 S 45 Part No 72136 March 2008 Section 5 Tro
222. if it is not properly attached to the overhead crane Component damage hazard CAUTION Hoses and cables can be damaged if they are kinked or pinched A TEREX COMPAN 7 18 S 40 S 45 REV A How to Repair the Boom Cable Track Component damage hazard CAUTION The boom cable track can be damaged if it is twisted A cable track repair kit is available through the Genie Industries Service Parts Department part no 46677 The kit includes a 4 link section of cable track fasteners other miscellaneous parts and detailed instructions Remove the boom cable track See 4 1 How to Remove the Boom Cable Track Visually inspect the cable track and determine which 4 link section needs to be replaced Drill out the 4 spot welds on each side of the cable track using a 17 64 inch drill bit Repeat this step for the other end of the 4 link section of cable track Component damage hazard CAUTION Cables and hoses can be damaged if the drill bit comes in contact with them Protect the hoses and cables with a block of wood to prevent drilling into the hoses and cables Remove the retaining fasteners from upper black rollers from the 4 link section of cable track to be replaced Remove the rollers Part No 72136 2008 Section 7 Repair Procedures REV A 5 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard CAUTION Hoses and cabl
223. il and filter is essential to good engine performance Operating the machine with an improper oil level or neglecting periodic oil and filter changes can damage engine components A daily check of machine hours against the hours noted on the oil filter will allow the inspector to anticipate and perform oil and filter changes at the 100 hour interval Perform this procedure after warming the engine to normal operating temperature Bodily injury hazard Beware of ACAUTION hot engine parts and oil Contact with hot engine oil and or engine parts may cause severe burns 1 Openthe engine side cover and remove the oil filler cap located on the valve cover 2 Pullthe oil drain hose out from underneath the engine Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES 3 Open the engine oil drain valve on the engine oil pan and allow all of the oil from the engine to drain into a suitable container See specifications A engine pivot plate pivot plate retaining bolts oil drain hose air baffle 4 the engine drain valve Remove the air baffle retaining fasteners Remove the air baffle 6 Remove the 2 engine pivot plate retaining bolts Pull the engine pivot plate away from the machine to access the oil filter 7 Place acontainer under the oil filter 8 Use an oil filter wrench and remove the filter 9 Apply a thin layer of fresh oil on the gasket of th
224. ilter for leaks Explosion and fire hazard If a fuel A DANGER leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST D PROCEDURES D 10 Change the Fuel Hoses Deutz Diesel Models Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition Explosion and fire hazard Engine fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be sure the fuel hoses are routed the same way the original hoses were CAUTION Perform this procedure with the engine off and cooled 1 Remove the air baffle retaining fasteners Remove the air baffle A TEREX CON S 40 S 45 REV B 2 Remove the 2 engine pivot plate retaining bolts and swing the engine out away from the machine to access the fuel hoses a engine pivot plate b pivot plate retaining bolts c air baffle 3 Place a suitable container under the engine pivot plate 4 Atthe fuel
225. in blu wire circuit from drive controller to TP36 then blu 1 wire circuit to TB36 Genie A TEREX COMPANY 5 60 S 40 5 45 Part No 72136 2008 REV B Continued from the previous page PartNo 72136 Section 5 Troubleshooting Flow Charts n n CHART 28 Install a 0 to 5000 PSI Check for mechanical 845 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer left function regulator valve item WW OR consult Genie Industries Service Department See Note 2 Repair replace steer cylinder OR steer manifold could have an internal defect Consult Note 1 Genie Industries Service 5 40 2600 psi or more Department 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi 5 40 5 45 5 61 Section 5 Troubleshooting Flow Charts March 2008 Chart 29 Steer Right Function Inoperative Be sure all other functions operate normally With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the RIGHT direction Check voltage on TB37 12V or mor
226. in the ow or orr position This function is particularly useful if the operator at the platform controls cannot return the boom to the stowed position 1 Pushin the platform red Emergency Stop button to the off position 2 Startthe engine from the ground controls 3 Atthe ground controls operate each boom function through a partial cycle O Result All boom functions should operate 4 37 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 15 Check the Directional Valve Linkage Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Perform this test only on models equipped with a oscillating axle Proper axle oscillation is essential to safe machine operation If the directional valve linkage is not operating correctly the stability of the machine is compromised and it may tip over 1 Remove the drive chassis cover from the non steer end 2 Inspect the linkage for the following Lock nut is tight against yoke Yoke clevis pins are installed Cotter pins are installed through clevis pins Linkage is properly attached to directional valve REV B B 16 Test the Platform Self leveling Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Automatic platform self leveling throughout the full cycle of boom raising and lowering is essentia
227. ine Oil capacity including filter 8 5 quarts 8 liters Cil viscosity requirements below 60 F 15 5 C synthetic 5W 30 10 F to 90 F 23 C to 32 10W 40 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CC SE or CC SF grades Perkins 704 30 Engine Oil capacity including filter 9 5 quarts 8 9 liters Cil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES A 5 Check the Engine Coolant Level Liquid Cooled Models Genie specifications require that this procedure be performed daily Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems Burn hazard Beware of hot ACAUTION engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Do not remove the radiator cap 4 8 S 40 S 45 REV B A 6
228. ining fasteners then remove the pivot pin from the adjustable end of the tie rod 7 Slide the tie rod off the yoke and adjust it by turning the end One half turn on the adjustable end equals approximately 1 8 inch 6 4 mm change in the front and rear measurements 8 Slide the tie rod onto the yoke Install the pivot pin then install the retaining fasteners 9 Tighten the jam nut against the tie rod 10 Lower the machine and recheck the front and back measurements step 2 If further adjustment is needed repeat steps 3 through 8 Toe in specification 0 1 8 inch 6 35 mm Section 7 Repair Procedures March 2008 4WD Steering Axle Components 15 1 Yoke and Hub How to Remove the Yoke and Hub The yoke installation utilizes bushings and a thrust washer that may reguire periodic replacement The yoke must be removed before the drive hub can be removed When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Remove the pin retaining fasteners from both the steering cylinder and the tie rod clevis pins Remove the pins Always use a new cotter pin when installing a clevis pin oscillate cylinder b yoke pivot pin drive hub d yoke e pivot pin f steer cylinder g tie rod A TEREX CON S 40 5 45 ME
229. inued on the next page Hold the function enable switch to either side and move the jib boom 12V toggle switch in the DOWN direction Check voltage at TB18 Repair open in red power wire circuit from key switch to TS12 to TS19 OR replace TS19 Press down the foot 12V switch and move the jib boom toggle switch in the DOWN direction Check voltage at TP18 With the key switch 12V turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and check voltage on the center terminal of the jib boom toggle switch Check the voltage at 0V terminal 30 on CR13 o tr 12V Check the voltage at terminal 87a on CR13 lt 12V Repair open in red wire from terminal 87a on CR13 to TS8 OR consult Genie Industries Service Department REV B Repair open in grn blk 4 wire from TB18 to jib boom down directional valve OR repair open in brn ground wire circuit to directional valve Repair open in grn blk wire from TS24 to TP18 Repair open in grn blk 3 wire from TP18 to TB18 OR replace TS24 Repair open in red wire from boom controller to CR13 OR repair open in brn ground wire circuit to CR13 Replace CR13 S 40 S 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV B previous page Continued from the CHART 27 Press down the foot switch a
230. ion way valve AM Platform rotate select 8 10 ft lbs 11 14 Nm 2 Orifice Disc 0 030 0 762 mm AN Platform rotate select Valve Coil Resistance Specification 3 position 4 way solenoid valve 12V 4 5 to 7 50 schematic item AM A TEREX COMPANY Part No 72136 S 40 5 45 7 59 Section 7 Repair Procedures March 2008 MANIFOLDS REV B 11 14 Jib Boom Platform Rotate Manifold Components 5 45 Models after serial number 5592 The jib boom platform rotate manifold is mounted on the platform end of the boom Index Schematic No Description Function Torgue 1 2 position way valve AC Platform rotate select 8 10 ft lbs 11 14 Nm Valve Coil Resistance Specification 2 position 3 way solenoid valve 12V 4 5 to 7 50 schematic item AC A TEREX COMPANY 7 60 5 40 5 45 72136 March 2008 Section 7 e Repair Procedures This page intentionally left blank A TEREX COMPANY Part No 72136 S 40 S 45 7 61 Section 7 Repair Procedures March 2008 Fuel and Hydraulic Tanks m 12 1 Plastic tanks Fuel Tank 5 Remove the fuel tank mounting fasteners 6 Support the fuel tank with 2 lifting straps Place How to Remove the Fuel Tank one lifting strap at each end of the tank and attach the lifting straps to a
231. ion 4 Scheduled Maintenance Procedures REV A 3 Replace the Fuel Filter Water Separator Element Perkins Diesel Models Engine specifications reguire that this procedure be performed every 500 hours or 12 months whichever comes first Replacing the diesel fuel filter water separator element is essential for good engine performance and service life A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage Extremely dirty conditions may reguired that the filter be replaced more often Explosion and fire hazard Engine ADANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Immediately clean up any fuel that CHECKLIS C PROCEDURES 2 Loosen the vent plug located on the fuel filter water separator head Fuel filter water separator head bolt b vent plug c drain plug d filter bowl e separator head 3 Place a suitable container under the filter bowl Loosen the drain plug located at the bottom of the bowl Completely drain the fuel Tighten the drain plug 4 Loosen the head bolt Rotate the filter bowl counterclockwise and remove it from the element 5 Rotate the filter element counterclockwise and remove it from the filter head 6 Insta
232. ion manifold may have an internal fault Consult Genie Industries Service Department REV B Replace the platform level up directional valve coil Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restrictions keeping platform level up function from operating OR replace slave cylinder OR replace slave cylinder counterbalance valves OR consult Genie Industries Service Department Replace faulty flow regulator valve Note 1 5 40 2600 psi or more 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Platform Level Down Function Inoperative With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the platform level toggle switch TS14 in the DOWN direction Check voltage at org blk 4 wire on platform level down directional valve item V Be sure all other functions operate normally Continued on the next page 12V or more Part No 72136 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the OV function enable switch to either side and move the platform level toggle switch in the DOWN direction Check voltage a
233. ipped with a filter condition indicator How to Remove the Hydraulic Tank 1 CAUTION Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications Remove the fuel tank See 12 1 How to Remove the Fuel Tank 2 Close the two hydraulic shutoff valves located at the hydraulic tank Part No 72136 A TEREX COMPAR S 40 5 45 FUEL AND HYDRAULIC TANKS open closed CAUTION Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition Remove the drain plug from the hydraulic tank Completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing Disconnect and plug the supply hose for the auxiliary power uni
234. irection Does the machine drive Repair open in blu wht wire from drive enable toggle switch to TP12 to TB12 OR replace drive enable toggle switch TS8 Activate limit switch by hand and check continuity from TB30 to TB12 no continuity Please begin troubleshooting from beginning of chart OR consult Genie Industries Service Department continuity Chart 35 Repair open in power supply circuit from TP24 The machine is operating properly If yes machine does not operate properly consult Genie Industries Service Department Replace drive enable limit switch contact OR replace drive enable limit switch LS3 Section 5 Troubleshooting Flow Charts March 2008 Chart 36 Auxiliary Functions Inoperative Be sure all other functions operate normally Be sure key switch is in the appropriate position and both Emergency Stop buttons are pulled out to the oN position Be sure engine is not running when using auxiliary power Note Operating auxiliary power with the engine running should immediately stop the engine Install a 010 5000 psi 345 bar pressure gauge into the pressure port of the auxiliary Lift the red auxiliary pump switch cover motor move the auxiliary operates 2000 psi power toggle switch TS9 to either side and listen for sound of auxiliary pump motor operating pump and move the auxiliary power toggle switch to either side and
235. itting on the platform end of the tank side bulkhead 2 Pump grease into the turntable rotation bearing Rotate the turntable in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 3 Apply grease to each tooth of the drive gear located under the turntable Grease type Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Part No 72136 A TEREX S 40 S 45 MPANY Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or every 12 months whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may cause component damage Drive Hubs 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove both plugs and drain the oil into a suitable container 3 Drive the machine until one plug is at the top and the other is at 90 degrees Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST D PROCEDURES REV B 4 Fill the hub with oil from the top hole until the oil level is even with the bottom of the side hole Apply pipe thread sealant to the plugs and then install the plugs 5 Repeat steps 1 through 4 for all the other dri
236. k red wire circuit from toggle switch to TB35 12V Check voltage at 0V Repair open in blk red terminal 30 on wire circuit from TB35 to terminal 30 12V Check voltage to oV Repair open in wht wire terminal 86 on CR3 circuit from terminal 87 on CR2 to TB21 to terminal 86 on CR3 12V do eue no Check continuity from ay Repair open in brn ground to brn wire at continuity ground wire circuit to terminal 85 on CR3 terminal 85 on CR3 continuity 0V Check voltage to Replace relay terminal 87 on 12V Continued on the next page S 40 5 45 5 21 Section 5 Troubleshooting Flow Charts March 2008 CHART 8 Continued from the previous page Check voltage at ov terminal 86 on CR4 12V Check continuity from bad ground to brn wire at terminal 85 on CR4 good Check voltage to oV terminal 30 on CR4 12V Check voltage at the blk red wire on the 2 speed solenoid 12V Check continuity from ground to brn wire at bad 2 speed solenoid to ground good solenoid Check if 2 speed binds solenoid moves in and out freely moves freely Replace 2 speed solenoid Note resistance across solenoid terminals should be approximately 0 3 ohms Genie REX COMPANY S 40 S 45 REV B Repair open in blk red wire circuit from CR3 to CR4 Repair open in brn ground wire circuit to terminal 85 on CR4 R
237. k the pressure Exchange boom flow regulator valve item H with boom extend retract flow regulator valve item G Check boom up function Repair cylinder or oylinder counterbalance valve OR boom function manifold could have an internal fault Consult Genie Industries Service Department function inoperative See Note 2 function inoperative 0 or infinite ohms Replace boom up down directional valve coil 2 5 to 3 5 ohms function operates Replace the faulty directional valve Check for mechanical restrictions keeping boom from moving OR repair cylinder or cylinder counterbalance valve OR consult Genie Industries Service Department function operates Replace the faulty flow regulator valve Note 1 5 40 2600 psi or more 5 45 2900 psi or more Note 2 5 40 less than 2600 psi S 45 less than 2900 psi A TEREX COMPANY REV B Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Boom Down Function Inoperative Be sure all other functions operate normally With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch to either side and move the boom up down toggle switch TS16 in the DOWN direction Check voltage on red wht wire on boom up down proportional valve coil item P 20V or more Continued on the next page
