Genie Z-80/60 Service And Repair Manual
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Genie Z-80/60 Service And Repair Manual

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See also: Service Manual , Maintenance Manual
Service and Repair Manual
Z-80/60
Serial Number Range
from Z80134592 to
Z8016H-6399
from Z80H-6400
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. 1268556
Rev A3
January 2017

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Summary of Contents for Genie Z-80/60

  • Page 1 Service and Repair Manual Serial Number Range Z-80/60 from Z80134592 to This manual includes: Z8016H-6399 Repair procedures from Z80H-6400 Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268556...

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1268556 Rev A, September 2015 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “Z” is a trademark of Terex South Dakota, Inc..
  • Page 3 January 2017 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 11/2015 Schematics Added new serial number (from Z8013-4592) Added Electrical Schematic (from Z8013-4592 to Z8015-5653) 9/2016 Introduction Serial Number Legend Specifications GM 3.0L engine Fault Codes...

  • Page 4: Serial Number Legend

    Service and Repair Manual September 2016 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code...

  • Page 5: Safety Rules

    September 2016 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Service and Repair Manual September 2016 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    September 2016 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications...................
  • Page 8 September 2016 Table of Contents Section 3 Repair Procedures ..................... 17 Introduction ......................17 Platform Controls ....................19 Platform Controls ....................19 1-1 Platform Circuit Board ..................20 How to Remove the LED Circuit Board ............21 1-2 Joysticks - How to Calibrate a Joystick ............21 How to Reset a Proportional Valve Coil Default ..........
  • Page 9 September 2016 Table of Contents Boom Components .................... 40 4-1 Primary Boom Cable Track ................41 How to Repair the Primary Boom Cable Track ..........43 4-2 Primary Boom ....................44 How to Shim the Primary Boom ..............44 How to Disassemble the Primary Boom ............46 4-3 Primary Boom Lift Cylinder ................
  • Page 10 September 2016 Table of Contents Hydraulic Pumps ....................79 7-1 Function Pump ....................79 7-2 Drive Pump ....................80 How to Prime the Pump .................. 81 Manifolds ......................82 8-1 Function Manifold Components - View 1 ............82 8-2 Function Manifold Components - View 2 ............84 8-3 Valve Adjustments - Function Manifold ............
  • Page 11 September 2016 Table of Contents Turntable Rotation Components ..............115 9-1 Turntable Rotation Assembly ............... 115 How to Adjust the Turntable Rotation Gear Backlash ........116 Axle Components ..................... 117 10-1 Steer Sensors .................... 117 How to Measure the Tire Alignment .............. 117 How to Adjust a Steer Sensor ...............
  • Page 12 September 2016 Table of Contents Section 5 Schematics ....................... 156 Introduction ......................156 Wire Circuit Legend ................... 157 Wire Color Legend ..................... 161 Limit Switches and Angle Sensors..............166 Drive Chassis and Platform Controller Pin Legend ........... 168 Turntable Controller Pin Legend ................ 169 Relay and Fuse Panel Legends .................

  • Page 13: Specifications

    September 2016 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Tires and wheels Drive speed, maximum (models with rough terrain tires) Tire size 18-625 FF (foam filled and non-marking) Stowed position 40 ft / 8.7 - 9.3 sec 12.2 m / 8.7 - 9.3 sec Tire size 445D50/70...

  • Page 14: Hydraulic Specification

    Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry. When incompatible designed to give maximum protection to hydraulic fluids are mixed, insoluble systems, have the ability to perform over a wide...
  • Page 15 September 2016 Service and Repair Manual Specifications Petro-Canada Environ MV 46 Chevron Rando HD Premium Oil Fluid Properties MV Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 16: Hydraulic Component Specifications

    Service and Repair Manual September 2016 Specifications Hydraulic Component Function manifold Specifications System relief valve pressure, maximum 3200 psi (measured at PTEST port) 220.6 bar Drive Pump Primary boom down relief valve pressure 1300 psi (measured at LS port) 89.6 bar Type: bi-directional variable displacement piston pump Secondary boom down relief pressure 2500 psi...
  • Page 17 2 position 3 way solenoid valve, 12V DC 9Ω (schematic items BC, BD, CE, CF, FB and FC) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 1268556...

  • Page 18: Continental Tme27 Engine Specifications

    Service and Repair Manual September 2016 Specifications Continental TME27 Engine Oil Pressure switch Installation torque 8 - 18 ft-lbs Displacement 164 cu. in 11 - 24 Nm 2.68 liters Pressure switch point 7 psi Number of cylinders 0.55 bar Bore and Stroke 3.58 x 4.06 inches Fuel pump 91 x 103.2 mm...

  • Page 19: Gm 3.0L Engine Specifications

    September 2016 Service and Repair Manual Specifications GM 3.0L Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 183 cu. in Manual for your engine. 3.0 liters Battery – Engine starting and control system Number of cylinders Type 12V DC, Group 31 Bore and Stroke...

  • Page 20: Deutz Td2011L04I Engine Specifications

    Service and Repair Manual September 2016 Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 220.9 cu. in 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.78 x 4.92 inches Oil Pressure switch 96 x 125 mm...

  • Page 21: Deutz Td 2.9 Engine Specifications

    September 2016 Service and Repair Manual Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...

  • Page 22: Perkins 404F-22T Engine Specifications

    Service and Repair Manual September 2016 Specifications Perkins 404F-22T Oil Pressure switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2.2 liters Pressure switch point 14.2 psi Number of cylinders 1 bar Bore and Stroke 3.31 x 3.94 inches Fuel injection system 84 x 100 mm...

  • Page 23: Perkins 804D-33 Engine Specifications

    September 2016 Service and Repair Manual Specifications Perkins 804D-33 Injection system Injection pump make Zexel Displacement 201 cu. in Injection pump pressure 1707 to 1849 psi 3.3 liters 117.7 to 127.5 bar Number of cylinders Injector opening pressure ~2000 psi Bore and Stroke 3.70 x 4.72 inches ~138 bar...

