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Genie S-65 XC CE, Service And Repair Manual

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Service and Repair Manual

 

September 2018

 

Introduction

 

 

 

ii 

S

®

-60 XC

™

 • S

®

-65 XC

™

 

Part No. 1288652GT 

 

 

Intr oducti on 

Intr oducti on 

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: [email protected] 

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 B, September 2018 

First Edition, First 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. 

 

Summary of Contents for S-65 XC CE

Page 1: ... S 65 XC from S65XCM 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 1288652GT Rev B September 2018 ...

Page 2: ...e 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 com...

Page 3: ...2018 New Release B 9 2018 Specifications Oscillate valve relief pressure Repair Display menu Schematics Update hydraulic and electrical schematics 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 ...

Page 4: ...pair Manual September 2018 Introduction iv S 60 XC S 65 XC 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 ...

Page 5: ...ury 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 R You are trained and qualified to perform maintenance on this machine R You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulatio...

Page 6: ...al 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 ...

Page 7: ...ations 2 Hydraulic Component Specifications 5 Ford MSG 425 EFI Engine Specifications 6 Deutz D2011 L03i Engine Specifications 7 Deutz TD2011L04i Engine Specifications 8 Deutz D 2 9 L4 Engine Specifications 10 Perkins 404D 22 Engine Specifications 11 Machine Torque Specifications 12 Hydraulic Hose and Fitting Torque Specifications 13 Torque Procedure 14 Section 3 Repair Procedures 16 Introduction 1...

Page 8: ...ow to Calibrate the Platform Overload System 38 How to Perform Zero Load Platform Overload Calibration 39 How to Replace the Platform Overload Load Cell 40 2 4 Platform 40 Jib Boom Components 42 3 1 Jib Boom 42 3 2 Jib Boom Lift Cylinder 43 Boom Components 44 4 1 Cable Track 44 How to Remove the Cable Track S 60 XC and S 60 TRAX 44 How to Remove the Cable Track S 65 XC and S 65 XC TRAX 45 How to R...

Page 9: ... Components 76 7 2 Valve Adjustments Function Manifold 80 How to Adjust the System Relief Valve 80 How to Adjust the Boom Down Relief Valv 80 How to Adjust the Boom Extend Relief Valve 80 7 3 Jib Boom Platform Rotate Manifold Components 81 7 5 Turntable Rotation Manifold Components 82 7 6 How to Set Up the Oscillate Directional Valve 83 7 7 Valve Adjustments Oscillate Relief Valve 83 7 8 Traction ...

Page 10: ...9 How to Retrieve Ford MSG 425 Engine Fault Codes 129 Ford MSG 425 Engine Fault Codes 130 Section 5 Schematics 135 Introduction 135 Electrical Symbol Legend 136 Hydraulic Symbols Legend 137 Limit Switches and Angle Sensors 138 Limit Switch Location Legend 139 Electrical Schematics 141 Electrical Schematic TCON 142 Electrical Schematic Deutz 2 9L Models 146 Electrical Schematic Deutz 2011 Models 14...

Page 11: ...e rotation drive hub 43 fl oz 1262 cc Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 For operational specifications refer to the Operator s Manual Performance Specifications Boom function speeds maximum from platform controls Jib boom up S 65 XC models 48 to 53 seconds Jib boom down S 65 XC models 28 to 33 seconds Boom up 65 to 75 seconds Boom down 65 to 75 s...

Page 12: ...ydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If...

Page 13: ...below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hy...

Page 14: ...hell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C ...

Page 15: ... relief valve pressure 3000 psi 207 bar Jib boom platform rotate flow regulator 0 8 gpm 3 L min Steer flow regulator 3 5 gpm 13 2 L min Oscillate relief valve pressure 2500 rpm 600 psi 41 4 bar Drive manifold Hot oil relief valve pressure 280 psi 19 3 bar Drive motors 4WD models Displacement per revolution high speed 0 79 cu in 13 cc Displacement per revolution low speed 1 83 cu in 30 cc Hydraulic...

Page 16: ...quirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Electronic fuel pump Fuel pressure static 60 psi 4 1 bar Fuel flow rate 0 43 gpm 1 6 L min Fuel requirement For fuel requirements refer to the engine Operator Manual for your engine Ignition system Spark plug type Motorcraft AYFS 32Y R ...

Page 17: ... 32 C 10W 40 Above 23 F 5 C 20W 50 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Temperature switch point 220 F 104 C Oil Pressure switch Oil pressure switch point 22 psi 1 5 bar Deutz D2011 L03i Engine continued Fuel injection system Injection pump...

Page 18: ...ugal mechanical Valve clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure hot at 2000 rpm 40 to 60 psi 2 8 to 4 1 bar Oil capacity including filter 12 8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may requ...

Page 19: ...njector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Starter motor Current draw normal load 140 200A Cranking speed 250 350 rpm Battery Type 12V DC Size 13 x 613 16 x 93 8 inches 33 x 17 3 x 23 8 cm Quantity 1 Cold cranking ampere 1000A Reserve capacity 25A rate 200 minutes Alternator output 80A 14V DC Fan belt defle...

