Genie S-65 Installation and operating manual

Service and Repair Manual
Serial Number Range
S
-
6
0
from S6013
-
29296 to S6016
-
31260
from S6016N-31261 to S6016N-35000
from S6016H-35001 to S6016H-36399
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
S
-
6
5
from S6014D
-
101 to S6016D
-
639
from S6016M-101 to S6016M-399
S
-
60
X
from S60X13-26296 to S60X16H-36399
from S60XC13-26296 to S60XC16H-36399
S
-
60X
C
from S60HC13-26296 to S60HC15A-29544
S
-
60 H
C
from S60TX13
-
26296 to S60TX16H
-
36399
from S60TX14D-101 to S60TX16D-639
from S65TX13-26296 to S65TX16H-36399 For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
S
-
60 Tra
X
from S65TX14D
-
101 to S65TX16D
-
639
S
-
65 Tra
X
from S60H
-
36400
from S60XH-36400
from S60XCH-36400
from S60TXH-36400
from S65TXH-36400
from S60D
-
640
from S60TXD-640
from S60XD-640
from S60M
-
400
Part No. 1268492
Rev A1
September 2016

Service and Repair Manual September 2016
Introduction
ii S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Intr oduct io n Intr oduct io n
Impor tant Inf ormati on
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 © 2015 by Terex Corporation
1268492 Rev A, September 2015
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
“S” is a trademark of Terex South Dakota, Inc.

September 2016 Service and Repair Manual
Introduction
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC iii
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 New Release
A1 9/2016 Introduction Serial Number Legend
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 September 2016
Introduction
iv S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Serial Number Legend
To August 31, 2016
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial label (located under cover)
6 Serial number (stamped on chassis)
From September 1, 2016
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual
Safety Rules
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC v
Section 1 Safet y Rul es Gener al Safety 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 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 September 2016
Safety Rules
vi S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
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 mi
nor 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 fir
e 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 capacity.
Be sure that fasteners intended for one
time use (i.e., cotte
r 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.

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC 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 2Specifications.......................................................................................................1
Machine Specifications...........................................................................................1
Performance Specifications....................................................................................2
Hydraulic Specification...........................................................................................3
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..................................................................11
Perkins 404D-22 Engine Specifications...............................................................13
Perkins 404F-22 Engine Specifications ...............................................................14
Machine Torque Specifications............................................................................16
Hydraulic Hose and Fitting Torque Specifications ...............................................17
Torque Procedure ................................................................................................18

September 2016
Table of Contents
viii S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Section 3 Repair Procedures.............................................................................................19
Introduction ..........................................................................................................19
Platform Controls...............................................................................................21
1-1 ALC-500 Circuit Board...................................................................................21
1-2 Joysticks ........................................................................................................22
How to Adjust the Joystick Threshold Setting ................................................23
How to Adjust the Joystick Max-out Setting ...................................................24
How to Adjust the Joystick Ramp Rate Setting ..............................................25
How to Calibrate the Boom Angle Sensor......................................................26
Platform Components .......................................................................................28
2-1 Platform Leveling Slave Cylinder...................................................................28
2-2 Platform Rotator.............................................................................................29
2-3 Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if
equipped) .....................................................................................................32
2-4 Platform Load Sense System, S-60 HC........................................................34
Platform Load Sense - How to Restore System Default Settings System, S-60
HC...........................................................................................................37
Jib Boom Components......................................................................................38
3-1 Jib Boom........................................................................................................38
3-2 Jib Boom Lift Cylinder....................................................................................39

