Terex S-60 J Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-60 J

from S60JH-101

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1285305GT

Rev A

December 2019

Service and Repair Manual December 2019

Introduction

ii S®-60 J Part No. 1285305GT

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.

1285305GT Rev A, December 2019

First Edition, First Printing

Genie and "S" are registered trademarks of Terex South Dakota,

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

December 2019 Service and Repair Manual

Introduction

Part No. 1285305GT S®-60 J iii

Revision History

Revision Date Section Procedure / Page / Description

A 9/2019

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 December 2019

Introduction

iv S®-60 J Part No. 1285305GT

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

December 2019 Service and Repair Manual

Safety Rules

Part No. 1285305GT S®-60 J 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 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 December 2019

Safety Rules

vi S®-60 J Part No. 1285305GT

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 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 prop

erly 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 stabili

zing 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.

December 2019

Table of Contents

Part No. 1285305GT S®-60 J 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....................................................................................1

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

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

Deutz D2011 L03i Engine Specifications ...............................................................6

Kubota D1105-E4B Engine Specifications.............................................................7

Kubota D1803-CR-TIE4 Engine Specifications......................................................8

Machine Torque Specifications ..............................................................................9

Machine Component Weights ................................................................................9

Hydraulic Hose and Fitting Torque Specifications ...............................................10

Torque Procedure ................................................................................................11

December 2019

Table of Contents

viii S®-60 J Part No. 1285305GT

Section 3 Repair Procedures..............................................................................................13

Introduction ...........................................................................................................13

Control System ...................................................................................................15

1-1 ALC-600 Platform Control Module .................................................................15

1-2 ALC-600 Service Mode ..................................................................................15

1-3 Full Machine Calibration.................................................................................16

1-4 Machine Functions .........................................................................................17

How to Adjust the Machine Maximum Speed Setting .....................................17

How to Adjust the Joystick Ramp Rate Setting...............................................18

How to Adjust the Joystick Threshold Setting .................................................19

1-5 How to Enter ALC600 Software Update Mode...............................................19

1-6 Display Module Menus ...................................................................................20

1-7 How to Replace the Display Controller (DISCON) Module ............................24

1-8 How to Replace the Ground Control Overlay.................................................25

Platform Components ........................................................................................27

2-1 Platform Leveling Slave Cylinder ...................................................................27

2-2 Platform Rotator .............................................................................................28

2-3 Platform Overload System .............................................................................30

How to Calibrate the Platform Overload System.............................................30

How to Perform a Zero Load Platform Overload Calibration ..........................32

How to Replace the Platform Overload Load Cell...........................................32

2-4 Platform ..........................................................................................................33

Jib Boom Components ......................................................................................34

3-1 Jib Boom.........................................................................................................34

3-2 Jib Boom Lift Cylinder ....................................................................................35

Boom Components ............................................................................................36

December 2019

Table of Contents

Part No. 1285305GT S®-60 J ix

Boom Components ............................................................................................37

4-1 Cable Track ....................................................................................................37

How to Remove the Cable Track ....................................................................37

How to Repair the Cable Track .......................................................................39

4-2 Primary Boom.................................................................................................40

4-3 Boom Lift Cylinder..........................................................................................41

4-4 Primary Boom Extension Cylinder .................................................................42

4-5 Platform Leveling Master Cylinder .................................................................43

4-6 Primary Boom Angle Sensor..........................................................................44

How to Repalce the Primary Boom Angle Sensor ..........................................45

Engines................................................................................................................46

5-1 RPM Adjustment - Kubota D1105 and Deutz D2011 Models ........................46

5-2 Flex Plate .......................................................................................................46

How to Install the Flex Plate............................................................................47

How to install the Pump and Bell Housing Assembly .....................................48

5-3 Engine Fault Codes - Kubota D1803 Models.................................................49

Hydraulic Pump ..................................................................................................50

6-1 Function Pump ...............................................................................................50

6-2 Drive Pump.....................................................................................................50

How to Install the Drive Pump Coupler ...........................................................51

6-3 How to Prime the Drive and Function Pumps ................................................51

6-4 Generator Pump.............................................................................................52

December 2019

Table of Contents

x S®-60 J Part No. 1285305GT

Manifolds .............................................................................................................54

7-1 Function Manifold Components......................................................................54

