Terex Genie S-60 FE Service And Repair Manual
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Terex Genie S-60 FE Service And Repair Manual

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Service and Repair Manual
S
-60 FE
®
S
-60 DC
®
Serial Number Range
from S60EM-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. 1299608GT
Rev A
July 2021

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  • Page 1 Service and Repair Manual Serial Number Range -60 FE ® This manual includes: from S60EM-101 Repair procedures -60 DC ® Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1299608GT Rev A July 2021...

  • Page 2: Introduction

    Copyright © 2021 by Terex Corporation 1299608GT Rev A, July 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. ® -60 DC • S ®...

  • Page 3: Revision History

    July 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 07/2021 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual July 2021 Introduction Serial Number Legend S60E M - 123 Model: Serial number: S60EM-123 Year of manufacture: Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model 2 Facility code...

  • Page 5: Safety Rules

    July 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 July 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    July 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 July 2021 Table of Contents Section 3 Repair Procedures ..................... 12 Introduction ......................12 Cailbration Process Steps ..................14 Platform Controls ....................15 1-1 Platform Controls ................... 15 How to Adjust the Joystick Threshold Setting ..........15 How to Adjust the Joystick Max-out Setting ........... 17 How to Adjust the Joystick Ramp Rate Setting ..........
  • Page 9 July 2021 Table of Contents Jib Boom Components ..................28 3-1 Jib Boom ......................28 3-2 Jib Boom Lift Cylinder ..................30 Boom Components .................... 31 Boom Legend ....................31 Boom Components .................... 32 4-1 Cable Track ....................32 How to Remove the Cable Track ..............32 How to Repair the Cable Track ...............
  • Page 10 July 2021 Table of Contents Manifolds ......................46 8-1 Function Manifold Components ..............46 8-2 Valve Adjustments - Function Manifold ............50 How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor .............. 50 8-3 Jib Boom / Platform Rotate Manifold Components ........51 8-4 Turntable Rotation Manifold Components .............
  • Page 11 July 2021 Table of Contents Section 4 Fault Codes ......................64 Introduction ......................64 Control System Fault Codes ................64 Fault Codes Ground Controls ................65 How to Retrieve Control System Fault Codes - Platform Controls ...... 66 Control System Fault Codes ................67 Charger Fault Codes ..................
  • Page 12 July 2021 Table of Contents Section 6 Schematics ....................... 129 Introduction ......................129 Electrical Symbol Legend .................. 130 Hydraulic Symbols Legend ................131 Electrical Component and Wire Color Legends ..........132 Kubota Engine Fuse and Relay Module ............137 Limit Switch/Angle Sensor Legend ..............138 Electrical Schematics ..................

  • Page 13: Specifications

    July 2021 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications Batteries Type L16G-AC lead acid Tires and Wheels Rough terrain AGM dry cell Tire size 355/55D625 Group 903-L16 (Rough terrain) Quantity Tire weight, foam-filled 426 lbs (minimum) (Rough terrain) 193 kg Capacity (lead acid) 390 AH...

  • Page 14: Performance Specifications

    Service and Repair Manual July 2021 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed 4.0 mph Genie specifications require hydraulic oils which are 6,44 km/h designed to give maximum protection to hydraulic systems, have the ability to perform over a wide 40 ft / 6.8 sec temperature range, and the viscosity index should 12,2 m / 6,8 sec...
  • Page 15 July 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 July 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 cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...

  • Page 17: Hydraulic Component Specifications

    July 2021 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Function Pump Viscosity index Type 2 section tandem gear pump Kinematic Viscosity cSt @ 149°F / 65°C Displacement per revolution cSt @ 104°F / 40°C (inner pump) cSt @ 0°F / -18°C 1300...

  • Page 18: Manifold Component Specifications

    Service and Repair Manual July 2021 Specifications Manifold Component Specifications Plug torque SAE No. 4 14 ft-lbs / 19 Nm SAE No. 6 23 ft-lbs / 31.2 Nm SAE No. 8 36 ft-lbs / 49 Nm SAE No.10 62 ft-lbs / 84 Nm SAE No.

  • Page 19: Kubota D1105 Engine Specifications

    July 2021 Service and Repair Manual Specifications Kubota D1105 Engine Fuel injection system Injection pump make Bosch MD Displacement 68.53 cu in Injection pump pressure, 1991 psi 1.123 liters maximum 137 bar Number of cylinders Injection timing 18° BTDC Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm...

  • Page 20: Machine Torque Specifications

    Service and Repair Manual July 2021 Specifications Machine Torque Specifications Machine Component Weights Platform Rotator Tire and wheel assembly 426 lbs 193 kg 1-8 center bolt, GR 5 Drive motor and hub 124.5 lbs Lubricated 483 ft-lbs 56.5 kg 655 Nm Engine assembly 552 lbs 1/2 -13 bolts, GR 8...

  • Page 21: Hydraulic Hose And Fitting Torque Specifications

    July 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 specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed...

  • Page 22: Torque Procedure

    Service and Repair Manual July 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 July 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 July 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

    July 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: Cailbration Process Steps

    Service and Repair Manual July 2021 Repair Procedures Calibration Process Steps Verify pump efficiency calibration: Refer to Repair Procedures, How to Check the It is required to perform the calibration process if Function Pump Calibration. system defaults have been reset or if new software Set hydraulic valve thresholds for turntable has been installed.

