Terex Genie S-80 J Service And Repair Manual
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Terex Genie S-80 J Service And Repair Manual

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Service and Repair Manual
S
-80 J
®
S
-80 J TraX
®
Serial Number Range
from S80JH-101
from S80JD-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. 1285307GT
Rev A
June 2021

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Summary of Contents for Terex Genie S-80 J

  • Page 1 Service and Repair Manual Serial Number Range -80 J ® from S80JH-101 This manual includes: from S80JD-101 Repair procedures -80 J TraX ® ™ Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No.

  • Page 2: Find A Manual For This Model

    Copyright © 2021 by Terex Corporation 1285307GT Rev A, June 2021 First Edition, First Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -80 J, S ®...

  • Page 3: Revision History

    June 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 05/2021 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 June 2021 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) ® -80 J, S ® -80 J TraX ™ Part No. 1285307GT...

  • Page 5: Safety Rules

    June 2021 Service and Repair Manual 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 performed.
  • Page 6 Service and Repair Manual June 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

    June 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 June 2021 Table of Contents Section 3 Repair Procedures ..................... 12 Introduction ......................12 Control System....................14 1-1 ALC-600 Platform Control Module ..............14 1-2 ALC-600 Service Mode .................. 14 1-3 Full Machine Calibration ................15 1-4 Machine Functions ..................16 How to Adjust the Machine Maximum Speed Setting........
  • Page 9 June 2021 Table of Contents Jib Boom Components ..................34 3-1 Jib Boom ......................34 3-2 Jib Boom Lift Cylinder ..................35 Boom Components .................... 36 Boom Components ..................36 Boom Components .................... 37 4-1 Cable Track ....................37 How to Remove the Cable Track ..............37 How to Repair the Cable Track ...............
  • Page 10 June 2021 Table of Contents Manifolds ......................56 7-1 Function Manifold Components ..............56 7-2 Valve Adjustments - Function Manifold ............60 How to Adjust the Boom Extend Relief Valve ..........60 7-3 Platform Function Manifold Components ............61 7-4 Turntable Rotation Manifold Components ............. 62 7-5 Valve Adjustments - Oscillate Relief Valve ............
  • Page 11 June 2021 Table of Contents Section 4 Fault Codes ......................82 Introduction ......................82 Control System Fault Codes ................83 How to Retrieve Control System Fault Codes ..........83 Control System Fault Codes ................84 Engine Fault Codes ..................101 Kubota D1803-CR-TIE4 Engine Fault Codes ..........
  • Page 12 June 2021 Table of Contents Section 5 Schematics ....................... 105 Introduction ......................105 Important Information ..................105 Electrical Symbol Legend .................. 106 Hydraulic Symbols Legend ................107 Limit Switch Location Legend ................108 Electrical Schematics – Options ..............109 Electrical Schematic, Generator Options ............110 Electrical Schematic, Positive Air Shutdown .............

  • Page 13: Specifications

    June 2021 Service and Repair Manual Specifications Performance Specifications Section 2 Specifications Machine Specifications Boom function speeds, maximum from platform Tires and Wheels controls Tire size (Rough terrain) 355/55D625 Jib boom up 30 to 35 seconds Tire weight (foam filled) 426 lbs Jib boom down 30 to 35 seconds...

  • Page 14: Hydraulic Oil Specifications

    Service and Repair Manual June 2021 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 June 2021 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 June 2021 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

    June 2021 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 29.7 gpm 112,4 L/min...

  • Page 18: Kubota D1803-Cr-Tie4 Engine Specifications

    Service and Repair Manual June 2021 Specifications Kubota D1803-CR-TIE4, D1803- Fuel injection system CR-TE5B Engines Injection pump make Bosch MD Injection pump pressure, maximum Displacement 111.4 cu in Low idle 3700 - 4300 psi 1,825 liters 255 - 296 bar Number of cylinders High idle 14500 - 15900 psi...

