Page 1 Service and Repair Manual Serial Number Range -60 XC ® ™ from S60XCH-45010 This manual includes: Repair procedures -60 HF ® Fault Codes Electrical and -60 TraX ® ™ Hydraulic Schematics -65 XC ® ™ from S65XCH-45001 from S65XCM-101 from S65XCD-101 -65 HF ®...
Page 2: Introduction
1288652GT Rev D, June 2020 First Edition, Fourth Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TraX" are trademarks of Terex South Dakota, Inc. ® -60/65 XC ™...
Page 3 April 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 7/2018 Initial Release 9/2018 Specifications Hydraulic Component Specifications Repair Display Menu Schematics Electrical schematics, Hydraulic Schematics 1/2019 All Sections Add ANSI model 3/2019 Repair 5/2019 Specifications...
Page 4: Serial Number Legend
Service and Repair Manual April 2021 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on drive chassis) ® -60/65 XC ™ • S ® -60/65 HF • S ®...
Page 5: Safety Rules
April 2021 Service and Repair Manual Safety Rules General Safety Rules Section 1 Safety Rules 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...
Page 6 Service and Repair Manual April 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...
Page 7: Table Of Contents
April 2021 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 April 2021 Table of Contents Section 3 Repair Procedures ..................... 19 Introduction ......................19 Control System....................21 1-1 ALC-600 Platform Control Module ..............21 1-2 ALC-600 Service Mode .................. 21 1-3 Full Machine Calibration ................22 1-4 Machine Functions ..................23 How to Adjust the Machine Maximum Speed Setting........
Page 9 April 2021 Table of Contents Boom Components .................... 45 Boom Components .................... 46 4-1 Cable Track ....................46 How to Remove the Cable Track, S-60 XC and S-60 TRAX ......46 How to Remove the Cable Track, S-65 XC and S-65 XC TRAX ....47 How to Repair the Cable Track ...............
Page 10 April 2021 Table of Contents Manifolds ......................76 7-1 Function Manifold Components - from S60XCH-45010 to 45345, S65XCH-45001 to 45345, S65XCM-101 to 302 .......... 76 7-1.1 Function Manifold Components - from S60XCH-45345, S65XCH-45345, S65SCM-303, S65XCD-101 ..........80 7-2 Valve Adjustments - Function Manifold ............84 How to Adjust the Boom Extend Relief Valve ..........
Page 11 April 2021 Table of Contents Section 4 Fault Codes ....................... 106 Introduction ......................106 Control System Fault Codes ................107 How to Retrieve Control System Fault Codes ..........107 Control System Fault Codes - Models with Revision G Software or Lower .......... 108 Control System Fault Codes - Models with Revision H Software or Higher ..........
Page 12 April 2021 Table of Contents Section 5 Schematics ....................... 171 Introduction ......................171 Electrical Symbol Legend .................. 172 Hydraulic Symbols Legend ................173 Limit Switch Location Legend ................174 Electrical Schematics ..................175 Electrical Schematic, Turntable Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101) .....................
Page 13: Specifications
April 2021 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications Machine Specifications Track Components, S-60 TraX and S-65 TraX Tires and wheels, S-60 XC, S-65 XC Track material Rubber Tire size (Rough terrain) 355/55D625 Tensioning system Pressurized grease Tire weight, new foam-filled (minimum) 426 lbs (Rough terrain)
Page 14: Performance Specifications
Service and Repair Manual April 2021 Specifications Performance Specifications Hydraulic Oil Specifications Performance Specifications Hydraulic Oil Specifications Boom function speeds, maximum from platform Hydraulic Fluid Specifications controls Genie specifications require hydraulic oils which are Jib boom up (S-65 XC models) 48 to 53 seconds designed to give maximum protection to hydraulic systems, have the ability to perform over a wide...
Page 15 April 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
Page 16 Service and Repair Manual April 2021 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 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 15.0 cSt @ 104°F / 40°C cSt @ 104°F / 40°C...
Page 17: Hydraulic Component Specifications
April 2021 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Hydraulic Component Specifications Properties Specifications ISO Grade Drive pump Viscosity index Type: bi-directional, variable displacement piston pump Kinematic Viscosity Flow rate @ 2500 rpm 30.3 gpm cSt @ 149°F / 65°C 115 L/min cSt @ 104°F / 40°C Drive pressure, maximum...
Page 18 Service and Repair Manual April 2021 Specifications Drive manifold Manifold Component Specifications Plug torque Hot oil relief valve pressure 280 psi 19.3 bar SAE No. 2 36 in-lbs / 4 Nm Drive motors, 4WD models SAE No. 4 10 ft-lbs / 13 Nm Displacement per 0.79 cu in SAE No.
Page 19: Ford Msg-425 Efi Engine Specifications
April 2021 Service and Repair Manual Specifications Ford MSG-425 EFI Engine Ford MSG-425 EFI Engine Specifications Fuel requirement For fuel requirements, refer to the engine Operator's Displacement 153 cu in Manual on your machine. 2.5 liters Ignition system Number of cylinders Spark plug type Motorcraft AYFS-32Y- Bore &...
Page 20: Deutz D2011 L03I Engine Specifications
Service and Repair Manual April 2021 Specifications Deutz D2011 L03i Engine Deutz D2011 L03i Engine Specifications Fuel injection system Injection pump make Bosch Displacement 142 cu in Injection pump pressure, 15000 psi 2.33 liters maximum 1034 bar Number of cylinders Injector opening pressure 3046 psi Bore and Stroke...
Page 21: Deutz Td2011L04I Engine Specifications
April 2021 Service and Repair Manual Specifications Deutz TD2011L04i Engine Deutz TD2011L04i Engine Specifications Oil temperature switch Installation torque 8-18 ft-lbs Displacement 220.9 cu in 11-24 Nm 3.62 liters Oil 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 22: Deutz Td 2.2 L3 Engine Specifications
Service and Repair Manual April 2021 Specifications Deutz TD 2.2 L3 Engine Deutz TD 2.2 L3 Engine Specifications Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2,2 liters Temperature switch point 257°F Number of cylinders 125°C...
