Genie S-40 TRAX User manual

Service Manual
Part No. 102521
Rev E
October 2013
Serial Number Range
from S40-7001 to
S4012-17231
S-40
S-45
TM
TM
Property of American Airlines

S-40 • S-45 Part No.102521
October 2013
ii
Introduction
Serial Number Information
Genie offers the following Service Manuals for
these models:
Title Part No.
S-40 and S-45 Service Manual
(before serial number 3804) ................................ 32222
S-40 and S-45 Service Manual
(from serial number 3804 to 4728) .......................52271
S-40 and S-45 Service Manual
(from serial number 4729 to 7000) .......................72136
Copyright © 2011 by Terex Industries
102521 Rev E October 2013
Fourth Edition, Fifth Printing
"Genie" and "S" are registered trademarks of
Terex South Dakota, Inc. in the USA and many
other countries.
Printed on recycled paper
Printed in U.S.A.
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate operator's
manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner and
user. It also provides troubleshooting fault codes
and repair procedures for qualified service
professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Property of American Airlines

Part No.102521 S-40 • S-45
October 2013
Revision Date Section Procedure / Schematic Page / Description
D 2/2012 2 - Spec. 2-1, 2-2, 2-13
3 - Maint. 3-1, 3-3, 3-9 to 3-15, 3-17, 3-35 to 3-38, 3-54
4 - Repair 4-4, 4-5, 4-6, 4-7, 4-48, 4-49, 4-50, 4-51, 4-60
6 - Schem. 6-4, 6-5, 6-32 to 6-64, 6-92 to 6-125, 6-138,
6-139, 6-150, 6-151, 6-153
D1 10/1012 2 - Spec. 2-1, 2-2
3 - Maint. 3-9, 3-33 to 3-34
4 - Repair 4-59 to 4-60
D2 10/2013 4- Repair 4-3
6 - Schem. 6-19, 6-29, 6-33, 6-93
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.
3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #.
Fault Codes_Section 5.
6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Revision History
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S-40 • S-45 Part No.102521
October 2013
REVISION HISTORY, CONTINUED
Revision Date Section Procedure / Schematic Page / Description
REFERENCE EXAMPLES:
2-1_Section 2_Specifications Page #.
3-3_Section 3_Maintenance Procedure Page #.
4-48_Section 4_Repair Procedure Page #.
Fault Codes_Section 5.
6-5_Section 6_Schematic Page #.
Electronic Version
Click on any procedure or page number
highlighted in blue to view the update.
Property of American Airlines

Part No.102521 S-40 • S-45
October 2013
S40 06 - 12345
Model
Model year
Sequence
number
PN - 77055
Country of manufacture: USA
This machine complies with:
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
ANSI A92.5
CAN B.354.4
Model: S-40
Serial number: S4006-12345
Electrical schematic number: ES0274
Machine unladen weight:
Rated work load (including occupants): 500 lb / 227 kg
Maximum allowable inclination of the chassis:
0deg
Gradeability: N/A
Maximum allowable side force : 150lb/670N
Maximum number of platfrm occupants: 2
Model year: Manufacture date: 01/05/06
2006
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 60 ft 6 in/ 18.3 m
Maximum platform reach : 34 ft 3 in/ 10.4 m
Sequence number
(stamped on chassis)
Serial label
(located under cover)
iii
Section 1 • Safety Rules
Serial Number Legend
Property of American Airlines

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

Part No.102521 S-40 • S-45
July 2007 Section 1 • Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules in
this manual, and the Genie S-40 and S-45
Operator's Manual will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting equipment
and a suitable workshop.
v
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S-40 • S-45 Part No.102521
July 2007
vi
SAFETY RULES
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine use
signal words to identify the following:
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may result in
property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Workplace Safety
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine components
and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self-locking
nuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.
