Terex Genie S-40, S-45 Telescopic Boom Lift Service Manual
304 pages · Publication 72136
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- Models
- Genie S-40, S-45
- Serial coverage
- from SN 1790 to 7000
- Manual type
- Service Manual
- Pages
- 304
- Publication
- 72136
- Condition
- Brand new
What's inside
From the manual's own table of contents: 195 topics. See sample pages (PDF, 630 KB)
- Important Information
- General Safety Rules
- Machine Specifications
- Performance Specifications
- Hydraulic Specifications
- Hydraulic Oil Specifications
- Ford LRG 425 EFI Engine Specifications
- Deutz F3L 1011F Engine Specifications
- Perkins 704-30 Engine Specifications
- Machine Torque Specifications
- Hydraulic Hose and Fitting Torque Specifications
- SAE and Metric Fastener Torque
- Power Source
- Hydraulic System
- Electrical System
- Limit Switches
- Introduction
- Maintenance Inspection Report
- Inspect the Operator's and Safety Manuals
- Inspect the Decals and Placards
- Inspect for Damage, Loose or Missing Parts
- Check the Engine Oil Level
- Check the Engine Coolant Level - Liquid Cooled Models
- Check for Fuel Leaks
Show all 195 topics
- Check the Hydraulic Oil Level
- Check for Hydraulic Leaks
- Check the Tire Pressure
- A-10 Test the Oscillate Axle (if equipped)
- A-11 Test the Platform and Ground Controls
- A-12 Test the Auxiliary Power Operation
- A-13 Test the Tilt Sensor
- A-14 Test the Limit Switches
- A-15 Drain the Fuel Filter/Water Separator - Diesel Models
- A-16 Perform 30 Day Service
- A-17 Replace the Engine Oil and Filter - Gasoline/LPG Models
- A-18 Check the Engine Belt - Gasoline/LPG and Perkins Models
- A-19 Replace the Fuel Filter - Gasoline/LPG Models
- Check the Exhaust System
- Inspect the Engine Air Filter
- Inspect the Radiator - Liquid Cooled Models
- Check the Battery
- Inspect the Electrical Wiring
- Check the Oil Cooler and Cooling Fins - Deutz Models
- Check the Hydraulic Tank Return Filter Condition Indicator
- Inspect the Tires, Wheels and Lug Nut Torque
- Confirm the Proper Brake Configuration
- B-10 Check the Oil Level in the Drive Hubs
- B-11 Check and Adjust the Engine RPM
- B-12 Test the Key Switch
- B-13 Test the Emergency Stop Buttons
- B-14 Test the Ground Control Override
- B-15 Check the Directional Valve Linkage
- B-16 Test the Platform Self-leveling
- B-17 Test the Horn
- B-18 Test the Foot Switch
- B-19 Test the Engine Idle Select Operation
- B-20 Test the Fuel Select Operation - Gasoline/LPG Models
- B-21 Test the Drive Enable System
- B-22 Test the Drive Brakes
- B-23 Test the Drive Speed - Stowed Position
- B-24 Test the Drive Speed - Raised or Extended Position
- B-25 Test the Alarm Package (if equipped)
- B-26 Perform Hydraulic Oil Analysis
- B-27 Replace the Hydraulic Tank Return Filter
- B-28 Replace the Engine Air Filter Element
- B-29 Replace the Spark Plugs - Gasoline/LPG Models
- Check the Engine Belt - Deutz Models
- Check the Engine Valve Clearances - Deutz Models
- Replace the Fuel Filter/Water Separator Element - Perkins Models
- Replace the Fuel Filter Element - Perkins Models
- Replace the Engine Oil and Filter - Perkins Models
- Check the Glow Plugs - Perkins Models
- Replace the PCV Valve - Gasoline/LPG Models
- Check the Boom Wear Pads
- Check the Free-wheel Configuration
- Check the Turntable Rotation Bearing Bolts
- Grease the Turntable Rotation Bearing and Rotate Gear
- Replace the Drive Hub Oil
- Replace the Drive Loop Hydraulic Filter
- Replace the Engine Oil and Filter - Deutz Models
- Clean the Fuel Pump Strainer - Deutz Models
- Replace the Diesel Fuel Filter/Water Separator - Deutz Models
- D-10 Change the Fuel Hoses - Deutz Models
- D-11 Check the Engine Valve Clearances - Perkins Models
- D-12 Clean the Engine Breather Assembly - Perkins Models
- Test or Replace the Hydraulic Oil
- Change or Recondition the Engine Coolant - Liquid Cooled Models
- Change the Fuel Hoses - Gasoline/LPG Models
- Replace the Engine Breather - Perkins Models
- Grease the Steer Axle Wheel Bearings, 2WD Models
- Check the Fuel Injectors - Perkins Models
- Fault Codes
- Engine Will Not Crank Over
