Terex S-60 J Service And Repair Manual
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Terex S-60 J Service And Repair Manual

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Service and Repair Manual
S
-60 J
®
Serial Number Range
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

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  • Page 1 Service and Repair Manual Serial Number Range -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: Introduction

    Copyright © 2019 by Terex Corporation 1285305GT Rev A, December 2019 First Edition, First Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -60 J Part No. 1285305GT...

  • Page 3: Revision History

    December 2019 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2019 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual December 2019 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) ® -60 J Part No. 1285305GT...

  • Page 5: Safety Rules

    December 2019 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 December 2019 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

    December 2019 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 December 2019 Table of Contents Section 3 Repair Procedures ....................13 Introduction ......................13 Control System ....................15 1-1 ALC-600 Platform Control Module ..............15 1-2 ALC-600 Service Mode .................. 15 1-3 Full Machine Calibration ................. 16 1-4 Machine Functions ..................17 How to Adjust the Machine Maximum Speed Setting ........
  • Page 9 December 2019 Table of Contents Boom Components .................... 37 4-1 Cable Track ....................37 How to Remove the Cable Track ..............37 How to Repair the Cable Track ............... 39 4-2 Primary Boom....................40 4-3 Boom Lift Cylinder ..................41 4-4 Primary Boom Extension Cylinder ..............
  • Page 10 December 2019 Table of Contents Manifolds ......................54 7-1 Function Manifold Components..............54 7-2 Valve Adjustments - Function Manifold ............58 How to Adjust the Boom Extend Relief Valve ..........58 7-3 Jib Boom / Platform Rotate Manifold Components ........59 7-4 Turntable Rotation Manifold Components ............
  • Page 11 December 2019 Table of Contents 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 ...........
  • Page 12 December 2019 Table of Contents Section 5 Schematics ......................98 Introduction ......................98 Important Information ................... 98 Electrical Symbol Legend ..................99 Hydraulic Symbols Legend ................. 100 Limit Switch Location Legend ................101 Electrical Schematics – Options ..............103 Electrical Schematic, Generator Options ............104 Electrical Schematic, Positive Air Shutdown ............

  • Page 13: Specifications

    December 2019 Service and Repair Manual Specifications Section 2 Performance Specifications Specific ati ons Machine Specifications Boom function speeds, maximum from platform Tires and Wheels controls Tire size (Rough terrain) 315/55D20 Jib boom up 25 to 35 seconds Tire weight (Foam filled) 290 lbs Jib boom down 15 to 25 seconds...

  • Page 14: Hydraulic Oil Specifications

    Service and Repair Manual December 2019 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 15 December 2019 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties 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 33.5 cSt @ 104°F / 40°C...
  • Page 16 Service and Repair Manual December 2019 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 17: Hydraulic Component Specifications

    December 2019 Service and Repair Manual Specifications Hydraulic Component Drive manifold Specifications Hot oil relief valve pressure 280 psi 19,3 bar Drive Pump Drive motor Type: bi-directional variable displacement piston pump Displacement per revolution, 1.53 cu in high speed 25 cc Flow rate @ 2500 rpm 21.1 gpm 80 L/min...

  • Page 18: Deutz D2011 L03I Engine Specifications

    Service and Repair Manual December 2019 Specifications Deutz D2011 L03i Engine Fuel injection system Injection pump make Bosch 142 cu in Displacement Injection pump pressure, 15000 psi 2.33 liters maximum 1034 bar Number of cylinders Injector opening pressure 3046 psi 3.7 x 4.4 inches Bore and Stroke 210 bar...

  • Page 19: Kubota D1105-E4B Engine Specifications

    December 2019 Service and Repair Manual Specifications Kubota D1105-E4B Engine Fuel injection system Injection pump make Bosch MD 68.53 cu in Displacement Injection pump pressure, 1991 psi 1,123 liters maximum 137 bar Number of cylinders Injection timing 18° BTDC 3.07 x 3.09 inches Bore and Stroke Fuel requirement 78 x 78,4 mm...

  • Page 20: Kubota D1803-Cr-Tie4 Engine Specifications

    Service and Repair Manual December 2019 Specifications Kubota D1803-CR-TIE4 Engine Fuel injection system Injection pump make Bosch MD 111.4 cu in Displacement Injection pump pressure, maximum 1,825 liters Low idle 3700 - 4300 psi Number of cylinders 255 - 296 bar 3.43 x 4.031 inches Bore and Stroke High idle...