238. key switch and tag the machine to inform personnel of the condition Remove the drain plug from the hydraulic tank Completely drain the tank into a suitable container See capacity specifications Tag disconnect and plug the two suction hoses that are attached to the hydraulic tank shutoff valves Disconnect and plug the T fitting located at the return filter with the 2 hoses connected to it Cap the fitting on the return filter housing Disconnect and plug the supply hose for the auxiliary power unit Cap the fitting on the hydraulic tank S 40 S 45 4 73 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST E PROCEDURES 8 Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if it is not properly supported and secured to the overheadcrane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using pipe thread sealant on the threads 14 Install the drain plug using pipe thread sealant on the threads 15 Install the hydra
239. km h when the primary boom is raised more than 2 feet 0 6 m OR when the primary boom is extended more than 18 inches 45 7 cm The function of the drive enable limit switch is to limit the ability of the machine to drive when the boom is rotated beyond the non steer wheels 3 2 S 40 5 45 REV A Machine Controls The Genie S 40 and Genie S 45 machines are eguipped with operational controls which are found in two locations the ground controls located on the tank side of the machine and the platform controls located in the platform All lift and drive functions are available at the platform controls Only boom functions are available at the ground controls Ground controls are activated by holding the function enable toggle switch to either side then moving a boom function toggle switch in the direction indicated on the control panel decal This will determine which boom function will operate and its direction of travel Platform controls use toggle switches and boom function controllers joysticks to operate the boom functions The drive controller joystick regulates the drive pump displacement through the EDC in direct relation to the drive controller position A thumb rocker switch on the top of the drive controller is used for steering Washing electronic components is not suggested Instead use compressed air to remove debris Part No 72136 2008 Section 4 Scheduled Maintenance Procedures
240. l 2 to 4 5 amp 6 no continuity infinite terminal 3 to 4 5 amp 6 no continuity infinite terminal 4 to 5 amp 6 no continuity infinite terminal 5 to 6 continuity zero Q Center position There are no terminal combinations that will produce continuity infinite O Right position terminal 1 to 2 continuity zero Q terminal 1 to 4 5 amp 6 no continuity infinite O terminal 2 to 3 4 5 amp 6 no continuity infinite O terminal 3 to 4 5 amp 6 no continuity infinite terminal 4 to 5 continuity zero O terminal 4 to 6 no continuity infinite O terminal 5 to 6 no continuity infinite O 7 10 S 40 S 45 Part No 72136 2008 Section 7 Repair Procedures REV A 2 1 Platform How to Remove the Platform 1 Open the platform control box 2 Disconnect the foot switch wiring from the terminal strip inside the platform control box Remove the cable from the machine 3 Remove the platform control box mounting fasteners Lower the control box and set it aside If your machine is eguipped with an airline to platform option the airline must be disconnected from the platform before removal 4 Raise the boom and place saw horses of ample capacity under the platform mounting weldment Lower the boom until the platform is resting on the saw horses just enough to support the platform Do not rest the entire weight of the boom on
241. l for safe machine operation The platform is maintained at level by the platform leveling slave cylinder which operates in a closed loop hydraulic circuit with the master cylinder located at the base of the boom A platform self leveling failure creates an unsafe working condition for platform and ground personnel 1 Start the engine from the ground controls and lower the boom to the stowed position 2 Hold the function enable toggle switch to either side and adjust the platform to a level position using the platform level toggle switch 3 Raise and lower the boom through a full cycle Result The platform should remain level at all times to within 5 degrees directional valve b clevis pin with cotter pin hidden yoke d lock nut Genie 4 38 S 40 5 45 72136 2008 Section 4 Scheduled Maintenance Procedures REV B B 17 Test the Foot Switch Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first A properly functioning foot switch is essential to safe machine operation Machine functions should activate and operate smoothly as long as the foot switch is pressed down and promptly stop when the foot switch is released The foot switch will also shift the engine into high idle if the idle select is switched to the rabbit and foot switch symbol An improperly functioning foot switch can cause an unsafe working condition an
242. latform is resting on the saw horses just enough to support the platform Do not rest the entire weight of the boom on the saw horses 4 Protect the slave cylinder rod from damage S 40 Models 5 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the union located near the platform rotate counterbalance valve manifold and connect them together using a connector Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray A TEREX COMI S 40 5 45 REV 5 45 Models 6 disconnect plug the slave cylinder hoses at the union 7 Pull the slave cylinder hoses through the platform rotator 8 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Do not remove the pin 9 Remove the external retaining fastener from the barrel end pivot pin 10 Use a soft metal drift to drive the rod end pivot pin out 11 Use a soft metal drift and drive the barrel end pin out 12 Carefully pull the cylinder out of the boom CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched How to Bleed the Slave Cylinder Do not start the engine Use auxiliary power for all machine functions in this procedure 1 Raise the boom to a horizontal position
243. lect toggle switches TS4 and 1512 Check voltage at TB35 Repair open in tan blu wire from TB35 to ECM OR consult Genie Industries Service Department Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Check voltage at center terminal on both RPM select toggle switches Replace RPM select toggle switch Repair open in blk red wire circuit from toggle switch to TB35 Chart 6 Refer to the fault code chart in this section for a description of the fault and recommended repairs Repair open in power supply circuit to center terminal of RPM select toggle switch Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 7 Engine Low Idle inoperative Gasoline LPG Models If low idle operates on LPG but not on gasoline see Ford service manual for carburetor troubleshooting If low idle operates on gasoline but not on LPG see Repair section for LPG regulator adjustments Be sure throttle linkage from governor to carburetor is not binding see Repair section See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory Start engine and move the RPM select toggle switch TS12 to low idle turtle symbol Check voltage at TB35 Replace ECM or consult Genie
244. lifting jack of ample capacity under the steering axle and Hub 4 Raise the machine approximately 1 Remove the pin retaining fasteners from the 6 inches 15 cm and place blocks under the steering cylinder and tie rod clevis pins chassis for support Remove the pins 5 Remove the lug nuts Remove the tire and Always use a new cotter pin when wheel assembly installing a clevis pin 6 Remove the pin retaining fasteners from the yoke pivot pins 7 Support and secure the yoke hub assembly to a lifting jack 8 Use a slide hammer to remove the upper yoke pivot pin 9 Use a soft metal drift to drive the lower yoke pivot pin down and out Crushing hazard The yoke hub ACAUTION assembly may become unbalanced and fall when the yoke pivot pins are removed if it is not properly supported and secured to the lifting jack Torque specifications Lug nut torque dry 170 ft lbs 230 Nm tie rod b axle Lug nut torque lubricated 130 ft lbs c yoke pivot pin 176 Nm d yoke e hub Before serial number 5370 f pivot pin 0 steering cylinder Drive hub mounting bolts dry 150 ft lbs 203 Nm Drive hub mounting bolts lubricated 110 ft Ibs 149 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm Genie A TEREX COMPANY 7 68 S 40 S 45 Part No 72136 2008 REV B After serial number 5369 Drive hub mounting
245. ll Lift and Steer Functions Inoperative Drive Functions Operational A TEREX COMPANY Part No 72136 Engine Low Idle Inoperative Gasoline LPG Models Engine High Idle Inoperative Diesel Models Engine Low Idle Inoperative Diesel Models 5 40 5 45 March 2008 TABLE OF CONTENTS Section 5 Rev Troubleshooting Flow Charts continued 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Ground Controls Inoperative Platform Controls Operate Normally 5 26 Platform Controls Inoperative Ground Controls Operate Normally 5 27 Boom Up Function Inoperative 5 28 Boom Down Function Inoperative 5 31 Boom Extend Function 5 34 Boom Retract Function Inoperative 5 36 Turntable Rotate Left Function Inoperative 5 38 Turntable Rotate Right Function Inoperative 5 42 All Platform Leveling Functions Inoperative 5 46 Platform Level Up Function Inoperative 5 47 Platform Level Down Function Inoperative 5 49 Platform
246. ll the bowl onto the new filter element may have spilled during this Genie part number 22942 procedure 1 Turn the manual fuel shutoff valve located at the fuel tank to the closed position Genio Part No 72136 S 40 5 45 4 53 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES 7 Fill the filter bowl assembly with clean diesel fuel Apply a thin layer of diesel fuel onto the element gasket Install the filter oowl assembly onto the filter head 8 Tighten the head bolt to 65 inch pounds 7 Nm 9 Clean up any diesel fuel that may have spilled during the installation procedure 10 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 11 Turn the manual fuel shutoff valve located at the fuel tank to the open position Bleed the fuel system Before bleeding the system fill the fuel tank 12 Loosen the vent plug located on the fuel filter water separator head 13 Operate the priming lever of the fuel lift pump until fuel free from air comes from the vent point Tighten the vent plug 14 Loosen the air vent screw located on top of the fuel injection pump 15 Tighten the air vent screw when air stops coming through the air vent 16 Clean up any diesel fuel that may have spilled during the bleeding procedure and dispose of properly 17 Start the engine from ground controls and check for leaks 4 54 Genie T
247. ller OR consult Genie Industries Service Department REV B Repair open in red wht 4 wire circuit from TB3 to boom up down proportional valve coil OR repair open in brn ground wire circuit to valve coil Repair open in red wht 3 wire from TP3 to TB3 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from boom controller to ground Genie REX COMPANY 5 28 S 40 5 45 Part No 72136 2008 REV B Continued from the previous page With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the function enable switch 10 either side and move the boom up down toggle switch TS16 in the UP direction Check voltage on red 4 wire on boom up down directional valve coil item B 20V or more Continued on the next page PartNo 72136 Section 5 Troubleshooting Flow Charts MT Hold the function enable switch to either side and move the boom up down toggle switch in the direction Check voltage at TB1 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the boom controller in the UP direction Check voltage at TB1 Press down the foot switch and move the boom controller in the uP direction Check voltage TP1 ov Press down the foot swi
248. ls 21 2008 Section 6 Schematics Ground Control Box Wiring Diagram Deutz Diesel Models 2008 Section 6 Schematics Ground Control Box Wiring Diagram Deutz Diesel Models A B 51 STACKED CONTACTS WHT RED 26A GRN GROUND WHT 21A WHT BLK 25A BLK 22A rl N i db 6 NO NO 1 WHT 23A Le NC G4 Ud NC y TS9 RED 27A TS11 TS10 t 9 O BLK RED 9A BLK WHT 8A BLK 7A RED 1A RED BLK 2A RED WHT 3A 516 WHT BLK 5A WHT 4A TS17 WHT RED 6A GRN 17A GRN BLK 18A TS12 CB1 CB2 514 513 GRN WHT 19A ORG BLK 15A ORG 14A ORG RED 16A RED R1 30 RED 20A BLK 33A BLK RED 35A BLK WHT 34A PLATFORM LEVEL DISABLE amp HYDRAULIC OIL COOLER OPTION RELAYS ORG 4 CR18A ORG TB14D ORG BLK TB15D RED 6 CR18B LF ORG BLK 4 eis FUSE INLINE RED TB20
249. lter and tighten it securely by hand 7 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 8 Fill the engine with new oil per specifications and install the oil filler cap 9 Start the engine from the ground controls and allow the engine to run for 30 seconds Stop the engine 10 Check the oil filter and drain hose for leaks Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV A 11 Wait 15 minutes after stopping the engine and check the engine oil level on the dipstick Add oil if needed 12 Dispose of the used oil and filter properly Perkins 704 30 Engine Oil capacity including filter 9 6 quarts 8 9 liters Oil viscosity requirements below 60 F 15 5 C 15W 40 10 F to 90 F 23 C to 32 C 10W 30 above 4 F 34 C 15W 40 Engine oil should have properties of API classification CF4 grade CHECKLIST C PROCEDURES C 6 Check the Specific Gravity of the Coolant Liquid Cooled Models Engine specifications require that this procedure be performed every 500 hours or 12 months whichever comes first Perform this procedure more often if dusty conditions exist The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling system Old or dirty coolant may cause the engine to perform poorly and continued use may cause Oil filter Genie part
250. m Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 1 5000 psi 0 to 345 bar pressure gauge to the test port index 25 on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable switch to either side and activate and hold the retract switch with the boom fully retracted Observe the pressure reading on the pressure gauge System relief valve specifications Pressure S 40 2600 psi 179 bar S 45 2900 psi 200 bar 4 Turn the engine off Use a wrench to hold the relief valve and remove the cap index 24 function manifold 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust AWARNING the relief valves higher than specified 6 Repeat steps 2 through 5 and check the relief valve pressure A TEREX COMI S 40 5 45 REV B How to Adjust the Boom Down Relief Valve Perform this procedure with the boom in the stowed position 1 Connect a 0 to 5000 psi 0 to 345 bar pressure gauge to the test port index 25 on the function manifold 2 Start the engine from the ground controls 3 Hold the function enable switch to the high rpm rabbit symbol side and activate and hold the boom down toggle switch with the boom fully lowered Observe the pressure reading on the pressure gauge Boom down
251. m x 76cm 1 8m x 76 cm Length x width 8 ft 96inx36in 96inx36in Turntable rotation 8 fl oz Maximum capacity 500 Ibs 500 Ibs 227 kg 227 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie S 40 S 45 Part No 72136 2008 REV A Performance Specifications All Models Drive speeds maximum Drive speed stowed Gasoline LPG models 2WD 4WD 4 mph 3 5 mph 6 4 km h 5 6 km h 40 ft 6 8 sec 40 ft 7 8 sec 12 2 m 6 8 sec 12 2 m 7 8 sec Drive speed stowed Deutz Diesel models 3 5 mph 3 mph 5 6 km h 4 8 km h 40 ft 7 8 sec 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec Drive speed raised or extended all models Gradeability 0 6 mph 0 6 mph 1 km h 1 km h 40 40 sec 40 ft 40 sec 12 2 m 40 sec 12 2 m 40 sec See Operator s Manual Part No 72136 A TEREX COMPANY Section 2 Specifications Boom function speeds maximum from platform controls SPECIFICATIONS Boom up 40 to 60 seconds Boom down 50 to 80 seconds Boom extend to 60 seconds Boom retract 25 to 55 seconds Turntable rotate 360 boom fully stowed 70 to 110 seconds Platform rotate 160 6 to 12 seconds Platform level up 25 to 50 seconds Platform level down 15 to 35 seconds Jib boom up S 45 models 35 to 45 seconds Jib boom down S 45 models 20 to
252. more Disable the starter by removing the blk wire at yoy the starter solenoid Move the start toggle switch to either side and check the voltage at positive terminal on fuel solenoid oV Move the start toggle switch to either side and 12V check voltage at wht 21 wire on terminal 87 of CR2 ov Check voltage at red wire on terminal 30 of CR2 12V Continued on the next page PartNo 72136 A TEREX COMPANY Chart 3 Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery 0 or infinite ohms Replace the fuel solenoid 3 5 ohms Deutz 11 5 ohms Perkins Turn the machine off and isolate the fuel solenoid Check the resistance of the solenoid See Deutz or Perkins service manual for troubleshooting fuel System Repair open in wht 21 wire from CR2 to fuel solenoid Repair open in red wire circuit from battery to CB1 to CR1 to CR2 Section 5 e Troubleshooting Flow Charts March 2008 lt lt T CHART 3 REV Move the start toggle switch to either side and check voltage at terminal 9 on the ignition start module Move the start toggle switch to either side and check voltage at terminal 86 of CR2 Continued from the previous page 12V oV Check voltage at terminal 6 and 7 on ignition start module 12V Check continuity from