  • Page 24: Machine Torque Specifications

    Service and Repair Manual September 2016 Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5, dry 640 ft-lbs (before SN 15-5630) 867 Nm 1-8 center bolt, GR 5, dull gray 615 ft-lbs (from SN 15-5630) 834 Nm 3/8 -16 bolts, GR 8 35 ft-lbs* *(use blue thread locking compound) 47.5 Nm*...

  • Page 25: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed 23 ft-lbs / 31.2 Nm...

  • Page 26: Torque Procedure

    Note: The O-ring in Parker Seal Lok™ fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612). Lubricate the O-ring before installation. Be sure the O-ring face seal is seated and retained properly.

  • Page 27: September

    September 2016 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 28: Sae And Metric Fasteners Torque Charts

    Service and Repair Manual September 2016 Specifications Part No. 1268556...

  • Page 29: Repair Procedures

     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.
  • Page 30 Service and Repair Manual September 2016 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 31: Platform Controls

    5 LED circuit board Controller. 6 primary boom up/down and turntable rotate Each joystick controller should operate smoothly left/right joystick and provide proportional speed control over its entire range of motion. For further information or assistance, consult Genie Product Support. Part No. 1268556...

  • Page 32: Platform Circuit Board

    Service and Repair Manual September 2016 Platform Controls Attach a grounded wrist strap to the ground screw inside the control box. Platform Circuit Board Electrocution/burn hazard. Electrocution/burn hazard. Contact with electrically charged Contact with electrically charged circuits could result in death or circuits could result in death or serious injury.

  • Page 33: How To Remove The Led Circuit Board

    September 2016 Service and Repair Manual Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Board Joysticks Push in the red Emergency Stop button to the off position at both the ground and platform How to Calibrate a Joystick controls.
  • Page 34 Service and Repair Manual September 2016 Platform Controls Drive functions: Steer functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to platform controls.
  • Page 35 September 2016 Service and Repair Manual Platform Controls Secondary boom up/down and extend/retract Primary boom extend/retract functions: functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...
  • Page 36 Service and Repair Manual September 2016 Platform Controls Primary boom up/down functions: Turntable rotate functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...

  • Page 37: How To Reset A Proportional Valve Coil Default

    September 2016 Service and Repair Manual Platform Controls How to R es et a Proportional Val ve Coil D efault How to Set the F unction T hresholds and D efault Func tions Speeds How to Reset a Proportional Valve How to Set the Function Coil Default Thresholds and Default Functions...
  • Page 38 Service and Repair Manual September 2016 Platform Controls Function speeds: Slowly move the joystick off center in the opposite direction just until the machine Note: Be sure the machine is in the stowed position function starts to move, then move the joystick and the boom is rotated between the circle end very slowly towards the neutral or center tires.

  • Page 39: How To Adjust The Function Speeds

    September 2016 Service and Repair Manual Platform Controls How to Adj ust the Functi on Speeds How to Adjust the Function 15 Once the function speeds have been set, press and hold the engine start button until the Speeds engine shuts off. Do not press the red Emergency Stop button.

  • Page 40: How To Adjust The Function Ramp Rate Setting

    Service and Repair Manual September 2016 Platform Components Press the enter button to save the setting in Press the previous button until the function to memory. be adjusted is displayed. Press the enter or previous button on the Press the plus button to increase the ramp rate or press the minus button to decrease the LCD screen until EXIT is displayed.

  • Page 41: Platform Leveling Cylinder

    September 2016 Service and Repair Manual Platform Components Platform Platform Leveling Cylinder The platform leveling cylinder keeps the platform How to Remove the Platform level through the entire range of boom motion. The platform is maintained level to the turntable. To Separate the foot switch quick disconnect accomplish this, the ECM at the ground controls plug.

  • Page 42: How To Bleed The Platform Leveling Cylinder

    Service and Repair Manual September 2016 Platform Components Tag, disconnect and plug the hydraulic hoses 10 Use a soft metal drift to tap the platform level from the platform leveling cylinder at the cylinder rod-end pivot pin half way out and bulkhead fittings located inside the boom tube lower one of the leveling arms to the ground.

  • Page 43: Platform Rotator

    September 2016 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the manifold. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.

  • Page 44: How To Bleed The Platform Rotator

    Service and Repair Manual September 2016 Platform Components How to Bleed the Pl atfor m R otator How to Bleed the Platform Rotator 11 Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure.

  • Page 45: Platform Overload System (If Equipped)

    September 2016 Service and Repair Manual Platform Components How to Calibrate the Platform Overload System (if equipped) Platform Overload System (if equipped) Proper calibration of the platform overload system is essential to safe machine operation. Continued The platform overload system is designed to use of an improperly calibrated platform overload prevent the machine from continuing to operate system could result in the system failing to sense an...
  • Page 46 Service and Repair Manual September 2016 Platform Components Move the platform up and down by hand, so it Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to bounces approximately 2.5 to 5 cm / 1 to 2 inches.
  • Page 47 September 2016 Service and Repair Manual Platform Components Move the platform up and down by hand, so it Test all machine functions from the platform bounces approximately 2.5 to 5 cm / 1 to controls. 2 inches. Allow the platform to settle. Result: All platform control functions should Result: The alarm should be off.

  • Page 48: Platform Overload Recovery Message

    Service and Repair Manual September 2016 Platform Components Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message (software V2.04 and Press the enter or previous button on the later) LCD screen until CLEAR OVERLOAD RECOVERY is displayed.

  • Page 49: Jib Boom Components

    September 2016 Service and Repair Manual Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
  • Page 50 Service and Repair Manual September 2016 Jib Boom Components Use a soft metal drift to remove the pin and let 15 Attach a lifting strap from an overhead crane to the cylinder hang down. the lug on the rod end of the jib boom lift cylinder.

  • Page 51: Jib Boom Lift Cylinder

    September 2016 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out and Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.

  • Page 52: Boom Components

    Service and Repair Manual September 2016 Boom Components primary boom link arm pivot pin 13 secondary boom pivot pin primary boom lift cylinder link arm 14 secondary lift cylinder pivot pin - barrel end primary lift cylinder pivot pin - rod end 15 secondary boom lift cylinder primary boom lift cylinder 16 secondary lift cylinder pivot pin - rod end...

