How to reset Genie boom lift?

Hard Reset PRESS and HOLD the down arrow button taking the door down to the ground. ... PRESS and HOLD the down arrow set button, count 10 seconds, then RELEASE the button. PRESS and HOLD the up arrow button taking the door up keeping it about 4 inches from the motor. More items...

What is the phone number for the Genie manual?

Please register your machine by visiting us on the web at www.genielift.com or by calling us toll free at 1-800-536-1800 . Failure to obey the instructions and safety rules in this manual will result in death or serious injury. machine operation contained in this operator's manual.

How to clear Genie fault code?

Release the left steer rocker switch. Scroll through and view the last ten stored faults by repeatedly depressing the left steer rocker switch. While in this display mode, depressing the horn key erases all saved fault codes.

What causes a Genie garage door opener to stop working?

Has your Genie opener stopped operating altogether? This issue can be caused by a number of things, but in most cases, the photo-eye sensors are to blame. You'll know that the sensors are the culprit if the little red lights on them start flashing.

Why is my Genie not working?

Make sure that the unit is plugged in and that the outlet is working . If the power supply is not the issue, check the sensors. These are located at the bottom of the door and help prevent the door from closing on objects in its path. If the sensors are misaligned or obstructed, the door will not close.

Can I open my Genie garage door with my phone?

The Aladdin Connect app is available for iOS and Android devices , syncing your phone or tablet to the Door Control Module. The Door Control Module is direct-wired to the garage door opener and connects to the Door Position Sensor via Bluetooth Technology.

What is the difference between a boom lift and a scissor lift?

Boom lifts move horizontally and vertically, whereas scissor lifts can only move up and down . While boom lifts attain a greater vertical reach, scissor lifts have larger platforms with higher weight capacities, enabling them to carry multiple people along with loads of material.

How to move a towable boom lift?

How do you transport a small boom lift? A towable boom lift can be transported on the back of a truck . The boom lift is usually suspended from an overhead beam and secured with chains. The chains are attached to the rear of the truck and then, as the truck moves, they move with it.

How do you reset a lift?

Troubleshooting: lift reset instructions This is the most common fix for the issue “Lift will go down, but not up”. On the control pad with the up and down arrows: Press and hold the down arrow continuously until the lift reaches the lowest point. Continue to hold for 10 seconds, then release.

How do you calibrate a genie lift?

Power up platform box with emergency stop. Hold controller full stroke each direction for 5-7 seconds . Note: DO NOT STEP ON FOOT SWITCH. After the second stroke of each joystick the alarm should sound indicating calibration.

Free Genie S-60X 2017 Service and Repair Manual PDF

Page 1

Service and Repair Manual

Serial Number Range

S-60 from S6013-26296 to S6016A-31260 from S6016N-31261 to S6016N-35000

from S6016H-35001 to S6016H-3699

This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics

S-65 from S6014D-101 to S6016D-639 from S6016M-101 to S6016M-399

S-60X from S60X13-26296 to S60X16H-36399 from S60XC13-26296 to S60XC16H-36399

S-60XC from S60HC13-26296 to S60HC15A-29544

S-60 HC from S60TX13-26296 to S60TX16H-36399 from S60TX14D-101 to S60TX16D-639

from S65TX13-26296 to S65TX16H-36399

For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

S-60TraX from S65TX14D-101 to S65TX16D-639

S-65 TraX from S60H-36400 from S60XH-36400 from S60XCH-3640

to S60XCH-45000

from S60TXH-36400 from S65TXH-36400

from S65TXM-101

from S60D-640 from S60TXD-640 from S60XD-640 from S60M-400

Part No. 1268492GT Rev B July 2017

Page 2

Service and Repair ManualJuly 2017

Introduction

ii S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Intr oducti on Intr oducti on

Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any procedure.

This manual provides troubleshooting and repair procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center.

Compliance

Machine Classification Group B/Type 3 as defined by ISO 16368

Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance.

Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.

Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

Contact Us: Internet: www.genielift.com E-mail: awp.techpub@terex.com

Find a Manual for this Model Go to http://www.genielift.com

Use the links to locate Service Manuals, Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals.

1268492GT Rev B, July 2017

First Edition, Second Printing

Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries.

S is a trademark of Terex South Dakota, Inc.

Page 3

July 2017Service and Repair Manual

Introduction

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC iii

Revision History Revision Date Section Procedure / Page / Description A 9/2015 New Release

A1 9/2016 Introduction Serial Number Legend

B 7/2017 Specifications Deutz D436 Engine Specifications, Machine Torque Specifications

Repair 5-5 Engine Fault Codes

Fault Codes Deutz D436 Engine Fault Codes

Schematics Deutz D436 Electrical Schematics

Reference Examples: Electronic Version

Click on any content or procedure in the Table of Contents to view the update.

Section Repair Procedure, 4-2

Section Fault Codes, All charts

Section Schematics, Legends and schematics

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Service and Repair ManualJuly 2017

Introduction

iv S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Serial Number Legend To August 31, 2016

1 Model 2 Model year 3 Facility code

4 Sequence number 5 Serial label (located under cover) 6 Serial number (stamped on chassis)

From September 1, 2016

1 Model 2 Facility code 3 Sequence number

4 Serial label (located under cover) 5 Serial number (stamped on chassis)

Page 5

July 2017Service and Repair Manual

Safety Rules

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC v

Section 1 Safety R ules

Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury.

Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.

Do Not Perform Maintenance Unless: You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

manufacturer's instructions and safety rules

employer's safety rules and worksite regulations

applicable governmental regulations

You have the appropriate tools, lifting equipment and a suitable workshop.

Page 6

Service and Repair ManualJuly 2017

Safety Rules

vi S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

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

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following:

Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

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

Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach.

Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity.

Be sure that fasteners intended for one time use (i.e., cotter pins and self-locking nuts) are not reused. These components may fail if they are used a second time.

Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe.

Be sure that your workshop or work area is properly ventilated and well lit.

Page 7

July 2017

Table of Contents

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC vii

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 ....................................................................................................... 1 Machine Specifications ........................................................................................... 1

Performance Specifications .................................................................................... 1

Hydraulic Oil Specifications .................................................................................... 3

Hydraulic Component Specifications...................................................................... 6

Ford MSG-425 EFI Engine Specifications ............................................................. 8

Deutz D436 L3i CN3 Engine Specifications ........................................................... 9

Deutz D2011 L03i Engine Specifications ............................................................. 11

Deutz TD2011L04i Engine Specifications ............................................................ 13

Deutz D 2.9 L4 Engine Specifications .................................................................. 15

Perkins 404D-22 Engine Specifications ............................................................... 17

Perkins 404F-22 Engine Specifications ............................................................... 18

Machine Torque Specifications ............................................................................ 20

Hydraulic Hose and Fitting Torque Specifications ............................................... 21

Torque Procedure ................................................................................................ 22

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viii S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Section 3 Repair Procedures ............................................................................................. 24 Introduction .......................................................................................................... 24

Platform Controls ............................................................................................... 26 1-1 ALC-500 Circuit Board ................................................................................... 26

1-2 Joysticks ........................................................................................................ 27

How to Adjust the Joystick Threshold Setting ................................................ 27

How to Adjust the Joystick Max-out Setting ................................................... 28

How to Adjust the Joystick Ramp Rate Setting .............................................. 29

How to Calibrate the Boom Angle Sensor ...................................................... 31

Platform Components ....................................................................................... 32 2-1 Platform Leveling Slave Cylinder ................................................................... 32

2-2 Platform Rotator ............................................................................................. 33

2-3 Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if equipped) ................................ 36

2-4 Platform Load Sense System, S-60 HC ........................................................ 38

How to Restore System Default Settings System .......................................... 41

Jib Boom Components ...................................................................................... 42 3-1 Jib Boom ........................................................................................................ 42

3-2 Jib Boom Lift Cylinder .................................................................................... 43

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Boom Components ............................................................................................ 44 4-1 Cable Track .................................................................................................... 44

How to Remove the Cable Track, S-60, S-60X, S-60XC, S-60 HC and S-60 TRAX .................................... 44

How to Remove the Cable Track, S-65 and S-65 TRAX ................................ 45

How to Repair the Cable Track ....................................................................... 47

4-2 Boom .............................................................................................................. 49

4-3 Boom Lift Cylinder .......................................................................................... 52

4-4 Boom Extension Cylinder ............................................................................... 53

4-5 Boom Extend/Retract Cables ......................................................................... 56

4-6 Platform Leveling Master Cylinder ................................................................. 59

4-7 Primary Boom Angle Sensor, S-60X and S-60XC ......................................... 60

Engines ................................................................................................................ 62 5-1 RPM Adjustment - Ford and Deutz Models ................................................... 62

5-2 RPM Adjustment - Perkins 404D-22 Models ................................................. 62

5-3 Flex Plate - Removal ...................................................................................... 62

How to Install a Type "A" Flex Plate................................................................ 64

How to Install a Type "B" Flex Plate................................................................ 65

How to install the Pump and Bell Housing Assembly ..................................... 66

5-4 Ford MSG-425 Engine Fault Codes ............................................................... 67

5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models ............. 68

Hydraulic Pump .................................................................................................. 69 6-1 Lift/Steer Pump .............................................................................................. 69

6-2 Drive Pump..................................................................................................... 70

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x S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Manifolds ............................................................................................................ 72 7-1 Function Manifold Components (to serial number 26514) ............................ 72

Function Manifold Components (from serial number 26515) .............................. 75

7-2 Valve Adjustments - Function Manifold ......................................................... 80

7-3 Jib Boom / Platform Rotate Manifold Components........................................ 81

7-4 Brake/Two-Speed Manifold Components ...................................................... 82

7-5 Turntable Rotation Manifold Components ..................................................... 83

7-6 Oscillate Directional Valve Components ....................................................... 84

How to Set Up the Oscillate Directional Valve ................................................ 85

7-7 Valve Adjustments - Oscillate Relief Valve .................................................... 86

7-8 Drive Oil Diverter Manifold Components (welder option) .............................. 87

7-9 Traction Manifold Components, 2WD ............................................................ 88

7-10 Valve Adjustments, 2WD Traction Manifold ................................................ 89

7-11 Traction Manifold Components, 4WD .......................................................... 90

7-12 Valve Adjustments, 4WD Traction Manifold ................................................ 92

7-13 Hydraulic Generator Manifold Components, 3kW ....................................... 93

7-14 Valve Coils ................................................................................................... 94

How to Test a Coil Diode ................................................................................ 95

Turntable Rotation Components ...................................................................... 96 8-1 Turntable Rotation Assembly ......................................................................... 96

How to Adjust the Turntable Rotation Gear Backlash .................................... 97

Axle Components............................................................................................... 99 9-1 Oscillating Axle Cylinders .............................................................................. 99

Track Components .......................................................................................... 100 10-1 Track Assembly, S-60 TRAX and S-65 TRAX ........................................... 100

How to Replace a Track ............................................................................... 100

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC xi

Section 4 Fault Codes ....................................................................................................... 103 Introduction ......................................................................................................... 103

Control System Fault Codes ........................................................................... 104 How to Retrieve Control System Fault Codes .............................................. 104

Control System Fault Codes ......................................................................... 105

Fault Code Display - Deutz and Perkins Models ........................................... 110 How to Retrieve Active Engine Fault Codes

Deutz D 2.9 L4, D436 L3i and Perkins 404F-22 Models ............................ 110

Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 111

Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models ....................................... 112

Main Menu Structure - Deutz D 2.9 L4 Models ............................................. 113

Main Menu Structure - Perkins 404F-22 Models .......................................... 114

Deutz D436 L3i Display ................................................................................. 115

Main Menu Structure - Deutz D436 L3i Models ............................................ 116

Deutz D 2.9 L4 Engine Fault Codes ................................................................ 118

Deutz D436 L3i Engine Fault Codes ............................................................... 129

Perkins 404F-22 Engine Fault Codes ............................................................. 131

Ford MSG-425 Engine Fault Codes ................................................................ 133 How to Retrieve Ford MSG-425 Engine Fault Codes ................................... 133

Ford MSG-425 Engine Fault Codes .............................................................. 134

Load Sense System Fault Codes .................................................................... 139 Platform Load Sense System, S-60 HC ............................................................. 139

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xii S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Section 5 Schematics ....................................................................................................... 147 Introduction ........................................................................................................ 147

Electrical Symbol Legend .................................................................................. 148

Hydraulic Symbols Legend ................................................................................ 149

Limit Switch Location Legend ............................................................................ 150

Ford Engine Relay Layout ................................................................................. 151

Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22 ............................ 152

Electrical Schematics Options .................................................................... 153 Ford MSG-425 EFI Engine Wire Harness ......................................................... 154

Deutz D 2.9 L4 Engine Wire Harness ................................................................ 155

Perkins 404F-22 Engine Wire Harness ............................................................. 158

Deutz D436 L3i Engine Wire Harness ............................................................... 159

Electrical Schematic, Options - Deutz D436 L3i ................................................ 162

Electrical Schematic, Options - Deutz D2011L03i, TD2011L04i and Perkins 404D-22 ............................... 163

Electrical Schematic, Options - Deutz D 2.9 L4 ................................................. 166

Electrical Schematic, Options - Perkins 404F-22 .............................................. 167

Wiring Diagram, 3kW Hydraulic Generator ........................................................ 170

Wiring Diagram, 12kW Hydraulic Generator - Welder Option ........................... 171

Electrical Schematic, 12kW Hydraulic Generator - Welder Option .................... 174

Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option ................... 175

Hydraulic Schematics ...................................................................................... 177 Hydraulic Schematic, 2WD Models.................................................................... 178

Hydraulic Schematic, 4WD Models.................................................................... 179

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC xiii

Electrical Schematics ANSI and CSA Models ............................................ 181 Electrical Schematic, Ford MSG-425 EFI Models (ANSI CSA) ....................... 182

Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 186

Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 187

Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 190

Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 191

Electrical Schematic, Deutz D2011L03i Models (ANSI CSA) .......................... 194

Electrical Schematic, Deutz TD2011L04i Models (ANSI CSA) ........................ 198

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 202

Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 203

Platform Control Box Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 206

Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 207

Electrical Schematic, Deutz D 2.9 L4 Models (ANSI CSA) .............................. 210

Ground Control Box Terminal Strip Wiring Diagram, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 214

Ground Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 215

Platform Control Box Wiring Diagram, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 218

Platform Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 219

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xiv S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Deutz D436 L3i Models (ANSI CSA) ............................ 222

Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ....................................................... 226

Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ....................................................... 227

Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ....................................................... 230

Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ....................................................... 231

Electrical Schematic, Perkins 404D-22 Models (ANSI CSA) .......................... 234

Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (ANSI CSA) ..................................................... 238

Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (ANSI CSA) ..................................................... 239

Platform Control Box Wiring Diagram, Perkins 404D-22 Models (ANSI CSA) ..................................................... 242

Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (ANSI CSA) ..................................................... 243

Electrical Schematic, Perkins 404F-22 Models (ANSI CSA) ........................... 246

Ground Control Box Terminal Strip Wiring Diagram, Perkins 404F-22 Models (ANSI CSA) ...................................................... 250

Ground Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI CSA) ...................................................... 251

Platform Control Box Wiring Diagram, Perkins 404F-22 Models (ANSI CSA) ...................................................... 254

Platform Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI CSA) ...................................................... 255

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC xv

Electrical Schematic, S-60X S-60XC Ford MSG-425 EFI Models (ANSI CSA) .................................................. 258

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 262

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 263

Platform Control Box Wiring Diagram, S-60X S-60XC, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 266

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Ford MSG-425 EFI Models (ANSI CSA) .................................................. 267

Electrical Schematic, S-60X S-60XC, Deutz D2011L03i Models (ANSI CSA) ..................................................... 270

Electrical Schematic, S-60X S-60XC, Deutz TD2011L04i Models (ANSI CSA) .................................................. 274

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 278

Ground Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 279

Platform Control Box Wiring Diagram, S-60X S-60XC, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 282

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Deutz D2011L03i TD2011L04i Models (ANSI CSA) .............................. 283

Electrical Schematic, S-60X S-60XC, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 286

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 290

Ground Control Box Switch Panel Wiring Diagram,S-60X S-60XC, Deutz D 2.9 L4 (ANSI CSA) ..................................................................... 291

Platform Control Box Wiring Diagram, S-60X S-60XC, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 294

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Deutz D 2.9 L4 Models (ANSI CSA) ........................................................ 295

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Electrical Schematic, S-60X S-60XC, Deutz D436 L3i Models (ANSI CSA) ....................................................... 298

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Deutz D436 L3i Models (ANSI CSA) ....................................................... 302

Ground Control Box Switch Panel Wiring Diagram,S-60X S-60XC, Deutz D436 L3i (ANSI CSA) .................................................................... 303

Platform Control Box Wiring Diagram, S-60X S-60XC, Deutz D436 L3i Models (ANSI CSA) ....................................................... 306

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Deutz D436 L3i Models (ANSI CSA) ....................................................... 307

Electrical Schematic, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA) ..................................................... 310

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA) ..................................................... 314

Ground Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA) ..................................................... 315

Platform Control Box Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA) ..................................................... 318

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA) ..................................................... 319

Electrical Schematic, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA) ...................................................... 322

Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA) ...................................................... 326

Ground Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA) ...................................................... 327

Platform Control Box Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA) ...................................................... 330

Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA) ...................................................... 331

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC xvii

Electrical Schematics CE Models ................................................................ 333 Electrical Schematic, Ford MSG-425 EFI Models (CE) ..................................... 334

Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (CE) ................................................................ 338

Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE) ................................................................ 339

Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (CE)........... 342

Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE) ................................................................ 343

Electrical Schematic, Deutz D2011L03i Models (CE) ........................................ 346

Electrical Schematic, Deutz TD2011L04i Models (CE) ...................................... 350

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE) ............................................ 354

Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE) ............................................ 355

Platform Control Box Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE) ............................................ 358

Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE) ............................................ 359

Electrical Schematic, Deutz D436 L3i Models (CE) ........................................... 362

Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 366

Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 367

Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 370

Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 371

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Electrical Schematic, Perkins 404D-22 Models (CE) ......................................... 374

Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (CE) ................................................................... 378

Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE) ................................................................... 379

Platform Control Box Wiring Diagram, Perkins 404D-22 Models (CE) .............. 382

Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE) ................................................................... 383

Electrical Schematic, S-60 HC (CE) .................................................................. 386

Chassis Wiring Diagram, S-60 HC (CE) ............................................................ 387

Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (CE) ................. 390

Platform Control Box Wiring Diagram, S-60 HC (CE)........................................ 391

Page 19

July 2017

Table of Contents

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC xix

Electrical Schematics AS Models ................................................................ 393 Electrical Schematic, Ford MSG-425 EFI Models (AS)...................................... 394

Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (AS) ................................................................ 398

Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS) ................................................................ 399

Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (AS) ........... 402

Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS) ................................................................ 403

Electrical Schematic, Deutz D2011L03i Models (AS) ........................................ 406

Electrical Schematic, Deutz TD2011L04i Models (AS) ...................................... 410

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS) ............................................ 414

Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS) ............................................ 415

Platform Control Box Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS) ............................................ 418

Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS) ............................................ 419

Electrical Schematic, Deutz D436 L3i Models (CE) ........................................... 422

Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 426

Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 427

Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 430

Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI CSA) ........................................................ 431

Electrical Schematic, Perkins 404D-22 Models (AS) ......................................... 434

Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (AS) .................................................................... 438

Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS) .................................................................... 439

Platform Control Box Wiring Diagram, Perkins 404D-22 Models (AS) .............. 442

Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS) .................................................................... 443

Page 21

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 1

Section 2 Specificati ons

Machine Specifications Tires and wheels, S-60, S-65, S-60 HC, S-60X and S-60XC Tire size (Rough terrain) 355/55D625 Tire weight, new foam-filled (minimum) (Rough terrain)

415 lbs 188 kg

Tire size (Hi-flotation)

41/18LL x 22.5

Tire ply rating (Rough terrain and Hi-flotation)

Wheel lugs 9@5/8 -18 Lug nut torque, dry 240 ft-lbs

325 Nm Lug nut torque, lubricated 180 ft-lbs

244 Nm Overall tire diameter (Rough terrain, low profile tires)

36.9 in 93.7 cm

Overall tire diameter (Hi-flotation tires)

40.3 in 102.4 cm

Tire pressure (Rough terrain, low profile tires)

70 psi 4.92 bar

Tire pressure (Hi-flotation tires)

60 psi 4.13 bar

Track Components, S-60 TRAX and S-65 TRAX Track material Rubber Tensioning system Pressurized

grease

Weight (each) 1,500 lbs 680 kg

Fluid capacities

Fuel tank (Deutz and Perkins Models) 35 gallons

132.5 liters (Ford models) 30 gallons

113.5 liters LPG tank 33.5 pounds

15.2 kg Hydraulic tank 45 gallons

170 liters Hydraulic system(including tank) 55 gallons

208 liters Drive hubs 20 fl oz

591 cc Turntable rotation drive hub (before serial number 20367)

40 fl oz

1183 cc (after serial number 20366) 43 oz

1262 cc

Drive hub oil type:SAE 90 multipurpose hypoid gear oil API service classification GL5

Page 22

Service and Repair ManualJuly 2017

Specifications

2 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Performance Specifications Boom function speeds, maximum from platform controls Jib boom up (S-65 models) 60 to 70 seconds Jib boom down (S-65 models) 40 to 50 seconds Boom up 60 to 70 seconds

Boom down 60 to 70 seconds Boom extend 58 to 66 seconds Boom retract 53 to 62 seconds Turntable rotate, 360 boom stowed

78 to 86 seconds

Turntable rotate, 360 boom extended

125 to 165 seconds

Platform rotate, 160 8 to 12 seconds

Braking distance, maximum

High range on paved surface 3 to 6 ft 0.9 to 1.8 m

Drive speed, maximum stowed position 2WD models 40 ft / 6.2 sec

12.2 m / 6.2 sec

4WD models 40 ft / 7.2 sec 12.2 m / 7.2 sec

S-60 TRAX and S-65 TRAX 40 ft / 12 sec 12.2 m / 12 sec

Drive speed, maximum raised or extended position S-60, S-65, S-60 HC, S-60X and S-60XC

40 ft / 40 sec 12.2 m / 40 sec

S-60 TRAX and S-65 TRAX 40 ft / 57 sec 12.2 m / 57 sec

Gradeability See Operator's Manual

For operational specifications, refer to the Operator's Manual.

Page 23

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 3

Hydraulic Oil Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation prevention, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Cleanliness level, minimum

ISO 15/13

Water content, maximum

250 ppm

Recommended Hydraulic Fluid

Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200

Optional Hydraulic Fluids

Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46

Shell Tellus S4 VX 32 Shell Shell Donax TG (Dexron III)

Chevron 5606A Biodegradable Petro Canada Environ MV 46 Fire resistant UCON Hydrolube HP-5046

Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult Genie Product Support before use.

Optional fluids may not have the same hydraulic lifespan and may result in component damage.

Note: Extended machine operation can cause the hydraulic fluid temperature to increase beyond it's maximum allowable range. If the hydraulic fluid temperature consistently exceeds 200F / 90C an optional oil cooler may be required.

Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filters, control valves and may result in component damage.

Note: Do not operate the machine when the ambient air temperature is consistently above 120F / 49C.

Hydraulic Fluid Temperature Range

Ambient air temperature

1 Chevron hydraulic oil 5606A 2 Petro-Canada Environ MV 46 3 UCON Hydrolube HP-5046D 4 Chevron Rando HD premium oil MV

Page 24

Service and Repair ManualJuly 2017

Specifications

4 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt @ 200F / 100C cSt @ 104F / 40C

7.5

33.5

Brookfield Viscosity cP @ -4F / -20C cP @ -22F / -30C

1040 3310

Flash point 375F / 190C

Pour point -58F / -50C Maximum continuous operating temperature

171F / 77C

Note: A hydraulic oil heating system is recommended when the ambient temperature is consistently below 0F / -18C.

Note: Do not operate the machine when the ambient temperature is below -20F / -29C with Rando HD Premium MV.

Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt @ 200F / 100C cSt @ 104F / 40C cSt @ -40F / -40C

5.5

15.0 510

Flash point 180F / 82C

Pour point -81F / -63C Maximum continuous operating temperature

124F / 51C

Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0F / -17C unless an oil heating system is used.

Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32F / 0C may result in component damage

Page 25

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 5

Petro-Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt @ 200F / 100C cSt @ 104F / 40C

8.0

44.4

Flash point 482F / 250C Pour point -49F / -45C Maximum continuous operating temperature

180F / 82C

Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300

Kinematic Viscosity cSt @ 200F / 100C cSt @ 104F / 40C

33.8 Brookfield Viscosity cSt @ -4F / -20C cSt @ -13F / -25C cSt @ -40F / -40C

481

702.4 2624

Flash point >100 Pour point -76F / -60C Maximum continuous operating temperature

103F / 75C

UCON Hydrolube HP-5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt @ 149F / 65C cSt @ 104F / 40C cSt @ 0F / -18C

22 46

1300 Flash point None

Pour point -81F / -63C Maximum continuous operating temperature

189F / 87C

Page 26

Service and Repair ManualJuly 2017

Specifications

6 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Hydraulic Component Specifications Drive pump Type: bi-directional, variable displacement piston pump Flow rate @ 2500 rpm 32.4 gpm

122.6 L/min

Drive pressure, maximum 3750 psi 259 bar

Charge pump

Type: gerotor

Displacement 0.85 cu in 13.9 cc

Flow rate @ 2500 rp 9.2 gpm 34.8 L/min

Charge pressure @ 2500 rpm 310 psi 21.4 bar

Function pump

Type: 2 section tandem gear pump Displacement - Pump 1 (inner)

1.4 cu in 23 cc

Flow rate @ 2500 rpm 15.3 gpm 58 L/min

Displacement - Pump 2 (outer)(oscillate models)

0.24 cu in 4 cc

Flow rate @ 2500 rpm 2 gpm 7.6 L/min

Auxiliary pump

Type: gear, fixed displacement Displacement 1.75 gpm

2.8 L/min

Function manifold

System relief valve pressure 3000 psi 207 bar

Steer flow regulator 3.5 gpm 13.2 L/min

Jib boom / platform rotate flow regulator

0.6 gpm 2.27 L/min

Oscillate relief valve pressure (@ 2500 rpm)

800 psi 55 bar

Drive manifold

Hot oil relief valve pressure 280 psi 19.3 bar

Drive motors, 4WD models

Displacement per revolution,high speed

0.79 cu in 13 cc

Displacement per revolution,low speed

1.83 cu in 30 cc

Drive motors, 2WD models

Displacement per revolution,high speed

1.28 cu in 20.9 cc

Displacement per revolution,low speed

2.14 cu in 35 cc

Page 27

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 7

Hydraulic filters

High pressure filter Beta 3 High pressure filter bypass pressure

51 psi 3.5 bar

Medium pressure filter Beta 3 Medium pressure filter bypass pressure

51 psi 3.5 bar

Hydraulic return filter 10 micron with 25 psi / 1.7 bar bypass

Manifold Component Specifications Plug torque SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm SAE No. 6 14 ft-lbs / 19 Nm SAE No. 8 38 ft-lbs / 51 Nm SAE No. 10 41 ft-lbs / 55 Nm

SAE No. 12 56 ft-lbs / 76 Nm .

Page 28

Service and Repair ManualJuly 2017

Specifications

8 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Ford MSG-425 EFI Engine Displacement 153 cu in

2.5 liters

Number of cylinders 4

Bore and Stroke 3.5 x 3.9 inches 89 x 100 mm

Horsepower 60 @ 2500 rpm 45 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low function idle (computer controlled)

1600 rpm 53.3 Hz

High function idle (computer controlled)

2500 rpm 83.3 Hz

Compression ratio 9.7:1

Compression pressure (approx.) Pressure (psi or bar) of lowest cylinder must be at least 75% of highest cylinder

Lubrication system

Oil pressure (operating temperature @ 2500 rpm)

29 to 39 psi 2 to 2.7 bar

Oil capacity (including filter)

6.7 quarts 6.4 liters

Oil Pressure switch

Oil pressure switch point 7 to 9 psi 0.48 to 0.62 bar

Oil viscosity requirements

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.

Electronic fuel pump

Fuel pressure, static 60 psi 4.1 bar

Fuel flow rate 0.43 gpm 1.6 L/min

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Ignition system

Spark plug type Motorcraft AYFS-32Y-R

Spark plug gap 0.049 to 0.053 inches 1.25 to 1.35 mm

Engine coolant

Capacity 10 quarts 9.5 liters

Coolant temperature switch

Temperature switch point 230F 110C

Cylinder head temperature sending unit Fault code set temperature 280F

138C

Engine shut-down temperature

300F 149C

Starter motor

Normal engine cranking speed 200 to 250 rpm Current draw, no load 140-200A Current draw, maximum load 800A

Alternator

Alternator output 95A, 13.8V DC

Battery

Type 12V DC, Group 31 Quantity 1 Cold cranking ampere @ 0F 1000A Reserve capacity @ 25A rate 200 minutes

Page 29

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 9

Deutz D436 L3i CN3 Engine Displacement 177 cu in

2.9 liters

Number of cylinders 4

Bore and Stroke 3.6 x 4.3 inches 92 x 110 mm

Horsepower 48.8 @ 2600 rpm 37 kW @ 2600 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1500 rpm 313 Hz

High idle 2500 rpm 521.7 Hz

Compression ratio 18.4:1

Compression pressure 362 to 435 psi 25 to 30 bar

Governor electronic

Lubrication system

Oil pressure (@ 2000 rpm) 40 to 60 psi 1.4 to 3 bar

Oil capacity (including filter)

9.4 quarts 9 liters

Oil viscosity requirements

-22 F to 86 F/ -30 C to 30 C 5W-30 (synthetic) -4 F to 90 F / -20 C to 32 C 10W-40 Above 23 F / -5 C 20W-50

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Temperature switch point 257F 125C

Oil Pressure switch

Oil pressure switch point 20 psi 1.4 bar

Engine coolant

Capacity 10 quarts 9.4 liters

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum

15000 psi 1034 bar

Injector opening pressure 3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Page 30

Service and Repair ManualJuly 2017

Specifications

10 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Deutz D436 L3i CN3 Engine, continued

Starter motor

Current draw, normal load 250A to 400A

Brush length, new 0.72 in 18.5 mm

Brush length, minimum 0.27 in 7 mm

Battery

Type 12V DC Quantity 1

Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Alternator output 95A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm

Page 31

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 11

Deutz D2011 L03i Engine Displacement 142 cu in

2.33 liters

Number of cylinders 3

Bore and Stroke 3.7 x 4.4 inches 94 x 112 mm

Horsepower 48 @ 2800 rpm 36 kW @ 2800 rpm

Firing order 1 - 2 - 3

Low idle 1500 rpm 313 Hz

High idle 2500 rpm 521.7 Hz

Compression ratio 19:01

Compression pressure 362 to 435 psi 25 to 30 bar

Governor centrifugal mechanical

Valve Clearance, cold

Intake 0.012 in 0.3 mm

Exhaust 0.020 in 0.5 mm

Lubrication system

Oil pressure 40 to 60 psi 1.4 to 3 bar

Oil capacity (including filter)

9.5 quarts 9 liters

Oil viscosity requirements

-22 F to 86 F/ -30 C to 30 C 5W-30 (synthetic) -4 F to 90 F / -20 C to 32 C 10W-40 Above 23 F / -5 C 20W-50 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Temperature switch point 220F 104C

Oil Pressure switch

Oil pressure switch point 22 psi 1.5 bar

Page 32

Service and Repair ManualJuly 2017

Specifications

12 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Deutz D2011 L03i Engine, continued

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum

15000 psi 1034 bar

Injector opening pressure 3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Starter motor

Current draw, normal load 140A to 200A

Brush length, new 0.72 in 18.5 mm

Brush length, minimum 0.27 in 7 mm

Battery

Type 12V DC, Group 34/78

Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Alternator output 60A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm

Page 33

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 13

Deutz TD2011L04i Engine Displacement 220.9 cu in

3.62 liters

Number of cylinders 4

Bore and stroke 3.78 x 4.92 inches 96 x 125 mm

Horsepower Net intermittent @ 2400 rpm

74 / 55 kW

Induction system turbocharged

Firing order 1 - 3 - 4 - 2

Low idle 1500 rpm 450 Hz

High idle 2350 rpm 705 Hz

Compression ratio 17.5:1

Compression pressure Pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder.

Governor centrifugal mechanical

Valve clearance, cold

Intake 0.012 in 0.3 mm

Exhaust 0.020 in 0.5 mm

Lubrication system

Oil pressure, hot(at 2000 rpm) 40to60psi 2.8to4.1bar

Oil capacity(including filter) 12.8 quarts 12.1 liters

Oil viscosity requirements

-22F to 86F / -30C to 30C 5W-30 (synthetic) -4F to 104F / -20C to 40C 10W-40

Above 5F / -15C 15W-40 Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Handbook on your machine.

Oil temperature switch

Installation torque 8-18 ft-lbs 11-24 Nm

Oil temperature switch point 275F 135C

Oil pressure switch

Installation torque 8-18 ft-lbs 11-24 Nm

Oil pressure switch point 22 psi 1.5 bar

Page 34

Service and Repair ManualJuly 2017

Specifications

14 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Deutz TD2011L04i Engine, continued Fuel injection system

Injection pump make Motorpal Injection pump pressure, maximum 15,000 psi

1034 bar

Injector opening pressure 3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's Manual on your machine.

Starter motor

Current draw, normal load 140-200A Cranking speed 250-350 rpm

Battery

Type 12V DC

Size 13 x 613/16 x 93/8 inches 33 x 17.3 x 23.8 cm

Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Alternator output 80A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm

Page 35

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 15

Deutz D 2.9 L4 Engine Displacement 177 cu in

2.9 liters

Number of cylinders 4

Bore and Stroke 3.6 x 4.3 inches 92 x 110 mm

Horsepower 48.8 @ 2600 rpm 37 kW @ 2600 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1500 rpm 313 Hz

High idle 2500 rpm 521.7 Hz

Compression ratio 18.4:1

Compression pressure 362 to 435 psi 25 to 30 bar

Governor electronic

Lubrication system

Oil pressure (@ 2000 rpm) 40 to 60 psi 1.4 to 3 bar

Oil capacity (including filter)

9.4 quarts 9 liters

Oil viscosity requirements

-22 F to 86 F/ -30 C to 30 C 5W-30 (synthetic) -4 F to 90 F / -20 C to 32 C 10W-40 Above 23 F / -5 C 20W-50

Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil temperature switch

Temperature switch point 257F 125C

Oil Pressure switch

Oil pressure switch point 20 psi 1.4 bar

Engine coolant

Capacity 10 quarts 9.4 liters

Fuel injection system

Injection pump make Bosch

Injection pump pressure, maximum

15000 psi 1034 bar

Injector opening pressure 3046 psi 210 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Page 36

Service and Repair ManualJuly 2017

Specifications

16 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Deutz D 2.9 L4 Engine, continued

Starter motor

Current draw, normal load 250A to 400A

Brush length, new 0.72 in 18.5 mm

Brush length, minimum 0.27 in 7 mm

Battery

Type 12V DC Quantity 1

Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Alternator output 95A @ 14V DC

Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm

Page 37

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 17

Perkins 404D-22 Engine Displacement 134 cu in

2.2 liters

Number of cylinders 4

Bore and Stroke 3.31 x 3.94 inches 84 x 100 mm

Horsepower 51 @ 2500 rpm 38 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1300 rpm 229.7 Hz

High idle 2500 rpm 441.7 Hz

Compression ratio 23.3:1

Compression pressure 426 psi 29.4 bar

Pressure (psi) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder

Governor centrifugal mechanical

Valve Clearance, cold

Intake 0.008 in 0.2 mm

Exhaust 0.008 in 0.2 mm

Lubrication system

Oil pressure, cold (at 2500 rpm) 60 psi 4.1 bar

Oil capacity (including filter)

9.3 quarts 8.8 liters

Oil viscosity requirements

Below 86F / 30C 5W-20

-4F to 104F / -20C to 40C 10W-30 Above 14F / -10C 15W-40 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil pressure sending unit

Oil pressure switch point 14.2 psi 1 bar

Fuel injection system

Injection pump make Zexel Injection pressure 2133 psi

147 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Alternator output 55A @ 12V DC

Fan belt deflection 3/8 in 10 mm

Starter motor

Current draw, no load 90A

Brush length, new 0.7480 in 19 mm

Brush length, minimum 0.5 in 12.7 mm

Battery

Type 12V DC

Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Engine coolant

Capacity 7.7 quarts 7.3 liters

Coolant temperature switch

Temperature switch point 221 F 105 C

Page 38

Service and Repair ManualJuly 2017

Specifications

18 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Perkins 404F-22 Engine Displacement 134 cu in

2.2 liters

Number of cylinders 4

Bore and Stroke 3.31 x 3.94 inches 84 x 100 mm

Horsepower 48 @ 2800 rpm 38 kW @ 2500 rpm

Firing order 1 - 3 - 4 - 2

Low idle 1300 rpm 229.7 Hz

High idle 2500 rpm 441.7 Hz

Compression ratio 23.3:1

Compression pressure 426 psi 29.4 bar

Pressure (psi) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder

Governor electronic

Valve Clearance, cold

Intake 0.008 in 0.2 mm

Exhaust 0.008 in 0.2 mm

Lubrication system

Oil pressure (@ 2000 rpm) 40 to 60 psi 1.4 to 3 bar

Oil capacity (including filter)

9.4 - 11.2 quarts 8.9 - 10.6 liters

Oil viscosity requirements

Below 86F / 30C 5W-20 -4F to 104F / -20C to 40C 10W-30 Above 14F / -10C 15W-40 Unit ships with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operator Manual for your engine.

Oil pressure sending unit

Oil pressure switch point 14.2 psi 1 bar

Fuel injection system

Injection pump make Zexel

Injection pressure 2133 psi 147 bar

Fuel requirement

For fuel requirements, refer to the engine Operator Manual for your engine.

