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Service ManualSerial Number RangeS-40S-45TMfrom S40-7001 toS4012-17231TMPart No. 102521Rev EOctober 2013
IntroductionOctober 2013ImportantSerial Number InformationRead, understand and obey the safety rules andoperating instructions in the appropriate operator'smanual on your machine before attempting anymaintenance or repair procedure.Genie offers the following Service Manuals forthese models:This manual provides detailed scheduledmaintenance information for the machine owner anduser. It also provides troubleshooting fault codesand repair procedures for qualified serviceprofessionals.Basic mechanical, hydraulic and electrical skills arerequired to perform most procedures. However,several procedures require specialized skills, tools,lifting equipment and a suitable workshop. In theseinstances, we strongly recommend thatmaintenance and repair be performed at anauthorized Genie dealer service center.TitlePart No.S-40 and S-45 Service Manual(before serial number 3804) . 32222S-40 and S-45 Service Manual(from serial number 3804 to 4728) . 52271S-40 and S-45 Service Manual(from serial number 4729 to 7000) . 72136ComplianceMachine ClassificationGroup B/Type 3 as defined by ISO 16368Machine Design LifeUnrestricted with proper operation, inspection andscheduled maintenance.Technical PublicationsGenie has endeavored to deliver the highest degreeof accuracy possible. However, continuousimprovement of our products is a Genie policy.Therefore, product specifications are subject tochange without notice.Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.Copyright 2011 by Terex Industries102521 Rev E October 2013Fourth Edition, Fifth Printing"Genie" and "S" are registered trademarks ofTerex South Dakota, Inc. in the USA and manyother countries.Contact Us:Printed on recycled paperPrinted in U.S.A.http://www.genielift.come-mail: awp.techpub@terex.comiiS-40 S-45Part No. 102521
October 2013Revision HistoryRevisionDateSectionProcedure / Schematic Page / DescriptionD2/20122 - Spec.2-1, 2-2, 2-133 - Maint.3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-544 - Repair4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-606 - Schem.6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138,6-139, 6-150, 6-151, 6-1532 - Spec.2-1, 2-23 - Maint.3-9, 3-33 to 3-344 - Repair4-59 to 4-604- Repair4-36 - Schem.6-19, 6-29, 6-33, 6-93D1D210/101210/2013REFERENCE EXAMPLES:2-1 Section 2 Specifications Page #.3-3 Section 3 Maintenance Procedure Page #.4-48 Section 4 Repair Procedure Page #.Fault Codes Section 5.6-5 Section 6 Schematic Page #.Part No. 102521S-40 S-45Electronic VersionClick on any procedure or page numberhighlighted in blue to view the update.
October 2013REVISION HISTORY, CONTINUEDRevisionDateSectionProcedure / Schematic Page / DescriptionREFERENCE EXAMPLES:2-1 Section 2 Specifications Page #.3-3 Section 3 Maintenance Procedure Page #.4-48 Section 4 Repair Procedure Page #.Fault Codes Section 5.6-5 Section 6 Schematic Page #.S-40 S-45Electronic VersionClick on any procedure or page numberhighlighted in blue to view the update.Part No. 102521
October 2013Section 1 Safety RulesSerial Number LegendModel: S-40S4006-12345Serial number:Model year: 2006 Manufacture date: 01/05/06Electrical schematic number: ES0274Machine unladen weight:Rated work load (including occupants): 500 lb / 227 kgMaximum number of platfrm occupants: 2Maximum allowable side force : 150 lb / 670 NMaximum allowable inclination of the chassis:0 degMaximum wind speed : 28 mph/ 12.5 m/sMaximum platform height : 60 ft 6 in/ 18.3 mS40 06 - 12345SequencenumberModelMaximum platform reach : 34 ft 3 in/ 10.4 mGradeability: N/AModel yearCountry of manufacture: USAThis machine complies with:ANSI A92.5CAN B.354.4Genie Industries18340 NE 76th StreetRedmond, WA 98052USASequence number(stamped on chassis)Serial label(located under cover)PN - 77055Part No. 102521S-40 S-45iii
Section 1 Safety RulesJuly 2007This page intentionally left blank.ivS-40 S-45Part No. 102521
July 2007Section 1 Safety RulesSafety RulesDangerFailure to obey the instructions and safety rules inthis manual, and the Genie S-40 and S-45Operator's Manual will result in death or seriousinjury.Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.Do Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this machine.You read, understand and obey:- manufacturer’s instructions and safety rules- employer’s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, lifting equipmentand a suitable workshop.Part No. 102521S-40 S-45v