Page 20: ... 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Temperature switch point 257 F 125 C Oil Pressure switch Oil pressure switch point 20 psi 1 4 bar Engine coolant Capacity 10 quarts 9 4 liters Fuel injection system Injection pump make Bosch Injection pump pressure max...

Page 21: ...Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel injection system Injection pump make Zexel Inject...

Page 22: ...on assembly Backlash pivot plate lubricated 317 ft lbs 430 Nm TRAX Torque Specifications Sprocket to hub adapter fasteners 3 4 10 nuts GR 8 dry 317 ft lbs 430 Nm 3 4 10 nuts GR 8 lubricated 281 ft lbs 381 Nm 1 2 13 FHS screws dry 80 ft lbs 108 Nm 1 2 13 FHS screws lubricated 60 ft lbs 81 Nm Hub adapter to drive hub fasteners Lug nut torque dry 240 ft lbs 325 Nm Lug nut torque lubricated 180 ft lbs...

Page 23: ...16 18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE ...

Page 24: ...eated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex...

Page 25: ...rect number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex ...

Page 26: ...ual on your machine R Be sure that all necessary tools and parts are available and ready for use R Use only Genie approved replacement parts R Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration R Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine park...

Page 27: ... 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 no...

Page 28: ...ystick controllers at the platform controls utilize Hall Effect technology and require no calibration Automatic calibration of center voltage occurs on power up if the signal value is in the valid range Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion The remaining boom functions operate by on off toggle switches 1 ALC 600 plat...

Page 29: ...ct the ground control mode using the key switch 2 Push and hold buttons numbered 2 and 3 underneath the display screen 3 Pull out the red Emergency Stop button 4 You will be prompted for a password Enter 3 3 2 4 5 Press the Gear button to access the settings menu Note There will be a delay while the menu is being loaded on the display screen 6 The machine will now operate normally and allow the vi...

Page 30: ... the operator at the platform controls to exit the platform 1 Move the key switch to the Ground Control position 2 Pull out the red Emergency Stop button at the ground controls 3 While pressing the ground function enable button push and hold the recovery toggle switch in the recovery position Result The auxiliary power unit will turn on and the boom will begin the following recovery sequence The p...

Page 31: ...ngle Sensor Primary boom length sensor Refer to Repair Procedure How to Calibrate the Primary Boom Length Sensor Select option configuration Refer to Repair Section Display Module Options 1 5 Machine Functions How to Adj ust the Machine M axi mum Speed Setti ng How to Adjust the Joystick Maximum Speed Setting The maximum speed of a joystick controlled machine function can be modified from the grou...

Page 32: ... 10 5 sec 12 2 m 8 10 5 sec Non stowed 40 ft 38 45 sec 12 2m 38 45 sec How to Adj ust the Joystick Ramp R ate Setting How to Adjust the Joystick Ramp Rate Setting The ramp rate setting is an adjustment that controls the way boom functions start and stop There are two types of ramp rates to adjust on separate menus Ramp Up Time the amount of time it takes to accelerate to speed Ramp Down Time the a...

Page 33: ...hold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate The boom function threshold current should be operating at near zero speed smoothly with no vibrations Note Perform this procedure with the boom in the stowed position 1 Enter the Service Mode 2 Press the SETTINGS button above the display screen 3...

Page 34: ...ove the four Torx head screws securing the Display Controller DISCON door and remove the door to expose the USB port 1 Insert the flash drive into the USB port 2 Set keyswitch to ground and pull out the red ground ESTOP while holding buttons 1 and 4 3 The Display Controller will go into the bootloader mode 4 Browse and select the desired software Follow the on screen guidance to start the update p...

Page 35: ...TZ D2011 L03i DEUTZ TD2011 L04I PERKINS 404D 22T PERKINS 404F E22T GM 3 0L FORD MSG425 select engine Tires ROUGH TERRAIN HIGH FLOAT select tires Footswitch Timeout 10 sec 2 min 30 min 2 min Drive Priority ON OFF OFF Drive Cutout ON OFF OFF Platform Level Cutout ON OFF OFF Generator NO GENERATOR GENERATOR INSTALLED NO GENERATOR Overload Recovery Evidence of Use ON OFF OFF Contact Alarm ON OFF ON Pl...

Page 36: ... Reverse Threshold 132 max 50 min 100 540 mA default Forward Max 150 max 72 min 100 1365 mA default Reverse Max 150 max 72 min 100 1250 mA default Forward Out of Stow Max 150 max 84 min 100 888 mA default Reverse Out of Stow Max 150 max 81 min 100 888 mA default Screen or Menu Item Default Drive Ramps Standard Acceleration 5000 ms max 100 ms min 4000 ms default Standard Deceleration 5000 ms max 10...