Section 1 • Safety Rules July 2007
Property of American Airlines

Part No.102521 S-40 • S-45
October 2013
Table of Contents
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iv
Section 1 Safety Rules
General Safety Rules .................................................................................................. v
Section 2 Rev Specifications
Machine Specifications .......................................................................................... 2 - 1
Hydraulic Oil Specifications ................................................................................... 2 - 2
Manifold Component Specifications ....................................................................... 2 - 5
Valve Coil Resistance Specifications ..................................................................... 2 - 5
Ford LRG-425 EFI Engine Specifications ............................................................... 2 - 6
Ford DSG-423 EFI Engine Specifications .............................................................. 2 - 7
Deutz F3L-1011F Engine Specifications ................................................................ 2 - 8
Deutz F3L-2011/Deutz D2011L03i Engine Specifications ....................................... 2 - 9
Perkins 704-30 Engine Specifications .................................................................. 2 - 10
Perkins 404-22 Engine Specifications .................................................................. 2 - 11
Machine Torque Specifications ............................................................................ 2 - 12
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 13
SAE and Metric Fastener Torque Chart ............................................................... 2 - 14
Section 3 Rev Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-Delivery Preparation ........................................................................................ 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
Checklist A Procedures
A-1 Inspect the Decals and Manuals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance ....................................................................... 3 - 9
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S-40 • S-45 Part No.102521
October 2013
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures, continued
A-5 Inspect the Track Components, TRAX option .............................................. 3 - 9
A-6 Perform 30 Day Service ............................................................................. 3 - 10
A-7 Perform Engine Maintenance - Deutz and Ford Models .............................. 3 - 10
A-8 Replace the Drive Hub Oil .......................................................................... 3 - 11
A-9 Perform Engine Maintenance - Perkins Models .......................................... 3 - 12
A-10 Inspect the Fuel Filter/Water Separator - Diesel Models ............................. 3 - 12
A-11 Perform Engine Maintenance - Ford Models ............................................... 3 - 13
A-12 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 14
A-13 Perform Engine Maintenance - Deutz 1011F Models .................................. 3 - 14
A-14 Perform Engine Maintenance - Ford Models ............................................... 3 - 15
Checklist B Procedures
B-1 Inspect the Battery ..................................................................................... 3 - 16
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 17
B-3 Inspect the Air Filter ................................................................................... 3 - 18
B-4 Test the Key Switch ................................................................................... 3 - 19
B-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 19
B-6 Check the Exhaust System ....................................................................... 3 - 20
B-7 Check the Oil Cooler and Cooling Fins - Deutz Models............................... 3 - 20
B-8 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 21
B-9 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 22
B-10 Confirm the Proper Brake Configuration...................................................... 3 - 23
B-11 Check and Adjust the Engine RPM ............................................................ 3 - 24
B-12 Test the Engine Idle Select ........................................................................ 3 - 25
B-13 Test the Fuel Select Operation - Ford Models ............................................ 3 - 26
B-14 Test the Ground Control Override ............................................................... 3 - 27
B-15 Check the Directional Valve Linkeage ........................................................ 3 - 27
B-16 Test the Platform Self-leveling ................................................................... 3 - 28
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Part No.102521 S-40 • S-45
October 2013
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Section 3 Rev Scheduled Maintenance Procedures, continued
B-17 Test the Drive Brakes ................................................................................ 3 - 28
B-18 Test the Drive Speed - Stowed Position ..................................................... 3 - 29
B-19 Test the Drive Speed - Raised or Extended Position .................................. 3 - 29
B-20 Perform Hydraulic Oil Analysis ................................................................... 3 - 30
B-21 Test the Alarm Package (if equipped) and the Descent Alarm .................... 3 - 31
B-22 Inspect the Fuel and Hydraulic Tank Cap Venting System ......................... 3 - 32
B-23 Check the Track Tension and Fastener Torque - TRAX Option .................. 3 - 33
B-24 Perform Engine Maintenance - Ford Models ............................................... 3 - 34
Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 35
C-2 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 36
C-3 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 36
C-4 Replace the Engine Air Filter - Deutz and Perkins Models .......................... 3 - 39
C-5 Replace the Inline Fuel Strainer .................................................................. 3 - 39
