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Terex Genie S-60 DC, Service And Repair Manual

The Operator's Manual for the Terex Genie S-60 DC is available for free download on our website. This comprehensive manual provides detailed instructions and guidelines for operating and maintaining this versatile product. Visit our website to download your manual and get the most out of your Genie S-60 DC.

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July 2021

 

 

Service and Repair Manual

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part No. 1299608GT

 

S

®

-60 DC • S

®

-60 FE

 

141 

 

 

 

 

 

Electrical Schematic, Ground Control Box 

 

 

CB2

15A

CB7

10A

30

86

87

85

87A

30

86

87

85

87A

X

Y

1

2

FB

1

2

FB

C3-5

C3-6

4

86

85

01

02
03
04
05
06
07
08

9

10

11

12

C3-11
C3-12

CB9

5A

C7-5

C3-16

C3-15

30

87A

87

C

2-

7

120

OHM

120

OHM

120

OHM

C1-18

C1-1

C3-14

C

3-

2

C7-1

C7-7

C7-6

C

3-

1

C

7-

3

C

7-

4

C

7-

2

C

3-

18

C3-7
C3-8

C

3-

17

C

7-

10

C

3-

4

C

7-

12

C

2-

1

C58-1

C2-4

1

2

1

2

A

C60

B

A

C23

B

C

2-

5

H

2B

H

2A

26VDC

48VDC

C

7-

14

C

2-

18

C

7-

13

C3-10

C58-5

C7-15

C

2-

12

ALARM

H5

G6

P4
FUNCTION
ENABLE

C

47

FE

 W

H

/B

K

G

R

O

U

N

D

PL

AT

.

G

R

O

U

N

D

PL

AT

.

RD

S7

DN

TS61

PRIM.

RET

EXT

TS63

PRIM.

UP

TILT SENSOR

+24V  1

B- 2

 

CAN1- GR  3

 

CAN1+ YL  4

 

HOUR

METER

B

B1

3

1

TS51
AUX

DN

TS59

PLAT LEVEL

UP

BAT

ENG

TS52

HYBRID MODE

DN

UP

TS58
JIB

CCW

CW

TS62
TT ROTATE

P22BAT BK/14

C134PWR RD/14

BATGND BR/14

SPARE

TS57

PLAT ROT.

TELEMATICS

RD

BR

 YL

D81CAN0- GR

A1

B1

WH

OR

BR

5 

+2

4V
  

8 

-V  

3 

H

EA

TE

R

  

2 

C

AN

0-

  

1 

C

AN

0+

  

1

1

1

1

TB5V

TB5V

TB2.5V

TS69

RECOVERY

PR

I R

ET

R

AC

T

PR

I D

O

W

N

D12

LA

R

G

E 

PU

M

P 

H

V

CAN1 YL/GR

TBBATGND

BATGND BR

BATGND BR

P109PWR GR/WH

C196PWR YL

P22BAT BK/14

TB22

YL
GR

G

AT

EW

AY

BA

TG

N

D

 B

R

P182BAT RD

C134PWR RD

BATGND BR

NC

 YL
D81CAN1- GR

TB27

C27AUX RD

P182PWR RD/14

P181BAT OR/14
P182BAT RD/14

P181BAT OR/14

P182BAT RD/14

P181PWR OR

P181PWR OR/16

TB181

C183RCV BL

C183RCV BL

TB134

R181PWR OR

R181PWR OR

TB134

V241HGP OR/RD

C134PWR RD/16

C134PWR RD

C134PWR RD

C17PR GR/BK

TCON

(PART1)

C

27

AU

X R

D

C165TRS WH/RD

C156JUD GR/WH

P2

2B

AT

 B

K/

14

C

17

4P

W

R

 W

H

TB23

TB134

C

13

4P

W

R

 R

D

DRIVE

LIGHT

FLASHING

BEACON

BATT

-

1

BATT

+

2

CAN0

+

3

CAN0

-

4

PRI EXT/RET TS 26

CAN1 + 20
CAN1 - 21

+5V

SENSOR

8

GND SENSOR

9

13
15

JIB UP/DOWN TS 5

FUNC ENABLE SW 17

PLATFORM ROT TS 22

TTR CW/CCW TS 25

TCON MODE KS

10

PLATFORM ESTOP

11

PCON MODE KS

12

ALARM 31

 

BATT + 49
BATT + 50

BATGND1 BR

C163PLS BL/WH

 YL
D81CAN1- GR

P109PWR GR/WH

P110RET BK
C27AUX RD

C164PES RD/WH
C156JUD GR/WH

C47FE WH/BK
C17PR GR/BK

C165TRS WH/RD
C174PWR WH
P23PWR WH
C22PWR BK

C134PWR(A) RD
C134PWR(A) RD

C130TA WH/RD

D6

CTA HORN CTRL

34

C46HRN BK/RD

GLOW PLUG RALAY

32

OVERLOAD LED

33

C34SA BK/WH
C133PLA GR/WH

L45

-

+

C46HRN BK/RD

C27AUX RD

NC

P23PWR WH

P182PWR RD

 YL

D81CAN1- GR

P48LPS WH/RD

BK
RD
WH/BK
BL
OR

YL+
GR-
WH/RD

ENGINE STATUS 19

C108ESL WH/BK

C

10

8E

SL

 W

H

/B

K

TB0V

P22BAT BK/14

GTPL

C4

C5

4

2

3

1

C21

1

2
3
4

CCW

CW

YL

C61

A2

B2

GR

1

1

YL

GR

3

1

6

4

YL

GR

C74

A

B
C
D
E

(T

O

 P

AG

E 

4)

 C

O

N

TR

O

L 

C

AB

LE

 1

8C

/1

8 

C

9

(T

O

 P

AG

E 

4)

 C

O

N

TR

O

L 

C

AB

LE

 3

C

/1

2

C19

C134PWR RD

1
2

3
4
5

9

10
12

(T

O

 P

AG

E 

4)

NO

30A

U35

2 SEC

5

2

COM

NO

3

+

-

C

7-

8

Summary of Contents for Genie S-60 DC

Page 1: ...S 60 FE from S60EM 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics S 60 DC For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1299608GT Rev A July 2021 ...

Page 2: ...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...

Page 3: ...istory Revision Date Section Procedure Page Description A 07 2021 Initial Release Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...umber 4 Serial number stamped on chassis 5 Serial label located under cover S60E M 123 1 2 3 4 5 Model Serial number Electrical schematic number Year of manufacture Machine unladen weight Rated work load including occupants Maximum number of platform occupants Maximum allowable side force Maximum allowable inclination of the chassis S60EM 123 ...

Page 5: ...perator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer 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 regulat...

Page 6: ... 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 fl...

Page 7: ...ection 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Manifold Component Specifications 6 Kubota D1105 Engine Specifications 7 Machine Torque Specifications 8 Machine Component Weights 8 Hydraulic Hose and Fitting Torque Specifications 9 Torque Procedure 10 ...

Page 8: ...ut Setting 17 How to Adjust the Joystick Ramp Rate Setting 19 1 2 How to Calibrate Boom Angle Sensor 20 1 3 How to Clear the Fault History 21 Platform Components 22 2 1 Platform Leveling Slave Cylinder 22 2 2 Platform Rotator 23 2 3 Platform Overload System 25 How to Perform a Zero Load Platform Calibration 25 How to Perform a Full Load Platform Calibration 26 How to Replace the Platform Overload ...

Page 9: ...ow to Repair the Cable Track 34 4 2 Primary Boom 35 4 3 Boom Lift Cylinder 36 4 4 Primary Boom Extension Cylinder 37 4 5 Platform Leveling Master Cylinder 38 4 6 Primary Boom Angle Sensor 40 Engines 41 5 1 RPM Adjustment 41 5 2 Air Intake Hose 41 Ground Controls 42 Control System Fault Recovery Switch 42 How to Use Control System Fault Recovery Switch 42 Hydraulic Pumps 44 7 1 Function Pump 44 How...

