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Terex Genie S-60 HF, Service And Repair Manual

The Terex Genie S-60 HF Service And Repair Manual is a comprehensive guide designed to assist users in maintaining and repairing their equipment. This essential manual is available for free download, offering easy access to step-by-step instructions and diagrams. Obtain your copy from manualshive.com and ensure the optimal performance of your Genie S-60 HF.

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April 2021

 

Service and Repair Manual

 

 

Deutz TD 2.2 L3 Engine Fault Codes

 

 

 

Part No. 1288652GT

 

S

®

-60/65 XC

™

 • S

®

-60/65 

HF • S

®

-60/65 TraX

™

 

151 

 

 

 

DTC = Diagnostic Trouble Code 
FMI = Failure Mode Identifier 
SPN = Suspect Parameter Number 

DTC  SPN  FMI  Description 

831  5359  6 

Engine cylinder 2 fuel injection 

quantity above normal or grounded 

circuit. Short circuit between high-

side and low-side of the power 

stage. 

832  5360  6 

Engine cylinder 3 fuel injection 

quantity above normal or grounded 

circuit. Short circuit between high-

side and low-side of the power 

stage. 

833  5361  6 

Engine cylinder 4 fuel injection 

quantity above normal or grounded 

circuit. Short circuit between high-

side and low-side of the power 

stage. 

834  5362  6 

Engine cylinder 5 fuel injection 

quantity above normal or grounded 

circuit. Short circuit between high-

side and low-side of the power 

stage. 

835  5363  6 

Engine cylinder 6 fuel injection 

quantity above normal or grounded 

circuit. Short circuit between high-

side and low-side of the power 

stage. 

836  105  3 

Engine intake manifold 

temperature voltage above normal 

or shorted to high. 

837  105  4 

Engine intake manifold 

temperature voltage below normal 

or shorted to low. 

838  2797  14 

Engine fuel 1 injector, group 

1 missing injector adjustment value 

programming injector 1. 

839  2798  14 

Engine fuel 1 injector, group 

2 missing injector adjustment value 

programming injector 2. 

 

 

 

 

DTC  SPN  FMI  Description 

840  4257  14 

Engine fuel 1 injector, group 

3 missing injector adjustment value 

programming injector 3. 

854  7103  5 

Engine fuel metering rail pump 

current below normal or open 

circuit. 

855  7103  3 

Engine fuel metering rail pump 

voltage above normal or shorted to 

high. Short circuit to battery on the 

high side power stage. 

856  7103  3 

Engine fuel metering rail pump 

voltage above normal or shorted to 

high. Short circuit to battery on the 

low side power stage. 

857  7103  4 

Engine fuel metering rail pump 

voltage below normal or shorted to 

low. Short circuit to battery on the 

high side power stage. 

858  7103  4 

Engine fuel metering rail pump 

voltage below normal or shorted to 

low. Short circuit to battery on the 

low side power stage. 

859  7103  6 

Engine fuel metering rail pump 

current above normal or grounded 

circuit. 

868  629  12 

Function monitoring: fault of ECU 

ADC. Null load test pulse. 

869  629  12 

Function monitoring: fault of ECU 

ADC. Test voltage. 

870  629  12 

ECU. DFC to indicate ICO request 

from MoCSOP module. 

871  91 

14 

Function monitoring: Monitoring of 

accelerator pedal position. 

875  190  2 

Function monitoring: Fault of 

engine speed check. 

876  5357  2 

Engine fuel injection error for 

multiple cylinders. Diagnostic fault 

check error between level 

1 energizing time and level 

2 information. 

 

 

 

 

Summary of Contents for Genie S-60 HF

Page 1: ... Repair procedures Fault Codes Electrical and Hydraulic Schematics S 60 HF S 60 TraX S 65 XC from S65XCH 45001 from S65XCM 101 from S65XCD 101 S 65 HF For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine S 65 TraX Part No 1288652GT Rev D1 April 2021 ...

Page 2: ...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 i...

Page 3: ...5 2019 Specifications Machine Specifications Repair Function manifold Generator manifold Fault Codes Control System Fault Codes Schematics Electrical schematics Hydraulic Schematics C3 6 2019 Fault Codes Control System Fault Codes C4 7 2019 Repair Display Menu D 5 2020 All Sections Add Deutz TD 2 2 L3 Engine Repair 2 3 D1 4 2021 Specifications Machine Torque Specifications Reference Examples Elect...

Page 4: ...nual April 2021 Introduction iv S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on drive chassis ...

Page 5: ...death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable govern...

Page 6: ... potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco aw...

Page 7: ...ormance Specifications 2 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Ford MSG 425 EFI Engine Specifications 7 Deutz D2011 L03i Engine Specifications 8 Deutz TD2011L04i Engine Specifications 9 Deutz TD 2 2 L3 Engine Specifications 10 Deutz D 2 9 L4 Engine Specifications 11 Deutz TD 2 9 Engine Specifications 12 Perkins 404D 22 Engine Specifications 13 Perkins 404F E22T Engine...

Page 8: ...o Adjust the Joystick Threshold Setting 25 1 5 How to Enter ALC600 Software Update Mode 25 1 6 Display Module Menus 26 1 7 How to Replace the Display Controller DISCON Module 31 1 8 How to Replace the Ground Control Overlay 32 Platform Components 35 2 1 Platform Leveling Slave Cylinder 35 2 2 Platform Rotator 36 2 3 Platform Overload System 39 How to Perform a Zero Load Platform Calibration 39 How...

Page 9: ...etract Cables 55 4 6 Platform Leveling Master Cylinder 58 4 7 Primary Boom Angle Sensor Calibration 59 4 8 Primary Boom Angle Sensor Replacement 60 4 9 Boom Length Sensor Calibration 62 Engines 64 5 1 RPM Adjustment Ford and Deutz Models 64 5 2 RPM Adjustment Perkins 404D 22 Models 64 5 3 Flex Plate Removal 64 How to Install a Type A Flex Plate 66 How to Install a Type B Flex Plate 67 How to insta...