253. motor mounting bolts dry 110 ft lbs 149 Nm Drive motor mounting bolts lubricated 80 ft lbs 109 Nm Turntable bearing Turntable bearing mounting bolts lubricated 180 ft lbs 7 _ _ 244 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice A TEREX COMPANY Part No 72136 S 40 S 45 2 9 Section 2 Specifications March 2008 SPECIFICATIONS Hydraulic Hose and Fitting Torgue Specifications Your machine is eguipped with Parker Seal Loke fittings and hose ends Genie specifications reguire that fittings and hose ends be torgued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torgue 4 14 ft lbs 18 9 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 48 8 Nm 10 62 ft lbs 84 1 Nm 12 84 ft lbs 113 9 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 250 Nm SAE O ring Boss Port REV B Seal Lok6 fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight The O rings used in the Parker Seal Lok6 fittings and hose ends are a custom size O ring They are not a standard SAE size O ring They are available in the O ring field service
254. n 5 e Troubleshooting Flow Charts March 2008 FAULT CODE CHART REV Fault Code Voltage to fuel pump is Test the fuel pump relay see the Repair Fuel pump greater than or egual to Section OR check for poor terminal low voltage 2 DC below ignition connection from the fuel pump relay to fuel voltage OR replace the fuel pump Water in the fuel misfiring cylinder Heated plugged fuel filter OR Oxygen HO2 the HO2 sensor wiring sensor low is shorted to ground O voltage there is a poor terminal connection OR the HO2 sensor is faulty Check for water in the fuel misfiring cylinder or plugged fuel filter OR check for R poor terminal connections or shorted wires from the HO2 sensor to the ECM to ground OR replace HO2 sensor Engine is overheating OR sensor wires Check engine coolant level OR check for shorted to ground or shorted wires or poor terminal connections poor terminal from the ECT sensor to the ECM OR connections OR ECT replace the ECT sensor sensor is faulty Engine is overheating Intake Air OR sensor wires Temerature shorted to ground or IAT sensor poor terminal high voltage connections OR ECT sensor is faulty Fuel pump is receiving voltage when the ECM is not sending the signal to the fuel pump to turn ON Engine Coolant Temperature ECT sensor high voltage Check for poor terminal connections or shorted wires from the IAT sensor to the ECM to ground OR replace IAT sensor Tes
255. n hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Do not adjust the controllers unless the static battery voltage is above 12V DC and the alternator is operating properly with 13 6 to 14 5V DC output Individual trim potentiometers trimpots are used to adjust various output signals from the drive and boom function controllers The trimpots will be identified as the following Max out trim potentiometer max out trimpot High range trim potentiometer max out trimpot Lo range trim potentiometer lo range trimpot Dual range trim potentiometer lo range trimpot Threshold trim potentiometer threshold trimpot Ramp rate trim potentiometer ramp rate trimpot Check the battery condition with a volt meter The reading should be 12V DC or more to accurately adjust the controller Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Do not start the engine Part No 72136 2008 Section 7 Repair Procedures REV A 3 Open the platform control box lid and locate the boom up down controller ramp rate trimpot lo range trimpot terminal R activates max out range not used terminal X not used terminal ground terminal positive terminal A proportional output threshold trimpot max out trimpot TO
256. n it is removed from the primary boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 6 Remove the external snap rings from the extension cylinder rod end pivot pins at the platform end of the extension tube Use a soft metal drift to remove the pin 7 Support and slide the extension cylinder out of the base end of the extension tube Crushing hazard The extension AWARNING cylinder could become unbalanced and fall when it is removed from the boom tube if it is not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 8 Remove and label the wear pads from the extension cylinder Pay careful attention to the location and amount of shims used with each wear pad REV A A TEREX CON S 40 5 45 MEANY 4 3 Boom Lift Cylinder How to Remove the Boom Lift Cylinder Bodily inj AWARNING Ped injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic
257. n overhead crane Explosion and hazard 7 Remove the fuel tank from the machine fuels are combustible Remove the fuel tank in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container 1 Turn the manual fuel shutoff valve to the closed position 2 Remove the tank side turntable cover See 5 1 How to Remove a Turntable Cover 3 Gasoline LPG models Disconnect drain and plug the fuel hose Diesel models Disconnect drain and plug the supply and return fuel hoses Cap the fuel return fitting on the fuel tank Steel tank 4 Remove the retaining fasteners from the fuel tank hold down straps Remove the straps from the fuel tank A TEREX COMPANY AWARNING Crushing hazard The fuel tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane Clean the fuel tank and inspect for rust and corrosion before installing 7 62 S 40 S 45 Part No 72136 2008 Section 7 e Repair Procedures REV A 12 2 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainers for the pump supply hoses and has an external return filter egu
258. n to the on position at the platform controls then press down the foot switch PartNo 72136 A TEREX COMPA CHECKLIST A PROCEDURES Lift the red auxiliary power toggle switch cover Simultaneously hold the auxiliary power toggle switch on and activate each function control handle or toggle switch Result All boom and steer functions should operate Drive functions should not operate with auxiliary power To conserve battery power test each function through a partial cycle S 40 S 45 4 13 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES A 13 Test the Tilt Sensor Genie specifications reguire that this procedure be performed daily The tilt sensor sounds an alarm located in the platform only when the machine is on a slope Select a level test area The tilt alarm should not be sounding prior to the test 1 Start the engine from the platform controls 2 Open the tank side turntable cover and press down on one side of the tilt sensor Result After a 1 5 second delay the alarm in the platform should sound Tip over hazard The alarm should AWARNING be audible at the ground controls If the alarm is not audible at the ground controls replace the alarm in the platform fuel tank b til sensor c X ground control box A TEREX COMPANY S 40 S 45 REV B A 14 Test the Limit Switches Genie specifications require that
259. nal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Indicates special operation or maintenance information Genie TEREX COMPANY vi S 40 5 45 other protective clothing if the situation gt Be sure to wear protective eye wear and warrants it such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed sho
260. nator is operating properly with 12 5 to 14 5V DC output Gasoline LPG models Perform this procedure in gasoline mode 1 Remove the fasteners from the platform control box lid Part No 72136 COMPANY 5 40 5 45 7 7 PLATFORM CONTROLS 2 Open the control box lid and locate the horsepower limiter board Electrocution hazard Contact AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Platform control box a horsepower limiter board 3 Connectthe black lead from a DC volt meter to the number 2 terminal and the red lead to the number 10 terminal 12V DC or greater ground engine rpm sensor not used not used low drive speed limit switch not used not used not used output to drive controller L eieiereieiesielele 0 06 8 4 9 S y EZ Horsepower limiter board a potentiometer maximum voltage output to the drive controller in the stowed position b B potentiometer maximum voltage output to the drive controller in the boom raised or extended position C potentiometer reaction rate or how fast the voltage output reacts to the change in engine rpm Section 7 Repair Procedures March 2008 PLATFORM CONTROLS 4 Start the engine from the platform controls 5 Move the engine control toggle switch to foot switch activated high idle
261. nce cold 10 her Intake 0 014 in Alternator output 65A 12V 0 35 mm Batter Exhaust 0 014 in 0 35 mm 12V Group 31 Lubrication system Quantity 1 Oil pressure 41psi Cold cranking ampere 1000A at 2600 rpm 2 8 bar Reserve capacity amp 25A rate 200 minutes Oil capacity 9 6 guarts including filter 9liters Fan belt deflection 3 8 in 10 mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie 5 40 5 45 72136 2008 Section 2 Specifications REV B SPECIFICATIONS Machine Torgue Specifications Platform rotator 1 8 center bolt GR 5 dry 640 ft lbs 868 Nm 1 8 center bolt GR 5 lubricated 480 ft lbs 651 Nm 3 8 16 bolts GR 8 lubricated 35 ft lbs use blue thread locking compound 47 5 Nm Turntable rotator Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs use blue thread locking compound 217 Nm Drive motor and hubs Before serial number 5370 Drive hub mounting bolts dry 150 ft lbs 203 Nm Drive hub mounting bolts lubricated 110 ft lbs 149 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm After serial number 5369 Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs 217 Nm Drive
262. nd continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steering wheels Center a lifting jack under the steer axle 3 Raise the machine approximately 6 inches 15 cm Place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly 5 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There should be no side to side or up and down movement Skip to step 10 if there is no movement PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut Always replace the cotter pin with a new one when removing the castle nut or when checking the torgue of the castle nut 7 Tighten the castle nut to 158 ft lbs 214 Nm to seatthe bearings Note Rotate the hub by hand while torgueing the castle nut to make sure the bearings seat properly 8 Loosen the castle nut one full turn and then torque to 35 ft lbs 47 9 Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down O Result If there is no side to side or up and down movement continue to step 11 and grease the
263. nd move the jib boom toggle switch TS6 in the DOWN direction Check voltage on the red and black wires at the jib platform rotate select valves item AC Replace CR13 function Install a 0 to 5000 psi Exchange jib operates 345 bar pressure boom platform rotate gauge at the quick directional valves item disconnect coupling on AC Press down the the function manifold foot switch and activate and activate the jib the jib boom down boom down function function Replace faulty valve function inoperative Check for mechanical restrictions keeping jib boom down function from operating OR repair or replace jib boom cylinder OR See Note 2 replace counterbalance valve OR 0 030 orifice may be plugged OR jib boom platform rotate select manifold has an internal fault OR consult Genie Industries Service Department function operates Exchange jib boom Replace faulty counterbalance valves counterbalance valve and activate jib boom Note 1 down function 5 40 2600 psi or more 5 45 2900 psi or more function inoperative Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi Consult Genie Industries Service Department A TEREX COMPANY Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 28 Steer Left Function Inoperative Be sure all other functions operate normally With key switch turned to platf
264. nd remain on while the boom is anywhere in the range shown 9 Repeat steps 6 and 7 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 22 Test the Drive Brakes Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydrostatic brakes and hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational Collision hazard Be sure that the AWARNING machine is not in free wheel or partial free wheel configuration Refer to B 9 in this section Confirm the Proper Brake Configuration Select a test area that is firm level and free of obstructions Be sure the boom is fully retracted and lowered to the stowed position 1 Mark a test line on the ground for reference PartNo 72136 CHECKLIST PROCEDURES Start the engine from the platform controls Move the lift drive select switch to the drive position if equipped Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line Bring the machine to top drive speed before reaching the test line Release the drive controller when your reference point on the machine crosses the test li
265. nd when the drive controller is moved off center in either direction B 26 Perform Hydraulic Oil Analysis See E 1 Test or Replace the Hyaraulic Oil Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 27 Replace the Hydraulic Tank Return Filter Genie requires that this procedure be performed quarterly or every 250 hours whichever comes first Perform this procedure more often if dusty conditions exist Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty CHECKLIST B PROCEDURES 2 Remove the filter with an oil filter wrench 3 Apply a thin layer of fresh oil to the new oil filter gasket 4 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled during the installation procedure 5 Use a permanent ink marker to write the date and number of hours from the hour meter on the oil filter 6 Start the engine from the ground controls 7 Inspect the filter and related components to be sure that there are no leaks Hydraulic tank return filter conditions may require that the filter be replaced Genie part number 46014 more often Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns Perform this procedure
266. nder must be at least 75 of highest cylinder 0 035 to 0 055 inches 0 889 to 1 397 mm Valve clearances collapsed tappet Lubrication system Oil pressure operating temperature amp 2000 rpm 40 to 60 psi 2 75 to 4 1 bar Oil capacity 5 guarts including filter 4 7 liters Oil viscosity requirements Temperature below 60 F 15 5 C 5W 30 10 F to 90 F 23 C to 32 C 10W 30 Temperature above 10W 40 to 10W 50 10 F 23 C REV A Starter motor Normal engine cranking speed 200 to 250 Current draw normal load 140 200A Current draw maximum load 800A Current draw minimum 60 80A Maximum circuit voltage drop 0 5V DC while starting normal temperature Brush length new 0 66 in 16 8 mm Brush length wear limit 0 25 in 6 35 mm Maximum commutator 0 005 inches run out 0 127 mm Battery Type 12V Group 31 Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Electronic fuel pump Fuel pressure static 64 psi 4 4 bar Fuel flow rate 0 58 gpm 2 18 liters per minute Ignition System Spark plug type Motorcraft AWSF 52 C 0 042 to 0 046 inches 1 07 to 1 18 mm Spark plug gap Engine coolant Capacity 111 2 quarts Temperature above 20 40 20W 50 10 9 liters 20 F 6 6 C Alternator Use oils meeting API classification SG labeled SG CC or SG CD as they offer improved wear prote
267. ne Measure the distance between the test line and your machine reference point Braking paved surface Stopping distance 2 to 4 ft 0 6 to 1 2m A TEREX COMPA S 40 S 45 4 43 The brakes must be able to hold the machine on any slope it is able to climb Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES REV B B 23 2 Start the engine from the platform controls Test the Drive Speed 3 Move the lift drive select switch to the drive Stowed Position position if equipped 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Genie specifications require that 5 Bring the machine to top drive speed before this procedure be performed every reaching the start line Begin timing when your 250 hours or guarterly whichever reference point on the machine crosses the comes first start line Proper drive function movement is essential to safe 6 Continue at full speed and note the time when machine operation The drive function should the machine reference point crosses the finish respond guickly and smoothly to operator control line Drive performance should also be free of hesitation jerking and unusual noise over the entire Drive speed proportionally controlledspeedrange stowed position 2WD 4WD Select a test area that is firm level Gasoline LPG models 40ft 6 8sec 40 7 8 sec and free of obstructions Be su
268. ne LPG models Connect the LPG hose to the LPG tank and open the valve on the tank Perkins Diesel models Connect the engine wiring harness to the fuel solenoid Deutz Diesel Models Release the manual fuel shut off valve Start the engine from the ground controls and check for hydraulic leaks Part No 72136 S 40 S 45 7 65 Section 7 Repair Procedures March 2008 Turntable Rotation Components REV A 13 1 2 Tag disconnect and plug the hydraulic hoses from the motor brake and manifold Cap the Rotation Hyd raulic Motor fittings on the motor brake and manifold How to Remove the Rotation AWARNING Podily injury hazard Spraying hydraulic oil can penetrate and Hydraulic Motor burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to 3 Remove the motor brake mounting fasteners Section Two Hydraulic Hose and then remove the motor from the brake Fitting Torque Specifications 1 Secure the turntable from rotating with the turntable rotation lock pin zd Unlocked position a motor brake mounting bolts b motor brake d drive hub mounting bolts e drive hub Locked position A TEREX COMPANY 7 66 S 40 S 45
