Terex S65XCM-101 Installation and operating manual

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
1
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.
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
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
B
9/2018
Specifications
Oscillate valve relief pressure
Repair
Display menu
Schematics
Update hydraulic and electrica
l schematics
C
1/2019
Added ANSI version
C1
3/2019
Repair
1
-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
y.
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