  • Page 21: Machine Torque Specifications

    December 2019 Service and Repair Manual Specifications Machine Torque Specifications Machine Component Weights Note: All torque values are shown lubricated unless Lift structure 5300 lbs otherwise noted. 2404 kg Turntable assembly without lift structure, 6700 lbs Platform Rotator includes counterweights 3040 kg 1-8 center bolt, GR 5 483 ft-lbs...

  • Page 22: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual December 2019 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) 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...

  • Page 23: Torque Procedure

    December 2019 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
  • Page 24 Service and Repair Manual December 2019 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 25: Repair Procedures

    December 2019 Service and Repair Manual Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures  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 Observe and Obey: removed ...

  • Page 26: About This Section

    Service and Repair Manual December 2019 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 27: Control System

    December 2019 Service and Repair Manual Control System How to Enter ALC-600 Service ALC-600 Control Module Mode Platform Controls The platform control box contains the ALC-600 platform Control Module. The platform Control Module receives all signals from the platform switches, joysticks and foot switch, and provides operator feedback through an Indicator Module.

  • Page 28: Full Machine Calibration

    Service and Repair Manual December 2019 Control System The Control System on this machine allows access to calibrations through the Service Mode. The Full Machine Calibration procedures that follow may require the operator to already be in the Service Mode. The Service Mode Full machine calibration must be completed in the can only be entered at machine start up and proper sequence when the ALC-600 controller...

  • Page 29: Machine Functions

    December 2019 Service and Repair Manual Control System 10 Record the time it takes for that function to complete a full cycle (ie; boom up). Machine Functions 11 Compare the machine function time with the How to Adj ust the Mac hine M axim um Speed Setti ng How to Adjust the Joystick function times listed in Refer to Specifications, Performance Specifications.

  • Page 30: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual December 2019 Control System How to Adj ust the Joystick Ram p R ate Setting How to Adjust the Joystick Ramp Start the engine from the ground controls. Rate Setting Start a timer and activate the machine function that needs to be adjusted.

  • Page 31: How To Adjust The Joystick Threshold Setting

    December 2019 Service and Repair Manual Control System How to Adj ust the Joystick Thr es hol d Setting How to Adjust the Joystick Threshold Setting How to Enter ALC600 Software Update Mode The threshold setting of a joystick is the minimum output at which a function proportional valve can Go to the Genie website open and allow the function to operate.

  • Page 32: Display Module Menus

    Service and Repair Manual December 2019 Control System Display Module Menus Screen or Menu Item Selection Default Display Settings Backlight 0 - 100% Contrast 0 - 100% Display Inversion On / Off Screen or Menu Item Selection Default Model Model S-40 / S-45 / S-60 / S-65 / S-60J / Select Model Configuration...
  • Page 33 December 2019 Service and Repair Manual Control System Screen or Menu Item Default Sensor Calibration Chassis Tilt Select OK to calibrate Load Sense Select OK to calibrate Boom Angle Select OK to calibrate Screen or Menu Item Default Auto Threshold Boom Up / Down Threshold Select OK to calibrate Calibration...
  • Page 34 Service and Repair Manual December 2019 Control System Screen or Menu Item Default Primary Lift Speeds Extend Thresholds 190% max, 1% min, 100% = 506 mA Retract Threshold 179% max, 1% min, 100% = 513 mA Up Threshold 250% max, 1% min, 100% = 450 mA Down Threshold 253% max, 1% min, 100% = 443 mA Extend Max...
  • Page 35 December 2019 Service and Repair Manual Control System Screen or Menu Item Default Jib Boom and Jib Up Threshold max 112% / min 1% / default 551 mA = 100% Platform Speeds Jib Down Threshold max 118% / min 1% / default 500 mA = 100% Platform Level Up Threshold max 127% / min 1% / default 450 mA = 100% Platform Level Down max 127% / min 1% / default 450 mA = 100%...

  • Page 36: How To Replace The Display Controller (Discon) Module

    Service and Repair Manual December 2019 Control System Remove the old DISCON gasket (2) from the ground box lid and clean the lid surface from How to Replace the Display any dirt, oil or old adhesive residue. Use a Controller (DISCON) Module 99% solution of isopropyl alcohol to clean the surface.

