Genie S-40 TRAX User manual

Service Manual
Part No. 102521
Rev A
January 2005
Refer to inside cover for serial number information

Genie S-40 and S-45 Part No. 102521
January 2005
ii
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the Genie S-40 and S-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 qualified service
professionals.
Basic mechanical, hydraulic and electrical skills
are required to perform most procedures.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
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://www.genielift.com
e-mail:[email protected]
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 no. 7001)......................................... 72136
Copyright © 2003 by Genie Industries
102521 Rev A January 2005
First Edition, First Printing
"Genie" and "S" are registered trademarks of
Genie Industries in the USA and many other
countries.
Printed on recycled paper
Printed in U.S.A.

Part No. 102521 Genie S-40 and S-45
January 2005
iii
Safety Rules
Section 1 • Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Genie S-40 and S-45 Part No. 102521
January 2005
SAFETY RULES
iv
Section 1 • Safety Rules
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
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
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
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.
Green—used to indicate operation
or maintenance information.
Workplace Safety
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Be sure to keep sparks, flames and
lighted tobacco away from flammable
and combustible materials like battery
gases and engine fuels. Always have an approved
fire extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

Part No. 102521 Genie S-40 and S-45
January 2005
Table of Contents
v
Introduction
ImportantInformation .................................................................................................. ii
Section 1 Safety Rules
General Safety Rules ................................................................................................. iii
Section 2 Rev Specifications
A Machine Specifications.......................................................................................... 2 - 1
A Hydraulic Specifications ........................................................................................ 2 - 2
A Manifold Component Specifications ...................................................................... 2 - 4
A Machine Torque Specifications.............................................................................. 2 - 4
A Ford LRG-425 EFI Engine Specifications.............................................................. 2 - 5
A Deutz F3L-1011F Engine Specifications................................................................ 2 - 6
A Deutz F4L-1011F Engine Specifications................................................................ 2 - 7
A Deutz F3L-2011 Engine Specifications.................................................................. 2 - 8
A Perkins 704-30 Engine Specifications ................................................................... 2 - 9
A Perkins 404-22 Engine Specifications ................................................................. 2 - 10
A Hydraulic Hose and Fitting Torque Specifications ............................................... 2 - 12
Section 3 Rev Scheduled Maintenance Procedures
Introduction ........................................................................................................... 3 - 1
Pre-Delivery Preparation ....................................................................................... 3 - 3
Maintenance Inspection Report ............................................................................. 3 - 5
AChecklist A Procedures
A-1 Perform Pre-operation Inspection ................................................................ 3 - 7
A-2 Perform Function Tests ............................................................................... 3 - 7
A-3 Perform Engine Maintenance - Deutz Models.............................................. 3 - 8
A-4 Perform Engine Maintenance - Ford Models................................................ 3 - 8
A-5 Perform Engine Maintenance - Perkins Models ........................................... 3 - 9
A-6 Drain the Fuel Filter/Water Separator - Diesel Models................................. 3 - 9

