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

September 2016
Table of Contents
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX xi
Section 5 Schematics........................................................................................................102
Introduction.........................................................................................................102
Electrical Symbol Legend...................................................................................103
Hydraulic Symbols Legend.................................................................................104
Electrical Component and Wire Color Legends .................................................105
Ford Engine Relay Layout..................................................................................109
Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22............................110
Electrical Schematics, S-40/45 – Deutz D2.9 and Perkins 404F Models.....111
Electrical Schematic - Deutz D2.9 L4 Models (ANSI / CSA)..............................112
Engine Harness - Deutz D2.9 L4 Models (ANSI / CSA).....................................116
Platform Control Box - Deutz D2.9 L4 Models (ANSI / CSA).............................120
Electrical Schematic - Perkins 404F Models (ANSI / CSA) ...............................124
Engine Harness - Perkins 404F Models (ANSI / CSA) ......................................128
Platform Control Box - Perkins 404F Models (ANSI / CSA)...............................132
Electrical Schematics, S-40/45 – Deutz 2011 and Perkins 404D Models....135
Electrical Schematic - Deutz 2011 and Perkins 404D Models (ANSI / CSA) ....136
Electrical Schematic - Deutz 2011 and Perkins 404D Models (CE) ..................140
Electrical Schematic - Deutz 2011 and Perkins 404D Models (AS)...................144
Ground Control Box - Deutz 2011 and Perkins 404D Models
(ANSI/CSA_CE_AS)...................................................................................148
Platform Control Box - Deutz 2011 and Perkins 404D Models
(ANSI/CSA_CE_AS)...................................................................................150
Electrical Schematics, S-40/45 – Ford MSG-425 Models..............................153
Electrical Schematic - Ford MSG-425 Models (ANSI / CSA).............................154
Electrical Schematic - Ford MSG-425 Models (CE)...........................................158
Electrical Schematic - Ford MSG-425 Models (AS)...........................................162
Ground Control Box - Ford MSG-425 Models (ANSI/CSA_CE_AS)..................166
Platform Control Box - Ford MSG-425 (ANSI/CSA_CE_AS).............................168
Hydraulic Schematics......................................................................................171
Hydraulic Schematic, 2WD Models....................................................................172
Hydraulic Schematic, 4WD Models....................................................................173

Service and Repair Manual September 2016
S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
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September 2016 Service and Repair Manual
Specifications
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX 1
Section 2 Speci ficati ons
Machi ne Spec ific ations
Machine Specifications
Tires and wheels
Tire size, 2WD
front tires only
Tire pressure
12.5L - 16SL
14 ply
16 in x 10 in wheel
40.6 cm x 25.4 cm wheel
52 psi / 3.58 bar
Tire size, 2WD & 4 WD
(Rough Terrain)
Tire pressure
12 - 16.5 NHS
8 ply
16.5 in x 9.75 in wheel
41.9 cm x 24.8 cm wheel
45 psi / 3.1 bar
Tire weight,
new foam
-filled
(minimum)
(Rough terrain)
300 lbs
136 kg
Tire size, 4WD
(High flotation)
Tire pressure
33/16LL 500
10 ply
19.5 in x 14 in wheel
49.5 cm x 35.6 cm wheel
38 psi / 2.62 bar
Tire weight, new
foam-filled (minimum)
(Rough terrain)
300 lbs
136 kg
Wheel lugs 9 @ 5/8 -
18
Lug nut torque, dry 230 ft-
lbs
325 Nm
Lug nut torque,
lubricated 170 ft-
lbs
244 Nm
Track Components, TRAX option
Track material
Rubber
Weight, assembly (each)
480 l
bs
218 k
g
Fluid capacities
LPG tank
33.5 p
ounds
15.2 k
g
Fuel tank
20 g
allons
75.7 l
iters
Fuel tank
(option)
30 g
allons
113.6 l
iters
Hydraulic tank
45 g
allons
170 l
iters
Hydraulic system
(including tank)
55 g
allons
208 l
iters
Drive hubs
20 f
l oz
592 c
c
Turntable rotate drive hub
8 fl oz
237 cc
Drive hub oil type:
SAE 9
0 multipurpose hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.

