Terex S-60 J Installation and operating manual

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.
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 © 2019 by Terex Corporation
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