Page 37: ...n or Menu Item Default Perkins 404D Anti Stall Threshold default 2350 rpm Drive Minimum default 50 Range default 125 rpm Hysteresis default 100 rpm Screen or Menu Item Default Perkins 404F Anti Stall Threshold default 2350 rpm Drive Minimum default 50 Range default 125 rpm Hysteresis default 100 rpm Screen or Menu Item Default Ford MSG425 Anti Stall Threshold default 2375 rpm Drive Minimum default...

Page 38: ...2500 ms default Extend Decelerating Rate 5000 ms max 250 ms min 1000 ms default Retract Accelerating Rate 5000 ms max 1000 ms min 2500 ms default Retract Decelerating Rate 5000 ms max 500 ms min 1000 ms default Up Accelerating Rate 5000 ms max 1000 ms min 3000 ms default Up Decelerating Rate 5000 ms max 500 ms min 3000 ms default Down Accelerating Rate 5000 ms max 1000 ms min 3000 ms default Down ...

Page 39: ...hreshold max 150 min 77 default 100 Platform Rotate CCW Threshold max 150 min 77 default 100 Jib Up Max Output max 150 min 80 default 114 Jib Down Max Output max 150 min 80 default 114 Platform Level Up Max Output max 150 min 83 default 100 Platform Level Down Max Output max 150 min 83 default 100 Platform Rotate CW Max Output max 150 min 77 default 100 Platform Rotate CCW Max Output max 150 min 7...

Page 40: ...rs Note the lanyard attachment point for reassembly 6 Remove the old DISCON gasket 2 from the ground box lid and clean the lid surface from any dirt oil or old adhesive residue Use a 99 solution of isopropyl alcohol to clean the surface Allow the surface to completely dry Note Both the ground box lid and new gasket must be 70 F 21 C or higher at the time of application Application of the new gaske...

Page 41: ...tart battery and auxiliary batteries if equipped 1 9 How to Replace the Ground Box Control Overlay 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the negative terminal from the start battery and auxiliary battery if equipped Illustration 1 3 Open the ground box lid and remove the switch contacts from the function enable and E Stop ...

Page 42: ... sure the temperature of the lid and overlay is between 80 100 F 26 38 C Application below 80 F 26 C is not recommended 10 Peel the adhesive protective film from the back of the overlay Carefully align the overlay making sure the LCD screen cutout push buttons and key switch are centered Apply the overlay to the ground box applying pressure evenly to eliminate any air bubbles Note Pay particular a...

Page 43: ...round box using the fasteners removed in step 7 Tighten the fasteners securely 15 Reinstall the E Stop button function enable button and key switch and the contact assemblies 16 Reinstall the wire harness from the ground box to the DISCON Secure the harness to the ground box lid using zip ties 17 Close and fasten the ground box lid 18 Reconnect the negative terminal to the start battery and auxili...

Page 44: ...ort 3 Lower the boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to drive the rod end pivot pin out Crushing hazard S 65 and S 65 TRAX The jib boom could fall when the slave cylinder rod end pivot pin i...

Page 45: ...fications 1 Remove the platform and platform support Note If the load sense components are disassembled and or removed from the platform support the platform load sense system will need to be calibrated Refer to Repair Procedure Platform Load Sense System 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator 3 Tag disconnect and plug the h...

Page 46: ...er the jib boom leveling arms Crushing hazard The platform rotator may become unbalanced and fall if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications S 65 XC 11 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins Do not remove the pins 12 Support the jib boom leveling arms 13...

Page 47: ...nable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw on the rotator but do not remove it Bodily injury hazard Spra...

Page 48: ... and start the calibration procedure 8 Follow the on screen instructions to set the zero load 9 Continue with the on screen prompts to set the maximum load 10 Place a 1 000 lb 454 kg test weight on the platform floor using a suitable lifting device Place the weight near the center entry point of the platform as far away from the operator controls as possible as shown in Illustration 1 Illustration...

Page 49: ...ty will be reduced until a full load calibration has been performed A full load calibration is required for rated load performance Note Perform this procedure with the machine on a firm level surface 1 Fully retract the boom Level the platform 2 Remove all material tools and equipment from the platform Remove the welder if equipped Tip over hazard Failure to remove all factory and non factory acce...

Page 50: ...hould not contact the flex plate when assembling onto the platform support 7 Assemble the load cell and foot assembly to the platform and securely tighten the two mounting screws Torque the bolts to 101 ft lbs 137 Nm Set the Load Cell Sensor Preload 8 Rotate the foot screw counter clockwise until the foot just contacts the flex plate finger tight 9 Using an open end wrench continue to rotate the f...

Page 51: ...switch Remove the cable from the back of the platform Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the platform control box mounting fasteners Lower the control box and set it aside Component damage hazard Cables can be damaged if they are kinked or pinched Note If your machine is eq...

Page 52: ...hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cyli...

Page 53: ...il pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remov...

Page 54: ...valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of t...

Page 55: ...le Track S 65 XC and S 65 XC TR AX How to Remove the Cable Track S 65 XC and S 65 XC TRAX Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Open the platform control box 2 Tag and disconnec...