7-2 Valve Adjustments - Function Manifold..........................................................58

How to Adjust the Boom Extend Relief Valve .................................................58

7-3 Jib Boom / Platform Rotate Manifold Components ........................................59

7-4 Turntable Rotation Manifold Components......................................................60

7-5 Valve Adjustments - Oscillate Relief Valve ....................................................61

How to Set Up the Oscillate Directional Valve ................................................61

7-6 Traction Manifold Components, 4WD ............................................................64

7-7 Valve Adjustments, 4WD Traction Manifold...................................................66

7-8 Brake/Two-Speed Manifold Components ......................................................67

7-9 Generator Manifold Components ...................................................................68

7-10 Turntable Rotation Manifold Components....................................................69

7-11 Valve Coils ...................................................................................................70

Turntable Rotation Components.......................................................................71

8-1 Turntable Rotation Assembly .........................................................................71

How to Adjust the Turntable Rotation Gear Backlash.....................................72

8-2 Turntable Angle Sensor Replacement ...........................................................73

Axle Components ...............................................................................................74

9-1 Oscillating Axle Cylinders...............................................................................74

Andere Handbücher für S-60 J

Inhaltsverzeichnis

Andere Terex Hubarbeitsbühne Handbücher

Terex

Terex Genie Z62D-150 Bedienungsanleitung

Terex

Terex Genie Z-34/22N Bedienungsanleitung

Terex

Terex GRJL-2298 Bedienungsanleitung

Terex

Terex S8016D-236 Bedienungsanleitung

Terex

Terex Genie GTH-4518 ER Bedienungsanleitung

Terex

Terex Genie S65XCD-1251 Bedienungsanleitung

Terex

Terex Genie Lift Guard S-45 Bedienungsanleitung

Terex

Terex Genie S-65 TraX Bedienungsanleitung

Terex

Terex Genie Z-45/25J Bi-Energy Bedienungsanleitung

Terex

Terex Z-33 Bedienungsanleitung

Terex

Terex Z331816M-1299 Bedienungsanleitung

Terex

Terex Genie Z-60 DC Bedienungsanleitung

Terex

Terex Gyro 4020 Bedienungsanleitung

Terex

Terex Genie GR-20J Bedienungsanleitung

Terex

Terex ZX13515-2558 Bedienungsanleitung

Terex

Terex Genie Z-60/37 DC Installations- und Betriebsanleitung

Terex

Terex Genie Z-60DC Bedienungsanleitung

Terex

Terex Genie GTH-636 Bedienungsanleitung

Terex

Terex SX15015H-101 Installations- und Betriebsanleitung

Terex

Terex Genie S-80 SC Bedienungsanleitung

Terex

Terex Genie S-3200 Bedienungsanleitung

Terex

Terex Genie Z-135/70 Installations- und Betriebsanleitung

Terex

Terex Genie S-80 Installations- und Betriebsanleitung

Terex

Terex SX15015-101 Bedienungsanleitung

Beliebte Hubarbeitsbühne Handbücher anderer Marken

Genie

Genie Z-80 Bedienungsanleitung

Genie

Genie Z-45/25 Bedienungsanleitung

JLG

JLG Skytrak 6036 Gebrauchs- und Pflegehandbuch

LGMG

LGMG T65JE Bedienungsanleitung

Genie

Genie Z-135/70 Bedienungsanleitung

Oshkosh Corporation

Oshkosh Corporation JLG H800AJ Gebrauchs- und Pflegehandbuch

Oshkosh

Oshkosh JLG 1500SJ Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ30AJE Bedienungsanleitung

Oshkosh

Oshkosh JLG 800A Installations- und Benutzerhandbuch

Skyjack

Skyjack SJ 46AJ Bedienungsanleitung

Molift

Molift Quick Raiser 205 Bedienungsanleitung

Snorkel

Snorkel SL26RTE Kurzanleitung

Oshkosh Corporation

Oshkosh Corporation JLG E300A Bedienungsanleitung

Skyjack

Skyjack SJ45 T+ Bedienungsanleitung

Genie

Genie S-105 Bedienungsanleitung

nifty

nifty 170SD series Montageanleitung

JLG

JLG 15MVL Series Bedienungsanleitung

Genie

Genie Z-45 XC Bedienungsanleitung