Terex Genie S-40XC Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-40 XC™

from S40XCH-3291

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S®-40 HF

S®-40 TraX™

S®-45 XC™

from S45XCH-3292

S®-45 HF

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

S®-45 TraX™

Original

Instructions

Part No. 1322629GT

Rev A

February 2023

Service and Repair Manual February 2023

Introduction

ii S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1322629GT

Intr od ucti o n Intr od ucti o n

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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

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.

1322629GT Rev A, February 2023

Second Edition, First Printing

Genie and "S" are registered trademarks of Terex South

Dakota, Inc. in the U.S.A. and many other countries.

"XC" and "TraX" aretrademarks of Terex South Dakota,

Inc.

February 2023 Service and Repair Manual

Introduction

Part No. 1322629GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™iii

Revision History

Revision Date Section Procedure / Page / Description

A 2/2023

Initial Release

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 February 2023

Introduction

iv S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1322629GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

February 2023 Service and Repair Manual

Safety Rules

Part No. 1322629GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™v

Section 1 Safet y 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 modify or alter a MEWP without prior

written permission from the manufacturer.

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 February 2023

Safety Rules

vi S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1322629GT

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 potential

ly 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 crushing 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 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

com

ponents 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.

February 2023

Table of Contents

Part No. 1322629GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™vii

Introduction Introduction...........................................................................................................ii

Important Information ............................................................................................. ii

Find a Manual for this Model .................................................................................. ii

Revision History..................................................................................................... iii

Serial Number Legend .......................................................................................... iv

Section 1 Safety Rules ..........................................................................................................v

General Safety Rules ............................................................................................. v

Section 2 Specifications .......................................................................................................1

Machine Specifications...........................................................................................1

Performance Specifications....................................................................................2

Hydraulic Oil Specifications ....................................................................................2

Hydraulic Component Specifications......................................................................5

Manifold Component Specifications .......................................................................6

Ford MSG-425 EFI Engine Specifications .............................................................7

Deutz D2011 L03i Engine Specifications ...............................................................8

Deutz D 2.9 L4 Tier IV Engine Specifications ........................................................9

Deutz D 2.9 L4 Stage IV Engine Specifications ...................................................10

Deutz TD 2.2 L3 Engine Specifications................................................................11

Perkins 404F-E22T Engine Specifications...........................................................12

Machine Torque Specifications ............................................................................13

Machine Component Weights ..............................................................................13

TRAX Torque Specifications ................................................................................14

Hydraulic Hose and Fitting Torque Specifications ...............................................15

Torque Procedure ................................................................................................16

February 2023

Table of Contents

viii S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1322629GT

Section 3 Repair Procedures ............................................................................................. 18

Introduction .......................................................................................................... 18

Control System................................................................................................... 20

1-1 ALC-600 Platform Control Module................................................................. 20

1-2 ALC-600 Service Mode.................................................................................. 20

1-3 Full Machine Calibration ................................................................................ 21

1-4 Machine Functions......................................................................................... 22

How to Adjust the Machine Maximum Speed Setting..................................... 22

How to Adjust the Joystick Ramp Rate Setting .............................................. 23

How to Adjust the Joystick Threshold Setting ................................................ 24

1-5 How to Enter ALC600 Software Update Mode .............................................. 25

1-6 Display Module Menus .................................................................................. 26

1-7 How to Replace the Display Controller (DISCON) Module ........................... 32

1-8 How to Replace the Ground Control Overlay ................................................ 33

Platform Components ....................................................................................... 36

2-1 Platform Leveling Cylinder............................................................................. 36

How to Remove the Platform Leveling Cylinder ............................................. 36

How to Bleed the Platform Leveling Cylinder ................................................. 36

2-2 Platform Rotator............................................................................................. 37

2-3 Platform Overload System............................................................................. 40

How to Perform a Zero Load Platform Calibration.......................................... 40

How to Perform a Full Load Platform Calibration ........................................... 41

How to Replace the Platform Overload Load Cell .......................................... 43

2-4 Platform.......................................................................................................... 44

2-5 Platform Level Sensor ................................................................................... 45

February 2023

Table of Contents

Part No. 1322629GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™ix

Jib Boom Components ......................................................................................46

3-1 Jib Boom ........................................................................................................46

3-2 Jib Boom Lift Cylinder ....................................................................................47

Primary Boom Components..............................................................................48

4-1 Cable Track ....................................................................................................48

How to Remove the Cable Track ....................................................................48

How to Repair the Cable Track .......................................................................49

4-2 Boom ..............................................................................................................49

4-3 Boom Lift Cylinder..........................................................................................51

4-4 Boom Extension Cylinder...............................................................................52

4-5 Primary Boom Angle Sensor Calibration .......................................................53

4-6 Boom Length Sensor .....................................................................................54

Engines................................................................................................................55

5-1 RPM adjustment - Deutz Models ...................................................................55

5-2 RPM adjustment - Perkins Models.................................................................55

5-3 Flex Plate .......................................................................................................55

How to install the Pump and Bell Housing Assembly .....................................58

5-4 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3...................................59

Hydraulic Pump ..................................................................................................60

6-1 Function Pump ...............................................................................................60

6-2 Drive Pump.....................................................................................................61

February 2023

Table of Contents

x S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1322629GT

Manifolds ............................................................................................................ 63

7-1 Function Manifold Components ..................................................................... 63

7-2 Valve Adjustments - Function Manifold ......................................................... 67

How to Adjust the System Relief Valve .......................................................... 67

How to Adjust the Boom Extend Relief Valve................................................. 67

7-3 Traction Manifold Components...................................................................... 68

7-4 Valve Adjustments, Traction Manifold ........................................................... 70

7-5 Valve Adjustment - Oscillate Relief Valve ..................................................... 71

How to Set Up the Oscillate Directional Valve................................................ 71

7-6 Platform Manifold Components, S-40 XC, S-40 HF, S-40 TraX.................... 73

7-7 Platform Manifold Components, S-45 XC, S-45 HF, S-45 TraX.................... 74

7-8 Platform Rotate Manifold Components.......................................................... 75

7-9 Generator Manifold Components .................................................................. 76

7-10 Valve Coils ................................................................................................... 77

How to Test a Coil Diode ................................................................................ 78

Turntable Rotation Components...................................................................... 79

8-1 Turntable Rotation Assembly......................................................................... 79

How to Adjust the Turntable Rotation Gear Backlash .................................... 80

How to Calibrate the Turntable Tilt Sensor..................................................... 81

Axle Components............................................................................................... 83

9-1 Oscillating Axle Cylinders .............................................................................. 83

Track Components ............................................................................................ 84

10-1 Track Assembly ........................................................................................... 84

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