Terex Genie S-80 HF Series Service And Repair Manual Download

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Service and Repair Manual

October 2019

Specifications

-80 XC

™

• S

-85 XC

™

•

80 HF • S

-85 HF

Part No. 1280490GT

Manifold Com ponent Specificati ons

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

SAE No. 8

38 ft-lbs / 51 Nm

SAE No. 10

41 ft-lbs / 55 Nm

SAE No. 12

56 ft-lbs / 76 Nm

Summary of Contents for Genie S-80 HF Series

Page 1: ... 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics S 80 HF S 85 XC from S85XCH 101 from S85XCD 101 S 85 HF For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1280490GT Rev C7 October 2019 ...

Page 2: ...ine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encourag...

Page 3: ...d Controls to Control System Schematics Electrical schematics C3 10 2018 Specifications Machine Specifications C4 5 2019 Specifications Machine Torque Specifications Repair Display Menu Fault Codes Control System Fault Codes Schematics Electrical schematics C5 6 2019 Fault Codes Control System Fault Codes C6 7 2019 Repair Display Menu C7 10 2019 Schematics Limit Switch Legend Reference Examples El...

Page 4: ...nual October 2019 Introduction iv S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Serial Number Legend 1 Model 2 Facility code 3 Sequence number 1 Serial label located under cover 2 Serial number stamped on drive chassis ...

Page 5: ... 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 gover...

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 awa...

Page 7: ...Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Manifold Component Specifications 6 Deutz TD2011 L04i Engine Specifications 7 Deutz TD 2 9 Engine Specifications 8 Perkins 404D 22T Engine Specifications 9 Perkins 404F E22TA Engine Specifications 10 GM 3 0L Engine Specifications 11 Machine Torque Specification...

Page 8: ...o Enter ALC600 Software Update Mode 22 1 6 Display Module Menus 23 1 7 How to Replace the Display Controller DISCON Module 27 1 8 How to Replace the Ground Control Overlay 28 Platform Components 31 2 1 Platform 31 2 2 Platform Leveling Slave Cylinder 31 How to Remove the Platform Leveling Slave Cylinder 31 How to Bleed the Slave Cylinder 32 2 3 Platform Rotator 32 How to Remove the Platform Rotato...

Page 9: ... Cylinder 46 4 4 Boom Extension Cylinder 47 4 5 Boom Extend Retract Cables 49 How to Adjust the Extend Retract Cables 49 How to Replace the Boom Extend Retract Cables 51 4 6 Platform Leveling Master Cylinder 53 4 7 Primary Boom Angle Sensor Calibration 54 4 8 Boom Length Sensor 55 Engines 56 5 1 RPM Adjustment 56 5 2 Flex Plate 56 How to Remove the Flex Plate 56 How to Install the Flex Plate 59 Ho...

Page 10: ...omponents S 85 XC 72 8 8 4WD Traction Manifold Components 74 8 9 Valve Adjustments Traction Manifold 76 8 10 Generator Manifold Components 77 8 11 Valve Coils 78 Valve Coil Resistance Specifications 78 Fuel and Hydraulic Tanks 80 9 1 Fuel Tank 80 9 2 Hydraulic Tank 81 Turntable Rotation Components 83 10 1 Turntable Rotation Drive Hub Assembly 83 How to Remove the Turntable Rotation Drive Hub Assem...

Page 11: ...tem Fault Codes 93 How to Retrieve Control System Fault Codes 93 Control System Fault Codes Models with Revision G Software or Lower 94 Control System Fault Codes Models with Revision H Software or Higher 111 Engine Fault Codes 128 Deutz D 2 9 L4 Engine Fault Codes 129 Perkins 404 22 Engine Fault Codes 140 GM 3 0L Engine Fault Codes 142 ...

Page 12: ...ematic Turntable Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to 1399 162 Electrical Schematic Platform Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 163 Electrical Schematic Turntable Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 166 Electrical Schematic Platform Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 167 Electrical Schematic De...

Page 13: ...4 6 cm Tire pressure 100 psi 6 89 bar Wheel diameter 22 5 in 57 2 cm Wheel width 14 in 35 6 cm Tire weight 250 lbs 113 4 kg Lugs and Lug Nut Torque Wheel lugs 11 3 4 16 Lug nut torque dry 420 ft lbs 569 Nm Lug nut torque lubricated 320 ft lbs 434 Nm Fluid capacities Fuel tank Diesel models 35 gallons 132 5 liters Fuel tank Gas models 30 gallons 113 5 liters LPG tank 33 5 lbs 15 2 kg Hydraulic tank...

Page 14: ...ed 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 minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydraulic o...

Page 15: ...y 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: ...istently 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 Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 10...