269. ne pivot plate retaining bolts with hot engine components may 7 Diesel models Replace the air baffle and cause severe burns install the air baffle retaining fasteners 1 Diesel models Remove the air baffle retaining fasteners Remove the air baffle 2 Diesel models Remove the 2 bolts from under the engine pivot plate Swing the engine pivot plate away from the machine to access the exhaust system A TEREX COMPANY 4 24 S 40 5 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 2 Inspect the Engine Air Filter Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Maintaining the engine air filter in good condition is essential to good engine performance and service life Failure to perform this procedure can lead to poor engine performance and component damage CHECKLIST PROCEDURES Perkins Diesel models Open the engine side cover and disconnect the retaining fasteners from the end cap of the air filter canister Remove the end cap Remove the filter element Empty the dust discharge valve by pressing together the sides of the discharge slot Clean discharge slot as needed Perform this procedure with the engine off Gasoline LPG and Deutz Diesel Models 1 Open the engine side cover and remove the retaining ring from the end cap of the air filter canister Remove the end cap from the
270. nformation An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Referto the Decals section in the Genie S 40 amp Genie S 45 Operator s Manualand use the decal list and illustrations to determine that all decals and placards are in place 2 Inspect all decals for legibility and damage Replace any damaged or illegible decal immediately Contact your authorized Genie distributor or Genie Industries if replacement decals are needed Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES A 3 Inspect for Damage and Loose or Missing Parts Daily machine condition inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage and discover loose or missing parts may result in an unsafe operating condition 1 Inspect the entire machine for damage and improperly installed or missing parts including Electrical components wiring and electrical cables Hydraulic hoses power units fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Boom wear pads Tires and wheels Engine and related components Limit switches alarms horn and beacon Nuts bolts and other fasteners Platform entry mid rail or gate A TEREX ct 4 6 5 40 S 45 REV B Check entire machine for Cracks in welds or structural c
271. nie REX COMPANY S 40 S 45 Part No 72136 2008 REV B Press down the foot switch and hold the drive controller in the full forward position Check voltage at terminal 6 on the drive controller Continued from the previous page 9 to 12V Connect the positve lead from a voltmeter to terminal 4 on the drive controller and the negative lead to terminal 5 on the drive controller Press down the foot switch and hold the drive controller in the full forward position Check voltage across the 4 and 5 terminals on the drive controller Connect the positve lead from a voltmeter to terminal 5 on the drive controller and the negative lead to terminal 4 on the drive controller Press down the foot switch and hold the drive controller in the full reverse position Check voltage across the terminals 5 and 4 on the drive controller 2V Continued on the next page Section 5 Troubleshooting Flow Charts m Repair open in wire from terminal 10 on horsepower limiter board to terminal 6 on the drive controller no Check continuity from continuity terminal 3 on drive controller to ground continuity Replace drive controller OR consult Genie Industries Service Department no Check continuity from continuity terminal 3 on drive controller to ground continuity Replace drive controller OR consult Genie Industries Service Department CHART 30
272. noise 1 Pull out the red Emergency Stop button at the ground controls to the on position Start the engine from the ground controls 3 Do not hold the function enable switch to either side Attempt to activate each boom and platform function toggle switch Result All boom and platform functions should not operate 4 Hold the function enable switch to either side and activate each boom and platform function toggle switch Result All boom and platform functions should operate through a full cycle Descent alarm if equipped should sound while the boom is lowering AT S 40 S 45 oo REV B Push in the red Emergency Stop button to the off position Result No function should operate the engine should stop Machines equipped with Platform Level Control Disable Function The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches Diesel models All functions should stop immediately The engine will shut off after 2 to 3 seconds Start the engine from the platform controls Do not press down on the footswitch Attempt to operate all machine functions Result All machine functions should not operate Press down the footswitch and activate each machine function Result All machine functions should operate through a full cycle 10 Push in the red Emergency Stop button to the EREX COMPANY off position at the plat
273. ns pulled out to the controller to ground controller a mr the foot switch an check voltage at terminal 2 on drive controller Repair open in brn ground wire circuit from ground to drive controller 12V or more With key switch turned hen Check continuity of brn Repair open in power to platform controls and 12V ground wire from continuity supply circuit from TP24 to terminal 1 on the horsepower limiter board terminal 2 on the horsepower limiter board to ground both Emergency Stop buttons pulled out to the ON position press down the foot switch and check voltage at terminal 1 on the horsepower limiter board no continuity Repair open in brn ground wire circuit from ground to terminal 2 on the horsepower limiter 12V or more board Press down the foot Adjust the A trimpot switch and check 7to gv See repair procedure voltage at terminal 3 on 1 2 How to Adjust the the horsepower limiter Horspower Limiter board Board OR replace horsepower limiter board Press down the foot switch and check the voltage at terminal 10 on the horsepower limiter board ov Press down the foot Repair open in org blk switch and check 7 to 8V 41 wire from alternator voltage on the org blk to TB41 and org blk 1 910 12V 41wire on the alterator wire from TP41 to terminal 3 on horsepower limiter OV board Repair or replace alternator Continued on the next page Ge
274. number 62422 engine damage Burn hazard Beware of hot ACAUTION engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns Perform this procedure with the machine on level ground Perform this procedure with the engine off 1 Put on protective clothing and eyewear 2 Operate the engine until it is warm enough to open the thermostat Continue to run the engine until the coolant has circulated the cooling system Part No 72136 S 40 5 45 4 57 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES 3 Stop the engine 4 Allow the engine to cool until the temperature of the coolant is below 140 F 60 Burn hazard Beware of hot ACAUTION coolant Contact with hot coolant may cause severe burns 5 Remove the radiator filler cap Inspect the cap for wear Replace as necessary Burn hazard Allow any pressure ACAUTION to dissipate gradually before removing the radiator cap 6 Drain some coolant from the cooling system into a suitable container 7 Use special coolant hydrometer to check the temperature and the specific gravity of the coolant 8 Adjust the strength of the coolant as necessary for your climate 9 Install the radiator filler cap A TEREX S 40 S 45 REV A 7 Check the Glow Plugs Perkins Diesel Models Engine specifications reguire that this procedure be performed initially at 500 hours or every 12 months
275. o components shown in the 8 manifold illustrations Refer to the Repair Section TEREX COMPANY Part No 72136 S 40 5 45 6 33 33 March 2008 Section 6 Schematics 5 40 45 2WD Hydraulic Schematic Non Oscillating Axle 34 REV S 45 JIB BOOM 5 45 JIB SELECT MANIFOLD AFTER SERIAL NO 5592 March 2008 Section 6 Schematics E S 40 45 2WD Hydraulic Schematic Oscillating Axle K J D PLATFORM ROTATE 1 SLAVE UP DOWN PRIMARY o MIU n b mr TURNTABLE zz J LT s ROTATE LU
276. odule terminal 1 on ignition start module Continued from the previous page Consult Genie Industries Service Department Move the start toggle Repair open in blk wire switch to either side and from terminal 1 on check voltage at ignition start module to terminal 86 on CR1 CR1 Repair open in red wire circuit from battery to CB1 to CR1 terminal 30 Check voltage at terminal 30 on CR1 Move the start toggle Check brn ground wire Repair open in brn switch to either side and to terminal 85 on CR1 ground wire circuit to check voltage at 1 terminal 87 on CR1 Replace CR1 relay Move the start toggle Repair open in blk wire Switch to either side and circuit from CR1 to check voltage at the blk starter solenoid wire on the starter solenoid Check voltage at starter cable Repair open in battery cable to starter Repair or replace starter or starter solenoid A TEREX COMPANY PartNo 72136 5 40 5 45 5 9 Section 5 Troubleshooting Flow Charts March 2008 Chart 2 Engine Cranks Over But Will Not Start Gasoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and engine coolant level Be sure the gasoline shut off valve is in the ON OPEN position Perform following tests in gasoline mode only Be sure that the water temperature gauge does not show an overheated condi
277. ols 54 11664 1 Flashing beacon 20189 ECCO Electronic Controls 6400A GEN 2 un ie Footswitch 2 13482 Linemaster Switch Corp 6326S ni Gy 1 Glan Gauge Voltage 53761 VDO ide 332 0300010C 1 Gauge Oil Pressure 53758 x MDO te 350 030021 1 39 Gauge Water Temp 53759 nn VDO iie exem 310 030023 1 EET Alarm Warble tone 45383 Floyd Bell Inc 09 530 1 H2 iode Horn 12V 81578 WESC 95346 1 Alarm intermittent 18963 Floyd Bell Inc XB 09 630 Q S 1 Hu niii Alarm chime tone 45462 Floyd Bell Inc CH 09 525 Q 1 HM Hourmeter 19506 ENM Corporation T40A4508 1 KS Contact Key switch 128497 Laughlin 2 2 LED Red 12V DC 56298 Laughlin 30XX 4 11 37610 000
278. om the previous page PartNo 72136 Section 5 Troubleshooting Flow Charts n CHART 29 Install a 0 to 5000 PSI Check for mechanical 845 bar pressure restrictions keeping gauge at the quick steer left function from disconnect coupling on operating OR repair or the boom function replace steer cylinder manifold and activate OR replace flow the steer right function regulator valve item WW OR consult Genie Industries Service Department See Note 2 Repair or replace steer cylinder OR steer manifold could have an internal defect Consult Note 1 Genie Industries Service 5 40 2600 psi or more Department 5 45 2900 psi or more Note 2 5 40 less than 2600 psi 5 45 less than 2900 psi 5 40 5 45 5 63 Section 5 e Troubleshooting Flow Charts March 2008 Chart 30 All Drive Functions Inoperative All Other Functions Operate Normally Be sure the rpm select switch is in the foot switch activated high idle position Be sure the hyydraulic tank shut off valves are in the OPEN position Be sure machine is not in the free wheel configuration REV 855 With key switch turned than Check continuity of brn Repair open in power to platform controls and yoy ground wire from continuity supply circuit from TP24 both Emergency Stop terminal 3 on drive to terminal 2 on drive butto
279. om the Disconnect both wires infinite previous page from boom down ohms Replace boom down directional valve coil item B and test the resistance of the valve coil See Repair Section directional valve coil 2 5 to 3 5 ohms function Hold the function enable operates switch to either side and move the boom up down toggle switch in the DOWN direction Manually override the directional valve by pushing in on the end of the valve spool Replace faulty directional valve function inoperative Install a 010 5000 PSI Check for mechanical 845 bar pressure restrictions keeping gauge at the quick boom from moving OR disconnect coupling on repair cylinder or the boom function cylinder counterbalance manifold and start the valve OR consult Genie engine Hold the Industries Service function enable switch to Department either side and move the boom up down toggle switch in the DOWN direction and check the pressure See Note 2 Reset boom down relief valve item F pressure see Repair Section OR Note 1 replace boom down S 40 2600 psi or more relief valve OR repair S 45 2900 psi or more cylinder or cylinder counterbalance valve OR function manifold a could have an internal Note 2 fault Consult Genie 5 40 less than 2600 psi Industries Service S 45 less than 2900 psi Department A TEREX COMPANY Part No 72136 S 40 S 45 5 33 Section 5 e
280. omponents Dents or damage to machine Battery and connections Compartment covers and latches Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened After you complete each inspection be sure that all compartment covers are in place and secured Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B A 4 Check the Engine Oil Level Genie specifications reguire that this procedure be performed daily Maintaining the proper engine oil level is essential to good engine performance and service life Operating the machine with an improper oil level can damage engine components Check the oil level with the engine off 1 Check the oil dipstick Gasoline LPG Engine located above the bellhousing on the bulkhead side of the engine Diesel Engine located on the engine block near the engine oil filter Result The oil level should be at the full mark on the dipstick Add oil as needed Ford LRG 425 EFI Engine Oil capacity including filter 5 guarts 4 7 liters Oil viscosity reguirements below 60 F 15 5 C 5W 30 10 to 90 F 23 to 32 C 5W 30 above 10 F 23 C 5W 30 above 25 F 4 C 10W 30 Use oils meeting API classification SH or SG grade Part No 72136 A TEREX S 40 S 45 MPANY CHECKLIST A PROCEDURES Deutz F3L 1011F Eng
281. on 5 Troubleshooting Flow Charts March 2008 CHART 23 Continued from the Disconnect the wires inte previous page from the platform rotate h left directional valve coil 071715 item CC and test the resistance of the valve coil 6 to 7 ohms function operates Exchange platform rotate left and right directional valves items CC and DD and activate the platform rotate left function function inoperative function Exchange platform operates rotate left and right counterbalance valves at the counterbalance valve manifold and activate the platform rotate left function function inoperative Install 0 to 3000 207 bar pressure gauge at s 1 the quick disconnect coupling on the function manifold and activate the platform rotate left function See Note 2 function operates Exchange platform rotate flow regulator valve item EE with the platform leveling flow regulator valve item U and activate the platform rotate left function function inoperative Consult Genie Industries Service Department A TEREX COMPANY REV B Replace the platform rotate left directional valve coil item CC Replace the faulty directional valve Replace the faulty counterbalance valve Check for mechanical restrictions keeping platform rotate left function from operating OR repair or replace platform rotator OR replace platform rotator counterbalance valve manifold OR
282. ontrols and let it run for 30 seconds Turn the engine off and inspect for leaks 14 Check the coolant level in the coolant recovery tank Add coolant if needed 15 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 16 Install the air baffle and the air baffle retaining fasteners 17 Start the engine from the ground controls and let it run until it reaches normal operating temperature 18 Turn the engine off Allow the engine to cool 19 Check the coolant level in the coolant recovery tank Add coolant if needed Coolant capacity Ford LRG 425 EFl Engine 11 5 quarts 10 9 liters Perkins 704 30 Engine 10 quarts 9 5 liters G A TEREX CON S 40 S 45 REV B E 3 Change the Fuel Hoses Gasoline LPG Models Engine specifications require that this procedure be performed every 2000 hours or 24 months whichever comes first Maintaining the fuel hoses in good condition is essential to safe operation and good engine performance Failure to detect a worn cracked or leaking fuel hose may cause an unsafe operating condition Explosion and fire hazard Engine fuels are combustible Replace the fuel lines in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Component damage hazard Be sure the fuel hoses are routed the same way the original hoses were CAU
283. opped and the indicator light turns on The drive enable switch must be held to either side to reactivate the drive function and should alert the operator that the machine will move in the opposite direction that the drive and steer controls are moved An improperly functioning drive enable system may allow the machine to be moved into an unsafe position 1 Start the engine from the platform controls 2 Move the lift drive selector toggle switch to the lift position if equipped Press down the foot switch Rotate the turntable to the right until the boom moves past the right non steering wheel Result The drive enable indicator light should turn on and remain on while the boom is anywhere in the range shown A TEREX CON S 40 S 45 REV B 5 Move the lift drive select toggle switch to the drive position if equipped 6 Slowly move the drive control handle off center Result The drive function should not operate 7 Hold the drive enable toggle switch to either side and slowly move the drive control handle off center Collision hazard Always use the ACAUTION color coded direction arrows on the platform control panel and the drive chassis to identify which direction the machine will travel Result The drive function should operate 8 Rotate the turntable to the left until the boom moves past the left non steering wheel Result The drive enable indicator light should come on a
