Terex Genie Lift Guard S-40 Installation and operating manual

Service and Repair Manual
Serial Number Range
S-40
S-45
from S4015-20505 to
S4016H-
23499
from S4515-20505
to
S4516H-
23499
from S40H-
23500
fromS45H-
23500
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
S-40 TRAX
S-45 TRAX
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for
your machine.
Part No. 1268491
Rev A3
May 2018

Service and Repair Manual September 2016
Introduction
ii S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Intr oduct io n Intr oduct io n
Impor tant Inf ormati on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting 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:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Copyright © 2015 by Terex Corporation
1268491 Rev A, September 2016
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“S” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual
Introduction
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX iii
Revision History
Revision
Date
Section
Procedure / Page / Description
A 9/2015 Initial Release
A1 7/2016 Repair Procedures Added Primary Boom Down and Extend Relief Valve
adjustment procedures.
A2 9/2016 Introduction Serial Number Legend
A3
5
-2018
Schematics
Fixed Deutz 2.9 ANSI/CSA Elec. Schematic
Reference Examples: Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

Service and Repair Manual September 2016
Introduction
iv S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located under cover)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX v
Section 1 Safet y Rul es Gener al Safety R ules
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine 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.

Service and Repair Manual September 2016
Safety Rules
vi S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
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.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause
minor or moderate
injury.
Indicates 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 crus
hing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
Workplace 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.
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 exting
uisher 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 a
nd 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.

September 2016
Table of Contents
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX vii
Introduction Introduction...........................................................................................................ii
Important Information .............................................................................................ii
Find a Manual for this Model..................................................................................ii
Serial Number Legend ..........................................................................................iv
Section 1 Safety Rules..........................................................................................................v
General Safety Rules .............................................................................................v
Section 2Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Specification...........................................................................................2
Hydraulic Component Specifications......................................................................4
Manifold Component Specifications.......................................................................5
Ford MSG-425 EFI Engine Specifications .............................................................6
Deutz D2011 L03i Engine Specifications...............................................................7
Deutz D 2.9 L4 Engine Specifications....................................................................8
Perkins 404D-22 Engine Specifications.................................................................9
Perkins 404F-22 Engine Specifications ...............................................................10
Machine Torque Specifications............................................................................11
TRAX Torque Specifications ................................................................................11
Hydraulic Hose and Fitting Torque Specifications ...............................................12
Torque Procedure ................................................................................................13
SAE and Metric Fasteners Torque Charts ...........................................................14

September 2016
Table of Contents
viii S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Section 3 Repair Procedures.............................................................................................15
Introduction ..........................................................................................................15
Platform Controls...............................................................................................17
1-1 ALC-500 Circuit Board...................................................................................17
1-2 Joysticks ........................................................................................................18
How to Adjust the Joystick Threshold Setting ................................................18
How to Adjust the Joystick Max-out Setting ...................................................19
How to Adjust the Joystick Ramp Rate Setting ..............................................20
Platform Components .......................................................................................22
2-1 Platform Leveling Slave Cylinder...................................................................22
2-2 Platform Rotator.............................................................................................24
2-3 Platform Overload System.............................................................................26
Jib Boom Components......................................................................................28
3-1 Jib Boom........................................................................................................28
3-2 Jib Boom Lift Cylinder....................................................................................29
Primary Boom Components .............................................................................30
4-1 Cable Track....................................................................................................30
How to Remove the Cable Track....................................................................30
How to Repair the Cable Track.......................................................................31
4-2 Boom..............................................................................................................31
4-3 Boom Lift Cylinder .........................................................................................33
4-4 Boom Extension Cylinder ..............................................................................34
4-5 Platform Leveling Master Cylinder.................................................................35
Engines ...............................................................................................................37
5-1 RPM adjustment - Deutz Models...................................................................37
5-2 RPM adjustment - Perkins Models ................................................................37
5-3 Flex Plate.......................................................................................................37
5-4 Ford MSG-425 Engine Fault Codes ..............................................................41
5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.............42

September 2016
Table of Contents
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX ix
Hydraulic Pumps................................................................................................43
6-1 Function Pump...............................................................................................43
6-2 Drive Pump.....................................................................................................44
Manifolds.............................................................................................................46
7-1 Function Manifold Components .....................................................................46
7-2 Valve Adjustments - Function Manifold..........................................................50
How to Adjust the System Relief Valve...........................................................50
How to Adjust the Boom Down Relief Valve...................................................50
How to Adjust the Boom Extend Relief Valve.................................................51
7-3 Jib Boom / Platform Rotate and Generator Manifold Components................52
7-4 Brake / Two Speed Manifold Components ....................................................53
7-5 Oscillate Directional Valve Manifold Components.........................................54
7-6 How to Set Up the Oscillate Directional Valve...............................................55
7-7 Valve Adjustment - Oscillate Relief Valve......................................................56
7-8 Traction Manifold Components, 2WD............................................................57
7-9 Traction Manifold Components, 4WD............................................................59
7-10 Valve Adjustments, Traction Manifold..........................................................61
7-11 Drive Oil Diverter Manifold Components (welder option).............................62
7-12 Hydraulic Generator Manifold Components, 3kW .......................................63
7-13 Valve Coils ...................................................................................................64
Turntable Rotation Components ......................................................................66
8-1 Turntable Rotation Assembly.........................................................................66
Axle Components...............................................................................................67
9-1 Oscillating Axle Cylinders...............................................................................67
Track Components.............................................................................................68
10-1 Track Assembly............................................................................................68
Generators ..........................................................................................................71
11-1 Hydraulic Generator.....................................................................................71

September 2016
Table of Contents
x S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Section 4 Fault Codes......................................................................................................... 72
Introduction ..........................................................................................................72
Control System Fault Codes.............................................................................73
How to Retrieve Control System Fault Codes................................................73
Control System Fault Codes...........................................................................74
Fault Code Display - Deutz and Perkins Models.............................................78
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models.........................................78
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 and Perkins 404F-22 Models.........................................79
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-22 Models.........................................80
Main Menu Structure - Deutz D 2.9 L4 Models ..............................................81
Main Menu Structure - Perkins 404F-22 Models............................................82
Deutz D 2.9 L4 Engine Fault Codes..................................................................83
Perkins 404F-22 Engine Fault Codes...............................................................94
Ford MSG-425 Engine Fault Codes..................................................................96
How to Retrieve Ford MSG-425 Engine Fault Codes.....................................96
Ford MSG-425 Engine Fault Codes ...............................................................97