Service and Repair Manual September 2016
Specifications
2 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Perf ormanc e Speci ficati ons
Performance Specifications
Drive speeds,
2WD and 4WD
Stowed
40 ft / 5.2 - 5.9 s
ec
12.2 m / 5.2 - 5.9 s
ec
Raised or extended
40 ft / 40 - 45 s
ec
12.2 m / 40 - 45 s
ec
Drive speeds,
TRAX option
Stowed
40 ft / 9 - 11 s
ec
12.2 m / 9 - 11 s
ec
Raised or extended
40 ft / 40 - 45 s
ec
12.2 m / 40 - 45 s
ec
Gradeability
See Operator's Manual
Braking distance, maximum
High range on paved surface
3 - 4 f
t
0.9 - 1.2
m
Boom function speeds, maximum
from platform controls
Jib boom up, S
-45 models 35 - 45 s
econds
Jib boom down, S
-45 models 20 - 30 s
econds
Platform level
(10° range of motion)
ANSI
CE/Australia
3 -5 s
econds
20 - 22 s
econds
Boom up
50 - 60 s
econds
Boom down
45 - 60 s
econds
Boom extend
30 - 30 s
econds
Boom retract
15 - 35 s
econds
Turntable rotate, 360°
Stowed
70 - 100 s
econds
Turntable rotate, 360°
Not stowed
120 - 140 s
econds
For operational specifications, refer to the
Operator's Manual.
Hydra ulic Sp ecific ation
Hydraulic Oil Specifications
Hydraulic Fluid Specifications
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,
ox
idation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

September 2016 Service and Repair Manual
Specifications
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX 3
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
pl
ugging hydraulic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @
-40°F / -40°C
5.5
15.0
510
Flash point
180°F / 82°C
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
124°F / 51°C
Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
are consistently below 0°F / -17°C unless an oil
heating system is used.
Continued use of Chevron 5606A
hydraulic fluid, or equivalent,
when ambient temperatures are
consistently above 32°F / 0°C
may result in component damage

Service and Repair Manual September 2016
Specifications
4 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F
/ 82°C
Shell Tellus S4 VX Fluid
Properties
ISO Grade
32
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
9
33.8
Brookfield Viscosity
cSt @
-4°F / -20°C
cSt @
-13°F / -25°C
cSt @
-40°F / -40°C
481
702.4
2624
Flash
point
>100
Pour point
-76°F / -
60°C
Maximum continuous operating
temperature
103°F / 75°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C
Hydra ulic C omp one nt Spec ifi cati ons
Hydraulic Component
Specifications
Drive Pump
Type: bi
-directional variable displacement piston pump
Flow rate
@ 2500 rpm 0 - 28 g
pm
0 -
122.6 L/min
Drive pressure, maximum
3625 p
si
250 b
ar
Charge Pump
Type
gerotor
Displacement per revolution
0.85 cu in
13.9 c
c
Flow rate @ 250
0 rpm 9 g
pm
34 L/min
Charge pressure @ 250
0 rpm 310 p
si
21.4 b
ar
Function pump
Type
gear, pressure
balanced
Displacement
1.04 cu in
17 c
c
Flow rate @ 250
0 rpm 10.69 g
pm
40.5 L/min
Auxiliary Pump
Type: fixed displacement gear pump
Displacement per revolution
1.75 g
pm
6.62 L/min
Auxiliary pump relief pressure
3200 p
si
220.6 b
ar

September 2016 Service and Repair Manual
Specifications
Part No. 1268491 S-40 • S-45 • S-40 TRAX • S-45 TRAX 5
Function manifold
Function relief valve pressure
S
-40
S
-45
2600 psi / 179 b
ar
2900 psi / 200 b
ar
Boom down
relief valve pressure
2200 p
si
152 b
ar
Boom extend
relief valve pressure
1950 p
si
134 b
ar
Steer regulator
all models 2 gpm / 7.6 lpm
Oscillate relief valve pressure
(@2500 rpm) 950 p
si
66 b
ar
Traction Manifold
Hot oil relief pressure
280 p
si
19.3 b
ar
Two
-speed drive motors, 2WD and 4WD models
Displacement per revolution
low speed
0.99 cu in / 16.3 c
c
Displacement per revolution
high speed
1.83 cu in / 30 c
c
Hydraulic Filters
Medium pressure filter
Beta 3 ˆ 200
Medium pressure filter bypass
pressure
51 p
si
3.5 b
ar
Hydraulic tank return filter
10 m
icron with
25 psi / 1.7 b
ar
bypass
Manif old Com pon e nt Sp eci fic ati on s
Manifold Component
Specifications
Plug torque
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
56 ft-
lbs / 75.9 Nm