Page 10: ...omponents 52 8 6 How to Set Up the Oscillate Directional Valve 53 How to Test a Coil Diode 54 Turntable Rotation Components 55 8 1 Turntable Rotation Assembly 55 How to Adjust the Turntable Rotation Gear Backlash 56 9 2 How to Replace the Universal Tilt Sensor 57 How to Calibrate the Universal Tilt Sensor 58 Axle Components 59 10 1 Oscillating Axle Cylinders 59 10 2 How to Remove the Steer Cylinde...

Page 11: ... Control System Fault Codes 67 Charger Fault Codes 87 Battery Charger 87 Charger Fault Codes 89 Charger Error Codes 90 Pump Control Fault Codes 94 Pump Controller Fault Handling 94 Drive Control Fault Codes 103 Drive Controller Fault Handling 103 Section 5 Navigation Menus 123 Faults Navigation Menu 124 Options Navigation Menu 125 Settings Navigation Sub Menu 126 Settings Navigation Sub Menu 127 S...

Page 12: ...itch Angle Sensor Legend 138 Electrical Schematics 139 Electrical Schematic DC FE Models 140 Electrical Schematic GBOX 141 Electrical Schematic Turntable Controller 144 Electrical Schematic PBOX 145 Electrical Schematic Kubota D1105 148 Electrical Schematic CAN BUS 149 Power Cable Wiring Diagram 152 Electrical Schematics Options 153 AC Power Wiring Diagram Options 154 RCBO Wiring Diagram Options 1...

Page 13: ...gh terrain low profile tires 36 9 in 93 7 cm Fluid capacities Fuel tank 17 gallons 64 4 liters Hydraulic tank 18 gallons 68 liters Hydraulic system including tank 26 gallons 97 liters Drive hubs 24 fl oz 710 cc Turntable rotation drive hub 8 fl oz 237 cc Drive hub oil type MOBIL SHC 626 gear oil or equivalent Batteries Type L16G AC lead acid AGM dry cell Group 903 L16 Quantity 8 Capacity lead acid...

Page 14: ...give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil typ...

Page 15: ...20 F 49 C Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375...

Page 16: ...ystem is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Sh...

Page 17: ... gear pump Displacement per revolution inner pump Outer pump 40 cu in 6 6 cc 20 cu in 3 3 cc Max flow rate inner pump outer pump 6 8 gpm 25 74 L min 3 4 gpm 12 87 L min Auxiliary Pump Type Fixed displacement gear pump Displacement per revolution 1 7 gpm 6 44 L min Function manifold Proportional relief valve pressure variable 50 to 3200 psi 3 4 to 220 6 bar Platform level relief valve pressure 3000...

Page 18: ...perature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Description Specification Proportional solenoid relief valve 24V DC schematic item AA 22 Ω Proportional solenoid valve 3 position 4 way 20V DC schematic items B G and...

Page 19: ...requirements Below 10 C 14 F SAE 10W 30 10 to 25 C 14 to 77 F SAE 10W 30 SAE 15W 40 Above 25 C 77 F SAE30 SAE10W 30 SAE15W 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 Engine coolant Capacity 3 3 quarts 3 1 liters Fuel injection system Injection pump make Bosch MD Inj...

Page 20: ...ne Component Weights Tire and wheel assembly 426 lbs 193 kg Drive motor and hub 124 5 lbs 56 5 kg Engine assembly 552 lbs 250 kg Primary boom 1960 lbs 889 kg Primary boom lift cylinder 360 lbs 163 3 kg Primary boom extend cylinder 330 lbs 149 6 kg Jib boom assembly 6 ft 1 8 m platform 800 lbs 363 kg Jib boom cylinder 85 lbs 38 5 kg Lift structure 5300 lbs 2404 kg Turntable assembly without lift st...

Page 21: ...3 4 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 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 49 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 22: ...ed 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 nu...

Page 23: ...ct 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 fi...

Page 24: ... on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a fir...

Page 25: ...lert 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 ...

Page 26: ... How to Calibrate Boom Angle Sensor Note The one point calibration is optional It allows 2 MPH 3 2 Km h travel if machine needs to be immediately moved 5 Calibrate the steer angle sensor Refer to Repair Procedures How to Calibrate the Steer Angle Sensor 6 Complete calibrating the primary boom ange sensor stowed and elevated positions Refer to Repair Procedures How to Calibrate Boom Angle Sensor 7 ...

Page 27: ...play 4 PCON platform control module How to Adjust the Joystick Threshold Setting How to Adjust the Joystick Threshold Setting The threshold setting is the minimum output current at which a function proportional valve can open and allow the function to operate There are two types threshold currents to adjust Joystick controlled functions Primary Up Down and Turntable Rotate Switch controlled functi...

Page 28: ... foot switch Continue to the next threshold current adjustment Switch Controlled Functions 12 Perform steps 1 through 9 to enter the sub menu THRESHOLD CURRENT on the display 13 Momentarily activate the speed select toggle switch in either direction until the bar graph is at about 50 on the display 14 Press down on the foot switch and select the toggle switch controlled boom function to be adjuste...

Page 29: ...until SETTINGS is shown on the display 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND SENSOR SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSOR is shown on the display 9 Momentarily activate steer in the right direction until VALVE MAXIMUM CURRENT is shown on the dis...

Page 30: ...t over the relief valve and back to tank Function speed is set by changing control current mA and is confirmed by timing the function travel time with a stop watch Refer to Specifications Performance Specifications for each boom function speed 18 Perform steps 1 through 10 to enter the sub menu VALVE MAXIMUM CURRENT on the display 19 Momentarily active a low flow boom function in one direction Res...

Page 31: ...the steer joystick Result The display will show FAULTS 6 Momentarily activate steer in the right direction until SETTINGS is shown on the display 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND SENSOR SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSOR is shown on the ...

Page 32: ...ibration procedure captures the signal with the cylinder fully extended and fully retracted to an angle measurement that is scaled to degrees within the program If the angle sensor is in the uncalibrated state drive speed is limited to out of stowed speed Note Start this procedure with the boom in a stowed position Position the machine in a suitable location with sufficient vertical space Refer to...

Page 33: ...history menu 1 being the most recent displayed It may be necessary to clear the fault history in order to acquire the most recent fault codes It is also good practice to clear fault history after performing any calibration procedure Note Perform this procedure with the boom in the stowed position Refer to Navigation Menus Faults Menu 1 Turn the key switch to platform controls Do not start the engi...

Page 34: ...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 The platform could fall when the slave cylinder rod end pivot pin is removed if not properly supported 5 From the ground controls use auxiliary power and activate platform level down to r...

Page 35: ...se 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 Remove the retaining fasteners securing the platform assembly to the platform rotator Remove the platform assembly and set aside 2 Tag disconnect and plug the hyd...

Page 36: ... removed from the machine if not properly supported Note When installing the platform rotator fasteners torque the fasteners to specifications Refer to Specifications Machine Torque Specifications How to Bleed the Platform Rotator 1 From the ground controls fully rotate the platform to the right and then the left Continue holding platform rotate in each direction for approximately 10 seconds 2 Rep...

Page 37: ...e in the stowed position 1 Fully retract and lower the boom Level the platform 2 Remove all weight tools accessories and equipment from the platform Note Options and accessories that are considered integrated components of the platform do not require removal to perform calibration Refer to Integrated Options and Accessories Tip over hazard Failure to remove all non integrated factory and non facto...