  • Page 37: How To Replace The Ground Control Overlay

    December 2019 Service and Repair Manual Control System Unscrew the nut holding the buttons and key switch and remove the key switch and buttons. How to Replace the Ground Box Note the orientation of the key switch so it can be Control Overlay reassembled in the same position.
  • Page 38 Service and Repair Manual December 2019 Control System Before placing the new overlay, make sure the temperature of the lid and overlay is between 80-100° F / 26-38° C. Application below 80° F / 26° C is not recommended. 10 Peel the adhesive protective film from the back of the overlay.

  • Page 39: Platform Components

    December 2019 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the slave cylinder. Platform Leveling Slave Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The slave cylinder and the rotator pivot are the two burn skin.

  • Page 40: Platform Rotator

    Service and Repair Manual December 2019 Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the rotator. The platform rotator is a hydraulically activated Tag, disconnect and plug the hydraulic hoses helical gear assembly used to rotate the platform from the platform rotator manifold.
  • Page 41 December 2019 Service and Repair Manual Platform Components How to Bleed the Platform Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to Rotator platform rotator pivot pins. Do not remove the pins. Note: This procedure will require two people. Do not start the engine.

  • Page 42: Platform Overload System

    Service and Repair Manual December 2019 Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System Bodily injury hazard. Spraying Proper calibration of the platform overload system hydraulic oil can penetrate and is essential to safe machine operation.
  • Page 43 December 2019 Service and Repair Manual Platform Components Confirm the setting: Navigate to the Load Sense calibration screen. 14 Lift the test weight off the platform floor using a Select and start the calibration procedure. suitable lifting device. Follow the on-screen instructions to set the 15 Start the engine from the ground control.

  • Page 44: How To Perform A Zero Load Platform Overload Calibration

    Service and Repair Manual December 2019 Platform Components How to Per form a Z ero Load Platform Ov erload C alibration How to R eplac e the Platform Ov erload Load C ell How to Perform a Zero Load How to Replace the Load Cell Platform Calibration Sensor Perform this procedure when the required weight...

  • Page 45: Platform

    December 2019 Service and Repair Manual Platform Components Install the new Load Cell Sensor Platform Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out How to Remove the Platform of the bottom of the sensor.The foot should not contact the flex plate when assembling Remove the cable clamp from the top of the...

  • Page 46: Jib Boom Components

    Service and Repair Manual December 2019 Jib Boom Components Attach a lifting strap from an overhead crane to the jib boom assembly. Jib Boom Place blocks under the platform leveling cylinder for support. Protect the cylinder rod How to Remove the Jib Boom from damage.

  • Page 47: Jib Boom Lift Cylinder

    December 2019 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. Then Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the How to Remove the Jib Boom Lift opposite leveling arm.

  • Page 48: Boom Components

    Service and Repair Manual December 2019 Boom Components 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 10 upper riser arm to turntable pivot pin ®...

  • Page 49: Boom Components

    December 2019 Service and Repair Manual Boom Components Tag, disconnect and plug the platform leveling slave cylinder hydraulic hoses from the Cable Track bulkhead fittings on the side of the primary boom. Cap the bulkhead fittings. The primary boom cable track guides the cables and hoses running up the boom.
  • Page 50 Service and Repair Manual December 2019 Boom Components 14 Tag, disconnect and plug all hydraulic hoses 21 Carefully remove the cable track from the that enter the cable track from the bulkhead machine and place it on a structure capable of fittings at the pivot end of the boom.

  • Page 51: How To Repair The Cable Track

    December 2019 Service and Repair Manual Boom Components How to R epair the C abl e Tr ack How to Repair the Cable Track Component damage hazard. The boom cable track can be damaged if it is twisted. Note: A 4 link repair section of cable track is available through the Genie Service Parts Department.

  • Page 52: Primary Boom

    Service and Repair Manual December 2019 Boom Components Tag, disconnect and plug the hydraulic hoses from the boom extend cylinder. Cap the Primary Boom fittings.Remove the cable tracks from both sides of the boom. Set them onto the machine How to Remove the Primary side covers.

  • Page 53: Boom Lift Cylinder

    December 2019 Service and Repair Manual Boom Components 13 Remove the boom lower pivot pin retaining fasteners. Use a soft metal drift to remove the Boom Lift Cylinder pin. The primary boom lift cylinder raises and lowers 14 Remove the boom upper pivot pin retaining the primary boom.