  • Page 19: Deutz D2011 L03I Engine Specifications

    June 2021 Service and Repair Manual Specifications Deutz D2011 L03i Engine 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 3.7 x 4.4 inches 210 bar...

  • Page 20: Machine Torque Specifications

    Service and Repair Manual June 2021 Specifications Machine Torque Specifications Machine Component Weights Note: All torque values are shown lubricated Lift structure 5300 lbs unless 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 21: Hydraulic Hose And Fitting Torque Specifications

    June 2021 Service and Repair Manual 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 22: Torque Procedure

    Service and Repair Manual June 2021 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 Replace the O-ring.
  • Page 23 June 2021 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 24: Repair Procedures

    Service and Repair Manual June 2021 Repair Procedures Machine Configuration: Section 3 Repair Procedures  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 25: About This Section

    June 2021 Service and Repair Manual 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 26: Control System

    Service and Repair Manual June 2021 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 27: Service Mode

    June 2021 Service and Repair Manual Control System 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 28: Machine Functions

    Service and Repair Manual June 2021 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 function times listed in Refer to Specifications, How to Adjust the Joystick How to Adjust the Machine Maximum Speed Setting Performance Specifications.

  • Page 29: How To Adjust The Joystick Ramp Rate Setting

    June 2021 Service and Repair Manual 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 30: How To Adjust The Joystick Threshold Setting

    Service and Repair Manual June 2021 Control System How to Adjust the Joystick How to Adjust the Joystick Threshold Setting 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 31: Display Module Menus

    June 2021 Service and Repair Manual 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-80 / S- Select Model Configuration...
  • Page 32 Service and Repair Manual June 2021 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 33 June 2021 Service and Repair Manual 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 34 Service and Repair Manual June 2021 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 35: How To Replace The Display Controller (Discon) Module

    June 2021 Service and Repair Manual 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 36: How To Replace The Ground Control Overlay

    Service and Repair Manual June 2021 Control System Unscrew the nut holding the buttons and key switch and remove the key switch and How to Replace the Ground Box buttons. Control Overlay Note the orientation of the key switch so it can be reassembled in the same position.
  • Page 37 June 2021 Service and Repair Manual 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 38: Platform Components

    Service and Repair Manual June 2021 Platform Components 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 39: Platform Rotator

    June 2021 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the manifold. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying hydraulic oil can penetrate and helical gear assembly used to rotate the platform 160 degrees.

  • Page 40: Platform Overload System

    Service and Repair Manual June 2021 Platform Components How to Bleed the Platform Rotator Platform Overload System From the ground controls, fully rotate the Proper calibration of the platform overload system platform to the right and then the left. is essential to safe machine operation. Continued Continue holding platform rotate in each use of an improperly calibrated platform overload direction for approximately 10 seconds.

  • Page 41: How To Perform A Full Load Platform Calibration

    June 2021 Service and Repair Manual Platform Components How to Perform a Full Load How to Perform a Full Load Platform Calibration Platform Calibration Perform this procedure if the platform support or load cell sensor has been replaced, or if a zero load platform calibration does not return the machine to full load capacity.
  • Page 42 Service and Repair Manual June 2021 Platform Components Enter Service Mode. Refer to Repair 10 Place a test weight on the platform floor using Procedure, How to Enter the Service Mode. a suitable lifting device. Place the weight near the center entry point of the platform, as far Press the settings button above the display away from the operator controls as possible.

  • Page 43: How To Replace The Platform Overload Load Cell

    June 2021 Service and Repair Manual Platform Components How to Replace the Load Cell How to Replace the Platform Overload Load Cell 11 Follow the prompts to accept the weight. Sensor 12 Calibration is now complete. Note: The preload adjustment should only be 13 Exit Service Mode.

  • Page 44: Platform

    Service and Repair Manual June 2021 Platform Components Platform How to Remove the Platform Remove the cable clamp from the top of the platform mounting weldment. Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side.

  • Page 45: Platform Function Manifold

    June 2021 Service and Repair Manual Platform Components Press and hold the jib boom up button until cylinder is at the end of the stroke and hold Platform Function Manifold the up button for an additional 5 seconds after the jib boom reaches full stroke. How to bleed the Platform Press and hold the jib boom down button until Function Manifold...

  • Page 46: Jib Boom Components

    Service and Repair Manual June 2021 Jib Boom Components Attach a lifting strap from an overhead supporting device 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

    June 2021 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 June 2021 Boom Components Boom Components 1 primary boom 2 mid pivot 3 sliding counterweight 4 lift cylinder 5 lower riser arm 6 upper riser arm 7 lower riser arm to turntable pivot pin 8 upper riser arm to turntable pivot pin ®...

  • Page 49: Boom Components

    June 2021 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 June 2021 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

    June 2021 Service and Repair Manual Boom Components How to Repair the Cable Track 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 June 2021 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

    June 2021 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 June 2021 Boom Components Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on Primary Boom Extension the 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

    June 2021 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 Service and Repair Manual June 2021 Boom Components Remove the retaining fastener securing the Using an overhead supporting device, support barrel end pivot pin. the master cylinder. Remove the retaining fastener securing the rod end pivot pin. Using a soft metal drift, remove the pivot pin. Crushing hazard.

  • Page 57: Primary Boom Angle Sensor

    June 2021 Service and Repair Manual Boom Components How to Replace the Primary How to Repalce the Primary Boom Angle Sensor Primary Boom Angle Sensor Boom Angle Sensor Push in the red Emergency Stop button to the The primary boom angle sensor is used to limit the off position at both the ground and platform angle of the primary boom relative to the angle of controls and turn the key switch to the off...

  • Page 58: Boom Extend/Retract Cables

    Service and Repair Manual June 2021 Boom Components Extend the boom until there is approximately 3 feet / 1 m of travel left. Do not fully extend Boom Extend and Retract Cables the boom. Locate the retract cable adjustment nut on the How to Adjust the Boom bottom of the number 1 boom tube at the Extend/Retract Cables...
  • Page 59 June 2021 Service and Repair Manual Boom Components 12 Visually inspect the cable break limit switch arm to verify the wheel of the limit switch arm is centered in the notch of the pivot plate. Note: If the boom extend cables are adjusted evenly, the wheel of the limit switch arm will be centered in the notch of the pivot plate.

  • Page 60: Engines

    Service and Repair Manual June 2021 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 Refer to Maintenance Procedure in the appropriate flywheel and has a splined center to drive the Service or Maintenance Manual for your machine, pump.

  • Page 61: How To Install The Flex Plate

    June 2021 Service and Repair Manual Engines How to Install the Flex 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 62: How To Install The Pump And Bell Housing Assembly

    Service and Repair Manual June 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. Apply Loctite ® removable threadlocker to the bell housing mounting fasteners. Torque the bell housing mounting fasteners in sequence.

  • Page 63: Engine Fault Codes - Kubota D1803 Models

    June 2021 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 64: Hydraulic Pump

    Service and Repair Manual June 2021 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 65: How To Install The Drive Pump Coupler

    June 2021 Service and Repair Manual Hydraulic Pump How to Install the Drive Pump How to Install the Drive Pump Coupler Coupler How to Prime the Drive and Function Pumps Install the coupler onto the pump shaft with the set screw towards the pump. Leave a Fill the tank with hydraulic oil until the fluid 1/32 inch / 0.8 mm gap between the coupler level is in the center of the sight glass at the...

  • Page 66: Generator Pump

    Service and Repair Manual June 2021 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 67 June 2021 Service and Repair Manual This page intentionally left blank. Part No. 1285307GT ® -80 J, S ® -80 J TraX ™...

  • Page 68: Manifolds

    Service and Repair Manual June 2021 Manifolds Function Manifold Components Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Turntable rotate left/right 15-20 ft-lbs 20-27 Nm Check valve Platform level down circuit 25-30 ft-lbs 34-41 Nm Solenoid Valve, 2 position 3 way Primary boom down 25-30 ft-lbs 34-41 Nm...
  • Page 69 June 2021 Service and Repair Manual Manifolds Part No. 1285307GT ® -80 J, S ® -80 J TraX ™...
  • Page 70 Service and Repair Manual June 2021 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Relief valve, 3200 psi / 221 bar System relief 25-30 ft-lbs 34-41 Nm Relief valve, 3000 psi / 207 bar Platform level relief valve 20-25 ft-lbs pressure 27-34 Nm...
  • Page 71 June 2021 Service and Repair Manual Manifolds Part No. 1285307GT ® -80 J, S ® -80 J TraX ™...

  • Page 72: Valve Adjustments - Function Manifold

    Service and Repair Manual June 2021 Manifolds How to Adjust the Boom Extend How to Adjust the Boom Extend Relief Valve Valve Adjustments - Function Relief Valve Manifold Note: Perform this procedure with the boom in the stowed position. How to Adjust the System Relief Note: Refer to Function Manifold Component list to Valve locate the boom extend relief valve.

  • Page 73: Platform Function Manifold Components

    June 2021 Service and Repair Manual Manifolds Platform Function Manifold Components The platform function manifold is mounted at the platform end of the boom. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform rotate left/right 20-25 ft-lbs / 27-34 Nm Solenoid valve, 3 position 4 way Jib boom up/down 20-25 ft-lbs / 27-34 Nm...

  • Page 74: Turntable Rotation Manifold Components

    Service and Repair Manual June 2021 Manifolds 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 75: Valve Adjustments - Oscillate Relief Valve

    June 2021 Service and Repair Manual Manifolds How to Set Up the Oscillate How to Set Up the Oscillate Directional Valve Valve Adjustments - Oscillate Directional Valve Linkage Relief Valve Note: Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced.
  • Page 76 Service and Repair Manual June 2021 Manifolds Adjust the heim joint until the hole lines up with the retaining fastener hole in the axle. Install the heim joint to the axle and tighten the jam nut. Verify the drive chassis is completely level. 10 Measure the distance between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis).

  • Page 77: Traction Manifold Components, 4Wd

    June 2021 Service and Repair Manual 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 78 Service and Repair Manual June 2021 Manifolds ® -80 J, S ® -80 J TraX ™ Part No. 1285307GT...

  • Page 79: Valve Adjustments, 4Wd Traction Manifold

    June 2021 Service and Repair Manual Manifolds Hold the charge pressure relief valve and remove the cap (item DI). Valve Adjustments - 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 80: Brake/Two-Speed Manifold Components

    Service and Repair Manual June 2021 Manifolds Brake / Two Speed Manifold Components The brake / two speed manifold is mounted to the engine tray below the hydraulic pumps. Index Schematic Description Function Torque Item Orifice, 0.025 inch / 0,635 mm Turntable rotation brake release Check valve Brake release circuit...

  • Page 81: Generator Manifold Components

    June 2021 Service and Repair Manual 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 82: Turntable Rotation Manifold Components

    Service and Repair Manual June 2021 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 83: Valve Coils

    June 2021 Service and Repair Manual 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 84: Turntable Rotation Components

    Service and Repair Manual June 2021 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 85: How To Adjust The Turntable Rotation Gear Backlash

    June 2021 Service and Repair Manual Turntable Rotation Components How to Adjust the Turntable How to Adjust the Turntable Rotation Gear Backlash Remove the drive hub mounting bolts. Carefully remove the drive hub assembly from Rotation Gear Backlash the machine. The turntable rotation drive hub is mounted on an Crushing hazard.

  • Page 86: Turntable Angle Sensor Replacement

    Service and Repair Manual June 2021 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 87: How To Calibrate The Turntable Tilt Sensor

    June 2021 Service and Repair Manual Turntable Rotation Components How to Calibrate the Turntable How to Calibrate the Turntable Tilt Sensor A graphic of the machine pitch will now be shown on the display. By pressing the UP or Tilt Sensor DOWN buttons, the graphic will change to show the counterweight being uphill or Note: Perform this procedure on a firm, level...
  • Page 88 Service and Repair Manual June 2021 Turntable Rotation Components 13 A graphic of the machine roll will now be shown on the display. By pressing the UP and DOWN buttons, the graphic will change to show whether the operator is on the uphill or downhill side of the machine..

  • Page 89: Axle Components

    June 2021 Service and Repair Manual 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 The oscillate system is designed so that all four barrel-end pivot pin.

  • Page 90: Track Components

    Service and Repair Manual June 2021 Track Components How to Replace the Track How to Replace the Track 10-1 Track Assembly Remove the track assembly from the machine. Refer to Repair Procedure, How to How to Remove a Track Remove a Track Assembly. Assembly Note: The sprocket is comprised of two halves.
  • Page 91 June 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 supporting device to the center-point of the track, above the sprocket.
  • Page 92 Service and Repair Manual June 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 93 June 2021 Service and Repair Manual Track Components 21 Continue to pump grease into the cylinder until the track has proper tension. NOTICE Component damage hazard. Do not over tighten the track. Over tightening the track will cause the machine to lose power during operation.

  • Page 94: Fault Codes

    Service and Repair Manual June 2021 Fault Codes Before Troubleshooting: Section 4 Fault 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 ...

  • Page 95: Control System Fault Codes

    June 2021 Service and Repair Manual 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 96: Control System Fault Codes

    Service and Repair Manual June 2021 Control System Fault Codes Control System Fault Codes ID Component ID Name Cause Effect Solution Engine Can 13 Not Engine CANBUS Disable engine start *Verify with a voltmeter that CAN+ detected CAN+ or CAN- for tier 4F engines and CAN- lines are not shorted.* shorted to supply.
  • Page 97 June 2021 Service and Repair Manual 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 98 Service and Repair Manual June 2021 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 Up / Down above 4.5 V. functions will not and cycle power.
  • Page 99 June 2021 Service and Repair Manual 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 recovery functions TCON J6-7) is at 12 V while the received by the system is running.
  • Page 100 Service and Repair Manual June 2021 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 101 June 2021 Service and Repair Manual 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 102 Service and Repair Manual June 2021 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 103 June 2021 Service and Repair Manual 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 104 Service and Repair Manual June 2021 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 105 June 2021 Service and Repair Manual 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 106 Service and Repair Manual June 2021 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 107 June 2021 Service and Repair Manual 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 108 Service and Repair Manual June 2021 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 109 June 2021 Service and Repair Manual 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 110 Service and Repair Manual June 2021 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 111 June 2021 Service and Repair Manual 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 112 Service and Repair Manual June 2021 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 113: Engine Fault Codes

    June 2021 Service and Repair Manual 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 114: Kubota D1803-Cr-Tie4 Engine Fault Codes

    Service and Repair Manual June 2021 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 115 June 2021 Service and Repair Manual 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 116 Service and Repair Manual June 2021 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 117: Schematics

    June 2021 Service and Repair Manual Schematics About This Section Section 5 Schematics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, ...

  • Page 118: Electrical Symbol Legend

    Service and Repair Manual June 2021 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 119: Hydraulic Symbols Legend

    June 2021 Service and Repair Manual 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) 3 way...

  • Page 120: Limit Switch Location Legend

    Service and Repair Manual June 2021 Limit Switch Location Legend S-80 J 1 LSB1RO 4 UTS 2 CBLS 5 LSB1DO 3 LST1O 6 PBAS Limit Switches and Sensors LSB1RO Limit switch boom fully retracted - operational CBLS Cable Break Limit Switch LST1O Limit switch drive turntable - operational Universal tilt sensors...

  • Page 121: Electrical Schematics - Options

    June 2021 Service and Repair Manual Electrical Schematic, Generator Options...