Page 17: ...nt per revolution 0 15 cu in 2 47 cc Generator Pump Displacement per revolution 1 4 cu in 23 cc Function manifold System relief valve pressure maximum 3200 psi 221 bar Primary boom extend relief pressure measured at PTEST port 2400 psi 165 bar Platform Manifold and Oscillate Valve Platform level flow regulator Platform rotate flow regulator 0 6 gpm 2 3 L min 0 3 gpm 1 1 L min Oscillate relief pres...

Page 18: ... XC S 80 HF S 85 HF Part No 1280490GT Manifold Com ponent Specificati ons 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 SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm ...

Page 19: ...8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships 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 sender Installation torque 8 18 ft lbs 11 24 Nm Oil Pressure se...

Page 20: ...8 quarts 12 1 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships 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 sender Installation torque 8 18 ft lbs 11 24 Nm Oil Pressure se...

Page 21: ...d at 2500 rpm 60 psi 4 1 bar Oil capacity including filter 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 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 Fuel injection system Injection pump m...

Page 22: ...0 6 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 CJ4 4 F to 104 F 20 C to 40 C 10W 40 CJ4 Above 5 F 15 C 15W 40 CJ4 Unit ships 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 Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 14 2...

Page 23: ...e at least 75 of the highest cylinder Governor electronic Lubrication system Oil pressure hot minimum 1000 rpm 6 psi 0 4 bar Oil capacity including filter 5 quarts 4 7 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 5W 30 Extreme operating temperatures may require the use of alternative engine oils For oil req...

Page 24: ...embly Rotate bearing mounting bolts lubricated 180 ft lbs 244 Nm Rotate drive hub mounting bolts lubricated 80 ft lbs 108 Nm Backlash plate mounting bolts lubricated 280 ft lbs 379 Nm Drive motors and hubs Drive hub mounting bolts lubricated 180 ft lbs 217 Nm Drive motor mounting bolts dry 110 ft lbs 149 Nm Drive motor mounting bolts lubricated LOCTITE 243 threadlocker 80 ft lbs 108 Nm Function Pu...

Page 25: ...ats 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 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting N...

Page 26: ...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 27: ...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 bo...

Page 28: ...operator 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 Machin...

Page 29: ...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 whic...

Page 30: ...ibration 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 modu...

Page 31: ...0 minutes while in Service Mode the ALC 600 will power down and the Service Mode will be exited unless the engine is running 1 3 Full M achi ne C alibration 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...

Page 32: ...Press 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 effe...

Page 33: ...n 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 ...

Page 34: ...ages 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 H ow to Enter ALC 600 Softw are U pdate Mode 1 5 How to Enter ALC600 Software Update Mode 1 Go to the Genie website http firmware genielift com select your machine and ALC600 controller type Enter the machine serial number and part numb...

Page 35: ...ta D1803 Perkins 404D 22 Perkins 404D 22T Perkins 404F E22T Perkins 404F E22TA Select Engine Platform Standard Platform 4m 13 ft Platform Select 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 Drive Cutout On Off Off...

Page 36: ...hreshold 128 max 1 min 100 800mA Reverse Threshold 134 max 1 min 100 720mA Forward Max 150 max 75 min 100 1665mA Reverse Max 150 max 73 min 100 1575mA Forward Out of Stow High Max 150 max 83 min 100 1147mA Reverse Out of Stow High Max 150 max 80 min 100 1211mA Screen or Menu Item Default Drive Ramps Standard Acceleration 5000 ms max 100 ms min 4000 ms Standard Deceleration 5000 ms max 100 ms min 1...

Page 37: ...mum 50 Range 125 rpm Hysteresis 100 rpm Screen or Menu Item Default GM 3 0L Anti Stall Threshold 2190 rpm Drive Minimum 70 Range 125 rpm Hysteresis 125 rpm Screen or Menu Item Default Primary Boom Lift Speeds Extend Threshold 212 max 1 min 100 460mA Retract Threshold 169 max 1 min 100 460mA Up Threshold 186 max 1 min 100 560mA Down Threshold 292 max 1 min 100 400mA Extend Max 150 max 66 min 100 14...

Page 38: ...enu Item Default Turntable Speeds Rotate CW Max 150 max 84 min 100 1210mA Rotate CCW Max 150 max 84 min 100 1210mA Rotate CW Threshold 105 max 1 min 100 800mA Rotate CCW Threshold 105 max 1 min 100 800mA CW Out of Stow Max 150 max 96 min 100 881mA CCW Out of Stow Max 150 max 96 min 100 881mA Screen or Menu Item Default Turntable Ramps CW Accelerating 5000 ms max 1000 ms min 3000 ms CW Decelerating...