Page 56: ...d burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 16 Pull the hydraulic hoses out of the primary boom 17 Remove the cotter pin from the upper cable track at the platform end of the boom Note Always replace the cotter pin with a new one 18 Remove the cable track pull tube guide fasteners from the cable track gui...

Page 57: ...e 4 link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable...

Page 58: ...oom 3 boom lift cylinder rod end pivot pin 4 boom lift cylinder 5 long link arm ground controls side 6 long link arm engine side 7 long link arm to turntable pivot pin 8 master cylinder cam 9 master cylinder cam link 10short link arm to turntable pivot pin 11long link arm to boom pivot pin 12master platform level cylinder 13short link arm weldment ...

Page 59: ...e workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Remove the cable track Refer to Repair Procedure How to Remove the Cable Track 3 Raise the boom until the short and long link arm to boom pivot...

Page 60: ...ect the electrical connector from the string potentiometer 13 Disconnect the electrical connector from the primary boom angle sensor Note The primary boom angle sensor is located on the pivot pin on the engine side of the boom 14 Remove the primary boom angle sensor bracket mounting fasteners and remove the primary boom angle sensor from the primary boom Do not remove the angle sensor from the bra...

Page 61: ...d disconnect all boom wire harness electrical connectors located at the pivot end of the boom 25 Support the platform leveling master cylinder Remove the master cylinder rod end pivot pin retaining fasteners Place a rod through the pin and twist to remove Carefully lower the master cylinder down 26 Tag disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom ...

Page 62: ...orizontal position 2 Attach a 5 ton 5000 kg overhead crane to the boom at the platform end for support Do not lift the boom 3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device 4 Remove the pin retaining fastener from the boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin Crushing hazard The boom will fall if not p...

Page 63: ...unterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommende...

Page 64: ...emove the cable retaining plates and pull the retract cables off of the pulleys Lay the cables flat and out of the way 11 Remove the fasteners from the retaining blocks from the extension cylinder saddle Remove the blocks Note Access the fasteners through the access hole in the outer boom tube at the pivot end 12 Disconnect the wire connector to the extend cable break limit switch 13 Remove the re...

Page 65: ...ying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 23 Attach a lifting strap from a 5 ton 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder 24 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 b...

Page 66: ...lean and in good condition with no damaged threads 4 Adjust the extend cable adjustment nuts until approximately 1 5 inches 4 cm of threads are visible past the nylock nut Note If the cables have been replaced be sure the adjustment nuts have been replaced Do not re use the existing nuts 5 Extend the boom until there is approximately 3 feet 1 m of travel left Do not fully extend the boom 6 Locate ...

Page 67: ...Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft metal drift to remove the pin Note When driving the pivot pin out be sure to drive it from the sh...

Page 68: ...o 94510 15 At the platform end of the boom pull on the boom retract cable that has the rope attached to it 16 Pull the old cable completely out of the boom tube Remove the rope Discard the old boom retract cable 17 Securely attach the rope to the same end of the new boom retract cable 18 At the pivot end of the boom carefully pull the rope with the new retract cable attached 19 Pull the new cable ...

Page 69: ...ise the boom until the master cylinder is above the turntable covers 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Place a 2 x 4 x 48 inches 5 x 10 x 1...

Page 70: ...or Calibrations menu 4 Navigate to the Boom Angle Sensor calibration screen 5 Select and start the calibration procedure 6 Start the engine 7 When the display prompts the operator to lower the boom press and hold the function enable button and the boom down buttons until the display indicates that the lower calibration point has been obtained This may require holding the buttons for several second...

Page 71: ...urn the key switch to the off position 3 Disconnect the negative terminal from the start battery and auxiliary battery if equipped 4 Using Illustration 1 as a guide remove the end boom cover 1 Tag and disconnect the wire harness going to the sensor Note how the sensor harness is routed under the boom cover for reassembly 5 Cut and discard the two zip ties securing the angle sensor harness to the s...

Page 72: ...eaded holes in the sensor carrier plate 10 Remove the sensor s magnet 3 from the pin guide mount by removing the two screws 4 using a 2 mm hex key Note the orientation of the magnet on the pin guide mount for reassembly Discard the screws 11 Remove any old blue thread locker dirt or oils from the threaded holes in the pin guide mount 12 Apply blue thread locker into the pin guide mount threaded ho...

Page 73: ...ate the boom angle sensor Refer to Repair Procedure How to Calibrate the Boom Angle Sensor 4 8 Boom Length Sensor How to Calibrate the Primary Boom Length Sensor Note The turntable level sensor must be calibrated prior to calibrating the primary boom Note Primary boom angle must be calibrated before calibrating boom length Note This procedure will establish the cross check angle with the boom limi...

Page 74: ...the maximum extension point 9 Press the function enable and boom extend buttons until the boom reaches its maximum extension Continue holding the buttons for several seconds after the boom reaches its maximum extension until the display indicates the calibration point has been captured 10 The calibration is complete 11 Exit the Service Mode ...