Page 23: Deutz D 2.9 L4 Engine Specifications
April 2021 Service and Repair Manual Specifications Deutz D 2.9 L4 Engine Deutz D 2.9 L4 Engine Specifications Engine coolant Capacity 10 quarts Displacement 177 cu in 9.4 liters 2.9 liters Fuel injection system Number of cylinders Injection pump make Bosch Bore and Stroke 3.6 x 4.3 inches...
Page 24: Deutz Td 2.9 Engine Specifications
Service and Repair Manual April 2021 Specifications Deutz TD 2.9 L4 Engine Deutz TD 2.9 Engine Specifications Oil Temperature sender Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2,9 liters Oil Pressure sender Number of cylinders Installation torque 8 - 18 ft-lbs Bore and Stroke...
Page 25: Perkins 404D-22 Engine Specifications
April 2021 Service and Repair Manual Specifications Perkins 404D-22 Engine Perkins 404D-22 Engine Specifications Oil pressure sending unit Oil pressure switch point 14.2 psi Displacement 134 cu in 1 bar 2.2 liters Fuel injection system Number of cylinders Injection pump make Zexel Bore and Stroke 3.31 x 3.94 inches...
Page 26: Perkins 404F-E22T Engine Specifications
Service and Repair Manual April 2021 Specifications Perkins 404F-E22T Engine Perkins 404F-E22T Engine Specifications Fuel injection system Injection pump make Zexel Displacement 134 cu in Injection pressure 2133 psi 2,2 liters 147 bar Number of cylinders Fuel requirement Bore and Stroke 3.31 x 3.94 inches For fuel requirements, refer to the engine Operator 84 x 100 mm...
Page 27: Machine Torque Specifications
April 2021 Service and Repair Manual Specifications Machine Torque Specifications TraX™ Torque Specifications Machine Torque Specifications Note: All torque values are shown lubricated Note: All torque values are shown lubricated unless otherwise noted. unless otherwise noted. Platform rotator Sprocket to hub adapter fasteners 1-8 center bolt, GR 5, ZAG 682 ft-lbs Nut, 3/4-16 UNF...
Page 28: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual April 2021 Specifications Hydraulic Hose and Fitting Hydraulic Hose and Fitting Torque Specifications 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°...
Page 29: Torque Procedure
April 2021 Service and Repair Manual Specifications Torque Procedure 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 Replace the O-ring.
Page 30 Service and Repair Manual April 2021 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 31: Repair Procedures
April 2021 Service and Repair Manual Repair Procedures Machine Configuration: Section 3 Repair Procedures Introduction  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 Repair procedures shall be completed by a...
Page 32 Service and Repair Manual April 2021 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 33: Control System
April 2021 Service and Repair Manual Control System Control System 1-2 ALC-600 Service Mode 1-1 ALC-600 Platform Control Module 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 34: Service Mode
Service and Repair Manual April 2021 Control System 1-3 Full Machine Calibration The Control System on this machine allows access to calibrations through the Service Mode. Full Machine Calibration The procedures that follow will require the operator to be in Service Mode. Service Mode can only be Full machine calibration must be completed in the entered at machine start up and requires a special proper sequence when the ALC-600 controller...
Page 35: Machine Functions
April 2021 Service and Repair Manual Control System 1-4 Machine Functions 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 function times listed in Refer to Specifications, Performance Specifications.
Page 36: How To Adjust The Joystick Ramp Rate Setting
Service and Repair Manual April 2021 Control System How to Adjust the Joystick Ramp How to Adjust the Joystick Ramp Rate Setting Start the engine from the ground controls. Rate Setting Start a timer and activate the machine function that needs to be adjusted. Using the The ramp rate setting is an adjustment that ground control functions is the same as controls the way boom functions start and stop.
Page 37: How To Adjust The Joystick Threshold Setting
April 2021 Service and Repair Manual Control System How to Adjust the Joystick How to Adjust the Joystick Threshold Setting 1-5 How to Enter ALC600 Software Update Mode 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 38: Display Module Menus
Service and Repair Manual April 2021 Control System 1-6 Display Module Menus 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...
Page 39 April 2021 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 Load Sense Select OK to calibrate Boom Length Select OK to calibrate Screen or Menu Item Default Auto Threshold...
Page 40 Service and Repair Manual April 2021 Control System Screen or Menu Item Default Deutz D2011 Threshold 2500 rpm Anti-Stall Drive Minimum 60 % Range 700 rpm Hysteresis 200 rpm Screen or Menu Item Default Perkins 404F Threshold 2350 rpm Anti-Stall Drive Minimum Range 125 rpm...
Page 41 April 2021 Service and Repair Manual Control System Screen or Menu Item Default Turntable Speeds Rotate CW Max 150% max, 81% min, 100% = 1294 mA Rotate CCW Max 150% max, 81% min, 100% = 1284 mA Rotate CW Threshold 114% max, 1% min, 100% = 800 mA Rotate CCW Threshold 114% max, 1% min, 100% = 800 mA...
Page 42 Service and Repair Manual April 2021 Control System Screen or Menu Item Default Jib and Platform Jib Up/Down Ramp max 2000 ms / min 200 ms / default 750 ms Ramps Platform Level Ramp max 2000 ms / min 200 ms / default 750 ms Platform Rotate Ramp max 2000 ms / min 200 ms / default 600 ms Screen or Menu...
Page 43: How To Replace The Display Controller (Discon) Module
April 2021 Service and Repair Manual Control System 1-7 How to Replace the Display Controller (DISCON) Module Open the ground box lid (1) and disconnect the wire harness going to the display How to Replace the Display controller (DISCON). Controller (DISCON) Module Remove the DISCON door from the back by loosening the four Torx head screws (8) and Push in the red Emergency Stop button to the...