Page 10: ...Rotation Manifold Components 86 7 5 Valve Adjustments Oscillate Relief Valve 87 How to Set Up the Oscillate Directional Valve 87 7 6 Traction Manifold Components 4WD 90 7 7 Valve Adjustments 4WD Traction Manifold 92 7 9 Generator Manifold Components 93 7 11 Hydraulic Generator 93 7 10 Valve Coils 95 How to Test a Coil Diode 96 Turntable Rotation Components 97 8 1 Turntable Rotation Assembly 97 How...

Page 11: ...w to Retrieve Control System Fault Codes 107 Control System Fault Codes Models with Revision G Software or Lower 108 Control System Fault Codes Models with Revision H Software or Higher 125 Engine Fault Codes 142 Deutz TD 2 2 L3 Engine Fault Codes 143 Deutz D 2 9 L4 Engine Fault Codes 153 Perkins 404 22 Engine Fault Codes 164 Ford MSG 425 Engine Fault Codes 166 ...

Page 12: ...45354 S65XCD 101 180 Electrical Schematic Platform Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 181 Electrical Schematic Deutz TD 2 2 L3 Models 184 Electrical Schematic Deutz TD 2 2 L3 Engine Harness 185 Electrical Schematic Deutz D 2 9 L4 Models 188 Electrical Schematic Deutz D2011 L03i TD2011 L04i Models 189 Electrical Schematic Perkins 404F E22T Models 192 Electrical Schematic Perkins 404...

Page 13: ... Rough terrain low profile tires 36 9 in 93 7 cm Overall tire diameter Hi flotation tires 40 3 in 102 4 cm Tire pressure Hi flotation tires 100 psi 6 89 bar Track Components S 60 TraX and S 65 TraX Track material Rubber Tensioning system Pressurized grease Weight each 1 500 lbs 680 kg Fluid capacities Fuel tank Deutz and Perkins Models 35 gallons 132 5 liters Ford models 30 gallons 113 5 liters LP...

Page 14: ...c Fluid Specifications Genie specifications require hydraulic oils which are designed to 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 mini...

Page 15: ...ly above 120 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...

Page 16: ... heating system 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...

Page 17: ...splacement piston pump Flow rate 2500 rpm 30 3 gpm 115 L min Drive pressure maximum 3625 psi 250 bar Charge pump Type gerotor Displacement 0 85 cu in 13 9 cc Flow rate 2500 rp 9 2 gpm 34 8 L min Charge pressure 2500 rpm 310 psi 21 4 bar Function pump Type 2 section tandem gear pump Displacement Pump 1 inner 1 52 cu in 25 cc Flow rate 2500 rpm 16 5 gpm 62 5 L min Auxiliary pump Type gear fixed disp...

Page 18: ... low speed 1 83 cu in 30 cc Hydraulic filters High pressure filter Beta 5 200 High pressure filter bypass pressure 100 psi 6 89 bar Medium pressure filter Beta 6 200 Medium pressure filter bypass pressure 51 psi 3 5 bar Hydraulic return filter 10 micron with 25 psi 1 7 bar bypass Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm...

Page 19: ...ilter 6 7 quarts 6 4 liters Oil pressure switch Oil pressure switch point 7 5 psi 0 51 bar Oil viscosity requirements 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 58 gpm 2 2 L min Fuel requirement For fuel requirements...

Page 20: ... to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 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 Fuel injection system Inje...

Page 21: ...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 require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Oil temperature switch point 275 F 135 C Oil pressure switch In...

Page 22: ...to 104 F 20 C to 40 C 10W 40 Above 5 F 15 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 temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 257 F 125 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure swit...

Page 23: ... to 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 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 ...

Page 24: ...arts 12 1 liters Oil viscosity requirements Low ash oil required 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 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 sender Installation torque 8 18 ft lbs 11 24 Nm ...

Page 25: ...lter 9 3 quarts 8 8 liters 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 Injec...

Page 26: ... quarts 8 9 10 6 liters 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 Injectio...

Page 27: ...rntable bearing Rotate bearing mounting bolts top 179 ft lbs 234 Nm Rotate bearing mounting bolts bottom 171 ft lbs 232 Nm Turntable rotate assembly Turntable rotate motor mounting bolts LOCTITE 243 threadlocker 85 ft lbs 115 Nm Backlash plate mounting bolts 203 ft lbs 275 Nm TraX Torque Specifications Note All torque values are shown lubricated unless otherwise noted Sprocket to hub adapter faste...

Page 28: ...lats 4 7 16 20 2 6 9 16 18 1 1 2 8 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 No...

Page 29: ...g face seal is seated 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 th...

Page 30: ... the correct 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 b...

Page 31: ...perator s manual 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...

Page 32: ... used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation whi...

Page 33: ...bration 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 platform control module 2 primary boom up down and turntable rotate left right joystick controller 3 LED indicator modul...

Page 34: ...tes while in Service Mode the ALC 600 will power down and Service Mode will be exited unless the engine is running 1 3 Full Machine Calibration 1 3 Full Machine Calibration Full machine calibration must be completed in the proper sequence when the ALC 600 controller TCON in the ground control box has been replaced How to Fully Calibrate the Machine Calibration procedures shall only be completed by...

Page 35: ...ess the SETTINGS button above the display screen 3 Select SPEEDS from the display screen 4 Navigate to the desired function s Maximum Speed setting 5 Select the desired setting to change and press OK 6 In the parameter adjustment screen use the display buttons to change the parameter Note that the factory default speed is considered 100 for maximum speeds 7 Scroll and press OK The change is effect...

Page 36: ... above the display screen 3 Select SPEEDS from the display screen 4 Navigate to the desired function s Ramp setting 5 Select the desired setting to change and press OK 6 In the parameter adjustment screen use the display buttons to change the parameter Note that the ramp rate is expressed in seconds to complete the ramp 7 Scroll and press OK The change is effective immediately 8 Start the engine f...

Page 37: ...ystick verify that the function engages smoothly and without sudden movement or excessive joystick dead spots 10 Adjust the parameter in the ground display to achieve a smooth function threshold 1 5 How to Enter ALC600 Software Update Mode 1 5 How to Enter ALC600 Software Update Mode 1 Go to the Genie website http firmware genielift com select your Machine Model and select Search 2 Download the so...

