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Genie S-60 XC
Terex Genie S-60 XC Service And Repair Manual
217 pages
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Service and Re
pair Manual
Serial Number Ran
ge
S
®
-60 XC
™
from
S60XCH-
45
010
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
S
®
-60 HF
S
®
-60
TraX
™
S
®
-65 XC
™
f
rom
S65XCH-45001
f
ro
m
S65XCM-
101
f
ro
m S65XCD-
101
S
®
-65 HF
For detailed maintenance
procedures, refer t
o the
appropriate Main
tenance
Manual for your machine.
S
®
-65 TraX
™
Part No.
1288652GT
Rev D1
April 2021
2
Table of Contents
Front Cover
1
Important Information
2
Find a Manual for this Model
2
Revision History
3
Serial Number Legend
4
General Safety Rules
5
Table of Contents
7
Specifications
13
Machine Specifications
13
Performance Specifications
14
Hydraulic Oil Specifications
14
Hydraulic Component Specifications
17
Ford MSG-425 EFI Engine Specifications
19
Deutz D2011 L03i Engine Specifications
20
Deutz TD2011L04i Engine Specifications
21
Deutz TD 2.2 L3 Engine Specifications
22
Deutz D 2.9 L4 Engine Specifications
23
Deutz TD 2.9 Engine Specifications
24
Perkins 404D-22 Engine Specifications
25
Perkins 404F-E22T Engine Specifications
26
Machine Torque Specifications
27
Hydraulic Hose and Fitting Torque Specifications
28
Torque Procedure
29
Repair Procedures
31
Introduction
31
Control System
33
1-1 ALC-600 Platform Control Module
33
1-2 ALC-600 Service Mode
33
1-3 Full Machine Calibration
34
1-4 Machine Functions
35
How to Adjust the Machine Maximum Speed Setting
35
How to Adjust the Joystick Ramp Rate Setting
36
How to Adjust the Joystick Threshold Setting
37
1-5 How to Enter ALC600 Software Update Mode
37
1-6 Display Module Menus
38
1-7 How to Replace the Display Controller (DISCON) Module
43
1-8 How to Replace the Ground Control Overlay
44
Platform Components
47
2-1 Platform Leveling Slave Cylinder
47
2-2 Platform Rotator
48
2-3 Platform Overload System
51
How to Perform a Zero Load Platform Calibration
51
How to Perform a Full Load Platform Calibration
52
How to Replace the Platform Overload Load Cell
53
2-4 Platform
54
Jib Boom Components
55
3-1 Jib Boom
55
3-2 Jib Boom Lift Cylinder
56
Boom Components
57
Boom Components
58
4-1 Cable Track
58
How to Remove the Cable Track, S-60 XC and S-60 TRAX
58
How to Remove the Cable Track, S-65 XC and S-65 XC TRAX
59
How to Repair the Cable Track
61
4-2 Boom Assembly
61
4-3 Boom Lift Cylinder
64
4-4 Boom Extension Cylinder
65
4-5 Boom Extend/Retract Cables
67
4-6 Platform Leveling Master Cylinder
70
4-7 Primary Boom Angle Sensor Calibration
71
4-8 Primary Boom Angle Sensor Replacement
72
4-9 Boom Length Sensor Calibration
74
Engines
76
5-1 RPM Adjustment - Ford and Deutz Models
76
5-2 RPM Adjustment - Perkins 404D-22 Models
76
5-3 Flex Plate - Removal
76
How to Install a Type "A" Flex Plate
78
How to Install a Type "B" Flex Plate
79
How to install the Pump and Bell Housing Assembly
80
5-4 Engine Fault Codes
81
5-5 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3
82
Hydraulic Pump
83
6-1 Lift/Steer Pump
83
6-2 Drive Pump
84
Manifolds
88
7-1 Function Manifold Components - from S60XCH-45010 to 45345, S65XCH-45001 to 45345, S65XCM-101 to 302
88
7-1.1 Function Manifold Components - from S60XCH-45345, S65XCH-45345, S65SCM-303, S65XCD-101
92
7-2 Valve Adjustments - Function Manifold
96
How to Adjust the Boom Extend Relief Valve
96
7-3 Jib Boom / Platform Rotate Manifold Components
97
7-4 Turntable Rotation Manifold Components
98
7-5 Valve Adjustments - Oscillate Relief Valve
99
How to Set Up the Oscillate Directional Valve
99
7-6 Traction Manifold Components, 4WD
102
7-7 Valve Adjustments, 4WD Traction Manifold
104
7-9 Generator Manifold Components
105
7-11 Hydraulic Generator
105
7-10 Valve Coils
107
How to Test a Coil Diode
108
Turntable Rotation Components
109
8-1 Turntable Rotation Assembly
109
How to Adjust the Turntable Rotation Gear Backlash
110
How to Calibrate the Turntable Tilt Sensor
111
Axle Components
113
9-1 Oscillating Axle Cylinders
113
Track Components
114
10-1 Track Assembly, S-60 TRAX and S-65 TRAX
114
How to Replace a Track
114
Fault Codes
118
Introduction
118
Control System Fault Codes
119
How to Retrieve Control System Fault Codes
119
Control System Fault Codes - Models with Revision G Software or Lower
120
Control System Fault Codes - Models with Revision H Software or Higher
137
Engine Fault Codes
154
Deutz TD 2.2 L3 Engine Fault Codes
155
Deutz D 2.9 L4 Engine Fault Codes
165
Perkins 404-22 Engine Fault Codes
176
Ford MSG-425 Engine Fault Codes
178
Schematics
183
Introduction
183
Electrical Symbol Legend
184
Hydraulic Symbols Legend
185
Limit Switch Location Legend
186
Electrical Schematics
187
Electrical Schematic, Turntable Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101)
188
Electrical Schematic, Platform Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101)
189
Electrical Schematic, Turntable Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101)
192
Electrical Schematic, Platform Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101)
193
Electrical Schematic, Deutz TD 2.2 L3 Models
196
Electrical Schematic, Deutz TD 2.2 L3 Engine Harness
197
Electrical Schematic, Deutz D 2.9 L4 Models
200
Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Models
201
Electrical Schematic, Perkins 404F-E22T Models
204
Electrical Schematic, Perkins 404D-22 Models
205
Electrical Schematic, Ford MSG-425 EFI Models
208
Electrical Schematic, Generators
209
Hydraulic Schematics
211
Hydraulic Schematic, (from S65XCM-101 to S65XCM-302)
212
Hydraulic Schematic, (from S60XCH-45010 to 45344, S65XCH-45001 to 45344)
213
Hydraulic Schematic, (from S60XCH-45345, S65XCH-45345, S65XCD-101)
215
Back Cover
217
Other manuals for Terex Genie S-60 XC
Operator's Manual
81 pages
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Terex Genie S-60 XC Specifications
General
Turntable Rotation
360° Continuous
Gradeability
45%
Engine Type
Diesel
Machine Length
27 ft 10 in (8.48 m)
Stowed Height
8 ft 10 in (2.69 m)
Tire Type
Solid
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