  • Page 27: Platform Controls

    July 2021 Service and Repair Manual Platform Controls How to Adjust the Joystick Threshold Setting How to Adjust the Joystick Threshold Setting Platform Controls The threshold setting is the minimum output The platform control box contains two control current at which a function proportional valve can modules;...
  • Page 28 Service and Repair Manual July 2021 Platform Controls Momentarily activate the drive enable toggle 14 Press down on the foot switch and select the switch in the right direction until CALIBRATE toggle switch controlled boom function to be TILT SENSOR is shown on the display. adjusted.

  • Page 29: How To Adjust The Joystick Max-Out Setting

    July 2021 Service and Repair Manual Platform Controls How to Adjust the Joystick Max-out Setting How to Adjust the Maximum Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE Speed Setting (Hydraulic TILT SENSOR is shown on the display. Functions) Momentarily activate steer in the right direction until VALVE MAXIMUM CURRENT...
  • Page 30 Service and Repair Manual July 2021 Platform Controls 14 Release the foot switch and momentarily 19 Momentarily active a low flow boom function activate steer in the right direction one time to in one direction. increase the value by 10 milliamps. Repeat Result: The display shows the name of the releasing the foot switch and momentarily function, direction and current value in...

  • Page 31: How To Adjust The Joystick Ramp Rate Setting

    July 2021 Service and Repair Manual Platform Controls How to Adjust the Joystick Ramp Rate Setting How to Adjust the Ramp Rate Momentarily activate the drive enable toggle switch in the right direction until VALVE AND Setting SENSOR SETTINGS is shown on the display. The ramp rate setting is an adjustment that Momentarily activate the drive enable toggle controls the way boom function starts and stops.

  • Page 32: How To Calibrate Boom Angle Sensor

    Service and Repair Manual July 2021 Platform Controls 13 Momentarily activate the drive enable toggle switch in the right direction to save the value. How to Calibrate Boom Angle Result: The alarm will sound indicating the Sensor setting has been saved. Continue to the next desired Ramp time adjustment.

  • Page 33: How To Clear The Fault History

    July 2021 Service and Repair Manual Platform Controls Momentarily activate steer in the right direction until BOOM ANGLE CALIBRATE is How to Clear Fault History shown on the display. There are 1 thru 16 fault codes shown in the fault Momentarily activate the drive enable toggle history menu, 1 being the most recent displayed.

  • Page 34: Platform Components

    Service and Repair Manual July 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 35: Platform Rotator

    July 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 helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.
  • Page 36 Service and Repair Manual July 2021 Platform Components How to Bleed the Platform Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to Rotator platform rotator pivot pins. Do not remove the pins. From the ground controls, fully rotate the platform to the right and then the left.

  • Page 37: Platform Overload System

    July 2021 Service and Repair Manual Platform Components Platform Overload System Calibrating the platform overload system regularly is essential to safe machine operation. Continued use of an improperly operating platform overload system, could result in the system not sensing an overloaded platform condition.

  • Page 38: How To Perform A Full Load Platform Calibration

    Service and Repair Manual July 2021 Platform Components How to Perform a Full Load Platform Calibration How to Perform a Full Load 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 39: How To Replace The Platform Overload Load Cell

    July 2021 Service and Repair Manual Platform Components Activate and hold primary boom up for 3 - How to Replace the Platform Overload Load Cell How to Replace the Load Cell 4 seconds. Sensor Result: Hour meter displays MAXRATED Note: The preload adjustment should only be LOAD CAL OK.

  • Page 40: How To Reset Overload Recovery Message

    Service and Repair Manual July 2021 Jib Boom Components How to Reset Overload Recovery Message How to Reset Overload Recovery Faults Platform The message OVERLOAD RECOVERY will be How to Remove the Platform displayed when a platform overload recovery occurs under auxiliary power. The message will Remove the cable clamp from the top of the persist until the reset overload recovery procedure platform mounting weldment.
  • Page 41 July 2021 Service and Repair Manual Jib Boom Components Attach a lifting strap from an overhead lifting 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 42: Jib Boom Lift Cylinder

    Service and Repair Manual July 2021 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 opposite leveling arm.

  • Page 43: Boom Components

    July 2021 Service and Repair Manual Boom Components Boom Legend 1 angle sensor 2 primary boom 3 cable track 4 upper riser arm to turntable pivot pin 5 lower riser arm to turntable pivot pin 6 lower riser arm 7 upper riser arm 8 lift cylinder 9 pivot link 10 pivot lever...

  • Page 44: Boom Components

    Service and Repair Manual July 2021 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 Bodily injury hazard.
  • Page 45 July 2021 Service and Repair Manual Boom Components 21 Carefully remove the cable track from the 14 Tag, disconnect and plug all hydraulic hoses machine and place it on a structure capable of that enter the cable track from the bulkhead supporting it.

  • Page 46: How To Repair The Cable Track

    Service and Repair Manual July 2021 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 47: Primary Boom

    July 2021 Service and Repair Manual 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 side covers. How to Remove the Primary Boom Bodily injury hazard.

  • Page 48: Boom Lift Cylinder

    Service and Repair Manual July 2021 Boom Components 13 Remove the boom lower pivot pin retaining fasteners. Use a soft metal drift to remove the Boom Lift Cylinder pin. 14 Remove the boom upper pivot pin retaining The primary boom lift cylinder raises and lowers fasteners.

  • Page 49: Primary Boom Extension Cylinder

    July 2021 Service and Repair Manual 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 50: Platform Leveling Master Cylinder

    Service and Repair Manual July 2021 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 51 July 2021 Service and Repair Manual Boom Components Remove the retaining fastener securing the Raise the boom until the rod end pivot pin of barrel end pivot pin. the master cylinder is accessible. Using an overhead supporting device, support the master cylinder. Remove the retaining fastener securing the rod end pivot pin.