C-6 Perform Engine Maintenance Ford Models ................................................. 3 - 40
Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 41
D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 42
D-3 Check the Free-wheel Configuration ........................................................... 3 - 43
D-4 Replace the Drive Hub Oil .......................................................................... 3 - 45
D-5 Perform Engine Maintenance - Deutz Models ............................................. 3 - 46
D-6 Replace the Hydraulic Filters ...................................................................... 3 - 47
D-7 Inspect for Turntable Bearing Wear ............................................................ 3 - 48
Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 50
E-2 Grease the Steer Axle Wheel Bearings, 2WD Models ................................ 3 - 52
E-3 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 53
E-4 Perform Engine Maintenance - Ford Models ............................................... 3 - 54
E-5 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 54
TABLE OF CONTENTS
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S-40 • S-45 Part No.102521
October 2013
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
E-6 Perform Engine Maintenance - Deutz and Perkins Models ......................... 3 - 55
E-7 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56
E-8 Perform Engine Maintenance - Deutz Models ............................................. 3 - 56
E-9 Perform Engine Maintenance - Ford Models ............................................... 3 - 57
Section 4 Rev Repair Procedures
Introduction ............................................................................................................ 4 - 1
Platform Controls
1-1 ALC-500 Circuit Board .................................................................................. 4 - 2
1-2 Joysticks ..................................................................................................... 4 - 3
Platform Components
2-1 Platform Leveling Slave Cylinder .................................................................. 4 - 8
2-2 Platform Rotator ........................................................................................... 4 - 9
2-3 Platform Overload System ......................................................................... 4 - 11
Jib Boom Components
3-1 Jib Boom.................................................................................................... 4 - 14
3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 15
Boom Components
4-1 Cable Track ................................................................................................ 4 - 16
4-2 Boom ......................................................................................................... 4 - 18
4-3 Boom Lift Cylinder ...................................................................................... 4 - 19
4-4 Boom Extension Cylinder ........................................................................... 4 - 20
4-5 Platform Leveling Master Cylinder .............................................................. 4 - 21
Engines
5-1 RPM Adjustment - Deutz Models ............................................................... 4 - 24
5-2 RPM Adjustment - Perkins Models............................................................. 4 - 24
5-3 Flex Plate................................................................................................... 4 - 24
5-4 Engine Fault Codes - Ford Models ............................................................. 4 - 28
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Part No.102521 S-40 • S-45
October 2013
Section 4 Rev Repair Procedures, continued
Hydraulic Pumps
6-1 Function Pump ........................................................................................... 4 - 29
6-2 Drive Pump ................................................................................................ 4 - 30
Manifolds
7-1 Function Manifold Components .................................................................. 4 - 32
7-2 Valve Adjustments - Function Manifold ...................................................... 4 - 36
7-3 Jib Select and Platform Rotate Manifold Components ................................ 4 - 37
7-4 Brake Manifold Components
(before serial number 7569) ........................................................................ 4 - 38
7-5 Brake/Two-Speed Manifold Components
(after serial number 7568) ........................................................................... 4 - 39
7-6 Oscillate Directional Valve Manifold Components....................................... 4 - 40
7-7 Valve Adjustments, Oscillate Relief Valve ................................................. 4 - 42
7-8 Traction Manifold Components, 2WD (before serial number 7569) .............. 4 - 43
7-9 Traction Manifold Components, 2WD (after serial number 7568) ................. 4 - 44
7-10 Valve Adjustments, 2WD Traction Manifold ............................................... 4 - 45
7-11 Traction Manifold Components, 4WD (before serial number 7569) .............. 4 - 46
7-12 Traction Manifold Components, 4WD (from serial number 7568 to 15822) .. 4 - 48
7-13 Traction Manifold Components, 4WD (from serial number 15823) ............... 4 - 50
7-14 Valve Adjustments, 4WD Traction Manifold ............................................... 4 - 52
7-15 Valve Coils ................................................................................................. 4 - 53
7-16 Drive Oil Diverter Manifold Components (welder option) ............................. 4 - 55
Turntable Rotation Components
8-1 Turntable Rotation Assembly ..................................................................... 4 - 56
Axle Components
9-1 Oscillate Axle Cylinders ............................................................................. 4 - 58
Track Components
10-1 Track Assembly - TRAX Option ................................................................. 4 - 59
Generators
10-1 Hydraulic Generator.................................................................................... 4 - 61
