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Terex S-60 J, Service And Repair Manual

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Terex S-60 J Service And Repair Manual Download Page 25

December 2019

 

Service and Repair Manual

 

 

Repair Procedures 

 

 

Part No. 1285305GT

 

S

®

-60 J

 

13 

 

 

Section 3 

Repair Pr ocedures 

 

Observe and Obey: 

 

Repair procedures shall be completed by a 

person trained and qualified on the repair of 

this machine. 

 

Immediately tag and remove from service a 

damaged or malfunctioning machine. 

 

Repair any machine damage or malfunction 

before operating the machine. 

Before Repairs Start: 

 

Read, understand and obey the safety rules 

and operating instructions in the appropriate 

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: 

•

  Machine parked on a firm, level surface 

•

  Key switch in the off position with the key 

removed 

•

  The red Emergency Stop button in the off 

position at both the ground and platform 

controls 

•

  Wheels chocked 

•

  All external AC power supply disconnected 

from the machine 

•

  Boom in the stowed position 

•

  Turntable secured with the turntable rotation 

lock 

Summary of Contents for S-60 J

Page 1: ...e S 60 J from S60JH 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1285305GT Rev A December 2019 ...

Page 2: ...368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions f...

Page 3: ...tory Revision Date Section Procedure Page Description A 9 2019 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: ...e and Repair Manual December 2019 Introduction iv S 60 J Part No 1285305GT 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: ...y 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 governmental regulations You...

Page 6: ...ushing 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 flamm...

Page 7: ...l Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 1 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Deutz D2011 L03i Engine Specifications 6 Kubota D1105 E4B Engine Specifications 7 Kubota D1803 CR TIE4 Engine Specifications 8 Machine Torque Specifications 9 Machine Component Weights 9 Hydraulic Hose and Fitting Torque Specification...

Page 8: ...shold Setting 19 1 5 How to Enter ALC600 Software Update Mode 19 1 6 Display Module Menus 20 1 7 How to Replace the Display Controller DISCON Module 24 1 8 How to Replace the Ground Control Overlay 25 Platform Components 27 2 1 Platform Leveling Slave Cylinder 27 2 2 Platform Rotator 28 2 3 Platform Overload System 30 How to Calibrate the Platform Overload System 30 How to Perform a Zero Load Plat...

Page 9: ...Cylinder 43 4 6 Primary Boom Angle Sensor 44 How to Repalce the Primary Boom Angle Sensor 45 Engines 46 5 1 RPM Adjustment Kubota D1105 and Deutz D2011 Models 46 5 2 Flex Plate 46 How to Install the Flex Plate 47 How to install the Pump and Bell Housing Assembly 48 5 3 Engine Fault Codes Kubota D1803 Models 49 Hydraulic Pump 50 6 1 Function Pump 50 6 2 Drive Pump 50 How to Install the Drive Pump C...

Page 10: ...illate Relief Valve 61 How to Set Up the Oscillate Directional Valve 61 7 6 Traction Manifold Components 4WD 64 7 7 Valve Adjustments 4WD Traction Manifold 66 7 8 Brake Two Speed Manifold Components 67 7 9 Generator Manifold Components 68 7 10 Turntable Rotation Manifold Components 69 7 11 Valve Coils 70 Turntable Rotation Components 71 8 1 Turntable Rotation Assembly 71 How to Adjust the Turntabl...

Page 11: ...t No 1285305GT S 60 J xi Section 4 Fault Codes 75 Introduction 75 Control System Fault Codes 76 How to Retrieve Control System Fault Codes 76 Control System Fault Codes 77 Engine Fault Codes 94 Kubota D1803 CR TIE4 Engine Fault Codes 95 ...

Page 12: ...end 101 Electrical Schematics Options 103 Electrical Schematic Generator Options 104 Electrical Schematic Positive Air Shutdown 105 Electrical Schematics 107 Electrical Schematic Turntable Controller 108 Electrical Schematic Platform Controller 109 Electrical Schematic Kubota D1803 112 Electrical Schematic Kubota D1105 113 Electrical Schematic Deutz D2011 116 Hydraulic Schematics 117 Hydraulic Sch...

Page 13: ...0 multipurpose hypoid gear oil API service classification GL5 For operational specifications refer to the Operator s Manual Performance Specifications Boom function speeds maximum from platform controls Jib boom up 25 to 35 seconds Jib boom down 15 to 25 seconds Primary boom up 60 to 66 seconds Primary boom down 60 to 66 seconds Primary boom extend 30 to 33 seconds Primary boom retract 30 to 33 se...

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

Page 15: ... 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 hydraul...

Page 16: ...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 cSt 1...

Page 17: ... Function manifold System relief valve pressure maximum 3200 psi 220 bar Steer flow regulator 2 gpm 7 6 L min Oscillate relief valve pressure 2500 rpm 650 psi 45 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 8 77 cc Hydraulic Filters High pressure filter Beta 5 Hig...

Page 18: ...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 Injection ...

Page 19: ...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 3 2 quarts 3 liters Fuel injection system Injection pump make Bosch MD Injectio...

Page 20: ...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 p...

Page 21: ...readlocker 170 ft lbs 230 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 Prima...

Page 22: ... 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 Non adjustable fitting 1 jam nut SAE O...

Page 23: ... 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 nut ...

Page 24: ...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 fitti...

Page 25: ...n 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 firm ...

Page 26: ...t 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 avo...

Page 27: ...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 module 4 drive steer joystick c...

Page 28: ...the Service Mode Note If there has been no input for 10 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 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 pr...

Page 29: ...on 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 Sta...

Page 30: ...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 gro...

Page 31: ... 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 and ALC600 controller type Enter the machine serial number and part number for the software 2 Download the s...

Page 32: ...rkins 404F E22T Perkins 404F E22TA Select Engine Platform configuration is not locked 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 Platfo...

Page 33: ...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 Decelera...

Page 34: ... 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 150 ma...

Page 35: ...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 Ram...

Page 36: ...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 up wi...

Page 37: ...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 cabl...

Page 38: ...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 door ...

Page 39: ...te 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 ret...

Page 40: ...ications 1 Remove the platform and platform support Note If the load sense components are disassembled and or removed from the platform support the platform load sense system will need to be calibrated Refer to Repair Procedure Platform Load Sense System 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Cap the fittings on the rotator 3 Tag disconnect and plug the hy...

Page 41: ...rt the engine Use auxiliary power for this procedure 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw ...

Page 42: ...rews for leaks 2 3 Platform Overload System Proper calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform How to C alibr ate the Pl atform Overl oad System How to Calibrate the Platform Overload System Note Perform this procedure with the...

Page 43: ...4 Lift the test weight off the platform floor using a suitable lifting device 15 Start the engine from the ground control 16 Place a 660 lb 300 kg test weight and an additional 50 lbs 23 kg on the platform floor using a suitable lifting device Place the weight near the center entry point of the platform as far away from the operator controls as possible as shown in Illustration 1 Result The alarm ...

Page 44: ...hine 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 the prompts...

Page 45: ...ettle the platform overload assembly 14 Perform a full platform overload system calibration Refer to Repair Procedure How to Calibrate the Platform Overload System 2 4 Platform How to Remove the Platform 1 Remove the cable clamp from the top of the platform mounting weldment 2 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to...

Page 46: ...ulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an overhead crane to the jib boom assembly 7 Place blocks under the platform leveling cylinder for support Protect the cylinder ...

Page 47: ...essure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin half way out Then lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the...

Page 48: ...om Components 36 S 60 J Part No 1285305GT 1 primary boom 2 mid pivot 3 timing link 4 pivot lever 5 pivot link 6 lift cylinder 7 upper riser arm 8 lower riser arm 9 lower riser arm to turntable pivot pin 10upper riser arm to turntable pivot pin ...

Page 49: ...stalled in the correct location 5 Remove the mounting fasteners from the power to platform outlet box bracket Lay the outlet box and bracket assembly off to the side 6 Remove the hose and cable clamps from the platform support and jib boom 7 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom Cap the bulkhead fitti...

Page 50: ...uide at the platform end of the boom Remove the cable track guide from the boom 18 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together Crushing hazard If the upper and lower cable tracks are not properly secured together the cable track could become unbalanced and fall when removed from the machine 19 Attach a lifting strap from an overhead crane...

Page 51: ...ink 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 trac...

Page 52: ... 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 spray 7 Using an overhead crane with a strap of adequate capacit...

Page 53: ...ng the boom to the mid pivot Crushing hazard The boom assembly will fall if not properly supported when removed from the machine 22 Remove the boom from the machine 4 3 Boom Lift Cylinder The primary boom lift cylinder raises and lowers the primary boom The primary boom lift cylinder is equipped with a counterbalance valve to prevent movement in the event of a hydraulic line failure How to Remove ...

Page 54: ...fully 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 movement ...

Page 55: ...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 platform l...

Page 56: ... primary boom relative to the angle of the turntable and gravity How to Calibrate the Primary Boom Angle Sensor Note Perform this procedure with the machine on a firm level surface with the boom in the stowed position Note The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor 1 Fully retract and lower the boom 2 Enter Service Mode...

Page 57: ...s and turn the key switch to the off position 2 Locate the boom angle sensor at the platform end of the upper riser arm 3 Tag and disconnect the electrical connector from the angle sensor 4 Remove the retaining fasteners Remove the angle sensor from the machine 5 Install the new angle sensor onto the machine 6 Securely connect the angle sensor harness to the main harness 7 Calibrate the angle sens...

Page 58: ...x 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 the f...

Page 59: ...quence 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 D1105 Pre torque to 13 ft lbs 17 5 Nm Then torque the flex plate mounting fasteners in sequence to 36 ft lbs 49 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 D1105 K...

Page 60: ...nting fasteners labeled A in sequence to 5 ft lbs 7 Nm Pre torque the bell housing mounting fasteners labeled B in sequence to 10 ft lbs 13 Nm Then torque the bell housing mounting fasteners labeled A in sequence to 15 ft lbs 20 Nm Then torque the bell housing mounting fasteners labeled B in sequence to 29 ft lbs 40 Nm Kubota D1803 Pre torque the bell housing mounting fasteners in sequence to 17 f...

Page 61: ...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 fault o...

Page 62: ...ully 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 Hydraulic H...

Page 63: ...p 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 mini...

Page 64: ...on 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 and ...

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Page 66: ...bs 27 34 Nm 8 Relief valve 2000 psi 138 bar AH Primary boom extend 25 30 ft lbs 34 41 Nm 9 Flow regulator valve 2 GPM 7 6 L min AI Steer left right 25 30 ft lbs 34 41 Nm 10 Proportional solenoid valve 2 position 2 way AJ Primary boom extend retract 30 35 ft lbs 41 47 Nm 11 Solenoid valve 2 position 2 way AK Primary boom extend retract 30 35 ft lbs 41 47 Nm 12 Check valve AL Primary boom extend ret...

Page 67: ...December 2019 Service and Repair Manual Manifolds Part No 1285305GT S 60 J 55 ...

Page 68: ...ensing valve AAA Primary boom extend retract 50 55 ft lbs 68 74 Nm 28 Sequence valve 850 psi 59 bar AAB Oscillate circuit 30 35 ft lbs 41 47 Nm 29 Pressure reducing valve 650 psi 45 bar AAC Oscillate circuit 30 35 ft lbs 41 47 Nm 30 Check valve AAE Steer circuit 8 10 ft lbs 11 13 Nm 31 Orifice 0 031 in 0 79 mm AAF Primary boom extend retract circuit 32 Check valve AAG Oscillate circuit 8 10 ft lbs...

Page 69: ...December 2019 Service and Repair Manual Manifolds Part No 1285305GT S 60 J 57 ...

Page 70: ... specified 6 Repeat step 2 to confirm relief valve pressure 7 Remove the pressure gauge How to Adj ust the Boom Extend R elief 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 start ...

Page 71: ...60 J 59 7 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way FF Platform rotate jib boom select 20 25 ft lbs 27 34 Nm ...

Page 72: ...table rotation motor Index No Description Schematic Item Function Torque 1 Counterbalance valve MM Turntable rotate right 35 40 ft lbs 47 54 Nm 2 Counterbalance valve NN Turntable rotate left 35 40 ft lbs 47 54 Nm 3 Shuttle valve 2 position 3 way OO Turntable rotation brake release 10 13 ft lbs 14 18 Nm 4 Orifice 0 030 inch 0 76 mm PP Brake release circuit located inside port ...

Page 73: ...irectional valve linkage How to Set U p the Oscillate Directional Valve How to Set Up the Oscillate Directional Valve Note Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced 1 Lower the boom to the stowed position 2 Use a bubble type level to be sure the floor is completely level Tip over hazard Failure to perform this procedure on a...

Page 74: ... tighten the jam nut 11 Check to be sure the drive chassis is completely level 12 Measure the distance between the drive chassis and the non steer axle on both sides from the inside of the drive chassis Note If the distance is not within 0 15in 3 8mm to 0 17in 4 3mm and the adjustment to the linkage was completed with the ground and drive chassis level repeat steps 6 through 11 OR consult Genie Pr...

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Page 76: ...ing 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 and RR...

Page 77: ...December 2019 Service and Repair Manual Manifolds Part No 1285305GT S 60 J 65 ...

Page 78: ...e from the drive pump Connect the gauge to the test port located on the traction manifold 7 Start the engine from the platform controls Press down the foot switch and slowly move the drive control handle off center just until the machine begins to move Note the reading on the pressure gauge Turn the machine off 8 Hold the charge pressure relief valve and remove the cap item DI 9 Adjust the interna...

Page 79: ...d 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 80: ...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 lbs...

Page 81: ...o 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 82: ...o 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 following coil resistan...

Page 83: ...ntable 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 oil ...

Page 84: ...Specifications Machine Torque Specifications 7 Adjust turntable rotation gear backlash Refer to Repair Procedure How to Adjust the Turntable Rotation Gear Backlash How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear a...

Page 85: ... 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 Loca...

Page 86: ...rqued 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 ver...

Page 87: ...ed 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 necessary...

Page 88: ...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 and...

Page 89: ...tion 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 Sta...

Page 90: ...en 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 Verify t...

Page 91: ... 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 circuits 2...

Page 92: ... 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 of ex...

Page 93: ...l 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 sea...

Page 94: ...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 Short...

Page 95: ...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 Prop...

Page 96: ... 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 C32BRK W...

Page 97: ...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 switch...

Page 98: ...ite 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 between...

Page 99: ...d 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 detect...

Page 100: ...ut 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 DISCON b...

Page 101: ...lag 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 limited function...

Page 102: ...N 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 short...

Page 103: ...le 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 is ma...

Page 104: ...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 10 ...

Page 105: ...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 supply ...

Page 106: ...ce tool This service tool may be connected to the Engine Service Connector located to the right of the battery tray The ground controls display and fault menu will show basic engine faults such as low oil pressure and high coolant temperature It will also show faults for engine warning and engine stop which correspond to the engine warning lamp and engine stop lamp indicators that the engine may r...

Page 107: ...take 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 Limit...

Page 108: ...or 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 3511 4 ...

Page 109: ...otor 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 0 Hig...

Page 110: ...azard 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 rul...

Page 111: ...inal 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 ope...

Page 112: ...ion 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid o...

Page 113: ...GT S 60 J 101 S 60 J 1 LSB1RO 2 LST1O 3 UTS 4 PBAS 5 LSB1DO Limit Switches and Sensors LSB1RO LST1O UTS PBAS LSB1DO Limit switch boom fully retracted operational Limit switch drive turntable operational Universal tilt sensors Primary boom angle sensor Limit switch boom down operational ...

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Page 115: ...December 2019 Service and Repair Manual 103 Electrical Schematic Generator Options ...

Page 116: ...Service and Repair Manual December 2019 104 S 60 J Part No 1285305GT Electrical Schematic Generator Options ...

Page 117: ...December 2019 Service and Repair Manual Part No 1285305GT S 60 J 105 Electrical Schematic Positive Air Shutdown ...

Page 118: ...Service and Repair Manual December 2019 106 Electrical Schematic Positive Air Shutdown ...

Page 119: ...December 2019 Service and Repair Manual 107 Electrical Schematic Turntable Controller ...

Page 120: ...Service and Repair Manual December 2019 108 S 60 J Part No 1285305GT Electrical Schematic Turntable Controller ...

Page 121: ...December 2019 Service and Repair Manual Part No 1285305GT S 60 J 109 Electrical Schematic Platform Controller ...

Page 122: ...Service and Repair Manual December 2019 110 Electrical Schematic Platform Controller ...

Page 123: ...December 2019 Service and Repair Manual 111 Electrical Schematic Kubota D1803 ...

Page 124: ...Service and Repair Manual December 2019 112 S 60 J Part No 1285305GT Electrical Schematic Kubota D1803 ...

Page 125: ...December 2019 Service and Repair Manual Part No 1285305GT S 60 J 113 Electrical Schematic Kubota D1105 ...

Page 126: ...Service and Repair Manual December 2019 114 Electrical Schematic Kubota D1105 ...

Page 127: ...December 2019 Service and Repair Manual 115 Electrical Schematic Deutz D2011 ...

Page 128: ...Service and Repair Manual December 2019 116 S 60 J Part No 1285305GT Electrical Schematic Deutz D2011 ...

Page 129: ...December 2019 Service and Repair Manual Part No 1285305GT S 60 J 117 Hydraulic Schematic ...

Page 130: ...Service and Repair Manual December 2019 118 Hydraulic Schematic S 60 J Part No 1285305GT Service and R epair M anual Decem ber 2019 ...

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