  • Page 52: Primary Boom Angle Sensor

    Service and Repair Manual July 2021 Boom Components Primary Boom Angle Sensor The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the turntable and gravity. How to Replace the Primary Boom Angle Sensor Note: If the angle sensor is replaced, both the sensor and magnet must be replaced as a set.

  • Page 53: Engines

    July 2021 Service and Repair Manual Engines Air Intake Hose RPM Adjustment Every time the engine tray is closed after Refer to Maintenance Procedure in the appropriate maintenance, the air intake hose must be correctly Service or Maintenance Manual for your machine, placed into its seat.

  • Page 54: Ground Controls

    Service and Repair Manual July 2021 Ground Controls How to Use Control System Fault Recovery Switch Control System Fault Recovery Switch The turntable The turntable control box (TCON) is the communication and operations center for the machine. The switch at the bottom of the control box is the control system fault Recovery switch.
  • Page 55 July 2021 Service and Repair Manual Ground Controls How to use Control System Fault In case of CAN communication loss or control system failure only, turn off the machine, wait Recovery Switch at least two seconds and turn the key switch in GROUND position.

  • Page 56: Hydraulic Pumps

    Service and Repair Manual July 2021 Hydraulic Pumps Tag, disconnect and plug function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic connections very slowly to allow Pump the oil pressure to dissipate...

  • Page 57: How To Check The Function Pump Calibration

    July 2021 Service and Repair Manual Hydraulic Pumps How to Check the Function Pump Calibration How to Check the Function Pump Momentarily activate the drive enable toggle switch in the right direction until you see the Calibration VALVE AND SENSOR SETTINGS screen. Pump efficiency is calibrated automatically but Momentarily activate the drive enable toggle must be verified after a new pump installation and...

  • Page 58: Manifolds

    Service and Repair Manual July 2021 Manifolds Function Manifold Components The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Valve, Proportional Relief System relief 19-21 ft lbs / 26-29 Nm Solenoid valve, 2 position 2 way P HI circuit enable 19-21 ft lbs / 26-29 Nm...
  • Page 59 July 2021 Service and Repair Manual Manifolds Part No. 1299608GT ® -60 DC • S ® -60 FE...
  • Page 60 Service and Repair Manual July 2021 Manifolds Function Manifold Components, continued Index Description Schematic Item Function Torque Check valve, 25 psi Tank return circuit 19-21 ft lbs / 26-29 Nm Check valve, 30 psi Tank return circuit 19-21 ft lbs / 26-29 Nm Pressure compensator, 150 psi Turntable rotate circuit 19-21 ft lbs / 26-29 Nm...
  • Page 61 July 2021 Service and Repair Manual Manifolds Part No. 1299608GT ® -60 DC • S ® -60 FE...

  • Page 62: Valve Adjustments - Function Manifold

    Service and Repair Manual July 2021 Manifolds Activate the platform level toggle switch in the up direction to increase the relief pressure or Valve Adjustments - Function in the down direction to decrease the relief Manifold pressure until the pressure gauge reads 3000 psi / 207 bar.

  • Page 63: Jib Boom / Platform Rotate Manifold Components

    July 2021 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Description Schematic Item Function Torque Solenoid valve, 3 position 4 way Platform rotate left/right 26-30 ft-lbs / 35-40 Nm Solenoid valve, 3 position 4 way Jib boom up/down...

  • Page 64: Turntable Rotation Manifold Components

    Service and Repair Manual July 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, 2 position 3 way...

  • Page 65: How To Set Up The Oscillate Directional Valve

    July 2021 Service and Repair Manual Manifolds Valve Coils How to Set Up the Oscillate Directional Valve Linkage How to Test a Coil Note: Adjustment of the oscillate directional valve A properly functioning coil provides an linkage is only necessary when the linkage or electromotive force which operates the solenoid valve has been replaced.

  • Page 66: How To Test A Coil Diode

    Service and Repair Manual July 2021 Manifolds How to Test a Coil Diode How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 67: Turntable Rotation Components

    July 2021 Service and Repair Manual Turntable Rotation Components Attach a suitable lifting device to the turntable rotator assembly. Turntable Rotation Assembly How to Remove the Turntable Rotation Drive Hub 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 68: How To Adjust The Turntable Rotation Gear Backlash

    Service and Repair Manual July 2021 Turntable Rotation Components Carefully remove the drive hub assembly from How to Adjust the Turntable Rotation Gear Backlash How to Adjust the Turntable the machine. Rotation Gear Backlash Crushing hazard. The turntable The turntable rotation drive hub is mounted on an rotate drive hub assembly could adjustable plate that controls the gap between the become unbalanced and fall...

  • Page 69: How To Replace The Universal Tilt Sensor

    July 2021 Service and Repair Manual Turntable Rotation Components Push the backlash pivot plate towards the turntable as far as possible (this will push the How to Replace the Universal Tilt rotation gear into the turntable bearing ring Sensor (UTS) gear).

  • Page 70: How To Calibrate The Universal Tilt Sensor

    Service and Repair Manual July 2021 Turntable Rotation Components How to Calibrate the Universal Tilt Sensor How to Calibrate the Universal Tilt Sensor (UTS) Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Refer to Navigation Menus, Settings Menu.

  • Page 71: Axle Components

    July 2021 Service and Repair Manual Axle Components 10-1 Attach a lifting strap from an overhead lifting device to the barrel end of the oscillating Oscillating Axle Cylinders cylinder. Remove the pin retaining fasteners from the The oscillating axle cylinders extend and retract barrel-end pivot pin.