Page 38: ...Options and Accessories 1 platform work lights 2 auxiliary top rail 3 platform full height mesh 4 platform half height mesh 5 swing gate latch guard 6 Contact alarm 7 control box cover 3 Perform a zero load calibration Refer to How to Perform a Zero Load Calibration 4 Place a test weight on the platform floor using a suitable lifting device Place the weight near the center entry point of the platf...

Page 39: ... the Load Cell Sensor Note The preload adjustment should only be performed after the load cell sensor has been replaced 1 Remove all equipment or tools from the platform Remove the welder if equipped 2 At the platform remove the plastic instruction holder from the document mount plate 3 Tag and disconnect the load cell sensor harness 4 Loosen the jam nut securing the load cell sensor foot and rota...

Page 40: ...y activating steer right three times then steer left one time Result A one second pulse alarm will sound indicating the reset procedure has been saved 2 4 Platform How to Remove the Platform 1 Remove the cable clamp from the top of the platform mounting weldment 2 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side Do ...

Page 41: ...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 lifting device to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cylinder ro...

Page 42: ...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 remove the pin 5 ...

Page 43: ...S 60 FE 31 Boom Legend 1 angle sensor 2 primary boom 3 cable track 4 upper riser arm to turntable pivot pin 5 lower riser arm to turntable pivot pin 6 lower riser arm 7 upper riser arm 8 lift cylinder 9 pivot link 10pivot lever 11timing link 12mid pivot 12 11 10 9 8 7 6 5 4 2 3 1 ...

Page 44: ...installed in the correct location 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side 6 Remove the hose and cable clamps from the platform support and jib boom 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom Cap the bulkhead fit...

Page 45: ...de at the platform end of the boom Remove the cable track guide from the boom 18 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 19 Attach a lifting strap from an overhead lifting...

Page 46: ...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 tra...

Page 47: ... the boom extend cylinder Cap the fittings Remove the cable tracks from both sides of the boom Set them onto the machine side covers 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 Using an overhead lifting device with a strap of adequate capacity ...

Page 48: ... the mid pivot Crushing hazard The boom assembly will fall if not properly supported when removed from the machine 22 Remove the boom from the machine 4 3 Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove the Boom Lift ...

Page 49: ...arefully remove the boom lift cylinder from the machine Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent moveme...

Page 50: ...ge hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platfor...

Page 51: ... right side of the mid pivot to remove the pivot pin 1 pivot pin 5 Raise the boom until the rod end pivot pin of the master cylinder is accessible 6 Using an overhead supporting device support the master cylinder 7 Remove the retaining fastener securing the rod end pivot pin 8 Using a soft metal drift remove the pivot pin Crushing hazard The cylinder could fall if not properly supported 9 Remove t...

Page 52: ... Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position 2 Locate the boom angle sensor on the primary boom 3 Tag and disconnect the electrical connector from the angle sensor 4 Remove the retaining fasteners Remove the angle sensor and magnet from the machine 5 Install the new angle sensor and magnet onto the m...

Page 53: ...djustment Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine Check and Adjust the Engine RPM 5 2 Air Intake Hose Every time the engine tray is closed after maintenance the air intake hose must be correctly placed into its seat 1 Air intake hose 1 ...

Page 54: ...control system fault Recovery switch Bypass and Recovery mode is only intended for certain circumstances and is not part of normal machine operation If the Recovery function is required this indicates there may be faults with the machine Contact trained personnel immediately Recovery is only to be used as a last attempt to retract and lower the platform when control system failures or CAN communic...

Page 55: ...prevent falling injury The Recovery switch allows the platform to be lowered in case of control system severe fault or CAN communication loss The recovery switch permits to retract the primary boom and lower the primary boom using the main pump at reduced speed to allow the operator to exit the platform 1 In case of CAN communication loss or control system failure only turn off the machine wait at...

Page 56: ...onent Damage hazard Do not perform any functions with hydraulic tank shut off valve closed Remove the key switch and tag the machine to inform personnel of the condition Open Closed 2 Tag disconnect and plug function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pre...

Page 57: ... and hold the drive enable toggle switch in the right direction while holding steer in the right direction 3 When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer joystick 4 Momentarily activate steer in the right direction until SETTINGS is shown on the display 5 Momentarily activate the drive enable toggle switch in the right direction until you see the V...

Page 58: ... 4 way SP3 Turntable rotate left right 19 30 ft lbs 26 41 Nm 7 Spool valve 3 position 4 way SP2 Platform level up down 19 30 ft lbs 26 41 Nm 8 Spool valve 3 position 4 way closed center SP1 Steer left right 16 20 ft lbs 24 27 Nm 9 Relief valve 2000 psi RV3 Boom extend relief 33 37 ft lbs 45 50 Nm 10 Relief valve 3000 psi RV1 Platform level up 33 37 ft lbs 45 50 Nm 11 Relief valve 3000 psi RV2 Plat...

Page 59: ...July 2021 Service and Repair Manual Manifolds Part No 1299608GT S 60 DC S 60 FE 47 15 17 13 11 9 19 20 6 1 18 14 12 2 3 7 4 5 8 16 22 10 21 23 ...

Page 60: ...em Function Torque 19 Check valve 25 psi CV1 Tank return circuit 19 21 ft lbs 26 29 Nm 20 Check valve 30 psi CV5 Tank return circuit 19 21 ft lbs 26 29 Nm 21 Pressure compensator 150 psi EC1 Turntable rotate circuit 19 21 ft lbs 26 29 Nm 22 Check valve 10 psi CV3 P HI circuit 19 21 ft lbs 26 29 Nm 23 Pressure transducer G Pressure monitor 11 ft lbs 15 Nm ...

Page 61: ...July 2021 Service and Repair Manual Manifolds Part No 1299608GT S 60 DC S 60 FE 49 15 17 13 11 9 19 20 6 1 18 14 12 2 3 7 4 5 8 16 22 10 21 23 ...

Page 62: ... switch to store the value Result The control system will continue to the next calibration procedure value 3000 psi 207 bar 6 Activate the platform level toggle switch in the up direction to increase the relief pressure or in the down direction to decrease the relief pressure until the pressure gauge reads 3000 psi 207 bar 7 Activate the platform rotate toggle switch to save the value Result The c...

Page 63: ... platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way X Platform rotate left right 26 30 ft lbs 35 40 Nm 2 Solenoid valve 3 position 4 way Y Jib boom up down 26 30 ft lbs 35 40 Nm 3 Check valve 27 psi 1 7 bar Z Tank return circuit 19 21 ft lbs 26 29 Nm ...

Page 64: ...rntable 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 65: ...mpleted with ground and drive chassis level repeat steps 4 thru 9 or consult Genie Product Support 8 7 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field Since coil resistance is sensitive to temperature resistance values outside specif...

Page 66: ... 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 up to 8...

Page 67: ... pin unlocked locked 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap the fittings on the motor 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 Attach a suitable lifting device to the turntable rotator assembly 1 backlash pivo...

Page 68: ...nting fasteners to 160 ft lbs 217 Nm How to Adjust the Turntable Rotation 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 pinion gear and the turntable bearing ring gear Note Perform this procedure with the machine on a firm level surface with the boom in the stowed ...

Page 69: ...just if necessary 9 2 How to Replace the Universal Tilt Sensor UTS This machine has a dual axis angle sensing device called the Universal Tilt Sensor UTS It is mounted on the turntable to monitor and communicate ground angle relative to gravity via CAN bus Should the turntable be tilted at the Allowable Tilt Angle or greater an alarm will sound at both the turntable and the platform If not calibra...

Page 70: ...toggle switch and the steer joystick Result The display will show FAULTS 4 Momentarily activate steer in the right direction until SETTINGS is shown on the display 5 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND SENSOR SETTINGS is shown on the display 6 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSO...