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC ix
Boom Components ............................................................................................40
4-1 Cable Track....................................................................................................40
How to Remove the Cable Track,
S-60, S-60X, S-60XC, S-60 HC and S-60 TRAX....................................40
How to Remove the Cable Track, S-65 and S-65 TRAX................................42
How to Repair the Cable Track.......................................................................43
4-2 Boom..............................................................................................................45
4-3 Boom Lift Cylinder..........................................................................................48
4-4 Boom Extension Cylinder...............................................................................49
4-5 Boom Extend/Retract Cables.........................................................................52
4-6 Platform Leveling Master Cylinder.................................................................55
4-7 Primary Boom Angle Sensor, S-60X and S-60XC.........................................56
Engines................................................................................................................58
5-1 RPM Adjustment - Ford and Deutz Models ...................................................58
5-2 RPM Adjustment - Perkins 404D-22 Models .................................................58
5-3 Flex Plate - Removal......................................................................................58
How to Install a Type "A" Flex Plate................................................................60
How to Install a Type "B" Flex Plate................................................................61
How to install the Pump and Bell Housing Assembly .....................................62
5-4 Ford MSG-425 Engine Fault Codes...............................................................63
5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.............64

September 2016
Table of Contents
x S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Hydraulic Pump..................................................................................................65
6-1 Lift/Steer Pump..............................................................................................65
6-2 Drive Pump....................................................................................................66
Manifolds ............................................................................................................68
7-1 Function Manifold Components (to serial number 26514) ............................68
Function Manifold Components (from serial number 26515) ..............................71
7-2 Valve Adjustments - Function Manifold .........................................................76
7-3 Jib Boom / Platform Rotate Manifold Components........................................77
7-4 Brake/Two-Speed Manifold Components......................................................78
7-5 Turntable Rotation Manifold Components.....................................................79
7-6 Oscillate Directional Valve Components .......................................................80
How to Set Up the Oscillate Directional Valve................................................81
7-7 Valve Adjustments - Oscillate Relief Valve....................................................82
7-8 Drive Oil Diverter Manifold Components (welder option) ..............................83
7-9 Traction Manifold Components, 2WD............................................................84
7-10 Valve Adjustments, 2WD Traction Manifold................................................85
7-11 Traction Manifold Components, 4WD..........................................................86
7-12 Valve Adjustments, 4WD Traction Manifold................................................88
7-13 Hydraulic Generator Manifold Components, 3kW.......................................89
7-14 Valve Coils...................................................................................................90
How to Test a Coil Diode................................................................................91
Turntable Rotation Components......................................................................92
8-1 Turntable Rotation Assembly.........................................................................92
How to Adjust the Turntable Rotation Gear Backlash....................................93
Axle Components...............................................................................................95
9-1 Oscillating Axle Cylinders..............................................................................95
Track Components ............................................................................................96
10-1 Track Assembly, S-60 TRAX and S-65 TRAX.............................................96
How to Replace a Track .................................................................................97

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC xi
Section 4 Fault Codes.......................................................................................................101
Introduction.........................................................................................................101
Control System Fault Codes...........................................................................102
How to Retrieve Control System Fault Codes ..............................................102
Control System Fault Codes.........................................................................103
Fault Code Display - Deutz and Perkins Models...........................................107
How to Retrieve Active Engine Fault Codes
Deutz D 2.9 L4 and Perkins 404F-22 Models.......................................107
Fault Code Display - Flashing and Solid LED's -
Deutz D 2.9 L4 and Perkins 404F-22 Models.......................................108
Soft Key Functions and Icons -
Deutz D 2.9 L4 and Perkins 404F-22 Models.......................................109
Main Menu Structure - Deutz D 2.9 L4 Models.............................................110
Main Menu Structure - Perkins 404F-22 Models ..........................................111
Deutz D 2.9 L4 Engine Fault Codes................................................................112
Perkins 404F-22 Engine Fault Codes .............................................................123
Ford MSG-425 Engine Fault Codes ................................................................125
How to Retrieve Ford MSG-425 Engine Fault Codes...................................125
Ford MSG-425 Engine Fault Codes..............................................................126
Load Sense System Fault Codes....................................................................131
Platform Load Sense System, S-60 HC.............................................................131