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TABLE OF CONTENTS
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S-40 • S-45 Part No.102521
October 2013
TABLE OF CONTENTS
Section 5 Rev Fault Codes
Introduction ............................................................................................................ 5 - 1
Fault Codes - Control System ................................................................................ 5 - 2
Fault Codes - Ford LRG-425 Engine....................................................................... 5 - 6
Fault Codes - Ford DSG-423 EFI Engine ............................................................. 5 - 12
Section 6 Rev Schematics
Introduction ............................................................................................................ 6 - 1
Electrical Symbols Legend .................................................................................... 6 - 2
Hydraulic Symbols Legend .................................................................................... 6 - 3
Ford DSG-423 Engine Relay Layout....................................................................... 6 - 4
Connector Pin Legend ............................................................................................ 6 - 5
Electrical Schematic, Deutz F3L 1011 Models
(before serial number 7544) .......................................................................... 6 - 8
Ground Control Box Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 11
Platform Control Box Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 14
Platform Control Box Switch Panel Wiring Diagram
Deutz F3L-1011F Models ........................................................................... 6 - 15
Electrical Schematic, Perkins 704-30 Models
(before serial number 7472) ........................................................................ 6 - 18
Ground Control Box Wiring Diagram
Perkins 704-30 Models ............................................................................... 6 - 21
Platform Control Box Wiring Diagram
Perkins 704-30 Models ............................................................................... 6 - 24
Platform Control Box Switch Panel Wiring Diagram
Perkins 704-30 Models ............................................................................... 6 - 25
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Part No.102521 S-40 • S-45
October 2013
xiii
Section 6 Rev Schematics, continued
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number7472 to 12509) ............................................................. 6 - 28
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (from serial number 12510 to 14831) ...................... 6 - 32
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (from serial number 14832 to 15662) ...................... 6 - 36
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS
Perkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 40
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models - CE
Perkins 404-22 Models (from serial number 15663 to 16419) ...................... 6 - 44
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models - ANSI / CSA / AS
Perkins 404-22 Models (from serial number 16420) .................................... 6 - 48
Electrical Schematic,
Deutz F3L-2011/Deutz D2011L03i Models - CE
Perkins 404-22 Models (from serial number 16420) .................................... 6 - 52
Ground Control Box Wiring Diagram,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (before serial number 14832) ................................. 6 - 56
Ground Control Box Wiring Diagram,
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (from serial number 14832) .................................... 6 - 57
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S-40 • S-45 Part No.102521
October 2013
xiv
Section 6 Rev Schematics, continued
Platform Control Box Wiring Diagram
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (before serial number 14832) ................................. 6 - 60
Platform Control Box Wiring Diagram
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (from serial number 14832) .................................... 6 - 61
Platform Control Box Switch Panel Wiring Diagram
Deutz F3L-2011/Deutz D2011L03i Models
(from serial number 7544 to 12509)
Perkins 404-22 Models
(from serial number 7472 to 12509) ............................................................ 6 - 64
Platform Control Box Switch Panel Wiring Diagram
Deutz F3L-2011/Deutz D2011L03i Models
Perkins 404-22 Models (from serial number 12510) .................................... 6 - 65
Electrical Schematic,
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 68
Ground Control Box Wiring Diagram,
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 71
Platform Control Box Wiring Diagram
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 74
Platform Control Box Switch Panel Wiring Diagram
Ford LRG-425 EFI Models (before serial number 7597) .............................. 6 - 75
Electrical Schematic,
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 78
Ground Control Box Wiring Diagram,
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 81
Platform Control Box Wiring Diagram
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 84
TABLE OF CONTENTS
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Part No.102521 S-40 • S-45
October 2013
Section 6 Rev Schematics, continued
Platform Control Box Switch Panel Wiring Diagram
Ford LRG-425 EFI Models
(from serial number 7597 to 11066) ............................................................ 6 - 85
Electrical Schematic, Ford DSG-423 EFI Models
(from serial number 11067 to 12509) .......................................................... 6 - 88
Electrical Schematic, Ford DSG-423 EFI Models
(from serial number 12510 to 14831) .......................................................... 6 - 92
Electrical Schematic, Ford DSG-423 EFI Models
(from serial number 12510 to 15662) .......................................................... 6 - 96
Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS
(from serial number 15663 to 16419) ......................................................... 6 - 100