- Engine Cranks Over But Will Not Start - Gasoline/LPG Models
- 2A Engine Runs While Cranking then Dies- Gasoline/LPG Models
- Engine Cranks Over But Will Not Start - Diesel Models
- Gasoline/LPG Models
- Engine High Idle Inoperative - Gasoline/LPG Models
- Engine Low Idle Inoperative - Gasoline/LPG Models
- Engine High Idle Inoperative - Diesel Models
- Engine Low Idle Inoperative - Diesel Models
- All Functions Inoperative, Engine Starts and Runs
- All Lift and Steer Functions Inoperative, Drive Functions Operational
- Ground Controls Inoperative, Platform Controls Operate Normally
- Platform Controls Inoperative, Ground Controls Operate Normally
- Boom Up Function Inoperative
- Boom Down Function Inoperative
- Boom Extend Function Inoperative
- Boom Retract Function Inoperative
- Turntable Rotate Left Function Inoperative
- Turntable Rotate Right Function Inoperative
- All Platform Leveling Functions Inoperative
- Platform Level Up Function Inoperative
- Platform Level Down Function Inoperative
- Platform Rotate Left Function Inoperative
- Platform Rotate Right Function Inoperative
- Oscillate Function Inoperative
- Jib Boom Up Function Inoperative
- Jib Boom Down Function Inoperative
- Steer Left Function Inoperative
- Steer Right Function Inoperative
- Drive Forward Or Reverse Function Inoperative
- Traction Function Inoperative
- Machine Will Not Drive At Full Speed
- Machine Drives At Full Speed With Platform Raised or Extended
- Drive Enable System Is Malfunctioning
- Auxiliary Functions Inoperative
- Electrical Components
- Electrical Symbols Legend
- Abbreviation Legend
- Hydraulic Symbols Legend
- Engine Wire Harness - Gasoline/LPG
- Electrical Schematic - Gasoline/LPG
- Ground Control Box Wiring Diagram - Gasoline/LPG
- Platform Control Box Wiring Diagram - Gasoline/LPG
- Electrical Schematic - Deutz Diesel
- Ground Control Box Wiring Diagram - Deutz Diesel
- Platform Control Box Wiring Diagram - Deutz Diesel
- Electrical Schematic - Perkins Diesel
- Ground Control Box Wiring Diagram - Perkins Diesel
- Platform Control Box Wiring Diagram - Perkins Diesel
- S-40/45 2WD Hydraulic Schematic - Non-oscillating axle
- S-40/45 2WD Hydraulic Schematic - Oscillating axle
- S-40/45 4WD Hydraulic Schematic - Oscillating axle
- Joystick Controllers
- Horsepower Limiter Board
- Foot Switch
- Toggle Switches
- Platform
- Platform Leveling Slave Cylinder
- Platform Rotator
- Jib Boom
- Jib Boom Lift Cylinder
- Boom Cable Track
- Boom
- Boom Lift Cylinder
- Extension Cylinder
- Platform Leveling Master Cylinder
- Turntable Covers
- RPM Adjustment
- Flex Plate
- Oil Temperature and Oil Pressure Gauges
- Coolant Temperature and Oil Pressure Gauges
- Timing Adjustment
- Control Relays
- Toggle Switches, See 1-4, Toggle Switches
- Wago® Components
- Engine Fault Codes - Gasoline/LPG Models
- 10-1 Lift/Steer Pump
- 10-2 Drive Pump
- 11-1 Function Manifold Components
- 11-2 Valve Adjustments - Function Manifold
- 11-3 Turntable Rotation Manifold Components
- 11-4 Oscillate Manifold Components
- 11-5 Valve Adjustments - Oscillate Manifold
- 11-6 Directional Valve Manifold Components
- 11-7 Steer/Oscillate Manifold Components, Oscillating Models
- 11-8 Steer Manifold Components, Non-oscillating Models
- 11-9 2WD Drive Manifold Components
- 11-10 Valve Adjustments, 2WD Drive Manifold
- 11-11 4WD Drive Manifold Components
- 11-12 Valve Adjustments, 4WD Drive Manifold
- (before serial number 5593)
- (after serial number 5592)
- 12-1 Fuel Tank
- 12-2 Hydraulic Tank
- 13-1 Rotation Hydraulic Motor
- 14-1 Yoke and Hub
- 14-2 Steering Cylinders
- 15-1 Yoke and Hub
- 15-2 Steering Cylinders, See 14-2, Steering Cylinders
- 16-1 Oscillating Axle Lock-out Cylinders
- 17-1 Drive Motor
- 17-2 Drive Hub
- 17-3 Wheel Brake
Inside this manual
Real pages from this service manual (304 pages). Open the sample pages (PDF, 630 KB)
- Specifications, page 19: Section 2 • Specifications
- Troubleshooting, page 119: FAULT CODE CHART
- Diagram, page 223: Section 6 • Schematics
- Foldout diagram: March 2008
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 304 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).