  • Page 54: Primary Boom Extension Cylinder

    Service and Repair Manual December 2019 Boom Components Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the Primary Boom Extension cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.

  • Page 55: Platform Leveling Master Cylinder

    December 2019 Service and Repair Manual Boom Components Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on Platform Leveling Master the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The platform leveling master cylinder acts as a burn skin.

  • Page 56: Primary Boom Angle Sensor

    Service and Repair Manual December 2019 Boom Components Remove the retaining fastener securing the barrel end pivot pin. Primary Boom Angle Sensor The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the turntable and gravity.

  • Page 57: How To Repalce The Primary Boom Angle Sensor

    December 2019 Service and Repair Manual Boom Components How to R epalc e the Primary Boom Angle Sensor How to Replace the Primary Boom Angle Sensor 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.

  • Page 58: Engines

    Service and Repair Manual December 2019 Engines Flex Plate RPM Adjustment - Kubota D1105 and Deutz D2011Models The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel Refer to Maintenance Procedure in the appropriate and has a splined center to drive the pump.

  • Page 59: How To Install The Flex Plate

    December 2019 Service and Repair Manual Engines How to Ins tall the Fl ex Plate How to Install the Flex Plate Install the flex plate onto the engine flywheel with the raised spline towards the pump. Apply Loctite ® removable thread locker to the flex plate mounting fasteners.

  • Page 60: How To Install The Pump And Bell Housing Assembly

    Service and Repair Manual December 2019 Engines How to i nstall the Pum p and Bell H ousing Ass embly How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Apply Loctite ® removable threadlocker to the bell housing mounting fasteners.

  • Page 61: Engine Fault Codes - Kubota D1803 Models

    December 2019 Service and Repair Manual Engines Engine Fault Codes - Kubota D1803 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition...

  • Page 62: Hydraulic Pump

    Service and Repair Manual December 2019 Hydraulic Pump Drive Pump Function Pump How to Remove the Drive Pump How to Remove the Function Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Note: When removing a hose assembly or fitting, end must be replaced.

  • Page 63: How To Install The Drive Pump Coupler

    December 2019 Service and Repair Manual Hydraulic Pump How to Ins tall the Driv e Pum p C oupler How to Install the Drive Pump Coupler How to Prime the Drive and Function Pumps Install the coupler onto the pump shaft with the set screw towards the pump.

  • Page 64: Generator Pump

    Service and Repair Manual December 2019 Hydraulic Pump Generator Pump How to Remove the Generator 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.
  • Page 65 December 2019 Service and Repair Manual This page intentionally left blank. Part No. 1285305GT ® -60 J...

  • Page 66: Manifolds

    Service and Repair Manual December 2019 Manifolds Function Manifold Components Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Function enable valve 15-20 ft-lbs / 20-27 Proportional directional valve, 3 position Platform rotate left/right and jib 25-30 ft-lbs / 34-41 4 way boom up/down Proportional directional valve, 3 position...
  • Page 67 December 2019 Service and Repair Manual Manifolds Part No. 1285305GT ® -60 J...
  • Page 68 Service and Repair Manual December 2019 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Flow regulator valve, 0.1 GPM / 0,37 Differential sensing circuit 25-30 ft-lbs / 34-41 L\mon Relief valve, 3200 psi / 221 bar System relief 20-25 ft-lbs / 27-34 Differential sensing valve Turntable rotate...
  • Page 69 December 2019 Service and Repair Manual Manifolds Part No. 1285305GT ® -60 J...

  • Page 70: Valve Adjustments - Function Manifold

    Service and Repair Manual December 2019 Manifolds How to Adj ust the Boom Ex tend R elief Valve 7-2 Valve Adjustments - Function How to Adjust the Boom Extend Manifold Relief Valve Note: Perform this procedure with the boom in the How to Adjust the System Relief stowed position.

  • Page 71: Jib Boom / Platform Rotate Manifold Components

    December 2019 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Platform rotate/jib boom select 20-25 ft-lbs / 27-34 Nm Part No.