September 2016
Table of Contents
xii S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Section 5 Schematics.......................................................................................................139
Introduction ........................................................................................................139
Electrical Symbol Legend ..................................................................................140
Hydraulic Symbols Legend................................................................................141
Limit Switch Location Legend............................................................................142
Ford Engine Relay Layout .................................................................................143
Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22............................144
Electrical Schematics – Options ....................................................................145
Ford MSG-425 EFI Engine Wire Harness .........................................................146
Deutz D 2.9 L4 Engine Wire Harness................................................................147
Perkins 404F-22 Engine Wire Harness .............................................................150
Electrical Schematic, Options -
Deutz D2011L03i, TD2011L04i and Perkins 404D-22...............................151
Electrical Schematic, Options - Deutz D 2.9 L4.................................................154
Electrical Schematic, Options - Perkins 404F-22 ..............................................155
Wiring Diagram, 3kW Hydraulic Generator........................................................158
Wiring Diagram, 12kW Hydraulic Generator - Welder Option ...........................159
Electrical Schematic, 12kW Hydraulic Generator - Welder Option....................162
Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option...................163
Hydraulic Schematics......................................................................................165
Hydraulic Schematic, 2WD Models....................................................................166
Hydraulic Schematic, 4WD Models....................................................................167

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC xiii
Electrical Schematics – ANSI and CSA Models............................................169
Electrical Schematic, Ford MSG-425 EFI Models (ANSI • CSA).......................170
Ground Control Box Terminal Strip Wiring Diagram,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................174
Ground Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................175
Platform Control Box Wiring Diagram,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................178
Platform Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................179
Electrical Schematic, Deutz D2011L03i Models (ANSI • CSA)..........................182
Electrical Schematic, Deutz TD2011L04i Models (ANSI • CSA)........................186
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)..............................190
Ground Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)..............................191
Platform Control Box Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)..............................194
Platform Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)..............................195
Electrical Schematic, Deutz D 2.9 L4 Models (ANSI • CSA)..............................198
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................202
Ground Control Box Switch Panel Wiring Diagram,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................203
Platform Control Box Wiring Diagram,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................206
Platform Control Box Switch Panel Wiring Diagram,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................207
Electrical Schematic, Perkins 404D-22 Models (ANSI • CSA)...........................210
Ground Control Box Terminal Strip Wiring Diagram,
Perkins 404D-22 Models (ANSI • CSA)......................................................214
Ground Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (ANSI • CSA)......................................................215
Platform Control Box Wiring Diagram,
Perkins 404D-22 Models (ANSI • CSA)......................................................218
Platform Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (ANSI • CSA)......................................................219

September 2016
Table of Contents
xiv S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Electrical Schematic, Perkins 404F-22 Models (ANSI • CSA)...........................222
Ground Control Box Terminal Strip Wiring Diagram,
Perkins 404F-22 Models (ANSI • CSA)......................................................226
Ground Control Box Switch Panel Wiring Diagram,
Perkins 404F-22 Models (ANSI • CSA)......................................................227
Platform Control Box Wiring Diagram,
Perkins 404F-22 Models (ANSI • CSA)......................................................230
Platform Control Box Switch Panel Wiring Diagram,
Perkins 404F-22 Models (ANSI • CSA)......................................................231
Electrical Schematic, S-60X • S-60XC
Ford MSG-425 EFI Models (ANSI • CSA)..................................................234
Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................238
Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................239
Platform Control Box Wiring Diagram, S-60X • S-60XC,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................242
Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Ford MSG-425 EFI Models (ANSI • CSA)..................................................243
Electrical Schematic, S-60X • S-60XC,
Deutz D2011L03i Models (ANSI • CSA)............................................................246
Electrical Schematic, S-60X • S-60XC,
Deutz TD2011L04i Models (ANSI • CSA)..................................................250
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).............................254
Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).............................255
Platform Control Box Wiring Diagram, S-60X • S-60XC,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).............................258
Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).............................259