  • Page 53: Primary Boom Cable Track

    September 2016 Service and Repair Manual Boom Components Remove the mounting fasteners from the power to platform outlet box. Remove the Primary Boom Cable Track outlet box and lay to the side. The primary boom cable track guides the cables Remove the hose clamp from the platform and hoses running up the boom.
  • Page 54 Service and Repair Manual September 2016 Boom Components 11 Tag, disconnect and plug the jib boom cylinder 18 Tag, disconnect and plug each hydraulic hose hydraulic hoses. Cap the fittings. from the bulkhead fittings that lead to the cable track. Cap the fittings. Bodily injury hazard.

  • Page 55: How To Repair The Primary Boom Cable Track

    Cables and hoses can be Note: A cable track repair kit is available through damaged if they are kinked or the Genie Service Parts Department. pinched. Visually inspect the cable track and determine Connect the ends of the replacement cable which 4-link section needs to be replaced.

  • Page 56: Primary Boom

    Service and Repair Manual September 2016 Boom Components How to Remove the Primary Boom Primary Boom Bodily injury hazard. This How to Shi m the Pri mar y Boom procedure requires specific repair How to Shim the Boom skills, lifting equipment and a suitable workshop.
  • Page 57 September 2016 Service and Repair Manual Boom Components Tag, disconnect and plug the primary boom 11 Use a soft metal drift to remove the upper extension cylinder hydraulic hoses. Cap the primary boom lift cylinder linkage arm pivot pin. fittings on the cylinder. Tag, disconnect and Using a suitable lifting device remove the plug the hydraulic hoses routed through the linkage arm from the machine.

  • Page 58: How To Disassemble The Primary Boom

    Service and Repair Manual September 2016 Boom Components How to Dis ass embl e the Primar y Boom How to Disassemble the Primary Use a soft metal drift to remove the pin. Boom Crushing hazard. The primary boom could become unbalanced Bodily injury hazard.

  • Page 59: Primary Boom Lift Cylinder

    September 2016 Service and Repair Manual Boom Components Use a soft metal drift to remove the pin. Primary Boom Lift Cylinder Crushing hazard. The extension cylinder could become The primary boom lift cylinder raises and lowers the unbalanced and fall when primary boom.

  • Page 60: Primary Boom Extension Cylinder

    Service and Repair Manual September 2016 Boom Components Place blocks under the primary boom lift cylinder linkage arms for support. Primary Boom Extension Cylinder Tag, disconnect and plug the primary boom lift The primary boom extension cylinder extends and cylinder hydraulic hoses. Cap the fittings on retracts the primary boom extension tube.The the cylinder.
  • Page 61 September 2016 Service and Repair Manual Boom Components Remove the access cover from the pivot end of 10 Working at the pivot end of the boom, support the primary boom. and slide the extension cylinder out of the boom extension. Place blocks under the barrel end of the primary boom extension cylinder for support.

  • Page 62: Primary Boom Angle Sensor

    Service and Repair Manual September 2016 Boom Components Remove the angle sensor and bracket assembly. Primary Boom Angle Sensor Remove the sensor retaining fasteners from A properly functioning primary boom angle sensor the sensor bracket. Remove the angle sensor. (PBAS) is essential to safe machine operation. The Install the new angle sensor onto the mounting primary boom angle sensor is used to limit the bracket.

  • Page 63: How To Calibrate The Primary Boom Angle Sensor

    September 2016 Service and Repair Manual Boom Components How to C alibr ate the Pri mar y Boom Angle Sensor How to Calibrate the Primary Loosen the Primary Boom Angle Sensor (PBAS) assembly bracket fasteners attached Boom Angle Sensor to the primary boom. Loosen the wing nut and hex nut on the threaded rod to allow the Note: Perform this procedure on a firm, level threaded rod to move upward.
  • Page 64 Service and Repair Manual September 2016 Boom Components 17 Press the previous button until EXIT is shown 25 Start the engine. on the display. Press the plus button to select 26 Activate the boom up function until the digital yes, then press the enter button to accept. level reads 65°.

  • Page 65: Secondary Boom Cable Track

    Note: A cable track repair kit is available through pinched. the Genie Service Parts Department. Connect the ends of the replacement cable Remove the secondary boom extension track section to the existing cable track using cylinder.

  • Page 66: Secondary Boom

    Service and Repair Manual September 2016 Boom Components Remove the primary boom. Refer to Repair Procedure, How to Remove the Primary Secondary Boom Boom. Tag, disconnect and plug the hydraulic hoses How to Disassemble the at the primary boom lift cylinder. Cap the Secondary Boom fittings on the cylinder.

  • Page 67: Secondary Boom Lift Cylinder

    September 2016 Service and Repair Manual Boom Components Tag and disconnect the electrical cables from the turntable. Secondary Boom Lift Cylinder Remove the hose protector bracket. 10 Working at the platform end, place blocks How to Remove the Secondary under the barrel end of the secondary boom Boom Lift Cylinder extension cylinder for support.
  • Page 68 Service and Repair Manual September 2016 Boom Components Remove the engine pivot plate retaining Using an approved hand-operated pump, drain fastener. Swing the engine pivot plate out the fuel tank into a suitable container. Refer to away from the machine. Specifications, Machine Specifications.

  • Page 69: Secondary Boom Extension Cylinder

    September 2016 Service and Repair Manual Boom Components 12 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the Secondary Boom Extension fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The secondary boom extension cylinder extends burn skin.
  • Page 70 Service and Repair Manual September 2016 Boom Components Remove the fasteners securing the cable track 11 Tag, disconnect and plug the secondary boom trays and cable track clamps to the secondary extension cylinder hydraulic hoses. Cap the extension boom. fittings on the cylinder. Remove the external snap rings from the Bodily injury hazard.

  • Page 71: Engines

    September 2016 Service and Repair Manual Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel Service or Maintenance Manual for your machine, and has a splined center to drive the pump.
  • Page 72 Service and Repair Manual September 2016 Engines Deutz TD2011L04i models: Carefully pull the pump and bell housing assembly away from the engine and secure it Tag and disconnect the wiring from the bell from moving. housing. Component damage hazard. Remove the U-bolt from the exhaust flex pipe Hoses can be damaged if they at the muffler.
  • Page 73 September 2016 Service and Repair Manual Engines Perkins 404F-22T models: Continental model: Tag and disconnect the wiring from the bell Tag and disconnect the wire harness from the housing. oxygen sensor. Remove the fasteners supporting the muffler Remove the exhaust pipe heat shield assembly from the bell housing.

  • Page 74: How To Install The Flex Plate

    Service and Repair Manual September 2016 Engines How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the Install the flex plate onto the engine flywheel appropriate gap between coupler and pump with the raised spline towards the pump.

  • Page 75: How To Install The Pump And Bell Housing Assembly

    September 2016 Service and Repair Manual Engines How to i nstall the Pump and Bell H ousing Ass embl y Deutz Pump Mounting Plate How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C"...

  • Page 76: How To Access Perkins 404F Engine Regeneration Service

    Service and Repair Manual September 2016 Engines How to Force or Inhibit DPF How to Access Perkins 404F Regeneration Engine Regeneration Service There are three modes available for DPF regeneration. Machines equipped with Perkins 404F-22T Diesel The default, AUTOMATIC MODE, allows for ECU engines will have a regeneration mode that should controlled regeneration.
  • Page 77 September 2016 Service and Repair Manual Engines Press the enter button until FORCE DPF REGENERATION or INHIBIT DPF REGENERATION is displayed. Press the plus button or the minus button to select YES to change the regeneration mode from the default automatic mode. The selection will automatically return to NO.

  • Page 78: Ground Controls

    Service and Repair Manual September 2016 Ground Controls Bypass/Recovery Key Switch The ground control box contains two key switches. The main key switch towards the top of the control box is for selection of ground or platform controls. The key switch at the bottom of the control box is the Bypass/Recovery key switch.
  • Page 79 September 2016 Service and Repair Manual Ground Controls How to Use the Bypass Mode Turn the bypass/recovery key switch to the bypass position. Tip-over hazard. Operating the Using auxiliary power, operate the ground machine outside of the operating control buttons to level the platform. envelope while in Bypass mode will result in death or serious injury Note: Only the auxiliary power unit can be used to...

  • Page 80: How To Use The Recovery Mode

    Service and Repair Manual September 2016 Ground Controls How to Us e the R ec overy Mode How to Use the Recovery Mode Turn the main key switch to ground controls. Remove the key from the main key switch and Recovery is only to be used as a last attempt to insert the key into the bypass/recovery key lower the platform when the operator in the platform...

  • Page 81: Circuit Boards

    (TCON) cannot be replaced by itself. If circuit boards OR use a the ECM circuit board is faulty and needs to be grounded wrist strap. replaced, contact the Genie Industries Service Department. Carefully disconnect the LCD circuit board ribbon cable from the ECM circuit board.

  • Page 82: Membrane Decal

    Service and Repair Manual September 2016 Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane on Contact with electrically charged the backside.

  • Page 83: Display Module

    September 2016 Service and Repair Manual Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.

  • Page 84: September

    Delete boom function speed on position. Release the enter button and press Delete lift function ramps (minus)(minus)(previous)(previous) Delete all (Contact Genie Product Support before using this option) Delete Faults Delete faults will reset active latching faults.
  • Page 85 September 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Drive Functions With key switch , press Forward not stowed drive speed % 120% (default) 50% (min) and hold the enter button Forward low drive speed % 120% (default) 50% (min) and turn key switch to on position.
  • Page 86 Service and Repair Manual September 2016 Display Module Screen or Menu Procedure Description Range or Selection Boom Function With key switch , press Primary boom up speed stowed 120% max, 50% min, Speeds and hold the enter button 100% (default) and turn key switch to on Primary boom up speed not stowed position.
  • Page 87 September 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and Primary boom up/down ramp 150% max and 50% min Ramps hold the enter button and turn key acceleration % 100% (default), switch to on position.
  • Page 88 Service and Repair Manual September 2016 Display Module Screen or Menu Procedure Description Range or Selection Valve Calibration With key switch , press and Reset drive valve defaults YES/NO hold the enter button and turn Reset primary boom up/down key switch to on position. valve defaults Release the enter button and Reset primary boom ext/ret...
  • Page 89 September 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection YES/NO Sensor Calibration With key switch , press Set unit levels to gravity and hold the enter button Unit Level Y-axis millivolts per and turn key switch to on degree position.
  • Page 90 Service and Repair Manual September 2016 Display Module Screen or Menu Procedure Description Range or Selection Options With key switch , press Boom Length Limit: No Limit (NO and hold the enter button LT), and turn key switch to on Secondary Extend disabled (EXT position.

  • Page 91: Hydraulic Pumps

    September 2016 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the hydraulic hoses at the function pump. Cap the fittings on the Function Pump pump. Bodily injury hazard. Spraying How to Remove the Function hydraulic oil can penetrate and Pump burn skin.

  • Page 92: Drive Pump

    Any internal service to the pump underneath the turntable. Close the valves. should be performed at an authorized Component damage hazard. Sauer-Danfoss service center. Contact Genie The engine must not be started Product Support to locate your local authorized with the hydraulic tank shut-off service center.

  • Page 93: How To Prime The Pump

    September 2016 Service and Repair Manual Hydraulic Pumps How to Prime the Pump Tag and disconnect and plug the hydraulic How to Prime the Pump hoses from the drive and function pumps. Cap the fittings on the pumps. Component damage hazard. Be sure that the hydraulic tank Bodily injury hazard.

