Terex Genie S-80 J Service And Repair Manual Download Page 18

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Service and Repair Manual

June 2021

Specifications

-80 J, S

-80 J TraX

™

Part No. 1285307GT

Kubota D1803-CR-TIE4, D1803-

CR-TE5B Engines

Displacement

111.4 cu in

1,825 liters

Number of cylinders

Bore and Stroke

3.43 x 4.031 inches

87 x 102,4 mm

Horsepower, gross

intermittent

49.6 @ 2700 rpm

37 kW @ 2700 rpm

Firing order

1 - 2 - 3

Low idle, standby

cold engine

1500 rpm

250 Hz

Low idle, standby

warm engine

1200 rpm

200 Hz

Low idle, function enable

1500 rpm

250 Hz

High idle

2700 rpm

450 Hz

Compression ratio

D1803-CR-TiE4

16:0

D1803-CR-TE5B

18:1

Compression pressure

428 to 468 psi

29,5 to 32,3 bar

Governor

centrifugal mechanical

Valve clearance, cold

0.0071 to 0.0086 in

0,18 to 0,22 mm

Lubrication system

Oil pressure

35 to 64 psi

2,4 to 4,4 bar

Oil capacity (including filter)

8.6 quarts

8,1 liters

Oil viscosity requirements

-22° F to 86° F/ -30° C 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.

Engine coolant

Capacity

10 quarts

9,5 liters

Fuel injection system

Injection pump make

Bosch MD

Injection pump pressure, maximum
Low idle

3700 - 4300 psi

255 - 296 bar

High idle

14500 - 15900 psi

1000 - 1096 bar

Injection timing

18° BTDC

Fuel requirement

For fuel requirements, refer to the engine Operator

Manual for your engine.

Starter motor

Cranking speed

200 - 300 RPM

Current draw, normal load

155A

Battery

Type

12V DC

Group

Quantity

Ampere hour

120AH

Cold cranking ampere

1000A

Reserve capacity @ 25A rate

175 minutes

Alternator output

40A @ 12V DC

Fan belt deflection

1/4 to 3/8 inch

7 to 9 mm

Summary of Contents for Genie S-80 J

Page 1: ...om S80JH 101 from S80JD 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics S 80 J TraX For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1285307GT Rev A June 2021 ...

Page 2: ...O 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestio...

Page 3: ...History Revision Date Section Procedure Page Description A 05 2021 Initial Release Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...d Repair Manual June 2021 Introduction iv S 80 J S 80 J TraX Part No 1285307GT Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis ...

Page 5: ... operator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regul...

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

Page 7: ...n 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 1 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Kubota D1803 CR TIE4 Engine Specifications 6 Deutz D2011 L03i Engine Specifications 7 Machine Torque Specifications 8 Machine Component Weights 8 Hydraulic Hose and Fitting Torque Specifications 9 Torque Proce...

Page 8: ... 17 How to Adjust the Joystick Threshold Setting 18 1 5 How to Enter ALC600 Software Update Mode 18 1 6 Display Module Menus 19 1 7 How to Replace the Display Controller DISCON Module 23 1 8 How to Replace the Ground Control Overlay 24 Platform Components 26 2 1 Platform Leveling Slave Cylinder 26 2 2 Platform Rotator 27 2 3 Platform Overload System 28 How to Perform a Zero Load Platform Calibrati...

Page 9: ...ylinder 42 4 5 Platform Leveling Master Cylinder 43 4 6 Primary Boom Angle Sensor 45 How to Repalce the Primary Boom Angle Sensor 45 4 5 Boom Extend Retract Cables 46 Engines 48 5 1 RPM Adjustment Kubota D1105 and Deutz D2011 Models 48 5 2 Flex Plate 48 How to Install the Flex Plate 49 How to install the Pump and Bell Housing Assembly 50 5 3 Engine Fault Codes Kubota D1803 Models 51 Hydraulic Pump...

Page 10: ...onal Valve 63 7 6 Traction Manifold Components 4WD 65 7 7 Valve Adjustments 4WD Traction Manifold 67 7 8 Brake Two Speed Manifold Components 68 7 9 Generator Manifold Components 69 7 10 Turntable Rotation Manifold Components 70 7 11 Valve Coils 71 Turntable Rotation Components 72 8 1 Turntable Rotation Assembly 72 How to Adjust the Turntable Rotation Gear Backlash 73 8 2 Turntable Angle Sensor Rep...

Page 11: ...307GT S 80 J S 80 J TraX xi Section 4 Fault Codes 82 Introduction 82 Control System Fault Codes 83 How to Retrieve Control System Fault Codes 83 Control System Fault Codes 84 Engine Fault Codes 101 Kubota D1803 CR TIE4 Engine Fault Codes 102 ...

Page 12: ...Limit Switch Location Legend 108 Electrical Schematics Options 109 Electrical Schematic Generator Options 110 Electrical Schematic Positive Air Shutdown 111 Electrical Schematics 113 Electrical Schematic Turntable Controller 114 Electrical Schematic Platform Controller 115 Electrical Schematic Kubota D1803 118 Electrical Schematic Deutz D2011 119 Hydraulic Schematics 121 Hydraulic Schematic 122 ...

Page 13: ...assification GL5 For operational specifications refer to the Operator s Manual Performance Specifications Boom function speeds maximum from platform controls Jib boom up 30 to 35 seconds Jib boom down 30 to 35 seconds Primary boom up extended 80 to 85 seconds Primary boom up retracted 65 to 70 seconds Primary boom down extended 80 to 85 seconds Primary boom down retracted 65 to 70 seconds Primary ...

Page 14: ...lube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range If the ...

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

Page 16: ...ell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C c...

Page 17: ...aximum 3200 psi 220 bar Primary boom extend relief pressure 2000 psi 138 bar Platform level relief valve pressure 3000 psi 207 bar Steer flow regulator 2 gpm 7 6 L min Oscillate relief valve pressure 2500 rpm 750 psi 52 bar Drive manifold Hot oil relief valve pressure 280 psi 19 3 bar Drive motor Displacement per revolution high speed 1 53 cu in 25 cc Displacement per revolution low speed 54 cu in...

Page 18: ... Oil capacity including filter 8 6 quarts 8 1 liters Oil viscosity requirements 22 F to 86 F 30 C 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 Engine coolant Capacity 10 quarts 9 5 liters Fuel ...

Page 19: ... 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 Injection pump make Bosch Inject...

Page 20: ...e threadlocker 99 ft lbs 134 Nm Backlash plate mounting bolts 282 ft lbs 382 Nm Machine Component Weights Lift structure 5300 lbs 2404 kg Turntable assembly without lift structure includes counterweights 6700 lbs 3040 kg Counterweight x2 1100 lbs 500 kg Drive chassis assembly 4800 lbs 2177 kg Tire and wheel assembly 290 lbs 132 kg Drive motor and hub 140 lbs 64 kg Engine assembly 475 lbs 215 kg Pr...

Page 21: ...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 Non adjustable fitting 1 jam nut SA...

Page 22: ...ated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex ...

Page 23: ...ect number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex f...

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

Page 25: ...alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not...

Page 26: ...urs 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 extend retract and turntable rotate left right joystick controller 3 LED indicator module 4 drive stee...

Page 27: ... Service Mode Note If there has been no input for 10 minutes 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 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 procedure...

Page 28: ...tton 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 effective immediately 8 S...

Page 29: ...e 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 from the g...

Page 30: ...9 Using the joystick 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 Go to the Genie website http firmware genielift com select your Machine Model and select Search 2 Download the software to a USB flash drive If ...

Page 31: ...rkins 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 Drive Cutout On O...

Page 32: ...100 755 mA Reverse Threshold 122 max 1 min 100 731 mA Forward Max 150 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 Ramps Standard Acceleration 5000 ms max 100 ms min 4000 ms Standard Deceleration 5000 ms max 100 ms min 1000 ms Torque Switching Dece...

Page 33: ... max 1000 ms min 2500 ms Retract Decelerating Rate 5000 ms max 500 ms min 1000 ms Up Accelerating Rate 5000 ms max 1000 ms min 3000 ms Up Decelerating Rate 5000 ms max 500 ms min 3000 ms Down Accelerating Rate 5000 ms max 1000 ms min 3000 ms Down Decelerating Rate 5000 ms max 1000 ms min 1000 ms Screen or Menu Item Default Turntable Speeds Rotate CW Max 150 max 81 min 100 1294 mA Rotate CCW Max 15...

Page 34: ... 87 default 680 mA 100 Platform Level Up Max Output max 150 min 83 default 700 mA 100 Platform Level Down Max Output max 150 min 83 default 700 mA 100 Platform Rotate CW Max Output max 150 min 89 default 654 mA 100 Platform Rotate CCW Max Output max 150 min 83 default 795 mA 100 Screen or Menu Item Default Jib and Platform Ramps Jib Up Down Ramp max 2000 ms min 200 ms default 750 ms Platform Level...

Page 35: ...dry Note Both the ground box lid and new gasket must be 70 F 21 C or higher at the time of application Application of the new gasket at lower temperatures is not recommended 7 Peel the adhesive protective film from the back of the new gasket Carefully line up the new gasket over the ground box lid making sure the cutouts for the LCD screen ribbon cables and mounting studs are centered and lining u...

Page 36: ...1 4 Unscrew the nut holding the buttons and key switch and remove the key switch and buttons Note the orientation of the key switch so it can be reassembled in the same position 5 Disconnect the wire harness connected to the DISCON and cut the zip ties securing the harness to the ground box lid Do not remove the wire harness from the ground box 6 Remove the DISCON door 4 and disconnect the ribbon ...

Page 37: ...and reapplying the overlay so take time to align the overlay before making contact with the ground box 11 Maintain the temperature of 80 100 F 26 38 C for a minimum of 20 minutes to allow the adhesive to cure 12 Install the provided ribbon cables first to the overlay and then the DISCON Be sure the connectors are applied evenly in the sockets and the tabs are fully locked 13 Reinstall the DISCON d...

Page 38: ...m Note Do not rest the entire weight of the boom on the blocks 4 Remove the pin retaining fastener from the slave cylinder rod end pivot pin Use a soft metal drift to drive the rod end pivot pin out Crushing hazard The platform could fall when the slave cylinder rod end pivot pin is removed if not properly supported 5 From the ground controls use auxiliary power and activate platform level down to...

Page 39: ...ssembly and set aside Crushing hazard The platform assembly may become unbalanced and fall if it is not properly supported 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold 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 D...

Page 40: ...ompromised and it could tip over How to Perform a Zero Load Platform Calibration How to Perform a Zero Load Platform Calibration Perform this procedure when platform overload is not operating within the calibration parameters This procedure will re calibrate the zero load point without affecting a previous full load calibration In most cases the machine will maintain full load capacity however in ...

Page 41: ...w to Perform a Full Load Platform Calibration Perform this procedure if the platform support or load cell sensor has been replaced or if a zero load platform calibration does not return the machine to full load capacity Note Perform this procedure on a firm level surface with the machine in the stowed position 1 Fully retract and lower the boom Level the platform 2 Remove all weight tools accessor...

Page 42: ... 10 Place a test weight on the platform floor using a suitable lifting device Place the weight near the center entry point of the platform as far away from the operator controls as possible Weight 660 lbs 300 kg Note If test weights are not available you may use an industrial scale to weigh available objects until it equals the platform s maximum capacity Note Alternate method for achieving rated ...

Page 43: ... cell sensor has been replaced 1 Remove all equipment or tools from the platform Remove the welder if equipped 2 At the platform remove the plastic instruction holder from the document mount plate 3 Tag and disconnect the load cell sensor harness 4 Loosen the jam nut securing the load cell sensor foot and rotate the foot screw clockwise to remove the preload 5 Remove the fasteners securing the loa...

Page 44: ...witch Remove the cable from the back of the platform Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Remove the platform control box mounting fasteners Lower the control box and set it aside Component damage hazard Cables can be damaged if they are kinked or pinched Note If your machine is equ...

Page 45: ...nd allow the engine to idle for 30 seconds 6 Press and hold the jib boom up button until cylinder is at the end of the stroke and hold the up button for an additional 5 seconds after the jib boom reaches full stroke 7 Press and hold the jib boom down button until cylinder is at the end of the stroke and hold the down button for an additional 5 seconds after the jib boom reaches full stroke 8 Repea...

Page 46: ...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 5 Attach a lifting strap from an overhead supporting device to the jib boom assembly 6 Place blocks under the platform leveling cylinder for support Protect the cylinder rod from damage ...

Page 47: ... 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib boom lift cylinder with a lifting device 6...

Page 48: ...onents 36 S 80 J S 80 J TraX Part No 1285307GT Boom Components 1 primary boom 2 mid pivot 3 sliding counterweight 4 lift cylinder 5 lower riser arm 6 upper riser arm 7 lower riser arm to turntable pivot pin 8 upper riser arm to turntable pivot pin ...

Page 49: ...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 Remove the hose and cable clamps from the platform support and jib boom 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom Cap...

Page 50: ...the boom 18 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 19 Attach a lifting strap from an overhead supporting device to the cable track 20 Remove the mounting fasteners that a...

Page 51: ... link section of cable track to be replaced Remove the rollers 4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 5 Remove the upper rollers from the replacement section of cable track 6 Lift up the hoses and cables and carefully insert the new 4 link section of cable tr...

Page 52: ... retract limit switch 6 Tag disconnect and plug the hydraulic hoses from the boom extend cylinder Cap the fittings Remove the cable tracks from both sides of the boom Set them onto the machine side covers Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spr...

Page 53: ...ot properly supported when removed from the machine 22 Remove the boom from the machine Note After replacement the platform function manifold must be bled Refer to Repair Procedure How to Bleed the Platform Function Manifold 4 3 Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent move...

Page 54: ...Carefully remove the boom lift cylinder from the machine Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movem...

Page 55: ...age hazard Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom 4 5 Platform Leveling Master Cylinder The platform leveling master cylinder acts as a pump for the slave cylinder It is part of the closed loop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platfo...

Page 56: ...he right side of the mid pivot to remove the pivot pin 1 pivot pin 5 Raise the boom until the rod end pivot pin of the master cylinder is accessible 6 Using an overhead supporting device support the master cylinder 7 Remove the retaining fastener securing the rod end pivot pin 8 Using a soft metal drift remove the pivot pin Crushing hazard The cylinder could fall if not properly supported 9 Remove...

Page 57: ...rt the calibration procedure 6 Start the engine 7 When the display prompts the operator to lower the boom press and hold the function enable button and the boom down buttons until the display indicates that the lower calibration point has been obtained This may require holding the buttons for several seconds 8 Press OK 9 Exit Service Mode How to Repalce the Primary Boom Angle Sensor How to Replace...

Page 58: ...ition with no damaged threads 4 Adjust the extend cable adjustment nuts until approximately 1 5 inches 4 cm of threads are visible past the nylock nut Note If the cables have been replaced be sure the adjustment nuts have been replaced Do not re use the existing nuts 5 Extend the boom until there is approximately 3 feet 1 m of travel left Do not fully extend the boom 6 Locate the retract cable adj...

Page 59: ...ot plate Note If the boom extend cables are adjusted evenly the wheel of the limit switch arm will be centered in the notch of the pivot plate 1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate 4 extend cable bracket 13 Visually inspect the sheaves for damage or uneven wear 14 Install the boom end cover at the pivot end of the boom 15 Fully retract and lower the bo...

Page 60: ... 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 How to Remove the Flex Plate 1 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 2 Carefully pull the pump away from the engine and secure it from moving 3 Remove t...

Page 61: ...plate mounting fasteners Torque the flex plate mounting fasteners in sequence Deutz D2011 Pre torque to 15 ft lbs 20 Nm Then torque the flex plate mounting fasteners in sequence to 42 5 ft lbs 57 5 Nm Kubota D1803 Pre torque to 14 ft lbs 19 Nm Then torque the flex plate mounting fasteners in sequence to 40 5 ft lbs 55 Nm Deutz D2011 Kubota D1803 3 Apply high viscosity coupling grease to the spline...

Page 62: ...ing mounting fasteners labeled C in sequence to 17 5 ft lbs 24 Nm Then torque the bell housing mounting fasteners in sequence to 50 ft lbs 67 5 Nm Kubota D1803 Pre torque the bell housing mounting fasteners in sequence to 17 ft lbs 23 Nm Then torque the bell housing mounting fasteners in sequence to 49 ft lbs 66 Nm Component damage hazard When installing the pump do not force the pump coupler into...

Page 63: ...its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriate sensor One or more fault LED s will illuminate on the display located at the ground control box The active fault code will also be displayed on the LCD screen If a fau...

Page 64: ...arefully remove the pump NOTE When installing a new pump it is necessary to prime the pump Refer to Repair Procedure How to Prime the Pump 6 2 Drive Pump How to Remove the Drive Pump 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 Hydraul...

Page 65: ...Pump After the pump is installed fasteners torqued and all hoses connected remove one of the hoses at the top of the pump port E or port F and add a minimum of 0 75 liter 25 ounces of hydraulic oil to the pump Install and torque the hose to specification Function Pump After the pump is installed fasteners torqued and all hoses connected remove the plug at the uppermost port of the pump and add a m...

Page 66: ...lation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the generator pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Support the pump with a strap ...

Page 67: ...June 2021 Service and Repair Manual Part No 1285307GT S 80 J S 80 J TraX 55 This page intentionally left blank ...

Page 68: ... Nm 8 Flow regulator valve 2 gpm 7 6 L min I Steer left right 25 30 ft lbs 34 41 Nm 9 Solenoid valve 3 position 4 way H Steer left right 25 30 ft lbs 34 41 Nm 10 Relief valve 2000 psi 138 bar E Primary boom extend 30 35 ft lbs 41 47 Nm 11 Proportional solenoid valve C Primary boom extend retract circuit 30 35 ft lbs 41 47 Nm 12 Solenoid Valve 2 position 3 way Q Primary boom up 8 10 ft lbs 11 13 Nm...

Page 69: ...June 2021 Service and Repair Manual Manifolds Part No 1285307GT S 80 J S 80 J TraX 57 ...

Page 70: ...lief valve pressure 20 25 ft lbs 27 34 Nm 23 Solenoid valve 2 position 2 way normally open Y Oscillate circuit 30 35 ft lbs 41 47 Nm 24 Relief valve 900 psi 62 bar M Oscillate circuit 20 25 ft lbs 27 34 Nm 25 Check valve AA Pressure Circuit 8 10 ft lbs 11 13 Nm 26 Flow control valve 0 5 gpm 1 9 L min Z Oscillate circuit 20 25 ft lbs 27 34 Nm 27 Proportional solenoid valve J Turntable rotate circui...

Page 71: ...June 2021 Service and Repair Manual Manifolds Part No 1285307GT S 80 J S 80 J TraX 59 ...

Page 72: ...cedure beginning with step 2 to confirm the 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 perform this procedure Do not st...

Page 73: ...ction manifold is mounted at the platform end of the boom Index No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way AB Platform rotate left right 20 25 ft lbs 27 34 Nm 2 Solenoid valve 3 position 4 way AC Jib boom up down 20 25 ft lbs 27 34 Nm 3 Check valve 30 psi 2 1 bar AD Tank return circuit 20 25 ft lbs 27 34 Nm ...

Page 74: ...d to the turntable rotation motor Index No Description Schematic Item Function Torque 1 Counterbalance valve AF Turntable rotate right 35 40 ft lbs 47 54 Nm 2 Counterbalance valve AE Turntable rotate left 35 40 ft lbs 47 54 Nm 3 Shuttle valve 2 position 3 way AG Turntable rotation brake release 10 13 ft lbs 14 18 Nm 4 Orifice 0 030 inch 0 76 mm AH Brake release circuit ...

Page 75: ... and assemble the directional valve linkage How to Set Up the Oscillate Directional Valve How to Set Up the Oscillate Directional Valve Linkage Note Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced Note Two people will be required to perform this procedure Note Perform this procedure on a firm level surface with the machine in the ...

Page 76: ... axle and tighten the jam nut 9 Verify the drive chassis is completely level 10 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 consult Genie Prod...

Page 77: ...llowing some bypass flow around the right flow divider 6 Relief valve 280 psi 19 3 bar DI Hot oil shuttle relief 35 40 ft lbs 14 16 Nm 7 Flow divider combiner valve 24 gpm DM Combines return flow from RF and RR motors 80 90 ft lbs 108 122 Nm 8 Flow divider combiner valve 24 gpm DB Combines return flow from LF and RR motors 80 90 ft lbs 108 122 Nm 9 Check valve 5 psi DD Prevents cavitation in LF an...

Page 78: ...Service and Repair Manual June 2021 Manifolds 66 S 80 J S 80 J TraX Part No 1285307GT ...

Page 79: ...ure gauge 5 Turn the engine 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 re...

Page 80: ...he engine tray below the hydraulic pumps Index No Description Schematic Item Function Torque 1 Orifice 0 025 inch 0 635 mm BD Turntable rotation brake release 2 Check valve BB Brake release circuit 20 25 ft lbs 27 34 Nm 3 Solenoid Valve 2 position 3 way BA Brake release 20 25 ft lbs 27 34 Nm 4 Solenoid Valve 2 position 3 way BC 2 speed motor shift 20 25 ft lbs 27 34 Nm ...

Page 81: ...tic 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 generator 24 26 ft...

Page 82: ...ed 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 ...

Page 83: ...ation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance W Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Valve Coil Resistance Specification Note The f...

Page 84: ... turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotation drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow ...

Page 85: ...fer 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 pinion gear...

Page 86: ...lash pivot plate to specification Refer to Specifications Machine Torque Specifications 8 Rotate the turntable through an entire rotation Check for tight spots that could cause binding Readjust if necessary 8 2 How to Replace the Turntable Angle Sensor 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position 2 ...

Page 87: ...ated to the left of the fuel tank Orient the level along the pitch axis of the machine 8 Enter the value as seen on the digital level into the ground control display If the digital 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 excluding the plus minus sign 9 A graphic of the machine pitch...

Page 88: ...l now be shown on the display By pressing the UP and DOWN buttons the graphic will change to show whether the operator is on the uphill or downhill side of the machine Select the image that corresponds to the current roll of the machine and press OK Turntable Roll 1 uphill 2 downhill 14 The calibration is now complete 15 Exit the Service Mode ...

Page 89: ...e 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 skin Loosen hydraulic connections...

Page 90: ... 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 the Track How to Replace the Track 1 Remove the track assembly from the machine Refer to Repair Procedu...

Page 91: ...ack 1 idler wheels 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 supportingdevice 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 the split ...

Page 92: ...ard 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 zerk ...

Page 93: ...en 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 to specific...

Page 94: ...hocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all neces...

Page 95: ...ll be reflected by the System Fault Indicator lights and the alarm Logged Faults The faults contained in the fault log have occurred in the past and may or may not still be in effect Both faults may be viewed by pressing the Fault Button above the ground display and navigating to either the Active Machine Faults screen or the Machine Fault Log screen The list of faults will by shown by fault code ...

Page 96: ...e 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 cable if issue persists 11 Platform Controls Engine...

Page 97: ...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 ON Veri...

Page 98: ... 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 short circui...

Page 99: ...imit 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 Value out o...

Page 100: ...ntrol 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 and dry Re...

Page 101: ...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 Coil 11 S...

Page 102: ...ate 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 measure Y71 ...

Page 103: ...ance 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 for C32B...

Page 104: ...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 with the sw...

Page 105: ...pposite 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 voltage is bet...

Page 106: ...d 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 has not de...

Page 107: ...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 the DISC...

Page 108: ...e telematics option Call machine owner to re enable machine functions 29 Software version mismatch TCON software is out of date Download latest software from firmware site and update machine 82 Overload 21 Recovery 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 m...

Page 109: ... 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 Check for s...

Page 110: ... 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 the boom i...

Page 111: ... 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 141 Boom...

Page 112: ...rted 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 Shorted to su...

Page 113: ...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 that the engine ...

Page 114: ...1 Intake Air Volume Low 132 3 MAF Sensor Abnormality 132 4 132 15 Boost Pressure Low 157 0 High Rail Pressure 157 3 Rail Pressure Sensor Abnormality 157 4 168 3 Battery Voltage Abnormality 168 4 SPN FMI Description 171 3 Intake Air Temperature Built in MAF Sensor Abnormality 171 4 172 3 Intake Air Temperature Error 172 4 190 0 Engine Overrun 628 2 ECU Flash ROM and CPU Abnormality 633 7 Pressure L...

Page 115: ... Sensor 1 T1 Abnormality 3242 4 3246 0 Exhaust Gas Temperature Sensor 2 Emergency High 3246 3 Exhaust Gas Temperature Sensor 2 T Abnormality 3246 4 3251 3 Differential Pressure Sensor 1 Abnormality 3251 4 3252 0 Emission Deterioration SPN FMI Description 3509 3 Sensor Supply Voltage 1 Abnormality 3509 4 3510 3 Sensor Supply Voltage 2 Abnormality 3510 4 3511 3 Sensor Supply Voltage 3 Abnormality 35...

Page 116: ... DC Motor Abnormality 523577 2 523578 2 No Communication with EGR 523580 2 Intake Throttle Feedback Error 523582 3 Intake Throttle Lift Sensor Abnormality 523582 4 SPN FMI Description 523589 17 Low Coolant Temperature in Parked Regeneration 523590 16 Parked Regeneration Tmi OUY 523591 2 523592 2 523595 2 CAN2 Frame Error 523596 2 523598 2 523599 0 All Exhaust Gas temperature Sensor Failure 523601 ...

Page 117: ...rn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics 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 Important Read understand and obey the safety...

Page 118: ...terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally...

Page 119: ...osition 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Soleno...

Page 120: ... 80 J 1 LSB1RO 2 CBLS 3 LST1O 4 UTS 5 LSB1DO 6 PBAS Limit Switches and Sensors LSB1RO CBLS LST1O UTS LSB1DO PBAS Limit switch boom fully retracted operational Cable Break Limit Switch Limit switch drive turntable operational Universal tilt sensors Limit switch boom down operational Primary boom angle sensor ...

Page 121: ...June 2021 Service and Repair Manual 109 Electrical Schematic Generator Options ...

Page 122: ... GENERATOR SINGLE RECEPTACLE 120 VAC 20 AMP GFCI SILVER BRASS GREEN WHITE GREEN BLACK L N G T3 ENCLOSURE 15 AMP CIRCUIT BREAKER T1 T2 T4 GREEN GREEN YELLOW RED WHITE 15 AMP CIRCUIT BREAKER BLACK WHITE GREEN J BOX BLACK WHITE GREEN RCBO 12 GA 3 CONDUCTOR FROM PLATFROM 2 1 N BROWN BLUE TO PLATFORM NO PLUG GREEN YELLOW AC POWER TO PLAT WIRING BRASS 110 VAC GFCI PLATFORM TURNTABLE BROWN BLUE GREEN SIL...

Page 123: ...June 2021 Service and Repair Manual Part No 1285307GT S 80 J S 80 J TraX 111 Electrical Schematic Positive Air Shutdown ...

Page 124: ...Service and Repair Manual June 2021 112 Electrical Schematic Positive Air Shutdown ...

Page 125: ...June 2021 Service and Repair Manual 113 Electrical Schematic Turntable Controller ...

Page 126: ...BK GR C15B 1 C15B 2 C13B 1 C13B 2 R21IGN WH BK R21IGN WH BK DRIVE LIGHT FLASHING BEACON C18B 4 C18B 1 C18B 2 C18B 3 RD WH BK GR GND1 BR J29 2 J29 1 C33 A P20LOG B LOG GND C PLUG D D82CAN E D81CAN RD WH BR YL GR C40C 1 C40C 3 C40C 2 C40D 2 C40D 1 C40D 3 C40D 4 LSB1RO WH BK C19 1 C19 2 WH BK C21A 1 C21A 2 LSB1DO C28A 6 GR WH RD C21B 1 C21B 2 WH BK C22 1 C22 2 LSB2S C21B 3 RD C21B 4 BR WH BK GR WH B ...

Page 127: ...12 C11 11 C11 10 C11 3 1A SELF RESETTING 4 3 2 1 C14PLU OR C15PLD OR BK C17PRL GR C18PRR GR BK C43JU BL P56PWR RD C44JD BL BK C90PRX RD BK C47AUX RD C29MS RD WH C33STR BK C194SPD WH RD C39LP BL RD C45GEN GR WH C143DEL BL RD JIB UP DN TS8 PROX KILL OPTION TS46 FUEL SELECT TS3 GAS LP MODELS GENERATOR OPTION TS47 LOG_GND BR P20LOG RD WH D82CAN YL D81CAN GR C28ALM RD BK C46PWR WH BK P22PWR BK RD P23PW...

Page 128: ...Service and Repair Manual June 2021 116 Electrical Schematic Platform Controller ...

Page 129: ...June 2021 Service and Repair Manual 117 Electrical Schematic Kubota D1803 ...

Page 130: ... C6 DTP REC GY FL GND1 BR P20DRV RD P20LOG RD WH C46HRN WH MAIN RELAY COIL CAN2 L CAN2 H START SW INPUT IGNITION SW INPUT HEATER RELAY COIL STARTER RELAY COIL NOT USED STARTER RELAY COIL HEATER RELAY COIL NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED C34RET BR C33ST3 BK C33RET BR C34SA RD P134PWR RD C33ST2 BK D228CAN YL D227CAN GR C135FP BL WH GND BR R135PWR BL WH MAIN RELAY CONTACT BATTER...

Page 131: ...6HYD OR BK C116HYD OR GND2 BR C7 DT REC GY FL C33ST1 BK C21IGN WH C35RPM RD BK C25PSR WH BK C26TSR WH RD C41RPM OR BK C34SA BK WH C6 DTP REC GY FL GND1 BR P20DRV RD P20LOG RD WH C46HRN WH C 9 B C 1 B C 8A B C 8B B C 10 B C 2 B P20DRV RD R33STR BK C33ST1 BK C34SA BK WH R34SA RD R34SA RD P20PWR RD C21IGN WH R46HRN WH RD C107AF RD P20PWR RD P20PWR RD C35RPM BK RD P20PWR RD R35RPM BK P20PWR RD R116HYD...

Page 132: ...Service and Repair Manual June 2021 120 Electrical Schematic Deutz D2011 ...

Page 133: ...June 2021 Service and Repair Manual 121 Hydraulic Schematic ...

Page 134: ... FUNCTION PUMP 1 5 cu in 25 cc RETURN FILTER 25 psi 1 7 bar HYDRAULIC TANK T1 T3 LS 3200 psi 221 bar 2000 psi 138 bar P1 PBE PBR P TP PBE TP E R V2 V1 TRL TRR PBU PBD PLU PLD ACCUM PRL PRR JU JD S1 A 0 030 in 0 76 mm R E R E TURNTABLE ROTATE 2 3 gpm 8 7 L min LIFT CYLINDER EXT 9 6 gpm 36 3 L min RET 6 0 gpm 22 7 L min EXTENSION CYLINDER EXT 4 5 gpm 17 L min RET 4 2 gpm 16 L min TANK 9 1 gpm 34 4 L...

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