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC xv
Electrical Schematic, S-60X • S-60XC,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................262
Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................266
Ground Control Box Switch Panel Wiring Diagram,S-60X • S-60XC,
Deutz D 2.9 L4 (ANSI • CSA).....................................................................267
Platform Control Box Wiring Diagram, S-60X • S-60XC,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................270
Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Deutz D 2.9 L4 Models (ANSI • CSA) ........................................................271
Electrical Schematic, S-60X • S-60XC,
Perkins 404D-22 Models (ANSI • CSA)......................................................274
Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC,
Perkins 404D-22 Models (ANSI • CSA)......................................................278
Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Perkins 404D-22 Models (ANSI • CSA)......................................................279
Platform Control Box Wiring Diagram, S-60X • S-60XC,
Perkins 404D-22 Models (ANSI • CSA)......................................................282
Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Perkins 404D-22 Models (ANSI • CSA)......................................................283
Electrical Schematic, S-60X • S-60XC,
Perkins 404F-22 Models (ANSI • CSA)......................................................286
Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC,
Perkins 404F-22 Models (ANSI • CSA)......................................................290
Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC,
Perkins 404F-22 Models (ANSI • CSA)......................................................291
Platform Control Box Wiring Diagram, S-60X • S-60XC,
Perkins 404F-22 Models (ANSI • CSA)......................................................294
Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Perkins
404F-22 Models (ANSI • CSA)...................................................................295

September 2016
Table of Contents
xvi S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Electrical Schematics – CE Models ...............................................................297
Electrical Schematic, Ford MSG-425 EFI Models (CE).....................................298
Ground Control Box Terminal Strip Wiring Diagram,
Ford MSG-425 EFI Models (CE)................................................................302
Ground Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (CE)................................................................303
Platform Control Box Wiring Diagram,
Ford MSG-425 EFI Models (CE)................................................................306
Platform Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (CE)................................................................307
Electrical Schematic, Deutz D2011L03i Models (CE)........................................310
Electrical Schematic, Deutz TD2011L04i Models (CE) .....................................314
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (CE) ...........................................318
Ground Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (CE) ...........................................319
Platform Control Box Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (CE) ...........................................322
Platform Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (CE) ...........................................323
Electrical Schematic, Perkins 404D-22 Models (CE).........................................326
Ground Control Box Terminal Strip Wiring Diagram,
Perkins 404D-22 Models (CE) ...................................................................330
Ground Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (CE) ...................................................................331
Platform Control Box Wiring Diagram, Perkins 404D-22 Models (CE)..............334
Platform Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (CE) ...................................................................335
Electrical Schematic, S-60 HC (CE) ..................................................................338
Chassis Wiring Diagram, S-60 HC (CE)............................................................339
Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (CE) .................342
Platform Control Box Wiring Diagram, S-60 HC (CE)........................................343

September 2016
Table of Contents
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC xvii
Electrical Schematics – AS Models................................................................345
Electrical Schematic, Ford MSG-425 EFI Models (AS)......................................346
Ground Control Box Terminal Strip Wiring Diagram,
Ford MSG-425 EFI Models (AS) ................................................................350
Ground Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (AS) ................................................................351
Platform Control Box Wiring Diagram,
Ford MSG-425 EFI Models (AS) ................................................................354
Platform Control Box Switch Panel Wiring Diagram,
Ford MSG-425 EFI Models (AS) ................................................................355
Electrical Schematic, Deutz D2011L03i Models (AS)........................................358
Electrical Schematic, Deutz TD2011L04i Models (AS)......................................362
Ground Control Box Terminal Strip Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (AS)............................................366
Ground Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (AS)............................................367
Platform Control Box Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (AS)............................................370
Platform Control Box Switch Panel Wiring Diagram,
Deutz D2011L03i • TD2011L04i Models (AS)............................................371
Electrical Schematic, Perkins 404D-22 Models (AS).........................................374
Ground Control Box Terminal Strip Wiring Diagram,
Perkins 404D-22 Models (AS)....................................................................378
Ground Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (AS)....................................................................379
Platform Control Box Wiring Diagram, Perkins 404D-22 Models (AS) ..............382
Platform Control Box Switch Panel Wiring Diagram,
Perkins 404D-22 Models (AS)....................................................................383