Genie S-40 and S-45 Part No. 102521
January 2005
TABLE OF CONTENTS
vi
Section 3 Rev Scheduled Maintenance Procedures, continued
A-7 Check for Fuel Leaks................................................................................. 3 - 10
A-8 Check the High Pressure Hydraulic Filter Condition Indicator.................... 3 - 11
A-9 Test the Oscillate Axle (if equipped) .......................................................... 3 - 11
A-10 Perform 30 Day Service............................................................................. 3 - 12
A-11 Perform Engine Maintenance - Deutz Models............................................ 3 - 12
A-12 Perform Engine Maintenance - Ford and Perkins Models.......................... 3 - 13
A-13 Inspect the Fuel Filter/Water Separator - Diesel Models............................ 3 - 13
A-14 Check and Adjust the Engine RPM - Perkins Models ................................ 3 - 15
A-15 Grease the Turntable Rotation Bearing and Rotate Gear .......................... 3 - 16
A-16 Perform Engine Maintenance - Deutz 1011F Models................................. 3 - 17
A-17 Perform Engine Maintenance - Ford Models.............................................. 3 - 17
AChecklist B Procedures
B-1 Inspect the Battery..................................................................................... 3 - 18
B-2 Inspect the Electrical Wiring....................................................................... 3 - 19
B-3 Perform Engine Maintenance - Deutz 1011F Models................................. 3 - 20
B-4 Check the Exhaust System........................................................................ 3 - 20
B-5 Check the Oil Cooler and Cooling Fins - Deutz Models ............................. 3 - 21
B-6 Inspect the Tire and Wheels (including lug nut torque) .............................. 3 - 22
B-7 Confirm the Proper Brake Configuration .................................................... 3 - 22
B-8 Check the Oil Level in the Drive Hubs ....................................................... 3 - 23
B-9 Check and Adjust the Engine RPM - Deutz Models................................... 3 - 23
B-10 Test the Engine Idle Select ........................................................................ 3 - 24
B-11 Test the Fuel Select Operation - Ford Models ........................................... 3 - 25
B-12 Test the Drive Brakes ................................................................................ 3 - 26
B-13 Test the Drive Speed - Stowed Position .................................................... 3 - 27
B-14 Test the Drive Speed - Raised or Extended Position ................................. 3 - 27
B-15 Perform Hydraulic Oil Analysis .................................................................. 3 - 28
B-16 Replace Hydraulic Filters ........................................................................... 3 - 28

Part No. 102521 Genie S-40 and S-45
January 2005
TABLE OF CONTENTS
vii
Section 3 Rev Scheduled Maintenance Procedures, continued
B-17 Replace the Fuel Filter/Water Separator Element - Perkins Models .......... 3 - 30
B-18 Test the Alarm Package (if equipped)........................................................ 3 - 32
B-19 Perform Engine Maintenance - Deutz Models............................................ 3 - 33
B-20 Perform Engine Maintenance - Ford Models.............................................. 3 - 33
B-21 Perform Engine Maintenance - Perkins Models ......................................... 3 - 34
AChecklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models............................................ 3 - 35
C-2 Grease the Platform Overload Mechanism (if equipped) ........................... 3 - 35
C-3 Test the Platform Overload Mechanism (if equipped) ................................ 3 - 36
C-4 Perform Engine Maintenance - Perkins Models ......................................... 3 - 38
C-5 Perform Engine Maintenance Ford Models................................................ 3 - 38
AChecklist D Procedures
D-1 Check the Boom Wear Pads ..................................................................... 3 - 39
D-2 Check the Turntable Rotation Bearing Bolts .............................................. 3 - 39
D-3 Check the Free-wheel Configuration.......................................................... 3 - 41
D-4 Replace the Drive Hub Oil ......................................................................... 3 - 42
D-5 Check and Adjust the Air/LPG Mixture - Ford Models................................ 3 - 43
D-6 Perform Engine Maintenance - Deutz Models............................................ 3 - 44
D-7 Calibrate the Platform Overload System (if equipped) ............................... 3 - 44
D-8 Replace the Hydraulic Filters ..................................................................... 3 - 46
AChecklist E Procedures
E-1 Test or Replace the Hydraulic Oil .............................................................. 3 - 47
E-2 Perform Engine Maintenance - Deutz Models............................................ 3 - 49
E-3 Perform Engine Maintenance - Deutz Models............................................ 3 - 49