Page 71: ...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 oscillate 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 al...

Page 72: ... from the machine Component damage hazard Hoses and cables can be damaged if they are kinked or pinched How to Calibrate the Steer Angle Sensor How to Calibrate the Steer Angle Sensor Note Perform this procedure on a firm level surface with the machine in the stowed position Refer to Navigation Menus Settings Menu 1 Turn the key switch to platform controls 2 Pull out the red Emergency Stop button ...

Page 73: ...ensor value in mV and ENABLE will appear at the bottom of the screen 10 Momentarily activate the drive enable toggle switch in the right direction to save calibrate steer center Result The alarm will sound and the mV value flashes to indicate the setting has been saved To exit programming mode 11 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY m...

Page 74: ...pe The charging profile must be programmed to match the specific battery type on the machine Charger status indicators 1 Error Fault USB indicator 2 AC power indicator 3 Battery charging indicator 4 USB port 5 Charging output indicator 6 Charger profile Error display 7 Charge profile selection button Remote charger status indicators 1 Error Fault USB indicator 2 Error Fault 3 Charge complete 4 Cha...

Page 75: ...your machine and battery type Refer to the chart below Profile Description P001 Flooded lead acid batteries Temperature compensated P003 Flooded lead acid batteries Not temperature compensated P007 Flooded lead acid batteries Not temperature compensated P043 AGM batteries Temperature compensated Temperature compensated Battery temperature sensor has been installed on the machine Not temperature co...

Page 76: ...eels 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 Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all...

Page 77: ...r meter will display unit hours and battery state of charge SOC whenever no faults are present on the system The value will cycle between unit hours and battery SOC every 5 seconds When the engine is running if equipped the display will cycle hours SOC and RPM Both Engine Hours and DC Function Enable Hours will be tracked DC Function enable hours will be displayed on the smart hour meter by defaul...

Page 78: ...tion to access the active fault codes 11 Activate steer in the right direction to scroll through the fault codes Active fault codes will be listed in sequence To access fault history list 12 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE FAULTS is shown on the display 13 Activate the steer rocker switch in the right direction until FAULT HISTORY is shown on...

Page 79: ...ortional Relief Valve 21 Fault Open or short circuit Warning Will cause poor operating efficiency Verify no open short circuit across C28 2 RRDCON C1 6 C3 3 V191PCE WH RD 19 AUX PUMP TOGGLE SWITCH 27 Active at Startup Stuck ON on power up AUX functions disabled Verify when activated 24V created by AUX toggle switch TS1 at platform or ground controls they are wired in parallel 24V at C35 11 to RRDC...

Page 80: ... value Verify 5V from C27 5 to C12 C P109PWR GR WH B at Pin C12 A Signal Output approximately 1000 4000 mV across range of motion at LRDCON C27 16 C123 PBS RD BK Cycle Power with problem corrected to clear fault To Calibrate Stowed mV must be between 2600 3400 mV Elevated mV must be between 400 1200 mV 16 Value at 0 V 0V 17 Not Calibrated Calibration Not Completed 19 Out of Range Reported angle se...

Page 81: ...cuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across PCON C47 3 BK or C10 1 B C19JSV GR WH 26 Value too low Short or Ohms 5 41 TURNTABLE JOYSTICK 11 Shorted to Supply 5V Turntable Rotate disabled Verify 5V at JC7 2 P162PJW OR B at JC7 1 JSGND BR 500 to 4500 mV at JC7 4 PCON C46 12 C165TRS WH RD through joystick motion 16 Value at 0 V 0V 17 Not Calibrated Not ...

Page 82: ... or Ohms 5 51 DRIVE JOYSTICK 11 Shorted to Supply 5V Drive disabled Verify 5V at JC3 2 P162JW OR B at JC3 1 JSGND BR 500 to 4500 mV at JC3 4 PCON C47 2 C160JPL WH RD through joystick motion 16 Value at 0 V 0V 17 Not Calibrated Not between 2000 3000 mV at startup 56 TELEMATICS DEVICE 13 Not Detected Genie Telematics device not detected when option is enabled Only basic telematics functionality Veri...

Page 83: ...ND CONTROLS 27 Active at Startup Stuck ON on power up Ground controlled functions disabled Verify no open short circuit across C3 14 or C20 2 C47FE WH BK to either 24V or B 71 E STOP RELAY 21 Fault Relay Contact Stuck Platform E stop detected when Key Switch is in Ground Position or Platform E stop not detected when Key Switch is in platform position All functions disabled Verify Relay in operable...

Page 84: ... Full load gain outside limits All functions disabled Check calibration weight and LC mounting repeat calibration change damaged LC 31 Invalid Calibration Crosscheck between controllers failed All functions disabled Repeat Calibration Check LC mounting Change damaged LC 36 Invalid Calibration crosscheck error Too much weight in the platform All functions disabled Remove weight from platform 77 VCO...

Page 85: ...lt Unit shut down via remote telematics command All functions disabled or drive speed reduced or lift speed reduced Contact machine owner to have functionality restored 84 TURNTABLE CHASSIS ANGLE 13 Not Detected No CAN communication 2WD or 4WD limited to 2 5 MPH ANSI 2WD or 4WD Elevated Drive disabled CE Tilt Alarm ON Sensor or calibration fault latches loss of CAN does not Verify 24V supply on C2...

Page 86: ...EL WH BK Oil Pressure Switch contacts open to B after engine start C108SEL WH BK Relay CR64 is operable Output of relay CR64 87 is connected to C27 4 LRDCON through C35 1 R108SEL WH BK 97 MOTOR BRAKING FAULT 21 Fault Drive motors do not slow during braking Electric Brakes set Verify Proper operation and calibration of the UTS level sensor Motor motor controller phase leads and main power connectio...

Page 87: ...oltage error Battery Voltage is too high to charge Check the battery voltage and cable connections Check battery size and condition This error will automatically clear once the condition has been corrected 2 Low battery voltage error detected prior to starting a charge cycle Battery Voltage is too low to charge 3 Charge timeout Charge Timeout caused by battery pack not reaching required voltage wi...

Page 88: ... 11 Charger is disabled by external command 12 Reverse polarity error Battery is connected the wrong way around Check the battery connections This error will automatically clear once the condition has been corrected 13 Battery does not take current Battery voltage is detected but the charger is unable to charge the battery This can be due to an electrical device connected between the charger and t...

Page 89: ...t running Contact Product Support 20 No active algorithm selected There is no active charge profile selected Select a charge profile 21 High battery voltage error detected while charging Battery voltage is too high as detected by the algorithm Check the battery voltage and cable connections This error will automatically clear once the condition has been corrected 22 Low battery voltage error detec...

Page 90: ...nt fault USB hardware overcurrent protection has been tripped Remove and reinsert USB flash drive If condition persists try using a different USB flash drive 28 Charge profile incompatibility USB hardware overcurrent protection has been tripped Update charger software or select a different charging profile 29 CAN Bus error CANbus network error Check the physical CAN connector electrical bus condit...

Page 91: ...ensor is required by charge profile battery temperature compensated algorithm by it is not installed Check if sensor is connected correctly if alarm is shown or ensure the charge profile installed does not require temperature compensation 37 Stalled Cooling Fan Motor Fan will not turn when commanded rotor must be locked Fan is obstructed inspect the fan and clear the blockage 38 CANOpen reprogramm...

Page 92: ... Cut Drive EM Brake Cycle Power 17 Severe B Undervoltage None Auto 18 Severe B Overvoltage Cut Drive EM Brake Cycle Power 22 Controller Overtemp Cutback None Auto 23 B Undervoltage Cutback None Auto 24 B Overvoltage Cutback None Auto 25 5V Supply Failure None Auto 26 Digital Out 6 Overcurrent None Auto 27 Digital Out 7 Overcurrent None Auto 28 Motor Temp Hot Cutback None Auto 29 Motor Temp Sensor ...