September 2016 Service and Repair Manual
Specifications
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC 1
Section 2 Speci ficati ons
Machi ne Spec ific ations
Machine Specifications
Tires and wheels, S
-60, S-65, S-60 HC, S-60X and
S
-60XC
Tire size (Rough terrain)
355/55D625
Tire
weight, new foam-filled (minimum)
(Rough terrain)
415 l
bs
188 k
g
Tire size
(Hi
-flotation)
41/18LL x 22.5
Tire ply rating
(Rough terrain and Hi
-flotation)
14
Wheel lugs
9 @ 5/8 -
18
Lug nut torque, dry
240 ft-
lbs
325 Nm
Lug nut torque, lubricated
180 ft-
lbs
244 Nm
Overall tire diameter
(Rough terrain, low profile tires)
36.9 i
n
93.7 c
m
Overall tire diameter
(Hi
-flotation tires) 40.3 i
n
102.4 c
m
Tire pressure
(Rough terrain, low profile tires)
70 p
si
4.92 b
ar
Tire pressure
(Hi
-flotation tires) 60 p
si
4.13 b
ar
Track Components, S
-60 TRAX and S-65 TRAX
Track material
Rubber
Tensioning system
Pressurized
grease
Weight (each)
1,500 l
bs
680 k
g
Fluid capacities
Fuel tank
(Deutz and Perkins Models)
35 g
allons
132.5 l
iters
(Ford models)
30 g
allons
113.5 l
iters
LPG tank
33.5 p
ounds
15.2 k
g
Hydraulic tank
45 g
allons
170 l
iters
Hydraulic system(including tank)
55 g
allons
208 l
iters
Drive hubs
20 f
l oz
591 c
c
Turntable rotation drive hub
(before serial number 20367)
40 f
l oz
1183 c
c
(after serial number 20366)
43 o
z
1262 c
c
Drive hub oil type:SAE 9
0 multipurpose
hypoid gear oil API service
classification GL5
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

Service and Repair Manual September 2016
Specifications
2 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 1268492
Perf ormanc e Speci ficati ons
Performance Specifications
Boom function speeds, maximum from platform
controls
Jib boom up (S
-65 models) 60 to 70 s
econds
Jib boom down (S
-65 models) 40 to 50 s
econds
Boom up
60 to 70 s
econds
Boom down
60 to 70 s
econds
Boom extend
58 to 66 s
econds
Boom retract
53 to 62 s
econds
Turntable rotate, 360°
boom stowed
78 to 86 s
econds
Turntable rotate, 360°
boom extended
125 to 165 s
econds
Platform
rotate, 160° 8 to 12 s
econds
Braking distance, maximum
High range on paved surface
3 to 6 f
t
0.9 to 1.8
m
Drive speed, maximum stowed position
2WD models
40 ft / 6.2 s
ec
12.2 m / 6.2 s
ec
4WD models
40 ft / 7.2 s
ec
12.2 m / 7.2 s
ec
S
-60 TRAX and S-65 TRAX 40 ft / 12 s
ec
12.2 m / 12 s
ec
Drive speed, maximum raised or extended position
S
-60, S-65, S-60 HC, S-60X
and S
-60XC 40 ft / 40 s
ec
12.2 m / 40 s
ec
S
-60 TRAX and S-65 TRAX 40 ft / 57 s
ec
12.2 m / 57 s
ec
Gradeability
See Operator's Manual
For operational specifications, refer to the
Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.

September 2016 Service and Repair Manual
Specifications
Part No. 1268492 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC 3
Hydra ulic Sp ecific ation
Hydraulic Oil Specifications
Hydra
ulic Fluid Specifications
Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should
provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same
hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV