Terex Genie S-40 - Service And Repair Manual

187 pages

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Service and Repair Manual

Serial Number Range

S-40

S-45

from S4015-20505 to

S4016H-

23499

from S4515-20505

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

Main Page

Default Chapter2
- Find a Manual for this Model2
- Serial Number Legend4
Safety Rules5
- Table of Contents7
Specifications13
- Machine Specifications13
- Performance Specifications14
- Hydraulic Specification14
- Hydraulic Component Specifications16
- Manifold Component Specifications17
- Ford MSG-425 EFI Engine Specifications18
- Deutz D2011 L03I Engine Specifications19
- Deutz D 2.9 L4 Engine Specifications20
- Perkins 404D-22 Engine Specifications21
- Perkins 404F-22 Engine Specifications22
- Machine Torque Specifications23
- TRAX Torque Specifications23
- Hydraulic Hose and Fitting Torque Specifications24
- Torque Procedure25
- SAE and Metric Fasteners Torque Charts26
Repair Procedures27
- Introduction27
Platform Controls29
- Circuit Board29
- Joysticks30
Platform Components34
- Platform Leveling Slave Cylinder34
- Platform Rotator36
- Platform Overload System38
Jib Boom Components40
- Jib Boom40
- Jib Boom Lift Cylinder41
Primary Boom Components42
- Cable Track42
  - How to Remove the Cable Track42
  - How to Repair the Cable Track43
- Boom43
- Boom Lift Cylinder45
- Boom Extension Cylinder46
- Platform Leveling Master Cylinder47
Engines49
- RPM Adjustment - Deutz Models49
- RPM Adjustment - Perkins Models49
- Flex Plate49
- Ford MSG-425 Engine Fault Codes53
Hydraulic Pumps55
- Function Pump55
- Drive Pump56
Manifolds58
- Function Manifold Components58
- Valve Adjustments - Function Manifold62
- Jib Boom / Platform Rotate and Generator Manifold Components64
- Brake / Two Speed Manifold Components65
- Oscillate Directional Valve Manifold Components66
- How to Set up the Oscillate Directional Valve67
- Valve Adjustment - Oscillate Relief Valve68
- Traction Manifold Components, 2WD69
- Traction Manifold Components, 4WD71
- Valve Adjustments, Traction Manifold73
- Drive Oil Diverter Manifold Components (Welder Option)74
- Hydraulic Generator Manifold Components, 3Kw75
- Valve Coils76
Turntable Rotation Components78
- Turntable Rotation Assembly78
Axle Components79
- Oscillating Axle Cylinders79
Track Components80
- Track Assembly80
Generators83
- Hydraulic Generator83
Fault Codes84
- Introduction84
Control System Fault Codes85
- How to Retrieve Control System Fault Codes85
- Control System Fault Codes86
Fault Code Display - Deutz and Perkins Models90
- How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 and Perkins 404F-22 Models90
- Deutz D 2.9 L4 and Perkins 404F-22 Models91
- Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models92
- Main Menu Structure - Deutz D 2.9 L4 Models93
- Main Menu Structure - Perkins 404F-22 Models94
Deutz D 2.9 L4 Engine Fault Codes95
Perkins 404F-22 Engine Fault Codes106
Ford MSG-425 Engine Fault Codes108
- How to Retrieve Ford MSG-425 Engine Fault Codes108
- Ford MSG-425 Engine Fault Codes109
Schematics114
- Introduction114
- Electrical Symbol Legend115
- Hydraulic Symbols Legend116
- Electrical Component and Wire Color Legends117
- Ford Engine Relay Layout121
- Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22122
Electrical Schematics, S-40/45 - Deutz D2.9 and Perkins 404F Models123
- Electrical Schematic Deutz D2.9 L4 Models (ANSI / CSA)124
- Engine Harness Deutz D2.9 L4 Models (ANSI / CSA)128
- Platform Control Box Deutz D2.9 L4 Models (ANSI / CSA)132
- Electrical Schematic Perkins 404F Models (ANSI / CSA)136
- Engine Harness Perkins 404F Models (ANSI / CSA)140
- Platform Control Box Perkins 404F Models (ANSI / CSA)144
Electrical Schematics, S-40/45 - Deutz 2011 and Perkins 404D Models147
- Electrical Schematic - Deutz 2011 and Perkins 404D Models (ANSI / CSA)148
- Electrical Schematic - Deutz 2011 and Perkins 404D Models (CE)152
- Electrical Schematic - Deutz 2011 and Perkins 404D Models (AS)156
- Ground Control Box - Deutz 2011 and Perkins 404D Models (ANSI/CSA_CE_AS)160
- Platform Control Box - Deutz 2011 and Perkins 404D Models (ANSI/CSA_CE_AS)162
Electrical Schematics, S-40/45 - Ford MSG-425 Models165
- Electrical Schematic Ford MSG-425 Models (ANSI / CSA)166
- Electrical Schematic Ford MSG-425 Models (CE)170
- Electrical Schematic Ford MSG-425 Models (AS)174
- Ground Control Box - Ford MSG-425 Models (ANSI/CSA_CE_AS)178
- Platform Control Box - Ford MSG-425 (ANSI/CSA_CE_AS)180
Hydraulic Schematics183
- Hydraulic Schematic, 2WD Models184
- Hydraulic Schematic, 4WD Models185

Terex Genie S-40 - Service And Repair Manual

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