Alternator output 85A @ 12V DC

Fan belt deflection 3/8 in 10 mm

Starter motor

Current draw, no load 140A - 200A

Brush length, new 0.7480 in 19 mm

Brush length, minimum 0.5 in 12.7 mm

Page 39

July 2017Service and Repair Manual

Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 19

Perkins 404F-22 Engine, continued

Battery

Type 12V DC

Quantity 1 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes

Engine coolant

Capacity 7.7 quarts 7.3 liters

Coolant temperature switch

Temperature switch point 221 F 105 C

Page 40

Service and Repair ManualJuly 2017

Specifications

20 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Machine Torque Specifications Platform rotator 1-8 center bolt, GR 5 640 ft-lbs

867 Nm

3/8 -16 bolts, GR 8 (use a removable thread locking compound)

33 ft-lbs *45 Nm

1/2 -13 bolts, GR 8 80 ft-lbs 108 Nm

Drive motor and hubs

Drive hub mounting bolts, lubricated 160 ft-lbs 217 Nm

Drive motor mounting bolts, lubricated 55 ft-lbs 75 Nm

Turntable bearing

Rotate bearing mounting bolts, lubricated (to serial number S60X15A-29677, S60XC15A-30038, S6016D-530)

180 ft-lbs 244 Nm

(from serial number S60X15A-29678, S60XC15A-30039, S60X16H-35108, S60XC16H-35119, S60XCM-101, S65XCH-101, S65XCM-101, S6016D-531)

160 ft-lbs 217 Nm

Turntable rotation assembly

Backlash pivot plate, lubricated 320 ft-lbs 433 Nm

TRAX Torque Specifications Sprocket to hub adapter fasteners 3/4 -10 nuts, GR 8, dry 317 ft-lbs

430 Nm

3/4 -10 nuts, GR 8, lubricated 281 ft-lbs 381 Nm

1/2 -13 FHS screws, dry 80 ft-lbs 108 Nm

1/2 -13 FHS screws, lubricated 60 ft-lbs 81 Nm

Hub adapter to drive hub fasteners

Lug nut torque, dry 240 ft-lbs 325 Nm

Lug nut torque, lubricated 180 ft-lbs 244 Nm

Sprocket bearing hub fasteners

1-14 bolts, GR 8, dry 650 ft-lbs 881 Nm

1-14 bolts, GR 8, lubricated 488 ft-lbs 662 Nm

Idler and bogey wheel fasteners

3/4 -10 bolts, GR 8, dry 375 ft-lbs 508 Nm

3/4 -10 bolts, GR 8, lubricated 281 ft-lbs3 81 Nm

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Specifications

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 21

Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-Lok ORFS or 37 JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed.

Seal-Lok Fittings (hose end - ORFS)

SAE Dash Size Torque -4 10 ft-lbs / 13.6 Nm -6 30 ft-lbs / 40.7 Nm -8 40 ft-lbs / 54.2 Nm

-10 60 ft-lbs / 81.3 Nm -12 85 ft-lbs / 115 Nm -16 110 ft-lbs / 150 Nm -20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 245 Nm

JIC 37 Fittings (swivel nut or hose connection)

SAE Dash Size Thread Size Flats -4 7/16-20 2 -6 9/16-18 1

-8 3/4-16 1 -10 7/8-14 1 -12 1 1/16-12 1 -16 1 5/16-12 1

-20 1 5/8-12 1 -24 1 7/8-12 1

SAE O-ring Boss Port (tube fitting - installed into Aluminum)

(all types)

SAE Dash Size Torque -4 14 ft-lbs / 19 Nm -6 23 ft-lbs / 31.2 Nm -8 36 ft-lbs / 54.2 Nm -10 62 ft-lbs / 84 Nm -12 84 ft-lbs / 114 Nm

-16 125 ft-lbs / 169.5 Nm -20 151 ft-lbs / 204.7 Nm -24 184 ft-lbs / 249.5 Nm

Adjustable Fitting Non-adjustable fitting

1 jam nut

SAE O-ring Boss Port (tube fitting - installed into Steel)

SAE Dash Size Torque -4 ORFS / 37 (Adj)

ORFS (Non-adj) 37 (Non-adj)

15 ft-lbs / 20.3 Nm 26 ft-lbs / 35.3 Nm

22 ft-lbs / 30 Nm -6 ORFS (Adj / Non-adj)

37 (Adj / Non-adj) 35 ft-lbs / 47.5 Nm 29 ft-lbs / 39.3 Nm

-8 ORFS (Adj / Non-adj) 37 (Adj / Non-adj)

60 ft-lbs / 81.3 Nm 52 ft-lbs / 70.5 Nm

-10 ORFS (Adj / Non-adj) 37 (Adj / Non-adj)

100 ft-lbs / 135.6 Nm 85 ft-lbs / 115.3 Nm

-12 (All types) 135 ft-lbs / 183 Nm -16 (All types) 200 ft-lbs / 271.2 Nm -20 (All types) 250 ft-lbs / 339 Nm

-24 (All types) 305 ft-lbs / 413.5 Nm

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Specifications

22 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Torque Procedure

Seal-Lok fittings 1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.

Note: The O-ring in Parker Seal Lok fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the O-ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure the O-ring face seal is seated and retained properly.

4 Position the tube and nut squarely on the face seal end of the fitting, and tighten the nut finger tight.

5 Tighten the nut or fitting to the appropriate torque. Refer to the appropriate torque chart in this section.

6 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks.

JIC 37 fittings 1 Align the tube flare (hex nut) against the nose

of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4 Nm.

2 Using a permanent ink marker, make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to Illustration 1.

Illustration 1

1 hex nut 2 reference mark 3 body hex fitting

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3 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.

Note: The marks indicate the correct tightening positions have been determined. Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened.

Illustration 2

1 body hex fitting 2 reference mark 3 second mark

4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting.

5 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks.

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Repair Procedures

24 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Section 3 Repair Pr ocedures

Observe and Obey: Repair procedures shall be completed by a

person trained and qualified on the repair of this machine.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Before Repairs Start: 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 parts are available and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

Machine Configuration: 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 removed

The red Emergency Stop button in the off position at both the ground and platform controls

Wheels chocked

All external AC power supply disconnected from the machine

Boom in the stowed position

Turntable secured with the turntable rotation lock

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Repair Procedures

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 25

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. Then to re-assemble, perform the disassembly steps in reverse order.

Symbols Legend

Safety alert symbolused to alert personnel to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Indicates a imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred after performing a series of steps.

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Platform Controls The platform control box contains one printed circuit board. The ALC-500 circuit board inside the platform control box controls all proportional machine functions from the platform. The joystick controllers at the platform controls utilize Hall Effect technology and require no adjustment. The operating parameters of the joysticks are stored in memory at the ECM circuit board at the platform controls. If a joystick error occurs or if a joystick is replaced, it will need to be calibrated before that particular machine function will operate. Refer to Repair Procedure, How to Calibrate a Joystick.

Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion.

1 ALC-500 circuit board 2 drive/steer joystick controller 3 primary boom up/down,extend/retract and

turntable rotate right/left joystick controller

1-1 ALC-500 Circuit Board Note: When the ALC-500 circuit board is replaced, the joystick controllers will need to be calibrated. Refer to Repair Procedure, How to Calibrate a Joystick.

How to Remove the ALC-500 Circuit Board 1 Push in the red Emergency Stop button to the

off position at both the ground and platform controls.

2 Remove the platform control box lid retaining fasteners. Open the control box lid.

3 Locate the ALC-500 circuit board mounted to the inside of the platform control box.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

4 Attach a grounded wrist strap to the ground screw inside the platform control box.

Component damage hazard. Electrostatic discharge (ESD) can damage printed circuit board components. Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap.

5 Carefully disconnect the wire connectors from the circuit board.

6 Remove the ALC-500 circuit board mounting fasteners.

7 Carefully remove the ALC-500 circuit board from the platform control box.

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1-2 Joysticks

How to Calibrate a Joystick The joystick controllers on this machine utilize digital Hall Effect technology for proportional control. If a joystick controller is disconnected or replaced, it must be calibrated before that particular machine function will operate.

Note: The joystick must be calibrated before the threshold, max-out or ramping can be set.

Note: Perform this procedure with the engine off.

1 Open the platform control box.

2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

3 Turn the key switch to platform control. Do not start the engine.

4 Select a joystick to calibrate.

5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds. Connect the wire harness connector to the joystick.

6 Move the joystick full stroke in either direction and hold for 5 seconds.

7 Return the joystick to the neutral position, pause for a moment, then move the joystick full stroke in the opposite direction. Hold for 5 seconds and return the joystick to the neutral position.

Result: The alarm should sound indicating successful joystick calibration.

Result: The alarm does not sound. Check the electrical connections or replace the joystick.

8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch.

Note: No machine function should operate while performing the joystick calibration procedure.

How to Adj ust the Joystick Thr eshol d Setting

How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate.

Note: Perform this procedure with the boom in the stowed position.

1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Turn the key switch to platform control. Do not start the engine.

3 Push in the platform controls red Emergency Stop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position.

6 When the alarm sounds, release the drive enable toggle switch.

7 Momentarily activate the drive enable toggle switch in the right direction 8 times.

Result: There should be a pause and the alarm should sound 8 times indicating that the machine is in threshold calibration mode.

Result: The alarm does not sound. Repeat steps 3 through 7.

8 Start the engine from the platform controls and press down the foot switch.

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28 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

9 Select a boom function joystick to set the threshold.

10 Slowly move the joystick off center in either direction just until the function begins to move.

11 Slowly move the joystick back towards the neutral position. Just before the function stops moving, move the drive enable toggle switch to either side to set the threshold.

Result: The alarm should sound indicating a successful calibration.

Note: For each joystick axis, the threshold must be set for both directions.

12 Repeat steps 9 through 11 for each direction of boom joystick controlled machine function (boom up/down, boom extend/retract and turntable rotate left/right).

13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved.

Result: The alarm should sound indicating that the settings have been saved in memory.

Note: Do not operate any machine function during the 10 second waiting time.

14 Cycle the red Emergency Stop button off, then back on.

How to Adj ust the Joystick Max- out Setting

How to Adjust the Joystick Max-out Setting The max-out setting of a joystick controls the maximum speed of a joystick-controlled machine function. Whenever a hydraulic cylinder, drive motor or hydraulic pump is replaced, the max-out setting should be adjusted to maintain optimum performance. The max-out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine.

Note: Perform this procedure with the boom in the stowed position.

1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Turn the key switch to platform control. Do not start the engine.

3 Push in the platform controls red Emergency Stop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position.

6 When the alarm sounds, release the drive enable toggle switch.

7 Momentarily activate the drive enable toggle switch in the right direction 4 times.

Result: There should be a pause and the alarm should sound 4 times indicating that the machine is in max-out calibration mode.

Result: The alarm does not sound. Repeat steps 3 through 7.

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 29

8 Start the engine from the platform controls and press down the foot switch.

9 Start a timer and activate the machine function that needs to be adjusted. Record the time it takes for that function to complete a full cycle (ie; boom up).

10 Compare the machine function time with the function times listed in Refer to Specifications, Performance Specifications. Determine whether the function time needs to increase or decrease.

11 While the joystick is activated, adjust the max-out setting to achieve the proper function cycle time. Momentarily move the drive enable toggle switch in the right direction to increase the function speed or momentarily move the drive enable toggle switch in the left direction to decrease the function speed.

Note: Each time the drive enable toggle switch is momentarily moved, the function speed will change in 2% increments from a default of 100%, with a minimum of 60% and a maximum of 120%.

12 Repeat steps 9 through 11 for each joystick controlled machine function.

13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved.

Result: The alarm should sound indicating that the settings have been saved in memory.

Note: Do not operate any machine function during the 10 second waiting time.

How to Adj ust the Joystick Ram p R ate Setting

How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output, when moved out of the neutral position. The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine.

Note: Perform this procedure with the boom in the stowed position.

1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

2 Turn the key switch to platform control. Do not start the engine.

3 Push in the platform controls red Emergency Stop button to the off position.

4 Do not press down the foot switch.

5 Move and hold the drive enable toggle switch in the right position and pull out the red Emergency Stop button to the on position.

6 When the alarm sounds, release the drive enable toggle switch.

7 Momentarily activate the drive enable toggle switch in the right direction 6 times.

Result: There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode.

Result: The alarm does not sound. Repeat steps 3 through 7.

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8 Start the engine from the platform controls and press down the foot switch.

9 Start a timer and simultaneously move the joystick in either direction full stroke. Note how long it takes the function to reach maximum speed. This is the ramp rate.

10 Compare the function ramp rate time with the table and determine whether the ramp rate time needs to increase or decrease.

11 Release the foot switch.

12 Activate the joystick and adjust the ramp rate. Momentarily move the drive enable toggle switch in the right direction to increase the time or momentarily move the drive enable toggle switch in the left direction to decrease the time.

Note: Each time the drive enable toggle switch is momentarily moved, the time will change in 5% increments from a default of 100%, with a minimum of 50% and a maximum of 150%.

13 Repeat steps 9 through 11 for each joystick controlled machine function.

14 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved.

Result: The alarm should sound indicating that the settings have been saved in memory.

Result: The alarm does not sound. The minimum or maximum adjustment has been obtained. No changes can be saved.

Note: Do not operate any machine function during the 10 second waiting time.

15 Cycle the red Emergency Stop button off, then back on.

Ramp rate (factory settings)

Boom up/down transition accelerate 1 second transition decelerate 10 seconds S ramp accelerate 1 second S ramp decelerate 0.45 second

Boom extend/retract accelerate 2 seconds decelerate 0.5 second

Turntable rotate accelerate 2 seconds decelerate 0.75 second

Drive accelerate 2 seconds decelerate to neutral 0.5 second decelerate, change of direction 0.5 second decelerate, coasting 0.75 second decelerate, braking 1 second decelerate, shift from low to high speed 1 second decelerate, shift from high to low speed 4 seconds

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 31

How to C alibr ate the Boom Angle Sensor

How to Calibrate the Boom Angle Sensor The boom angle sensor controls the maximum angle that the boom can attain.

Note: Perform this procedure on a firm, level surface.

1 Pull out the red Emergency Stop button to the on position at the ground controls.

2 Turn the key switch to platform controls.

3 Move and hold the drive enable toggle switch to the right and pull out the red Emergency Stop button to the on position.

4 When the alarm sounds, release the drive enable toggle switch.

5 Momentarily activate the drive enable toggle switch to the right 12 times.

Result: There should be a pause and the alarm should sound 12 times indicating that the machine is in Angle Sensor calibration mode.

6 Start the engine from the platform controls and press down the foot switch.

7 Momentarily activate the drive enable toggle switch to the right 1 time to set the stowed position.

Note: The alarm will not sound indicating the setting.

8 Raise the primary boom to the fully elevated position.

Note: Manually reduce the boom speed as it reaches the fully elevated position.

9 Momentarily activate the drive enable toggle switch to the right 1 time to set the elevated position.

Result: The alarm will sound indicating that the angle sensor has been calibrated.

10 Release the joystick and the foot switch and wait for 10 seconds.

Result: The alarm will sound indicating that the settings have been saved and is leaving calibration mode.

11 Cycle the red Emergency Stop button off, then back on. Start the machine and return to the stowed position.

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2-1 Platform Leveling Slave Cylinder The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closed-circuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Platform Leveling Slave Cylinder Note: Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop.

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. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Extend the boom until the slave cylinder barrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks under the platform for support.

3 Lower the boom until the platform is resting on the blocks just enough to support the platform.

Note: Do not rest the entire weight of the boom on the blocks.

4 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to drive the rod-end pivot pin out.

Crushing hazard. S-65 and S-65 TRAX: The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly supported.

5 Remove the external snap rings from the barrel-end pivot pin.

6 Use a soft metal drift to drive the barrel-end pivot pin out.

7 Carefully pull the cylinder out of the boom to access the hydraulic hoses.

8 Tag, disconnect and plug the hydraulic hoses from the slave cylinder. Cap the fittings on the cylinder.

Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray.

How to Bleed the Slave Cylinder Note: Do not start the engine. Use auxiliary power for this procedure.

1 Simultaneously activate the boom up function and the platform level up function until the boom is fully raised.

2 Simultaneously activate the boom down function and the platform level down function until the boom is fully lowered.

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Platform Components

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 33

2-2 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees.

How to Remove the Platform Rotator

Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position.

1 Remove the platform and platform support.

Note: S-60 HC: If the load sense components are disassembled and/or removed from the platform support, the platform load sense system will need to be calibrated. Refer to Repair Procedure, Platform Load Sense System, S-60 HC.

2 S-60 HC: Tag and disconnect the electrical connector from the platform load sense module.

3 Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the fittings on the rotator.

4 S-65 and S-65 TRAX: Support the jib boom leveling arms and the platform mounting weldment with an appropriate lifting device. Do not apply any lifting pressure.

5 Remove the mounting bolts from the platform mounting weldment. Remove the center bolt and slide the platform mounting weldment off of the platform rotator.

Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported.

6 Support the platform rotator with an appropriate lifting device. Do not apply any lifting pressure.

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S-60, S-60X, S-60XC and S-60 TRAX:

7 Support the rod end of the platform leveling slave cylinder. Protect the cylinder rod from damage.

8 Remove the pivot pin retaining fasteners from both the slave cylinder rod-end pivot pin and the rotator pivot pin.

9 Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the machine.

Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported.

Note: When installing the platform rotator fasteners, torque the fasteners to specifications.

10 Lower the jib boom leveling arms.

Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported.

Note: When installing the platform rotator fasteners, torque the fasteners to specifications.

S-65 and S-65 TRAX:

11 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins. Do not remove the pins.

12 Support the jib boom leveling arms.

13 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine.

Bodily injury hazard. The jib boom leveling arms may fall if not properly supported.

14 Lower the jib boom leveling arms.

Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported.

Note: When installing the platform rotator fasteners, torque the fasteners to specifications.

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 35

How to Bleed the Platform Rotator Note: This procedure will require two people. Do not start the engine. Use auxiliary power for this procedure.

1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right.

2 Place a suitable container underneath the platform rotator.

3 Open the top bleed screw on the rotator, but do not remove it.

4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw.

Crushing hazard. Keep clear of the platform during rotation.

5 Open the bottom bleed screw on the rotator, but do not remove it.

6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw.

Crushing hazard. Keep clear of the platform during rotation.

7 Clean up any hydraulic oil that may have spilled.

8 Rotate the platform fully in both directions and inspect the bleed screws for leaks.

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2-3 Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if equipped)

How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.

Note: For S-60 HC models, Refer to Repair Procedure, Platform Load Sense System, S-60 HC.

Note: Perform this procedure with the machine on a firm, level surface.

1 Turn the key switch to platform control. Start the engine and level the platform.

2 Determine the maximum platform capacity. Refer to the machine serial plate.

3 Remove all weight, tools and accessories from the platform.

Note: Failure to remove all weight, tools and accessories from the platform will result in an incorrect calibration.

4 Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor.

5 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle.

Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 6.

Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Slowly tighten the load spring adjustment nut in a clockwise direction in 10 increments until the overload indicator light turns off, and the alarm does not sound. Proceed to step 8.

Note: The platform will need to be moved up and down and allowed to settle between each adjustment.

Note: There may be a 2 second delay before the platform overload indicator light and alarm responds.

6 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle.

Result: The overload indicator lights are off at the platform and ground controls, and the alarm does not sound. Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light flashes at both the platform and ground controls, and the alarm sounds. Proceed to step 7.

Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5.

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Note: The platform will need to be moved up and down and allowed to settle between each adjustment.

Note: There may be a 2 second delay before the platform overload indicator lights and alarm responds.

7 Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to 2 inches. Allow the platform to settle.

Result: The overload indicator lights are off and the alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashing at the platform and ground controls, and the alarm is sounding. Repeat this procedure beginning with step 5.

Note: There may be a 2 second delay before the platform overload indicator light and alarm responds.

8 Add an additional 10 lb / 4.5 kg test weight to the platform.

Result: The overload indicator light is flashing at both the ground and platform controls, and the alarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at both the ground and platform controls, and the alarm does not sound. Remove the additional 10 lb / 4.5 kg test weight. Repeat this procedure beginning with step 6.

Note: There may be a 2 second delay before the platform overload indicator light and alarm responds.

9 Test all machine functions from the platform controls.

Result: All platform control functions should not operate.

10 Turn the key switch to ground control.

11 Test all machine functions from the ground controls.

Result: All ground control functions should not operate.

12 Using a suitable lifting device, lift the test weight off the platform floor.

Result: The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound.

Note: There may be a 2 second delay before the overload indicator lights and alarm turn off.

13 Test all machine functions from the ground controls.

Result: All ground control functions should operate normally.

14 Turn the key switch to platform control.

15 Test all machine functions from the platform controls.

Result: All platform control functions should operate normally.

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38 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

2-4 Platform Load Sense System, S-60 HC

How to Calibrate the Platform Load Sense System Proper calibration of the load sense system is essential to safe machine operation. Continued use of an improperly calibrated load sense system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised and it could tip over.

Note: For S-60, S-65, S-60 TRAX and S-65 TRAX models, Refer to Repair Procedure, Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if equipped).

Note: Perform this procedure with the boom fully retracted and in the stowed position and with the machine on a firm, level surface.

Note: The platform overload system will not allow partial calibration and must be completed in its entirety.

1 At the ground controls, turn the key switch to the off position and push in the red Emergency Stop button to the off position. Pull out the red Emergency Stop button to the on position at the platform controls.

2 Remove all weight, tools and equipment from the platform.

Tip-over hazard. Failure to remove all weight, options, accessories and/or tools from the platform or subtracting the weight of those items from the test weights, will result in the platform load sense system not calibrating correctly. This will allow too much weight to be added to the platform which will result in the machine tipping over.

3 Open the ground control box and locate the calibration toggle switch near the relays.

Note: If either the operational and/or safety controller has been replaced or if the software has been updated, restore the system to the default settings and then continue to step 4. Refer to Repair Procedure, How to Restore the Default Settings. Otherwise, continue to step 4 to enter calibration mode.

4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position.

Result: The alarm sound for approximately 2 seconds.

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5 Activate and release the calibration toggle switch 3 times within 2 seconds after the alarm sounds to enter calibration mode.

Result: The alarm should sound for 1 second indicating the first calibration step was accepted. The green LED on the operational controller should be blinking fast and the red LED should be blinking twice indicating that step 2 of calibration is next.

Result: The alarm did not sound and the green LED on the operational controller is not blinking fast. Repeat this procedure beginning with step 1.

Note: Once calibration mode is entered and begun, there is a 8 minute time limit between each calibration step. If any one step passes the 8 minute time limit, the system will time out and the calibration process will need to be repeated beginning with step 1.

1 green LED (operational control module) 2 red LED (operational control module) 3 operational control module 4 safety control module 5 red LED (safety control module) 6 green LED (safety control module)

6 Start the engine from the ground controls.

7 Raise the boom until the distance, when measured between the centers of the pivot pins shown, equals 108.75 inches / 276 cm 0.75 inch / 19 mm.

Crushing hazard. Keep clear of all moving parts of the boom while the boom is raising. Do not attempt to measure between the pivot pins while the boom is moving.

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Operational Control Module LED Status Description Definition Green and Red LED's not flashing

System calibrated

Green LED flashing rapidly

System in calibration mode

Red LED flashing with pauses

Indicates next calibration step (ie; 2, 3, etc.)

Safety Control Module LED Status Description Definition Green and Red LED's not flashing

System calibrated

Green and Red LED's flashing alternately

System not calibrated

8 Activate the calibration toggle switch inside the ground control box 1 time.

Result: The alarm should sound for 1 second indicating the second calibration step was accepted. The green LED on the operational controller should be blinking fast and the red LED should be blinking three times indicating that step 3 of calibration is next.

9 Raise the boom until the distance, when measured between the centers of the pivot pins shown, equals 167.25 inches / 424.8 cm 0.75 inch / 19 mm.

Crushing hazard. Keep clear of all moving parts of the boom while the boom is raising. Do not attempt to measure between the pivot pins while the boom is moving.

10 Activate and release the calibration toggle switch inside the ground control box 1 time.

Result: The alarm should sound for 1 second indicating the third calibration step was accepted. The green LED on the operational controller should be blinking fast and the red LED should be blinking four times indicating that step 4 of calibration is next.

11 Fully raise and extend the boom.

12 Activate and release the calibration toggle switch inside the ground control box 1 time.

Result: The alarm should sound for 1 second indicating the fourth calibration step was accepted. The green LED on the operational controller should be blinking fast and the red LED should be blinking five times indicating that step 5 of calibration is next.

13 Fully retract and lower the boom to the stowed position.

14 Using a suitable lifting device, place an appropriate test weight equal to 750 lbs / 340.2 kg on to the center of the platform floor.

Note: If your machine is equipped with any platform accessories or options, they must be removed from the platform OR the weights of those options or accessories must be subtracted from the test weights to accurately calibrate the platform load sense system.

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15 Activate and release the calibration toggle switch inside the ground control box 1 time.

Result: The alarm should sound for 1 second indicating the fifth calibration step was accepted. The green LED on the operational controller should be blinking fast and the red LED should be blinking six times indicating that step 6 of calibration is next.

16 Using a suitable lifting device, place an additional test weight equal to 510 lbs / 231.3 kg on to the center of the platform floor. The total weight in the platform must equal 1260 lbs / 571.5 kg.

17 Activate and release the calibration toggle switch inside the ground control box 1 time.

Result: The alarm should sound for 1 second indicating the sixth calibration step was accepted. The engine may turn off and the alarm may sound indicating an overloaded platform.

18 At the ground controls, push in the red Emergency Stop button to the off position, then pull out the red Emergency Stop button to the on position to reset the system.

19 Visually inspect the LEDs on the controllers.

Result: All LEDs on both controllers should be off indicating the platform load sense system is calibrated.

20 At the ground controls, push in the red Emergency Stop button to the off position.

21 Using a suitable lifting device, remove the test weights from the platform.

22 Pull out the red Emergency Stop button to the on position at the ground controls and visually inspect the LEDs on the operational and safety controllers.

Result: Both the green and red LEDs on both controllers should be off indicating the system is calibrated.

Note: If an LED is blinking on either controller, the load sense system is not calibrated correctly or a fault may exist. Refer to Fault Codes Section to determine the system fault. How to R estore System Default Setti ngs System

How to Restore the System Default Settings 1 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on position.

Result: The alarm should sound a long tone.

2 Activate and hold the calibration toggle switch for 5 seconds.

Result: The alarm should sound a tone for 1 second.

3 Push in the red Emergency Stop button to the off position.

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3-1 Jib Boom

How to Remove the Jib Boom Note: Perform this procedure with the boom in the stowed position.

1 Remove the platform.

2 Remove the platform mounting weldment.

3 Remove the hose and cable cover from the side of the jib boom.

4 Remove the hose and cable clamp from the jib boom pivot pin. Lay all hoses and cables to the side.

Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.

5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.

6 Attach a lifting strap from an overhead crane to the jib boom assembly.

7 Place blocks under the platform leveling cylinder for support. Protect the cylinder rod from damage.

8 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

Crushing hazard. The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly attached to the overhead crane.

9 Remove the pin retaining fastener from the jib boom bellcrank to primary boom pivot pin.

10 Use a soft metal drift to remove the pin and carefully remove the jib boom assembly from the primary boom.

Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

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3-2 Jib Boom Lift Cylinder

How to Remove the Jib Boom Lift Cylinder Note: Perform this procedure with the boom in the stowed position.

1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform.

Note: Do not rest the entire weight of the boom on the blocks.

2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.

3 Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin.

4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin.

5 Support the jib boom lift cylinder with a lifting device.

6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.

Crushing hazard. The platform and jib boom could become unbalanced and fall when the jib boom barrel-end pivot pin is removed if not properly supported.

7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder.

8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the cylinder from the machine.

Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane.

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4-1 Cable Track The primary boom cable track guides the cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire primary boom cable track is only necessary when performing major repairs that involve removing the primary boom. How to R emove the Cable Track , S-60, S-60X, S-60XC , S- 60 HC and S-60 TR AX

How to Remove the Cable Track, S-60, S-60X, S-60XC, S-60 HC and S-60 TRAX 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. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Raise the boom to a horizontal position.

2 Locate the cables from the boom cable track to the platform control box. Number each cable and its entry location at the platform control box.

3 Disconnect the cables from the platform control box.

4 Remove the electrical outlet box bracket mounting fasteners. Remove the outlet box and lay it to the side.

5 Remove the hose and cable clamp from the platform support.

6 Tag, disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator. Cap the fittings on the manifold.

7 Tag, disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom. Cap the bulkhead fittings.

8 Locate all electrical cables under the boom at the pivot end that enter the cable track.

9 Tag and disconnect the electrical connectors for all cables that enter the cable track.

10 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track.

11 Carefully pull the cables and connector receptacles out of the primary boom.

12 Tag, disconnect and plug all hydraulic hoses that enter the cable track from the bulkhead fittings at the pivot end of the boom.

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13 Pull the four hydraulic hoses toward the platform to clear the rod end of the primary boom lift cylinder.

14 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together.

Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

15 Attach a strap from an overhead crane to the cable track.

16 Remove the cotter pin from the cable track pull tube at the platform end of the boom.

Note: Always replace the cotter pin with a new one.

17 Remove the cable track pull tube guide fasteners from the cable track guide at the platform end of the boom. Remove the cable track guide from the boom.

18 Remove the cable track mounting fasteners that attach the lower cable track to the primary boom.

19 Carefully remove the cable track from the machine and place it on a structure capable of supporting it.

Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Component damage hazard. The cable track can be damaged if it is twisted.

How to R emove the Cable Track , S-65 and S-65 TR AX

How to Remove the Cable Track, S-65 and S-65 TRAX 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. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Open the platform control box.

2 Tag and disconnect the foot switch wiring from the terminal strip inside the platform control box. Pull the wiring out of the platform control box.

3 Raise the boom to a horizontal position.

4 Disconnect the wire connectors from the bottom of the platform control box.

Note: When installing the wire connectors to the bottom of the platform control box, match the color of the connectors to those on the control box to be sure they are installed in the correct location.

5 Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side.

6 Remove the hose and cable clamps from the platform support and jib boom.

7 Tag, disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the side of the primary boom. Cap the bulkhead fittings.

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8 Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports of the jib boom/platform rotate manifold. Cap the fittings on the manifold.

9 Remove the hose and cable cover from the side of the jib boom.

10 Locate all electrical cables under the boom at the pivot end that enter the cable track.

11 Tag and disconnect the electrical connectors for all cables that enter the cable track.

12 Remove the retaining fasteners from the electrical connector receptacles for the cables that enter the cable track.

13 Carefully pull the cables and connector receptacles out of the primary boom.

14 Tag, disconnect and plug all hydraulic hoses that enter the cable track from the bulkhead fittings at the pivot end of the boom.

15 Pull the hydraulic hoses out of the primary boom.

16 Remove the cotter pin from the upper cable track at the platform end of the boom.

Note: Always replace the cotter pin with a new one.

17 Remove the cable track pull tube guide fasteners from the cable track guide at the platform end of the boom. Remove the cable track guide from the boom.

18 Place blocks in between the upper and lower cable tracks and secure the upper and lower tracks together.

Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine.

19 Attach a lifting strap from an overhead crane to the cable track.

20 Remove the mounting fasteners that attach the lower cable track to the boom.

21 Carefully remove the cable track from the machine and place it on a structure capable of supporting it.

Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane.

Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched.

Component damage hazard. The cable track can be damaged if it is twisted.

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How to R epair the C abl e Tr ack

How to Repair the Cable Track

Component damage hazard. The boom cable track can be damaged if it is twisted.

Note: A 4 link repair section of cable track is available through the Genie Service Parts Department.

1 Visually inspect the cable track and determine which 4 link section needs to be replaced.

2 Carefully remove the snap rings from each end of the damaged section of cable track.

3 Remove the retaining fasteners from the upper black rollers from the 4 link section of cable track to be replaced. Remove the rollers.

4 Lift up the hoses and cables and carefully remove the damaged 4 link section of cable track.

Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.

5 Remove the upper rollers from the replacement section of cable track.

6 Lift up the hoses and cables and carefully insert the new 4 link section of cable track.

Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched.

7 Connect the ends of the replacement cable track section to the existing cable track using the snap rings.

8 Install the rollers onto the new section of cable track.

9 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track.

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Boom components 1 short link arm to boom pivot pin 2 boom 3 boom lift cylinder rod-end pivot pin 4 boom lift cylinder 5 long link arm (ground controls side) 6 long link arm (engine side) 7 long link arm to turntable pivot pin 8 master cylinder cam 9 master cylinder cam link 10 short link arm to turntable pivot pin 11 long link arm to boom pivot pin 12 master platform level cylinder 13 short link arm weldment

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4-2 Boom

How to Remove the Boom

TIp-over hazard. This procedure requires the removal of the turntable counterweight. Failure to remove the counterweight before removing the boom assembly will result in the machine tipping over. Do not remove the boom without first removing the counterweight.

TIp-over hazard. When installing the boom onto the machine, the boom assembly must be first installed prior to the installation of the counterweight. If the counterweight is installed before the boom assembly, the machine will tip over resulting in death or serious injury.

TIp-over hazard. The turntable counterweight is essential for machine stability. Failure to install the counterweight after installing the boom assembly will compromise machine stability resulting in the machine tipping over. Death or serious injury will result.

Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended.

Note: Perform this procedure with the boom in the stowed position.

1 Remove the jib boom. Refer to Repair Procedure, How to Remove the Jib Boom.

2 Remove the cable track. Refer to Repair Procedure, How to Remove the Cable Track.

Note: S-60X and S-60XC: Disconnect the two limit switch connectors at the platform end of the cable track.

3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers.

4 Place a block of wood measuring 4 x 4 x 60 inches / 10 x 10 x 152 cm under the long link arm, across the turntable covers.

5 Slowly lower the boom until the long link arm contacts the wood block. Do not rest the entire weight of the boom on the block. Turn the machine off.

Component damage hazard. The turntable covers can become damaged if the weight of the boom is allowed to rest on the block.

6 Place wood blocks between the short link arm and the turntable weldment for support.

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7 Insert a 1.125 x 12 inches / 32 x 300 mm eye-bolt through each hole located on the top surface of the counterweight. Secure the eye-bolts in position with flat washers and nuts.

8 Securely attach lifting straps or chains with a minimum rating of 5 tons / 5000 kg to the lifting points on the top of the turntable counterweight. Attach the lifting straps or chains to a 5 ton / 5000 kg overhead crane.

Note: A spreader bar and other hardware may be needed to safely remove the counterweight.

9 Slowly operate the overhead crane to apply tension to the lifting straps. Do not attempt to lift the machine with the overhead crane.

10 Locate and remove the counterweight retaining fastener at the center of the counterweight. Carefully lift the counterweight upwards and remove the counterweight from the machine. Set the counterweight on the ground. Do not leave the counterweight suspended above the ground.

Crushing hazard. The turntable counterweight will fall if not properly supported by the overhead crane resulting in death or serious injury. Keep personnel away from the area when removing the counterweight.

11 Attach lifting straps from a 5 ton / 5000 kg overhead crane to each end of the boom. Support the boom. Do not apply any lifting pressure.

12 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device.

13 Remove the lift cylinder rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin.

Crushing hazard. The boom could fall if not properly supported when the lift cylinder rod-end pivot pin is removed.

14 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off.

Crushing hazard. The boom lift cylinder could fall if not properly supported and secured to the lifting device.

15 Using the overhead crane, carefully lower the boom lift cylinder and allow it to rest on the boom rest pad. Protect the cylinder rod from damage.

16 S-60, S-60X, S-60XC, S-65, S-60 TRAX and S-65 TRAX: Remove the boom end cover retaining fasteners and remove the cover.S-60 HC: Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover. Rest the cover and string potentiometer on the counterweight.

Component damage hazard. The cable from the string potentiometer can become damaged if it is kinked or pinched.

17 S-60 HC: Remove the string potentiometer cable break limit switch mounting fasteners.

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18 S-60 HC:Remove the pulley retaining plate from the string potentiometer pulley bracket. Carefully remove the string potentiometer cable and limit switch assembly from the boom.

19 S-60X and S-60XC: Disconnect the boom angle sensor harness.

20 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

21 Tag and disconnect the electrical connector for the cable break limit switch.

22 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom.

23 Support the platform leveling master cylinder. Remove the master cylinder rod-end pivot pin retaining fasteners. Place a rod through the pin and twist to remove. Carefully lower the master cylinder down.

24 Tag, disconnect and plug the hydraulic hoses from the bulkhead fittings at the pivot end of the boom. Cap the bulkhead fittings.

25 Remove the external snap rings from both boom pivot pins at the short and long link arms. Do not remove the pins.

26 Using the overhead crane, adjust the boom as necessary to relieve pressure from the pivot pins.

27 Use a soft metal drift to remove each boom pivot pin. Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it.

Crushing hazard. The boom assembly can fall if not properly supported by the overhead crane.

Crushing hazard. The long and short link arms may fall if not properly supported when the boom pivot pins are removed.

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4-3 Boom Lift Cylinder The boom lift cylinder raises and lowers the boom. The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Boom Lift Cylinder

1 Raise the boom to a horizontal position.

2 Attach a 5 ton / 5000 kg overhead crane to the boom at the platform end for support. Do not lift the boom.

3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device.

4 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin.

Crushing hazard. The boom will fall if not properly supported when the primary boom rod-end pivot pin is removed.

5 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off.

6 Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder.

7 Remove the pin retaining fasteners from the boom lift cylinder barrel-end pivot pins. Do not remove the pins.

8 Use a slide hammer to remove the barrel-end pivot pins.

Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device.

9 Move the boom lift cylinder towards the counterweight end of the machine. Rotate the boom lift cylinder until the barrel-end pivot pin bores will clear the boom linkage.

10 Carefully remove the boom lift cylinder from the machine.

Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device.

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4-4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube. The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure.

How to Remove the Boom Extension Cylinder

Note: Perform this procedure with the boom fully retracted.

1 Raise the boom to a horizontal position.

2 S-60, S-60X, S-60XC, S-65, S-60 TRAX and S-65 TRAX: Remove the boom end cover retaining fasteners and remove the cover.S-60 HC: Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover. Rest the cover and string potentiometer on the counterweight.

Component damage hazard. The cable from the string potentiometer can become damaged if it is kinked or pinched.

3 S-60 HC: Remove the string potentiometer cable break limit switch mounting fasteners.

4 S-60 HC:Remove the pulley retaining plate from the string potentiometer pulley bracket. Carefully remove the string potentiometer cable and limit switch assembly from the boom.

5 Remove the access covers from both sides of the boom at the pivot end.

6 Fully loosen the lock nuts on the extend cables. Do not remove the nuts.

7 Loosen the retract cable nut at the platform end of the boom. Pull the cable rod from the support and let it hang down.

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8 Remove the cable guard fasteners and remove the cable guard.

1 cable guard 2 retaining block

9 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube.

10 Remove the cable retaining plates and pull the retract cables off of the pulleys. Lay the cables flat and out of the way.

11 Remove the fasteners from the retaining blocks from the extension cylinder saddle. Remove the blocks.

Note: Access the fasteners through the access hole in the outer boom tube at the pivot end.

12 Disconnect the wire connector to the extend cable break limit switch.

13 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube.

1 extend cable lock nuts 2 extend cable mounting plate 3 extend cable mounting plate fastener 4 extend cable bracket

14 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube.

15 Lift up the extend cable mounting plate and push the extend cables towards the platform to create slack in the cables. Rest the cable and bracket assembly on top of the extend cylinder.

16 Locate the lower extend cable bracket on the bottom of the number 3 boom tube.

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17 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom tube.

18 While pushing the lower extend cable bracket towards the platform, pull the extend cable mounting plate towards the pivot end of the boom.

19 Secure the extend cable bracket and cables to the cylinder to prevent them from falling off when removing the cylinder.

20 Remove the external snap rings from the extension cylinder pin at the pivot end of the boom.

21 Use a soft metal drift to remove the pin.

22 Tag, disconnect and plug the boom extension cylinder hydraulic hoses. Cap the fittings on the cylinder.

23 Attach a lifting strap from a 5 ton / 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder.

24 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube.

25 Carefully support and slide the extension cylinder out of the boom.

Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported.

Component damage hazard. Be careful not to damage the cable break limit switch.

Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom.

Note: During removal of the extension cylinder, the overhead crane strap will need to be carefully adjusted for proper balancing.

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4-5 Boom Extend/Retract Cables

How to Adjust the Boom Extend/Retract Cables The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Proper adjustment of the boom extend/retract cables and related components on a regular basis is essential to good machine performance and safe machine operation. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise.

Note: Perform this procedure with the boom in a horizontal position.

1 Fully retract the boom.

2 S-60, S-60X, S-60XC, S-65, S-60 TRAX and S-65 TRAX: Remove the boom end cover retaining fasteners and remove the cover.

S-60 HC: Remove the boom end cover from the pivot end of the boom while guiding the small cable from the string potentiometer out of the slot of the cover. Rest the cover and string potentiometer on the counterweight.

Component damage hazard. The cable from the string potentiometer can become damaged if it is kinked or pinched.

3 Inspect the threaded ends of the boom extend cables. The threads must be clean and in good condition with no damaged threads.

4 Adjust the extend cable adjustment nuts until approximately 1.5 inches / 4 cm of threads are visible past the nylock nut.

Note: If the cables have been replaced, be sure the adjustment nuts have been replaced. Do not re-use the existing nuts.

5 Extend the boom until there is approximately 3 feet / 1 m of travel left. Do not fully extend the boom.

6 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom.

7 Using a dial type torque wrench, torque the retract cable adjustment nut to 32-36 ft lbs / 43-49 Nm using gentle and steady torque.

8 Retract and extend the boom approximately 3 feet / 1 m two times and stop during the extension cycle. This will create slack in the retract cables.

Note: Be sure to not fully extend the boom. Stop when there is approximately 3 feet / 1 m of travel left.

9 Repeat steps 7 and 8 two to three times.

10 Fully extend the boom then retract the boom approximately 12 inches / 30 cm.

11 At the pivot end of the boom, visually inspect the boom extend cables for even cable droop or sag.

Note: If the boom extend cables are uneven, tighten the boom extend cable adjustment nut at the pivot end of the boom for the appropriate cable.

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12 Visually inspect the cable break limit switch arm to be sure 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 should be centered in the notch of the pivot plate.

1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate

13 Install the boom end cover at the pivot end of the boom.

14 Fully retract and lower the boom to the stowed position.

How to Replace the Boom Extend/Retract Cables Note: The cable pulleys must also be replaced when replacing the cables.

1 Remove the boom extension cylinder. Refer to Repair Procedure, How to Remove the Boom Extension Cylinder.

Boom extend cables:

2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube.

3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch.

4 Remove the external snap rings from the boom extend cable pulley pivot pin. Use a soft metal drift to remove the pin.

Note: When driving the pivot pin out, be sure to drive it from the shaped end of the pin.

5 Remove the pulley and boom extend cables from the extension cylinder assembly. Discard the old cables and pulleys.

6 Route the new boom extend cables through the boom extend pulley bracket.

7 Install the new boom extend cable pulley, pivot pin and snap rings.

Note: Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder.

8 Install the boom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch.

9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube.

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Boom retract cables:

10 Remove the cotter pins and clevis pins from the boom retract cables at the platform end of the boom.

Note: Always use a new cotter pin when installing a clevis pin.

11 Remove the wear pad fasteners from the upper wear pads on the number 1 boom tube. Remove the wear pads.

Note: Pay attention to the location of each wear pad and the quantity of shims for each one.

12 Attach a lifting strap from an overhead crane to the platform end of the boom.

13 Raise the boom using the overhead crane and place a wood block under the number 2 boom tube between the number 1 and number 2 boom tubes for support. This will create clearance between the boom tubes to remove the retract cables.

14 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom.

Note: A cable pulling tool is available through Genie Service Parts Department (Genie part no. 94510)

15 At the platform end of the boom, pull on the boom retract cable that has the rope attached to it.

16 Pull the old cable completely out of the boom tube. Remove the rope. Discard the old boom retract cable.

17 Securely attach the rope to the same end of the new boom retract cable.

18 At the pivot end of the boom, carefully pull the rope with the new retract cable attached.

19 Pull the new cable towards the pivot end of the boom until the end of the cable is at the end of the boom tube. Remove the rope.

20 Repeat steps 14 through 19 for the other boom retract cable.

21 At the platform end of the boom, install the retract cables, clevis pins and new cotter pins to the adjustment plate.

22 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder.

23 Install the new boom retract pulleys to the pivot end of the boom extension cylinder.

24 Install the boom extension cylinder assembly into the boom.

Note: Before lowering the extension cylinder into the saddles of the number 1 boom tube, wrap the boom retract cables around the pulleys.

25 Adjust the boom extend/retract cables. Refer to Repair Procedure, How to Adjust the Boom Extend/Retract Cables.

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4-6 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder. Its part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion. The master cylinder is located at the pivot end of the boom.

How to Remove the Platform Leveling Master Cylinder 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. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Raise the boom until the master cylinder is above the turntable covers.

2 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder.

3 Place a 2 x 4 x 48 inches / 5 x 10 x 120 cm block of wood across the turntable covers. Position the block under the master cylinder.

4 Remove the pin retaining fastener from the master cylinder rod-end pivot pin.

5 Place a rod through the rod-end pivot pin and twist to remove the pin. Lower the rod end of the master cylinder onto the block.

6 Remove the pin retaining fastener from the barrel-end pivot pin.

7 Place a rod through the barrel-end pivot pin and twist to remove the pin.

8 Remove the master cylinder from the machine.

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4-7 Primary Boom Angle Sensor, S-60X and S-60XC The primary boom angle sensor works in conjunction with the boom extend limit switches when restricted maximum platform load is selected from the platform controls maintaining the working envelope. The primary boom angle sensor is located on the ground control side long link arm.

How to Replace the Primary Boom Angle Sensor 1 From the ground controls raise the primary

boom until it is fully elevated.

2 Push in the red Emergency Stop button to the off position and turn the key switch to the off position.

3 Locate the primary boom angle sensor mounted on the ground control side long link arm.

4 Cut and discard the two button cable ties securing the angle sensor harness to the gusset plate.

5 Locate and disconnect the angle sensor harness connector.

6 Remove the angle sensor retaining fasteners and set aside. Remove the angle sensor.

7 Install the angle sensor onto the hex key. Refer to the illustration for proper alignment.

1 button cable ties 2 start orientation 3 finish orientation 4 gusset plate

8 Install the angle sensor retaining fastners. Do not tighten at this time.

9 Route the angle sensor harness through the gusset plate and secure using two button cable ties.

10 Securely connect the angle sensor harness to the main harness.

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11 Turn the key switch to platform controls. Pull up red Emergency Stop buttons at the ground and platform controls to the on position.

12 Using a volt meter set to DC volts, back probe the angle sensor harness connector. Insert the negative lead into terminal 2, the positive lead into terminal 3.

13 Adjust the angle sensor until the volt meter reads 3.8V dc to 4.2V dc and securely tighten the fasteners.

14 Calibrate the boom angle sensor. Refer to Repair Procedure, How to Calibrate the Boom Angle Sensor.

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5-1 RPM Adjustment - Ford and Deutz Models Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine, Check and Adjust the Engine RPM.

5-2 RPM Adjustment - Perkins 404D-22 Models Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine, Check and Adjust the Engine RPM.

5-3 Flex Plate The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump.

Two different styles of flex plates have been used in the production of your machine model. Type "A" flex plates utilize a flex plate installed onto the flywheel of the engine and a separate coupler installed onto the pump splined shaft.

Type "B" flex plates combines the pump coupler, as part of the flex plate, which is installed onto the engine flywheel.

Type "A" (flexplate with separate

coupler)

Type "B" (flexplate with coupler

combined)

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How to Remove the Flex Plate Deutz models:

1 Remove the tailpipe bracket mounting fasteners from the engine bell housing.

2 Support the drive pump assembly with an appropriate lifting device.

3 Remove all of the engine bell housing fasteners.

4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving.

Component damage hazard. Hoses can be damaged if they are kinked or pinched.

5 Remove the flex plate mounting fasteners, then remove the flex plate from the engine flywheel.

Ford models:

1 Disconnect the electrical connectors from both oxygen sensors at the tailpipe and exhaust manifold. Do not remove the oxygen sensors.

2 Remove the exhaust pipe fasteners at the muffler.

3 Support the muffler and bracket assembly with a suitable lifting device.

4 Remove the muffler bracket mounting fasteners from the bell housing. Carefully remove the muffler and bracket assembly from the engine.

5 Support the engine with an overhead crane or other suitable lifting device. Do not lift it.

6 Remove the engine mounting plate to bell housing fasteners.

7 Raise the engine slightly using the overhead crane and place a block of wood under the oil pan for support.

8 Support the drive pump assembly with an overhead crane or other suitable lifting device. Do not apply any lifting pressure.

9 Remove all of the engine bell housing retaining fasteners.

10 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving.

Component damage hazard. Hoses can be damaged if they are kinked or pinched.

11 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel.

Perkins models:

1 Remove the fuel filter/water separator mounting fasteners.

2 Remove the fuel filter/water separator and lay it to the side. Do not disconnect the hoses.

3 Support the drive pump assembly with an appropriate lifting device.

4 Remove all of the engine bell housing fasteners.

5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving.

Component damage hazard. Hoses can be damaged if they are kinked or pinched.

6 Remove the flex plate mounting fasteners.

7 Remove the flex plate from the flywheel.

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How to Ins tall a Type " A" Flex Plate

How to Install a Type "A" Flex Plate 1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.

2 Ford models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm.

Deutz models: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm.

Perkins models: Torque the flex plate mounting bolts in sequence to 49 ft-lbs / 66 Nm. Then torque the flex plate mounting bolts in sequence to 70 ft-lbs / 95 Nm.

Ford and Deutz Models

Perkins Models

3 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine.

1 pump 2 pump shaft 3 pump coupler 4 flex plate with raised spline 5 engine flywheel 6 3/16 inch / 4.8 mm gap - Diesel Models

0.080 inch / 2 mm gap - Ford Models

4 Apply Loctite removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm.

5 Proceed to Repair Procedure, How to Install the Pump and Bell Housing Assembly.

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How to Ins tall a Type " B" Flex Plate

How to Install a Type "B" Flex Plate 1 Install the flex plate onto the engine flywheel

with the rubber vibration isolators towards the pump.

2 Apply Loctite removable thread sealant to the flex plate fasteners and loosely install the fasteners.

3 Deutz models: Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Then torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm.

Ford and Perkins models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm. Then torque the flex plate mounting bolts in sequence to 20 ft-lbs / 27 Nm.

4 Apply a high viscosity coupling grease (Genie part number 128025) to the splines of the pump shaft and flex plate.

Grease Specification Shell Alvania Grease CG, NLGI 0/1 or equivalent.

Ford Models

Deutz Models

Perkins Models

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How to i nstall the Pum p and Bell H ousing Assembly

How to install the Pump and Bell Housing Assembly 1 Install the pump and bell housing assembly.

Deutz models: Torque the bell housing mounting bolts labeled "C" in sequence to 28 ft-lbs / 38 Nm. Then torque the bell housing mounting bolts labeled "C" in sequence to 40 ft-lbs / 54 Nm.

Ford models: Torque the bell housing mounting bolts labeled "A" and "B" in sequence to 28 ft-lbs / 38 Nm and the mounting bolts labeled "C" to 49 ft-lbs / 66 Nm. Then torque the bell housing mounting bolts labeled "A" and "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "C" to 70 ft-lbs / 95 Nm.

Perkins models: Torque the bell housing mounting bolts labeled "B" in sequence to 28 ft-lbs / 38 Nm and the mounting bolts labeled "A" to 49 ft-lbs / 66 Nm. Then torque the bell housing mounting bolts labeled "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "A" to 70 ft-lbs / 95 Nm.

Component damage hazard. Type "A" flexplate: When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur.

Component damage hazard. Do not force the drive pump during installation or the flex plate teeth may become damaged.

Ford Models

Deutz Models

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Perkins 404D-22 models

Perkins 404F-22 models

5-4 Ford MSG-425 Engine Fault Codes

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 at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light.

Refer to Fault Codes Section, How to Retrieve Ford MSG-425 Engine Fault Codes for your specific model of engine. Use the Fault Code Charts to aid in identifying the fault.

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5-5 Engine Fault Codes - Deutz D 2.9 L4, D436 L3i and Perkins 404F-22 Models

If a fault occurs that does not result in an engine shutdown, the engine rpm will go into limp home mode resulting in the loss of high rpm.

Refer to Fault Codes Section, How to Retrieve Active Engine Fault Codes for your specific model of engine. Use the Fault Code Charts to aid in identifying the fault.

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 69

6-1 Function 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 end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

1 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves.

Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition.

open closed

2 Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pum

3 Remove the pump mounting bolts. Carefully remove the pump.

Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.

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6-2 Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electro-proportional controller, located on the pump. The only adjustment that can be made to the pump is the neutral or null adjustment. Any internal service to the pump should only be performed at an authorized Eaton Hydraulics center. Call Genie Industries Service Department to locate your local authorized service center.

How to Remove the Drive Pump

Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended.

1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump.

2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable. Close the valves.

open closed

3 Tag and disconnect and plug the hydraulic hoses from the drive and function pumps. Cap the fittings on the pumps.

4 Support the pump with a lifting device and remove the two drive pump mounting fasteners.

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5 Carefully pull the drive pump out until the pump coupler separates from the flex plate.

6 Remove the drive pump from the machine.

Component damage hazard. The pump(s) may become unbalanced and fall if not properly supported.

Component damage hazard. When installing the pump, do not force the pump coupler into the flexplate or damage to the pump shaft seal may occur.

Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump.

How to Prime the Pump 1 Connect a 0 to 600 psi / 0 to 41 bar pressure

gauge to the test port on the drive pump.

2 Remove the safety pin from the engine pivot plate latch.

Note: The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine.

3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine.

4 Ford models: Close the valve on the LPG tank then disconnect the hose from the tank. Then move the fuel select switch to the LPG position.

Perkins 404D-22 models: Disconnect the engine wiring harness from the fuel solenoid at the injector pump.

Deutz D2011L03i, D436 L3i and TD2011L04i models: Hold the manual fuel shutoff valve clockwise to the closed position.

1 manual fuel shutoff valve

5 Have another person crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the engine an additional 15 seconds or until the pressure reaches 320 psi / 22 bar.

6 Ford models: Connect the LPG hose to the LPG tank and open the valve on the tank.

Perkins 404D-22 models: Connect the engine wiring harness to the fuel solenoid.

Deutz D2011L03i, D436 L3i and TD2011L04i models: Release the manual fuel shutoff valve.

7 Start the engine from the ground controls and check for hydraulic leaks.

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7-1 Function Manifold Components (to serial number 26514) The function manifold is located underneath the ground controls side turntable cover.