Page 93: ...ge None Auto 71 OS General Cut Drive EM Brake Cycle Power 72 PDO Timeout None Auto 73 Stall Detected LOS Reduce Drive Cycle Power 77 Supervisor Fault Cut Drive EM Brake Cycle Power 78 Supervisor Incompatible Cut Drive EM Brake Cycle Power 82 Bad Calibrations Cut Drive EM Brake Cycle Power 83 Driver Supply Fault Cut Drive EM Brake Cycle Power 84 Following Error Fault Cut Drive EM Brake Cycle Power ...

Page 94: ...ontroller Fault Reduced Speed Drive Wheel affected locked Verify Mechanical motor gearbox coupling EM brake functionality Phases wiring 25 Value too high Motor is stalled and or locked EM brake set Main Contactor Open No Drive 192 RIGHT FRONT DRIVE MOTOR 21 Fault Internal Motor Controller Fault Reduced Speed Drive Wheel affected locked Verify Mechanical motor gearbox coupling EM brake functionalit...

Page 95: ...actor wiring or possible component damage 27 Active at Startup Main contactor is found closed at power ON welded contactor No Drive on any wheel drive Check Main Contactor wiring or possible component damage 255 RIGHT REAR DRIVE MOTOR TEMPERATURE 20 Generic Warning Motor Temperature exceeded warning temperature limit Limited Speed Drive Allow the motors to cool down check for damaged gearbox or mo...

Page 96: ...ure exceeded maximum rated temperature limit No Drive Allow the motors to cool down check temperature sensor wirings check for damaged gearbox or motor 258 LEFT FRONT DRIVE MOTOR TEMPERATURE 20 Generic Warning Motor Temperature exceeded warning temperature limit Limited Speed Drive Allow the motors to cool down check for damaged gearbox or motor 21 Generic Fault Motor Temperature exceeded maximum ...

Page 97: ...erature limit Limited Speed Drive Allow the motor controller to cool down or allow the to exit from too low Temperature warning temperature threshold 23 Value too high Motor Controller Temperature exceeded the maximum temperature limit No Drive Allow the motor controller to cool down check dissipation plate connection status check for component damage 24 Value too low Motor Controller Temperature ...

Page 98: ...r to cool down check dissipation plate connection status check for component damage 24 Value too low Motor Controller Temperature exceeded the minimum temperature limit No Drive Move the machine in a warmer place or de freeze 269 OSCILLATE PROPORTIONAL ELECTRICAL PRESSURE REDUCING VALVE 25 Value too high Open circuit or resistance 334 ohm Extend Functions disabled Check Ohms Verify no open short c...

Page 99: ...e P code Indicates charger programming mode is active This will occur when the charger profile is being configured Type USB code Indicates the USB interface is active and the USB should not be removed This will occur when the charger firmware is being updated Solid red Internal fault condition Type F fault code Flashing amber External fault condition Type E error code Flashing green USB interface ...

Page 100: ...Repair Manual July 2021 Charger Fault Codes 88 S 60 DC S 60 FE Part No 1299608GT Charger status indicators Remote charger status indicators 1 Error Fault USB indicator 2 Charger profile Error display 3 Error Fault ...

Page 101: ... Solution F 0 0 1 DC DC failure LLC excessive leakage fault Internal charger fault Disconnect AC input and battery pack for 30 seconds If fault does not clear contact Genie Product Support F 0 0 2 PFC failure PFC excessive leakage fault F 0 0 3 PFC taken too long to boost F 0 0 4 Charger unable to calibrate current offset F 0 0 5 Output relay voltage too high when closed ...

Page 102: ...afe time limit Charge output reduced due to high temperature Charge at lower temperature Check battery condition Replace damaged battery Check battery connections Battery pack deep discharge Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 0 4 Defective battery Battery pack could not be trickle charged up to the minimum voltage Check battery condition Rep...

Page 103: ...ype Installed from a different machine with different battery type Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 1 6 Software update failed Software update failed Confirm USB Flash Drive is formatted with correct software If software update continues to fail contact Genie Product support E 0 1 7 USB error USB not connected correctly Remove and re inser...

Page 104: ...ween 85 270 VAC 45 65 Hz Self clearing when condition has been corrected E 0 2 4 Failure to initialize Charger failed to turn on correctly Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 2 5 Low AC voltage oscillation AC voltage unstable Connect to a stable AC source between 85 270 VAC 45 65 Hz Using an undersized generator Self clearing when condition has bee...

Page 105: ... 0 3 1 Vref for ADC measurements triggered alarm Internal charger error Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 3 2 CAN Bus heartbeat error CAN Bus heartbeat error CAN Bus devices not functioning correctly E 0 3 6 Battery temperature sensor charge profile Battery temperature sensor is required by charger profile but is not installed Check battery tempe...

Page 106: ...ED s The controller status LED s produce flash code ID s displaying all the currently set faults in a repeating cycle Each code ID consists of two digits The red LED flashes once to indicate that the first digit of the code ID will follow the yellow LED then flashes the appropriate number of times for the first digit The red LED flashes twice to indicate that the second digit of the code ID will f...

Page 107: ...cted by the Supervisor or Primary microprocessor Missing or corrupt software Interrupting a software download may cause corruption of the software Cycle the key switch to clear Reload software or replace controller if necessary Alternating red and yellow flash pattern Active fault When a fault is detected and no wiring or component failure can be found cycle the key switch off and back on to see i...

Page 108: ...harge failed to charge the capacitor bank from the external precharge resistor Clear Cycle Interlock input or use VCL function Enable_Precharge 15 Controller Severe Undertemp 1 See Monitor menu Controller Temperature 2 Controller is operating in an extreme environment ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Heatsink temperature below 40 C Clear Bring heat...

Page 109: ...isadjusted 3 Non controller system drain on battery 4 Battery resistance too high 5 Battery disconnected while driving 6 See Monitor menu Battery Capacitor Voltage 7 Blown B fuse or main contactor did not close Reduced drive torque Set Capacitor bank voltage dropped below the Undervoltage limit with the FET bridge enabled Clear Bring capacitor voltage above the Undervoltage limit 25 5V Supply Fail...

Page 110: ...0 V Clear Bring the motor thermistor input voltage within range 31 Main Open Short 1 Open or short on driver load 2 Dirty connector pin 3 Bad crimps or faulty wiring ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Main contactor driver pin 6 is either open or shorted This fault can be set only when Main Enable On Clear Correct open or short and cycle driver 32 EM...

Page 111: ...o KSI 39 Main Contactor Did Not Close 1 Main contactor did not close 2 Main contactor tips are oxidized burned or not making good contact 3 External load on capacitor bank B connection terminal that prevents capacitor bank from charging 4 Blown B fuse ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Just prior to the main contactor closing the capacitor bank volta...

Page 112: ...ault detected Clear Cycle Power to KSI 72 PDO Timeout Time between CAN PDO messages received exceeded the PDO Timeout Period ShutdownThrottle CAN NMT State set to Pre operational Set Time between CAN PDO messages received exceeded the PDO Timeout Period Clear Cycle KSI or receive CAN NMT message 73 Stall Detected 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Problems with...

Page 113: ...tdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Internal controller fault detection Clear Cycle Power to KSI 84 Following Error Fault 1 vThe Following Error Limit has been exceeded for the Following Error Time 2 Incorrect or overly restrictive Following Error Limit and Following Error Time parameter settings 3 Motor or drive train rotation obstruction or degradation ShutdownMotor...

Page 114: ...en commanded to set 2 EM Brake will not hold the motor from rotating ShutdownEMBrake ShutdownThrottle Position Hold is engaged when Interlock On Set After the EM Brake was commanded to set time has elapsed to allow the brake to fully engage vehicle movement sensed Clear Activate the Interlock 98 Illegal Model Number 1 Model_Number variable contains illegal value 2 Software and hardware do not matc...

Page 115: ...d including the fault type Cause Effect and Solution are also listed Effect is what the controller will do when the fault is active Diagnostics information can be obtained by observing the flash pattern issued by the status LED The controller status LED produces flash code ID s displaying all the currently set faults in a repeating cycle Each code ID consists of two digits The LED flashes red indi...

Page 116: ...rdware fault detected by the Supervisor or Primary microprocessor Missing or corrupt software Interrupting a software download may cause corruption of the software Cycle the key switch to clear Reload software or replace controller if necessary Red LED flashing Non production device profile software When a fault is detected and no wiring or component failure can be found cycle the key switch off a...

Page 117: ...An external load on the capacitor bank B connection terminal that prevents the capacitor bank from charging See Programmer System Monitor menu Controller Capacitor Voltage ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set The precharge failed to charge the capacitor bank Clear Cycle Interlock or Reset Controller 2141 1 5 Controller Seve...

Page 118: ...KSI voltage above Brownout Voltage 2130 1 8 Severe B Overvoltage 1 Battery parameters are misadjusted 2 Battery resistance too high for given regen current 3 Battery disconnected while regen braking See Programmer System Monitor menu Controller Capacitor Voltage ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Capacitor bank voltage ex...

Page 119: ...is too old to fully support the FOS version Clear 100 Internal Fault 100 Update CIT version re package the project and re flash the application package 210A 1 12 OS General 2 Fault Program execution within the controller encountered a serious problem and could not recover from this 100 Internal Fault kindly contact your Curtis representative immediately 100 Ill formed or corrupted application pack...

Page 120: ...regen braking Controller is performance limited at this voltage 2 Battery parameters are mis adjusted 3 Battery resistance too high for given regen current 4 Battery disconnected while regen braking See Programmer System Monitor menu Controller Currents OverVoltageCutback See Programmer System Monitor menu Controller Capacitor Voltage Reduced brake torque Note This fault is declared only when the ...

Page 121: ...On then Regen Braking Torque is reduced Fault Action None unless a fault action is programmed in VCL Set Motor temperature is at or above the Temperature Hot parameter setting Clear Bring the motor temperature within range 2150 2 9 Motor Temp Sensor 1 Motor thermistor is not connected properly 2 Sensor polarity between Pin 8 and Pin 18 is incorrect 3 The motor temperature and sensor parameters are...

Page 122: ...232 3 6 Sin Cos Motor Feedback 1 The signals from the sensor are above the configuration by 10 or at above the supply rails for 100ms 2 Sensor failure 1 Motor encoder failure 2 Bad crimps or faulty wiring See Programmer System Monitor menu Hardware Inputs Analog 3 ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Motor position speed Si...

Page 123: ...r not making good contact 3 An external load on the capacitor bank B connection terminal is preventing the capacitor bank from charging 4 Blown B fuse 5 Main contactor parameters mis tuned 6 Main Pull in Voltage 7 Main Holding Voltage Type 2 1 Main contactor opened during operation while commanded closed 2 Driver wiring to contactor s coil e g pin 3 wiring removed during operation 3 Contactor coil...

Page 124: ...roller and Reset Controller 2211 4 7 HPD Sequencing 1 Incorrect sequence in application of Keyswitch Interlock Direction or Throttle 2 Faulty wiring crimps or switches at KSI Interlock Direction or Throttle 3 Moisture in above noted digital input switches causing invalid real On Off state Verify input switch status See Programmer System Monitor menu Inputs Switch Status Verify Throttle See Program...

Page 125: ...cation between left and right motor control sections Clear Repower with CAN wiring problem corrected or replace controller 2712 5 3 User 3 Fault Invalid Motor Type Selection Incompatible motor selected See User 1 fault above Set Invalid Motor Type Selection Clear Select valid Motor Type 2713 5 4 User 4 Fault Front to Back CAN bus fault 1 CAN wiring 2 Damaged Controller See User 1 fault above Set L...

Page 126: ...or Reset Controller 2231 7 3 Stall Detected 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Problems with power supply for the motor encoder See Programmer System Monitor menu AC Motor Motor RPM ShutdownEMBrake ShutdownThrottle ShutdownMotor Control Mode changed to LOS Limited Operating Strategy Set No motor encoder movement detected Clear Either Reset Controller Or if para...

Page 127: ...sage disabled Fault Action None unless a fault action is programmed in VCL Set Incorrect PDO map detected Clear Reset Controller 2835 8 3 Internal Hardware Fault Internal controller fault detected ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Internal controller fault detected Clear Reset Controller 2850 8 7 Motor Characterization E...

Page 128: ...et 1 Vehicle movement sensed after the EM Brake has been commanded to set 2 EM Brake will not hold the motor from rotating Position Hold is engaged when Interlock ON Fault Action None unless a fault action is programmed in VCL Set After the EM Brake was commanded to set and time has elapsed to allow the brake to fully engage vehicle movement has been sensed Clear 1 Activate the Throttle EM Brake t...

Page 129: ...ters ShutdownAll ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 to 7 ShutdownPD FullBrake ShutdownPump ShutdownCoilSupply ShutdownVehicle ShutdownLower ShutdownLift Clear Fix parameter mismatch and reset the controller 2332 9 10 Interlock Braking Supervision Fault Type s 1 Motor speed is outside the Interlock Brake Supervision Speed Limit 2 I...

Page 130: ...ownDriver1 Set Driver 1 is either open or shorted or Driver 1 exceeded its overcurrent setting Clear Correct the open or short and then Reset Controller 2161 10 2 Driver 2 Fault Fault Type s See Driver 1 Fault See Driver 1 Fault ShutdownDriver2 See Driver 1 Fault 2162 10 3 Driver 3 Fault Fault Type s See Driver 1 Fault See Driver 1 Fault ShutdownDriver3 See Driver 1 Fault 2163 10 4 Driver 4 Fault ...

Page 131: ...ShutdownDriver1 to 7 ShutdownPD FullBrake ShutdownPump ShutdownCoilSupply ShutdownVehicle ShutdownLower ShutdownLift Set Short detected after the startup check has passed A low side driver short is detected and the respective fault action fails to cut off driver current Coil supply startup test fails Clear Reset Controller 2620 11 1 Analog 1 Out of Range Fault Type s 1 above High limit 2 below Low...

Page 132: ...Analog 1 Out of Range 262A 11 11 See Analog 1 Out of Range See Analog 1 Out of Range See Analog 1 Out of Range See Analog 1 Out of Range 2631 11 12 Analog Assignment Fault Fault Type s 13 X Analog Input number that caused the fault X 1 9 14 18 19 31 1 An Analog Input is used for two or more functions 2 An Analog Input is outside the range of analog inputs See Programmer Controller Setup IO Assignm...

Page 133: ... to controller connector 3 Check if configured correctly for NC NO Clear Change the bit flag PWM_Drivers such that the number of bits set are lesser than or equal to Max_PWM_Drivers 2629 12 5 PWM INPUT 10 OUT OF RANGE PWM Input 10 Out of Range Fault Type s 1 The input is disconnected 2 The measured input frequency is below the tolerance 3 The measured input frequency is above the tolerance 4 The m...