Service and Repair Manual September 2016
Specifications
6 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Ford M SG-42 5 EFI En gine Sp ecific ations
Ford MSG-425 EFI Engine
Displacement
153 c
u in
2.5 l
iters
Number of cylinders
4
Bore & stroke
3.5 x 3.9 i
nches
89 x 100 m
m
Horsepower
60 @ 2500 r
pm
45 kW @ 2500 r
pm
Firing order
1 - 3 - 4 -
2
Low engine idle (computer
controlled)
1000 r
pm
33.3 Hz
Low function idle
(computer
controlled)
1600 r
pm
53.3 Hz
High function idle (computer
controlled)
2500 r
pm
83.3 Hz
Compression ratio
9.7:1
Compression pressure (approx.)
Pressure (psi or bar) of lowest cylinder must be at least
75% of highest cylinder
Lubrication
system
Oil pressure (operating
temperature @ 200
0 rpm) 29 to 39 p
si
2.75 to 4.1 b
ar
Oil capacity (including filter)
6.7 q
uarts
6.4 l
iters
Oil pressure switch
Oil pressure switch point
7.5 p
si
0.51 b
ar
Oil viscosity requirements
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Electronic fuel pump
Fuel pressure, static
60 p
si
4.1 b
ar
Fuel flow rate
0.58 g
pm
2.2 L/min
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Ignition system
Spark plug type
Motorcraft AYFS-32Y-
R
Spark plug gap
0.04
9 to 0.053 inches
1.2
5 to 1.35 mm
Engine coolant
Capacity
11.5 q
uarts
10.9 liters
Coolant temperature switch
Temperature switch point
230°F
110°C
Starter motor
Normal engine cranking speed
200 to 250 r
pm
Current draw, normal load
140-
200A
Current draw, maximum load
800A
Alternator
Output
95A, 13.8V DC
Battery
Type
12V DC, Group 34/78
Quantity
1
Cold cranking ampere @ 0°F
900A
Reserve capacity @ 25A rate
200 m
inutes

September 2016 Service and Repair Manual
Specifications
Part No. 1268491S-40 • S-45 • S-40 TRAX • S-45 TRAX 7
Deutz D 2011 L0 3i Engi ne Speci ficat ions
Deutz D2011 L03i Engine
Displacement
142 c
u in
2.33 l
iters
Number of cylinders
3
Bore and stroke
3.7 x 4.4 i
nches
94 x 112 m
m
Horsepower
48 @ 2800 r
pm
36 kW @ 2800 r
pm
Firing order
1 - 2 -
3
Low idle
1500 r
pm
313 Hz
High idle
2500 r
pm
521.7 Hz
Compression ratio
19:01
Compression pressure
362 to 435 p
si
25 to 30 b
ar
Governor
centrifugal mechanical
Valve clearance, cold
Intake
0.012 i
n
0.3 m
m
Exhaust
0.020 i
n
0.5 m
m
Lubrication system
Oil pressure
20 to 44 p
si
1.4 to 3 b
ar
Oil capacity
(including filter)
9.5 q
uarts
9 l
iters
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
Units ship with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your
machine.
Oil temperature switch
Temperature switch point
300°F
149°C
Oil pressure switch
Oil pressure switch point
22 p
si
1.5 b
ar
Fuel injection system
Injection pump make
Bosch
Injection pump pressure,
maximum
15000 p
si
1034 b
ar
Injector
opening pressure 3046 p
si
210 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Starter motor
Current draw, no load
90A
Brush length, new
0.72 i
n
18.5 m
m
Brush length, minimum
0.27 i
n
7 m
m
Battery
Type
12V DC, Group 34/78
Quantity
1
Cold cranking ampere
900A
Reserve capacity @ 25A rate
200 m
inutes
Alternator output
60A @ 14V DC
Fan belt deflection
3/8 to 1/2 i
nch
9 to 12 m
m

Service and Repair Manual September 2016
Specifications
8 S-40 • S-45 • S-40 TRAX • S-45 TRAX Part No. 1268491
Deutz D 2. 9 L4 En gine Sp ecific ation s
Deutz D 2.9 L4 Engine
Displacement
177 c
u in
2.9 l
iters
Number of cylinders
4
Bore and stroke
3.6 x 4.3 i
nches
92 x 110 m
m
Horsepower
48.8 @ 2600 r
pm
37 kW @ 2600 r
pm
Firing order
1 - 3 - 4 -
2
Low idle
1500 r
pm
313 Hz
High idle
2500 r
pm
521.7 Hz
Compression ratio
18.4:1
Compression pressure
362 to 435 p
si
25 to 30 b
ar
Governor
electronic
Lubrication system
Oil pressure (@ 200
0 rpm) 40 to 60 p
si
1.4 to 3 b
ar
Oil capacity
(including filter)
9.4 q
uarts
9 l
iters
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
Units ship with 15W
-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.
Oil temperature switch
Temperature switch point
257°F
125°C
Oil pressure switch
Oil pressure switch point
20 p
si
1.4 b
ar
Engine coolant
Capacity
10 quarts
9.4 liters
Fuel injection system
Injection
pump make Bosch
Injection pump pressure,
maximum
15000 p
si
1034 b
ar
Injector opening pressure
3046 p
si
210 b
ar
Fuel requirement
For fuel requirements, refer to the engine Operator's
Manual on your machine.
Starter motor
Cranking speed
150-
250 RPM
Current draw, normal load
250A to 400A
Output
3.2kW
Battery
Type
12V DC
Quantity
1
Cold cranking ampere
1000A
Reserve capacity @ 25A rate
200 m
inutes
Alternator output
95A @ 14V DC
Fan belt deflection
3/8 to 1/2 inch
9 to 12 m
m