Page 38: ...rkins 404D 22 Perkins 404D 22T Perkins 404F E22T Perkins 404F E22TA Select Engine Platform configuration is not locked Platform Standard Platform 4m Platform Standard Platform Region ANSI CSA AUS CE Select Region Screen or Menu Item Selection Default Options Footswitch Timeout 10 sec 2 min 30 min 2 min Note Some options may not be visible with earlier software revisions Drive Priority On Off Off D...

Page 39: ... max 78 min 100 1365 mA Reverse Max 150 max 79 min 100 1275 mA Forward Out of Stow Max 150 max 85 min 100 1092 mA Reverse Out of Stow Max 150 max 85 min 100 1059mA Screen or Menu Item Default Drive Speeds TraX Forward Threshold 149 max 1 min 100 730 mA Reverse Threshold 152 max 1 min 100 708 mA Forward Max 150 max 64 min 100 2700 mA Reverse Max 150 max 65 min 100 2500 mA Forward Out of Stow Max 15...

Page 40: ...A Retract Threshold 179 max 1 min 100 513 mA Up Threshold 250 max 1 min 100 450 mA Down Threshold 253 max 1 min 100 443 mA Extend Max 150 max 68 min 100 1425 mA Retract Max 150 max 70 min 100 1325 mA Up Max 150 max 63 min 100 1800 mA Down Max 150 max 63 min 100 1800 mA Screen or Menu Item Default Primary Lift Ramps Extend Accelerating Rate 5000 ms max 1000 ms min 2500 ms Extend Decelerating Rate 5...

Page 41: ...Decelerating 5000 ms max 500 ms min 2000 ms Screen or Menu Item Default Jib Boom and Platform Speeds Jib Up Threshold max 112 min 1 default 551 mA 100 Jib Down Threshold max 118 min 1 default 500 mA 100 Platform Level Up Threshold max 127 min 1 default 450 mA 100 Platform Level Down Threshold max 127 min 1 default 450 mA 100 Platform Rotate CW Threshold max 114 min 1 default 510 mA 100 Platform Ro...

Page 42: ...t 750 ms Platform Level Ramp max 2000 ms min 200 ms default 750 ms Platform Rotate Ramp max 2000 ms min 200 ms default 600 ms Screen or Menu Item Default Machine Disable Options Drive Disable On Off Machine Disable On Off Remote Disable Disable Engine Start Drive Speed Cripple Lift Speed Cripple Reset to Defaults OK to reset Model Configuration and Options Software Update OK to enter Software Upda...

Page 43: ...assembly 5 Remove the DISCON from the ground control box lid by removing the five hex nuts and washers 4 5 Discard the nuts and washers 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 completel...

Page 44: ...er the ribbon cables have been fully inserted 11 Reconnect the wire harness going to the DISCON then close and fasten the ground box lid 12 Reconnect the negative terminal to the start battery and auxiliary batteries if equipped 1 8 How to Replace the Ground Control Overlay 1 8 How to Replace the Ground Box Control Overlay 1 Push in the red Emergency Stop button to the off position at both the gro...

Page 45: ...ure 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 attention to the ou...

Page 46: ... 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 auxiliary batteries if equipped ...

Page 47: ...y and place blocks under the platform for support 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 The platform could fall when the slave c...

Page 48: ...tting Torque Specifications 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 disconn...

Page 49: ... 10 Lower 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 ...

Page 50: ...nction enable 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 haz...

Page 51: ...ill maintain full load capacity however in some situations the platform load capacity may be reduced until a full load calibration has been performed Note Perform this procedure with the machine on a firm level surface 1 Fully retract and lower the boom Level the platform 2 Remove all weight tools accessories and equipment from the platform Note Remove the welder if equipped Tip over hazard Failur...

Page 52: ... the Service Mode 4 Press the settings button above the display and select the Calibrations menu 5 Navigate to the Sensor calibration screen 6 Navigate to the Load Sense calibration screen 7 Select and start the calibration procedure 8 Follow the on screen prompts to set the zero load 9 Continue with the on screen prompts to set the maximum load 10 Place a test weight on the platform floor using a...

Page 53: ... the alarm sounds 17 Test all machine functions from the ground controls Result Engine does not start Limited APU functionality Elevate and extend functions do not operate 18 Remove the weight or rated load from the platform How to Replace the Platform Overload Load Cell How to Replace the Load Cell Sensor Note The preload adjustment should only be performed after the load cell sensor has been rep...

Page 54: ...s to settle the platform overload assembly 14 Perform a full platform overload system calibration Refer to Repair Procedure How to Calibrate the Platform Overload System 2 4 Platform 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 brac...

Page 55: ... jib boom lift 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 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for ...

Page 56: ...slowly to allow the oil 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 leve...

Page 57: ...om pivot pin 2 boom 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 58: ...rom the counterbalance 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 fi...

Page 59: ...e the Cable Track S 65 XC and S 65 XC TRAX How to Remove the Cable Track S 65 XC and S 65 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 disc...

Page 60: ...rate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 15 Pull the hydraulic hoses out of the primary boom 16 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 17 Remove the cable track pull tube guide fasteners from the cable tr...

Page 61: ...e existing cable track using the snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 2 Boom Assembly 4 2 Boom Assembly How to Remove the Boom Tip over hazard This procedure requires the removal of the turntable counterweight Failure to remove the counterwe...

Page 62: ...tempt to lift the machine with the overhead crane 9 Locate and remove the counterweight retaining fastener at the center of the counterweight Carefully lift the counterweight upwards and remove the counterweight from the machine Set the counterweight on the ground Do not leave the counterweight suspended above the ground Crushing hazard The turntable counterweight will fall if not properly support...

Page 63: ...n 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 Tag and disconnect the electrical connector for the cable break limit switch 24 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom 25 Support the platform leveling master cylinder Remove the maste...

Page 64: ...etaining 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 properly supported when the primary boom rod end pivot pin is removed 5 Using auxiliary power activate the boom down function so the cylinder will retract Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket...

Page 65: ... Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position 2 Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover Rest the cover and string potentiometer on the counterweight Component damage hazard The cable from the string potentiometer can become damaged if it is kin...