  • Page 72: How To Remove The Steer Cylinder

    Service and Repair Manual July 2021 Axle Components 10-2 How to Calibrate the Steer Angle Sensor How to Calibrate the Steer Angle How to Remove the Steer Sensor Cylinder Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Adjust the steer tires so they are in a straight Refer to Navigation Menus, Settings Menu.
  • Page 73 July 2021 Service and Repair Manual Axle Components Momentarily activate the drive enable toggle switch in the right direction. Result: The display will show steer sensor value in mV and ENABLE will appear at the bottom of the screen. 10 Momentarily activate the drive enable toggle switch in the right direction to save calibrate steer center.

  • Page 74: Battery Charger

    Service and Repair Manual July 2021 Battery Charger 11-1 Battery Charger The charger contains selectable charging profiles stored in its internal memory to charge batteries. These profiles are specific to each battery type. The charging profile must be programmed to match the specific battery type on the machine.

  • Page 75: Selecting A Charge Profile

    July 2021 Service and Repair Manual Battery Charger Selecting a Charge Profile Selecting a Charge Profile Press and hold the charge profile selection button until the error indicator and charging Electrocution/burn hazard. indicator lights turn off and the AC status Contact with electrically charged indicator light turns on to confirm selection circuits could result in death or...

  • Page 76: Fault Codes

    Service and Repair Manual July 2021 Control System 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 equipment are available and ready for use.

  • Page 77: Fault Codes Ground Controls

    July 2021 Service and Repair Manual Control System Fault Codes Both Engine Hours and DC Function Enable Hours Fault Codes Ground Controls will be tracked. DC Function enable hours will be displayed on the smart hour meter by default. Standard Genie fault codes shall be displayed and Engine Hours will be displayed if the hybrid mode the red LED will illuminate when any faults are select switch is held for three (3) seconds.

  • Page 78: How To Retrieve Control System Fault Codes - Platform Controls

    Service and Repair Manual July 2021 Control System Fault Codes How to Retrieve Control System To access fault history list: Fault Codes from the Platform 12 Momentarily activate the drive enable toggle Controls switch in the right direction until ACTIVE FAULTS is shown on the display.

  • Page 79: Control System Fault Codes

    July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Stuck ON Release foot switch and 21 Fault (on @ power up) recycle power Verify: (when activated) · 24V supply on C11-1 FOOT Platform controlled (P22PWR WH)
  • Page 80 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit or · Check Ohms 25 Value too high Ohms > 60 PRIMARY DOWN Associated · Verify no open/short circuit VALVE Function disabled across PCON C20-6 BK &...
  • Page 81 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit · Check Ohms 25 Value too high · Verify no open/short circuit Ohms > 60 JIB UP/PLATFORM Associated across PCON C47-4 BK or C9- ROTATE LEFT...
  • Page 82 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit · Check Ohms 25 Value too high SMALL PUMP · Verify no open/short circuit Ohms > 60 ENABLE VALVE fault indicator across PCON C47-6 BK or C9-...
  • Page 83 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution 11 Shorted to Supply 12V Verify: · 12V (P198SEN RD) on 16 Value at 0 V Pin A Warning ·...
  • Page 84 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Overload All functions Unload the exceeding weight on 12 Overload condition disabled the Platform detected No CAN All functions 13 Not Detected Verify CAN connection to LC communication...
  • Page 85 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Verify: ROUND LCD · 24V supply on C61-5 No CAN DISPLAY 13 Not Detected Warning · B- at C61-8 communication (GROUND ·...
  • Page 86 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Engine Speed Verify: Value too · Proper operation engine high higher than setting high RPM solenoid Hybrid Mode ENGINE RPM disabled ·...
  • Page 87 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: · 24V supply on (+) Charger Terminal No CAN No Response configuration not · B- on (-) Terminal communication possible ·...
  • Page 88 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution · Replace battery pack · Check DC Safety limit exceeded, possible causes: connections · Poor battery health. · Disconnect parasitic Ah Limit ·...
  • Page 89 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution · Remove and re-insert the USB Drive There has been a problem · If the condition persists 17 USB error mounting or un-mounting the then remove AC and USB Flash Drive.
  • Page 90 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Connect charger to an AC source that provides stable AC source is unstable. Could AC between 85 - 270 VAC / Low AC voltage be caused by undersized 45-65 HZ.
  • Page 91 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Check if sensor is Battery temperature sensor is connected correctly if required by charge profile alarm is shown or ensure Battery Temperature (battery temperature the charge profile...
  • Page 92 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: No CAN 48V on C25-1, C25- No Response Drive disabled communication 11, C25-12 (R181PWR OR) 12 Controller Overcurrent Cut Drive, EM Brake Cycle Power 13 Current Sensor Fault Cut Drive, EM Brake Cycle Power 14 Precharge Failed...
  • Page 93 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 36 Encoder Fault Limit Speed to LOS Cycle Power 37 Motor Open Cut Drive, EM Brake Cycle Power 38 Main Contactor Welded Cut Drive, EM Brake Cycle Power 39 Main Contactor Did Not Close Cut Drive, EM Brake...
  • Page 94 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: STEER LEFT Associated Function · no open/short circuit 21 Fault Open or Shorted VALUE disabled across RRDCON C28-4 & B- (V37SCC BL/BK) Verify: STEER RIGHT Associated Function...
  • Page 95 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution RIGHT REAR SPEED SENSOR LEFT REAR Motor Sin/Cos Verify: SPEED SENSOR Encoder 21 Fault · Motor Encoder (Sin/Cos) feedback signal RIGHT FRONT wirings fault...
  • Page 96 Service and Repair Manual July 2021 Control System Fault Codes Motor Temperature Allow the motors to cool Limited Speed 20 Generic Warning exceeded down, check for damaged Drive warning gearbox or motor RIGHT FRONT temperature limit DRIVE MOTOR Motor Allow the motors to cool TEMPERATURE Temperature down, check temperature...
  • Page 97 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Motor Controller Allow the motor controller to Temperature Limited cool down or allow the to 20 Generic Warning exceeded or is below Speed exit from too low the warning...
  • Page 98 Service and Repair Manual July 2021 Control System Fault Codes Motor Controller Allow the motor controller to Temperature Limited cool down or allow the to 20 Generic Warning exceeded or is below Speed exit from too low the warning Drive Temperature warning temperature limit temperature threshold...