Page 39: ...reassembly 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 complet...

Page 40: ...r the ribbon calbes 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 H ow to Replace the Ground Contr ol 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 gr...

Page 41: ...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 42: ...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 43: ...m mounting fasteners and remove the platform from the machine Crushing hazard The platform could become unstable and fall when it is removed from the machine if not properly supported 2 2 Platform Leveling Slave Cyli nder 2 2 Platform Leveling Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform The slave cylinder keeps the platform level through the enti...

Page 44: ...s procedure 1 Raise the boom to a horizontal position 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system 2 3 Platform Rotator 2 3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees How to R emove the Pl atform Rotator How to Remove the Pl...

Page 45: ... any lifting pressure S 80 6 Support the rod end of the platform leveling slave cylinder Protect the cylinder rod from damage 7 Remove the pivot pin retaining fasteners from both the slave cylinder rod end pivot pin and the rotator pivot pin 8 Use a soft metal drift to remove both pivot pins Remove the platform rotator from the machine Crushing hazard The platform rotator may become unbalanced and...

Page 46: ...r spray 4 Move the function enable button 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 Bod...

Page 47: ...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 instructions to set the zero load 9 Continue with the on screen prompts to set the maximum load 10 Place a 1 000 lb 454 kg test weight on the platform floor using a suitable lifting device Place the weight near the center entry point of the platform a...

Page 48: ...t in the machine tipping over causing death or serious injury 3 Enter Service Mode Refer to Repair Procedure How to Enter the Service Mode 4 Press the settings button above the display and navigate to the Sensor Calibrations menu 5 Navigate to the Load Sense calibration screen 6 Select and start the calibration procedure 7 Follow the on screen instructions to set the zero load 8 Continue to follow...

Page 49: ... the flex plate finger tight 9 Using an open end wrench continue to rotate the foot counter clockwise an additional 1 2 turn 180 Then while holding the foot bolt securely tighten the jam nut Torque the jam nut to 55 ft lbs 75 Nm 10 Attach the load cell sensor harness 11 Install the plastic instruction holder 12 Place a 1 000 lb 454 kg test weight on the platform floor using a suitable lifting devi...

Page 50: ...ot pin Lay all hoses and cables to the side Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 5 Tag disconnect and plug the 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...

Page 51: ...lowly 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 level...

Page 52: ...match the color of the connectors to those on the control box to be sure they are 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 S 80XC Tag disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator Cap the fittings on the ma...

Page 53: ... platform end of the boom Remove the cable track guides from the boom 16 Remove the cable clamp from the pivot end of the boom 17 Place blocks 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 18 A...

Page 54: ...e replacement cable track section to the 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 4 2 Boom How to Shim the Boom How to Shim the Boom 1 Measure each wear pad Boom wear pad specifications Boom number one Minim...

Page 55: ...ols could result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the jib boom Refer to Repair Procedure How to Remove the Jib Boom 2 Remove the cable track Refer to Repair Procedure How to Remove the Cable Track 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers 4 Place a block of wood mea...

Page 56: ...r from the primary boom Do not remove the angle sensor from the bracket Note When the primary boom is installed the primary boom angle sensor will need to be calibrated Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor 15 Remove the hose and cable guide fasteners at the primary boom pivot pin Remove the hose and cable guide 16 Attach lifting straps from a 5 ton 5000 kg overh...

Page 57: ...lower the master cylinder down 26 Tag disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom Cap the bulkhead fittings 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 27 Remove the external snap rings from bot...

Page 58: ...taining 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 59: ...n 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 Note Perform this procedure with the boom fully retracted 1 Raise the boom to a horizontal position 2 Remove the boom end cover retaining fasteners and remove the cover 3 Remove the access covers from both sides...

Page 60: ...ket assembly on top of the extend cylinder 15 Locate the lower extend cable bracket on the bottom of the number 3 boom tube 16 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube 17 While pushing the lower extend cable bracket towards the platform pull the extend cable mounting plate towards the pivot end of the boom 18 Se...

Page 61: ...Retract Cables How to Adj ust the Extend R etract C abl es 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 ...

Page 62: ...d the boom Illustration 1 1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom 12 Using a dial type torque wrench torque the retract cable adjustment nut to 32 36 ft lbs 43 49 Nm using gentle and steady torque 13 Retract and extend the boom approximately...

Page 63: ...linder Refer to Repair Procedure How to Remove the Boom Extension Cylinder Boom extend cables 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch 4 Remove the external snap rings from the boom extend cable pulley pivot pin Use a soft m...

Page 64: ...he rope Discard the old boom retract cable 14 Securely attach the rope to the same end of the new boom retract cable 15 At the pivot end of the boom carefully pull the rope with the new retract cable attached 16 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube Remove the rope 17 Repeat steps 14 through 19 for the other boom retract cabl...

Page 65: ... the master cylinder rod end pivot pin is accessible 2 Remove the turntable end cover to access the master cylinder 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt ...

Page 66: ...tton above the display and navigate to the Sensor Calibrations menu 4 Navigate to the Boom Angle Sensor calibration screen 5 Select and start the calibration procedure 6 Start the engine 7 When the display prompts the operator to lower the boom press and hold the function enable button and the boom down buttons until the display indicates that the lower calibration point has been obtained This may...

Page 67: ...vice Mode See Repair Procedure How to Enter Service Mode 3 Press the settings button above the display and navigate to Sensor Calibrations 4 Navigate to the Boom Length Sensor calibration screen 5 Select and start the calibration procedure 6 Start the engine 7 When the display prompts the operator to retract the boom press and hold the function enable and boom retract buttons until the display ind...

Page 68: ... pump Type B flex plates combines the pump coupler as part of the flex plate which is installed onto the engine flywheel Type B flexplate with coupler combined How to R emove the Flex Pl ate How to Remove the Flex Plate Note Perform this procedure with the engine off and cool to the touch 1 Open the engine side turntable cover 2 Tag and disconnect the battery cables from the battery s Electrocutio...

Page 69: ... bell housing engine fasteners 5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 6 Remove the flex plate mounting fasteners and remove the flex plate from the engine flywheel Deutz TD 2 9 models 1 Tag and disconnect the wiring from the bell housing 2 Support the drive pump wi...

Page 70: ... pipe heat shield fasteners from the top of the muffler Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 3 Remove the muffler retainer bracket fasteners 4 Remove the muffler fasteners securing the muffler to the exhaust manifold Remove the muffler from the bracket 5 Remove the relay housing from the muffler mount Do not disconnect the relays...

Page 71: ...et screw toward the pump Leave the appropriate gap between coupler and pump end plate for your engine 4 Apply Loctite removable thread locker to the pump coupler set screw Torque the set screw to 61 ft lbs 83 Nm 5 Install the pump onto the pump mounting plate Apply Loctite removable thread sealant to the pump retaining fasteners Torque the pump retaining fasteners to 57 ft lbs 77 Nm Component dama...

Page 72: ...unting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A to 70 ft lbs 95 Nm GM 3 0L model Torque the bell housing mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the bell housing mounting in sequence to 40 ft lbs 54 Nm bolt...

Page 73: ...ine 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 pump Bodily injury hazard Spraying hydraulic oil can penetrate a...

Page 74: ...ing 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 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves open closed Com...

Page 75: ...ff 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 1 Connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump 2 GM models If equipped close the valve on the LPG tank then disconnect the hose from the tank Move the fuel select tog...

Page 76: ...0 Nm 8 Solenoid valve 3 position 4 way SL Steering directional 20 25 ft lbs 27 34 Nm 9 Proportional solenoid valve SE Swing proportional 20 25 ft lbs 27 34 Nm 10 Solenoid valve 3 position 4 way SI Swing directional 26 30 ft lbs 35 41 Nm 11 Flow regulator valve SD Oscillate flow control 20 25 ft lbs 27 34 Nm 12 Relief valve 2600 psi 179 bar SN Boom down relief 20 25 ft lbs 27 34 Nm 13 Relief valve ...

Page 77: ...October 2019 Service and Repair Manual Manifolds Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 65 ...

Page 78: ...terclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 5 Repeat step 2 to confirm relief valve pressure 6 Remove the pressure gauge How to Adj ust the Boom Dow n R elief Valve How to Adjust the Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Compo...

Page 79: ...gnostic nipple located next to the auxiliary pump 2 Simultaneously activate and hold the auxiliary power button and the primary boom extend button with the boom fully extended Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Specifications 3 Locate the boom extend relief valve on the function manifold Use a wrench to hold the relief valve and remove the cap 4 Ad...

Page 80: ...rake two speed manifold is mounted inside the drive chassis Index No Description Schematic Item Function Torque 1 Orifice 0 025 inch 0 63 mm BE Turntable rotation brake release 2 Check valve BF Brake release circuit 20 25 ft lbs 27 34 Nm 3 Solenoid Valve 2 position 3 way BG Brake release 20 25 ft lbs 27 34 Nm 4 Solenoid Valve 2 position 3 way BH Two speed motor shift 20 25 ft lbs 27 34 Nm ...

Page 81: ...unted to the turntable rotation motor at the ground control side of the machine Index No Description Schematic Item Function Torque 1 Counterbalance valve 1000 psi RA Turntable rotate left 25 30 ft lbs 34 41 Nm 2 Counterbalance valve 1000 psi RB Turntable rotate right 25 30 ft lbs 34 41 Nm 3 Shuttle valve 2 position 3 way RD Turntable rotation brake release 8 10 ft lbs 10 15 Nm 4 Orifice 0 030 inc...

Page 82: ...old C om ponents 8 5 Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator Index No Description Schematic Item Function Torque 1 Counterbalance valve 3300 psi PA Platform rotate right 37 44 ft lbs 50 60 Nm 2 Counterbalance valve 3300 psi PB Platform rotate left 37 44 ft lbs 50 60 Nm ...

Page 83: ...Item Function Torque 1 Solenoid valve 3 position 4 way EF Platform rotate CW CCW 30 35 ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 4 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Needle valve EA Platform level 20 25 ft lbs 27 34 N...

Page 84: ... 30 35 ft lbs 41 47 Nm 2 Solenoid valve 3 position 4 way EB Platform level up down 30 35 ft lbs 41 47 Nm 3 Solenoid valve 3 position 4 way EH Jib boom up down 30 35 ft lbs 41 47 Nm 4 Counterbalance valve 3500 psi EC Platform level CB valve 26 30 ft lbs 35 41 Nm 5 Counterbalance valve 3500 psi ED Platform level CB valve 26 30 ft lbs 35 41 Nm 6 Needle valve EA Platform level 20 25 ft lbs 27 34 Nm 7 ...

Page 85: ...October 2019 Service and Repair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 73 This page intentionally left blank ...

Page 86: ...ls flow to flow divider combiner valves 2 and 13 80 90 ft lbs 108 122 Nm 6 Check valve DD Non steer end drive motor circuit 60 70 ft lbs 81 95 Nm 7 Orifice 0 040 inch 1 mm DL Equalizes pressure on both sides of flow divider combiner valve 5 8 Orifice 0 040 inch 1 mm DA Equalizes pressure on both sides of flow divider combiner valve 2 9 Orifice 0 040 inch 1 mm DN Equalizes pressure on both sides of...

Page 87: ...October 2019 Service and Repair Manual Manifolds Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 75 ...

Page 88: ...a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump 2 Start the engine from the platform controls and allow the engine to run at low idle Note the pressure reading on the pressure gauge 3 Turn the engine off and connect a 0 to 600 psi 0 to 40 bar pressure gauge to the diagnostic nipple located on the traction manifold 4 Start the engine from the platform controls a...

Page 89: ...ex No Description 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 CF Adds backpressure to generator circuit 6 Check valve GE Prevents o...

Page 90: ...rically 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 C oil Resistance Speci ficati ons Valve Coi...

Page 91: ... 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 800...

Page 92: ... the closed position if equipped 2 Remove the fuel filler cap from the tank 3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Specifications Machine Specifications Explosion and fire hazard When transferring fuel connect a grounding wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline...

Page 93: ...ions 1 Remove the fuel tank Refer to Repair Procedure How to Remove the Fuel Tank 2 Close the two hydraulic tank valves located at the hydraulic tank if equipped 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 i...

Page 94: ...e thread sealant on the threads 13 Install the drain plug using pipe thread sealant on the threads 14 Install the hydraulic tank onto the machine 15 Install the two suction hoses and the supply hose for the auxiliary power unit 16 Fill the tank with hydraulic oil until the level is within the top 2 inches 5 cm of the sight gauge Do not overfill 17 Clean up any oil that may have spilled 18 Open the...

Page 95: ...om rotating with the turntable rotation lock pin 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 Loosen the backlash pivot plate and adjustment bolts 4...

Page 96: ...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 Secure the turntable from rotating with the turntable rotation lock pin 2 Tag disconnect and plug the hydraulic hoses from the drive motor Cap t...

Page 97: ...ive 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 boom between the non steer end tires and 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...

Page 98: ... 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 the ma...

Page 99: ...is 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 A...

Page 100: ...le capacity under the steer axle 5 Raise the machine approximately 6 inches 15 cm and place blocks under the chassis for support 6 Remove the lug nuts Remove the tire and wheel assembly 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin 8 Remove the drive motor mounting fasteners 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from...

Page 101: ...allow oil to squirt or spray 3 Remove the drive motor mounting fasteners 4 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine 11 3 Drive Hubs 11 3 Drive Hub How to Remove a Drive Hub 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 in...

Page 102: ...uency counter 1 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 c...

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Page 104: ...ontrols 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 sur...

Page 105: ...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 106: ...allow 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 ...

Page 107: ...ce 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 PC...

Page 108: ...p 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 T...

Page 109: ...n 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 In...

Page 110: ... 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 seated...

Page 111: ...ed 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 Enabl...

Page 112: ...unctions 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 113: ...ral 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 check...

Page 114: ...g 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 i...

Page 115: ...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 th...

Page 116: ...ion 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 117: ...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 118: ...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 119: ...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 120: ...at 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 open...

Page 121: ...re 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 Toggle...

Page 122: ...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 123: ... 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 10 Ground Controls Engine Start Switch 27 Active at startup Engine start button held at startup Engine start is disabled Release engine start button check DISCON overlay and ribbon...

Page 124: ... and 12 V when held down 28 Timeout Foot switch depressed too long without action Machine will not be functional 17 Aux Pump Coil 11 Shorted to supply voltage TCON detected that C27AUX circuit is shorted to 12V Machine will not be functional Check C27AUX RD TCON J3 3 wiring With a voltmeter verify that C27AUX RD TCON J3 3 is 0 V when the Auxiliary Power toggle switch is OFF and 12 V when switch is...

Page 125: ... range of 2 5 V 0 2 V 22 Pri Boom Up coil 11 Shorted to supply voltage 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 sho...

Page 126: ... LST3S limit switch arm Verify that with the boom above 12 degrees C68LS BL TCON J7 3 is 0V and that the boom is not making contact with the LST3S limit switch arm Check LST3S limit switch for physical damage 17 Not 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 Val...

Page 127: ...round 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 an...

Page 128: ...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 C...

Page 129: ... 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 130: ...f 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 131: ...ange 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 wit...

Page 132: ...ys 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 voltag...

Page 133: ...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 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 TCON ha...

Page 134: ...oftware 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 135: ... 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 limi...

Page 136: ...CE 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 Che...

Page 137: ...the boom angle sensor cord is hooked up 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 Verify that with the boom retracted C24LS OR RD TCON J7 4 is 12V and that th...

Page 138: ...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 139: ...rce 11 Shorted to supply voltage TCON detected that ESTOP 1 is at 12 V but ESTOP 3 is at 0 V ESTOP circuit cannot complete preventing machine functions Using a voltmeter and with the system turned OFF check the resistance between TCON J5 pins 9 and 10 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 Sho...

Page 140: ...gine 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 indicators...

Page 141: ... 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 142: ...ow sensor load correction factor exceeding the maximum drift limit 157 3 877 Sesnor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low batte...

Page 143: ...heck 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 Se...

Page 144: ...98 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 ran...

Page 145: ...ow 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 measurement...

Page 146: ...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 147: ...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 148: ...R SPN FMI KWP Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment...

Page 149: ...essages 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 calibrat...

Page 150: ...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 151: ... 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 152: ...ltage 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 Abnorma...

Page 153: ...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 154: ... expected 51 1 DTC 273 Injector 5 open or short to ground 655 5 DTC 122 TPS1 voltage low 51 4 DTC 274 Injector 5 coil shorted 655 6 DTC 123 TPS1 voltage high 51 3 DTC 276 Injector 6 open or short to ground 656 5 DTC 127 IAT higher than expected stage 2 105 0 DTC 277 Injector 6 coil shorted 656 6 DTC 129 BP pressure low 108 1 DTC 279 Injector 7 open or short to ground 657 5 DTC 134 EGO1 open lazy 7...

Page 155: ...earn LPG low 520202 1 DTC 616 Start relay ground short 1321 4 DTC 1163 Adaptive learn NG high 520203 0 DTC 617 Start relay coil short to power 1321 3 DTC 1164 Adaptive learn NG low 520203 1 DTC 627 Fuel pump relay coil open 1348 5 DTC 1165 Catalyst inactive on LPG 520213 10 DTC 628 Fuel pump high side open or short to ground 1347 5 DTC 1166 Catalyst inactive on NG 520214 0 DTC 628 Fuel pump relay ...

Page 156: ...n expected stage 2 442 0 DTC 1555 Water Intrusion Detection 520224 3 DTC 1419 ERWT1 voltage high 443 3 DTC 1556 AUX digital 3 low voltage 520224 4 DTC 1420 ERWT2 voltage high 444 3 DTC 1561 AUX analog Pull Down 2 high voltage 0 3 DTC 1421 ERWT1 voltage low 443 4 DTC 1561 AUX analog Pull Down 3 high voltage 0 4 DTC 1422 ERWT2 voltage low 444 4 DTC 1561 AUX analog Pull Down 2 low voltage 0 4 DTC 142...

Page 157: ...r control short to power 920 3 DTC 2300 Spark coil 1 primary open or short to ground 1268 5 DTC 1644 MIL control ground short 1213 4 DTC 2301 Spark coil 1 primary shorted 1268 6 DTC 1645 MIL control short to power 1213 3 DTC 2303 Spark coil 2 primary open or short to ground 1269 5 DTC 1651 J1939 ETC message receipt loss while in gear 91 9 DTC 2304 Spark coil 2 primary shorted 1269 6 DTC 1661 PWM6 ...

Page 158: ...GO microprocessor internal fault 3221 1 DTC 8911 UEGO sense cell voltage low 3218 4 DTC 8902 UEGO heater supply high voltage 3222 3 DTC 8912 UEGO pump voltage at high drive limi 3217 3 DTC 8903 UEGO heater supply low voltage 3222 4 DTC 8913 UEGO pump voltage at low drive limit 3217 3 DTC 8904 UEGO cal resistor voltage high 3221 3 DTC 8914 UEGO sense cell slow to warm up 3225 4 DTC 8905 UEGO cal re...

Page 159: ...rstand 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 Re...

Page 160: ...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 161: ...or 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 an...

Page 162: ...SB1RS 5 LST3S 6 S8O S8S 7 LST1O 8 S24 Limit Switches and Sensors S17 S22 LSB2S LSB1RS LST3S S8O S8S LST1O S24 Boom angle sensor Boom length sensor Limit switch cable tension safety Limit switch boom fully retracted safety Limit switch boom angle safety Universal tilt sensor operational Universal tilt sensor safety Limit switch turntable operational Load cell platform overload ...

Page 163: ...ts CB8B 30A See Elec Schem for circuits F19 15A See Elec Schem for circuits F21 10A See Elec Schem for circuits CB9 30A See Elec Schem for circuits CB10 20A See Elec Schem for circuits CB1 30A See Elec Schem for circuits CB2 15A See Elec Schem for circuits Diode D22 6A Alternator Ext Relays CR1 Ignition on CR5 Horn CR6 Fuel pump CR15A Glow plugs CR15B Glow plugs CR17 Hydraulic oil cooler CR27 Auxi...

Page 164: ...m for circuits CB8B 30A See Elec Schem for circuits F19 5A See Elec Schem for circuits F21 5A See Elec Schem for circuits CB9 30A See Elec Schem for circuits CB10 20A See Elec Schem for circuits CB1 30A See Elec Schem for circuits CB2 15A See Elec Schem for circuits Diode D22 6A Alternator Ext Relays CR1 Engine start CR3 High RPM CR15A Glow plug 1 CR15B Glow plug 2 CR17 Hydraulic Oil Cooler CR23 D...

Page 165: ...chem for circuits CB2 15A See Elec Schem for circuits CB9 30A See Elec Schem for circuits CB10 20A See Elec Schem for circuits CB8A 30A See Elec Schem for circuits CB8B 30A See Elec Schem for circuits Fuses F19 5A See Elec Schem for circuits F21 5A See Elec Schem for circuits Diode D22 6A Alternator Ext Relays CR1 Start CR3 High RPM CR4 Low RPM CR5 Horn CR17 Hydraulic oil cooler option CR15A Glow ...

Page 166: ... for circuits CB8B 30A See Elec Schem for circuits F19 5A See Elec Schem for circuits F21 5A See Elec Schem for circuits CB9 30A See Elec Schem for circuits CB10 20A See Elec Schem for circuits CB1 30A See Elec Schem for circuits CB2 15A See Elec Schem for circuits Diode D22 6A Alternator Ext Relays CR1 Engine start CR3 High RPM CR5 Horn CR17 Hydraulic OIl Cooler CR23 Drive CR41 R21IGN ...

Page 167: ... engine connector C19 LST3S C20 LST1O C21 LSB1RS C22 LSB2S C23 Generator from engine harness C24 Welder encloser C25 GM3 0 vehicle interface conn 1 C26 GM3 0 vehicle interface conn 2 C27 Load sense C28 Boom angle sensor C29 Boom extension string pot C30 Canbus terminating resistor C31 Crew alarm proximity switch C32 Crew alarm lights C33 GBOX service port C34 PBOX service port C35 404D speed senso...

Page 168: ...logic J16 PCON toggles J17 PCON toggles J18 PCON joysticks J19 PCON unused J20 Boom angle sensor operational not used J21 Boom angle sensor safety not used J22 Fuel level sensor J23 Platform level sensor operational not used J24 Platform level sensor safety not used J25 Boom function joystick J26 Drive function joystick J27 404D ECG black J28 404D ECG gray J29 D2 9 ECU 1 J30 D2 9 ECU 2 J31 D2 9 en...

Page 169: ...October 2019 Service and Repair Manual 157 Electrical Schematics Electrical Schematic Turntable Controller to serial number S80XCH 513 S85XCH 518 ...

Page 170: ...Manual October 2019 158 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic TCON to Serial number S80XCH 513 S85XCH 518 Electrical Schematic Turntable Controller to serial number S80XCH 513 S85XCH 518 ...

Page 171: ...pair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 159 Electrical Schem atic Pl atform C ontroller to Serial num ber S80XCH 513 S85XCH 518 Electrical Schematic Platform Controller to serial number S80XCH 513 S85XCH 518 ...

Page 172: ...Service and Repair Manual October 2019 160 Electrical Schematic Platform Controller to serial number S80XCH 513 S85XCH 518 ...

Page 173: ...October 2019 Service and Repair Manual 161 Electrical Schematic Turntable Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 ...

Page 174: ...S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic Tur ntabl e C ontroll er from S80XCH 514 to S80XCH 1393 S85XCH 519 to 1399 Electrical Schematic Turntable Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 ...

Page 175: ...o 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 163 Electrical Schem atic Pl atform C ontroller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 Electrical Schematic Platform Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 ...

Page 176: ...Service and Repair Manual October 2019 164 Electrical Schematic Platform Controller from S80XCH 514 to S80XCH 1393 S85XCH 519 to S85XCH 1399 ...

Page 177: ...October 2019 Service and Repair Manual 165 Electrical Schematic Turntable Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 ...

Page 178: ...6 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic Tur ntabl e C ontroll er from S80XCD 101 S85XC D 101 S80XCH 1394 S85XCH 1400 Electrical Schematic Turntable Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 ...

Page 179: ...Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 167 Electrical Schem atic Pl atform C ontroller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 Electrical Schematic Platform Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 ...

Page 180: ...Service and Repair Manual October 2019 168 Electrical Schematic Platform Controller from S80XCD 101 S85XCD 101 S80XCH 1394 S85XCH 1400 ...

Page 181: ...October 2019 Service and Repair Manual 169 Electrical Schematic Deutz TD2 9 L4 Engine ...

Page 182: ...Service and Repair Manual October 2019 170 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic Deutz TD2 9 L4 Engi ne Electrical Schematic Deutz TD2 9 L4 Engine ...

Page 183: ...October 2019 Service and Repair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 171 Electrical Schem atic Deutz TD2011 L04i Engine Electrical Schematic Deutz TD22011 Engine ...

Page 184: ...Service and Repair Manual October 2019 172 Electrical Schematic Deutz TD2011 Engine ...

Page 185: ...October 2019 Service and Repair Manual 173 Electrical Schematic Perkins 404D 22T Engine ...

Page 186: ...Service and Repair Manual October 2019 174 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic Perkins 404D 22T Engine Electrical Schematic Perkins 404D 22T Engine ...

Page 187: ...October 2019 Service and Repair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 175 Electrical Schem atic Perkins 404F E22TA Engi ne Electrical Schematic Perkins 404F E22TA Engine ...

Page 188: ...Service and Repair Manual October 2019 176 Electrical Schematic Perkins 404F E22TA Engine ...

Page 189: ...October 2019 Service and Repair Manual 177 Electrical Schematic GM 3 0L Engine ...

Page 190: ...Service and Repair Manual October 2019 178 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Electrical Schem atic GM 3 0L Engine Electrical Schematic GM 3 0L Engine ...

Page 191: ...019 Service and Repair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 179 Electrical Schem atic 12 kW Wel der Generator and 3 kW Generator Electrical Schematic 12 kW Welder Generator and 3 kW Generator ...

Page 192: ...Service and Repair Manual October 2019 180 Electrical Schematic 12 Kw Welder Generator and 3 kW Generator ...

Page 193: ...October 2019 Service and Repair Manual 181 Hydraulic Schematics Hydraulic Schematic S 80 XC 4WD Models ...

Page 194: ...Service and Repair Manual October 2019 182 S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Hydraulic Schem atic S80XC 4WD M odel Hydraulic Schematic S 80 XC 4WD Models ...

Page 195: ...October 2019 Service and Repair Manual Part No 1280490GT S 80 XC S 85 XC S 80 HF S 85 HF 183 Hydraulic Schem atic S85 XC 4WD M odels Hydraulic Schematic S 85 XC 4WD Models ...

Page 196: ...Service and Repair Manual October 2019 184 Hydraulic Schematic S 85 XC 4WD Models S 80 XC S 85 XC S 80 HF S 85 HF Part No 1280490GT Service and R epair M anual October 2019 ...

Page 197: ......

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