Index No. Description Schematic

Item Function Torque

1 Counterbalance valve H Platform level down 30-35 ft-lbs / 41-47 Nm 2 Counterbalance valve G Platform level up 30-35 ft-lbs / 41-47 Nm 3 Proportional solenoid valve M Boom extend/retract 30-35 ft-lbs / 41-47 Nm

4 Solenoid valve, 2 position 3 way C Boom retract 30-35 ft-lbs / 41-47 Nm 5 Solenoid valve, 2 position 3 way B Boom extend 30-35 ft-lbs / 41-47 Nm 6 Solenoid valve, 3 position 4 way D Turntable rotate 20-25 ft-lbs / 27-34 Nm 7 Proportional solenoid valve T Boom up/down circuit 30-35 ft-lbs / 41-47 Nm 8 Solenoid valve, 3 position 4 way BB Steer left/right 20-25 ft-lbs / 27-34 Nm

9 Check valve, 30 psi / 2 bar I Differential sensing circuit,platform rotate left and jib boom up (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

10 Check valve, 30 psi / 2 bar J Differential sensing circuit,platform rotate right and jib boom down (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

11 Check valve N Differential sensing circuit,boom extend/retract

10-12 ft-lbs / 14-16 Nm

12 Solenoid valve, 2 position 3 way F Boom down 30-35 ft-lbs / 41-47 Nm

13 Solenoid valve, 2 position 3 way E Boom up 30-35 ft-lbs / 41-47 Nm 14 Check valve O Differential sensing

circuit,turntable rotate 10-12 ft-lbs / 14-16 Nm

15 Check valve R Differential sensing circuit,boom up/down

10-12 ft-lbs / 14-16 Nm

16 Priority flow regulator valve, 3.5 gpm / 13.2 L/min

AA Steer left/right circuit 30-35 ft-lbs / 41-47 Nm

17 Differential sensing valve, 110 psi / 7.6 bar

S Boom up/down circuit 30-35 ft-lbs / 41-47 Nm

18 Differential sensing valve, 150 psi / 10.3 bar

P Turntable rotate circuit 30-35 ft-lbs / 41-47 Nm

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Function Manifold Components, continued (to serial number 26514)

Index No. Description Schematic

Item Function Torque

19 Check valve, 5 psi / 0.3 bar A Blocks flow from auxiliary pump to function pump

30-35 ft-lbs / 41-47 Nm

20 Relief valve, 3000 psi / 206.8 bar K System relief 30-35 ft-lbs / 41-47 Nm

21 Flow control valve, 0.1 gpm / 0.38 L/min DD Bleeds off differential sensing valves to tank

20-25 ft-lbs / 27-34 Nm

22 Differential sensing valve, 150 psi / 10.3 bar

CC Differential sensing circuit,meters flow to functions

30-35 ft-lbs / 41-47 Nm

23 Check valve W Differential sensing circuit,platform level up

10-12 ft-lbs / 14-16 Nm

24 Check valve X Differential sensing circuit,platform level down

10-12 ft-lbs / 14-16 Nm

25 Proportional solenoid valve Q Turntable rotate left/right 20-25 ft-lbs / 27-34 Nm

26 Flow control valve, 0.6 gpm / 2.27 L/min Z Platform rotate and jib boom (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

27 Check valve, 30 psi / 2 bar EE Platform rotate and jib boom circuit (S-65, S-65 TRAX) (prevents hydraulic hoses from draining back to tank)

20-25 ft-lbs / 27-34 Nm

28 Differential sensing valve, 110 psi / 7.6 bar

L Boom extend/retract circuit 30-35 ft-lbs / 41-47 Nm

29 Needle valve U Platform level circuit 30-35 ft-lbs / 41-47 Nm

30 Solenoid valve, 3 position 4 way V Platform level up/down 20-25 ft-lbs / 27-34 Nm

31 Solenoid valve, 3 position 4 way Y Platform rotate and jib boom up/down (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

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Function Manifold Components (from serial number 26515) The function manifold is located underneath the ground controls side turntable cover.

Index No. Description Schematic

Item Function Torque

1 Counterbalance valve H Platform level down 30-35 ft-lbs / 41-47 Nm

2 Counterbalance valve G Platform level up 30-35 ft-lbs / 41-47 Nm

3 Proportional solenoid valve M Boom extend/retract 30-35 ft-lbs / 41-47 Nm

4 Solenoid valve, 2 position 3 way C Boom retract 30-35 ft-lbs / 41-47 Nm

5 Solenoid valve, 2 position 3 way B Boom extend 30-35 ft-lbs / 41-47 Nm

6 Solenoid valve, 3 position 4 way D Turntable rotate 20-25 ft-lbs / 27-34 Nm

7 Proportional solenoid valve T Boom up/down circuit 30-35 ft-lbs / 41-47 Nm

8 Solenoid valve, 3 position 4 way BB Steer left/right 20-25 ft-lbs / 27-34 Nm

9 Check valve, 30 psi / 2 bar I Differential sensing circuit,platform rotate left andjib boom up (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

10 Check valve, 30 psi / 2 bar J Differential sensing circuit,platform rotate right andjib boom down (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

11 Check valve N Differential sensing circuit,boom extend/retract

10-12 ft-lbs / 14-16 Nm

12 Solenoid valve, 2 position 3 way F Boom down 30-35 ft-lbs / 41-47 Nm

13 Solenoid valve, 2 position 3 way E Boom up 30-35 ft-lbs / 41-47 Nm

14 Check valve O Differential sensing circuit,turntable rotate

10-12 ft-lbs / 14-16 Nm

15 Check valve R Differential sensing circuit,boom up/down

10-12 ft-lbs / 14-16 Nm

16 Priority flow regulator valve, 3.5 gpm / 13.2 L/min

AA Steer left/right circuit 30-35 ft-lbs / 41-47 Nm

17 Differential sensing valve, 110 psi / 7.6 bar S Boom up/down circuit 30-35 ft-lbs / 41-47 Nm

18 Differential sensing valve, 150 psi / 10.3 bar P Turntable rotate circuit 30-35 ft-lbs / 41-47 Nm

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Function Manifold Components, continued (from serial number 26515)

Index No. Description Schematic

Item Function Torque

19 Check valve, 5 psi / 0.3 bar A Blocks flow from auxiliary pump to function pump

30-35 ft-lbs / 41-47 Nm

20 Relief valve, 3000 psi / 206.8 bar K System relief 30-35 ft-lbs / 41-47 Nm

21 Flow control valve, 0.1 gpm / 0.38 L/min DD Bleeds off differential sensing valves to tank

20-25 ft-lbs / 27-34 Nm

22 Differential sensing valve, 150 psi / 10.3 bar

CC Differential sensing circuit,meters flow to functions

30-35 ft-lbs / 41-47 Nm

23 Check valve W Differential sensing circuit,platform level up

10-12 ft-lbs / 14-16 Nm

24 Check valve X Differential sensing circuit,platform level down

10-12 ft-lbs / 14-16 Nm

25 Proportional solenoid valve Q Turntable rotate left/right 20-25 ft-lbs / 27-34 Nm

26 Flow control valve, 0.6 gpm / 2.27 L/min Z Platform rotate and jib boom (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

27 Check valve, 30 psi / 2 bar EE Platform rotate and jib boom circuit (S-65, S-65 TRAX)(prevents hydraulic hoses from draining back to tank)

20-25 ft-lbs / 27-34 Nm

28 Differential sensing valve, 110 psi / 7.6 bar

L Boom extend/retract circuit 30-35 ft-lbs / 41-47 Nm

29 Needle valve U Platform level circuit 30-35 ft-lbs / 41-47 Nm

30 Solenoid valve, 3 position 4 way V Platform level up/down 20-25 ft-lbs / 27-34 Nm

31 Solenoid valve, 3 position 4 way Y Platform rotate and jib boom up/down (S-65, S-65 TRAX)

20-25 ft-lbs / 27-34 Nm

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7-2 Valve Adjustments - Function Manifold

How to Adjust the System Relief Valve Note: Perform this procedure with the boom in the stowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the ptest port on the function manifold.

2 Start the engine from the ground controls.

3 Hold the function enable/rpm select toggle switch to the high idle position. Activate and hold the boom retract toggle switch with the boom fully retracted.

4 Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications.

5 Turn the engine off. Use a wrench to hold the relief valve and remove the cap (item K).

6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap..

Tip-over hazard. Do not adjust the relief valve higher than specified.

7 Repeat steps 2 through 5 and recheck relief valve pressure.

8 Remove the pressure gauge.

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7-3 Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support.

Index No. Description Schematic

Item Function Torque

1 Solenoid valve, 2 position 3 way FF Platform rotate/jib boom select 20-25 ft-lbs / 27-34 Nm

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7-4 Brake/Two-Speed Manifold Components The brake/two-speed manifold is mounted near the turntable rotator.

Index No. Description Schematic

Item Function Torque

1 Solenoid valve, 2 position 3 way KK Brake release 20-25 ft-lbs / 27-34 Nm

Orifice, 0.025 inch / 0.64 mm JJ Brake release

2 Solenoid valve, 2 position 3 way LL Two-speed motor shift 20-25 ft-lbs / 27-34 Nm

3 Check valve II Brake release circuit 20-25 ft-lbs / 27-34 Nm

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7-5 Turntable Rotation Manifold Componentss The turntable rotation manifold is mounted to the turntable rotation motor.

Index No. Description Schematic

Item Function Torque

1 Counterbalance valve MM Turntable rotate right 35-40 ft-lbs / 47-54 Nm 2 Counterbalance valve NN Turntable rotate left 35-40 ft-lbs / 47-54 Nm 3 Shuttle valve, 2 position 3 way OO Turntable rotation brake release 10-13 ft-lbs / 14-18 Nm

4 Orifice, 0.030 inch / 0.76 mm PP Brake release circuit(located inside port)

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7-6 Oscillate Directional Valve Components The oscillate directional valve is mounted inside the drive chassis at the non-steer end.

Index No. Description Schematic Item Function Torque 1 Cap Breather 20-25 ft-lbs / 27-33

2 Spool valve JJ Directional control 3 Relief valve, 800 psi / 55 bar LL Oscillate relief 30-35 ft-lbs / 41-47

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How to Set U p the Oscillate Directional Valve

How to Set Up the Oscillate Directional Valve Note: Adjustment of the oscillate directional valve linkage is only necessary when the linkage or valve has been replaced.

1 Lower the boom to the stowed position.

2 Use a "bubble type" level to be sure the floor is completely level.

Tip-over hazard. Failure to perform this procedure on a level floor could compromise the stability of the machine resulting in the machine tipping over.

3 Check the tire pressure in all four tires and add air if needed to meet specification.

Note: The tires on some machines are foam-filled and do not need air added to them.

4 Remove the drive chassis cover and the non-steer axle covers.

5 Place a "bubble type" level across the drive chassis non-steer end. Check to be sure the drive chassis is completely level.

6 Remove the heim joint retaining fastener from the axle.

7 To level the drive chassis, start the engine and push up or pull down on the threaded rod until the machine is completely level.

8 Verify that the ground and drive chassis are completely level.

9 Adjust the heim joint until the hole lines up with the retaining fastener hole in the axle.

10 Install the heim joint to the axle and tighten the jam nut.

11 Check to be sure the drive chassis is completely level.

12 Measure the distance between the drive chassis and the non-steer axle on both sides (from the inside of the drive chassis).

Note: If the distance is not equal and the adjustment to the linkage was completed with the ground and drive chassis level, repeat steps 6 through 11 OR consult Genie Product Support.

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7-7 Valve Adjustments - Oscillate Relief Valve

How to Adjust the Oscillate Relief Valve Pressure 1 Remove the drive chassis cover from the

non-steer end of the machine.

2 Connect a 0 to 2000 psi / 0 to 150 bar pressure gauge to the diagnostic nipple located near the oscillate directional valve.

3 Disconnect the directional valve linkage, by removing the heim joint and retaining fastener from the axle.

4 Start the engine from the platform controls. Move the engine idle toggle switch to the maintained high idle position.

5 With the engine running in high rpm, manually activate the valve and observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications.

6 Turn the engine off.

7 Locate the relief valve on the directional valve and loosen the jamb nut.

8 Adjust the hex screw. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Tighten the jamb nut.

Tip-over hazard. Do not adjust the relief valve higher than specified.

9 Repeat steps 4 through 7 and manually activate the valve to confirm the valve pressure.

10 Turn the engine off, remove the pressure gauge and assemble the directional valve linkage.

11 Install the cover on the non-steer end of the drive chassis.

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7-8 Drive Oil Diverter Manifold Components (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.

Index No. Description Schematic

Item Function Torque

1 Directional valve CU Diverter valve 80-90 ft-lbs / 108-122 Nm

2 Orifice disc, 0.030 inch / 0.080 cm

CV Delays shift to drive

3 Solenoid valve CW Pilot valve to diverter 35-40 ft-lbs / 47-54 Nm

4 Relief valve CX Charge pressure circuit 35-40 ft-lbs / 47-54 Nm

5 Pressure switch 200 psi / 18.6 bar

CZ Generator relay switch 16 ft-lbs / 22 Nm

6 Connector fitting 11 ft-lbs / 15 Nm 7 Check valve CY Prevents oil to generator 35-40 ft-lbs / 47-54

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7-9 Traction Manifold Components, 2WD The traction manifold is mounted inside the drive chassis at the non-steer end.

Index No. Description Schematic

Item Function Torque

1 Relief valve, 280 psi / 19.3 bar

TT Charge pressure circuit 30-35 ft-lbs / 41-47 Nm

2 Flow divider/combiner valve WW Controls flow to drive motors in forward and reverse

90-100 ft-lbs / 122-136 Nm

3 Check valve SS Drive circuit 30-35 ft-lbs / 41-47 Nm

4 Check valve XX Drive circuit 30-35 ft-lbs / 41-47 Nm

5 Shuttle valve, 3 position 3 way

UU Charge pressure circuit tha tdirects hot oil out of low pressure side of drive pump

50-55 ft-lbs / 68-75 Nm

6 Orifice, 0.070 inch / 1.78 mm VV Drive motor circuit

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7-10 Valve Adjustments, 2WD Traction Manifold

How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.

2 Hold the charge pressure relief valve and remove the cap (item TT).

3 Turn the internal hex socket clockwise fully until it stops. Install the cap.

4 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. Note the reading on the pressure gauge.

5 Turn the engine off.

6 Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold.

7 Start the engine from the platform controls. Press down the foot switch and slowly move the drive control handle off center just until the machine begines to move. Note the reading on the pressure gauge. Turn the machine off.

8 Hold the charge pressure relief valve and remove the cap (item TT).

9 Adjust the internal hex socket until the pressure reading on the gauge is 30 psi / 2 bar less than the pressure reading on the pump. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the valve cap.

10 Repeat steps 7 through 9 until the pressure reading at the drive manifold is 30 psi / 2 bar less than the pressure reading at the pump.

11 Turn the engine off and remove the pressure gauge.

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7-11 Traction Manifold Components, 4WD The traction manifold is mounted inside the drive chassis at the non-steer end.

Index No. Description Schematic

Item Function Torque

1 Flow divider/combiner valve XX Controls flow to non-steer end drive motors in forward and reverse

80-90 ft-lbs / 108-122 Nm

2 Relief valve, 280 psi / 19.3 bar UU Charge pressure circuit 35-40 ft-lbs / 14-16 Nm

3 Check valve TT Steer end drive motor circuit 35-40 ft-lbs / 14-16 Nm

4 Flow divider/combiner valve AB Controls flow to flow divider/combiner valves 1 and 13

80-90 ft-lbs / 108-122 Nm

5 Orifice, 0.040 inch / 1 mm WW Equalizes pressure on both sides of flow divider/combiner valve 1

6 Orifice, 0.040 inch / 1 mm AE Equalizes pressure on both sides of flow divider/combiner valve 13

7 Orifice, 0.040 inch / 1 mm AC Equalizes pressure on both sides of flow divider/combiner valve 4

8 Check valve SS Non-steer end drive motor circuit 35-40 ft-lbs / 14-16 Nm

9 Check valve AF Non-steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm

10 Check valve ZZ Steer end drive motor circuit 35-40 ft-lbs / 14-16 Nm

11 Check valve AG Steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm

12 Shuttle valve, 3 position 3 way VV Charge pressure circuit that directs hot oil out of low pressure side of drive pump

80-90 ft-lbs / 108-122 Nm

13 Flow divider/combiner valve AD Controls flow to steer end drive motors in forward and reverse

80-90 ft-lbs / 108-122 Nm

14 Check valve YY Non-steer end drive motor circuit 35-40 ft-lbs / 14-16 Nm

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7-12 Valve Adjustments, 4WD Traction Manifold

How to Adjust the Charge Pressure Relief Valve 1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to the test port on the drive pump.

2 Hold the charge pressure relief valve and remove the cap (item UU).

3 Turn the internal hex socket clockwise fully until it stops. Install the cap.

4 Start the engine and move and hold the function enable/rpm select toggle switch to the high rpm (rabbit symbol) position. Note the reading on the pressure gauge.

5 Turn the engine off.

6 Remove the pressure gauge from the drive pump. Connect the gauge to the test port located on the traction manifold.

8 Hold the charge pressure relief valve and remove the cap (item UU).

10 Repeat steps 7 through 9 until the pressure reading at the drive manifold is 30 psi / 2 bar less than the pressure reading at the pump.

11 Turn the engine off and remove the pressure gauge.

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7-13 Hydraulic Generator Manifold Components, 3kW The generator manifold is mounted to the hydraulic generator located in the engine compartment.

Index No. Description Schematic

Item Function Torque

1 Proportional solenoid valve HH Generator speed 33-37 ft-lbs / 45-50 Nm

2 Relief valve, 3000 psi / 207 bar GG Generator circuit 20-25 ft-lbs / 27-34 Nm

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7-14 Valve Coils

How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance indicates the coil has failed.

Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases.

While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Tag and disconnect the wiring from the coil to be tested.

2 Test the coil resistance.

Result: The resistance should be within specification, plus or minus 30%.

Result: If the resistance is not within specification, plus or minus 30%, replace the coil.

Valve Coil Resistance Specification Note: The following coil resistance specifications are at an ambient temperature of 68F / 20C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18F / 10C that your air temperature increases or decreases from 68F / 20C.

Description Specification Solenoid valve, 3 position 4 way, 10V DC (schematic items D, V and Y)

5 to 7

Solenoid valve, 3 position 4 way, 10V DC (schematic item BB)

4 to 6

Solenoid valve, 2 position 3 way, 10V DC (schematic items B, C, E, F and FF)

5 to 7

Solenoid valve, 2 position 3 way, 10V DC (schematic items KK and LL)

5.5 to 7.5

Proportional solenoid valve, 12V DC (schematic items M and T)

4 to 6

Proportional solenoid valve, 12V DC (schematic item Q)

3.7 to 5.7

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How to Test a Coil Di ode

How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its directional valve coils except proportional valves and those coils with a metal case. Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Test the coil for resistance. Refer to, How to Test a Coil.

2 Connect a 10 resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil.

Resistor, 10 Genie part number 27287

Note: The battery should read 9V DC or more when measured across the terminals.

1 multimeter 2 9V DC battery 3 10 resistor 4 coil

Note: Dotted lines in illustration indicate a reversed connection as specified in step 6.

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA.

4 Connect the negative lead to the other terminal on the coil.

Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil.

5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery. Note and record the current reading.

6 At the battery or coil terminals, reverse the connections. Note and record the current reading.

Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good.

Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its internal diode are faulty and the coil should be replaced

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Turntable Rotation Components

96 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

8-1 Turntable Rotation Assembly

How to Remove the Turntable Rotation Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications.

Note: Perform this procedure with the machine on a firm and level surface.

1 Secure the turntable from rotating with the turntable rotation lock pin.

Note: The turntable rotation lock pin is located next to the boom rest pad.

2 Tag, disconnect and plug the hydraulic hoses from the turntable rotation drive motor. Cap the fittings on the drive motor.

3 Loosen the backlash pivot plate and adjustment bolts.

1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts

4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly.

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5 Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub assembly from the machine.

Crushing hazard. The turntable could rotate unexpectedly when the rotation drive hub assembly is removed if the turntable is not secured with the turntable rotation lock pin.

Crushing hazard. The turntable rotation assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

When installing the drive hub assembly:

6 Install the drive hub. Torque the back lash pivot plate to specification. Refer to Specifications, Machine Torque Specifications.