  • Page 99: Charger Fault Codes

    July 2021 Service and Repair Manual Charger Fault Codes Battery Charger The charger continuously monitors internal and external conditions. Fault and Error codes are generated by the charger to indicate that an internal or external malfunction has been detected in the electrical system.
  • Page 100 Service and Repair Manual July 2021 Charger Fault Codes Charger status indicators Remote charger status indicators 1 Error / Fault / USB indicator 2 Charger profile / Error display 3 Error / Fault ® -60 DC • S ® -60 FE Part No.

  • Page 101: Charger Fault Codes

    July 2021 Service and Repair Manual Charger Fault Codes Charger Fault Codes Charger Fault Codes Description Fault Code Possible Causes Solution DC-DC failure: LLC excessive leakage F-0-0-1 fault. PFC failure: PFC excessive leakage F-0-0-2 Disconnect AC input and battery fault. pack for 30 seconds.

  • Page 102: Charger Error Codes

    Service and Repair Manual July 2021 Charger Fault Codes Charger Error Codes Charger Error Codes Description Possible Causes Error Code Condition E-0-0-1 High battery voltage Battery voltage too high to Check battery voltage and cable connections. charge. Self clearing when condition has been corrected.
  • Page 103 July 2021 Service and Repair Manual Charger Fault Codes Charger Error Codes Error Code Description Condition Possible Causes Battery temperature out Check temperature sensor and electrical E-0-0-8 Battery temperature sensor. of range connections. Rest charger. Disconnect AC power for 30 seconds. Self clearing when condition has been corrected.
  • Page 104 Service and Repair Manual July 2021 Charger Fault Codes Charger Error Codes Error Code Description Condition Possible Causes High battery voltage Battery voltage too high as Check battery voltage and cable E-0-2-1 detected while charging detected by charger profile. connections. Confirm charger profile is programmed for correct battery type.
  • Page 105 July 2021 Service and Repair Manual Charger Fault Codes Charger Error Codes Error Code Description Condition Possible Causes E-0-2-9 CAN Bus error CAN Bus network error. Check CAN Bus connections. CAN modules not functioning correctly. Termination resistance is ~60 ohms. E-0-3-0 COMM battery module error CAN Bus battery module...

  • Page 106: Pump Control Fault Codes

    Service and Repair Manual July 2021 Pump Control Fault Codes Pump Controller Fault Handling The pump controller is located on the engine side of the machine and mounted to the battery compartment. The pump controller can detect faults or error conditions. Faults can also be detected by the machine control system and PCON display.
  • Page 107 July 2021 Service and Repair Manual Pump Control Fault Codes LED Display Format: The LEDs have five different display modes, indicating the type of information they are providing. Display Status Neither LED illuminated • Controller is not powered on. • Faulty battery. •...
  • Page 108 Service and Repair Manual July 2021 Pump Control Fault Codes Name Cause Effect Solution 1. External short of phase U,V, or W motor connections ShutdownMotor; Set: Phase current exceeded the 2. Motor parameters are miss- ShutdownMainContactor; current measurement limit Controller tuned ShutdownEMBrake;...
  • Page 109 July 2021 Service and Repair Manual Pump Control Fault Codes Name Cause Effect Solution 1. See Monitor menu » Battery: Set: Capacitor bank voltage Capacitor Voltage ShutdownMotor; exceeded the Severe Overvoltage 2. Battery parameters are ShutdownMainContactor; limit with FET bridge enabled Severe B+ misadjusted ShutdownEMBrake;...
  • Page 110 Service and Repair Manual July 2021 Pump Control Fault Codes Name Cause Effect Solution 1. Motor temperature is at or above the programmed Temperature Hot setting, and the current is being cut back Set: Motor temperature is at or 2. Motor Temperature Control above the Temperature Hot Menu parameters are miss-tuned Motor Temp Hot...
  • Page 111 July 2021 Service and Repair Manual Pump Control Fault Codes Name Cause Effect Solution Proportional Driver Set: Proportional driver (pin 2) is either 1. Open or short on driver load Open/Short open or shorted 2. Dirty connector pins ShutdownPD (Proportional Relief Clear: Correct open or short, and cycle 3.
  • Page 112 Service and Repair Manual July 2021 Pump Control Fault Codes Name Cause Effect Solution 1. VCL code encountered a runtime ShutdownMotor; VCL error ShutdownMainContactor; Set: Runtime VCL code error condition ShutdownEMBrake; 2. See Monitor menu » Controller: VCL Clear: Edit VCL application software to VCL Runtime ShutdownThrottle;...
  • Page 113 July 2021 Service and Repair Manual Pump Control Fault Codes Name Cause Effect Solution ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; Set: Incompatible software Supervisor In- The main OS is not compatible ShutdownThrottle; Clear: Load properly matched OS code or ShutdownInterlock; compatible with the Supervisor OS update the Supervisor code;...
  • Page 114 Service and Repair Manual July 2021 Pump Control Fault Codes Name Cause Effect Solution ShutdownMotor; ShutdownMainContactor; Motor Type The Motor_Type parameter value is ShutdownEMBrake; Cycle Power Fault out of range ShutdownThrottle; FullBrake ShutdownMotor; Set: VCL & OS software do not match; ShutdownMainContactor;...