Page 44: How To Replace The Ground Control Overlay
Service and Repair Manual April 2021 Control System 1-8 How to Replace the Ground Control Overlay Install the new DISCON onto the ground box lid and fasten it using the new hex nuts and How to Replace the Ground Box washers.
Page 45 April 2021 Service and Repair Manual Control System Unscrew the nut holding the buttons and key Remove the ground box lid (1) from the switch and remove the key switch and ground box. buttons. Remove the old overlay and clean the ground Note the orientation of the key switch so it can be box lid surface from any dirt, oils or old reassembled in the same position.
Page 46 Service and Repair Manual April 2021 Control System 15 Reinstall the E-Stop button, function enable button and key switch and the contact assemblies. 16 Reinstall the wire harness from the ground box to the DISCON. Secure the harness to the ground box lid using zip ties. 17 Close and fasten the ground box lid.
Page 47: Platform Components
April 2021 Service and Repair Manual Platform Components Platform Components 2-1 Platform Leveling Slave Cylinder Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft Platform Leveling Slave Cylinder metal drift to drive the rod-end pivot pin out. The slave cylinder and the rotator pivot are the two Crushing hazard.
Page 48: Platform Rotator
Service and Repair Manual April 2021 Platform Components 2-2 Platform Rotator 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 49 April 2021 Service and Repair Manual Platform Components S-60 XC: S-65 XC: Support the rod end of the platform leveling 11 Remove the pin retaining fasteners from the slave cylinder. Protect the cylinder rod from jib boom and jib boom leveling arms to damage.
Page 50 Service and Repair Manual April 2021 Platform Components How to Bleed the Platform Open the bottom bleed screw on the rotator, but do not remove it. Rotator Bodily injury hazard. Spraying Note: This procedure will require two people. Do hydraulic oil can penetrate and not start the engine.
Page 51: Platform Overload System
April 2021 Service and Repair Manual Platform Components 2-3 Platform Overload System Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode. Platform Overload System Press the settings button above the display Proper calibration of the platform overload system and select the Calibrations menu.
Page 52: How To Perform A Full Load Platform Calibration
Service and Repair Manual April 2021 Platform Components How to Perform a Full Load How to Perform a Full Load Platform Calibration 10 Place a test weight on the platform floor using a suitable lifting device. Place the weight near Platform Calibration the center entry point of the platform, as far away from the operator controls as possible.
Page 53: How To Replace The Platform Overload Load Cell
April 2021 Service and Repair Manual Platform Components 11 Follow the prompts to accept the weight. How to Replace the Load Cell How to Replace the Platform Overload Load Cell Sensor 12 Calibration is now complete. 13 Exit Service Mode. Note: The preload adjustment should only be performed after the load cell sensor has been 14 Push in the red Emergency Stop button to the...
Page 54: Platform
Service and Repair Manual April 2021 Platform Components 2-4 Platform 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 of the bottom of the sensor. The foot should How to Remove the Platform not contact the flex plate when assembling onto the platform support.
Page 55: Jib Boom Components
April 2021 Service and Repair Manual Jib Boom Components Jib Boom Components 3-1 Jib Boom 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 56: Jib Boom Lift Cylinder
Service and Repair Manual April 2021 Jib Boom Components 3-2 Jib Boom Lift Cylinder 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 57: Boom Components
April 2021 Service and Repair Manual Boom Components Boom Components Boom components 1 short link arm to boom pivot pin 2 boom 3 boom lift cylinder rod-end pivot pin 4 boom lift cylinder 5 long link arm (ground controls side) 6 long link arm (engine side) 7 long link arm to turntable pivot pin 8 master cylinder cam...
Page 58: Boom Components
Service and Repair Manual April 2021 Boom Components Boom Components 4-1 Cable Track Tag, disconnect and plug the platform leveling Cable Track slave cylinder hydraulic hoses from the 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 59: How To Remove The Cable Track, S-65 Xc And S-65 Xc Trax
April 2021 Service and Repair Manual Boom Components How to Remove the Cable Track - How to Remove the Cable Track, S-65 XC and S-65 XC TRAX 14 Place blocks in between the upper and lower cable tracks and secure the upper and lower S-65 XC and S-65 TraX tracks together.
Page 60 Service and Repair Manual April 2021 Boom Components Tag, disconnect and plug the hydraulic hoses 17 Remove the cable track pull tube guide from the "V1" and "V2" ports of the jib fasteners from the cable track guide at the boom/platform rotate manifold.
Page 61: How To Repair The Cable Track
April 2021 Service and Repair Manual Boom Components How to Repair the Cable Track How to Repair the Cable Track 4-2 Boom Assembly Boom Assembly Component damage hazard. The boom cable track can be How to Remove the Boom damaged if it is twisted. Tip-over hazard.
Page 62 Service and Repair Manual April 2021 Boom Components Remove the jib boom. Refer to Repair Locate and remove the counterweight retaining fastener at the center of the Procedure, How to Remove the Jib Boom. counterweight. Carefully lift the counterweight Remove the cable track. Refer to Repair upwards and remove the counterweight from Procedure, How to Remove the Cable Track.
Page 63 April 2021 Service and Repair Manual Boom Components 16 Attach lifting straps from a 5 ton / 5000 kg 24 Tag and disconnect all boom wire harness overhead crane to each end of the boom. electrical connectors located at the pivot end Support the boom.
Page 64: Boom Lift Cylinder
Service and Repair Manual April 2021 Boom Components 4-3 Boom Lift Cylinder Using auxiliary power, activate the boom down function so the cylinder will retract. Boom Lift Cylinder Retract the cylinder just enough until the rod end of the cylinder will clear the mounting The boom lift cylinder raises and lowers the boom.
Page 65: Boom Extension Cylinder
April 2021 Service and Repair Manual Boom Components 4-4 Boom Extension Cylinder Remove the pulley retaining plate from the string potentiometer pulley bracket. Carefully Boom Extension Cylinder remove the string potentiometer cable and limit switch assembly from the boom. The boom extension cylinder is located inside the boom assembly and incorporates cables and Remove the access covers from both sides of pulleys that are responsible for extending the...
Page 66 Service and Repair Manual April 2021 Boom Components 11 Remove the fasteners from the retaining 17 Remove the lower extend cable bracket blocks from the extension cylinder saddle. mounting fasteners and pull back on the Remove the blocks. bracket to release it from the number 3 boom tube.
Page 67: Boom Extend/Retract Cables
April 2021 Service and Repair Manual Boom Components 4-5 Boom Extend/Retract Cables 24 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside Boom Extend/Retract Cables the number 2 boom tube. 25 Carefully support and slide the extension How to Adjust the Boom cylinder out of the boom.
Page 68 Service and Repair Manual April 2021 Boom Components Adjust the extend cable adjustment nuts until 12 Visually inspect the cable break limit switch approximately 1.5 inches / 4 cm of threads arm to be sure the wheel of the limit switch are visible past the nylock nut.
Page 69 April 2021 Service and Repair Manual Boom Components How to Replace the Boom Boom retract cables: Extend/Retract Cables 10 Remove the cotter pins and clevis pins from the boom retract cables at the platform end of Note: The cable pulleys must also be replaced the boom.
Page 70: Platform Leveling Master Cylinder
Service and Repair Manual April 2021 Boom Components 4-6 Platform Leveling Master Cylinder 18 At the pivot end of the boom, carefully pull the rope with the new retract cable attached. Platform Leveling Master Cylinder 19 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube.
Page 71: Primary Boom Angle Sensor Calibration
April 2021 Service and Repair Manual Boom Components 4-7 Primary Boom Angle Sensor Calibration Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm block of wood across the turntable covers. Primary Boom Angle Sensor Position the block under the master cylinder.
Page 72: Primary Boom Angle Sensor Replacement
Service and Repair Manual April 2021 Boom Components 4-8 Primary Boom Angle Sensor Replacement Press OK on the display to continue with the procedure to capture the maximum angle How to Replace the Primary point. Boom Angle Sensor Operate the boom up function until the boom reaches its maximum angle.
Page 73 April 2021 Service and Repair Manual Boom Components Cut and discard the two zip ties securing the 10 Remove the sensor's magnet (3) from the pin- angle sensor harness to the sensor retainer guide mount by removing the two screws (4) bracket.
Page 74: Boom Length Sensor Calibration
Service and Repair Manual April 2021 Boom Components 4-9 Boom Length Sensor Calibration 13 Apply blue thread locker into the sensor carrier plate threaded holes. Attach the Boom Length Sensor provided sensor onto the sensor carrier plate. Used the provided 14 mm screws. Securely How to Calibrate the Primary tighten the fasteners.
Page 75 April 2021 Service and Repair Manual Boom Components Press the OK button to continue to capture the maximum extension point. Press the function enable and boom extend buttons until the boom reaches its maximum extension. Continue holding the buttons for several seconds after the boom reaches its maximum extension until the display indicates the calibration point has been captured.
Page 76: Engines
Service and Repair Manual April 2021 Engines Engines 5-3 Flex Plate - Removal 5-1 RPM Adjustment - Ford and Deutz Models Flex Plate RPM Adjustment - Ford and The flex plate acts as a coupler between the Deutz Models engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the Refer to Maintenance Procedure in the appropriate pump.
Page 77 April 2021 Service and Repair Manual Engines How to Remove the Flex Plate Remove the engine mounting plate to bell housing fasteners. Deutz models: Raise the engine slightly using the overhead Remove the tailpipe bracket mounting crane and place a block of wood under the oil fasteners from the engine bell housing.
Page 78: How To Install A Type "A" Flex Plate
Service and Repair Manual April 2021 Engines How to Install a Type "A" Flex How to Install a Type "A" Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave Plate the appropriate gap between coupler and pump end plate for your engine.
Page 79: How To Install A Type "B" Flex Plate
April 2021 Service and Repair Manual Engines How to Install a Type "B" Flex How to Install a Type "B" Flex Plate Plate Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump. Apply Loctite ®...
Page 80: How To Install The Pump And Bell Housing Assembly
Service and Repair Manual April 2021 Engines How to Install the Pump and Bell How to install the Pump and Bell Housing Assembly Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C" in sequence to 28 ft-lbs / 38 Nm.
Page 81: Engine Fault Codes
April 2021 Service and Repair Manual Engines 5-4 Engine Fault Codes 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 82: Diesel Particle Filter Regeneration - Deutz Td 2.2 L3
Service and Repair Manual April 2021 Engines 5-5 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 Engine The combustion of diesel fuel results in soot, which is separated in the diesel particle filter (DPF).
Page 83: Hydraulic Pump
April 2021 Service and Repair Manual Hydraulic Pump Hydraulic Pump 6-1 Lift/Steer Pump Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pum Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin.
Page 84: Drive Pump
Service and Repair Manual April 2021 Hydraulic Pump 6-2 Drive Pump Locate the two hydraulic tank valves at the hydraulic tank through the access hole Drive Pump underneath the turntable. Close the valves. The drive pump is a bi-directional variable Component damage hazard.
Page 85 April 2021 Service and Repair Manual Hydraulic Pump How to Prime the Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Connect a 0 to 600 psi / 0 to 41 bar pressure Remove the drive pump from the machine.
Page 86 Service and Repair Manual April 2021 Hydraulic Pump Ford models: Close the valve on the LPG tank then disconnect the hose from the tank. Then move the fuel select switch to the LPG position. Perkins 404D-22 models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump.
Page 87 April 2021 Service and Repair Manual This page intentionally left blank. Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 88 Service and Repair Manual April 2021 Manifolds Manifolds 7-1 Function Manifold Components 7-1 Function Manifold Components - from S60XCH-45010 to 45345, S65XCH-45001 to 45345, S65XCM-101 to 302 (from S60XCH-45010 to 45344, S65XCH-45010 to 45344, S65XCM- 101 to 302) The function manifold is located underneath the ground controls side turntable cover. Index Schematic Description...
Page 89 April 2021 Service and Repair Manual Manifolds Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 90 Service and Repair Manual April 2021 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Check valve, 30 psi / 2 bar Platform rotate tank line 20-25 ft-lbs / 27-34 Proportional directional valve, 4 way, Platform level up/down 33-37 ft-lbs / 45-50 3 position Check valve...
Page 91 April 2021 Service and Repair Manual Manifolds Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 92 Service and Repair Manual April 2021 Manifolds 7-1.1 Function Manifold Components 7-1.1 Function Manifold Components - from S60XCH-45345, S65XCH-45345, S65SCM-303, S65XCD-101 (from SN S60XCH-45345, S65XCH-45345, S65XCM-303, S65XCD-101) The function manifold is located underneath the ground controls side turntable cover. Index Schematic Description Function...
Page 93 April 2021 Service and Repair Manual Manifolds Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 94 Service and Repair Manual April 2021 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Check valve, 30 psi / 2 bar Platform level down circuit 20-25 ft-lbs / 27-34 Check valve, 30 psi / 2 bar Platform level up circuit 20-25 ft-lbs / 27-34 Solenoid valve, 2 way poppet Differential sensing, turntable...
Page 95 April 2021 Service and Repair Manual Manifolds Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 96 Service and Repair Manual April 2021 Manifolds 7-2 Valve Adjustments - Function How to Adjust the Boom Extend 7-2 Valve Adjustments - Function Manifold How to Adjust the Boom Extend Relief Valve Manifold Relief Valve Note: Perform this procedure with the boom in the How to Adjust the System Relief stowed position.
Page 97 April 2021 Service and Repair Manual Manifolds 7-3 Jib Boom / Platform Rotate Manifold Components 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...
Page 98 Service and Repair Manual April 2021 Manifolds 7-4 Turntable Rotation Manifold Components 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...
Page 99 April 2021 Service and Repair Manual Manifolds 7-5 Valve Adjustments - Oscillate Relief Valve How to Set Up the Oscillate Directional Valve Valve Adjustments - Oscillate How to Set Up the Oscillate Relief Valve Directional Valve Note: Adjustment of the oscillate directional valve How to Adjust the Oscillate Relief linkage is only necessary when the linkage or valve has been replaced.
Page 100 Service and Repair Manual April 2021 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 101 April 2021 Service and Repair Manual This page intentionally left blank. Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 102 Service and Repair Manual April 2021 Manifolds 7-6 Traction Manifold Components, 4WD 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...
Page 103 April 2021 Service and Repair Manual Manifolds Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 104 Service and Repair Manual April 2021 Manifolds 7-7 Valve Adjustments, 4WD Traction Manifold Hold the charge pressure relief valve and remove the cap (item DI). Valve Adjustments, 4WD Traction Manifold Adjust the internal hex socket until the pressure reading on the gauge is 30 psi / 2 bar less than the pressure reading on the How to Adjust the Charge pump.
Page 105 April 2021 Service and Repair Manual Manifolds 7-9 Generator Manifold Components 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 106 Service and Repair Manual April 2021 Repair Procedures Adjust the valve counter-clockwise to increase Hydraulic Generator the frequency and clockwise to decrease the frequency, until the correct value is reached according to the table below. How to Adjust the Generator Frequency ANSI 12 kW Generator...
Page 107 April 2021 Service and Repair Manual Manifolds 7-10 Valve Coil Resistance 7-10 Valve Coils Valve Coils Specification 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 electromotive force which operates the solenoid...
Page 108 Service and Repair Manual April 2021 Manifolds How to Test a Coil Diode How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes.
Page 109 April 2021 Service and Repair Manual Turntable Rotation Components Loosen the backlash pivot plate and Turntable Rotation Components 8-1 Turntable Rotation Assembly adjustment bolts. Turntable Rotation Assembly 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 110 Service and Repair Manual April 2021 Turntable Rotation Components How to Adjust the Turntable How to Adjust the Turntable Rotation Gear Backlash Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub Rotation Gear Backlash assembly from the machine. The turntable rotation drive hub is mounted on an Crushing hazard.
Page 111 April 2021 Service and Repair Manual Turntable Rotation Components How to Calibrate the Turntable How to Calibrate the Turntable Tilt Sensor Push the backlash pivot plate towards the turntable as far as possible (this will push the Tilt Sensor rotation gear into the turntable bearing ring gear).
Page 112 Service and Repair Manual April 2021 Turntable Rotation Components A graphic of the machine pitch will now be 13 A graphic of the machine roll will now be shown on the display. By pressing the UP or shown on the display. By pressing the UP and DOWN buttons, the graphic will change to DOWN buttons, the graphic will change to show the counterweight being uphill or...
Page 113 April 2021 Service and Repair Manual Axle Components Axle Components 9-1 Oscillating Axle Cylinders 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 The oscillate system is designed so that all four barrel-end pivot pin.
Page 114 Service and Repair Manual April 2021 Track Components How to Replace a Track Track Components How to Replace a Track 10-1 10-1 Track Assembly, S-60 TRAX and S-65 TRAX Assembly Track Assembly, S-60 TraX and S-65 TraX Note: Perform this procedure on firm, level surface with the boom in the stowed position.
Page 115 April 2021 Service and Repair Manual Track Components Install the new track onto the undercarriage. Rotate the sprocket half until the split tooth of the sprocket is lower than the other side. Attach a lifting strap from an overhead crane to the center-point of the track, above the sprocket.
Page 116 Service and Repair Manual April 2021 Track Components 14 Using the pry bars, lift the sprocket half into 19 Pump grease into the grease zerk fitting until position. Install the 2 sprocket retaining grease, free from air, comes out of the grease fasteners and torque to specification.
Page 117 April 2021 Service and Repair Manual Track Components 21 Continue to pump grease into the cylinder until the track has proper tension. Component damage hazard. Do not over tighten the track. Overtightening the track will cause the machine to lose power during operation.
Page 118 Service and Repair Manual April 2021 Fault Codes Before Troubleshooting: Section 4 Fault Codes Introduction  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 ...
Page 119 April 2021 Service and Repair Manual Control System Fault Codes Control System Fault Codes Control System How to Retrieve Control System Fault Codes 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 120 Service and Repair Manual April 2021 Control System Fault Codes Control System Fault Codes - Models with Revision G Software or Lower Models with Revision G Software or Lower Component ID Name Cause Effect Solution Keyswitch 19 Fault Signals Machine will not Verify with a voltmeter that signals switch C134PLT be functional.
Page 121 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Foot switch Machine will not * Release foot switch and cycle power. Foot Switch 19 Stuck ON at power input was be functional. * If problem persists, with a voltmeter up, or detected as verify that C24FS (WH, PCON J12-2) is...
Page 122 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Primary 12 Joystick Circuit Boom Up and * Leave joystick in neutral position and Boom Up / voltage too C164PUD is Down functions cycle power. Down high.
Page 123 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Boom Up, * Verify sensor power P85PWR (GR, Boom Angle 13 No signal No CAN Sensor messages have Extend and TCON J6-7) is at 12 V while the system is been received by Turntable running.
Page 124 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y26. Boom shorted to that C7PBE Extend and Proper resistance should be between 5 - Extend Valve circuit is shorted Retract...
Page 125 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Turntable 12 Joystick Circuit C165TTR Turntable * Leave joystick in neutral position and Rotate voltage too is above 4.5 V. Rotate cycle power. Joystick high.
Page 126 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y70. Rotate CW shorted to that V17PRL Rotate CW Proper resistance should be between 5 - Valve circuit is shorted function will...
Page 127 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Brake 12 Circuit TCON detected Machine will * With a voltmeter, measure Y2. Proper Release shorted to that C32BRK not be resistance should be between 5 - Valve circuit is shorted functional.
Page 128 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Mistmatched ESTOP 15 ESTOP ESTOP * Inspect PCON J15 pins 11 and 12 for Circuit Return signals detected circuit cannot open or short circuits. Using a voltmeter, circuit on ESTOP complete,...
Page 129 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Boom Up Contact 36 Switch PCON detected * Using a voltmeter, verify that the voltage on C248CA (OR/BK, PCON J12-1) is always the Alarm state that inputs from and Extend...
Page 130 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution 17 Invalid The platform load * Run the platform overload calibration process and verify fault is no longer active. calibration sensor has no valid calibration data, either because the sensor was...
Page 131 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution All functions Platform 21 Internal The secondary * Cycle power and verify condition clears itself. Overload check platform overload will not * If problem persists, run the platform overload Detection check detected operate...
Page 132 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Turntable 13 Not The DISCON has Machine will * Verify TCON is receiving power. Check for 12 V on J5-2 (+) and J5-1 (-). Controller detected not detected the...
Page 133 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution Function 12 Circuit TCON detected Only * With a voltmeter, measure Y74. Enable Valve shorted to that C155PCE Auxiliary Proper resistance should be between 5 - circuit is shorted Power is 60 ohms.
Page 134 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution Engine Oil 21 Value too The engine oil Engine may * Stop engine as soon as possible. Pressure pressure is not attempt * Verify the engine oil level. measured as too to start until * Verify the engine oil pump.
Page 135 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 Steer Left 12 Circuit TCON detected Steer Left * With a voltmeter, measure Y3. Proper Valve shorted to that C37STL function will resistance should be between 5 - circuit is shorted not operate.
Page 136 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution 178 Engine 21 Fault The engine has Machine will * Check the engine fault codes with an Warning triggered the function as engine diagnostic tool. Lamp Engine Warning normal.
Page 137 April 2021 Service and Repair Manual Control System Fault Codes Control System Fault Codes - Models with Revision H Software or Higher Models with Revision H software or higher ID Component ID Name Cause Effect Solution Engine Can 13 Not Engine CANBUS Disable engine start *Verify with a voltmeter that CAN+...
Page 138 Service and Repair Manual April 2021 Control System Fault Codes ID Component ID Name Cause Effect Solution 12 Machine 13 Not Machine CANBUS Machine will not be *Verify with a voltmeter that CAN+ CAN Bus detected CAN+ or CAN- functional. and CAN- lines are not shorted.
Page 139 April 2021 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 20 Pri Boom 11 Shorted Circuit C163PER is Boom Extend and * Leave joystick in neutral position Ext / Ret above 4.5 V. Retract functions will and cycle power.
Page 140 Service and Repair Manual April 2021 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, TCON J6-7) is at 12 V while the system is Angle detected have been...
Page 141 April 2021 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 142 Service and Repair Manual April 2021 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 143 April 2021 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 144 Service and Repair Manual April 2021 Control System Fault Codes ID Component ID Name Cause Effect Solution 52 Drive 11 Shorted TCON detected Drive Forward, Brake * With a voltmeter, measure Y6. Forward that C30FWD Release and possibly Proper resistance should be between Pump Coil supply circuit is shorted to...
Page 145 April 2021 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 Joystick C159STA is above functions will not and cycle power.
Page 146 Service and Repair Manual April 2021 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 147 April 2021 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 operate C26TSR ( WH/RD, TCON J6P8) is sensor is shorted not shorted to ground and voltage is to ground...