Page 75: ...Adjust the Engine RPM 5 3 Flex Plate The flex plate acts as a coupler between the engine and the pump It is bolted to the engine flywheel and has a splined center to drive the pump Two different styles of flex plates have been used in the production of your machine model Type A flex plates utilize a flex plate installed onto the flywheel of the engine and a separate coupler installed onto the pump...

Page 76: ...th an overhead crane or other suitable lifting device Do not lift it 6 Remove the engine mounting plate to bell housing fasteners 7 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support 8 Support the drive pump assembly with an overhead crane or other suitable lifting device Do not apply any lifting pressure 9 Remove all of the engine bell housi...

Page 77: ...n sequence to 40 ft lbs 54 Nm Perkins models Torque the flex plate mounting bolts in sequence to 49 ft lbs 66 Nm Then torque the flex plate mounting bolts in sequence to 70 ft lbs 95 Nm Ford and Deutz Models Perkins Models 3 Install the pump coupler onto the pump shaft with the set screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 1 pump 2 pump shaf...

Page 78: ... fasteners 3 Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm Ford and Perkins models Torque the flex plate mounting bolts in sequence to 14 ft lbs 19 Nm Then torque the flex plate mounting bolts in sequence to 20 ft lbs 27 Nm 4 Apply a high viscosity coupling grease Genie part number 128025 to...

Page 79: ...m Then torque the bell housing mounting bolts labeled A and B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts ...

Page 80: ...t and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engi...

Page 81: ...at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor One or more fault LED s will illuminate on the display located at the ground control box The active fault code will also be displayed on the LCD screen If a ...

Page 82: ...ent damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pum Bodily injury hazard Spraying hydra...

Page 83: ...hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valve...

Page 84: ... the counterweight end of the machine 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position Perkins 404D 22 models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Deutz D2011L03i D436 ...

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Page 86: ...rm level pilot check 20 25 ft lbs 27 34 Nm 8 Solenoid valve 2 position 2 way AH Two speed motor shift 26 30 ft lbs 35 40 Nm 9 Solenoid valve 3 position 4 way KK Steering directional 33 37 ft lbs 45 50 Nm 10 Proportional valve R Boom up down proportional 33 37 ft lbs 45 50 Nm 11 Pressure compensated flow control valve AM Primary lift 30 35 ft lbs 41 47 Nm 12 Pressure compensated flow control valve ...

Page 87: ...September 2018 Service and Repair Manual Manifolds Part No 1288652GT S 60 XC S 65 XC 77 ...

Page 88: ...ase circuit 8 10 ft lbs 10 15 Nm 22 Solenoid valve 2 position 2 way AS Brake release 26 30 ft lbs 35 40 Nm 23 Orifice 0 024 in 0 6 mm AW Brake release circuit 24 Load shuttle valve BG Shuttle port relief 20 25 ft lbs 27 34 Nm 25 Differential relief valve 3200 psi 221 bar B System relief 20 25 ft lbs 27 34 Nm 26 Relief valve 3500 psi 241 bar BF Platform level 20 25 ft lbs 27 34 Nm 27 Check valve 65...

Page 89: ...September 2018 Service and Repair Manual Manifolds Part No 1288652GT S 60 XC S 65 XC 79 ...

Page 90: ...relief valve pressure 7 Remove the pressure gauge How to Adj ust the System Reli ef Val ve How to Adj ust the Boom Down R elief Val v How to Adj ust the Boom Extend R elief Val ve How to Adjust the Boom Extend Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate the boom extend relief valve Note Auxiliary power will ...

Page 91: ...C S 65 XC 81 7 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way FF Platform rotate jib boom select 20 25 ft lbs 27 34 Nm ...

Page 92: ... turntable rotation motor Index No Description Schematic Item Function Torque 1 Counterbalance valve MM Turntable rotate right 35 40 ft lbs 47 54 Nm 2 Counterbalance valve NN Turntable rotate left 35 40 ft lbs 47 54 Nm 3 Shuttle valve 2 position 3 way OO Turntable rotation brake release 10 13 ft lbs 14 18 Nm 4 Orifice 0 030 inch 0 76 mm PP Brake release circuit located inside port ...

Page 93: ... drive chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Remove the heim joint retaining fastener from the axle 7 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and drive chassi...

Page 94: ...le switch to the maintained high idle position 5 With the engine running in high rpm manually activate the valve and observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Specifications 6 Turn the engine off 7 Locate the relief valve on the directional valve and loosen the jamb nut 8 Adjust the hex screw Turn it clockwise to increase the pressure or counterclockwise ...

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Page 96: ...allowing some bypass flow around the right flow divider 6 Relief valve 280 psi 19 3 bar DI Hot oil shuttle relief 35 40 ft lbs 14 16 Nm 7 Flow divider combiner valve 24 gpm DM Combines return flow from RF and RR motors 80 90 ft lbs 108 122 Nm 8 Flow divider combiner valve 24 gpm DB Combines return flow from LF and RR motors 80 90 ft lbs 108 122 Nm 9 Check valve 5 psi DD Prevents cavitation in LF a...

