Terex Genie Lift Guard S-60 User manual

Service Manual
Serial Number Range
S-60
from S6013-26296]
S-65
from S6013-26296
S-60X
from S60X13-26296
S-60XC
from S60XC13-26296
S-60 HC
from S60HC13-26296
S-60 TraX
from S60TX13-26296
S-65 TraX
from S65TX13-26296
Part No. 825591
Rev A1
February 2015

Service Manual February 2015
Introduction
ii S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 825591
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
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also 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 Operator's, Parts or Service
Manuals.
Copyright © 2012 by Terex Corporation
825591 Rev A1, February 2015
Seventh 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.

February 2015 Service Manual
Introduction
Part No. 825591 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 12/2013 New Release
A1 2/2015 Maintenance Added B-22 Test the Emergency Power System
Reference Examples:
Section – Maintenance, B-3 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 Manual February 2015
Introduction
iv S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 825591
Revision History
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3 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

February 2015 Service Manual
Introduction
Part No. 825591 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC v
Serial Number Legend
1 Model
2 Model year
3 Sequence number
4 Serial number (stamped on chassis)
5 Serial label

Service Manual February 2015
Safety Rules
vi S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 825591
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.

February 2015 Service Manual
Safety Rules
Part No. 825591 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC vii
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
ma
nual 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
si
tuation 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
wa
rrants 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 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 int
ended 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.

February 2015
Table of Contents
viii S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 825591
Introduction Introduction..........................................................................................................ii
Important Information..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History.....................................................................................................iii
Serial Number Legend........................................................................................... v
Section 1 Safety Rules.........................................................................................................vi
General Safety Rules.............................................................................................vi
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 .................................................................12
Perkins 404D-22 Engine Specifications...............................................................14
Perkins 404F-22 Engine Specifications...............................................................15
Machine Torque Specifications............................................................................17
Hydraulic Hose and Fitting Torque Specifications...............................................18
Torque Procedure................................................................................................19

February 2015
Table of Contents
Part No. 825591 S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC ix
Section 3 Scheduled Maintenance Procedures ...............................................................21
Introduction...........................................................................................................21
Pre-Delivery Preparation Report..........................................................................24
Maintenance Inspection Report............................................................................25
Checklist A Procedures.....................................................................................27
A-1 Inspect the Manuals and Decals....................................................................27
A-2 Perform Pre-operation Inspection..................................................................28
A-3 Perform Function Tests .................................................................................28
A-4 Perform Engine Maintenance - Ford Models.................................................29
A-5 Perform Engine Maintenance - Deutz Models...............................................29
A-6 Perform Engine Maintenance - Perkins Models............................................30
A-7 Check the High Pressure Hydraulic Filter Condition Indicator ......................30
A-8 Test the Oscillate Axle...................................................................................31
A-9 Inspect the Track Components, S-60 TRAX and S-65 TRAX.......................31
A-10 Perform 30 Day Service...............................................................................32
A-11 Check the Track Tension and Fastener Torque,
S-60 TRAX and S-65 TRAX.........................................................................32
A-12 Perform Engine Maintenance - Ford Models...............................................34
A-13 Perform Engine Maintenance - Ford Models...............................................34
A-14 Inspect the Fuel Filter/ Water Separator - Perkins Models..........................35
A-15 Check and Adjust the Engine RPM - Perkins 404D-22 Models ..................36
A-16 Grease the Turntable Rotation Bearing and Rotate Gear...........................37
A-17 Replace the Drive Hub Oil...........................................................................37
A-18 Perform Engine Maintenance - Ford Models...............................................39

February 2015
Table of Contents
x S-60 • S-65 • S-60 TRAX • S-65 TRAX • S-60 HC • S-60X • S-60XC Part No. 825591
Checklist B Procedures.....................................................................................40
B-1 Inspect the Battery ........................................................................................40
B-2 Inspect the Electrical Wiring..........................................................................41
B-3 Check the Exhaust System...........................................................................42
B-4 Perform Engine Maintenance - Perkins Models............................................43
B-5 Check the Oil Cooler and Cooling Fins - Deutz D2011 L03i Models...........43
B-6 Inspect the Tires, Wheels and Lug Nut Torque,
S-60, S-65, S-60 HC, S60X and S-60XC.....................................................44
B-7 Confirm the Proper Brake Configuration.......................................................45
B-8 Check the Drive Hub Oil Level and Fastener Torque ...................................45
B-9 Check and Adjust the Engine RPM -
Deutz D2011 L03i and TD2011L04i.............................................................47
B-10 Test the Ground Control Override...............................................................48
B-11 Check the Oscillate Directional Valve Linkage............................................49
B-12 Test the Platform Self-leveling ....................................................................49
B-13 Test the Engine Idle Select .........................................................................50
B-14 Test the Fuel Select Operation - Ford Models ............................................51
B-15 Test the Drive Brakes..................................................................................52
B-16 Test the Drive Speed - Stowed Position .....................................................52
B-17 Test the Drive Speed - Raised or Extended Position..................................53
B-18 Test the Alarm Package (if equipped).........................................................54
B-19 Perform Hydraulic Oil Analysis....................................................................55
B-20 Inspect the Fuel and Hydraulic Tank Cap Venting Systems.......................55
B-21 Inspect the Boom Extend/Retract Cables ...................................................56
B-22 Test the Emergency Power System............................................................58
B-23 Perform Engine Maintenance - Ford Models ..............................................59