Page 148 Service and Repair Manual April 2021 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 platform will not Check for 12 V on J15-2 (+) and J15- (PCON) PCON primary...
Page 149 April 2021 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 150 Service and Repair Manual April 2021 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 Only Auxiliary Power * With a voltmeter, measure Y74.
Page 151 April 2021 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 and Turntable Rotate TCON J6-7) is at 12 V while the Length received by the...
Page 152 Service and Repair Manual April 2021 Control System Fault Codes Component ID Name Cause Effect Solution 100 Platform 11 Shorted PCON detected Platform Level Up * With a voltmeter, measure Y20. Proper resistance should be between 5 - Level Up Coil to supply that V14PLU circuit and possibly Level...
Page 153 April 2021 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 LF Steer (L 11 Shorted TCON detected Steer Left function * With a voltmeter, measure Y3. or R) Coil that C37STL circuit will not operate. Proper resistance should be between supply is shorted to 12 V...
Page 154 Service and Repair Manual April 2021 Engine Fault Codes 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 155 April 2021 Service and Repair Manual Deutz TD 2.2 L3 Engine Fault Codes Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1077 411 Engine exhaust gas recirculation. SPN = Suspect Parameter Number Signal value above maximum limit.
Page 156 Service and Repair Manual April 2021 Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1134 3251 3 DPF voltage above normal or SPN = Suspect Parameter Number shorted to high.
Page 157 April 2021 Service and Repair Manual Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1209 157 Engine fuel injector metering rail SPN = Suspect Parameter Number pressure voltage below normal or shorted to low.
Page 158 Service and Repair Manual April 2021 Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1308 677 Engine starter motor relay current SPN = Suspect Parameter Number below normal or shorted to low. DTC SPN FMI Description 1310 677...
Page 159 April 2021 Service and Repair Manual Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1392 51 Engine throttle valve 1, position SPN = Suspect Parameter Number 1 voltage below normal or shorted to low.
Page 160 Service and Repair Manual April 2021 Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 3349 Timeout Error of CAN receive SPN = Suspect Parameter Number frame TSC1TR; control signal. DTC SPN Description 1485...
Page 161 April 2021 Service and Repair Manual Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier Ambient air temperature sensor SPN = Suspect Parameter Number voltage above normal or shorted to high.
Page 162 Service and Repair Manual April 2021 Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 5363 5 Engine cylinder 6 fuel injection SPN = Suspect Parameter Number quantity current below normal or open circuit.
Page 163 April 2021 Service and Repair Manual Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 4257 14 Engine fuel 1 injector, group SPN = Suspect Parameter Number 3 missing injector adjustment value programming injector 3.
Page 164 Service and Repair Manual April 2021 Deutz TD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier Actual engine percent torque. SPN = Suspect Parameter Number DFC to report the fault in energizing time comparison.
Page 165 April 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1231 Actuator error EGR-Valve; KWP = Keyword Protocol Power stage over temp due to high current SPN FMI...
Page 166 Service and Repair Manual April 2021 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 167 April 2021 Service and Repair Manual 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 168 Service and Repair Manual April 2021 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 169 April 2021 Service and Repair Manual 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 KWP = Keyword Protocol exhaust gas mass flow; plausibility error SPN FMI Description...
Page 170 Service and Repair Manual April 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of CAN-Receive- KWP = Keyword Protocol Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of CAN-Receive-...
Page 171 April 2021 Service and Repair Manual 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 172 Service and Repair Manual April 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI SPN Description FMI = Failure Mode Identifier 523788 Timeout Error of CAN-Transmit- KWP = Keyword Protocol Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of CAN-Receive- Frame UAA10;...
Page 173 April 2021 Service and Repair Manual 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 exceeded FMI KWP Description 523947...
Page 174 Service and Repair Manual April 2021 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 175 April 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of CAN-Transmit- KWP = Keyword Protocol Frame A1DOC KWP Description 524115 9 1660 Timeout error of CAN-Transmit- Frame AT1S...
Page 176 Service and Repair Manual April 2021 Perkins 404-22 Engine Fault Codes Perkins 404-22 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Engine Speed Sensor #2: Voltage Description Above Normal Accelerator Pedal Position 2: Voltage Engine Speed Sensor #2: Voltage Above Normal Below Normal...
Page 177 April 2021 Service and Repair Manual Perkins 404-22 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 178 Service and Repair Manual April 2021 Ford MSG-425 Engine Fault Codes Ford MSG-425 Engine Fault Codes Code Description Code Description TIP Low Voltage Never crank synced at start TIP High Voltage FP low voltage Injector Loop Open or Low-side short to FP high voltage Ground MAP Low Voltage...
Page 179 April 2021 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description Emissions/catalyst damaging misfire 5VE1 low voltage Emissions/catalyst damaging misfire 5VE1 high voltage Emissions/catalyst damaging misfire MIL open Emissions/catalyst damaging misfire 5VE2 low voltage Emissions/catalyst damaging misfire 5VE2 high voltage Emissions/catalyst damaging misfire Relay Coil Open...
Page 180 Service and Repair Manual April 2021 Ford MSG-425 Engine Fault Codes Code Description Code Description 1173 Megajector comm lost 1551 AUX DIG1 high 1174 Megajector voltage supply high 1552 AUX DIG1 low 1175 Megajector voltage supply low 1553 AUX DIG2 high 1176 Megajector internal actuator fault detection 1554...
Page 181 April 2021 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description 1629 J1939 TSC1 message receipt lost 2130 IVS stuck at-idle, FPP1/2 match 1630 J1939 ETC message receipt lost 2131 IVS stuck off-idle, FPP1/2 match 1631 PWM1-Gauge1 open / ground short 2135 TPS1/2 simultaneous voltages out of range...