Genie S-40 and S-45 Part No. 102521
January 2005
Section 4 Rev Repair Procedures
Introduction ........................................................................................................... 4 - 1
APlatform Controls
1-1 ALC-500 Circuit Board................................................................................. 4 - 2
1-2 Joysticks...................................................................................................... 4 - 3
APlatform Components
2-1 Platform Leveling Slave Cylinder ................................................................. 4 - 7
2-2 Platform Rotator........................................................................................... 4 - 8
AJib Boom Components
3-1 Jib Boom.................................................................................................... 4 - 10
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 11
ABoom Components
4-1 Cable Track ............................................................................................... 4 - 12
4-2 Boom ......................................................................................................... 4 - 14
4-3 Boom Lift Cylinder ..................................................................................... 4 - 15
4-4 Boom Extension Cylinder .......................................................................... 4 - 16
4-5 Platform Leveling Master Cylinder ............................................................. 4 - 17
AEngines
5-1 RPM Adjustment - Deutz Models............................................................... 4 - 18
5-2 RPM Adjustment - Perkins Models ............................................................ 4 - 18
5-3 Flex Plate................................................................................................... 4 - 18
5-4 Engine Fault Codes - Ford Models ............................................................ 4 - 20
AHydraulic Pumps
6-1 Function Pump .......................................................................................... 4 - 21
6-2 Drive Pump................................................................................................ 4 - 22
viii
TABLE OF CONTENTS

Part No. 102521 Genie S-40 and S-45
January 2005
Section 4 Rev Repair Procedures, continued
AManifolds
7-1 Function Manifold Components ................................................................. 4 - 24
7-2 Valve Adjustments - Function Manifold...................................................... 4 - 28
7-3 Jib Select and Platform Rotate Manifold Components ............................... 4 - 29
7-4 Brake Manifold Components
(before serial no. 7569).............................................................................. 4 - 30
7-5 Brake/Two-Speed Manifold Components
(after serial no. 7568)................................................................................. 4 - 31
7-6 Oscillate Directional Valve Manifold Components...................................... 4 - 32
7-7 Valve Adjustments, Oscillate Relief Valve ................................................. 4 - 34
7-8 Traction Manifold Components, 2WD (before serial no. 7569)................... 4 - 35
7-9 Traction Manifold Components, 2WD (after serial no. 7568)...................... 4 - 36
7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 37
7-11 Traction Manifold Components, 4WD (before serial no. 7569)................... 4 - 38
7-12 Traction Manifold Components, 4WD (after serial no. 7568)...................... 4 - 40
7-13 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 42
7-14 Valve Coils................................................................................................. 4 - 43
ATurntable Rotation Components
8-1 Turntable Rotation Assembly..................................................................... 4 - 45
AAxle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 47
ix
TABLE OF CONTENTS

Genie S-40 and S-45 Part No. 102521
January 2005
TABLE OF CONTENTS
Section 5 Rev Fault Codes
Introduction ........................................................................................................... 5 - 1
A Fault Codes - Control System ............................................................................... 5 - 2
A Fault Codes - Ford Engine .................................................................................... 5 - 6
Section 6 Rev Schematics
Introduction ........................................................................................................... 6 - 1
A Electrical Symbols Legend .................................................................................... 6 - 2
A Electrical Schematic, Deutz F3L 1011 Models (before serial no. 7544)................. 6 - 4
A Ground Control Box Wiring Diagram,
Deutz F3L 1011 Models (before serial no. 7544) ......................................... 6 - 6
A Platform Control Box Wiring Diagram,
Deutz F3L 1011 Models (before serial no. 7544) ......................................... 6 - 7
A Electrical Schematic, Perkins 704-30 Models (before serial no. 7472) .................. 6 - 9
A Ground Control Box Wiring Diagram,
Perkins 704-30 Models (before serial no. 7472) ........................................ 6 - 11
A Platform Control Box Wiring Diagram,
Perkins 704-30 Models (before serial no. 7472) ........................................ 6 - 12
A Electrical Schematic, Ford LRG-425 EFI Models (before serial no. 7597 ).......... 6 - 14
A Ground Control Box Wiring Diagram,
Ford LRG-425 EFI Models (before serial no. 7597 ) .................................. 6 - 16
A Platform Control Box Wiring Diagram,
Ford LRG-425 EFI Models (before serial no. 7597 ) .................................. 6 - 17
A Hydraulic Schematic, 2WD Non-oscillating S-40 Models
(before serial no. 7569).............................................................................. 6 - 19
A Hydraulic Schematic, 2WD Non-oscillating S-45 Models
(before serial no. 7569).............................................................................. 6 - 20
A Hydraulic Schematic, 2WD Oscillating S-40 Models (before serial no. 7569)...... 6 - 21
A Hydraulic Schematic, 2WD Oscillating S-45 Models (before serial no. 7569)...... 6 - 22
A Electrical Schematic, Deutz F3L 2011 Models (after serial no. 7543).................. 6 - 23
A Ground Control Box Wiring Diagram,
Deutz F3L 2011 Models (after serial no. 7543) .......................................... 6 - 25
A Platform Control Box Wiring Diagram,
Deutz F3L 2011 Models (after serial no. 7543) .......................................... 6 - 26
x

