Terex Genie S-40XC Installation and operating manual

Service and Repair Manual
Serial Number Range
S®-40 XC™
from S40XCH-101
to S40XCH-
3290
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic
Schematics
S®-40 HF
S®-40 TraX™
S®-45 XC™
from S45XCH-104
to S45XCH-329
1
S®-45 HF
from S45XCD-167
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
S®-45 TraX™
Original Instructions
Part No. 1286829GT
Rev C
February 2023

Service and Repair Manual February 2023
Introduction
ii S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1286829GT
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.
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 © 2019 by Terex Corporation
1286829GT Rev C, February 2023
First Edition, Third Printing
Genie and "S" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
"XC" and "TraX" are trademarks of Terex South Dakota,
Inc.

February 2023 Service and Repair Manual
Introduction
Part No. 1286829GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™iii
Revision History
Revision Date Section Procedure / Page / Description
A 2/2019 Initial Release
A1 7/2019 Repair Display Menu
B 10/2019 Add S-40/45 HF
Specifications Machine Specifications
Repair 2-3, 7-6
Fault Codes Ford MSG-425
Schematics Limit Switch Legend
C 2/2023 All Sections Add Deutz TD 2.2 L3, D 2.9 L4 CN4 Engines
Repair 2-3
Front cover Add ending serial break
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. 1286829GT
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. 1286829GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™v
Section 1 Safet y R ul es
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. 1286829GT
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
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 cap
acity.
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. 1286829GT 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
TRAX Torque Specifications ................................................................................13
Machine Component Weights ..............................................................................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. 1286829GT
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 .............................................. 24
1-6 Display Module Menus .................................................................................. 25
1-7 How to Replace the Display Controller (DISCON) Module ........................... 31
1-8 How to Replace the Ground Control Overlay ................................................ 32
Platform Components ....................................................................................... 35
2-1 Platform Leveling Slave Cylinder................................................................... 35
2-2 Platform Rotator............................................................................................. 36
2-3 Platform Overload System............................................................................. 39
How to Perform a Zero Load Platform Calibration.......................................... 39
How to Perform a Full Load Platform Calibration ........................................... 40
How to Replace the Platform Overload Load Cell .......................................... 42
2-4 Platform.......................................................................................................... 43
Jib Boom Components...................................................................................... 44
3-1 Jib Boom ........................................................................................................ 44
3-2 Jib Boom Lift Cylinder.................................................................................... 45

February 2023
Table of Contents
Part No. 1286829GT S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™ix
Primary Boom Components..............................................................................46
4-1 Cable Track ....................................................................................................46
How to Remove the Cable Track ....................................................................46
How to Repair the Cable Track .......................................................................47
4-2 Boom ..............................................................................................................47
4-3 Boom Lift Cylinder..........................................................................................50
4-4 Boom Extension Cylinder...............................................................................51
4-5 Platform Leveling Master Cylinder .................................................................52
4-6 Primary Boom Angle Sensor Calibration .......................................................53
4-7 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
Manifolds.............................................................................................................63
7-1 Function Manifold Components .....................................................................63
7-2 Valve Adjustments - Function Manifold..........................................................67
How to Adjust the Boom Extend Relief Valve .................................................67
7-3 Jib Boom and Platform Rotate Manifold Components ...................................68
7-4 Traction Manifold Components, 4WD ............................................................69
7-5 Valve Adjustments, Traction Manifold............................................................71
7-6 Valve Adjustment - Oscillate Relief Valve......................................................71
How to Set Up the Oscillate Directional Valve ................................................72
7-7 Generator Manifold Components ...................................................................73
7-8 Valve Coils .....................................................................................................74
How to Test a Coil Diode ................................................................................75

February 2023
Table of Contents
x S®-40/45 XC™• S®-40/45 HF • S®-40/45 TraX™Part No. 1286829GT
Turntable Rotation Components...................................................................... 76
8-1 Turntable Rotation Assembly......................................................................... 76
How to Adjust the Turntable Rotation Gear Backlash .................................... 77
How to Calibrate the Turntable Tilt Sensor..................................................... 78
Axle Components............................................................................................... 80
9-1 Oscillating Axle Cylinders .............................................................................. 80
Track Components ............................................................................................ 81
10-1 Track Assembly ........................................................................................... 81