Page 97: ...September 2018 Service and Repair Manual Manifolds Part No 1288652GT S 60 XC S 65 XC 87 ...

Page 98: ... gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Start the engine from the platform controls Press down the foot switch and slowly move the drive control handle off center just until the machine begines to move Note the reading on the pressure gauge Turn the machine off 8 Hold the charge pressure relief valve and remove the cap item DI 9 Adjust the i...

Page 99: ...atic Item Function Torque 1 Relief valve GA Generator relief valve 50 ft lbs 67 Nm 2 Solenoid Valve GB Charge pressure circuit 60 65 ft lbs 81 88 Nm 3 Needle valve GD Charge pressure circuit 50 ft lbs 67 Nm 4 Differential sensing valve GC Pilot valve to diverter valve 50 ft lbs 67 Nm 5 Counterbalance valve CF Adds backpressure to generator circuit 6 Check valve GE Prevents oil to generator 24 26 f...

Page 100: ...zard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Spec...

Page 101: ...tor to a terminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9V DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading u...

Page 102: ...vel surface 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotation drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to al...

Page 103: ...Refer to Specifications Machine Torque Specifications 7 Adjust turntable rotation gear backlash Refer to Repair Procedure How to Adjust the Turntable Rotation Gear Backlash How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pini...

Page 104: ...ition and with the machine on a firm level surface Note A digital level will be required to perform this procedure 1 Enter Service Mode Refer to Repair Procedure How to Enter the Service Mode 2 Press the settings button above the display and navigate t the Sensor Calibrations menu 3 Navigate to the Chassis Tilt Sensor calibration screen 4 Select and start the calibration procedure 5 If the machine...

Page 105: ...ing plate which is located to the left of the fuel tank Orient the level along the roll axis of the machine 12 Enter the value as seen on the digital level onto the ground control display If the level is showing a negative value enter it as a positive number Press OK when the value on the ground control display matches the value of the digital level sensor excluding the plus minus sign 13 A graphi...

Page 106: ...tions Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires or tracks 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do ...

Page 107: ...chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting R Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine R Be sure that all ...

Page 108: ...will be reflected by the System Fault Indicator lights and the alarm Logged Faults The faults contained in the fault log have occurred in the past and may or may not still be in effect Both faults may be viewed by pressing the Fault Button above the ground display and navigating to either the Active Machine Faults screen or the Machine Fault Log screen The list of faults will by shown by fault cod...

Page 109: ... 29 System not functioning CAN bus system is not functioning properly Machine will not be functional Verify CAN bus is functional Pull out connector J5 from the TCON and with a voltmeter set to resistance verify that pins 3 and 4 on the harness connector measure between 55 and 65 Ohms and that neither pin has a short to power or ground Check wiring and boom cable for open or short circuits if resi...

Page 110: ...ter than 5 ohms If not replace the solenoid 15 Solenoid output shorted to GND TCON detected that C27AUX circuit is shorted to GND Auxiliary Power function will not operate 19 Stuck ON at power up Toggle switch input was detected as HIGH at start up Auxiliary Power function will not operate from platform Verify with a voltmeter that the AUX Power Switch TS1 is operating properly C47AUX RD PCON J17 ...

Page 111: ... 12 Circuit shorted to V TCON detected that C1PBU circuit is shorted to 12 V Boom Up function will not operate Boom Down will also not operate if short is to 12 V With a voltmeter measure Y22 Proper resistance should be between 5 60 ohms Replace Y22 if resistance is outside of those values Verify wiring for C1PBU RD TCON J4 10 and check for open or short circuits 15 Circuit shorted to GND TCON det...

Page 112: ...inimum or maximum values Run the boom angle calibration process and verify fault is no longer active If fault persists verify LST3S C68LS RD TCON J7 3 operates properly The signal should be 12 V when the boom is stowed and 0 V when the boom is up 36 Internal check The two internal sensing channels inside the Angle Sensor have registered a significant difference Run the boom angle calibration proce...

Page 113: ...bbon cables if necessary Replace ground control overlay 36 Jib Up Valve 12 Circuit shorted to V PCON detected that V43JU circuit is shorted to 12 V Jip Up function will not operate With a voltmeter measure Y68 Proper resistance should be between 5 60 ohms Replace Y68 if resistance is outside of those values Verify wiring for V43JU BL PCON J12 8 and check for open or short circuits 15 Circuit short...

Page 114: ... V with the switch held in the ON position Cycle power to allow the machine to re test the fault 45 Platform Level Up Down Switch 19 Stuck ON at power up Toggle switch input was detected as HIGH at start up Platform Level Up or Down functions may not operate depending on which direction the switch fault occurred Verify with a voltmeter that the Platform Level Up Down Toggle Switch TS9 is operating...