Part No. 102521 Genie S-40 and S-45
January 2005
TABLE OF CONTENTS
xi
Section 6 Rev Schematics, continued
A Electrical Schematic, Perkins 404-22 Models (after serial no. 7471) ................... 6 - 28
A Ground Control Box Wiring Diagram,
Perkins 404-22 Models (after serial no. 7471) ........................................... 6 - 30
A Platform Control Box Wiring Diagram,
Perkins 404-22 Models (after serial no. 7471) ........................................... 6 - 31
A Electrical Schematic, Ford LRG-425 EFI Models (after serial no. 7596).............. 6 - 33
A Ground Control Box Wiring Diagram,
Ford LRG-425 EFI Models (after serial no. 7596) ...................................... 6 - 35
A Platform Control Box Wiring Diagram,
Ford LRG-425 EFI Models (after serial no. 7596) ...................................... 6 - 36
A Hydraulic Schematic, 2WD (after serial no. 7568) ............................................... 6 - 38
A Hydraulic Schematic, 4WD (after serial no. 7568) ............................................... 6 - 39

Genie S-40 and S-45 Part No. 102521
January 2005
This page intentionally left blank.

Part No.102521 Genie S-40 and S-45 2 - 1
Section 2 • SpecificationsJanuary 2005
REV A Specifications
Machine Specifications
S-40 Models
Tires and wheels
Tire size, 2WD
front tires only 12.5L-16SL
rear tires only 12-16.5 NHS
Tire size,
2WDRT & 4WD front & rear 12-16.5 NHS
Tire ply rating 12 8
Tire contact area 88 sq in 57 sq in
568 sq cm 368 sq cm
Overall tire diameter 33.7 in 33.2 in
85.6 cm 84.3 cm
Tire pressure 45 psi 45 psi
3.1 bar 3.1 bar
Wheel diameter 16 in 161/2in
40.6 cm 41.9 cm
Wheel width 10 in 9 3/4in
25.4 cm 24.8 cm
Wheel lugs 8@ 5/8 -18 9@ 5/8 -18
Lug nut torque, dry 125 ft-lbs 169.5 Nm
Lug nut torque, lubricated 94 ft-lbs 127.4 Nm
Fluid capacities
Fuel tank 30 gallons
114 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 50 gallons
(including tank) 189 liters
Drive hubs 17 fl oz
0.5 liters
Turntable rotation 8 fl oz
drive hub 0.24 liters
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
Machine Specifications
S-45 Models
Tires and wheels
Tire size, 2WD
front tires only 12.5L-16SL
rear tires only 12-16.5 NHS
Tire size,
2WDRT & 4WD front & rear 12-16.5
NHS
Tire ply rating 12 8
Tire contact area 88 sq in 57 sq in
568 sq cm 368 sq cm
Overall tire diameter 33.7 in 33.2 in
85.6 cm 84.3 cm
Tire pressure 45 psi 45 psi
3.1 bar 3.1 bar
Wheel diameter 16 in 161/2in
40.6 cm 41.9 cm
Wheel width 10 in 9 3/4in
25.4 cm 24.8 cm
Wheel lugs 8@ 5/8 -18 9@ 5/8 -18
Lug nut torque, dry 125 ft-lbs 169.5 Nm
Lug nut torque, lubricated 94 ft-lbs 127.4 Nm
Fluid capacities
Fuel tank 30 gallons
114 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 50 gallons
(including tank) 189 liters
Drive hubs 17 fl oz
0.5 liters
Turntable rotation 8 fl oz
drive hub 0.24 liters
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.