284. orm controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage on TB36 12V or more With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage on blu 36 wire on steer left directional valve coil item TT on steer manifold Disconnect wires to steer left directional valve coil on steer manifold and test the resistance of the valve coil 5 to 6 ohms Continued on the next page 12V or more With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and hold the steer rocker switch on drive controller in the LEFT direction Check voltage at the controller terminal with the blu wire attached Repair or replace steer microswitch on drive controller Consult Genie Industries Service Department Repair open in blu 36 wire circuit from TB36 to steer left directional valve coil on steer manifold OR repair open in brn ground wire circuit to steer left directional valve coil Replace steer left directional valve coil OR repair open in brn ground wire circuit to steer left valve coil REV Repair open
285. orm every 200 hours A 18 Engine belt Ford Perkins Models B 5 Electrical Wiring B 6 Oil Cooler Fins Deutz B 7 Hydraulic tank condition B 8 Tires and wheels B 9 Brake configuration B 10 Drive hub oil level B 11 Engine RPM B 12 Key switch B 13 Emergency Stop B 14 Ground control override B 15 Directional valve B 16 Platform leveling B 17 Foot switch B 18 Horn B 19 Engine idle select B 20 Fuel select Gas LPG B 21 Drive enable system B 22 Drive brakes B 23 Drive speed stowed B 24 Drive speed raised B 25 Alarm package A 19 Fuel filter Ford Models B 26 Hydraulic oil analysis Comments A TEREX COMPANY Part No 72136 B 27 Replace hydraulic tank return filter Perform every 400 hours B 28 Replace engine air filter B 29 Replace spark plugs Ford Models Section 4 Scheduled Maintenance Procedures March 2008 mm MAINTENANCE INSPECTION REPORT Instructions CheckistC RevA Y NR CheckistE RevB YNR Make copies of this report to use for C 1 Engine belt E 1 Hydraulic oil each inspection Deutz Models 2 Engine coolant Select the appropriate checklist s for C 2 Valves Deutz Models Ford Perkins Models the type of inspection to be C 3 Fuel filter water E 3 Fuel hoses Ford Models performed separator Perkins Model E 4 Repl
286. osition hold the function enable switch to either side and move the platform rotate toggle switch TS13 in the LEFT direction Check voltage at grn wire on platform rotate left directional valve item CC Be sure all other functions operate normally Continued on the next page 12V or more Part No 72136 With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position hold the OV function enable switch to either side and move the platform rotate toggle switch in the LEFT direction Check voltage at TB17 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the platform rotate toggle switch in the LEFT direction Check voltage at TB17 12V or more Troubleshoot platform rotate toggle switch TS13 OR repair open in red power wire circuit to TS13 OR repair open in grn wire circuit from TS13to TB17 OR consult Genie Industries Service Department A TEREX COMPANY Chart 23 Repair open in grn 4 wire from TB17 to platform rotate left directional valve coil item CC OR repair open in brn ground wire circuit to valve coil Troubleshoot platform rotate toggle switches TS13 and TS5 OR repair open in red power wire circuit to TS13 and TS5 OR repair open in grn wire circuit from TS13 and TS5 to TB17 OR consult Genie Industries Service Department Secti
287. oving the castle nut or when checking the torque of the castle nut 23 Install the dust cap then the tire and wheel assembly Torque the wheel lug nuts to specification Refer to Section 2 Specifications 24 Center a lifting jack under the steer axle 25 Raise the machine approximately 6 inches 15 cm Remove the blocks from under the drive chassis 26 Lower the machine Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST E PROCEDURES E 6 Check the Fuel Injectors Perkins Diesel Models Engine specifications require that this procedure be performed every 3000 hours or 18 months whichever comes first A dirty or clogged injector may cause the engine to perform poorly and continued use may cause component damage Replacing a faulty injector is essential for good engine performance and service life Checking the Injectors 1 After warming the engine operate the engine at a fast idle speed Loosen and tighten the union nut of the high pressure fuel pipe at each injector Result When the union nut of the defective injector is loosened it has little or no effect on the engine speed CAUTION Component damage hazard Use a separate wrench to prevent movement of the outlets of the fuel injection pump when the high pressure pipes are released or tightened REV Replacing an Injector 1 Thoroughly clean the area around the injector to be removed Remove the fuel le
288. p Faulty drive pump null neutral Consult no improvement contact authorized Genie Industries Service repair facility Department symptoms improve Re adjust horsepower limiter board OR if problem persists consult Genie Industries Service Department A TEREX COMPANY Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 32 Traction Any type of problem consult Genie Function Industries Service Inoperative Department Be sure that all other functions operate REV normally Genie 5 68 S 40 5 45 PartNo 72136 March 2008 Section 5 Troubleshooting Flow Charts Chart 33 Machine Will With the boom in the Repair short 1 stowed position check in wht wires to limit Not Drive At continuity from TB40 to ONE a LS2 ground repair or replace Full Speed boom lift limit switch or Be sure all other functions operate normally Be sure the machine is not raised above or extended beyond the drive limit switches Be sure the drive limit switches are clear of any debris and are not activated when the boom is in the stowed position Be sure the wiring to limit switches is intact and show no signs of damage or corrosion Be sure the free wheel valve is closed on the drive pump With the boom in the stowed position check terminal 6 on horsepower limiter board for continuity to ground Re adjust or replace horsepowe
289. p to regulator filter b hose from fuel pre filter to fuel pump hose from fuel tank to fuel pre filter d high pressure hose from regulator filter to engine e hose from regulator filter to tank 7 Clean up any fuel that may have spilled during this procedure 8 Startthe engine from the ground controls Inspect the fuel filter and hoses for leaks Explosion and fire hazard If a fuel ADANGER leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 9 Swing the engine pivot plate back to its original position and install the two engine pivot plate retaining bolts 10 Install the air baffle and the air baffle retaining fasteners Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST E PROCEDURES E 4 Replace the Engine Air Breather Perkins Diesel Models Engine specifications require that this procedure be performed every 2000 hours or 24 months whichever comes first Complete information to perform this procedure is available in the Perkins 700 Series Workshop Manual Perkins part number TPD 1359E Genie part number 62424 A TEREX CON S 40 S 45 REV B E 5 Grease the Steer Axle Wheel Bearings 2WD Models Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition a
290. pany Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Guarterly or 250 hour Inspection Six Month or 500 hour Inspection Annual or 1000 hours Inspection A B C D 2 Year or 2000 hour Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in section 4 to learn how to perform these inspections If any inspection receives tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Rev B Checklist Rev B A 1 Manuals B 1 Exhaust system A 2 Decals and placards 2 Air Filter A 3 Damage and loose or B 3 Radiator missing parts B 4 Battery 4 Engine oil level A 5 Engine coolant Ford Perkins Models A 6 Fuel leaks A 7 Hydraulic oil level A 8 Hydraulic leaks A 9 Tire pressure A 10 Oscillate axle A 11 Platform and ground controls A 12 Auxiliary power A 13 Tilt sensor A 14 Limit switches A 15 Drain filter separator Deutz Perkins Models A 16 30 Day Service Perform every 100 hours A 17 Replace engine oil and filter Ford Models Perf
291. patch of a tire as a visual reference for use when crossing the start and finish lines 7 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 8 Continue at full speed and note the time when the machine reference point crosses the finish line 9 Move the lift drive select switch to the lift position if equipped 10 Press down the foot switch and lower the boom to the stowed position 11 Extend the boom 1 foot 30 cm 12 Move the lift drive select switch to the drive position if eguipped 13 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 14 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 15 Continue at top speed and note the time when the machine reference point crosses the finish line Drive speed maximum raised or extended position All models 1 foot per second 0 6 mph 0 13 meter per second 0 97 km h PartNo 72136 5 40 5 45 4 45 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST PROCEDURES B 25 Test the Alarm Package if equipped Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first The alarm package includes Travel alarm
292. previous page CHART 2 Disable starter by See Ford LRG 425 removing blk wire at the Service Manual for starter solenoid move troubleshooting the the start toggle switch to ignition system OR either side and check consult Genie Industries voltage at the light green Service Department wire on the ignition coil plug Repair open in light green wire from the ECM to ignition coil OR check for loose or bad connections from the ECM to the ignition coil OR replace the ignition coil OR consult Genie Industries Service Department Part No 72136 A TEREX COMPANY Section 5 Troubleshooting Flow Charts March 2008 Chart 2A Engine Cranks Over But Will Not Start or Engine Runs While Cranking Then Dies Gasoline LPG Models Be sure to check the engine oil level and fill as needed Be sure to check fuel levels and the engine coolant level Be sure that the radiator overflow tank is at the FULL mark Be sure that all vacuum hoses are connected and show no signs of gamage Perform these tests in gasoline mode only See Repair Section How to Retreive Fault Codes Is there a fault code stored in the ECM memory With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position move the start toggle switch TS2 to either side and check voltage at terminal 2 on ignition start module Check voltage at terminal 4 on the ignition sta
293. r limiter board OR check for misalignment of limit switches 51 and LS2 OR consult Genie Industries Service Department no continuity no continuity boom extend limit switch Repair short to ground in orange wire from TB40 to TP40 to terminal 6 on horsepower limiter board A TEREX COMPANY Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 34 Machine Drives At Full Speed With Platform Raised or Extended Be sure boom up drive limit switch is being activated by the cam on the boom when the boom is raised Be sure that the boom extend drive limit switch is not being held down or being activated when the boom is extended Be sure the wiring to limit switches is intact and show no signs of damage or corrosion Extend the boom past the limit switch LS1 and check continuity from ground to terminal 6 on the horsepower limiter board Test limit switches See procedure A 14 in the Maintenance Section Repair open from wht wires at TB40 to drive limit switches LS1 and LS2 then from brn ground wires to ground Genie S 40 S 45 REV B Replace horsepower limiter board OR re adjust horsepower limiter board OR consult Genie Industries Service Department Repair open in org wire circuit from TB40 to 40 to terminal 6 on horsepower limiter board Replace faulty limit switch contact OR replace limit switch Part No
294. r wheel Result The drive enable indicator light should be on Drive function should not operate until the drive enable override toggle switch is activated Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV A 15 Drain the Fuel Filter Water Separator Diesel Models Genie specifications reguire that this procedure be performed every 100 hours or monthly whichever comes first Proper maintenance of the fuel filter water separator is essential for good engine performance Failure to perform this procedure can lead to poor engine performance andcomponent damage ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off Perkins Models 1 Open the engine side cover and locate the fuel filter water separator Part No 72136 A TEREX COMPANY CHECKLIST A PROCEDURES 2 Loosen the vent plug located on the fuel filter water separator head Fuel filter water separator head bolt b vent plug c drain plug d filter bowl e separator head 3 Loosen the drain plug located at the bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 4 Tighten
295. rabbit and foot switch symbol 6 Press down the foot switch and adjust the A potentiometer counterclockwise to increase voltage or clockwise to decrease voltage A potentiometer specifications all models Voltage setting 10 5 to 11 5V DC 7 Move the engine idle control toggle switch to low idle turtle symbol 8 Press down the foot switch and adjust the C potentiometer to obtain the correct DC voltage reading Diesel Models 0 1V DC Gasoline LPG Models 3 5V DC 9 Move the engine idle control toggle switch to foot switch activated high idle rabbit and foot switch symbol 10 Press down the foot switch and re adjust the A potentiometer to the previous voltage setting in step 6 REV 11 Be sure that the boom is in the stowed position then drive the machine and observe how the engine rpm reacts to drive control handle movement If the engine surges or hunts adjust the C potentiometer counterclockwise until surging is minimized Under an extreme load an excessive counterclockwise adjustment to the potentiometer will cause the engine to stall The potentiometer adjustment is a compromise between engine stability surging and engine rpm drop 12 Disconnect the volt meter 13 Raise the boom above horizontal 14 Drive the machine for 40 feet 12 m and record the elapsed time Repeat this step in the opposite drive direction 15 Adjust the B potentiometer to obtain the correc
296. radually Do not allow oil to squirt or spray Remove the pin retaining fasteners from the rod end pivot pin Use a soft metal drift to remove the pin Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder Remove the pin retaining fasteners from the barrel end pivot pin Use a soft metal drift to remove the pin 7 AWARNING Remove the cylinder from the machine Crushing hazard The oscillate cylinder could become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane 5 40 5 45 Part No 72136 2008 Section 7 Repair Procedures REV B 17 1 Non steering Axle Components Drive Motor How to Remove a Drive Motor CAUTION CAUTION Component damage hazard Repairs to the motor should only be performed by an authorized Sundstrand Sauer dealer Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to sguirt or spray 3
297. rative function Exchange platform level operates down and up counterbalance valves items GG and FF and activate the platform level down function Replace the faulty counterbalance valve function inoperative Install a 010 3000 207 Check for mechanical bar pressure gauge at See restrictions keeping the quick disconnect Note 1 platform level down from operating OR replace slave cylinder OR coupling on the function manifold and activate the platform level down replace slave cylinder function counterbalance valves OR consult Genie Industries Service See Note 2 Department function operates Exchange platform level flow regulator valve item U with jib boom flow regulator valve item EE and activate the platform level down function Replace faulty flow regulator valve function inoperative Note 1 5 40 2600 psi or more Test master cylinder S 45 2400 psl or more see Chart 20 OR repair or replace slave cylinder or slave cylinder Note 2 counterbalance valves S 40 less than 2600 psi OR function manifold S 45 less than 2900 psi may have an internal fault Consult Genie Industries Service Department Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Platform Rotate Left Function Inoperative With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON p
