Terex S65XCM-101 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

S®-60 XC™

from S65XCM-101

from S60XCH-

45010

from S65XCH-

45001

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

S®-65 XC™

S®-60 TraX™

S®-65 TraX™

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1288652GT

Rev C

March 2019

Service and Repair Manual March 2019

Introduction

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

Intr oduct io n Intr oduct io 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.

1288652GT Rev C, January 2019

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.

March 2019 Service and Repair Manual

Introduction

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

Revision History

Revision Date Section Procedure / Page / Description

A 7/2018

New Release

9/2018

Specifications

Oscillate valve relief pressure

Repair

Display menu

Schematics

Update hydraulic and electrica

l schematics

1/2019

Added ANSI version

3/2019

Repair

-5 Joystick Threshold Setting

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 March 2019

Introduction

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

Serial Number Legend

1 Model

2 Facility code

3 Sequence number

1 Serial label (located under cover)

2 Serial number (stamped on drive chassis)

March 2019 Service and Repair Manual

Safety Rules

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

Section 1 Safet y Rul 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:

RYou are trained and qualified to perform

maintenance on this machine.

RYou read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

RYou have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual March 2019

Safety Rules

vi S®-60 XC™• S®-65 XC™S®-60 TraX™S®-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 iden

tify 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

injur

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 mov

ing 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 support

ing 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 a

nd well lit.

March 2019

Table of Contents

Part No. 1288652GT S®-60 XC™• S®-65 XC™S®-60 TraX™S®-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....................................................................................1

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............................................................10

Deutz D 2.9 L4 Engine Specifications..................................................................12

Deutz TD 2.9 Engine Specifications.....................................................................14

Perkins 404D-22 Engine Specifications...............................................................15

Perkins 404F-E22T Engine Specifications...........................................................16

Machine Torque Specifications............................................................................18

Hydraulic Hose and Fitting Torque Specifications ...............................................19

Torque Procedure ................................................................................................20

March 2019

Table of Contents

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

Section 3 Repair Procedures..............................................................................................22

Introduction...........................................................................................................22

Control System...................................................................................................24

1-1 ALC-600 Platform Control Module .................................................................24

1-2 ALC-600 Service Mode ..................................................................................25

1-3 How to Use the Recovery Mode ....................................................................26

1-4 Full Machine Calibration.................................................................................27

1-5 Machine Functions .........................................................................................27

How to Adjust the Machine Maximum Speed Setting.....................................27

How to Adjust the Joystick Ramp Rate Setting...............................................28

How to Adjust the Joystick Threshold Setting.................................................29

1-6 How to Enter ALC600 Software Update Mode...............................................30

1-8 How to Replace the Display Controller (DISCON) Module............................36

1-9 How to Replace the Ground Control Overlay.................................................37

Platform Components........................................................................................39

2-1 Platform Leveling Slave Cylinder ...................................................................39

2-2 Platform Rotator .............................................................................................40

2-3 Platform Overload System .............................................................................43

How to Calibrate the Platform Overload System.............................................43

How to Perform Zero Load Platform Overload Calibration .............................44

How to Replace the Platform Overload Load Cell...........................................45

2-4 Platform..........................................................................................................46

March 2019

Table of Contents

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

Jib Boom Components......................................................................................48

3-1 Jib Boom ........................................................................................................48

3-2 Jib Boom Lift Cylinder ....................................................................................49

Boom Components ............................................................................................50

4-1 Cable Track....................................................................................................50

How to Remove the Cable Track, S-60 XC and S-60 TraX............................50

How to Remove the Cable Track, S-65 XC and S-65 TraX............................51

How to Repair the Cable Track.......................................................................53

4-2 Boom..............................................................................................................55

How to Remove the Boom ..............................................................................55

4-3 Boom Lift Cylinder..........................................................................................58

4-4 Boom Extension Cylinder...............................................................................59

4-5 Boom Extend/Retract Cables.........................................................................62

4-6 Platform Leveling Master Cylinder.................................................................65

4-7 Primary Boom Angle Sensor Calibration .......................................................66

4-8 Primary Boom Angle Sensor Replacement ...................................................67

4-9 Boom Length Sensor Calibration...................................................................69

March 2019

Table of Contents

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

Engines................................................................................................................71

5-1 RPM Adjustment - Ford and Deutz Models....................................................71

5-2 RPM Adjustment - Perkins 404D-22 Models..................................................71

5-3 Flex Plate - Removal......................................................................................71

How to Install a Type "A" Flex Plate................................................................73

How to Install a Type "B" Flex Plate................................................................74

How to install the Pump and Bell Housing Assembly .....................................75

5-4 Ford MSG-425 Engine Fault Codes...............................................................76

5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404-22 Models ...............77

Hydraulic Pump ..................................................................................................78

6-1 Lift/Steer Pump...............................................................................................78

6-2 Drive Pump.....................................................................................................79

Manifolds.............................................................................................................82

7-1 Function Manifold Components .....................................................................82

7-2 Valve Adjustments - Function Manifold..........................................................86

How to Adjust the Boom Extend Relief Valve.................................................86

7-3 Jib Boom / Platform Rotate Manifold Components........................................87

7-5 Turntable Rotation Manifold Components......................................................88

7-6 How to Set Up the Oscillate Directional Valve..........................................89

7-7 Valve Adjustments - Oscillate Relief Valve ....................................................90

7-8 Traction Manifold Components, 4WD............................................................92

7-9 Valve Adjustments, 4WD Traction Manifold...................................................94

7-10 Generator Manifold Components.................................................................95

7-11 Valve Coils ...................................................................................................96

How to Test a Coil Diode.................................................................................97

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