2 - 2 Genie S-40 and S-45 Part No.102521
Section 2 • Specifications January 2005
REV ASPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalent
Approximate SAE grade 5W-20
Viscosity index rating 200
Chevron Rykon MV oil is fully compatible and
mixable with Shell Donax TG (Dexron III) oils.
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and have a minimum viscosity index
rating of 150. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus T32
Shell Tellus T46
Chevron Aviation A
Genie specifications require
additional equipment and special
installation instructions for the
approved optional fluids. Consult
the Genie Industries Service
Department before use.
Performance Specifications
All Models
Drive speeds, maximum 2WD 4WD
Drive speed, stowed 4 mph 3.5 mph
Gasoline/LPG models 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 3.5 mph 3 mph
Deutz Diesel models 5.6 km/h 4.8 km/h
40 ft/7.8 sec 40 ft/9.1 sec
12.2 m/7.8 sec12.2 m/9.1 sec
Drive speed, 0.6 mph 0.6 mph
raised or extended 1 km/h 1 km/h
- all models 40 ft/40 sec 40 ft/40 sec
12.2 m/40 sec 12.2 m/40 sec
Gradeability (boom stowed) 2WD 4WD
Rough terrain 30% 40%
Boom function speeds, maximum
from platform controls
Boom up 40 to 60 seconds
Boom down 50 to 80 seconds
Boom extend 30 to 60 seconds
Boom retract 25 to 55 seconds
Turntable rotate, 360°
boom fully stowed 70 to 110 seconds
Platform rotate, 160° 6 to 20 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 30 seconds
Braking distance, maximum
High range on paved surface 3 to 4 ft
0.9 to 1.2 m

Part No.102521 Genie S-40 and S-45 2 - 3
Section 2 • SpecificationsJanuary 2005
REV A SPECIFICATIONS
Drive pump
Type: piston - hydrostatic transmission
Displacement - 2500 rpm 0 to 30 gallons per minute
0 to 113.6 liters per minute
Maximum drive pressure 3625 psi
249.9 bar
Charge pump
Type: fixed displacement
Displacement - static .85 cu in
14 cc
Charge pressure 313 psi 22 bar
Displacement - 2500 rpm 9 gallons per minute
34.1 liters per minute
Filters
Medium pressure filter Beta 3 ³200
Medium pressure filter 51 psi
bypass pressure 3.5 bar
Hydraulic tank circuit 10 micron with
return line filter 25 psi / 1.7 bar bypass
Drive manifold
Brake relief pressure 250 psi
17.2 bar
Steer end drive motors 4WD models
4WD front motor 2.5 to 8 gallons per minute
flow regulators 9.4 to 30.2 liters per minute
4WD rear motor 5 to 15 gallons per minute
flow regulators 18.9 to 56.7 liters per minute
2WD rear motor 8 to 22 gallons per minute
flow regulators 30.2 to 83.2 liters per minute
Front drive motors 4WD models
Displacement
per revolution 1.52 cu in 25 cc
Non-steer end drive motors
Displacement
per revolution 2.13 cu in 35 cc
Function pump
Type: pressure balanced gear
Pump one (inter)
Displacement - static 1.02 cu in
17 cc
Displacement - 2500 rpm 11 gallons per minute
41.6 liters per minute
Pump two
Displacement - static 0.25 cu in
4.1 cc
Displacement - 2500 rpm 3 gallons per minute
11.4 liters per minute
Function manifold
Function relief valve pressure
S-40 2600 psi 179 bar
S-45 2900 psi 200 bar
Boom down 2200 psi
relief valve pressure 152 bar
Boom extend 1950 psi
134 bar
Oscillate axle 950 psi
66 bar
Steer regulator, 2 gallons per minute
All models 7.6 liters per minute
Auxiliary pump
Type: fixed displacement gear pump
Displacement - static 0.152 cu in
2.5 cc
Displacement 1.4 gallons per minute
5.3 liters per minute
Oscillate Pump
Displacement - static 0.26 cu in
4.3 cc
Displacement - 2500 rpm 2.8 gallons per minute
10.6 liters per minute