298. re Chart 21 Repair open in org 4 wire from TB14 to platform level up directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot platform level toggle switches TS14 and TS6 OR repair open in red power wire circuit to 1514 and TS6 OR repair open in org 4 wire circuit from 514 and TS6 to TB14 OR consult Genie Industries Service Department Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 CHART 21 Continued from the rigidis infinite previous directional valve coil 4 item and test the resistance of the valve coil 6 to 7 ohms function operates Exchange platform level directional valves items T and V and activate the platform level up function function inoperative function Exchange platform level operates counterbalance valves items FF and GG and activate the platform level up function function inoperative Install a 0 to 3000 207 bar pressure gauge at See the quick disconnect Note 1 coupling on the function manifold and activate the platform level up function See Note 2 function operates Exchange platform level flow regulator valve item U with the jib boom flow regulator valve item EE and activate the platform level up function function inoperative Test master cylinder see Chart 20 OR repair or replace slave oylinder or slave cylinder counterbalance valves OR funct
299. re the boom is fully retracted and lowered to the stowed position 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 12 2 m 6 8 sec 12 2 m 7 8 sec Diesel models 40 7 8 sec 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec A TEREX COMPANY S 40 S 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 24 Test the Drive Speed Raised or Extended Position Genie specifications reguire that this procedure be performed every 250 hours or guarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond guickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range Select a test area that is firm level and free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 apart 2 Start the engine from the platform controls 3 Move the lift drive select switch to the lift position if eguipped 4 Move the engine idle select switch to foot switch activated high idle rabbit and foot switch Press down the foot switch and raise the boom above horizontal 5 Move the lift drive select switch to the drive position if eguipped CHECKLIST PROCEDURES 6 Choose a point on the machine i e contact
300. reguired to perform this procedure Indicates that a warm engine will be reguired to perform this procedure Indicates that dealer service is reguired to perform this procedure A TEREX CON 4 2 S 40 S 45 Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly six months annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are reguired to perform a scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Guarterly or every 250 hours Six months or every 500 hours Annual or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with employer jobsite and governmental regulations and requirements Part No 72136 2008 Section 4 Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector com
301. rt module Replace ignition start module OR consult Genie Industries Service Department Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Crank engine and check voltage at org blk 41 wire on alternator Repair open in org blk 41 wire circuit from alternator to TB41 to terminal 2 on the ignition start module Disconnect red wire from terminal 4 on the ignition start module and check voltage at terminal 4 Test auxiliary power toggle switches TS1 and TS9 See Repair Section REV B Refer to the fault code chart in this section for a description of the fault and recommended repairs Check alternator wiring OR repair or replace alternator OR contact Genie Industries Service Department Replace ignition start module OR consult Genie Industries Service Department S 40 S 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV B Engine Cranks Over But Will Not Start Diesel Models Be sure to check the engine oil level and fill as needed Be sure to check fuel level Be sure the fuel shut off valve is in the position Be sure that the battery is fully charged less Move the start toggle switch to either side and ma check battery voltage while engine is cranking 11V or
302. rt the engine from the ground controls and check the fuel filter water separator for leaks Explosion and fire hazard If a fuel leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately 4 18 S 40 S 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV A 16 Perform 30 Day Service The 30 day maintenance procedure is a one time seguence of procedures to be performed after the first 30 days or 50 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Perform the following maintenance procedures A 17 Replace the Engine Oil and Filter Gasoline LPG Models if applicable OR C 5 Replace the Engine Oil and Filter Perkins Models if applicable OR D 7 Replace the Engine Oil Filter Deutz Models if applicable B 8 Inspect the Tires Wheels and Lug Nut Torque B 27 Replace the Hydraulic Tank Return Filter D 3 Check the Turnable Rotation Bearing Bolts Part No 72136 A TEREX S 40 S 45 MPANY CHECKLIST A PROCEDURES A 17 Replace the Engine Oil and Filter Gasoline LPG Models Ford engine specifications require that this procedure be performed every 100 hours Perform this procedure more often if dusty conditions exist or the machine is subjected to extended low idle operation Periodic replacement of the engine o
303. rvice Department OR 3 Carefully pull the pump away from the your local Ford dealer engine and secure it from moving Component damage hazard 8 2 CAUTION Hoses can be damaged if they are E kinked or pinched Flex Plate 4 Remove the flex plate mounting fasteners then remove the flex plate from the engine fly The flex plate acts as a coupler between the wheel engine and the pump It is bolted to the engine flywheel and has a splined center to drive How to Install the Flex Plate the pump 1 Install the flex plate onto the engine flywheel AO with the raised spline towards the pump Torgue the flex plate mounting bolts to 34 ft lbs 46 2 Install the pump coupler onto the pump shaft with the set screw towards the pump Leave a 1 1einch 1 59 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump pump coupler set screw Torque the set screw ine flywheel plate fasteners to 34 ft lbs 46 Nm a b pump shaft to 45 ft lbs 61 Nm d flex plate with raised spline 4 Install the pump and torque the pump mounting f Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged A TEREX COMPANY Part No 72136 S 40 5 45 7 31 Section 7 Repair Procedures March 2008 FORD LRG 425 EFI ENGINE 8 3 Coolant Temperature and Oil Press
304. ry of manufacture USA This machine complies with ANSI A92 5 CAN B 354 4 Model year Genie Industries 18340 NE 76th Street Redmond WA 98052 USA Sequence number Serial label stamped on chassis located under cover PN 77055 Part No 72136 March 2008 EEE L LL L Ll I d IL Lu L uuhu I AI This page intentionally left blank Genie iv S 40 S 45 Part No 72136 2008 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie S 40 amp Genie S 45 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting eguipment and a suitable workshop Genie TEREX 72136 5 40 5 45 V Section 1 Safety Rules March 2008 SAFETY RULES Perso
305. s March 2008 PLATFORM CONTROLS 13 Start a timer and simultaneously move the control handle all the way to the left or right Note how long it takes to reach the maximum voltage recorded in step 14 This is the ramp rate 14 Set the ramp rate Turn the ramp rate trimpot to obtain a 5 second ramp speed Turn the ramp rate trimpot clockwise to increase the time or counterclockwise to decrease the time Turntable rotation specifications Threshold 3 5V DC Turntable rotation REVA 1 2 Horsepower Limiter Board The horsepower limiter board is responsible for governing drive pump output It senses engine rpm from the alternator The horsepower limiter board senses drops in rpm normally due to increased drive resistance rough terrain or incline and decreases voltage to the drive controller which in turn decreases voltage to the drive pump thereby reducing pump output to maintain optimum engine rpm and horsepower Three adjustments are required for optimum performance Max out Cycle time 7810 83 seconds Ramp rate 5 seconds Genie 7 6 S 40 S 45 Part No 72136 2008 Section 7 Repair Procedures REV A How to Adjust the Horsepower Limiter Board The engine rpm must be correct before performing this procedure See Maintenance Procedure B 11 Check and Adjust the Engine RPM Do not adjust the horsepower limiter board unless the static battery voltage is above 12V DC and the alter
306. s REV A ORG BLK 1 a ala I lu tr tc HIGH RPM n T ENGINE SPEED A 51 gt oe BLK RED 1 FLASHING BEACON E NA OPTION id B o FUNCTION ENABLE d HIGH RPM BLI RED h 1 HIGH IDLE RELAY OG 3 me i Bg o HIGH IDLE CUTOUT i RELAY m9 OF o BLK RED R E H iT RPM SOLENOID LAORE GENERATOR amp TS20 NOTE CIRCUIT CONNECTION TO TP24 IS FOR UNITS WITHOUT GENERATOR OPTION Section 6 Schematics Electrical Schematic Perkins Diesel Models March 2008 LON 2 GRN WHT 1 z GRN WHT 4 E H GENERATOR 9 a WHT 1 2 HOUR METER N VOLT METER n Eu qn WHTBLK WHTIBLKEH OIL PRESSURE
307. s and other jewelry Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Section 5 e Troubleshooting Flow Charts March 2008 TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test eguipment are reguired voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem A TEREX CON 5 2 S 40 5 45 MPANY REV B General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem Still exists Return to P erform service problem repair solved PartNo 72136 March 2
308. s 2WD RT 4WD RT 667 667 CE 90 Ibs 90 Ibs Length 27 ft 10 in 27 ft 10 in 400 N 400 N 8 5 8 5 Tires and wheels 2WD Rear Width 7ft6in 7ft6in 2WD Front 4WD Front 2 3 m 2 3m Tires Only and Rear Height 8ft2in 8ft2in size 12 5L 16SL 12 16 5 NHS 2 5m 2 5m Tire ply rating 12 8 Weight a e Tire contact area 88 sq in 57 sgin d 9 9 568 sg 368 54 Ground clearance 12 1 2 in 12 2in Overall tire diameter 33 7 in 33 2 in Operational dimensions Tire pressure 45 psi 45 psi 3 1 bar 3 1 bar Maximum platform height 45 ft 45 ft 13 7 13 7 Wheel diameter 16in 161 2 in 40 6 41 9 cm Maximum horizontal reach 36 ft 8 in 36 ft 8 in 112m 112m Wheel width 10 in 9 3 4 in 25 4 cm 24 8 cm Maximum turntable tailswing 34 in 34 in 5 a Et 86 4 cm 86 4 Wheel lugs 80 5 8 18 9 5 8 18 Lug nut torque dry 170 ft lbs 230 Nm Wheelbase 7ft3in 7ft3in yg nut torque lubricated 130 ft lbs 176 Nm 2 2m 2 2m Fluid capacities Minimum turning radius 15 ft 8 in 15 ft 8 in outside 4 8m 4 8m Fuel tank 30 gallons 114 liters 22 turning radius 6 ft a 6 ft 2m LPG tank 33 5 pounds 15 2 kg Turntable rotation continuous continuous Hydraulic tank 45 gallons Platform rotation 160 160 3 Hydraulic system 50 gallons Platform dimensions 6 ft Standard 6 ft Standard including tank 189 liters 8 ft Optional 8 ft Optional Drive hubs 17 fl oz Length x width 6 ft 72inx 30in 72 30 0 5 liters 1 8
309. s removed from the extension boom if it is not Remove the turntable end cover properly supported 6 Tag disconnect and plug the extension cylinder hydraulic hoses Cap the fittings on the cylinder Note the length of the cylinder after removal The cylinder must be at the same length for Bodily injury hazard Spraying installation AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Remove the barrel end pivot pin retaining fasteners 8 Place a rod through the barrel end pivot pin and twist to remove the pin A TEREX COMPANY 7 24 S 40 5 45 72136 March 2008 Section 7 e Repair Procedures EE REV A BOOM COMPONENTS 4 5 4 Attach a lifting strap from an overhead crane to Platform Leveling the lug on the rod end of the master cylinder 5 Remove the pin retaining fasteners from the Master Cylinder master cylinder barrel end pivot pin The master cylinder acts as a pump for the slave 6 Place a rod through the barrel end pivot pin and cylinder It is part of the closed circuit hydraulic twist to remove the pin loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the base of the boom How to Remove the Platform Leveling Master Cylinder When removing a hose assembly or fitting the O ring on the fitting
310. service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie S 40 amp Genie S 45 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a flat level surface Boom in the stowed position Turntable rotated with the boom between the non steering wheels Turntable secured with the turntable rotation lock pin Key switch in the off position with the key removed Wheels chocked Part No 72136 A TEREX S 40 S 45 7 1 MPANY Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a Suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order Symbols Legend A Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messag
311. switch to function enable toggle switch to each function toggle switch Replace key switch contact for ground yes controls S 40 S 45 Part No 72136 March 2008 Section 5 Troubleshooting Flow Charts Rue Chart 13 Platform yes Start engine from Test or replace foot platform controls platform controls press switch see Repair Controls down the foot switch and Section OR fopa open 1 check voltage at TP24 in wht wire circuit from Inoperative foot switch to TP24 Ground 12V Controls Repair open in wht wire Operate circuit from TP24 to function toggle switches Normal ly and function controllers Be sure all cables from chassis m meum eck voltage a epair open in red wire through the cable circuit from key switch to track are in good TB22 OR Replace the condition with no platform controls contact kinks or abrasions im atthe key switch ov Check voltage at TP22 12V Check voltage at blk wire on input side of platform Emergency Stop button contact 12V With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position check the voltage on the output side of the platform Emergency Stop button contact 12V ov Check voltage at TP23 12V Repair open in blk wire circuit from platform Emergency Stop button to TP26 to foot switch OR replace foot switch OR consult Genie Industries Service Department Part No
312. t Cap the fitting on the hydraulic tank Remove the retaining fasteners from the hydraulic tank hold down straps Remove the hold down straps from the hydraulic tank Section 7 Repair Procedures March 2008 FUEL AND HYDRAULIC TANKS 9 Support the hydraulic tank with 2 lifting straps Place one lifting strap at each end of the tank and attach the lifting straps to an overhead crane 10 Remove the hydraulic tank from the machine Crushing hazard The hydraulic AWARNING tank could become unbalanced and fall if it is not properly supported and secured to the overhead crane 11 Remove the suction strainers from the tank and clean them using a mild solvent 12 Rinse out the inside of the tank using a mild solvent 13 Install the suction strainers using pipe thread sealant on the threads 14 Install the drain plug using pipe thread sealant on the threads 15 Install the hydraulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 7 64 A TEREX CON S 40 5 45 MEANY REVA 18 Clean up any oil that may have spilled 19 Open the hydraulic tank shutoff valves CAUTION Component damage hazard Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Always use pipe
313. t No 72136 2008 Section 4 Section 5 TABLE CONTENTS Rev Scheduled Maintenance Procedures continued B Checklist E Procedures E 1 Testor Replace the Hydraulic 2 2 0040000 4 73 E 2 Change or Recondition the Engine Coolant Liquid Cooled Models E 3 Change the Fuel Hoses Gasoline LPG Models E 4 Replace the Engine Breather Perkins Models E 5 Grease the Steer Axle Wheel Bearings 2WD Models E 6 Check the Fuel Injectors Perkins Rev Troubleshooting Flow Charts B nies Brei E Fault CodeS cu eiu tiet tete ete ades 1 Engine Will Not Crank 2 20 0 0 2 Engine Cranks Over But Will Not Start Gasoline LPG Models 2A Engine Runs While Cranking then Dies Gasoline LPG Models Engine Cranks Over But Will Not Start Diesel Models 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models 8004 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models 2 2 Engine High Idle Inoperative Gasoline LPG Models o o 10 All Functions Inoperative Engine Starts and Runs 11 A
314. t No 72136 March 2008 Section 7 e Repair Procedures REV B MANIFOLDS Part No 72136 S 40 S 45 7 57 Section 7 Repair Procedures March 2008 MANIFOLDS 11 12 Valve Adjustments 4WD Drive Manifold How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the diagnostic nipple index 9 located on the drive manifold 2 Start the engine from the platform controls 3 Drive the machine slowly in either direction and observe the pressure reading on the pressure gauge Charge Pressure Relief valve specifications Pressure 250 psi 17 2 bar 4 Turn the engine off Hold the charge pressure relief valve with a wrench and remove the cap index 2 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the valve cap 6 Start the engine from the platform controls Drive the machine in either direction and recheck the valve pressure 7 Turn the engine off Remove the pressure gauge A TEREX COMPANY REV B 7 58 S 40 5 45 Part No 72136 March 2008 Section 7 e Repair Procedures REV B 11 13 Jib Boom Platform Rotate Manifold Components S 45 Models before serial number 5593 The jib boom platform rotate manifold is mounted on the platform end of the boom Index Schematic No Description Function Torgue 1 2 posit