Page 134: ...ing Clear Reset Controller 210C 12 11 PWM INPUT 28 OUT OF RANGE See PWM input 10 See PWM input 10 See PWM input 10 See PWM input 10 210D 12 12 PWM INPUT 29 OUT OF RANGE See PWM input 10 See PWM input 10 See PWM input 10 See PWM input 10 2101 13 2 PHASE PWM MISMATCH Phase PWM Mismatch Fault Type s 0 U phase 1 V phase 2 W phase Internal to Controller Motor Phase PWM ShutdownVehicle ShutdownMotor Shu...

Page 135: ...roller Fault Handling Part No 1299608GT S 60 DC S 60 FE 123 Section 5 Navigation Menus Navigation Menu Top Menus Drive enable switch Drive Joystick Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right ENT EXIT ...

Page 136: ...SAGE ENTER PASSWORD X X X X EXIT ENT NOTES 1 MENU EXITS AFTER 5 MINUTES OF NO ACTIVITY 2 ADVANCED PARAMETER AUTHORIZATION RESETS TO OFF 2 MINUTES AFTER EXITING THE MENU ENT EXIT SETTINGS hold 4 SEC ENT EXIT hold 4 SEC ENT EXIT hold 4 SEC OPTIONS DISPLAY CONTRAST DISPLAY CONTRAST enable EXIT ENT SEE BELOW ENT EXIT STEERING LEFT MINUS RIGHT PLUS DRIVE ENABLE WITCH LEFT EXIT RIGHT ENTER First press o...

Page 137: ...SYSTEM READY GENIE LOGO ENT EXIT SETTINGS hold 4 SEC OPTIONS ENT ENT EXIT EXIT EXIT EXIT EXIT EXIT EXIT EXIT SVENSKA NEDERLANDS ITALIANO PORTUGUES LANGUAGE ENGLISH DEUTSCH FRANCAIS ESPANOL DESCENT ALARM LOW VOLTAGE INTERRUPT LVI TRAVEL ALARM MOTION ALARM POWER SAVER MODE SOUNDS ALARM SELECT BATTERY TYPE FUEL LEVEL SENSING ENT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT ...

Page 138: ...RAL PARAMETER Y N RESET CALIBRATION Y N EXECUTE PARAMETERS RESET Y N EXIT EXIT EXIT EXIT EXIT EXIT RAMP DOWN TIME IN MILLISECONDS RAMP UP TIME IN MILLISECONDS VALVE MAXIMUM CURRENT IN MILLIAMPS VALVE THRESHOLD CURRENT IN MILLIAMPS BOOM ANGLE CALIBRATION CALIBRATE TILT SENSOR PUMP EFFICIENCY CALIBRATION VALVE SENSOR SETTINGS SETTINGS FUNCTION SETUP SEQUENCE 1 UTS CALIBRATE 2 THRESHOLD CURRENT MA 3 ...

Page 139: ...W TIMEOUT 0 1800 SECONDS ENT EXIT ENT EXIT ENT EXIT PLATFORM LEVEL CUTOUT ON OFF MARKET SELECTION ENT EXIT ENT EXIT ENT EXIT ENTER EXIT EXIT EXIT EXIT EXIT ENTER EXIT DRIVE SETTINGS SETTINGS WITH REQUIRE AUTHORIZE EXIT EXIT EXIT EXIT EXIT CALIBRATE STEER SENSOR CENTER MAX SPEED IN TENTHS OF A MILE PER HOUR SPEED ACCEL RAMPTIME IN TENTHS OF A SECOND DECEL RAMPTIME IN TENTHS OF A SECOND RELEASE DELA...

Page 140: ...E LIFT CUTOUT OFF DISABLE PROPEL DISABLE LIFT PROPEL DISABLE ALL FUNCTIONS OFF DISABLE PROPEL DISABLE LIFT PROPEL DISABLE ALL FUNCTIONS ADVANCED SETUP SETTINGS WITH REQUIRE AUTHORIZE LOW VOLTAGE INTERRUPT LVI CUT OFF CHASSIS TILT CUTOUT MODE ENT EXIT ENT EXIT ENT EXIT ENT EXIT MACHINE TYPE CONFIGURATION ENT EXIT ENT EXIT CHARGER INTER LOCK ON OFF ENT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EX...

Page 141: ...e safety rules and operating instructions in the appropriate operator s manual on your machine 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 rings wat...

Page 142: ...erminal 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 normally ...

Page 143: ...ition 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 Solenoid...

Page 144: ...ect PCON C24 Hydraulic pressure sensor C25 C26 C27 Rear L R AC motor controller C28 Front L R AC motor controller C29 Telematics Unit Option C30 Jumper plug Dual Output AC MC to Pump AC MC C31 C32 Steer sensor extender C33 AC Pump Motor C34 ECON AC motor Generator controller C35 Engine harness C36 Battery status LED C37 Drive enable limit switch C38 Left front AC motor to front MC harness C39 Righ...

Page 145: ...e relief C96 Small pump enable C97 Large pump enable C98 Jib Up C99 Jib Down C100 Oscillate pressure reducing valve Item Description CB Circuit Breaker CB1 Fuel pump 15A CB2 Controls power 24V DC 15A CB4 Charger box 12V 10A CB7 Engine RPM 10A CB9 Telematics 5A option CR Control Relay CR1 Engine start CR2 Fuel pump CR3 Auxiliary relay CR4 Engine RPM CR5 Horn CR13 CR14 CR15a b Glow plugs relays CR20...

Page 146: ...LED L45 Platform overload led AS CE models L48 Tilt alarm led ANSI CSA models L53 Charger LED LS Limit Switch LS1 Primary boom retract LS3 Drive enable LS18 Platform overload AS CE models Item Description M Motor M1 Function pump motor generator M2 Auxiliary pump M3 Engine starter P Button P1 Red emergency stop ground P2 Red emergency stop platform P3 Horn P4 Function enable PR Power Relay PR1 Mai...

Page 147: ...r shift high low TS15 Drive enable TS18 Work light option TS46 Proximity kill option TS47 Inverter option TS51 Auxiliary pump TS52 Mode select TS57 Platform rotate TS58 Jib boom up down TS59 Platform level up down TS61 Primary boom up down TS62 Turntable rotate TS63 Primary boom extend retract TS69 Recovery U Module U3A DCON RR AC motor controller U3B DCON LR AC motor controller U3C DCON RF AC mot...

Page 148: ...iption BL Blue BK Black BR Brown GR Green OR Orange PP Purple RD Red WH White YL Yellow BL BK Blue Black BL RD Blue Red BL WH Blue White BK RD Black Red GR BK Green Black GR WH Green White OR BK Orange Black OR RD Orange Red OR WH Orange White RD BK Red Black RD WH Red White WH BK White Black WH RD White Red WH YL White Yellow YL BK Yellow Black ...

Page 149: ...e 3 30A glow plug 3 Circuit breaker 1 15A Engine start Fuel pump 4 Control Relay 64 Engine fault 5 Control Relay 2 Fuel pump 6 Circuit breaker 7 10A Engine RPM 7 Control Relay 1 Engine start 8 Control Relay 15A glow plug 1 9 Fuse 5 15A spare 10Control Relay 15B glow plug 2 11Diode 6A 12Control Relay 4 Engine RPM 13Connector 1 Blue 14Connector 2 Orange ...

Page 150: ...pair Manual July 2021 Limit Switch Angle Sensor Legend 138 S 60 DC S 60 FE Part No 1299608GT 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS3 Drive enable 4 S13 Steer Angle sensor inside steer cylinder ...

Page 151: ...July 2021 Service and Repair Manual 139 Electrical Schematic DC FE Models ...

Page 152: ...66 C40 RIGHT REAR AC MOTOR LEFT REAR AC MOTOR BRAKE ENCODER BRAKE ENCODER 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 SHIELD BK C R 26TSR R WH RD D185SEN R H R W D18 SEN R 6 R BL P198SEN A RD SENGND A BK P181RET A OR C32BRK RR WH BK SHIELD BK C L LR 26TS WH RD D185SEN H LR W D18 SEN 6 LR BL D1 SEN 98 A RD P 81R T A OR 1 E C32BRK LR WH RD SENGND A BK MOTOR2 REAR RIGHT REAR MOTORS CONTROLLER F2F...