Page 66: ...cket assembly on top of the extend cylinder 16 Locate the lower extend cable bracket on the bottom of the number 3 boom tube 17 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 18 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 19 S...

Page 67: ... Cables 4 5 Boom Extend Retract Cables How to Adjust the Boom Extend Retract Cables The boom extend retract cables are responsible for the extension and retraction of the number 3 boom tube Proper adjustment of the boom extend retract cables and related components on a regular basis is essential to good machine performance and safe machine operation The boom extend and retract functions should ope...

Page 68: ...cle This will create slack in the retract cables Note Be sure to not fully extend the boom Stop when there is approximately 3 feet 1 m of travel left 9 Repeat steps 7 and 8 two to three times 10 Fully extend the boom then retract the boom approximately 12 inches 30 cm 11 At the pivot end of the boom visually inspect the boom extend cables for even cable droop or sag Note If the boom extend cables ...

Page 69: ...oom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube Boom retract cables 10 Remove the cotter pins and clevis pins from the boom retract cables at the platform end of the boom Note Always use a new cotter pin when installing a clevis pin 11 Remove the ...

Page 70: ...25 Adjust the boom extend retract cables Refer to Repair Procedure How to Adjust the Boom Extend Retract Cables 4 6 Platform Leveling Master Cylinder 4 6 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is located at the...

Page 71: ...rm this procedure with the machine on a firm level surface with the boom in the stowed position Note The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor Note This procedure will establish the cross check angle with the boom limit switch LST3S If LST3S does not switch its state properly during the calibration the calibration will...

Page 72: ...e calibration is complete If this step isn t done the boom will be in the safety envelope when the calibration procedure ends 11 The calibration is now complete 12 Exit the Service Mode 4 8 Primary Boom Angle Sensor Replacement 4 8 How to Replace the Primary Boom Angle Sensor 1 From the ground controls raise the primary boom until the sensor assembly is above the counterweight 2 Push in the red Em...

Page 73: ...the sensor 6 from the sensor carrier plate by removing the two screws 5 using a 2 mm hex key Note the sensor orientation on the sensor carrier plate for reassembly 9 Remove any old blue thread locker dirt or oils from the threaded 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 ...

Page 74: ...inal to the start battery and the auxiliary battery if equipped 20 Calibrate the boom angle sensor Refer to Repair Procedure How to Calibrate the Boom Angle Sensor 4 9 Boom Length Sensor Calibration 4 9 Boom Length Sensor How to Calibrate the Primary Boom Length Sensor Note The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor Not...

Page 75: ...apture 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 76: ...enance Manual for your machine Check and Adjust the Engine RPM 5 3 Flex Plate Removal 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 flywh...

Page 77: ...gine with 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 bel...

Page 78: ... bolts in 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 p...

Page 79: ...all the 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 12...

Page 80: ...s 66 Nm 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 ...

Page 81: ...s to initiate sequential fuel injection and make constant 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 t...

Page 82: ...e operator does not need to perform any actions Standstill regeneration If passive regeneration does not attain an adequate reduction of the soot contamination the particle filter will continue to become contaminated with soot and a standstill regeneration will be required by the operator To perform standstill regeneration refer to the Operator s Manual on your machine Service regeneration If a fa...

Page 83: ...e Close the valves Component 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 inj...

Page 84: ...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 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 ...

Page 85: ...orce the pump coupler into the flexplate or damage to the pump shaft seal may occur Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin from the engine pivot plate latch Note The engine pivot plate latch ...

Page 86: ...Hold the manual fuel shutoff valve clockwise to the closed position 1 manual fuel shutoff valve 5 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 Ford models Connect the LPG hose to the LPG tank and open the valve on the tank Perkins 404D 22 models Connect the en...

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Page 88: ... operated solenoid valve F Boom extend 33 37 ft lbs 45 50 Nm 7 Check valve 65 psi 5 bar P Platform 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...

Page 89: ...April 2021 Service and Repair Manual Manifolds Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 77 ...

Page 90: ...ake release circuit 8 10 ft lbs 10 15 Nm 22 Solenoid valve 2 position 3 way AS Brake release 26 30 ft lbs 35 40 Nm 23 Load shuttle valve BG Shuttle port relief 20 25 ft lbs 27 34 Nm 24 Differential relief valve 3200 psi 221 bar B System relief 20 25 ft lbs 27 34 Nm 25 Sequence valve ANSI version only BD Controls oscillate pressure 26 Relief valve 3500 psi 241 bar BF Platform relief 20 25 ft lbs 27...

Page 91: ...April 2021 Service and Repair Manual Manifolds Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 79 ...

Page 92: ...5 50 Nm 6 Solenoid valve NO poppet E Boom retract 33 37 ft lbs 45 50 Nm 7 Pressure reducing valve BC Oscillate pressure control 33 37 ft lbs 45 50 Nm 8 Solenoid valve 3 position 4 way spool type K Turntable rotate 26 30 ft lbs 35 40 Nm 9 Solenoid valve 2 position 2 way T Boom down 33 37 ft lbs 45 50 Nm 10 Solenoid valve 2 position 2 way S Boom up 33 37 ft lbs 45 50 Nm 11 Pressure compensated flow ...

Page 93: ...April 2021 Service and Repair Manual Manifolds Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 81 ...

Page 94: ...t lbs 35 40 Nm 22 Check valve 30 psi 2 bar W Platform rotate tank line 20 25 ft lbs 27 34 Nm 23 Check valve 30 psi 2 bar AT Platform level circuit 20 25 ft lbs 27 34 Nm 24 Differential sensing valve NO proportional D Boom extend 50 55 ft lbs 68 75 Nm 25 Differential relief valve 2300 psi 159 bar CC Boom extend relief 20 25 ft lbs 27 34 Nm 26 Check valve AN Brake release circuit 8 10 ft lbs 10 15 N...

Page 95: ...April 2021 Service and Repair Manual Manifolds Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 83 ...

Page 96: ...just the relief valve higher than specified 6 Repeat step 2 to confirm relief valve pressure 7 Remove the pressure gauge How to Adjust the Boom Extend Relief Valve 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 be used to perfo...