315. t TB15 With key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position press down the foot switch and move the platform level toggle switch TS6 in the DOWN direction Check voltage at TB15 12V or more Troubleshoot platform level toggle switch TS14 OR repair open in red power wire circuit to TS14 OR repair open in org blk wire circuit from TS14 to TB15 OR consult Genie Industries Service Department A TEREX COMPANY Chart 22 Repair open in org blk 4 wire from TB15 to platform level down directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot platform level toggle switches TS14 and TS6 OR repair open in red power wire circuit to TS14 and TS6 OR repair open in org blk wire circuit from TS14 and TS6 to TB15 OR consult Genie Industries Service Department Section 5 e Troubleshooting Flow Charts March 2008 EE I Y CHART 22 REV 0 or infinite ohms Replace the platform Disconnect the wires from the platform level down directional valve Continued from the previous page level down directional valve coil coil item V and test the resistance of the valve coil 6 to 7 ohms function Exchange platform level operates down and up directional Replace the faulty valves items V and T directional valve and activate the platform level down function function inope
316. t raised drive speed of 1 foot per second 30 5 cm per second Turn the B potentiometer clockwise to increase voltage or counterclockwise to decrease voltage 16 Close the platform control box lid and install the fasteners Drive speed specifications Stowed position distance 40 ft 12m 2WD 4WD 40 ft 6 8 sec 40 ft 7 8 sec 12 2 m 6 8 sec12 2 m 7 8 sec 40 7 8 sec 40 ft 9 1 sec 12 2 m 7 8 sec 12 2 m 9 1 sec Gasoline LPG models Diesel models Boom raised or distance 40ft 12 m extended 1 foot per second All models 30 5 cm per second 7 8 S 40 S 45 Part No 72136 2008 Section 7 Repair Procedures REV A 1 3 Foot Switch How to Test the Foot Switch Perform this procedure with the key switch in the off position 1 Remove the foot switch cover plate fasteners from the platform PLATFORM CONTROLS 6 Press down the foot switch Connect the leads from an ohmmeter or continuity tester to each wire combination listed below and check for continuity Test Desired result red to black no continuity infinite O red to white no continuity infinite O 2 Remove the foot switch guard mounting fasteners from the platform black to white continuity zero Q 3 Remove the foot switch mounting fasteners that attach the foot switch to the foot switch guard 4 Remove the cover plate from the bottom of the foot switch to access the foot switch wire t
317. t the fuel pump relay see the Repair Section OR check for poor terminal connection from the fuel pump relay to fuel pump OR replace the ECM Fuel pump high voltage Genie 5 4 S 40 5 45 PartNo 72136 March 2008 Section 5 Troubleshooting Flow Charts REV FAULT CODE CHART Fault Code A leaking or malfunctioning fuel injector misfiring cylinder faulty TP Test for a leaking or malfunctioning fuel sensor or injector misfiring cylinder or bad TP contamination of fuel sensor Remove HO2 sensor and check OR use of improper condition of sensor for contamination OR thread sealant on check for poor terminal connections or sensor threads OR shorted wires from the HO2 sensor to the sensor wires shorted to to ground OR replace HO2 sensor ground or poor terminal connections OR HO2 sensor is faulty Heated Oxygen HO2 sensor high voltage Engine Coolant Temperature ECT sensor low voltage ECM detects Check engine coolant level OR check for excessively low signal shorted wires or poor terminal connections voltage from the ECT from the ECT sensor to the ECM OR sensor replace the ECT sensor The IAT sensor shares the same ground Intake Air ECM detects an wire as the ECT and MAP sensors Check Temperature excessively low signal for shorted wires or poor terminal IAT sensor voltage from the IAT connections from the IAT sensor to the low voltage ECT and MAP sensors to the ECM
318. tall the pump coupler onto the pump shaft with the set screw toward the pump Leave a 1 4 inch 6 4 mm gap between the pump coupler and pump end plate 3 Apply removable thread locking material to the pump coupler set screw Torque the set screw to 45 ft Ibs 61 Nm Component damage hazard Do CAUTION not force the drive pump during installation or the flex plate teeth may become damaged 4 Install the pump and torque the pump mounting plate fasteners to 34 ft lbs 46 Nm A TEREX COMPANY Part No 72136 S 40 5 45 7 29 Section 7 Repair Procedures March 2008 PERKINS 704 30 ENGINE 7 3 Coolant Temperature and Oil Pressure Gauges The engine coolant temperature gauge is an electrical gauge The engine coolant temperature sending unit has limit contacts that are factory set The contacts will close at approximately 221 F 105 C When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine coolant temperature will be indicated on the gauge when the key is on and the Emergency Stop Button is pulled out to the oN position The engine oil pressure gauge is an electrical gauge The engine oil presure sending unit has limit contacts that are factory set The contacts will close at approximately 4 2 psi 0 3 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on t
319. tch and check voltage at terminal on the boom controller 12V or more Re adjust controller see Repair Section OR replace controller OR consult Genie Industries Service Department 12V or more 12V or more 12V or more CHART 14 Repair open in red 4 wire circuit from TB1 to boom up down directional valve coil OR repair open in brn ground wire circuit to valve coil Troubleshoot boom n down toggle switch O repair open in red wire circuit from 7516 to TB1 OR consult Genie Industries Service Department Repair open in red 3 wire from TP1 to TB1 Repair open in power supply circuit from TP24 to boom controller OR repair open in brn ground wire circuit from ground to boom controller Section 5 e Troubleshooting Flow Charts March 2008 CHART 14 Disconnect wires from boom up down directional valve coil item B and test the resistance of the valve coil See Repair Section Continued from the previous page Hold function enable switch to either side and move the boom up down toggle switch in the UP direction Manually override the directional valve by pushing in on the end of the valve spool Install a 0 to 5000 PSI 845 bar pressure gauge at the quick disconnect coupling on the boom function manifold and start the engine Hold the function enable switch to either side and move the boom up down toggle switch in the UP direction and chec
320. te gradually Do not allow oil to sguirt or spray A TEREX COMPAN REV A Remove the pin retaining fasteners from the steering cylinder clevis pins Remove the clevis pins from the steer cylinder Always use a new cotter pin when installing a clevis pin Remove the steering cylinder from the machine 7 70 S 40 5 45 72136 2008 Section 7 Repair Procedures REV A 14 3 Tie Rod How to Remove the Tie Rod 1 Remove the cotter pins from the clevis pins at each end of the tie rod then remove the clevis pins Always use a new cotter pin when installing a clevis pin 2 Remove the tie rod How to Perform the Toe in Adjustment before serial number 3536 Perform this procedure on a firm level surface Block the non steering tires and be sure that the machine is in the stowed position Machines manufactured after serial number 3535 have non adjustable tie rods 1 Straighten the steer wheels 2 Measure the steer tires front to front and back to back using a measuring fixture Part No 72136 A TEREX 5 40 5 45 MPANY 2WD STEERING AXLE COMPONENTS 3 Block the non steering wheels and center a lifting jack of ample capacity under the steering axle 4 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 5 Loosen the jam nut on the adjustable end of the tie rod 6 Remove the pin reta
321. te O terminal 87a to 30 continuity zero O 3 Connect 12V DC to terminal 85 and a ground wire to terminal 86 then test the following terminal combinations Test Desired result terminal 87 to 87a amp 30 no continuity terminal no 87a N C terminal no 85 coil negative terminal no 30 common terminal no 86 coil positive terminal no 87 N O Control Relay Schematic without resistor O 85 87 87a E O 86 30 Control Relay Schematic with resistor infinite 0 J N terminal 87 to 30 continuity zero 86 30 Genie Part No 72136 S 40 S 45 7 33 Section 7 Repair Procedures March 2008 GROUND CONTROLS 9 2 Toggle Switches See 1 5 Toggle Switches 9 3 Wago Components How to Remove a Wago Component Electrocution hazard Contact with AWARNING electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry Wago tools are available from the Genie Service Parts Department Genie part number 33996 1 Label the wiring from the component to be removed 2 Use a small screwdriver to push and release the wire from the component 3 Locate the removal tab on the bottom or top of the component 4 Usea small screwdriver to gently pry up on the tab of the component and remove it
322. tform mounting weldment for support Then lower the jib boom until the platform is resting on the blocks Do not rest the entire weight of the boom on the blocks A TEREX COMI REV A 2 Tag disconnect and plug the jib boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 3 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Lower one of the leveling arms to the ground Tap the pin the opposite direction and lower the second leveling arm Do not remove the pin 4 Attach a strap from an overhead crane to the jib boom lift cylinder 5 Remove the pin retaining fastener from the jib boom lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin 6 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the cylinder from the machine Crushing hazard The jib boom lift AWARNING cylinder could become unbalanced and fall when it is removed from the machine if it is not properly supported 7 16 S 40 S 45 Part No 72136 2008 Section 7 Repair Procedures REV A 4 1
323. the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition A TEREX CON REV A 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts Carefully remove the pump CAUTION Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump See 10 2 How to Prime the Pump 7 36 S 40 S 45 Part No 72136 March 2008 Section 7 e Repair Procedures REV A HYDRAULIC PUMPS 10 2 2 Close the two hydraulic tank valves located at the hydraulic tank Drive Pump The drive pump is a bi directional variable displacement piston pump The pump output is controlled by the electronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should only be performed at an authorized Sundstrand Sauer service center Call Genie Industries Service Department to locate your local authorized service center How to Remove the Drive Pump CAUTION Component damage ha
324. the vent plug If the fuel filter water separator is completely drained you must prime the fuel filter water separator before starting the engine Refer to C 4 in this section Replace The Fuel Filter Element Perkins Diesel Models for instructions on how to prime the fuel filter water separator S 40 S 45 4 17 Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES REV 5 Clean up any fuel that may have spilled 3 Clean up any fuel that may have spilled 6 Start the engine from the ground controls and check the fuel filter water separator and vent plug for leaks Explosion and fire hazard If a fuel ADANGER leak is discovered keep any additional personnel from entering the area and do not operate the machine Repair the leak immediately Deutz Models 1 Open the engine side cover and locate the fuel filter water separator ADANGER 2 Loosen the drain plug located at the bottom of the filter Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug 9 fuel filter b drain plug Genie A TEREX COMPANY If the fuel filter is completely drained you must prime the fuel filter water separator before starting the engine Refer to D 9 in this section Replace The Diesel Fuel Filter Water Separator Deutz Diesel Models for instructions on how to prime the fuel filter water separator 4 Sta
325. then return to normal operation Genie 5 6 S 40 5 45 PartNo 72136 March 2008 Section 5 Troubleshooting Flow Charts REV FAULT CODE CHART Fault Code The received an illegal interruption signal from one or more ECM Illegal engine sensors and has Interuption gone into a default program and then return to normal operation Replace the ECM Under normal operation the ECM will store numbers into memory If this does not happen it will reset itself and set fault code 56 ECM Computer Operating Properly COP failure Replace the ECM Battery supply voltage battery and or alternator condition to the ECM is 8V DC or JOR check for shorted wires or poor terminal connections from the battery to the ECM System voltage low Battery supply voltage battery and or alternator condition to the ECM is 18V OR check for shorted wires or poor terminal connections from the battery to the ECM System voltage high A TEREX COMPANY PartNo 72136 5 40 5 45 5 7 Section 5 Troubleshooting Flow Charts March 2008 Chart 1 Engine Will Not Crank Over Be sure the key switch is in the appropriate position Be sure that both Emergency Stop buttons are pulled out to the position Be sure the circuit breakers are not tripped Be sure the battery is fully charged less than Check battery voltage 12V 12V or more With ke
326. tion See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the on position move the start toggle switch to either side and check battery voltage while engine is cranking With the key switch turned to the OFF sition and both mergency Stop buttons pulled out to the position turn the key switch to ground controls and listen for the fuel pump to turn ON for approximately 2 seconds and then shut OFF Did the fuel pump turn on Remove 1 spark plug and ground spark plug body Crank engine and observe spark Continued on the next page more than 11V weak or no spark Check for poor terminal connections OR check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Check battery condition OR check alternator OR check for short circuits OR check battery cables OR replace the battery Test the fuel pump relay See Repair Section OR replace the fuel pump Consult Genie Industries Service Department REV B Refer to the fault code chart in this section for a description of the fault and recommended repairs S 40 S 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV B Continued from the
327. tion 7 Repair Procedures March 2008 Oscillating Axle Components 16 1 Oscillating Axle Lock out Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the oscillating axle The cylinders are eguipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure How to Remove an Oscillating Axle Cylinder AWARNING Bodily injury hazard This procedure reguires specific repair skills and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Perform this procedure on a firm level surface with the boom in the stowed position When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Rotate the turntable until the boom is between the steer tires A TEREX COMPANY REV A 2 Remove the fasteners from drive chassis cover at the steer end Remove the cover 3 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate g
328. ts and Runs Check hydraulic Fill with Dexron fluid level equivalent hydraulic fluid Check pump suction line shutoff valves In the with valves closed it open position the valve may have damaged one handles should be or both pumps Please parallel with hose contact the Genie Industries Service Department Do the pumps feel excessively hot If engine has been run Open valves and start the engine Check all machine functions for correct operation Disconnect ignition coil Troubleshoot connector plug from inoperative boom ignition coils On Deutz functions and OR Perkins diesel inoperative drive models hold manual functions separately fuel shutoff lever to the closed position Remove function pump from main pump but leave all hoses connected Hold start toggle switch and crank engine over while observing spline drive at rear of main pump spline does not turn Engine to pump flex plate coupling Is faulty OR main pump is faulty Consult Genie Industries Service Department Genie REX COMPANY 5 24 S 40 5 45 PartNo 72136 2008 Section 5 Troubleshooting Flow Charts REV B All Lift and Steer Functions inoperative Drive Functions Operational Be sure the generator on off toggle switch if equipped is in the OFF position Be sure the hydraulic suction line shutoff valve for the lift steer pump is in the position Be sure all grounding
329. ubleshooting Flow Charts Q srt REV B CHART 4 Crank engine for 15 Repair open in dk grn seconds and check for continuity wire from ECM to continuity to ground at terminal 86 on OR terminal 486 on CR3 replace ECM Continued from the previous page continuity Crank engine for 15 no seconds and check for continuity continuity to ground at terminal 30 Replace LPG relay continuity 0 or infinite ohms Check resistance of LPG solenoid Replace LPG solenoid 9to 10 ohms Reconnect LPG tank and starter then see Maintenance section for LPG adjustments OR consult Genie Industries Service Department A TEREX COMPANY Part No 72136 S 40 S 45 5 17 Section 5 Troubleshooting Flow Charts March 2008 Chart 5 Engine Will Not Start On Gasoline But Will Start On LPG Gasoline LPG Models Be sure fuel select switch is switched to gasoline Be sure to check gasoline fuel level See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory With key switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at LPG side blu red wire of fuel select toggle switch TS11 Move the start toggle switch to either side and check voltage across the wires on the fuel pump witho
