Terex Genie S-60XC Installation and operating manual

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.
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 © 2018 by Terex Corporation
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
an
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
e.
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