  • Page 72: Turntable Rotation Manifold Components

    Service and Repair Manual December 2019 Manifolds Turntable Rotation Manifold Componentss The turntable rotation manifold is mounted to the turntable rotation motor. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotate right 35-40 ft-lbs / 47-54 Nm Counterbalance valve Turntable rotate left 35-40 ft-lbs / 47-54 Nm Shuttle valve, 2 position 3 way...

  • Page 73: Valve Adjustments - Oscillate Relief Valve

    December 2019 Service and Repair Manual Manifolds How to Set U p the Oscillate Directional Valv e How to Set Up the Oscillate Valve Adjustments - Oscillate Directional Valve Relief Valve Note: Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve How to Adjust the Oscillate Relief has been replaced.
  • Page 74 Service and Repair Manual December 2019 Manifolds Adjust the heim joint until the hole lines up with the retaining fastener hole in the axle. 10 Install the heim joint to the axle and tighten the jam nut. 11 Check to be sure the drive chassis is completely level.
  • Page 75 December 2019 Service and Repair Manual This page intentionally left blank. Part No. 1285305GT ® -60 J...

  • Page 76: Traction Manifold Components, 4Wd

    Service and Repair Manual December 2019 Manifolds Traction Manifold Components, 4WD The traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Flow divider/combiner valve Divides flow between diagonal pairs of 80-90 ft-lbs / 108-122 motors Check valve, 5 psi Prevents cavitation in LF motor...
  • Page 77 December 2019 Service and Repair Manual Manifolds Part No. 1285305GT ® -60 J...

  • Page 78: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual December 2019 Manifolds Hold the charge pressure relief valve and remove the cap (item DI). Valve Adjustments, 4WD Traction Adjust the internal hex socket until the Manifold pressure reading on the gauge is 30 psi / 2 bar less than the pressure reading on the pump.

  • Page 79: Brake/Two-Speed Manifold Components

    December 2019 Service and Repair Manual Manifolds Brake / Two Speed Manifold Components The brake/two speed manifold is mounted inside the drive chassis. Index Schematic Description Function Torque Item Orifice, 0.025 inch / 0.63 mm Turntable rotation brake release Check valve Brake release circuit 20-25 ft-lbs / 27-34 Nm Solenoid Valve, 2 position 3 way...

  • Page 80: Generator Manifold Components

    Service and Repair Manual December 2019 Manifolds 12 Kw Generator Manifold The generator manifold is mounted on the turntable tray by the fuel tank. Index Schematic Description Function Torque Item Relief valve Generator relief valve 50 ft-lbs / 67 Nm Solenoid Valve Charge pressure circuit 60-65 ft lbs / 81-88 Nm...

  • Page 81: Turntable Rotation Manifold Components

    December 2019 Service and Repair Manual Manifolds 7-10 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotate right 35-40 ft-lbs / 47-54 Nm Counterbalance valve Turntable rotate left 35-40 ft-lbs / 47-54 Nm Shuttle valve.

  • Page 82: Valve Coils

    Service and Repair Manual December 2019 Manifolds Valve Coil Resistance 7-11 Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromagnetic force which operates the solenoid...

  • Page 83: Turntable Rotation Components

    December 2019 Service and Repair Manual Turntable Rotation Components Loosen the backlash pivot plate mounting bolts and adjustment bolts. Pull the turntable Turntable Rotation Assembly rotation assembly away from the turntable bearing. How to Remove the Turntable Rotation Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 84: How To Adjust The Turntable Rotation Gear Backlash

    Service and Repair Manual December 2019 Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable Remove the drive hub mounting bolts. Carefully remove the drive hub assembly from Rotation Gear Backlash the machine.

  • Page 85: Turntable Angle Sensor Replacement

    December 2019 Service and Repair Manual Turntable Rotation Components Push the backlash pivot plate towards the turntable as far as possible (this will push the How to Replace the Turntable rotation gear into the turntable bearing ring Angle Sensor gear). Loosen the lock nut on the adjustment bolt.

  • Page 86: Axle Components

    Service and Repair Manual December 2019 Axle Components Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. Oscillating Axle Cylinders Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to The oscillate system is designed so that all four remove the pin.

  • Page 87: Fault Codes

    December 2019 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  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 88: Control System Fault Codes

    Service and Repair Manual December 2019 Control System Fault Codes How to R etrieve Contr ol Sy stem F ault Codes Control System How to Retrieve Control System Fault Codes The machine control system contains two different types of fault codes Active Faults: These faults have been detected in the current operating session.