7 Adjust turntable rotation gear backlash. Refer to Repair Procedure, How to Adjust the Turntable Rotation Gear Backlash.

How to Adj ust the Tur ntabl e R otati on Gear Backlash

How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear.

Note: Perform this procedure with the boom between the non-steer end tires and with the machine on a firm and level surface.

1 Secure the turntable from rotating with the turntable rotation lock pin.

Note: The turntable rotation lock pin is located next to the boom rest pad.

2 Loosen the backlash pivot plate mounting fasteners.

1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts

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3 Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation gear into the turntable bearing ring gear).

4 Loosen the lock nut on the adjustment bolt.

5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate.

6 Turn the adjustment bolt 1/2 turn counterclockwise. Tighten the lock nut on the adjustment bolt.

7 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt. Then torque the mounting fasteners on the backlash pivot plate to specification. Refer to Specifications, Machine Torque Specifications.

8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary.

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Axle Components

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 99

9-1 Oscillating Axle Cylinders The oscillating axle cylinders extend and retract between the drive chassis and the axle to maintain a level chassis while driving over uneven terrain. The cylinders are equipped with counterbalance valves to prevent movement in the event of a hydraulic hose failure.

How to Remove an Oscillate Axle Cylinder Note: Perform this procedure on firm, level surface with the boom in the stowed position.

1 Rotate the turntable until the boom is between the steer tires or tracks.

2 Tag, disconnect and plug the oscillating axle cylinder hydraulic hoses. Cap the fittings on the cylinder.

3 Remove the pin retaining fasteners from the rod-end pivot pin. Use a soft metal drift to remove the pin.

4 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder.

5 Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to remove the pin.

6 Remove the cylinder from the machine.

Crushing hazard. The oscillate cylinder may become unbalanced and fall when removed from the machine if not properly attached to the overhead crane.

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Track Components

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10-1 Track Assembly, S-60 TRAX and S-65 TRAX

How to Remove a Track Assembly Note: Perform this procedure on firm, level surface with the boom in the stowed position.

1 Select a track assembly to remove. Loosen and remove as many sprocket retaining fasteners as possible from the hub adapter.

2 Drive the machine in either direction just enough to access the remaining fasteners. Do not remove the retaining fasteners.

3 Chock the tracks at the opposite end of the machine to prevent the machine from rolling.

4 Center a lifting jack of ample capacity (20,000 lbs / 10,000 kg) under the drive chassis between the tracks.

5 Lift the machine until the tracks are off the ground and then place jack stands under the drive chassis for support.

6 Attach a lifting strap from an overhead crane to the center-point of the track assembly, above the sprocket.

7 Remove the remaining sprocket retaining fasteners from the hub adapter.

8 Carefully remove the track assembly from the drive hub and set aside.

Crushing hazard. The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane.

How to R eplace a Tr ack

How to Replace a Track Assembly Note: Perform this procedure on firm, level surface with the boom in the stowed position.

1 Remove the track assembly from the machine. Refer to Repair Procedure, How to Remove a Track Assembly.

Note: The sprocket is comprised of two halves. Before removing the track assembly from the machine and to ease the removal of the sprocket, drive the machine until one complete half of the sprocket is located above the undercarriage of the track assembly.

2 Loosen the grease plug on the track tension cylinder to relieve the track tension. Clean up any grease that has spilled.

3 Remove the 2 sprocket retaining fasteners. Remove the sprocket half from the track assembly.

4 Carefully remove the track from the undercarriage.

5 Use an overhead crane to lay the undercarriage on its side with the drive sprocket bearing assembly facing upward and the track tension cylinder towards the ground.

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6 Install the new track onto the undercarriage.

7 Attach a lifting strap from an overhead crane to the center-point of the track, above the sprocket.

8 Use the overhead crane to raise the track assembly to an upright position. Rest the assembly on the floor or ground to remove any slack in the lower portion of the track.

Note: Be sure the idler and bogey wheels are aligned with the inside surface of the track.

1 idler wheels 2 bogey wheels

9 Rotate the sprocket half until the split tooth of the sprocket is lower than the other side.

1 split tooth

10 Using an overhead crane or other suitable lifting device, lift up on the rubber track to create enough room to install the other sprocket half.

11 Install the sprocket half, removed in step 3, while engaging the sprocket teeth with the rubber track.

Note: Be sure to align the split tooth in both of the sprocket halves.

12 Insert a pin or rod through the wheel stud hole closest to the split tooth to hold the sprocket in place.

13 Insert a pointed pry bar into the wheel stud hole near the top of the sprocket. Insert another pointed pry bar into the wheel stud hole at the opposite side of the split tooth.

14 Using the pry bars, lift the sprocket half into position. Install the 2 sprocket retaining fasteners and torque to specification. Refer to Specifications, TRAX Torque Specifications.

15 Attach a lifting strap from an overhead crane to the center-point of the track assembly, above the sprocket.

16 Install the track assembly onto the drive hub adapter while guiding the hub adapter studs into the sprocket of the track assembly. Install as many sprocket retaining fasteners as possible to the hub adapter and torque to specification. Refer to Specifications, TRAX Torque Specifications.

Crushing hazard. The track assembly could become unbalanced and fall when installed onto the machine if not properly supported by the overhead crane.

17 Adjust the track tension. Locate the grease plug on the track tension cylinder. Loosen the plug, but do not remove it.

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18 Locate the grease zerk fitting on the other side of the track tension cylinder.

1 grease zerk 2 grease plug

19 Pump grease into the grease zerk fitting until grease, free from air, comes out of the grease plug. Securely tighten the grease plug. Do not overtighten.

20 Continue to pump grease into the grease fitting just until the idler wheel moves. Check the track tension.

Result: There should be less than 1 inch / 2.5 cm of gap between the bogey wheels and the inside surface of the track. Proceed to step 22.

Result: There is 1 inch / 2.5 cm or more of gap between the bogey wheels and the inside surface of the track. Proceed to step 21.

1 bogey wheels

21 Continue to pump grease into the cylinder until the track has proper tension.

Component damage hazard. Do not over tighten the track. Overtightening the track will cause the machine to lose power during operation.

Note: If the track becomes too tight, loosen the grease plug on the cylinder to remove grease and loosen the track.

22 Raise the machine, remove the jack stands and lower the machine.

23 Drive the machine in either direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter. Turn the machine off.

24 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to specification. Refer to Specifications, TRAX Torque Specifications.

Grease Specification Chevron Ultra-duty grease, EP NLGI 1 (lithium based) or equivalent

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Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 103

Section 4 Faul t Codes

Observe and Obey: Troubleshooting and repair procedures shall

be completed by a person trained and qualified on the repair of this machine

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Unless otherwise specified, perform each procedure with the machine in the following configuration:

Machine parked on a firm, level surface

Key switch in the off position with the key removed

The red Emergency Stop button in the off position at both the ground and platform controls

Wheels chocked

All external AC power supply disconnected from the machine

Boom in the stowed position

Turntable secured with the turntable rotation lock

Welder disconnected from the machine (if equipped with the weld cable to platform option)

Before Troubleshooting: Read, understand and obey the safety rules

and operating instructions in the appropriate operator's manual on your machine.

Be sure that all necessary tools and test equipment are available and ready for use.

Read each appropriate fault code thoroughly. Attempting short cuts may produce hazardous conditions.

Be aware of the following hazards and follow generally accepted safe workshop practices.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Note: Two persons will be required to safely perform some troubleshooting procedures.

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Control System Fault Codes

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How to R etrieve Contr ol System Fault Codes

Control System

How to Retrieve Control System Fault Codes At least one fault code is present when the alarm at the platform controls produces two short beeps every 30 seconds for 10 minutes.

Perform this procedure with the engine off, the key switch turned to platform controls and the red Emergency Stop button pulled out to the on position at both the ground and platform controls.

1 Open the platform control box lid.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

2 Locate the red and yellow fault LEDs on the ALC-500 circuit board inside the platform control box. Do not touch the circuit board.

3 Determine the error source: The red LED indicates the error source and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second.

Note: When the red LED is flashing the code, the yellow LED will be on solid.

4 Determine the error type: The yellow LED indicates the error type and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second.

Note: When the yellow LED is flashing the code, the red LED will be on solid.

5 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected.

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Control System Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 105

Control System Fault C odes

Error Source Error Type Condition Solution ID Name ID Name

21 Primary Up / Down Joystick

11 Value at 5.0 V Function is inoperative.Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected. 12 Value Too High

15 Value Too Low

16 Value at 0 V

17 Not calibrated Calibrate Joystick

22 Primary Up / Down Directional Valves

21 Fault Valve is operating outside of limits. Cycle power off, then on after problem has been corrected.

Alarm sounds indicating a fault.

23 Primary Up / Down Flow Valve

12 Value Too High Valve is operating outside of limits. Cycle power off, then on after problem has been corrected. 15 Value Too Low Alarm sounds indicating a fault.

17 Not calibrated Normal function except threshold for one or both directions is zero.

Calibrate valve threshold.

24 Angle sensor 11 Value at 5.0 V Reduced speed function. Cycle power off, then on after problem has been corrected. 12 Value Too High Alarm sounds indicating a fault.

15 Value Too Low

16 Value at 0 V

17 Not calibrated Calibrate angle sensor.

31 Invalid setup Initiate 1 -second beep of Alarm Buzzer and required retract into safe envelope

Calibrate angle sensor.

26 Angle sensor cross check

19 Out of Range Reduced speed, required retract into safe envelope

Power up controller with problem corrected.

31 Secondary Up / Down. Joystick

11 Value at 5.0 V Function is inoperative. Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected. 12 Value Too High

15 Value Too Low

16 Value at 0 V

17 Not calibrated Calibrate Joystick

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Control System Fault Codes

106 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source Error Type Condition Solution ID Name ID Name

32 Secondary Up / Down. Directional Valves

21 Fault Valve is operating outside of limits. Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected.

33 Secondary Up / Down Flow Valve

12 Value Too High Valve is operating outside of limits. Cycle power off, then on after problem has been corrected. 15 Value Too Low Alarm sounds indicating a fault.

17 Not calibrated Normal function except threshold for one or both directions is zero.

Calibrate valve threshold.

34 Ext. Ret. Limit Switch

31 Invalid setup Initiate 1-second beep of Alarm Buzzer Fully retract, then lower boom

1000lb. Mode: Required retract into FULLY RETRACTED state before lowering.

Check and service ext/ret and fully stowed switches

500lb. Mode: Operates normally

36 Cross check fault Alarm sounds indicating a fault. Check primary boom retracted operational (LS1) and safety (LS5) limit switches. Boom retracted: 0 volts at C42LS of LS1. 12 volts at C166LS of LS5.

Overload LED is on.

Functions disabled, engine shutdown.

Auxiliary functions enabled except extend.

41 Turntable Rotate Joystick

11 Value at 5.0 V Limited speed and direction frozen at zero and neutral.

Cycle power off, then on after problem has been corrected. 12 Value Too High Alarm sounds indicating a fault.

15 Value Too Low

16 Value at 0 V

17 Not calibrated Calibrate Joystick

42 Turntable Rotate Directional Valves

21 Fault Limited direction. Frozen at zero and neutral. Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected.

43 Turntable Rotate Flow Valve

12 Value Too High Limited speed and direction. Cycle power off, then on after problem has been corrected. 15 Value Too Low Frozen at zero and neutral.

Alarm sounds indicating a fault.

17 Not calibrated Normal function except threshold for one or both directions is zero.

Calibrate valve threshold.

44 Drive Enable Override Switch

21 Fault Drive enable override direction is frozen at neutral.

Cycle power off, then on after problem has been corrected.

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Control System Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 107

Error Source Error Type Condition Solution ID Name ID Name

45 Platform Level Switch

21 Fault Platform level frozen at neutral Power up controller with problem corrected.

46 Primary Extend/Retract Switch

21 Fault Platform Ext/Ret frozen at neutral Power up controller with problem corrected.

51 Drive Joystick 11 Value at 5.0 V Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected.

12 Value Too High

15 Value Too Low

16 Value at 0 V

17 Not calibrated Calibrate Joystick

53 Drive Flow Valve (EDC)

12 Value Too High Limited speed and direction. Frozen at zero and neutral. Alarm sounds indicating a fault.

Cycle power off, then on after problem has been corrected.

15 Value Too Low

17 Not calibrated Normal function except threshold for one or both directions is zero.

Calibrate valve threshold.

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Control System Fault Codes

108 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source Error Type Condition Solution ID Name ID Name

75 SCON 34 Software mismatch Primary and secondary micro-controllers software do not match.

Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown. Auxiliary functions enabled except extend.

Install correct software part number and version in secondary micro-controller.

12 Value Too High Platform overloaded.

13 No Response Check CAN bus circuit for open or short.

Check for cable damage to load cell. Check for power at load cell.

15 Value Too Low Confirm the platform load cell is properly pre-loaded and is free of obstructions.

76 Platform load cell overloaded

17 Not calibrated Zero load not calibrated: Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown Auxiliary functions enabled except extend. Zero load calibrated, gain is not: Unit operates with reduced load capacity.

Calibrate the load cell.

21 Internal load cell status

Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown. Auxiliary functions enabled except extend.

Inspect load cell for damage. Cycle power off then back on. If fault persist, replace load cell.

31 Invalid setup Calibrate load cell with proper. load or replace

36 Cross check fault Inspect load cell for damage. Cycle power off then back on. If fault persist, replace load cell.

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Control System Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 109

Error Source Error Type Condition Solution ID Name ID Name

79 Hour meter 13 No Response Loss of communication to hour meter. Machine functions normal.

Check power and ground to hour meter. Check CAN bus circuit for open or short. Check CAN bus resistance between CAN high and CAN low. 60 ohms.

82 Overload recovery 21 Fault Platform overloaded and machine operated using auxiliary power. Fault remains active until reset is performed.

Enter reset code using calibration mode. ( )

102 Overload function cutout relay

12 Value Too High SCON detects 12VDC from CR54 or CR55 terminal 87 when terminals 85 and 86 are not activated. Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown. Auxiliary functions enabled except extend.

Check for 12VDC at SCON C41-6. Should be 0VDC. Replace CR54 or CR55. Check for short to 12VDC in harness to SCON C41-6.

15 Value Too Low SCON detects 0VDC from CR54 or CR55 terminal 87 when terminals 85 and 86 are activated. Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown. Auxiliary functions enabled except extend.

Check for 0VDC at SCON C41-6. Should be 12VDC. Replace CR54 or CR55. Check for open in harness to SCON C41-6.

103 Overload engine cutout relay

12 Value Too High SCON detects input from TB21 when CR56 terminals 85 and 86 are not activated. Alarm sounds indicating a fault. Overload LED is on. Functions disabled, engine shutdown. Auxiliary functions enabled except extend.

Replace CR56. Check for short from TB21 in harness to SCON C42-2.

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Fault Code Display - Deutz and Perkins Models

110 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

How to Retrieve Active Engine Fault Codes - Deutz D 2.9 L4, D436 L3i and Perkins 404F-22 Models 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 at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor. One or more fault LED's will illuminate on the display located at the ground control box. The active fault code will also be displayed on the LCD screen.

Note: The Perkins 404F-22 is equipped with an engine fault LED located at the platform control box.

If an engine fault occurs that does not result in an engine shutdown, the engine rpm will go into limp home mode resulting in the loss of high rpm.

When operating from the platform, if the red Emergency Stop button is pushed in, the active fault code(s) will be erased from the display.

Start the engine from the ground control box and operate various boom functions to verify that an active engine fault occurs and is shown on the display.

Note: All faults are stored in the Previous Fault history menu. These faults will not be erased when corrective action has been completed.

With an active fault and the engine running: (preferred method)

1 At the ground controls, activate the auxiliary pump toggle switch to shut the engine off.

Note: Do not push in the red Emergency Stop button or turn the key switch to the off position.

2 Press any soft key below the display.

3 Use the scroll up / down keys to check for multiple engine fault codes.

With the engine not running:

1 At the ground controls, turn the key switch to ground controls and pull out the red Emergency Stop button.

2 Navigate to the Active Fault Menu and use the scroll up / down keys to check for multiple engine fault codes.

Note: Deutz D436 L3i models, refer to the main menu structure.

Deutz D 2.9 L4 and Perkins 404F-22 models:

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 111

Flashi ng and Soli d LED's - D eutz D 2.9 L4 and Perkins 404F- 22 Models

Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models

1 Left green LED: Flashing, engine fault detected. Contact service. Solid, fault acknowledged. Contact service.

2 Left amber LED: (Perkins models) Solid, a) Regeneration is inhibited. No service required. b) High exhaust temperature during regeneration mode. No service required.

3 Left red LED: Flashing, engine fault detected. Contact service. Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact service.

4 Right green LED: Flashing, engine fault detected. Contact service. Solid, fault acknowledged. Contact service.

5 Right amber LED: (Perkins models) Solid with left amber LED on solid, regeneration has been inhibited and engine soot level is between 80 - 100%. Regeneration is required. Flashing with left amber LED on solid, regeneration has been inhibited and soot level is between 100 - 140%. Engine rpm is de-rated. Regeneration is required. Flashing with left and right red LED's flashing, engine soot level over 140%. Engine shut down. Contact service.

6 Right red LED: Flashing, engine fault detected. Contact service. Flashing with right flashing amber LED, engine soot level over 140%. Engine shut down. Contact service.

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Fault Code Display - Deutz and Perkins Models

112 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Soft Key Func tions and Icons - Deutz D 2.9 L4 and Perki ns 404F-22 M odels

Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models

1 Next menu Exit / Back one screen Decrease brightness (-)

2 Brightness / Contrast Scroll up Increase Increase brightness (+)

3 Regeneration forced Scroll down Decrease Decrease contrast (-)

4 Regeneration inhibited Select / Next Main menu Increase contarst (+)

Note: Regeneration, initiate, inhibit and soot only apply to the Perkins 404F-22 models.

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 113

Main M enu Str ucture - Deutz D 2.9 L4 Model s

Main Menu Structure - Deutz D 2.9 L4 Models

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Fault Code Display - Deutz and Perkins Models

114 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Main M enu Str ucture - Perkins 404F-22 M odels

Main Menu Structure - Perkins 404F-22 Models

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 115

Deutz D 436 L3i Displ ay

Deutz D436 L3i Display

1 Amber LED: Solid, engine fault detected. Contact service.

2 Red LED: Solid, engine power deration or engine shutdown.

3 LCD display 4 Scroll down

Navigate menus and display functions.

5 Scroll up Navigate menus and display functions.

Note: Momentarily press scroll up and scroll down at the same time to enter the main menu structure, enter sub-menus, activate menu selections and return to previous menus.