  • Page 94: Manifolds

    Service and Repair Manual September 2016 Manifolds Function Manifold Components - View 1 The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Differential sensing valve Secondary boom up/extend and 30-35 ft-lbs / 41-47 Nm down/retract Relief valve, 2500 psi / 172 bar Secondary boom up...
  • Page 95 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 96: Function Manifold Components - View 2

    Service and Repair Manual September 2016 Manifolds Function Manifold Components - View 1 The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Secondary boom extend circuit 20-25 ft-lbs / 27-34 Nm Relief valve, 2600 psi / 179 bar Secondary boom extend...
  • Page 97 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 98: Valve Adjustments - Function Manifold

    Service and Repair Manual September 2016 Manifolds 8-3 Valve Adjustments - Function Simultaneously push and hold the function enable/high speed button and the primary Manifold boom retract button with the primary boom fully retracted. Observe the reading on the pressure How to Adj ust the System Reli ef Val ve gauge.

  • Page 99: How To Adjust The Primary Boom Down Relief Valve

    September 2016 Service and Repair Manual Manifolds How to Adj ust the Pri mar y Boom Down R elief Val ve How to Adjust the Primary Boom Adjust the internal hex socket. Turn it clockwise to increase the pressure or Down Relief Valve counterclockwise to decrease the pressure.

  • Page 100: How To Adjust The Primary Boom Extend Relief Valve

    Service and Repair Manual September 2016 Manifolds How to Adj ust the Pri mar y Boom Extend R elief Val ve How to Adjust the Primary Boom Turn the engine off. Use a wrench to hold the relief valve and remove the cap. Extend Relief Valve 10 Adjust the internal hex socket.

  • Page 101: How To Adjust The Secondary Boom Up Relief Valve

    September 2016 Service and Repair Manual Manifolds How to Adj ust the Sec ondary Boom U p Reli ef Val ve How to Adjust the Secondary Continue holding the function enable/high speed button and the secondary boom Boom Up Relief Valve up/extend button while observing the reading on the pressure gauge.

  • Page 102: How To Adjust The Secondary Boom Down Relief Valve

    Service and Repair Manual September 2016 Manifolds How to Adj ust the Sec ondary Boom D own Relief Val ve How to Adjust the Secondary Adjust the internal hex socket. Turn it clockwise to increase the pressure or Boom Down Relief Valve counterclockwise to decrease the pressure.

  • Page 103: How To Adjust The Secondary Boom Extend Relief Valve

    September 2016 Service and Repair Manual Manifolds How to Adj ust the Sec ondary Boom Extend R elief Val ve How to Adj ust the Pl atfor m M anifold Reli ef Val ve How to Adjust the Secondary How to Adjust the Platform Boom Extend Relief Valve Manifold Relief Valve Note: Perform this procedure with the secondary...

  • Page 104: Platform Manifold

    Service and Repair Manual September 2016 Manifolds Platform Manifold The platform Manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Check valve, 5 psi Platform load sense/level circuit 12-14 ft-lbs / 16-19 Nm Differential sensing valve, N.C. Directs flow to functions 19-21 ft-lbs / 26-29 Nm Check valve, 5 psi...
  • Page 105 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 106: Turntable Rotation Manifold

    Service and Repair Manual September 2016 Manifolds Turntable Rotation Manifold The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index Schematic Description Function Torque Item Shuttle valve, 2 position 3 way Turntable rotation brake release 10-13 ft-lbs / 14-18 Nm Counterbalance valve Turntable rotate right...

  • Page 107: Platform Rotate Manifold

    September 2016 Service and Repair Manual Manifolds Platform Rotate Manifold The platform rotate manifold is mounted on the platform rotator. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotation brake release 35-40 ft-lbs / 47-54 Nm Counterbalance valve Turntable rotate left 35-40 ft-lbs / 47-54 Nm Part No.

  • Page 108: Two Wheel Steer And Oscillate Manifold

    Service and Repair Manual September 2016 Manifolds Two Wheel Steer and Oscillate Manifold The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the machine. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Steer left/right, yellow side steer 26-30 ft-lbs / 35-41 Nm cylinder...
  • Page 109 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 110: How To Adjust The Oscillate Relief Valve

    Service and Repair Manual September 2016 Manifolds How to Adj ust the Oscill ate R elief Val ve How to Adjust the Oscillate Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: This procedure will require two people. Note: Refer to Oscillate Manifold Component list to locate the oscillate relief valve.
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  • Page 112: Four Wheel Steer And Oscillate Manifold

    Service and Repair Manual September 2016 Manifolds Four Wheel Steer and Oscillate Manifold The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the machine. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Steer left/right, square endyellow 26-30 ft-lbs / 35-41 Nm side steer cylinder...
  • Page 113 September 2016 Service and Repair Manual Manifolds Part No. 1268556...
  • Page 114 Service and Repair Manual September 2016 Manifolds Four Wheel Steer and Oscillate Manifold, continued Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Steer left/right, circle endblue 26-30 ft-lbs / 35-41 Nm side steer cylinder Solenoid valve, 3 position 4 way Steer left/right, circle endyellow 26-30 ft-lbs / 35-41 Nm side steer cylinder...
  • Page 115 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 116: How To Adjust The Oscillate Relief Valve

    Service and Repair Manual September 2016 Manifolds How to Adj ust the Oscill ate R elief Val ve How to Adjust the Oscillate Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: This procedure will require two people. Note: Refer to Oscillate Manifold Component list to locate the oscillate relief valve.

  • Page 117: Oil Diverter Manifold Components (Welder Option)

    September 2016 Service and Repair Manual Manifolds Oil Diverter Manifold Components (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Pilot Operated Directional valve, Activates generator 80-90 ft-lbs / 108-122 Nm 2 position 3 way Orifice disc, 0.031 inch / 0.79 mm...

  • Page 118: Traction Manifold Components, 2Wd

    Service and Repair Manual September 2016 Manifolds 8-10 Traction Manifold Components, 2WD The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Drive motor anti-cavitation 30-35 ft-lbs / 41-47 Nm Check valve, 5 psi / 0.34 bar...
  • Page 119 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 120: Valve Adjustments, 2Wd Traction Manifold

    Service and Repair Manual September 2016 Manifolds 8-11 Move rpm select switch to high rpm (rabbit symbol). Valve Adjustments, 2WD Traction Begin driving the machine forward at a Manifold medium speed while one person monitors the pressure gauge. Continue driving until the How to Adjust the Charge pressure stabilizes.
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  • Page 122: Traction Manifold Components, 4Wd

    Service and Repair Manual September 2016 Manifolds 8-12 Traction Manifold Components, 4WD The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Drive motor anti-cavitation 30-35 ft-lbs / 41-47 Nm Solenoid valve, 2 position 3 way...
  • Page 123 September 2016 Service and Repair Manual Manifolds Part No. 1268556...

  • Page 124: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual September 2016 Manifolds 8-13 Move rpm select switch to high rpm (rabbit symbol). Valve Adjustments, 4WD Traction Begin driving the machine forward at a Manifold medium speed while one person monitors the pressure gauge. Continue driving until the How to Adjust the Charge pressure stabilizes.

  • Page 125: Valve Coils

    September 2016 Service and Repair Manual Manifolds 8-14 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...

  • Page 126: September

    6. Resistor 10Ω Set a multimeter to read DC current. Genie part number 27287 Note: The multimeter, when set to read DC current, Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.

  • Page 127: Turntable Rotation Components

    September 2016 Service and Repair Manual Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.

  • Page 128: How To Adjust The Turntable Rotation Gear Backlash

    Service and Repair Manual September 2016 Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Bac klash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear.

  • Page 129: Axle Components

    September 2016 Service and Repair Manual Axle Components 10-1 Measure the distance between the inside of one circle-end tire and the chassis side plate Steer Sensors on both sides of the axle. he steer sensor measures steer angle and Result: Both measurements should be the communicates that information to the ground same to indicate that the tires are parallel with controls ECM.

  • Page 130: How To Adjust A Steer Sensor

    Service and Repair Manual September 2016 Axle Components How to Adj ust a Steer Sens or How to Adjust a Steer Sensor Circle-end steer sensors: 10 At the platform controls, press the square-end Start the engine from the platform controls. steer mode button.

  • Page 131: How To Calibrate The Steer Sensors

    January 2017 Service and Repair Manual Axle Components How to C alibr ate the Steer Sens ors How to Calibrate the Steer Enter sensor calibration mode by pressing the buttons at the ground controls in the following Sensors sequence: (plus)(enter)(enter)(plus). If a steer sensor reaches the limit of travel before a Use the previous button to scroll through the tire is adjusted parallel to the chassis, the steer...

  • Page 132: How To Adjust The Oscillate Limit Switches

    Use a digital level to confirm. the ground and drive chassis level, consult Genie Product Support. Note: This procedure will require two people. Lower the boom to the stowed position.

  • Page 133: Oscillating Axle Cylinders

    September 2016 Service and Repair Manual Axle Components 10-2 Remove the pin retaining fasteners from the oscillate cylinder rod-end pivot pin. Use a soft Oscillating Axle Cylinders metal drift to remove the pin. The oscillating axle cylinders extend and retract Attach a lifting strap from an overhead crane to between the drive chassis and the oscillating axle.

  • Page 134: Fault Codes

    Service and Repair Manual September 2016 Fault Codes Section 4 Faul t Codes 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 tools and test equipment are available and ready for use.

  • Page 135: Control System Fault Codes

    September 2016 Service and Repair Manual Control System Fault Codes How to Read Control System Using Web GPI Fault Codes Connect the device containing the WEB GPI software to the TCON with an RS-232 cable. Note: Initial fault testing occurs at power-up. Select the Secondary Boom, then the Safety Faults are abnormal conditions that exist due to Switch Status Flags screen.
  • Page 136 Service and Repair Manual September 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
  • Page 137 September 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Up/Down Speed Not calibrated Perform auto calibrate procedure. Display message on LCD and allow operation at default speed Primary Extend/Retract Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
  • Page 138 Service and Repair Manual September 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
  • Page 139 September 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Not calibrated Secondary Boom Up/Down Display message on LCD and allow See service manual on how to perform Speed operation at default speed this procedure.
  • Page 140 Service and Repair Manual September 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Steer Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
  • Page 141 September 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Motor Valve Speed Fault Check Limited Speed and Direction frozen at Check for defective or damaged zero and neutral, Alarm sounds wiring. Check for an open or shorted valve coil.
  • Page 142 Service and Repair Manual September 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Display message on LCD Power up controller with problem P3 SAFETY SWITCH FAULT corrected. Safety Switch P6R1 Fault Check Display message on LCD Power up controller with problem P6R1 SAFETY SWITCH FAULT...

  • Page 143: Fault Code Display - Deutz And Perkins Models

    September 2016 Service and Repair Manual Fault Code Display - Deutz and Perkins Models How to R etrieve Ac ti ve Engine F ault Codes D eutz D 2.9 L4 and Per ki ns 404F- 22 Models How to Retrieve Active Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models The ECM constantly monitors the engine by the use...

  • Page 144: Deutz D 2.9 L4 Engine Fault Codes

    Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1231 Actuator error EGR-Valve; Power FMI = Failure Mode Identifier stage over temp due to high KWP = Keyword Protocol current SPN FMI Description...
  • Page 145 September 2016 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
  • Page 146 Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
  • Page 147 September 2016 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
  • Page 148 Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature exhaust KWP = Keyword Protocol gas mass flow; plausibility error SPN FMI Description 2659 12...
  • Page 149 September 2016 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of KWP = Keyword Protocol CAN-Receive-Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of 4766...
  • Page 150 Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
  • Page 151 September 2016 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523788 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of 523717...
  • Page 152 Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value FMI KWP Description exceeded 523922...
  • Page 153 September 2016 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
  • Page 154 Service and Repair Manual September 2016 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame A1DOC KWP Description 524115 9 1660 Timeout error of 524102 9 1674 Timeout error of...

  • Page 155: Perkins 404F-22 Engine Fault Codes

    September 2016 Service and Repair Manual Perkins 404F-22 Engine Fault Codes Description SPN = Suspect Parameter Number Engine Speed Sensor #2: Voltage FMI = Failure Mode Identifier Above Normal Description Engine Speed Sensor #2: Voltage Accelerator Pedal Position 2: Voltage Below Normal Above Normal Engine Speed Sensor#2: Abnormal...
  • Page 156 Service and Repair Manual September 2016 Perkins 404F-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Description Below Normal 3251 Particulate Trap Differential Pressure: 4201 Engine Speed Sensor #1: Abnormal Voltage Above Normal Frequency, Pulse \Nidth, or Period 3251...

  • Page 157: Continental Tme27 Engine Fault Codes

    September 2016 Service and Repair Manual Continental TME27 Engine Fault Codes How to R etrieve Conti nental Engine F ault C odes Note: Once a fault code has been retrieved and the How to Retrieve Continental repair has been completed, the ECM memory must Engine Fault Codes be reset to clear the fault code from the ECM.

  • Page 158: Continental Tme27 Engine Fault Codes

    Service and Repair Manual September 2016 Continental TME27 Engine Fault Codes Continental TME27 Engine F ault Codes System Code Fault Name 2 3 4 5 6 Fault Conditions MAP Pressure High MAP pressure > 16 psi and TPS < 10% and RPM >...
  • Page 159 September 2016 Service and Repair Manual Continental TME27 Engine Fault Codes System Code Fault Name 3 4 5 6 Fault Conditions 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc 2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc Engine Max Govern Speed Override RPM >...
  • Page 160 Service and Repair Manual September 2016 Continental TME27 Engine Fault Codes System Code Fault Name 3 4 5 6 Fault Conditions 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc 2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc Engine Max Govern Speed Override RPM >...
  • Page 161 September 2016 Service and Repair Manual Continental TME27 Engine Fault Codes System Code Fault Name 1 2 3 4 5 6 Fault Conditions EGO Open/Lazy Pre-cat 1 EGO cold persistently > 120 seconds Sensors EGO Open/Lazy Post-cat 1 EGO cold persistently > 120 seconds Injectors Injector Loop Open or n Y Y Y...
  • Page 162 Service and Repair Manual September 2016 Continental TME27 Engine Fault Codes System Code Fault Name 1 2 3 4 5 Fault Conditions Cam Crank Cam Loss No cam pulse in 4 cycles and RPM > 1000 Sensors Crank Loss Cam pulses without crank activity > 6 cam pulses Cam Sync Noise Number of invalid cam re-syncs = 1 within a time...

  • Page 163: Gm 3.0L Engine Fault Codes

    September 2016 Service and Repair Manual GM 3.0L Engine Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position error 520800 / 7 DTC 221: TPS1-2 higher than expected 653/6 DTC 16: Crank and/or cam no sync during start 636 / 8...

  • Page 164: September

    Service and Repair Manual September 2016 GM 3.0L Engine Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 420: Catalyst inactive on gasoline (Bank 1) 520211 / 10 DTC 1111: RPM above fuel rev limit level 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank 2) 520212 / 10 DTC 1112: RPM above spark rev limit level 515 / 0...
  • Page 165 September 2016 Service and Repair Manual GM 3.0L Engine Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / SPN-2 / FMI-2 FMI-2 DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage 520220 / 3 DTC 1316: Cylinder 6 misfire detected 1328 / 11 DTC 1544: AUX analog Pull-Up/Down 2 low voltage...
  • Page 166 Service and Repair Manual September 2016 GM 3.0L Engine Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 1634: PWM2-Gauge2 short to power 698 / 6 DTC 2126: FPP1-2 higher than expected 91 / 16 DTC 1635: PWM3-Gauge3 open / ground short 699 / 6...
  • Page 167 September 2016 Service and Repair Manual GM 3.0L Engine Fault Codes GM Fault Code Chart DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI-2 SPN-2 / FMI-2 DTC 2618: Tach output ground short 645 / 4 DTC 8909: UEGO pump voltage shorted low 3218 / 3 DTC 2619: Tach output short to power 645 / 3...

  • Page 168: Schematics

    Service and Repair Manual September 2016 Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, ...

  • Page 169: Wire Circuit Legend

    September 2016 Service and Repair Manual Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. Control The circuit prefix indicates the type of circuit. Data The circuit number describes the function of the circuit.
  • Page 170 Service and Repair Manual September 2016 Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
  • Page 171 September 2016 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
  • Page 172 Service and Repair Manual September 2016 Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...

  • Page 173: Wire Color Legend

    September 2016 Service and Repair Manual Wire Color Legend Wire Coloring Color Circuit # Primary Function Primary boom up drive All cylinder extension colors are solid and all RD/BK Primary boom down drive retract functions are striped black. When using black wire, the stripe shall be white.
  • Page 174 Service and Repair Manual September 2016 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Auxiliary power Axle retract RD/BK Platform level alarm Boom stowed (safety) RD/WH Drive motor shift (speed) OR/RD Power to boom envelope safety switch Forward/EDC-A OR/BK...
  • Page 175 September 2016 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Tether power WH/BK Secondary boom lockout (Riser Down Enable) Tether ESTOP power ECU test switch J1708 + (high) OR/RD Low engine speed J1708 - (low) RD/BK Descent alarm...
  • Page 176 Service and Repair Manual September 2016 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function BL/RD Spare Encode A BL/WH Steer joystick signal Encode B WH/RD Propel joystick signal Bootstrap or program enable WH/BK Sec boom joystick signal Safety cross check Joystick 5 VDC power Data receive...
  • Page 177 September 2016 Service and Repair Manual Wire Color Legend Types of Limit Switches Types of Limit Switches There are two types of limit switches, found in LSP1AO Primary boom angle stowed various locations throughout the machine: LSP1RO Primary boom length retracted mechanical-type operational or safety switches.

  • Page 178: Limit Switches And Angle Sensors

    Service and Repair Manual September 2016 Limit Switches and Angle Sensors Limit Switch Legend LSP1RO LSS2AS LSS2AO 10 LSA1OS LSP1EO 11 LSA2OS LSP1AO 12 LST1O LSJ1EO 13 Turntable Angle Sensor Platform Angle Sensor 14 LSS1AO LSS1RO 15 LSS1RS LSS3AO 16 Primary Boom angle Sensor Part No.
  • Page 179 September 2016 Service and Repair Manual Schematics Limit Switch Functions LSS2AS: Limit switch, Secondary Boom #2 Angle Safety Switch. Secondary boom angle full LSA1OS: Limit switch, Axle #1 Oscillating extension, angle up all the way (secondary boom Operational. Activates the axle oscillate circuit on extend allowed).