Section 1 Safety RulesJuly 2007SAFETY RULESBe sure to wear protective eye wear andother protective clothing if the situationwarrants it.Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.Read each procedure thoroughly. Thismanual and the decals on the machine usesignal words to identify the following:Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inminor or moderate injury.Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads. Always wear approved steel-toedshoes.Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy reach.Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and freeof debris that could get into machine componentsand cause damage.Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second time.Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.Be sure that your workshop or work areais properly ventilated and well lit.viS-40 S-45Part No. 102521
October 2013Table of ContentsIntroductionImportant Information . iiSerial Number Legend . ivSection 1Safety RulesGeneral Safety Rules . vSection 2RevSpecificationsMachine Specifications . 2 - 1Hydraulic Oil Specifications . 2 - 2Manifold Component Specifications . 2 - 5Valve Coil Resistance Specifications . 2 - 5Ford LRG-425 EFI Engine Specifications . 2 - 6Ford DSG-423 EFI Engine Specifications . 2 - 7Deutz F3L-1011F Engine Specifications . 2 - 8Deutz F3L-2011/Deutz D2011L03i Engine Specifications . 2 - 9Perkins 704-30 Engine Specifications . 2 - 10Perkins 404-22 Engine Specifications . 2 - 11Machine Torque Specifications . 2 - 12Hydraulic Hose and Fitting Torque Specifications . 2 - 13SAE and Metric Fastener Torque Chart . 2 - 14Section 3RevScheduled Maintenance ProceduresIntroduction . 3 - 1Pre-Delivery Preparation . 3 - 3Maintenance Inspection Report . 3 - 5Checklist A ProceduresPart No. 102521A-1Inspect the Decals and Manuals . 3 - 7A-2Perform Pre-operation Inspection . 3 - 8A-3Perform Function Tests . 3 - 8A-4Perform Engine Maintenance . 3 - 9S-40 S-45vii
October 2013TABLE OF CONTENTSSection 3RevScheduled Maintenance Procedures, continuedA-5Inspect the Track Components, TRAX option . 3 - 9A-6Perform 30 Day Service . 3 - 10A-7Perform Engine Maintenance - Deutz and Ford Models . 3 - 10A-8Replace the Drive Hub Oil . 3 - 11A-9Perform Engine Maintenance - Perkins Models . 3 - 12A-10 Inspect the Fuel Filter/Water Separator - Diesel Models . 3 - 12A-11 Perform Engine Maintenance - Ford Models . 3 - 13A-12 Grease the Turntable Rotation Bearing and Rotate Gear . 3 - 14A-13 Perform Engine Maintenance - Deutz 1011F Models . 3 - 14A-14 Perform Engine Maintenance - Ford Models . 3 - 15Checklist B ProceduresB-1Inspect the Battery . 3 - 16B-2Inspect the Electrical Wiring . 3 - 17B-3Inspect the Air Filter . 3 - 18B-4Test the Key Switch . 3 - 19B-5Perform Engine Maintenance - Deutz and Perkins Models . 3 - 19B-6Check the Exhaust System . 3 - 20B-7Check the Oil Cooler and Cooling Fins - Deutz Models . 3 - 20B-8Inspect the Tires, Wheels and Lug Nut Torque . 3 - 21B-9Check the Drive Hub Oil Level and Fastener Torque . 3 - 22B-10 Confirm the Proper Brake Configuration . 3 - 23B-11 Check and Adjust the Engine RPM . 3 - 24B-12 Test the Engine Idle Select . 3 - 25B-13 Test the Fuel Select Operation - Ford Models . 3 - 26B-14 Test the Ground Control Override . 3 - 27B-15 Check the Directional Valve Linkeage . 3 - 27B-16 Test the Platform Self-leveling . 3 - 28viiiS-40 S-45Part No. 102521
October 2013TABLE OF CONTENTSSection 3RevScheduled Maintenance Procedures, continuedB-17 Test the Drive Brakes . 3 - 28B-18 Test the Drive Speed - Stowed Position . 3 - 29B-19 Test the Drive Speed - Raised or Extended Position . 3 - 29B-20 Perform Hydraulic Oil Analysis . 3 - 30B-21 Test the Alarm Package (if equipped) and the Descent Alarm . 3 - 31B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System . 3 - 32B-23 Check the Track Tension and Fastener Torque - TRAX Option . 3 - 33B-24 Perform Engine Maintenance - Ford Models . 3 - 34Checklist C ProceduresC-1Perform Engine Maintenance - Deutz and Perkins Models . 3 - 35C-2Grease the Platform Overload Mechanism (if equipped) . 3 - 36C-3Test the Platform Overload Mechanism (if equipped) . 3 - 36C-4Replace the Engine Air Filter - Deutz and Perkins Models . 3 - 39C
Service Manual Part No. 102521 Rev E October 2013 Serial Number Range from S40-7001 to S-40 S4012-17231 S-45 TM TM