  • Page 115: Drive Control Fault Codes

    July 2021 Service and Repair Manual Drive Control Fault Codes Drive Controller Fault Handling The drive controllers are located on the ground controls side of the machine and mounted to the bulkhead. The drive controller can detect faults or error conditions. Faults can also be detected by the machine control system and PCON display.
  • Page 116 Service and Repair Manual July 2021 Drive Control Fault Codes LED Display Format: The LED has six different display modes, indicating the type of information it is providing. Display Status LED not illuminated • Controller is not powered on. • Faulty battery. •...
  • Page 117 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Controller Overcurrent 1. External short of phase U, 1 = Controller V, or W motor connections ShutdownVehicle: Over Current Phase U 2.
  • Page 118 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type 1. Non-controller system drain on battery No drive torque. 2. Battery resistance too Set: When Main is closed and the FET high Fault Action: Bridge is enabled, either the undervoltage...
  • Page 119 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type 1. With the vehicle in the stopped state, the detected motor frequency and/or ShutdownVehicle: phase current exceeds the Set: The motor frequency and/or and limit set by the Travel phase-current are above their Travel ShutdownMotor...
  • Page 120 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Fault Type Cause Effect Solution Object Pattern 1. Batteries need recharging. Controller is performance limited at this voltage 2. Battery parameters are mis-adjusted. Reduced drive Non-controller system- torque Set: Capacitor bank voltage drain on battery...
  • Page 121 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Ext 12V Supply Set: Failure (1) The 12V supply (pin 23) is Fault Type(s): External load impedance on outside 12V ± 15% the +12V supply is too low Disables the 12V Supply (2) The current is outside the limits...
  • Page 122 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Fault Name Cause Effect Solution Object Pattern Type Set: Electromagnetic brake EM Brake Driver driver (pin 4) is either open or 1. Open or short on shorted Fault Type(s): driver load ShutdownEMBrake...
  • Page 123 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Set: Just prior to the main 1. Main contactor tips are contactor closing, the capacitor ShutdownVehicle: welded closed bank voltage (B+ connection 2.
  • Page 124 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Motor offset has shifted so Motor Clear: controller is producing 2102 3-11 Misalignment Shudown Vehicle; torque in an uncommanded Error Reset Controller direction NV Memory...
  • Page 125 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Parameter While the Interlock was ON, a ShutdownVehicle: Change safety-based parameter was Set: Adjustment of a parameter changed ShutdownMotor setting that requires cycling of Fault Type(s): ShutdownMainContactor 2813...
  • Page 126 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type ShutdownAll: ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock 1. Physical damage from Internal Controller Clear: 2831 ShutdownDriver1 to 7 external sources/events Fault Reset Controller ShutdownPD FullBrake...
  • Page 127 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type 1. Home switch disconnected, or broken 2. Check wiring to ensure both Interlock Input Clear: 22A2 switches have continuity to ShutdownVehicle Conflict Reset Controller...
  • Page 128 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type ShutdownVehicle: Parameter Out of 1. Parameter value Range detected outside of the Set: Parameter detected outside of ShutdownMotor limits limits ShutdownMainContactor 2811 Fault Type(s):...
  • Page 129 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Type Cause Effect Solution Object Pattern 1. External short of Clear: pump motor 2520 Pump Overcurrent Shutdown Pump Reset Controller 2. Controller defective Set: Pump activated when the 1.
  • Page 130 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Fault Type Cause Effect Solution Object Pattern Driver 1 Fault 1. Open or short on driver load Fault Type(s): Dirty connector pins at controller 1 = Driver Short or contactor coil 2 = Driver Overcurrent Set: Driver 1 is either open or...
  • Page 131 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type A Driver Output is used for two Set: Driver assignment Driver Assignment or more functions conflict (i.e., duplicate items See Programmer » Controller Fault Action: assigned to the same driver) Fault Type(s): 5...
  • Page 132 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Fault Type Cause Effect Solution Object Pattern See Analog 1 Out of See Analog 1 Out of 2624 11-5 See Analog 1 Out of Range See Analog 1 Out of Range Range Range See Analog 1 Out of...
  • Page 133 July 2021 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Name Cause Effect Solution Object Pattern Type Software and hardware Set: Software / hardware ShutdownVehicle: branding mismatch incompatibly For technical support on ShutdownMotor this fault, contact the Clear: As applicable: ShutdownMainContactor 2860...
  • Page 134 Service and Repair Manual July 2021 Drive Control Fault Codes Flash Description & Name Cause Effect Solution Object Pattern Fault Type See the associated VCL VCL Watchdog Functions: The time interval of the Set_Watchdog_Timeout( ) Clear: VCL watchdog Set_Watchdog_Fault_Action( ) Kick_Watchdog( ).

  • Page 135: Navigation Menus

    July 2021 Service and Repair Manual Drive Controller Fault Handling Section 5 Navigation Menus Navigation Menu - Top Menus EXIT Drive enable switch Drive Joystick Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right Part No. 1299608GT ®...

  • Page 136: Faults Navigation Menu

    Service and Repair Manual July 2021 Faults Navigation Menu Faults Navigation Menu GENIE LOGO 3 SEC. @ POWER UP EXIT EXIT REVISION LEVEL & 3 SEC. SYSTEM (hold) ACTIVE FAULT CLEAR COMPONENT ENTER CODE TO FAULTS 4 SEC. READY RESET OVER- FAULTS FAULTS HISTORY...

  • Page 137: Options Navigation Menu

    July 2021 Service and Repair Manual Options Navigation Menu Options Navigation Menu GENIE LOGO 3 SEC. @ POWER UP REVISION LEVEL & 3 SEC. SYSTEM (hold) FAULTS READY 4 SEC. EXIT (hold) 4 SEC. SETTINGS ENT/ EXIT OPTIONS LANGUAGE ENGLISH EXIT MOTION ENT/...

  • Page 138: Settings Navigation Sub Menu

    Service and Repair Manual July 2021 Settings Navigation Sub Menu Settings Navigation Menu SETTINGS ENTER EXIT EXIT EXIT RESET TO AUTHORIZE TO SET VALVE & SENSOR DEFAULTS ADVANCED VALUES* SETTINGS ENTER ENTER ENTER RESET GENERAL ENTER CALIBRATE TILT PARAMETER AUTH. CODE EXIT SENSOR EXIT...

  • Page 139: Settings Navigation Sub Menu

    July 2021 Service and Repair Manual Settings Navigation Sub Menu Settings Navigation Menu EXIT EXIT To "VALVE & SENSOR SETTINGS" + ADVANCED SETUP, DRIVE SETTINGS SETTINGS WITH (*) SETTINGS WITH (*) REQUIRE AUTHORIZE REQUIRE AUTHORIZE ENTER ENTER NONE EXIT *LOW VOLTAGE CALIBRATE STEER INTERRUPT (LVI) SENSOR CENTER?

  • Page 140: Settings Navigation Sub Menu

    Service and Repair Manual July 2021 Settings Navigation Sub Menu Settings Navigation Menu EXIT To "VALVE & SENSOR SETTINGS" + ADVANCED SETUP, SETTINGS WITH (*) REQUIRE AUTHORIZE ENTER *LOW VOLTAGE INTERRUPT (LVI) EXIT CUT OFF % *CHASSIS TILT NONE CUTOUT MODE: EXIT EXIT LIFT TILT...

  • Page 141: Schematics

    July 2021 Service and Repair Manual Schematics About This Section Section 6 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, Troubleshooting and repair procedures shall ...

  • Page 142: Electrical Symbol Legend

    Service and Repair Manual July 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 Connection - no T-circuits connect at Circuits crossing no...

  • Page 143: Hydraulic Symbols Legend

    July 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 144: Electrical Component And Wire Color Legends

    Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Jumper plug - Dual Output AC MC to Pump Description AC MC Battery Engine Start - 12V DC Steer sensor extender Left/Right side battery packs, 48V DC AC Pump Motor Connector ECON, AC motor / Generator controller...
  • Page 145 July 2021 Service and Repair Manual Electrical Component and Wire Color Legends RR AC Motor Item Description Inverter (option) Circuit Breaker Charger interlock 2 Fuel pump, 15A 12V charger Controls power, 24V DC, 15A Recovery Pump Override Charger box 12V, 10A Extend/Retract limit switch Engine RPM, 10A Contact alarm...
  • Page 146 Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Description Item Description Horn or Alarm Motor Tilt / Platform overload Function pump motor/generator Horn Auxiliary pump Alarm (multifunction) Engine starter Joystick Button Drive/steer proportional joystick Red emergency stop (ground) Boom proportional joystick: primary Red emergency stop (platform) up/down, turntable rotate...
  • Page 147 July 2021 Service and Repair Manual Electrical Component and Wire Color Legends Toggle Switch Auxiliary pump Hybrid mode Function speed Platform rotate Jib boom up/down Platform level up/down TS13 Primary boom extend/retract TS14 Motor shift (high / low) TS15 Drive enable TS18 Work light (option) TS46...
  • Page 148 Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Wire Color Legend Item Description Blue Black Brown Green Orange Purple White Yellow BL/BK Blue/Black BL/RD Blue/Red BL/WH Blue/White BK/RD Black/Red GR/BK Green/Black GR/WH Green/White OR/BK Orange/Black OR/RD Orange/Red OR/WH Orange/White...

  • Page 149: Kubota Engine Fuse And Relay Module

    July 2021 Service and Repair Manual Kubota Engine Fuse and Relay Module Kubota D1105-E4B 1 Fuse 1 - 15A (spare) 2 Fuse 3 - 30A glow plug 3 Circuit breaker 1 - 15A Engine start / Fuel pump 4 Control Relay 64 Engine fault 5 Control Relay 2 Fuel pump 6 Circuit breaker 7 - 10A Engine RPM 7 Control Relay 1 Engine start...

  • Page 150: Limit Switch/Angle Sensor Legend

    Service and Repair Manual July 2021 Limit Switch/Angle Sensor Legend 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS3 Drive enable 4 S13 Steer Angle sensor (inside steer cylinder) ® -60 DC • S ® -60 FE Part No.

  • Page 151: Electrical Schematics

    July 2021 Service and Repair Manual Electrical Schematic, DC/FE Models...