Page 97: ...Jib Boom Platform Rotate Manifold Components 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 98: ...n manifold is mounted to the 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 ...

Page 99: ...e pressure gauge and assemble the directional valve linkage How to Set Up the Oscillate Directional Valve How to Set Up the Oscillate Directional Valve Note Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Fail...

Page 100: ... the axle and tighten the jam nut 11 Check to be sure the drive chassis is completely level 12 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Note If the distance is not within 0 15in 3 8mm to 0 17in 4 3mm and the adjustment to the linkage was completed with the ground and drive chassis level repeat steps 6 through 11 OR con...

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Page 102: ...b at high steer angles by 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 P...

Page 103: ...April 2021 Service and Repair Manual Manifolds Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 91 ...

Page 104: ...gine off 6 Remove the pressure 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 begins to move Note the reading on the pressure gauge Turn the machine off 8 Hold the charge pressure relief valve and remove t...

Page 105: ...iption Schematic 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 GF Adds backpressure to generator circuit 6 Check valve GE Prevents oil to gener...

Page 106: ... Set the multimeter to read frequency and 110 vac and connect the leads to the 110 vac receptacle 2 Start the engine and then start the generator The engine will go to high idle 3 Locate the generator manifold on the turntable tray by the fuel tank and loosen the jam nut on the needle valve identified in the illustration Generator Manifold 1 needle valve 4 Adjust the valve counter clockwise to inc...

Page 107: ...rocution burn hazard 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...

Page 108: ...e resistor 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 re...

Page 109: ...dure with the machine on a firm and level 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 h...

Page 110: ...ification 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 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...

Page 111: ... firm level surface with the machine in the stowed position 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 to the Sensor Calibrations menu 3 Navigate to the Chassis Tilt Sensor calibration screen 4 Select and start the calibration procedure 5 If t...

Page 112: ...sis bearing 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 ...

Page 113: ...e replaced All connections must be torqued to specification during installation Refer to Specifications 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 ...

Page 114: ...ove the remaining sprocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane How to Replace a Track How to Replace a Track Assembly Note Perform this procedure on firm level surface with the b...

Page 115: ...eels 2 bogey wheels 9 Rotate the sprocket half until the split tooth of the sprocket is lower than the other side 1 split tooth 10 Using an overhead crane or other suitable lifting device lift up on the rubber track to create enough room to install the other sprocket half 11 Install the sprocket half removed in step 3 while engaging the sprocket teeth with the rubber track Note Be sure to align th...

Page 116: ...hazard The track assembly could become unbalanced and fall when installed onto the machine if not properly supported by the overhead crane 17 Adjust the track tension Locate the grease plug on the track tension cylinder Loosen the plug but do not remove it 18 Locate the grease zerk fitting on the other side of the track tension cylinder 1 grease zerk 2 grease plug 19 Pump grease into the grease ze...

Page 117: ...o tight loosen the grease plug on the cylinder to remove grease and loosen the track 22 Raise the machine remove the jack stands and lower the machine 23 Drive the machine in either direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter Turn the machine off 24 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque...

Page 118: ...ntrols Wheels 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...

Page 119: ...e of an active fault 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 ...

Page 120: ...llow the machine to re test the fault 12 CAN Bus 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 a...

Page 121: ...nce greater 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 P...

Page 122: ...Up Valve 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 ...

Page 123: ...on process and verify fault is no longer active 19 Out of range Sensor disagrees with boom position sensed by LST3S or boom exceeded the calibrated minimum 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 I...

Page 124: ...d to GND 35 Ground Buttons 19 Held at startup Buttons were held at system start or are shorted on the ground control panel The function associated with the stuck button will not operate Release the ground control buttons and cycle power If problem persists open ground control box and open the Display Controller access door being careful to keep water out Verify the ribbon cables are properly seate...

Page 125: ...ted to V TCON detected that C5TRR circuit is shorted to 12 V Turntable Rotate functions will not operate With a voltmeter measure Y23 Proper resistance should be between 5 60 ohms Replace Y23 if resistance is outside of those values Verify wiring for C5TRR WH BK TCON J3 1 and check for open or short circuits 15 Circuit shorted to GND TCON detected that C5TRR circuit is shorted to GND 44 Drive Enab...

Page 126: ...functions will not operate Leave joystick in neutral position and cycle power If fault persists with a voltmeter check that C160DRV WH RD PCON J18 10 is at 2 5V 0 2 V at startup and does not go above 4 5 V or below 0 5 V when fully stroked in each direction Replace joystick if voltage check fails 15 Joystick voltage too low Circuit C160DRV is below 0 5 V 19 Joystick held at startup Circuit C160DRV...

Page 127: ...tral position and cycle power If fault persists identify which circuit is the steer circuit Check C159STA BL WH PCON J18 11 for a joystick steer option Check C159STD BL RD PCON J18 9 for the rocker joystick steer option With a voltmeter check that the circuit is at 2 5V 0 2 V at startup and does not go above 4 5 V or below 0 5 V when fully stroked in each direction Replace joystick if voltage chec...

Page 128: ...ng Check P56PWR RD TCON J5 7 for open or short circuits Verify power is reaching the P1 ESTOP contact block When ESTOP is pulled out verify power is reaching the KS1 keyswitch contact blocks 21 ESTOP Return circuit mismatch TCON detected that ESTOP Return circuits are not matching indicating a fault with either P23PWR or P23RET Check for open and short circuits in the boom cable Verify that there ...

Page 129: ... machine with latest software Check http firmware genielift com for the latest software version 76 Platform Load Sensor 13 No signal No CAN messages have been received by the TCON from the platform load sensor Boom Up Extend and Turntable Rotate functions will not operate Verify sensor power P26PWR BK PCON J13 9 is at 12 V while the system is running Verify 12 V across pins on C27 2 and C27 3 on t...

Page 130: ...tion data either because the sensor was replaced or the prior calibration was cleared from memory or was unsuccessful Run the platform overload calibration process and 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...

Page 131: ...system revision level Boom Up and Extend functions will not operate Reprogram the machine with latest software Check http firmware genielift com for the latest software version 36 Secondary processor not detected TCON has not detected the PCON secondary processor on the communications bus Controls from the platform will not operate Reprogram the machine with latest software Check http firmware gen...

Page 132: ...test software version 83 Telematics 21 Remote disable The telematics module has locked out machine operation Machine will not be functional or have limited functionality depending on the telematics option Call machine owner to re enable machine functions 84 Turntable Tilt Sensor 13 Not detected The tilt sensors S8O and or S8S have not been detected on the CAN bus Boom Up Extend and Drive functions...

Page 133: ...Sensor Boom Up Extend and Turntable Rotate functions will not operate Verify sensor power P85PWR GR TCON J6 7 is at 12 V while the system is running Verify the sensor is receiving power Unplug 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...

Page 134: ...hat V14PLU 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 ope...

Page 135: ...ure Y15 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 Toggl...

Page 136: ...N detected 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 S...

Page 137: ... the Engine Stop Lamp condition Control system will not allow engine restart until power cycle Engine may stop itself depending on the engine option Check the engine fault codes with an engine diagnostic tool Note The control system shuts off the engine immediately upon receiving this fault from the engine 9 Engine 21 Fault Engine is reporting an engine specific fault This is a generic engine warn...

Page 138: ...the switch OFF and 12 V with the switch held in the DOWN position Cycle power to allow the machine to re test the fault 15 Foot Switch 27 Active at startup Foot switch input was detected as HIGH at start up or the footswitch was held for too long and caused the footswitch timer to elapse Machine will not be functional Release foot switch and cycle power If problem persists with a voltmeter verify ...

Page 139: ...t C164PUD RD WH PCON J18 3 is at 2 5V 0 2 V at startup and does not go above 4 5 V or below 0 5 V when fully stroked in each direction Replace joystick if voltage check fails 27 Active at startup Circuit C164PUD voltage was not within the startup voltage range of 2 5 V 0 2 V 28 22 Pri Boom Up coil 11 Shorted to supply voltage TCON detected that C1PBU circuit is shorted to 12 V Boom Up function wil...

Page 140: ... calibrated Sensor has been replaced and requires calibration or calibration in memory has been erased Run the boom angle calibration process and verify fault is no longer active 19 Value out of expected range Min or max boom angle out of expected range Crosscheck limit switch disagrees with boom angle sensor Machine limited to recovery functions Verify that with the boom stowed C68LS BL TCON J7 3...

Page 141: ...Ground Control Button 27 Active at startup Buttons were held at system start or are shorted on the ground control panel The function associated with the stuck button will not operate Release the ground control buttons and cycle power If problem persists open ground control box and open the Display Controller access door being careful to keep water out Verify the ribbon cables are properly seated a...

Page 142: ... 2 5 V 0 2 V 42 Turntable Rotate CW Coil 11 Shorted to supply voltage TCON detected that C4TRL circuit is shorted to 12 V or GND Turntable Rotate functions will not operate With a voltmeter measure Y24 Proper resistance should be between 5 60 ohms Replace Y24 if resistance is outside of those values Verify wiring for C4TRL WH TCON J3 12 and check for open or short circuits 43 Turntable Rotate CCW ...

Page 143: ... not operate With a voltmeter measure Y70 Proper resistance should be between 5 60 ohms Replace Y70 if resistance is outside of those values Verify wiring for V17PRL GR PCON J12 5 and check for open or short circuits 47 Platform Rotate CCW Coil 11 Shorted to supply voltage PCON detected that V18PRR circuit is shorted to 12 V or GND Platform Rotate CCW function will not operate With a voltmeter mea...

Page 144: ...if resistance is outside of those values Verify wiring for C31REV WH BK TCON J2 7 and check for open or short circuits 54 Brake Release Coil 11 Shorted to supply voltage TCON detected that C32BRK circuit is shorted to 12 V or GND Machine will not be functional With a voltmeter measure Y2 Proper resistance should be between 5 60 ohms Replace Y2 if resistance is outside of those values Verify wiring...

Page 145: ...range of 2 5 V 0 2 V 62 Prox Override Togggle Switch 27 Active at startup Toggle switch input was detected as HIGH at start up The Jib Up or Down functions will not operate Verify with a voltmeter that the Jib Up Down Toggle Switch TS8 is operating properly C43JU BL PCON J17 6 should be 0 V with the switch OFF and 12 V with the switch held in the UP position C44JD BL BK PCON J17 8 should be 0 V wi...

Page 146: ...ays the opposite of C247CA OR PCON J12 11 Check wiring for open or short circuits Verify SW30 is receiving power and ground by verifying 12 V across C31 pins 1 and 3 Replace SW30 if necessary 21 Fault 73 Engine Oil Pressure 12 Sensor value too high Engine oil pressure sender is shorted to 12V Engine will not operate With a voltmeter check that C25PSR WH BK TCON J6P9 is not shorted to 12V and volta...

Page 147: ... Rotate functions will not operate Verify sensor power P26PWR BK PCON J13 9 is at 12 V while the system is running Verify 12 V across pins on C27 2 and C27 3 on the harness connector Measure resistance across C27 pins 4 and 5 on the harness connector If resistance is not between 55 and 65 ohms check CAN wire harnesses Replace sensor if necessary 14 Cross check failed The two internal sensing chann...

Page 148: ...software is out of date Machine limited to recovery functions Download latest software from firmware site and update machine 79 Display Controller DISCON 13 Not detected TCON has not detected the DISCON on the communications bus Controls from the ground will not operate Verify DISCON is operating by checking that the display on the front is operating properly If there is no display try to power up...

Page 149: ...y This is a flag that indicates that the platform was overloaded and that auxiliary function enable was used while overloaded Advisory condition Machine is fully functional Power up the machine in service mode and clear the flag in the service menu on the ground control display 83 Disabled 21 By owner The telematics module has locked out machine operation Machine will not be functional or have lim...

Page 150: ...PCE OR RD TCON J2 5 and check for open or short circuits 89 Fuel Level Sensor 12 Value to high Fuel sensor shorted to B Information only With a voltmeter check voltage on C65FLI BL WH TCON J7 11 The voltage should be between 1V and 5V Check for shorts to B 15 Value to low Fuel sensor shorted to GND With a voltmeter check voltage on C65FLI BL WH TCON J7 11 The voltage should be between 1V and 5V Ch...

Page 151: ...p to the bracket on the boom and that the cord extends and retracts smoothly Calibrate boom length sensor Replace sensor if necessary 17 Not calibrated Boom length sensor not calibrated Calibrate boom length sensor 19 Value out of expected range Min or max length out of expected range Crosscheck limit switch disagrees with length sensor Verify that with the boom retracted C24LS OR RD TCON J7 4 is ...

Page 152: ...ly C17PRL GR PCON J16 4 and C18PRR GR BK PCON J17 5 should be 12 V when the switch is pressed in their respective directions Cycle power to allow the machine to re test the fault 116 Model Configuration 31 Setup invalid Machine is not fully configured or set to wrong model Machine will not operate Navigate to Settings Model Configuration and ensure model engine tires and region are set and correct...

Page 153: ... Replace TCON if resistance is more than 5 ohms Check P79PWR BK TCON J5 9 and P23PWR RD TCON J5 10 for open or short circuits 186 ESTOP Return 11 Shorted to supply voltage Mismatched signals detected on ESTOP Return circuits Either PCON ESTOP 2 and ESTOP 4 do not match or TCON ESTOP 2 and ESTOP 4 do not match ESTOP circuit cannot complete preventing machine functions Inspect PCON J15 pins 11 and 1...

Page 154: ...ngine s dedicated service 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 indicator...

Page 155: ...tion Negative measured differential pressure 1075 411 2 Engine exhaust gas recirculation Positive measured differential pressure DTC SPN FMI Description 1077 411 3 Engine exhaust gas recirculation Signal value above maximum limit 1078 411 4 Engine exhaust gas recirculation Signal value below maximum limit 1079 108 0 Ambient air pressure sensor above normal operational range 1080 108 1 Ambient air ...

Page 156: ... voltage above normal or shorted to high 1131 1209 4 Engine exhaust pressure sensor voltage below normal or shorted to low DTC SPN FMI Description 1134 3251 3 DPF voltage above normal or shorted to high 1135 3251 4 DPF voltage below normal or shorted to low 1136 3251 14 DPF reporting communication error 1137 3251 14 DPF reporting data error 1138 3251 14 DPF reporting fast channel 1 error 1139 3251...

Page 157: ...ure 1202 157 0 Maximum rail pressure exceeded in limp home mode 1208 157 3 Engine fuel injector metering rail pressure voltage above normal or shorted to high DTC SPN FMI Description 1209 157 4 Engine fuel injector metering rail pressure voltage below normal or shorted to low 121 520252 2 Wrong checksum in the CAN message EAT Control 1212 629 12 ECU Keep alive error during runtime at an external d...

Page 158: ...tage 2 from ECU below normal operational range 1306 677 3 Engine starter motor relay voltage above normal or shorted to high 1307 677 4 Engine starter motor relay voltage below normal or shorted to low DTC SPN FMI Description 1308 677 5 Engine starter motor relay current below normal or shorted to low 1310 677 3 Engine starter motor relay voltage above normal or shorted to high 1311 677 4 Engine s...

Page 159: ...ngine throttle valve 1 position 1 mechanical system not responding or out of adjustment Valve stuck open 1391 51 3 Engine throttle valve 1 position 1 voltage above normal or shorted to high DTC SPN FMI Description 1392 51 4 Engine throttle valve 1 position 1 voltage below normal or shorted to low 1397 105 0 Engine intake manifold 1 temperature above normal operational range 1398 105 1 Engine intak...

Page 160: ... 0 Timeout error of CAN receive frame TSC1AR Retarder 365 3349 0 Timeout error of CAN receive frame TSC1TE Setpoint DTC SPN FMI Description 367 3349 0 Timeout Error of CAN receive frame TSC1TR control signal 38 1485 3 ECM main relay voltage above normal or shorted to high 39 1485 3 ECM main relay voltage above normal or shorted to high of actuator relay 2 40 1485 3 ECM main relay voltage above nor...

Page 161: ...above warning threshold Overrun Mode 610 171 15 Environment temperature sensor temperature above upper physical threshold DTC SPN FMI Description 613 171 3 Ambient air temperature sensor voltage above normal or shorted to high 614 171 4 Ambient air temperature sensor voltage below normal or shorted to low 615 723 8 Camshaft speed sensor abnormal frequency or pulse width or period 616 723 14 Camsha...

Page 162: ...t 819 5361 5 Engine cylinder 4 fuel injection quantity current below normal or open circuit 820 5362 5 Engine cylinder 5 fuel injection quantity current below normal or open circuit DTC SPN FMI Description 821 5363 5 Engine cylinder 6 fuel injection quantity current below normal or open circuit 822 2797 6 Engine fuel 1 injector Group 1 current above normal or grounded circuit 823 2798 6 Engine fue...

Page 163: ...ent value programming injector 1 839 2798 14 Engine fuel 1 injector group 2 missing injector adjustment value programming injector 2 DTC SPN FMI Description 840 4257 14 Engine fuel 1 injector group 3 missing injector adjustment value programming injector 3 854 7103 5 Engine fuel metering rail pump current below normal or open circuit 855 7103 3 Engine fuel metering rail pump voltage above normal o...

Page 164: ...ltiple cylinders Diagnostic fault check to report the error due to injection quantity correction 884 5442 2 Engine fuel injection pressure error for multiple cylinders 885 29 2 Accelerator pedal 2 position 886 677 2 Engine starter motor relay Function monitoring Fault of ECU power train active DTC SPN FMI Description 887 513 2 Actual engine percent torque DFC to report the fault in energizing time...

Page 165: ...t 51 6 1230 Actuator error 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...

Page 166: ...low sensor load correction factor exceeding the maximum drift limit 157 3 877 Sensor 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 batt...

Page 167: ...check high 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 S...

Page 168: ...898 9 305 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 ra...

Page 169: ...low 2659 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 measuremen...

Page 170: ...n control 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 Functi...

Page 171: ...nitoring 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...

Page 172: ...TR SPN FMI SPN 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 adjustmen...

Page 173: ...messages 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 calibra...

Page 174: ...nt to actual 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 ...

Page 175: ... 9 1670 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 SCR...

Page 176: ...oltage Above Normal 558 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 Abnorm...

Page 177: ...ue to System 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 o...

Page 178: ...tage 188 FT Gaseaous fuel high voltage 217 ECT higher than expected 2 219 Max 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 ...

Page 179: ...tart relay control ground short 617 Start relay coil short to power 627 Fpump relay 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 Op...

Page 180: ...AUX analog PD1 low 1517 AUX analog PU3 high 1518 AUX analog PU3 low 1521 CHT higher 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 ...

Page 181: ...2115 FPP1 higher than IVS limit 2116 FPP2 higher than IVS limit 2120 FPP1 invalid 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 m...

Page 182: ...Primary Loop Open or Low side Short to Ground 2313 Primary Coil Shorted 2315 Primary 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 Ford MSG 425 EFI Diagnostic Manual ...

Page 183: ...stand and obey the 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 Rem...

Page 184: ...lenoid Connection no 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 temper...

Page 185: ...tor Shuttle valve 2 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 a...

Page 186: ...otentiometer 5 Rotary Sensor 6 LST3S 7 LST1O 8 UTS Limit Switches and Sensors S24 LSB1RS LSB2S String pot Rotary sensor LST3S LST1O UTS 2 Platform overload sensor Limit switch boom fully retracted safety 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 ...

Page 187: ...April 2021 Service and Repair Manual 175 Electrical Schematics Electrical Schematic Turntable Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 ...

Page 188: ...65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Turntable Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 Electrical Schematic Turntable Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 ...

Page 189: ...1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 177 Electrical Schematic Platform Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 Electrical Schematic Platform Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 ...

Page 190: ...Service and Repair Manual April 2021 178 Electrical Schematic Platform Controls from S60XCH 45010 to 45353 S65XCH 45001 to 45353 S65XCM 101 ...

Page 191: ...April 2021 Service and Repair Manual 179 Electrical Schematic Turntable Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 ...

Page 192: ...ril 2021 180 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Turntable Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 Electrical Schematic Turntable Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 ...

Page 193: ...ir Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 181 Electrical Schematic Platform Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 Electrical Schematic Platform Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 ...

Page 194: ...Service and Repair Manual April 2021 182 Electrical Schematic Platform Controls from S60XCH 45354 S65XCH 45354 S65XCD 101 ...

Page 195: ...April 2021 Service and Repair Manual 183 Electrical Schematic Deutz TD 2 2 L3 Models ...

Page 196: ...Service and Repair Manual April 2021 184 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Deutz TD 2 2 L3 Models Electrical Schematic Deutz TD 2 2 L3 Models ...

Page 197: ...April 2021 Service and Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 185 Electrical Schematic Deutz TD 2 2 L3 Engine Harness Electrical Schematic Deutz TD 2 2 L3 Engine Harness ...

Page 198: ...Service and Repair Manual April 2021 186 Electrical Schematic Deutz TD 2 2 L3 Engine Harness ...

Page 199: ...April 2021 Service and Repair Manual 187 Electrical Schematic Deutz D 2 9 L4 Models ...

Page 200: ...Service and Repair Manual April 2021 188 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Deutz D 2 9 L4 Models Electrical Schematic Deutz D 2 9 L4 Models ...

Page 201: ...il 2021 Service and Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 189 Electrical Schematic Deutz D2011 L03i TD2011 L04i Models Electrical Schematic Deutz D2011 L03i TD2011 L04i Models ...

Page 202: ...Service and Repair Manual April 2021 190 Electrical Schematic Deutz D2011 L03i TD2011 L04i Models ...

Page 203: ...April 2021 Service and Repair Manual 191 Electrical Schematic Perkins 404F E22T Models ...

Page 204: ...Service and Repair Manual April 2021 192 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Perkins 404F E22T Models Electrical Schematic Perkins 404F E22T Models ...

Page 205: ...April 2021 Service and Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 193 Electrical Schematic Perkins 404D 22 Models Electrical Schematic Perkins 404D 22 Models ...

Page 206: ...Service and Repair Manual April 2021 194 Electrical Schematic Perkins 404D 22 Models ...

Page 207: ...April 2021 Service and Repair Manual 195 Electrical Schematic Ford MSG 425 EFI Models ...

Page 208: ...Service and Repair Manual April 2021 196 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Electrical Schematic Ford MSG 425 EFI Models Electrical Schematic Ford MSG 425 EFI Models ...

Page 209: ...April 2021 Service and Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 197 Electrical Schematic Generators Electrical Schematic Generators ...

Page 210: ...Service and Repair Manual April 2021 198 Electrical Schematic Generators ...

Page 211: ...April 2021 Service and Repair Manual 199 Hydraulic Schematics Hydraulic Schematic from S65XCM 101 to S65XCM 302 ...

Page 212: ...Service and Repair Manual April 2021 200 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Hydraulic Schematic from S65XCM 101 to S65XCM 302 Hydraulic Schematic from S65XCM 101 to S65XCM 302 ...

Page 213: ...nd Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 201 Hydraulic Schematic from S60XCH 45010 to 45344 S65XCH 45001 to 45344 Hydraulic Schematic from S60XCH 45010 to 45344 S65XCH 45001 to 45344 S65XCM 303 ...

Page 214: ...Service and Repair Manual April 2021 202 Hydraulic Schematic from S60XCH 45010 to S60XCH 45344 S65XCH 45001 to S65XCH 45344 S65XCM 303 ...

Page 215: ...21 Service and Repair Manual Part No 1288652GT S 60 65 XC S 60 65 HF S 60 65 TraX 203 Hydraulic Schematic from S60XCH 45345 S65XCH 45345 S65XCD 101 Hydraulic Schematic from S60XCH 45345 S65XCH 45345 S65XCD 101 ...

Page 216: ...Service and Repair Manual April 2021 204 Hydraulic Schematic from S60XCH 45345 S65XCH 45345 S65XCD 101 S 60 65 XC S 60 65 HF S 60 65 TraX Part No 1288652GT Service and Repair Manual April 2021 ...

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