330. uel Filter Element Perkins Models 4 54 C 5 Replace the Engine Oil and Filter Perkins Models 4 56 C 6 Check the Specific Gravity of Engine Coolant Liquid Cooled Models 4 57 C 7 Check the Glow Plugs Perkins Models 4 58 C 8 Replace the PCV Valve Gasoline LPG 4 59 Checklist D Procedures D 1 Check the Boom Wear 4 60 D 2 Check the Free wheel 4 60 D 3 Check the Turntable Rotation Bearing Bolts 4 62 0 4 Grease the Turntable Rotation Bearing and Rotate Gear 4 63 D 5 Replace the Drive Hub Oil 4 63 D 6 Replace the Drive Loop Hydraulic 4 65 D 7 Replace the Engine Oil and Filter Deutz Models 4 66 D 8 Clean the Fuel Pump Strainer Deutz 4 68 D 9 Replace the Diesel Fuel Filter Water Separator Deutz Models 4 69 D 10 Change the Fuel Hoses Deutz Models 4 70 D 11 Check the Engine Valve Clearances Perkins Models 4 71 D 12 Clean the Engine Breather Assembly Perkins Models 4 72 Genie X S 40 S 45 Par
331. uld move freely and spring return to center A distinct click should be felt and heard Part No 72136 A TEREX COMPANY S 40 S 45 CHECKLIST A PROCEDURES 8 Turn the key switch to platform controls and fully retract the boom 9 Move the lift drive selector switch to the drive position if equipped 10 Press down the foot switch and slowly move the drive control handle off center Result The machine should move at normal drive speeds 11 Move the lift drive selector switch to the lift position if equipped 12 Raise the boom to just above horizontal 13 Move the lift drive selector switch to the drive position if equipped 14 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed 15 Move the lift drive selector switch to the lift position if equipped 16 Lower the boom to the stowed position then extend the boom 3 feet 0 9 m 17 Move the lift drive selector switch to the drive position if equipped 18 Slowly move the drive control handle off center Result The machine should move at a reduced drive speed Drive speed maximum raised or extended position All models 1 foot per second 0 3 meter per second 0 6 mph 0 97 km h Section 4 Scheduled Maintenance Procedures March 2008 CHECKLIST A PROCEDURES Drive Enable Limit Switch A properly functioning drive enable limit switch is essential for safe machine oper
332. ulic tank onto the machine 16 Install the two suction hoses and the supply hose for the auxiliary power unit A TEREX S 40 S 45 REV B 17 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 18 Clean up any oil that may have spilled 19 Open the hydraulic tank shutoff valves Component damage hazard ACAUTION Be sure to open the two hydraulic tank shutoff valves and prime the pump after installing the hydraulic tank Refer to Repair Section 12 2 How to Prime the Pump Always use pipe thread sealant when installing the drain plug and strainers Use only Rykon MV eguivalent hydraulic fluid PartNo 72136 2008 Section 4 Scheduled Maintenance Procedures REV CHECKLIST E PROCEDURES E 2 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the Change or Recondition the machine to access the cooling system Engine Coolant Liguid Cooled Models Engine specifications reguire that this procedure be performed every 2000 hours or 24 months whichever comes first Replacing or reconditioning the engine coolant is essential to good engine performance and service life Old or dirty coolant may cause the engine to b pivot plate retaining bolts perform poorly and continued use may cause c air baffle engine damage Extremely dirty conditions may require coolant to be changed more
333. under the non steering axle Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support Remove the wheel lug nuts then the tire and wheel assembly A TEREX CO S 40 5 45 MEANY ACAUTION Crushing hazard The drive hub may become unbalanced and fall if it is not properly supported and secured to the lifting jack Torque specifications Lug nut torque dry 170 ft lbs 230 Nm Lug nut torque lubricated 130 ft lbs 176 Nm Before serial number 5370 Drive hub mounting bolts dry 150 ft lbs 203 Nm Drive hub mounting bolts lubricated 110 ft lbs 149 Nm Drive motor mounting bolts dry 75 ft lbs 102 Nm Drive motor mounting bolts lubricated 56 ft lbs 76 Nm After serial number 5369 Drive hub mounting bolts dry 210 ft lbs 284 Nm Drive hub mounting bolts lubricated 160 ft lbs 217 Nm Drive motor mounting bolts dry 110 ft Ibs 149 Nm Drive motor mounting bolts lubricated 80 ft lbs 109 Nm Part No 72136 2008 Section 7 Repair Procedures REV B 17 3 Wheel Brake How to Remove a Wheel Brake When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torgued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torgue Specifications 1 Remove the drive motor See 17 1 How to Remove a Drive Motor 2 Tag disconnect and plug the h
334. ure Gauges The coolant temperature gauge is an electrical gauge The coolant temperture sending unit has limit contacts that are factory set The contacts will close at pproximately 230 F 112 When the contacts close the engine will shut off to prevent damage and will not start until the temperature drops below the contact point Engine coolant temperature will be indicated on the gauge when the key switch is and the Emergency Stop button is pulled out to the on position The oil pressure gauge is an electrical gauge The oil pressure sending unit has limit contacts that are factory set The contacts will close at approximately 8 psi 0 55 bar When the contacts close the engine will shut off to prevent damage Engine oil pressure will be indicated on the gauge when the engine is running How to Remove the Coolant Temperature and Oil Pressure Gauge Sending Units Perform this procedure with the engine off 1 Remove the air baffle retaining fasteners Remove the air baffle 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the water temperature and oil pressure sending units REVA 3 Locate the oil pressure and coolant temperature sending units oil pressure sending unit b coolant temperature sending unit hidded from view 4 Tag and disconnect the wiring from the desired sending unit Remove the sending unit from the engine block
335. urntable Index Schematic No Description Item Function 1 Shuttle valve 2 position way Turntable rotation brake release 2 Counterbalance valve Turntable rotate right 3 Counterbalance valve KK Turntable rotate left 4 Orifice plug 0 030 inch 0 76 mm LL Brake circuit Torque 10 13 ft Ibs 14 18 Nm 35 40 ft Ibs 47 54 Nm 35 40 ft lbs 47 54 Nm D I C JJ f 9 Plug Torgue Specifications e Description Hex size Torque SAE No 2 1 8 50 in Ibs 6 Nm SAE No 4 3 16 13 ft lbs 18 Nm SAE No 6 1 4 18 ft lbs 24 Nm Genie A TEREX COMPANY 7 46 S 40 5 45 Part No 72136 March 2008 Section 7 e Repair Procedures This page intentionally left blank A TEREX COMPANY Part No 72136 S 40 5 45 7 47 Section 7 Repair Procedures March 2008 MANIFOLDS REV B 11 4 Oscillate Manifold Components The oscillate manifold is mounted inside the drive chassis at the non steer end Index Schematic No Description Item Function Torque 1 Orifice plug 0 052 inch 1 32 mm MM Differential sensing circuit 2 Differential sensing valve NN Differential sensing 10 12 ft Ibs 14 16 Nm 3 Check valve OO Oscillate check left
336. ustries Service Department yes 12V Disconnect wht 24 wire from oil pressure sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained Disconnect wht 24 wire from engine temperature sender and check continuity to ground on signal post of sender while cranking the engine Is continuity maintained no Repair short to ground in wht 24 wire from sending units to TB24 to terminal 10 on ignition start module Disconnect red wire from terminal 4 on ignition start module and check voltage at terminal 4 oV Test auxiliary power toggle switches TS1 and TS9 See Repair Section yes yes 12V Check oil level OR replace oil pressure sending unit OR refer to Deutz or Perkins service manual for troubleshooting low oil pressure Check oil level OR replace engine temperature sending unit OR refer to Deutz or Perkins service manual for troubleshooting a overheated engine Replace ignition start module OR consult Genie Industries Service Department A TEREX COMPANY Part No 72136 Section 5 Troubleshooting Flow Charts March 2008 Chart 4 Engine Will Not Start On LPG But Will Start On Gasoline Gasoline LPG Models Be sure fuel select switch is switched to LPG Be sure the valve on the LPG tank is fully opened Be sure to check LPG fuel level See Repair Section How to Retr
337. ut disconnecting the wires With key switch turned to the OFF position and both Emergency Stop buttons pulled out to the ON position turn the key switch to ground controls and listen for the fuel pump to turn ON for approximately 2 seconds Did the fuel pump turn on See Ford LRG 425 service manual for fuel system troubleshooting OR consult Genie Industries Service Department REX COMPANY Check for poor terminal connections check for shorted or damaged wires that go from the ECM to the sensor that is causing the fault OR replace the sensor OR consult Genie Industries Service Department Replace fuel select toggle switch Replace the fuel pump relay B of the engine harness OR consult Genie Industries Service Department Repair open in fuel pump wires from fuel pump relay B of the engine harness OR replace the fuel pump REV B Refer to the fault code chart in this section for a description of the fault and recommended repairs S 40 S 45 Part No 72136 2008 Section 5 Troubleshooting Flow Charts REV Engine High Idle Inoperative Gasoline LPG Models See Repair Section How to Retrieve Fault Codes Is there a fault code stored in the ECM memory Start the engine then move and hold the RPM toggle switch to the high idle rabbit symbol position for the following tests Check voltage at blk red wire on RPM se
338. ve hubs Oil capacity per hub 17floz 0 5 liters Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Turntable Rotate Drive Hub motor brake mounting bolt motor drive hub drive hub mounting bolt plug brake 1 Secure the turntable from rotating with the turntable rotation lock pin 3 Remove the drive hub mounting bolts and use a lifting device to remove the drive hub from the machine unlocked locked 2 Remove the motor brake mounting bolts and then remove the motor and brake from the drive hub and set them to the side Component damage hazard ACAUTION Hoses can be damaged if they are kinked or pinched A TEREX COMPANY 4 64 S 40 5 45 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 4 Remove the plug from the side of the drive hub Then drain the oil from the hub 5 Install the drive hub Torque the hub mounting bolts to 180 ft lbs 244 Nm Install the brake and motor onto the drive hub 7 Fill the hub with oil from the side hole until the oil level is even with the bottom of the hole Apply pipe thread sealant to the plug and then install the plug Turntable rotate drive hub 8 fluid ounces 0 24 liters Oil capacity Type SAE 90 multipurpose hypoid gear oil API service classification GL5 Part No 72136 A TEREX S 40 S 45 MPANY CHECKLIST D PROCEDURES D
339. ve the upper retaining clip from the gas strut 3 Gently pry the strut pivot socket off of the ball stud and lower the strut Protect the strut cylinder rod from damage Mark the location of the hinge support bracket on the bulkhead to ensure proper cover alignment during installation 4 Remove the cover hinge bolts that fasten the hinge support bracket to the bulkhead A TEREX COMPANY REV A 5 Carefully lift and remove the cover from the machine AWARNING AWARNING Bodily injury hazard Safety decals are essential to safe machine operation Failure to replace all safety and instructional decals could result in death or serious injury If a turntable cover must be replaced be sure that all appropriate safety and instructional decals are applied to the new cover Crushing hazard The turntable cover could become unbalanced and fall if it is not properly supported and secured to an appropriate lifting device Alignment adjustments may be necessary when a new cover is installed S 40 5 45 Part No 72136 March 2008 Section 7 e Repair Procedures m Deutz F3L 1011F Engine 6 1 How to Remove the Flex Plate RPM Adjustment Refer to Maintenance Procedures B 11 Check and Adjust the Engine RPM 6 2 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump pump pump shaft coupl
340. y pressing apart the lips of the discharge slot Clean discharge slot as needed a airfilter b dust discharge valve 4 Clean the inside of the canister and the canister end cap with a damp cloth 5 Install the new filter element 6 Install the end cap onto the canister Secure the retaining fasteners Air filters Genie part numbers Ford LRG 425 EFI Engine 27916 Deutz F3L 1011F Engine 27916 Perkins 704 30 Engine 62420 Part No 72136 2008 Section 4 Scheduled Maintenance Procedures REV B 29 Replace the Spark Plugs Gasoline LPG Models Engine specifications reguires that this procedure be performed every 400 hours Periodic replacement of the spark plugs is essential to good engine performance and service life Worn loose or corroded spark plugs will cause the engine to perform poorly and may result in component damage Perform this procedure with the engine off 1 Remove the air baffle retaining fasteners Remove the air baffle 2 Remove the 2 engine pivot plate retaining bolts Swing the engine pivot plate away from the machine to access the spark plugs 3 Label then disconnect the plug wires from the spark plugs by grasping the handle on the spark plug boot Do not pull on the plug wire 4 Blow out any debris around spark plugs Remove all the spark plugs from the engine 6 Adjust the gap on each new spark plug Part No 72136 A TEREX S 40 S 45 MPA
341. y switch turned to ground controls and both Emergency Stop buttons pulled out to the ON position check voltage at the center terminal on the start toggle switch TS10 12V Move the start toggle switch to either side and check the voltage at either side terminal on start toggle switch 12V Move the start toggle switch to either side and check voltage at terminal TB33 12V Move the start toggle switch to either side and check voltage at terminal 3 on ignition start module 12V Check voltage at terminal 6 on the ignition start module 12V Continued on the next page REX COMPANY S 40 S 45 Genie REV B Check battery condition OR check alternator OR check battery cables OR replace the battery Trace circuit back through the key switch Emergency Stop button 2 Repair open Replace start toggle switch Repair open in blk wire circuit from start toggle switch to TB33 Repair open in blk wire circuit from TB33 to terminal 3 on ignition start module Repair open in red power supply wire circuit from CB1 to CR1 to CR2 then to terminal 6 to on ignition start module PartNo 72136 March 2008 Section 5 Troubleshooting Flow Charts REV B CHART 1 Move the start toggle Check ground wire to Repair open in brn switch to either side and terminal 5 on ignition ground wire to ignition check voltage at start module start m
342. ydraulic hose from the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to sguirt or spray 3 Remove the brake from the machine A TEREX COMPANY NON STEERING AXLE COMPONENTS Part No 72136 S 40 S 45 California Proposition 65 WARNING The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 0800 180 9017 Phone 49 422 149 1818 Fax 4494221491820 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 China Phone 86 21 53852570 Fax 86 21 53852569 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 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
343. yoke drive hub assembly on a flat surface with the drive hub facing down 14 Remove the drive hub mounting fasteners that attach the yoke to the drive hub Remove the yoke weldment from the drive hub Replace the thrust washer when installing the yoke drive hub assembly onto the axle Torgue specifications Lug nut torgue dry Lug nut torgue lubricated Before serial number 5370 Drive hub mounting bolts dry Drive hub mounting bolts lubricated Drive motor mounting bolts dry Drive motor mounting bolts lubricated After serial number 5369 Drive hub mounting bolts dry Drive hub mounting bolts lubricated Drive motor mounting bolts dry Drive motor mounting bolts lubricated Part No 72136 4WD STEERING AXLE COMPONENTS 15 2 Steering Cylinders How to Remove a Steering Cylinder This procedure is the same as the 2WD procedure See 14 2 How to Remove a Steering Cylinder orbs 5 3 230Nm Tie Rod 130 ft lbs i 176Nm How to Remove the Tie Rod This procedure is the same as the 2WD procedure See 14 3 1SOftlbs How to Remove the Tie Rod 203 Nm omps How to Perform the Toe in 149Nm Adjustment 75 ft lbs before serial number 3536 102 Nm This procedure is the same as the 2WD procedure 56 ft lbs See 14 3 76Nm Howto Perform the Toe in Adjustment 210 ft lbs 284 Nm 160 ft lbs 217 Nm 110 ft lbs 149 Nm 80 ft lbs 109 Nm S 40 S 45 7 73 Sec
344. zard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connection at the electronic displacement controller EDC located on the drive pump Part No 72136 A TEREX S 40 5 45 MPANY open closed Component damage hazard The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition CAUTION 3 Tagand disconnect and plug the hydraulic hoses from the drive and lift steer pumps Cap the fittings on the pumps Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 7 37 Section 7 Repair Procedures March 2008 HYDRAULIC PUMPS 5 Carefully pull t

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