Page 182 Service and Repair Manual April 2021 Ford MSG-425 Engine Fault Codes Code Description 2309 Primary Loop Open or Low-side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low-side Short to Ground 2313 Primary Coil Shorted Primary Loop Open or Low-side Short to 2315 Ground 2316...
Page 183 April 2021 Service and Repair Manual Schematics About This Section Section 5 Schematics Introduction 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 184 Service and Repair Manual April 2021 Electrical Symbol Legend 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...
Page 185 April 2021 Service and Repair Manual Hydraulic Symbols Legend Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor)
Page 186 Service and Repair Manual April 2021 Limit Switch Location Legend Limit Switch Location Legend 1 S24 5 Rotary Sensor 2 LSB1RS 6 LST3S 3 LSB2S 7 LST1O 4 String Potentiometer 8 UTS Limit Switches and Sensors Platform overload sensor LSB1RS Limit switch boom fully retracted- safety LSB2S Limit switch cable tension- safety...
Page 187 April 2021 Service and Repair Manual Electrical Schematics Electrical Schematic, Turntable Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101)
Page 188 Service and Repair Manual April 2021 Electrical Schematic, Turntable Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101) Electrical Schematic, Turntable Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101) ® -60/65 XC ™ • S ® -60/65 HF • S ®...
Page 189 April 2021 Service and Repair Manual Electrical Schematic, Platform Controls Electrical Schematic, Platform Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101) (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101) Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF •...
Page 190 Service and Repair Manual April 2021 Electrical Schematic, Platform Controls (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101)
Page 191 April 2021 Service and Repair Manual Electrical Schematic, Turntable Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101)
Page 192 Service and Repair Manual April 2021 Electrical Schematic, Turntable Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101) Electrical Schematic- Turntable Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101) ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 193 April 2021 Service and Repair Manual Electrical Schematic, Platform Controls Electrical Schematic, Platform Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101) (from S60XCH-45354, S65XCH-45354, S65XCD-101) Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 194 Service and Repair Manual April 2021 Electrical Schematic, Platform Controls (from S60XCH-45354, S65XCH-45354, S65XCD-101)
Page 195 April 2021 Service and Repair Manual Electrical Schematic, Deutz TD 2.2 L3 Models...
Page 196 Service and Repair Manual April 2021 Electrical Schematic, Deutz TD 2.2 L3 Models Electrical Schematic, Deutz TD 2.2 L3 Models ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 197 April 2021 Service and Repair Manual Electrical Schematic, Deutz TD 2.2 L3 Engine Harness Electrical Schematic, Deutz TD 2.2 L3 Engine Harness Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 198 Service and Repair Manual April 2021 Electrical Schematic, Deutz TD 2.2 L3 Engine Harness...
Page 199 April 2021 Service and Repair Manual Electrical Schematic, Deutz D 2.9 L4 Models...
Page 200 Service and Repair Manual April 2021 Electrical Schematic, Deutz D 2.9 L4 Models Electrical Schematic, Deutz D 2.9 L4 Models ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 201 April 2021 Service and Repair Manual Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Models Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Models Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 202 Service and Repair Manual April 2021 Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Models...
Page 203 April 2021 Service and Repair Manual Electrical Schematic, Perkins 404F-E22T Models...
Page 204 Service and Repair Manual April 2021 Electrical Schematic, Perkins 404F-E22T Models Electrical Schematic, Perkins 404F-E22T Models ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 205 April 2021 Service and Repair Manual Electrical Schematic, Perkins 404D-22 Models Electrical Schematic, Perkins 404D-22 Models Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 206 Service and Repair Manual April 2021 Electrical Schematic, Perkins 404D-22 Models...
Page 207 April 2021 Service and Repair Manual Electrical Schematic, Ford MSG-425 EFI Models...
Page 208 Service and Repair Manual April 2021 Electrical Schematic, Ford MSG-425 EFI Models Electrical Schematic, Ford MSG-425 EFI Models ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 209 April 2021 Service and Repair Manual Electrical Schematic, Generators Electrical Schematic, Generators Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 210 Service and Repair Manual April 2021 Electrical Schematic, Generators...
Page 211 April 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic, (from S65XCM-101 to S65XCM-302)
Page 212 Service and Repair Manual April 2021 Hydraulic Schematic, (from S65XCM-101 to S65XCM-302) Hydraulic Schematic, (from S65XCM-101 to S65XCM-302) ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™ Part No. 1288652GT...
Page 213 April 2021 Service and Repair Manual Hydraulic Schematic, Hydraulic Schematic, (from S60XCH-45010 to 45344, S65XCH-45001 to 45344) (from S60XCH-45010 to 45344, S65XCH-45001 to 45344, S65XCM-303) Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 214 Service and Repair Manual April 2021 Hydraulic Schematic, (from S60XCH-45010 to S60XCH-45344, S65XCH-45001 to S65XCH-45344, S65XCM-303)
Page 215 April 2021 Service and Repair Manual Hydraulic Schematic, Hydraulic Schematic, (from S60XCH-45345, S65XCH-45345, S65XCD-101) (from S60XCH-45345, S65XCH-45345, S65XCD-101) Part No. 1288652GT ® -60/65 XC ™ • S ® -60/65 HF • S ® -60/65 TraX ™...
Page 216 Service and Repair Manual April 2021 Hydraulic Schematic, (from S60XCH-45345, S65XCH-45345, S65XCD-101) S®-60/65 XC™ • S®-60/65 HF • S®-60/65 TraX™ Part No. 1288652GT Service and Repair Manual April 2021...

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Genie s-60 hf Genie s-60 trax Genie s-65-xc Genie s-65 hf Genie s-65 trax

Terex Genie S-60 XC Service And Repair Manual

Introduction

Safety Rules

Specifications

Repair Procedures

Control System

Platform Components

Jib Boom Components

Boom Components

Boom Components

Engines

Hydraulic Pump

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