2 - 4 Genie S-40 and S-45 Part No.102521
Section 2 • Specifications January 2005
REV ASPECIFICATIONS
Manifold Component
Specifications
Plug torque
SAE No. 2 50 in-lbs / 6 Nm
SAE No. 4 13 ft-lbs / 18 Nm
SAE No. 6 18 ft-lbs / 24 Nm
SAE No. 8 50 ft-lbs / 68 Nm
SAE No. 10 55 ft-lbs / 75 Nm
SAE No. 12 75 ft-lbs / 102 Nm
Machine Torque Specifications
Platform rotator
1-8 center bolt 480 ft-lbs
651 Nm
3/8-16 bolts 47 ft-lbs
63.7 Nm
Drive motor and hubs
Drive hub mounting bolts, dry 220 ft-lbs
299 Nm
Drive hub mounting bolts, lubricated 170 ft-lbs
231 Nm
Drive motor mounting bolts, dry 50 ft-lbs
68 Nm
Drive motor mounting bolts, lubricated 38 ft-lbs
52 Nm
Turntable bearing
Turntable bearing mounting bolts, dry 220 ft-lbs
298 Nm
Turntable bearing mounting bolts, lubricated 170 ft-lbs
230 Nm

Part No.102521 Genie S-40 and S-45 2 - 5
Section 2 • SpecificationsJanuary 2005
REV A SPECIFICATIONS
Ford LRG-425 EFI Engine
Displacement 153 cu in
2.5 liters
Number of cylinders 4
Bore & stroke 3.78 x 3.4 inches
96.01 x 86.36 mm
Horsepower,
gross intermittent 97
continuous 82
horsepower @ 2500 rpm 70
Firing order 1 - 3 - 4 - 2
Low idle (computer controlled) 1600 rpm
320 Hz
High idle (computer controlled) 2500 rpm
500 Hz
Compression ratio 9.4:1
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be
at least 75% of highest cylinder
Valve clearances - 0.035 to 0.055 inches
collapsed tappet 0.889 to 1.397 mm
Lubrication system
Oil pressure 40 to 60 psi
(operating temperature @ 2500 rpm) 2.75 to 4.1 bar
Oil capacity 4.5 quarts
(including filter) 4.3 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
Temperature above 20W-40 or 20W-50
20°F / -6.6°C
Use oils meeting API classification SG (labeled SG/CC
or SG/CD) as they offer improved wear protection.
Units ship with 10W-40 SG/CC.
Starter motor
Normal engine cranking speed 200 to 250 rpm
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 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 930A
Reserve capacity @ 25A rate 175 minutes
Electronic fuel pump
Fuel pressure, static 63 psi
4.3 bar
Fuel flow rate 0.58 gpm
2.2 L/min
Ignition System
Spark plug type Motorcraft AWSF-52-C
(before serial no. 7597)
Spark plug type Motorcraft AGSF-32-FM
(after serial no. 7596)
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.17 mm
Engine coolant
Capacity 11.5 quarts
10.9 liters
Alternator
Output 95A, 14.5V DC