Page 115: ...CON J2 6 and check for open or short circuits 15 Circuit shorted to GND TCON detected that C30FWD circuit is shorted to GND ID Component ID Name Cause Effect Solution 53 Drive Reverse Valve 12 Circuit shorted to V TCON detected that C31REV circuit is shorted to 12 V Drive Reverse Brake Release and possibly Engine will not operate With a voltmeter measure Y5 Proper resistance should be between 5 60...

Page 116: ... or down functions to bring the platform back within the operational envelope ID Component ID Name Cause Effect Solution 69 Generator Control Circuit 12 Circuit shorted to V TCON detected that C45GEN circuit is shorted to 12 V Generator function will not operate With a voltmeter measure Y29 Proper resistance should be between 5 60 ohms Replace Y29 if resistance is outside of those values Verify wi...

Page 117: ...R RD TCON J5 10 for open or short circuits 31 ESTOP Source circuit mismatch TCON detected that ESTOP 1 is at 0 V but ESTOP 3 is at 12 V ID Component ID Name Cause Effect Solution 72 Contact Alarm 36 Switch state mismatch PCON detected that inputs from SW30 contact alarm proximity sensor are the same voltage Boom Up and Extend functions will not operate Using a voltmeter verify that the voltage on ...

Page 118: ...nd verify fault is no longer active 21 Internal check The two internal sensing channels inside the Angle Sensor have registered a significant difference Run the platform overload calibration process and verify fault is no longer active If fault persists replace the sensor ID Component ID Name Cause Effect Solution 77 Platform Overload Detection 21 Internal check The secondary platform overload che...

Page 119: ...wer up the DISCON by setting the keyswitch to Ground pull out the ground ESTOP and press the Ground Function Enable button The display should start If there is still no display check DISCON power on J10 pins 2 and 1 If DISCON operates but fault persists check the CAN bus wiring Disconnect J10 and with a voltmeter set to resistance verify that the resistance between pins 3 and 4 on the harness conn...

Page 120: ...harness connector pins 1 and 2 measure 12 V Verify S8S is receiving power Disconnect sensor connector and verify harness connector pins 1 and 2 measure 12 V Verify CAN bus wiring With a voltmeter set to resistance check the resistance between pins 3 and 4 on the harness connector not the sensor s integrated connector Resistance should be between 55 and 65 ohms Check CAN wiring if resistance check ...

Page 121: ...nplug the sensor and verify 12 V across pins 1 and 2 on the harness connector Verify the CAN bus wiring With the sensor still unplugged measure resistance across harness connector pins 3 and 4 If resistance is not between 55 and 65 ohms check CAN wire harnesses Replace sensor if necessary 17 Invalid calibration Sensor has been replaced and requires calibration or calibration in memory has been era...

Page 122: ...LU circuit is shorted to GND 101 Platform Level Down Valve 12 Circuit shorted to V PCON detected that V15PLD circuit is shorted to 12 V Platform Level Down and possibly Level Up functions will not operate With a voltmeter measure Y19 Proper resistance should be between 5 60 ohms Replace Y19 if resistance is outside of those values Verify wiring for V15PLD OR BK PCON J12 7 and check for open or sho...

Page 123: ...Proper resistance should be between 5 60 ohms Replace Y15 if resistance is outside of those values Verify wiring for C9PEF BK RD TCON J4 5 and check for open or short circuits Verify resistance between Recovery Module pins J37 6 and J37 7 is zero ohms 15 Circuit shorted to GND TCON detected that C9PEF circuit is shorted to GND 174 Platform Rotate Toggle Switch 19 Stuck ON at power up Toggle switch...

Page 124: ...ted that P85PWR circuit is shorted to GND 241 Sensor Power P109PWR 12 Circuit shorted to V TCON detected that P109PWR circuit is shorted to 12 V Boom Up and Extend functions will not operate Turn on machine and verify sensor power P109PWR GR WH TCON J7 7 is at 12 V Inspect wiring for open or shorts circuits 15 Circuit shorted to GND TCON detected that P109PWR circuit is shorted to GND 242 Sensor P...

Page 125: ...tool This service tool may be connected to the Engine Service Connector located to the right of the battery tray The ground controls display and fault menu will show basic engine faults such as low oil pressure and high coolant temperature It will also show faults for engine warning and engine stop which correspond to the engine warning lamp and engine stop lamp indicators that the engine may requ...

Page 126: ...r EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressure warning threshold exceed...

Page 127: ...or load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low battery volt...

Page 128: ...gh 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR Setpoint ...

Page 129: ...5 Timeout Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal range chec...

Page 130: ... 1 1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Ba...

Page 131: ...ol 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Function Mode...

Page 132: ...g detection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail pressu...

Page 133: ...MI KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value ...

Page 134: ... 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calibration inj...

Page 135: ...ctual value downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator due to over...

Page 136: ... Timeout error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame SCR2 52411...