Electrical Schematic, Ford DSG-423 EFI Models - CE
(from serial number 15663 to 16419) ......................................................... 6 - 104
Electrical Schematic, Ford DSG-423 EFI Models - ANSA / CSA / AS
(from serial number 16420) ........................................................................6 - 108
Electrical Schematic, Ford DSG-423 EFI Models - CE
(from serial number 16420) ........................................................................6 - 112
Ground Control Box Wiring Diagram,
Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 116
Ground Control Box Wiring Diagram,
Ford DSG-423 EFI Models (from serial number 14832).............................. 6 - 117
Platform Control Box Wiring Diagram
Ford DSG-423 EFI Models (before serial number 14832) ........................... 6 - 120
Platform Control Box Wiring Diagram
Ford DSG-423 EFI Models (from serial number 14832).............................. 6 - 121
Platform Control Box Switch Panel Wiring Diagram,
Ford DSG-423 EFI Models (from serial number 11067 to 12509) ...............6 - 124
Platform Control Box Switch Panel Wiring Diagram
Ford DSG-423 EFI Models (from serial number 12510).............................. 6 - 125
TABLE OF CONTENTS
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S-40 • S-45 Part No.102521
October 2013
TABLE OF CONTENTS
Section 6 Rev Schematics, continued
Engine Harness, Ford LRG-425 EFI Models
(before serial number 11067) ..................................................................... 6 - 128
Engine Harness, Ford DSG-423 EFI Models
(from serial number 11067 to 11784) ......................................................... 6 - 129
Engine Harness, Ford DSG-423 EFI Models
(from serial number 11785) ........................................................................6 - 132
Joystick Connector Diagram ............................................................................... 6 - 133
CTE Option Wiring Diagram ................................................................................ 6 - 136
MTE Hydraulic Generator Option Wiring Diagram ................................................ 6 - 138
Hydraulic Generator Wiring Diagram (welder option) ............................................ 6 - 139
Hydraulic Schematic, 2WD Non-oscillating S-40 Models
(before serial number 7569) .......................................................................6 - 142
Hydraulic Schematic, 2WD Non-oscillating S-45 Models
(before serial number 7569) .......................................................................6 - 143
Hydraulic Schematic, 4WD Oscillating S-40 Models
(before serial number 7569) .......................................................................6 - 146
Hydraulic Schematic, 4WD Oscillating S-45 Models
(before serial number 7569) .......................................................................6 - 147
Hydraulic Schematic, 2WD (from serial number 7569) ........................................ 6 - 150
Hydraulic Schematic, 4WD (from serial number 7569) ........................................ 6 - 151
Generator Hydraulic Schematic (welder option) ................................................... 6 - 153
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Part No.102521 S-40 • S-45 2 - 1
Section 2 • SpecificationsOctober 2013
Specifications
Machine Specifications
S-40 and 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 weight, new foam-filled (minimum) 300 lbs
(Rough terrain) 136 kg
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
(Rough terrain) 3.1 bar 3.1 bar
Tire pressure 60 psi 60 psi
(Rough terrain) 4.1 bar 4.1 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 - Drive and 9-bolt non-drive hubs
Lug nut, dry 230 ft-lbs
312 Nm
Lug nut, lubricated 170 ft-lbs
230 Nm
Lug nut torque - 8-bolt non-drive spindles
Lug nut, dry 170 ft-lbs
230 Nm
Lug nut, lubricated 130 ft-lbs
176 Nm
Track Components, TRAX option
Track material Rubber
Weight, assembly (each) 480 lbs
218 kg
Fluid capacities
Fuel tank 20 gallons
75.7 liters
Fuel tank, Option 30 gallons
114 liters
LPG tank 33.5 pounds
15.2 kg
Hydraulic tank 45 gallons
170 liters
Hydraulic system 55 gallons
(including tank) 208 liters
Drive hub 17 fl oz
(before serial number 7569) 0.5 liters
Drive hub 24 fl oz
(from serial number 7569 to 15677) 0.71 liters
Drive hub 20 fl oz
(from serial number 15678) 0.6 liters
Turntable rotation 8 fl oz
drive hub 0.24 liters
Drive hub oil type:
SAE 90 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a Genie
policy. Product specifications are subject to change
without notice.
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2 - 2 S-40 • S-45 Part No.102521
Section 2 • Specifications October 2013
SPECIFICATIONS
Continuous improvement of our products is a
Genie policy. Product specifications are subject
to change without notice.
Performance Specifications
All Models
Drive speeds, 2WD and 4WD
Drive speed, stowed 40 ft / 5.2 - 5.9 sec
12.2 m / 5.2 - 5.9 sec
Drive speed, raised or extended 40 ft / 40 - 45 sec
12.2 m / 40 - 45 sec
Drive speed, TRAX option
Drive speed, stowed 40 ft / 11 sec
12.2 m / 11 sec
Drive speed, raised or extended 40 ft / 40 sec
12.2 m / 40 sec
Gradeability See Operator's Manual
Boom function speeds, maximum
from platform controls
Boom up 50 to 60 seconds
Boom down 45 to 60 seconds
Boom extend 30 to 60 seconds
Boom retract 15 to 35 seconds
Turntable rotate, 360°
boom fully stowed 70 to 100 seconds
Turntable rotate, 360°
boom fully extended 120 to 140 seconds
Platform level (10° range of motion)
ANSI 3 to 5 seconds
CE/Austrailia 20 to 22 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
Hydraulic Oil Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rando HD MV equivalent
Viscosity grade Multi-viscosity
Viscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rando HD 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 the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation, corrosion inhibition, seal conditioning, and
foam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV46
Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046
Quintolubric 822
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron Aviation A
Eni Arnica 32
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