2 - 6 Genie S-40 and S-45 Part No.102521
Section 2 • Specifications January 2005
REV ASPECIFICATIONS
Injection system
Injection pump make OMAP
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement 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 930A
Reserve capacity @ 25A rate 175 minutes
Fan belt deflection 3/8to 1/2inch
9 to 12 mm
Deutz F3L 1011F Engine
Displacement 125 cu in
2.05 liters
Number of cylinders 3
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 36 @ 3000 rpm
Firing order 1 - 2 - 3
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1500 rpm
High idle 2300 rpm
Governor centrifugal mechanical
Valve clearance, cold
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 requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification
SG/CC or CD/SG grades.
Units ship with 10W-40 SG/CC.

Part No.102521 Genie S-40 and S-45 2 - 7
Section 2 • SpecificationsJanuary 2005
REV A SPECIFICATIONS
Deutz F4L 1011F Engine
Displacement 166.7 cu in
2.732 liters
Number of cylinders 4
Bore and stroke 3.58 x 4.13 inches
91 x 105 mm
Horsepower 56 @ 3000 rpm
Firing order 1 - 3 - 4 - 2
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Low idle 1200 rpm
High idle 2200 rpm
Governor centrifugal mechanical
Valve clearance, cold
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 11 quarts
(including filter) 10.5 liters
Oil viscosity requirements
Temperature below 60°F / 15.5°C (synthetic) 5W-30
-10°F to 90°F / -23°C to 32°C 10W-40
Temperature above -4°F / -34°C 15W-40
Engine oil should have properties of API classification
CC/SE, CD/SE, CC/SF or CD/SF grades.
Injection system
Injection pump make OMAP
Injection pump pressure 4351 psi
300 bar
Injector opening pressure 3626 psi
250 bar
Fuel requirement diesel number 2-D
Alternator output 55A, 14V
Starter motor
Current draw, no load 90A
Brush length, new 0.7480 in
19mm
Brush length, minimum 0.5 in
12.7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 930A
Reserve capacity @ 25A rate 175 minutes
Fan belt deflection 3/8to 1/2inch
9 to 12 mm

2 - 8 Genie S-40 and S-45 Part No.102521
Section 2 • Specifications January 2005
REV A
SPECIFICATIONS
Deutz F3L 2011 Engine
Displacement 142 cu in
2.33 liters
Number of cylinders 3
Bore and stroke 3.7 x 4.409 inches
94 x 112 mm
Horsepower 48 @ 2800 rpm
Firing order 1 - 2 - 3
Low idle 1500 rpm
High idle 2500 rpm
Compression ratio 18.5:1
Compression pressure 362 to 435 psi
25 to 30 bar
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 20 to 44 psi
1.4 to 3 bar
Oil capacity 7.6 quarts
(including filter) 8 liters
Oil viscosity requirements
-22° F to 86° F/ -30° C to 30° C 5W-30
(synthetic)
-4° F to 90° F / -20° C to 32° C 10W-40
Above 23° F / -5° C 20W-50
Engine oil should have minimum properties of API
classification CC/SG or CD/SG grades.
Units ship with 10W-40 CH-4
Oil temperature switch
Torque 8-18 ft-lbs
11-24 Nm
Temperature switch point 220° F
104° C
Oil pressure switch
Torque 8-18 ft-lbs
11-24 Nm
Oil pressure switch point 15 psi
1 bar
Fuel injection system
Injection pump make Bosch
Injection pump pressure, maximum 15000 psi
1034 bar
Injector opening pressure 3046 psi
210 bar
Fuel requirement #2 Diesel
Starter motor
Current draw, no load 90A
Brush length, new 0.72 in
18.5 mm
Brush length, minimum 0.27 in
7 mm
Battery
Type 12V, Group 31
Quantity 1
Cold cranking ampere 930A
Reserve capacity @ 25A rate 175 minutes
Alternator output 60A @ 14V DC
Fan belt deflection 3/8to 1/2inch
9 to 12 mm