Page 137: ...4 Accelerator Pedal1 Low Idle Switch Voltage Below Normal 638 6 Engine Fuel Rack Actuator Current Above Normal 639 14 J1939 Network 1 Special Instruction SPN FMI Description 723 3 Engine Speed Sensor 2 Voltage Above Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period 723 10 Engine Speed Sensor 2 Abnormal Rate of Change 733 3 ...

Page 138: ...ystem Timeout 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 3719 16 Particulate Trap 1 Soot Load Percent High moderate severity 2 4016 6 High Current Auxiliary Power Relay 1 Current Above Normal 4201 3 Engine Speed Sensor 1 Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor 1 Voltage Below Normal 4201 8 Engine Speed Sensor 1 Abnormal Frequency Pulse Nidth or Perio...

Page 139: ...t should begin to blink 4 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1 6 5 4 three times After the fault codes the check engine light will blink a code 1 6 5 4 three times again indicating the end of the stored codes Note If any fault codes are present the ECM will blink a ...

Page 140: ...govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side short to Ground 268 Injector Coil Shorted 270 I...

Page 141: ...elay coil open 628 FPump motor loop open or high side shorted to ground 628 Fpump relay control ground short 629 FPump motor high side shorted to power 629 Fpump relay coil short to power Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 Fuel rev l...

Page 142: ...gher than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high Code Description 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog PD2 high 1562 AUX analog PD2 lo...

Page 143: ...id voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage Code Description 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1 2 simultaneous voltages out of range 2139 FPP1 lower than IVS li...

Page 144: ...imary Loop Open or Low side Short to Ground 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2618 Tach output ground short 2619 Tach output short to power For further engine fault code troubleshooting and diagnostic information refer to the Ford MSG 425 EFI Diagnostic ...

Page 145: ...bey the safety rules and operating instructions in the appropriate operator s manual on your machine R Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all r...

Page 146: ... terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normall...

Page 147: ...position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solen...

Page 148: ...oves through its range of operational functions The rotation or angle sensors utilize Hall Effect technology and must be calibrated when replaced Included in this group are envelope limit switches which sense the extended length and angle of the booms and rotational position of the turntable An example is the drive enable limit switch which disables the drive function anytime the boom is rotated p...

Page 149: ...otary Sensor 2 LST3S 3 LST1O 4 UTS Limit Switches and Sensors S24 LSB1RS LSB2S String pot Rotary sensor LST3S LST1O UTS 2 Platform overload sensor Limit switch boom fully retracted operational Limit switch cable tension safety Measures boom extension Measures boom angle Limit switch boom angle safety Limit switch turntable operational Universal tilt sensors fuel tank plate ...

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Page 151: ...September 2018 Service and Repair Manual 141 Electrical Schematic TCON ...

Page 152: ...Service and Repair Manual September 2018 142 S 60 XC S 65 XC Part No 1288652GT Electrical Schematic TCON ...

Page 153: ...September 2018 Service and Repair Manual Part No 1288652GT S 60 XC S 65 XC 143 Electrical Schematic PCON ...

Page 154: ...Service and Repair Manual September 2018 144 Electrical Schematic PCON ...

Page 155: ...September 2018 Service and Repair Manual 145 Electrical Schematic Deutz 2 9L Models ...

Page 156: ...Service and Repair Manual September 2018 146 S 60 XC S 65 XC Part No 1288652GT Electrical Schematic Deutz 2 9L Models ...

Page 157: ...September 2018 Service and Repair Manual Part No 1288652GT S 60 XC S 65 XC 147 Electrical Schematic Deutz D2011 Models ...

Page 158: ...Service and Repair Manual September 2018 148 Electrical Schematic Deutz D2011 Models ...

Page 159: ...September 2018 Service and Repair Manual 149 Electrical Schematic Perkins 404F Models ...

Page 160: ...Service and Repair Manual September 2018 150 S 60 XC S 65 XC Part No 1288652GT Electrical Schematic Perkins 404F Models ...

Page 161: ...September 2018 Service and Repair Manual Part No 1288652GT S 60 XC S 65 XC 151 Electrical Schematic Perkins 404D Models ...

Page 162: ...Service and Repair Manual September 2018 152 Electrical Schematic Perkins 404D Models ...

Page 163: ...September 2018 Service and Repair Manual 153 Electrical Schematic Ford MSG425 Models ...

Page 164: ...Service and Repair Manual September 2018 154 S 60 XC S 65 XC Part No 1288652GT Electrical Schematic Ford MSG425 Models ...

Page 165: ...September 2018 Service and Repair Manual Part No 1288652GT S 60 XC S 65 XC 155 Electrical Schematic Generators ...

Page 166: ...Service and Repair Manual September 2018 156 Electrical Schematic Generators ...

Page 167: ...September 2018 Service and Repair Manual Part No 1288652GT S 60 XC S 65 XC 157 Hydraulic Schematic 4WD Models ...

Page 168: ...Service and Repair Manual September 2018 158 Hydraulic Schematic 4WD Models S 60 XC S 65 XC Part No 1288652GT Ser vice and R epair M anual September 2018 ...

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