Terex Genie S-60XC Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-60 XC™

from S60XCH-45010

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S®-60 HF

S®-60 TraX™

S®-65 XC™

from S65XCH-45001

from S65XCM-

101

from S65XCD-101

S®-65 HF

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

S®-65 TraX™

Part No.

1288652GT

Rev D1

April 2021

Service and Repair Manual April 2021

Introduction

ii S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™Part No. 1288652GT

Introducti on Introduction

Important Information

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.

1288652GT Rev D, June 2020

First Edition, Fourth 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.

April 2021 Service and Repair Manual

Introduction

Part No. 1288652GT S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™iii

Revision History

Revision Date Section Procedure / Page / Description

A 7/2018

Initial Release

B 9/2018 Specifications Hydraulic Component Specifications

Repair Display Menu

Schematics Electrical schematics, Hydraulic Schematics

C 1/2019 All Sections Add ANSI model

C1 3/2019 Repair 1-5

C2 5/2019 Specifications Machine Specifications

Repair Function manifold, Generator manifold

Fault Codes Control System Fault Codes

Schematics Electrical schematics, Hydraulic Schematics

C3 6/2019 Fault Codes Control System Fault Codes

C4 7/2019 Repair Display Menu

D 5/2020 All Sections Add Deutz TD 2.2 L3 Engine

Repair 2-3

D1 4/2021 Specifications Machine Torque Specifications

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 April 2021

Introduction

iv S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™Part No. 1288652GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on drive chassis)

April 2021 Service and Repair Manual

Safety Rules

Part No. 1288652GT S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™v

Section 1 Safety Rules General Safety Rules

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 April 2021

Safety Rules

vi S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™Part No. 1288652GT

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 avoid

ed, may result in

property damage.

Be sure to wear protective eye wear

d 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 plac

ing 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 sur

e to keep sparks, flames and

lighted tobacco away from flammable

and combu

stible 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

condit

ion 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 tim

Be sure to properly dispose of old oil

or other fluids. Us

e an approved

container. Please be environmentally

safe.

Be sure that your workshop or work

area is properly ventilated and well lit.

April 2021

Table of Contents

Part No. 1288652GT S®-60/65 XC™• S®-60/65 HF • S®-60/65 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

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

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

Deutz TD2011L04i Engine Specifications..............................................................9

Deutz TD 2.2 L3 Engine Specifications................................................................10

Deutz D 2.9 L4 Engine Specifications..................................................................11

Deutz TD 2.9 Engine Specifications.....................................................................12

Perkins 404D-22 Engine Specifications ...............................................................13

Perkins 404F-E22T Engine Specifications...........................................................14

Machine Torque Specifications ............................................................................15

Hydraulic Hose and Fitting Torque Specifications ...............................................16

Torque Procedure ................................................................................................17

April 2021

Table of Contents

viii S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™Part No. 1288652GT

Section 3 Repair Procedures ............................................................................................. 19

Introduction .......................................................................................................... 19

Control System................................................................................................... 21

1-1 ALC-600 Platform Control Module................................................................. 21

1-2 ALC-600 Service Mode.................................................................................. 21

1-3 Full Machine Calibration ................................................................................ 22

1-4 Machine Functions......................................................................................... 23

How to Adjust the Machine Maximum Speed Setting..................................... 23

How to Adjust the Joystick Ramp Rate Setting .............................................. 24

How to Adjust the Joystick Threshold Setting ................................................ 25

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 ........................... 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.......................................... 41

2-4 Platform.......................................................................................................... 42

Jib Boom Components...................................................................................... 43

3-1 Jib Boom ........................................................................................................ 43

3-2 Jib Boom Lift Cylinder.................................................................................... 44

April 2021

Table of Contents

Part No. 1288652GT S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™ix

Boom Components ............................................................................................45

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

4-1 Cable Track....................................................................................................46

How to Remove the Cable Track, S-60 XC and S-60 TRAX ..........................46

How to Remove the Cable Track, S-65 XC and S-65 XC TRAX ....................47

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

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

4-3 Boom Lift Cylinder..........................................................................................52

4-4 Boom Extension Cylinder...............................................................................53

4-5 Boom Extend/Retract Cables.........................................................................55

4-6 Platform Leveling Master Cylinder .................................................................58

4-7 Primary Boom Angle Sensor Calibration .......................................................59

4-8 Primary Boom Angle Sensor Replacement ...................................................60

4-9 Boom Length Sensor Calibration ...................................................................62

Engines................................................................................................................64

5-1 RPM Adjustment - Ford and Deutz Models ...................................................64

5-2 RPM Adjustment - Perkins 404D-22 Models .................................................64

5-3 Flex Plate - Removal......................................................................................64

How to Install a Type "A" Flex Plate................................................................66

How to Install a Type "B" Flex Plate................................................................67

How to install the Pump and Bell Housing Assembly .....................................68

5-4 Engine Fault Codes........................................................................................69

5-5 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3...................................70

Hydraulic Pump ..................................................................................................71

6-1 Lift/Steer Pump ..............................................................................................71

6-2 Drive Pump.....................................................................................................72

April 2021

Table of Contents

x S®-60/65 XC™• S®-60/65 HF • S®-60/65 TraX™Part No. 1288652GT

Manifolds ............................................................................................................ 76

7-1 Function Manifold Components - from S60XCH-45010 to 45345,

S65XCH-45001 to 45345, S65XCM-101 to 302 .......................................... 76

7-1.1 Function Manifold Components - from S60XCH-45345,

S65XCH-45345, S65SCM-303, S65XCD-101 ............................................. 80

7-2 Valve Adjustments - Function Manifold ......................................................... 84

How to Adjust the Boom Extend Relief Valve................................................. 84

7-3 Jib Boom / Platform Rotate Manifold Components........................................ 85

7-4 Turntable Rotation Manifold Components ..................................................... 86

7-5 Valve Adjustments - Oscillate Relief Valve.................................................... 87

How to Set Up the Oscillate Directional Valve................................................ 87

7-6 Traction Manifold Components, 4WD............................................................ 90

7-7 Valve Adjustments, 4WD Traction Manifold .................................................. 92

7-9 Generator Manifold Components .................................................................. 93

7-11 Hydraulic Generator..................................................................................... 93

7-10 Valve Coils................................................................................................... 95

How to Test a Coil Diode................................................................................ 96

Turntable Rotation Components...................................................................... 97

8-1 Turntable Rotation Assembly......................................................................... 97

How to Adjust the Turntable Rotation Gear Backlash .................................... 98

How to Calibrate the Turntable Tilt Sensor..................................................... 99

Axle Components............................................................................................. 101

9-1 Oscillating Axle Cylinders ............................................................................ 101

Track Components .......................................................................................... 102

10-1 Track Assembly, S-60 TRAX and S-65 TRAX........................................... 102

How to Replace a Track ............................................................................... 102

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