  • Page 180: Drive Chassis And Platform Controller Pin Legend

    Service and Repair Manual September 2016 Drive Chassis and Platform Controller Pin Legend Pin Numbering - 23 pin connector Plat Controller Plat Controller Drive Chassis J32 Drive Chassis GND PCON - BR VLVRET7 - BR GND-DCON - BR VLVRET - BR P52PCON - BL/RD (UNUSED) P21DCON - WH...

  • Page 181: Turntable Controller Pin Legend

    September 2016 Service and Repair Manual Turntable Controller Pin Legend Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin connector Turntable Controller J11 Turntable Turntable J14 Turntable Controller Controller Controller GNDDCON - BR GNDPCON - BR Vl.VRET1 - BR VLVRET4 - BR...

  • Page 182: Relay And Fuse Panel Legends

    Service and Repair Manual September 2016 Relay and Fuse Panel Legends Part No. 1268556...
  • Page 183 September 2016 Service and Repair Manual Relay and Fuse Panel Legends Part No. 1268556...

  • Page 184: Electrical Symbol Legend

    Service and Repair Manual September 2016 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing - no Quick disconnect...

  • Page 185: Hydraulic Symbols Legend

    September 2016 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Double acting cylinder Differential sensing valve or motor) 3 way...

  • Page 186: Electrical Schematics

    Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Deutz TD2.9 Engine...

  • Page 187: Electrical Schematic - Engine Options, Deutz Td2.9 Engine

    September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TD2.9 Engine Part No. 1268556...

  • Page 188: Electrical Schematic - Engine Options, Deutz Td2.9 Engine Harness

    Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Deutz TD2.9 Engine Harness Part No. 1268556...
  • Page 189 September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TD2.9 Engine Wiring...
  • Page 190 Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Perkins 404F-22T Engine...

  • Page 191: Electrical Schematic - Engine Options,Perkins 404F-22T Engine

    September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 404F-22T Engine Part No. 1268556...

  • Page 192: Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness

    Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Perkins 404F-22T Engine Harness Part No. 1268556...
  • Page 193 September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 404F-22T Engine Wiring...
  • Page 194 Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Perkins 804D Engine...

  • Page 195: Electrical Schematic - Engine Options, Perkins 804D Engine

    September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 804D Engine Part No. 1268556...

  • Page 196: Electrical Schematic - Engine Options, Continental Tme27 Engine

    Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Continental TME27 Engine Part No. 1268556...
  • Page 197 September 2016 Service and Repair Manual Electrical Schematic - Engine Options, Continental TME27 Engine...
  • Page 198 Service and Repair Manual September 2016 Electrical Schematic - Engine Options, Perkins 804D Engine...

  • Page 199: Electrical Schematic - Engine Options, Gm 3.0 Engine

    September 2016 Service and Repair Manual Electrical Schematic - Engine Options, GM 3.0 Engine Part No. 1268556...
  • Page 200 Service and Repair Manual September 2016 Electrical Schematic - Engine Options, GM 3.0 Engine Part No. 1268556...
  • Page 201 September 2016 Service and Repair Manual Electrical Schematic - Safety Circuits Part No. 1268556...

  • Page 202: Electrical Schematic - Safety Circuits

    Service and Repair Manual September 2016 Electrical Schematic - Safety Circuits Part No. 1268556...

  • Page 203: Electrical Schematic - Generator Options

    September 2016 Service and Repair Manual Electrical Schematic - Generator Options Part No. 1268556...
  • Page 204 Service and Repair Manual September 2016 Electrical Schematic - Generator Options...
  • Page 205 September 2016 Service and Repair Manual Electrical Schematic - Welder Generator Option...

  • Page 206: Electrical Schematic - Welder Generator Option

    Service and Repair Manual September 2016 Electrical Schematic - Welder Generator Option Part No. 1268556...

  • Page 207: Electrical Schematic - Hydraulic Generator Options

    September 2016 Service and Repair Manual Electrical Schematic - Hydraulic Generator Options Part No. 1268556...
  • Page 208 Service and Repair Manual September 2016 Electrical Schematic - Hydraulic Generator Options...

  • Page 209: Hydraulic Schematics

    September 2016 Service and Repair Manual Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)

  • Page 210: Hydraulic Schematic - 2 Wheel Drive (2 And 4 Wheel Steer)

    Service and Repair Manual September 2016 Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer) Part No. 1268556...

  • Page 211: Hydraulic Schematic - 4 Wheel Drive (2 And 4 Wheel Steer)

    September 2016 Service and Repair Manual Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer) Part No. 1268556...
  • Page 212 Service and Repair Manual September 2016 Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)

  • Page 213: Electrical Schematic - (From Z8013-4592 To Z8015-5653)

    (~SM)+(AH) MICRO GBOX HARN BTS621 BOOM RET RECOVERY SIGNAL OUT 1 P22R P22R BOOM DWN RECOVERY SIGNAL OUT 2 Genie Z-80 GROUND BTS621 P22R BOOM EXT/RET FC RECOVERY SIGNAL OUT 1 ((~SM)+(AH))(P_22) BOOM UP/DWN FC RECOVERY SIGNAL PLAT OUT 2...
  • Page 214 )+(AH) BOOM RET RECOVERY SIGNAL GBOX HARN BTS621 BOOM DWN RECOVERY SIGNAL OUT 1 P22R P22R OUT 2 BOOM EXT/RET FC RECOVERY SIGNAL Genie Z-80 GROUND BTS621 P22R OUT 1 ((~SM)+(AH))(P_22) OUT 2 BOOM UP/DWN FC RECOVERY SIGNAL PLAT BTS650...
  • Page 215 Part No. 1268556 Ser vic e and R epair M anual September 2016...

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