  • Page 89: Control System Fault Codes

    December 2019 Service and Repair Manual Control System Fault Codes Control System F ault C odes ID Component ID Name Cause Effect Solution Engine Can 13 Not Engine CANBUS Disable engine start *Verify with a voltmeter that CAN+ and detected CAN+ or CAN- for tier 4F engines CAN- lines are not shorted.* Measure...
  • Page 90 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 13 Jib 27 Active Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib Up/Down was detected as functions will not Up/Down Toggle Switch (TS8) is Switch...
  • Page 91 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 21 Pri Boom 11 Shorted Circuit C164PUD is Boom Up and Down * Leave joystick in neutral position and Up / Down above 4.5 V. functions will not cycle power.
  • Page 92 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 24 Pri Boom 13 Not No CAN messages Machine limited to * Verify sensor power P85PWR (GR, Angle detected have been received recovery functions TCON J6-7) is at 12 V while the by the TCON from system is running.
  • Page 93 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 26 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y26. Ext Coil C7PBE circuit is Retract functions will Proper resistance should be between supply shorted to 12 V or...
  • Page 94 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 40 Jib Select 11 Shorted PCON detected Jib and platform *With a voltmeter, measure Y18. Coil V18PRR is short to functions will not Proper resistance should be between supply supply...
  • Page 95 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 45 Platform 27 Active Toggle switch input Platform Level Up or *Verify with a voltmeter that the Level was detected as Down functions may Platform Level Up/Down Toggle Toggle startup...
  • Page 96 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 52 Drive 11 Shorted TCON detected that Drive Forward, Brake * With a voltmeter, measure Y6. Forward C30FWD circuit is Release and possibly Proper resistance should be between Pump Coil supply...
  • Page 97 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 61 Steer 11 Shorted Circuit C159STD or Drive and steer * Leave joystick in neutral position and Joystick C159STA is above functions will not cycle power.
  • Page 98 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 69 AC 11 Shorted TCON detected that Generator function * With a voltmeter, measure Y29. Generator C45GEN circuit is will not operate. Proper resistance should be between Output supply shorted to 12 V.
  • Page 99 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 74 Engine 15 Sensor Engine Engine will not * With a voltmeter, check that Temperature value too temperature sensor operate C26TSR ( WH/RD, TCON J6P8) is is shorted to not shorted to ground and voltage is ground...
  • Page 100 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 78 Platform 13 Not TCON has not Controls from the * Verify PCON is receiving power. Controller detected detected the PCON platform will not Check for 12 V on J15-2 (+) and J15-1 (PCON) primary processor...
  • Page 101 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 80 Turntable 13 Not The DISCON has Machine limited to * Verify TCON is receiving power. Controller detected not detected the recovery functions Check for 12 V on J5-2 (+) and J5-1 (TCON) TCON on the CAN...
  • Page 102 Service and Repair Manual December 2019 Control System Fault Codes ID Component ID Name Cause Effect Solution 85 Chassis 13 Not Tilt sensor not Machine limited to Calibrate tilt sensor. Angle detected calibrated recovery functions Safety 88 Function 11 Shorted TCON detected that Only Auxiliary Power * With a voltmeter, measure Y74.
  • Page 103 December 2019 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 94 Primary 13 Not No CAN messages Boom Up, Extend * Verify sensor power P85PWR (GR, Boom detected have been received and Turntable Rotate TCON J6-7) is at 12 V while the Length by the TCON from...
  • Page 104 Service and Repair Manual December 2019 Control System Fault Codes Component ID Name Cause Effect Solution 100 Platform 11 Shorted PCON detected Platform Level Up * With a voltmeter, measure Y20. Level Up Coil to supply that V14PLU circuit and possibly Level Proper resistance should be voltage is shorted to 12 V...
  • Page 105 December 2019 Service and Repair Manual Control System Fault Codes Component ID Cause Effect Solution 160 LF Steer (L 11 Shorted TCON detected that Steer Left function * With a voltmeter, measure Y3. or R) Coil C37STL circuit is will not operate. Proper resistance should be between supply shorted to 12 V or...

  • Page 106: Engine Fault Codes

    Service and Repair Manual December 2019 Engine Fault Codes Engine Fault Codes Some engine options have their own Electronic Control Module that contains more detailed fault information that is specific to the engine. This system can be accessed by using the engine's dedicated service tool.

  • Page 107: Kubota D1803-Cr-Tie4 Engine Fault Codes

    December 2019 Service and Repair Manual Kubota D1803-CR-TIE4 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Intake Air Temperature Built-in MAF Description Sensor Abnormality Accelerator Position Sensor 2 Abnormality Intake Air Temperature Error Accelerator Position Sensor Engine Overrun Correlation Errorl ECU Flash ROM and CPU...
  • Page 108 Service and Repair Manual December 2019 Kubota D1803-CR-TIE4 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 3509 Sensor Supply Voltage 1 Abnormality Description 3509 1077 ECU Flash ROM and CPU 3510 Sensor Supply Voltage 2 Abnormality Abnormality 3510 1077...
  • Page 109 December 2019 Service and Repair Manual Kubota D1803-CR-TIE4 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 523589 17 Low Coolant Temperature in Parked Description Regeneration 523538 2 QR (IQA) Data Abnormality 523590 16 Parked Regeneration Tmi OUY 523538 7 523591 2 523543 2...

  • Page 110: Schematics

    Service and Repair Manual December 2019 Schematics Section 5 About This Section Schem atics 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.

  • Page 111: Electrical Symbol Legend

    December 2019 Service and Repair Manual 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 112: Hydraulic Symbols Legend

    Service and Repair Manual December 2019 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, Cylinder, double acting Differential sensing valve or motor) 3 way...

  • Page 113: Limit Switch Location Legend

    December 2019 Service and Repair Manual Limit Switch Location Legend S-60 J 1 LSB1RO 2 LST1O 3 UTS 4 PBAS 5 LSB1DO Limit Switches and Sensors LSB1RO Limit switch boom fully retracted - operational LST1O Limit switch drive turntable - operational...
  • Page 114 Service and Repair Manual December 2019 This page intentionally left blank. ® -60 J Part No. 1285305GT...

  • Page 115: Electrical Schematics - Options

    December 2019 Service and Repair Manual Electrical Schematic, Generator Options...

  • Page 116: Electrical Schematic, Generator Options

    Service and Repair Manual December 2019 Electrical Schematic, Generator Options ® -60 J Part No. 1285305GT...

  • Page 117: Electrical Schematic, Positive Air Shutdown

    December 2019 Service and Repair Manual Electrical Schematic, Positive Air Shutdown Part No. 1285305GT ® -60 J...
  • Page 118 Service and Repair Manual December 2019 Electrical Schematic, Positive Air Shutdown...

  • Page 119: Electrical Schematics

    December 2019 Service and Repair Manual Electrical Schematic, Turntable Controller...

  • Page 120: Electrical Schematic, Turntable Controller

    Service and Repair Manual December 2019 Electrical Schematic, Turntable Controller ® -60 J Part No. 1285305GT...

  • Page 121: Electrical Schematic, Platform Controller

    December 2019 Service and Repair Manual Electrical Schematic, Platform Controller Part No. 1285305GT ® -60 J...
  • Page 122 Service and Repair Manual December 2019 Electrical Schematic, Platform Controller...
  • Page 123 December 2019 Service and Repair Manual Electrical Schematic, Kubota D1803...

  • Page 124: Electrical Schematic, Kubota D1803

    Service and Repair Manual December 2019 Electrical Schematic, Kubota D1803 ® -60 J Part No. 1285305GT...

  • Page 125: Electrical Schematic, Kubota D1105

    December 2019 Service and Repair Manual Electrical Schematic, Kubota D1105 Part No. 1285305GT ® -60 J...
  • Page 126 Service and Repair Manual December 2019 Electrical Schematic, Kubota D1105...
  • Page 127 December 2019 Service and Repair Manual Electrical Schematic, Deutz D2011...

  • Page 128: Electrical Schematic, Deutz D2011

    Service and Repair Manual December 2019 Electrical Schematic, Deutz D2011 ® -60 J Part No. 1285305GT...

  • Page 129: Hydraulic Schematics

    December 2019 Service and Repair Manual Hydraulic Schematic Part No. 1285305GT ® -60 J...
  • Page 130 Service and Repair Manual December 2019 Hydraulic Schematic S®-60 J Part No. 1285305GT Servic e and R epair M anual Decem ber 2019...

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