Page 153: ...D82CAN1 YL D81CAN1 GR TB27 C27AUX RD P182PWR RD 14 P181BAT OR 14 P182BAT RD 14 P181BAT OR 14 P182BAT RD 14 P181PWR OR P181PWR OR 16 TB181 C183RCV BL C183RCV BL TB134 R181PWR OR R181PWR OR TB134 V241HGP OR RD C134PWR RD 16 C134PWR RD C134PWR RD C17PR GR BK TCON PART1 C27AUX RD C165TRS WH RD C156JUD GR WH P22BAT BK 14 C174PWR WH TB23 TB134 C134PWR RD DRIVE LIGHT FLASHING BEACON BATT 1 BATT 2 CAN0 3 ...

Page 154: ...Service and Repair Manual July 2021 142 Electrical Schematic Ground Control Box ...

Page 155: ...July 2021 Service and Repair Manual 143 Electrical Schematic Turntable Controller ...

Page 156: ... HV 27 28 30 35 36 37 38 39 C66LS BL C42LS OR RD C65FP BL WH C123PBS RD BK V36SCW BL V37SCC BL BK V07PBE BK V08PBR BK WH V01PBU RD V02PBD RD BK V04TRL WH V05TRR WH BK V14PLU OR V14PLD OR BK 40 41 42 43 44 LEV UP HV 45 LEV DOWN HV 46 47 48 P110RET BK P109PWR GR WH C94 2 C94 1 C93 2 C93 1 C80 2 C80 1 C81 2 C81 1 C82 2 C82 1 C83 2 C83 1 C86 2 C86 1 C87 2 C87 1 C92 2 C92 1 C91 2 C91 1 C97 1 C97 2 C96 ...

Page 157: ...C46HRN BK RD C27AUX RD P23PWR WH P182PWR RD NC D82CAN1 YL D81CAN1 GR NC P48LPS WH RD V241HGP OR RD V242HGP WH BK C45GEN GR WH NC V17PRL GR V18PRR GR BK P22BAT BK 14 C134PWR RD 14 BATGND BR 14 C134PWR RD C110RET BK C90PXS RD BK V44JD GR BK C90PXS RD BK P49LPS WH RD BATGND BR SW30 PROX KILL P26PWR BK C56FTS RD N C WORK LT WORK LT FOOTSWITCH BK WH BL BK BK RD WH BK BL OR RD BK YL GR RD WH WH RD OR BK...

Page 158: ...Service and Repair Manual July 2021 146 Electrical Schematic Platform Control Box ...

Page 159: ...July 2021 Service and Repair Manual 147 Electrical Schematic Kubota D1105 ...

Page 160: ...RPM SOLENOID ENG BLOCK FUEL SOLENOID EXCT REGULATOR BAT IND BAT STA OIL TEMP SW SHUT DOWN RLY ENG START RLY ENG RUN RLY GP RLY ENG RPM RLY TACH SENSOR WATER TEMP SR OIL PRESS SENDER OIL PRESS SW ENGGND ENG BLOCK AUXGND BK AUXGND BK 12V VOLT METER OPTION OPTION OPTION KUBOTA FUSE RELAY MODULE 6S B1 5S B1 R108ESL WH BK C35RPM BK RD C34SA BK WH PLUG C21IGN WH R181PWR OR C33STR BK C134PWR RD PLUG PLUG...

Page 161: ... C9 9 C9 10 C4 9 C4 10 C21 4 C21 3 C19 20 C19 21 C3 12 C3 11 J157 5 J157 4 C10 5 C10 4 C46 4 C46 3 C49 2 C49 1 C74 D C74 E C23 A C23 B C17 B C17 A C60 A C60 B C27 23 C28 35 C28 23 C1 2 C1 3 C1 15 C1 17 PCON D82CAN1 YL D81CAN1 GR VCON LOAD CELL D82CAN0 YL D81CAN0 GR D82CAN0 YL D81CAN0 GR D82CAN0 YL D81CAN0 GR SP2 SP1 SP14 SP13 SP5 SP6 SP17 SP18 SP14 SP15 SP11 SP12 SP28 SP27 SP26 SP25 SP9 SP10 SP7 S...

Page 162: ...Service and Repair Manual July 2021 150 CAN BUS Wiring Diagram ...

Page 163: ...July 2021 Service and Repair Manual 151 Power Cable Wiring Diagram ...

Page 164: ... 2 TO DC DC P181BAT A OR 14GA 1 TO GBOX P181RET C OR 5 C179RET GR 4 BATTERY PACK TRACTION AC MOTOR CONTROLLER PUMP GENERATOR AC MOTOR CONTROLLER CHARGER 2C 10GA 2 1 1 2 2 P181RET B OR 3 C180RET BK 6 2 FROM 12V BATTERY CHARGER 175A INVERTOR OPTION 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 10 4 4 2 8 10 10 4 4 2 1 1 2 2 2 2 2 2 2 2 2 2 48V CHARGER ...

Page 165: ...July 2021 Service and Repair Manual 153 Wiring Diagram AC Power Options ...

Page 166: ...XGND BK P20BAT RD C14 R27AUX RD P20BAT RD BATGND BR BK BK U4 BAT BK U4 INT2 YL GND GR YL N WH L1 BK L1 BK N WH GND GR YL L1 BK N WH GND GR YL BK WH BK BK L1 BK N WH AC INPUT WALL PLUG AC INPUT TO 48V CHARGER CHARGER CONTROL IN TO 13 8V CHARGER TO RELAY AC INPUT BOX 1 24VDC GND L1 N GND GR YL N WH L1 BK GND GR YL N WH L1 BK TERMINAL BLOCK 1 AC INPUT WALL PLUG 2 AC INPUT 48V CHARGER L1 BK N WH 4 TO ...

Page 167: ...GROUND TO PLATFORM CHASSIS RCBO BOX GROUND TO MACHINE CHASSIS SOCKET PLATFORM GROUND TO PLATFORM CHASSIS RCBO BOX PLUG CHASSIS RCBO OPTION USING PTP RCBO OPTION USING INVERTER L1 BR N BL GND GR YL 2 L1 BK N WH GND GR YL L1 BK N WH GND GR YL 1 3 GND GR YL GND GR YL GND GR YL GND GR YL L1 BR N BL GND GR YL 2 L1 BK N WH GND GR YL L1 BK N WH GND GR YL 1 3 GND GR YL GND GR YL L1 BK N WH GND GR YL ...

Page 168: ...Service and Repair Manual July 2021 156 Wiring Diagram RCBO Options ...

Page 169: ...July 2021 Service and Repair Manual 157 Hydraulic Schematic DC FE Models ...

Page 170: ...M EXTEND B A TURNTABLE ROTATE 2 7 GPM PLU PLD PBR PBE PD PU STR STL PT T1 TRR TRL MASTER OSCILLATE CYLINDERS P T B A PRESSURE TRANSDUCER OSCILLATE VALVE STEERING 3 5 GPM R E E R R E 6 6 8 6 6 6 6 4 4 4 6 P1 8 3500 PSI 4 5 1 1000 PSI 3 1 COUNTERBALANCE VALVES PRESS RATIO 1000 PSI 3 1 3 1 2000 PSI 3300 PSI 3 1 4 5 1 3500 PSI 3500 PSI 3 1 10 1 3000 PSI SP1 SP3 SP5 EC1 HYBRID PUMP NO APU PRR PRL PLATF...

Page 171: ......

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