  • Page 122: Electrical Schematic, Generator Options

    Service and Repair Manual June 2021 Electrical Schematic, Generator Options 3kW 115V-230V/50Hz GENERATOR AC WIRING 3kW 120V/60Hz GENERATOR AC WIRING ENCLOSURE SINGLE RECEPTACLE J-BOX GENERATOR GENERATOR 15 AMP BLACK BLACK CIRCUIT TO PLATFORM BREAKER RCBO WHITE 25 AMP BLACK BLACK BROWN CIRCUIT 15 AMP...

  • Page 123: Electrical Schematic, Positive Air Shutdown

    June 2021 Service and Repair Manual Electrical Schematic, Positive Air Shutdown Part No. 1285307GT ® -80 J, S ® -80 J TraX ™...
  • Page 124 Service and Repair Manual June 2021 Electrical Schematic, Positive Air Shutdown...

  • Page 125: Electrical Schematics

    June 2021 Service and Repair Manual Electrical Schematic, Turntable Controller...

  • Page 126: Electrical Schematic, Turntable Controller

    Service and Repair Manual June 2021 Electrical Schematic, Turntable Controller C1-1 P20DRV RD P20DRV RD DRV_GND BR C1-4 DRV_GND BR P20LOG RD/WH C1-2 P20LOG RD/WH LOG_GND BR C1-3 LOG_GND BR C2-6 C46HRN WH C2-1 P23PWR RD C2-2 P23RET BK C2-4 D81CAN- GR C2-3 D82CAN+ YL...

  • Page 127: Electrical Schematic, Platform Controller

    June 2021 Service and Repair Manual Electrical Schematic, Platform Controller P20DRV RD C17-1 DRV_GND BR C17-4 P20LOG RD/WH C17-2 LOG_GND BR C17-3 C46HRN WH C12-6 P23PWR RD C12-1 P23RET BK C12-2 D81CAN- GR C12-4 D82CAN+ YL C12-3 SPARE BL/WH C12-5 SPARE WH/BL C12-8 HORN...
  • Page 128 Service and Repair Manual June 2021 Electrical Schematic, Platform Controller...
  • Page 129 June 2021 Service and Repair Manual Electrical Schematic, Kubota D1803...

  • Page 130: Electrical Schematic, Kubota D1803

    Service and Repair Manual June 2021 Electrical Schematic, Kubota D1803 CR46 CR17 KUBOTA 1803 CR1A MAIN RELAY CONTACT BATTERY NEGATIVE MAIN RELAY COIL (-) CAN2-L CR1B CAN2-H START SW INPUT IGNITION SW INPUT HEATER RELAY COIL (+) CBBA CR15A STARTER RELAY COIL (-) NOT USED STARTER RELAY COIL (+) HEATER RELAY COIL (-)

  • Page 131: Electrical Schematic, Deutz D2011

    June 2021 Service and Repair Manual Electrical Schematic, Deutz D2011 ENGINE C41RPM OR/BK C107AF RD C26TSR WH/RD C25PSR WH/BK R21IGN WH/BK GND2 BR ES0609C Part No. 1285307GT ® -80 J, S ® -80 J TraX ™...
  • Page 132 Service and Repair Manual June 2021 Electrical Schematic, Deutz D2011...

  • Page 133: Hydraulic Schematics

    June 2021 Service and Repair Manual Hydraulic Schematic...

  • Page 134: Hydraulic Schematic

    Service and Repair Manual June 2021 Hydraulic Schematic TURNTABLE ROTATE EXTENSION CYLINDER 2.3 gpm / 8,7 L/min LIFT CYLINDER JIB CYLINDER EXT - 4.5 gpm / 17 L/min EXT - 9.6 gpm / 36,3 L/min PLATFORM LEVEL PLATFORM MEDIUM RET - 4.2 gpm / 16 L/min CYLINDERS ROTATE RET - 6.0 gpm / 22,7 L/min...

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