  • Page 152: Electrical Schematic, Dc/Fe Models

    Service and Repair Manual July 2021 Electrical Schematic, DC/FE Models C2-11 P181BAT OR/14 P181BAT(A) OR/14 DC/DC C2-8 P182BAT RD/14 P182BAT RD/14 CONVERTER 48/26V PROPEL DRIVER RELIEF HV C95-1 C95-2 SHT 11 V191PCE WH/RD C -1 FRONT MORE SHIELD BK C134PWR RD W V U MOTORS C58-7...

  • Page 153: Electrical Schematic, Gbox

    July 2021 Service and Repair Manual Electrical Schematic, Ground Control Box P181BAT OR/14 TELEMATICS C2-4 P181PWR OR P182BAT RD/14 DRIVE FLASHING P182BAT RD LIGHT BEACON TB181 P181PWR OR/16 48VDC C134PWR RD P181BAT OR/14 26VDC P182BAT RD/14 P182PWR RD/14 TS69 RECOVERY D82CAN0+ YL C183RCV BL P22BAT BK/14...
  • Page 154 Service and Repair Manual July 2021 Electrical Schematic, Ground Control Box...
  • Page 155 July 2021 Service and Repair Manual Electrical Schematic, Turntable Controller...

  • Page 156: Electrical Schematic, Turntable Controller

    Service and Repair Manual July 2021 Electrical Schematic, Turntable Controller HYDRAULIC TO BATTERY DRIVE ENABLE PRIMARY RETRACTED FUEL SENSOR PRIMARY PRESSURE LIMIT SWITCH LIMIT SWITCH OPTION ANGLE SENSOR B7 48V TRANSDUCER PAGE 1 POWER PLATFORM 2 C37 POWER TCON (PART2) C68-1 4 ENABLE DRIVE ENABLE 6...

  • Page 157: Electrical Schematic, Pbox

    July 2021 Service and Repair Manual Electrical Schematic, Platform Control Box C73 CONTACT ALARM POWER RD/BK C249CTA BK/RD C249CTAC BK/RD BATGND BR SYNC. C250CTA YL P23PWR WH TB134 POWER RD/BK C249CTA BK/RD C134PWR RD 1 BATT + BATGND BR GND BR 2 BATT - SYNC.
  • Page 158 Service and Repair Manual July 2021 Electrical Schematic, Platform Control Box...
  • Page 159 July 2021 Service and Repair Manual Electrical Schematic, Kubota D1105...

  • Page 160: Electrical Schematic, Kubota D1105

    Service and Repair Manual July 2021 Electrical Schematic, Kubota D1105 ENGINE CONNECTOR TO CR88; CHARGER SELECT RLY; PIN 3 AND 6. PAGE 1 P20BAT RD L LINE N NEUTRAL R181PWR OR P20BAT RD + 12VDC - AUXGND P20BAT RD RD/16 AUXGND BK AUXGND BK CONN 1 = ORANGE...

  • Page 161: Electrical Schematic, Can Bus

    July 2021 Service and Repair Manual CAN BUS Wiring Diagram LOAD CELL SP18 SP15 SP25 SP27 SP17 SP26 SP28 SP14 PCON VCON SP13 SP14 C3-11 C74-D C3-12 C74-E SP12 SP11 C3-7 C3-8 C61-1 SP10 C61-2 C2-13 C2-14 C1-15 C29-11 C1-17 C29-12 SP12 SP10...
  • Page 162 Service and Repair Manual July 2021 CAN BUS Wiring Diagram...
  • Page 163 July 2021 Service and Repair Manual Power Cable Wiring Diagram...

  • Page 164: Power Cable Wiring Diagram

    Service and Repair Manual July 2021 Power Cable Wiring Diagram CHARGER P181RET(C) OR[5] C180RET BK[6] C179RET GR[4] P181RET(B) OR[3] TRACTION P181BAT(B) OR(14GA)[2]TO DC/DC AC MOTOR P181BAT(A) OR(14GA)[1]TO GBOX CONTROLLER BATTERY PACK FROM 12V BATTERY CHARGER ® -60 DC • S ®...

  • Page 165: Electrical Schematics - Options

    July 2021 Service and Repair Manual Wiring Diagram, AC Power Options...

  • Page 166: Ac Power Wiring Diagram - Options

    Service and Repair Manual July 2021 Wiring Diagram, AC Power Options P20BAT RD (BK) (BK) AUX RLY 24VDC R27AUX RD BATGND BR TO RELAY AC INPUT BOX TO 13.8V TO 13.8V CHARGER CHARGER TERMINAL BLOCK U4-INT2 YL CHARGER U4-BAT(-) BK CONTROL IN.

  • Page 167: Rcbo Wiring Diagram - Options

    July 2021 Service and Repair Manual Wiring Diagram, RCBO Options RCBO OPTION RCBO OPTION PLATFORM PLATFORM SOCKET SOCKET USING INVERTER USING PTP GROUND TO GROUND TO PLATFORM CHASSIS PLATFORM CHASSIS RCBO BOX RCBO BOX 110/220Vac INVERTER GROUND TO GND GR/YL INVERTER CASE GND GR/YL PLUG...
  • Page 168 Service and Repair Manual July 2021 Wiring Diagram, RCBO Options...

  • Page 169: Hydraulic Schematics

    July 2021 Service and Repair Manual Hydraulic Schematic, DC/FE Models...

  • Page 170: Hydraulic Schematic, Dc/Fe Models

    Service and Repair Manual July 2021 Hydraulic Schematic, DC/FE Models HYBRID PUMP (NO APU) OSCILLATE VALVE PRESSURE TRANSDUCER 3000 3000 2000 50-3000 VARIABLE HS0277B S®-60 DC • S®-60 FE Part No. 1299608GT Service and Repair Manual July 2021 ® -60 DC • S ®...

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