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116 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Main M enu Str ucture - Deutz D436 L3i Models

Main Menu Structure - Deutz D436 L3i Models

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 117

Main Menu Structure - Deutz D436 L3i Models - continued

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Deutz D 2.9 L4 Engine Fault Codes

118 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 51 3 1019 EGR-Valve, short circuit to

battery

51 3 1024 Position sensor error of actuator EGR-Valve; signal range check high

51 3 1226 EGR-Valve; short circuit to battery (A02)

51 3 1227 EGR-Valve; short circuit to battery (A67)

51 4 1020 EGR-Valve; short circuit to ground

51 4 1025 Position sensor error actuator EGR-Valve; signal range check low

51 4 1228 EGR-Valve; short circuit to ground (A02)

51 4 1229 EGR-Valve; short circuit to ground (A67)

1 4 1232 Actuator error EGR-Valve; Voltage below threshold

51 5 1015 Actuator error EGR-Valve; signal range check low

51 5 1017 Actuator EGR-Valve; open load 51 5 1023 Actuator error EGR-Valve; signal

range check low

51 5 1223 Actuator EGR-Valve; open load 51 6 1014 Actuator error EGR-Valve; signal

range check high 51 6 1022 Actuator error EGR-Valve; signal

range check high

51 6 1224 Actuator EGR-Valve; over current

51 6 1230 Actuator error EGR-Valve; Overload by short-circuit

51 7 1016 Actuator position for EGR-Valve not plausible

SPN FMI KWP Description 51 11 1231 Actuator error EGR-Valve; Power

stage over temp due to high current

51 12 1018 Actuator EGR-Valve; powerstage over temperature

51 12 1021 Mechanical actuator defect EGR-Valve

51 12 1225 Actuator EGR-Valve; over temperature

94 1 474 Low fuel pressure; warning threshold exceeded

94 1 475 Low fuel pressure; shut off threshold exceeded

94 3 472 Sensor error low fuel pressure; signal range check high

94 4 473 Sensor error low fuel pressure; signal range check low

97 3 464 Sensor error water in fuel; signal range check high

97 4 465 Sensor error water in fuel; signal range check low

97 12 1157 Water in fuel level prefilter; maximum value exceeded

100 0 734 High oil pressure; warning threshold exceeded

100 0 735 High oil pressure; shut off threshold exceeded

100 1 736 Low oil pressure; warning threshold exceeded

100 1 737 Low oil pressure; shut off threshold exceeded

100 3 732 Sensor error oil pressure; signal range check high

100 4 733 Sensor error oil pressure sensor; signal range check low

102 2 88 Charged air pressure above warning threshold

102 2 89 Charged air pressure above shut off threshold

102 4 777 Sensor error charged air press.; signal range check low

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 119

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 105 0 996 High charged air cooler

temperature; warning threshold exceeded

105 0 997 High charged air cooler temperature; shut off threshold exceeded

105 3 994 Sensor error charged air temperature; signal range check high

105 4 995 Sensor error charged air temperature; signal range check low

108 3 412 Sensor error ambient air press.; signal range check high

108 4 413 Sensor error ambient air press.; signal range check low

110 0 98 High coolant temperature; warning threshold exceeded

110 0 99 High coolant temperature; shut off threshold exceeded

110 3 96 Sensor error coolant temp.; signal range check high

110 4 97 Sensor error coolant temp.; signal range check low

111 1 101 Coolant level too low 132 11 1 Air flow sensor load correction

factor exceeding the maximum drift limit; plausibility error

132 11 2 Air flow sensor load correction factor exceeding drift limit; plausibility error

132 11 3 Air flow sensor low idle correction factor exceeding the maximum drift limit

132 11 4 Air flow sensor load correction factor exceeding the maximum drift limit

157 3 877 Sesnor error rail pressure; signal range check high

157 4 878 Sensor error rail pressure; signal range check low

SPN FMI KWP Description 168 0 1180 Physical range check high for

battery voltage

168 1 1181 Physical range check low for battery voltage

168 2 47 High battery voltage; warning threshold exceeded

168 2 48 Low battery voltage; warning threshold exceeded

168 3 45 Sensor error battery voltage; signal range check high

168 4 46 Sensor error battery voltage; signal range check low

171 3 417 Sensor error environment temperature; signal range check high

171 4 418 Sensor error environment temperature; signal range check low

172 0 1182 Physical range check high for intake air temperature

172 1 1183 Physical range check low for intake air temperature

172 2 9 Sensor ambient air temperature; plausibility error

172 2 983 Intake air sensor; plausibility error

172 3 981 Sensor error intake air; signal range check high

172 4 982 Sensor error intake air sensor; signal range check low

174 0 481 High low fuel temperature; warning threshold exceeded

174 0 482 High Low fuel temperature; shut off threshold exceeded

175 0 740 Physical range check high for oil temperature

175 0 745 High oil temperature; warning threshold exceeded

175 0 746 High oil temperature; shut off threshold exceeded

175 1 741 Physical range check low for oil temperature

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120 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 175 2 738 Sensor oil temperature;

plausibility error 175 2 739 Sensor oil temperature;

plausibility error oil temperature too high

175 3 743 Sensor error oil temperature; signal range check high

175 4 744 Sensor error oil temperature; signal range check low

190 0 389 Engine speed above warning threshold (FOC-Level 1)

190 2 421 Offset angle between crank- and camshaft sensor is too large

190 8 419 Sensor camshaft speed; disturbed signal

190 8 422 Sensor crankshaft speed; disturbed signal

190 11 390 Engine speed above warning threshold (FOC-Level 2)

190 12 420 Sensor camshaft speed; no signal

190 12 423 Sensor crankshaft speed; no signal

190 14 391 Engine speed above warning threshold (Overrun Mode)

190 14 1222 Camshaft- and Crankshaft speed sensor signal not available on CAN

411 0 791 Physical range check high for differential pressure Venturiunit (EGR)

411 1 792 Physical range check low for differential pressure Venturiunit (EGR)

411 3 795 Sensor error differential pressure Venturiunit (EGR); signal range check high

411 4 381 Physical range check low for EGR differential pressure

411 4 796 Sensor error differential pressure Venturiunit (EGR); signal range check low

SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler

downstream temperature; signal range check high

412 4 1008 Sensor error EGR cooler downstream temperature; signal range check low

520 9 306 Timeout Error of CAN-Receive-Frame TSC1TR; Setpoint

597 2 49 Break lever mainswitch and break lever redundancy switch status not plausible

624 3 971 SVS lamp; short circuit to batt.

624 4 972 SVS lamp; short circuit to grd. 624 5 969 SVS lamp; open load 624 12 970 SVS lamp; powerstage over

temperature

630 12 376 Access error EEPROM memory (delete)

630 12 377 Access error EEPROM memory (read)

630 12 378 Access error EEPROM memory (write)

639 14 84 CAN-Bus 0 "BusOff-Status" 651 3 580 Injector 1 (in firing order); short

circuit

651 4 586 High side to low side short circuit in the injector 1 (in firing order)

651 5 568 Injector 1 (in firing order); interruption of electric connection

652 3 581 Injector 2 (in firing order); short circuit

652 4 587 High side to low side short circuit in the injector 2 (in firing order)

652 5 569 Injector 2 (in firing order); interruption of electric connection

653 3 582 Injector 3 (in firing order); short circuit

653 4 588 High side to low side short circuit in the injector 3 (in firing order)

653 5 570 Injector 3 (in firing order); interruption of electric connection

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 121

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 654 3 583 Injector 4 (in firing order); short

circuit 654 4 589 High side to low side short circuit

in the injector 4 (in firing order) 654 5 571 Injector 4 (in firing order);

interruption of electric connection 676 11 543 Cold start aid relay error.

676 11 544 Cold start aid relay open load 677 3 956 Starter relay high side; short

circuit to battery

677 3 960 Starter relay low side; short circuit to battery

677 4 957 Starter relay high side; short circuit to ground

677 4 961 Starter relay low side; short circuit to ground

677 5 958 Starter relay; no load error 677 12 959 Starter relay; powerstage over

temperature

703 3 426 Engine running lamp; short circuit to battery

703 4 427 Engine running lamp; short circuit to ground

703 5 424 Engine running lamp; open load 703 12 425 Engine running lamp;

powerstage over temperature

729 5 545 Cold start aid relay open load 729 12 547 Cold start aid relay; over

temperature error

898 9 305 Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint

1079 13 946 Sensor supply voltage monitor 1 error (ECU)

1080 13 947 Sensor supply voltage monitor 2 error (ECU)

SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for

ECU temperature

1136 1 1399 Physikal range check low for ECU temperature

1136 3 1400 Sensor error ECU temperature; signal range check high

1136 4 1401 Sensor error ECU temperature; signal range check low

1176 3 849 Sensor error pressure sensor upstream turbine; signal range check high

1176 4 850 Sensor error pressure sensor downstream turbine; signal range check high

1180 0 1193 Physical range check high for exhaust gas temperature upstream turbine

1180 0 1460 Turbocharger Wastegate CAN feedback; warning threshold exceeded

1180 0 1462 Exhaust gas temperature upstream turbine; warning threshold exceeded

1180 1 1194 Physical range check low for exhaust gas temperature upstream turbine

1180 1 1461 Turbocharger Wastegate CAN feedback; shut off threshold exceeded

1180 1 1463 Exhaust gas temperature upstream turbine; shut off threshold exceeded

1180 3 1067 Sensor error exhaust gas temperature upstream turbine; signal range check high

1180 11 1066 Sensor exhaust gas temperature upstream turbine; plausibility error

1188 2 1414 Wastegate; status message from ECU missing

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122 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 1188 7 1415 Wastegate actuator; blocked 1188 11 1411 Wastegate actuator; internal

error

1188 11 1412 Wastegate actuator; EOL calibration not performed correctly

1188 11 1416 Wastegate actuator; over temperature (> 145C)

1188 11 1417 Wastegate actuator; over temperature (> 135C)

1188 11 1418 Wastegate actuator; operating voltage error

1188 13 1413 Wastegate actuator calibration deviation too large, recalibration required

1231 14 85 CAN-Bus 1 "BusOff-Status" 1235 14 86 CAN-Bus 2 "BusOff-Status" 1237 2 747 Override switch; plausibility error 1322 12 610 Too many recognized misfires in

more than one cylinder 1323 12 604 Too many recognized misfires in

cylinder 1 (in firing order) 1324 12 605 Too many recognized misfires in

cylinder 2 (in firing order) 1325 12 606 Too many recognized misfires in

cylinder 3 (in firing order) 1326 12 607 Too many recognized misfires in

cylinder 4 (in firing order) 2659 0 1524 Physical range check high for

EGR exhaust gas mass flow 2659 1 1525 Physical range check low for

EGR exhaust gas mass flow

2659 2 1523 Exhaust gas recirculation AGS sensor; plausibility error

SPN FMI KWP Description 2659 2 1527 AGS sensor temperature

exhaust gas mass flow; plausibility error

2659 12 1526 Exhaust gas recirculation; AGS sensor has "burn off" not performed

2797 4 1337 Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 0

2798 4 1338 Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 1

2798 4 1339 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0

2798 4 1340 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1

3224 2 127 DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream cat; DPF-system downstream cat); length of frame incorrect

3224 9 128 Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor upstream

3248 4 1047 Sensor error particle filter downstream temperature; signal range check low

3699 2 1616 DPF differential pressure sensor and a further sensor or actuator CRT system defective

3699 2 1617 Temperature sensor us. and ds. DOC simultaneously defect

3699 14 1615 Maximum stand-still-duration reached; oil exchange required

4765 0 1039 Physical range check high for exhaust gas temperature upstream (DOC)

4765 1 1042 Physical range check low for exhaust gas temperature upstream (DOC)

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 123

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 4766 0 1029 Physical range check high for

exhaust gas temperature downstream (DOC)

4766 1 1032 Physical range check low for exhaust gas temperature downstream (DOC)

4768 2 1036 Sensor exhaust gas temperature upstream (DOC); plausibility error

4768 3 1044 Sensor error exhaust gas temperature upstream (DOC); signal range check high

4768 4 1045 Sensor error exhaust gas temperature upstream (DOC) signal range check low

4769 2 1026 Sensor exhaust gas temperature downstream (DOC); plausibility error

4769 3 1034 Sensor error exhaust gas temperature downstream (DOC); signal range check high

4769 4 1035 Sensor error exhaust gas temperature downstream (DOC); signal range check low

523006 3 34 Controller mode switch; short circuit to battery

523006 4 35 Controller mode switch; short circuit to ground

523008 1 648 Manipulation control was triggered

523008 2 649 Timeout error in Manipulation control

523009 9 825 Pressure Relief Valve (PRV) reached maximun allowed opening count

523009 10 833 Pressure relief valve (PRV) reached maximun allowed open time

SPN FMI KWP Description 523212 9 171 Timeout Error of

CAN-Receive-Frame ComEngPrt; Engine Protection

523216 9 198 Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat command, engine command

523240 9 179 Timeout CAN-message FunModCtl; Function Mode Control

523350 4 565 Injector cylinder-bank 1; short circuit

523352 4 566 Injector cylinder-bank 2; short circuit

523354 12 567 Injector powerstage output defect 523470 2 826 Pressure Relief Valve (PRV)

forced to open; performed by pressure increase

523470 2 827 Pressure Relief Valve (PRV) forced to open; performed by pressure shock

523470 7 876 Maximum rail pressure in limp home mode exceeded (PRV)

523470 11 831 The PRV can not be opened at this operating point with a pressure shock

523470 11 832 Rail pressure out of tolerance range

523470 12 828 Open Pressure Relief Valve (PRV); shut off condition

523470 12 829 Open Pressure Relief Valve (PRV); warning condition

523470 14 830 Pressure Relief Valve (PRV) is open

523550 12 980 T50 start switch active for too long

523601 13 948 Sensor supply voltage monitor 3 error (ECU)

523603 9 126 Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor

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Service and Repair ManualJuly 2017

Deutz D 2.9 L4 Engine Fault Codes

124 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 523605 9 300 Timeout Error of

CAN-Receive-Frame TSC1AE; Traction Control

523606 9 301 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder

523612 12 387 Internal software error ECU; injection cut off

523612 12 612 Internal ECU monitoring detection reported error

523612 12 613 Internal ECU monitoring detection reported error

523612 12 614 Internal ECU monitoring detection reported error

523612 12 615 Internal ECU monitoring detection reported error

523612 12 616 Internal ECU monitoring detection reported error

523612 12 617 Internal ECU monitoring detection reported error

523612 12 618 Internal ECU monitoring detection reported error

523612 12 619 Internal ECU monitoring detection reported error

523612 12 620 Internal ECU monitoring detection reported error

523612 12 621 Internal ECU monitoring detection reported error

523612 12 623 Internal ECU monitoring detection reported error

523612 12 624 Internal ECU monitoring detection reported error

523612 12 625 Internal ECU monitoring detection reported error

523612 12 627 Internal ECU monitoring detection reported error

523612 12 628 Internal ECU monitoring detection reported error

SPN FMI KWP Description 523612 12 637 Internal ECU monitoring

detection reported error

523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2

523613 0 856 Maximum positive deviation of rail pressure exceeded (RailMeUn0)

523613 0 857 Maximum positive deviation of rail pressure in metering unit exceeded (RailMeUn1)

523613 0 858 Railsystem leakage detected (RailMeUn10)

523613 0 859 Maximum negative deviation of rail pressure in metering unit exceeded (RailMeUn2)

523613 0 860 Negative deviation of rail pressure second stage (RailMeUn22)

523613 0 862 Maximum rail pressure exceeded (RailMeUn4)

523613 1 861 Minimum rail pressure exceeded (RailMeUn3)

523613 2 864 Setpoint of metering unit in overrun mode not plausible

523615 3 594 Metering unit (Fuel-System); short circuit to battery highside

523615 3 596 Metering unit (Fuel-System); short circuit to battery low side

523615 4 595 Metering unit (Fuel-System); short circuit to ground high side

523615 4 597 Metering Unit (Fuel-System); short circuit to ground low side

523615 5 592 Metering unit (Fuel-System); open load

523615 12 593 Metering unit (Fuel-System); powerstage over temperature

523619 2 488 Physical range check high for exhaust gas temperature upstrem (SCR-CAT)

523698 11 122 Shut off request from supervisory monitoring function

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July 2017Service and Repair Manual

Deutz D 2.9 L4 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 125

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 523717 12 125 Timeout Error of

CAN-Transmit-Frame AmbCon; Weather environments

523718 3 1488 SCR mainrelay; short circuit to battery (only CV56B)

523718 4 1489 SCR mainrelay; short circuit to ground (only CV56B)

523718 5 1486 SCR mainrelay; open load (only CV56B)

523718 12 1487 SCR mainrelay; powerstage over temperature (only CV56B)

523766 9 281 Timeout Error of CAN-Receive-Frame Active TSC1AE

523767 9 282 Timeout Error of CAN-Receive-Frame Passive TSC1AE

523768 9 283 Timeout Error of CAN-Receive-Frame Active TSC1AR

523769 9 284 Timeout Error of CAN-Receive-Frame Passive TSC1AR

523770 9 285 Timeout Error of CAN-Receive-Frame Passive TSC1DE

523776 9 291 Timeout Error of CAN-Receive-Frame TSC1TE - active

523777 9 292 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint

523778 9 293 Active Timeout Errorof CAN-Receive-Frame TSC1TR

523779 9 294 Passive Timeout Error of CAN-Receive-Frame TSC1TR

SPN FMI KWP Description 523788 12 299 Timeout Error of

CAN-Transmit-Frame TrbCH; Status Wastegate

523793 9 202 Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service message

523794 9 203 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data

523895 13 559 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order)

523896 13 560 check of missing injector adjustment value programming (IMA) injector 2 (in firing order)

523897 13 561 check of missing injector adjustment value programming (IMA) injector 3 (in firing order)

523898 13 562 check of missing injector adjustment value programming (IMA) injector 4 (in firing order)

523910 6 1261 Air Pump; over current

523913 3 74 Sensor error glow plug control diagnostic line voltage; signal range check high

523913 4 75 Sensor error glow plug control diagnostic line voltage; signal range check low

523914 3 78 Glow plug control; short circuit to battery

523914 4 79 Glow plug control; short circuit to ground

523914 5 76 Glow plug control; open load 523914 5 1216 Glow plug control release line;

short circuit error

523914 11 1217 Glow plug control; internal error 523914 12 77 Glow plug control; powerstage

over temperature

523919 2 1378 Sensor air pump airpressure; plausibility error

523920 2 1379 Sensor exhaust gas back pressure burner; plausibility error

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Service and Repair ManualJuly 2017

Deutz D 2.9 L4 Engine Fault Codes

126 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 523922 7 1262 Burner Shut Off Valve; blocked

closed

523922 7 1264 Burner Shut Off Valve; blocked closed

523929 0 109 Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded

523929 1 115 Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded

523930 0 110 Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded

523930 1 116 Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded

523931 0 111 Fuel Balance Control integrator injector 3 (in firing order); maximum value exceeded

523931 1 117 Fuel Balance Control integrator injector 3 (in firing order); minimum value exceeded

523932 0 112 Fuel Balance Control integrator injector 4 (in firing order); maximum value exceeded

523932 1 118 Fuel Balance Control integrator injector 4 (in firing order); minimum value exceeded

523935 12 168 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages

523936 12 169 Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages

523946 0 1158 Zero fuel calibration injector 1 (in firing order); maximum value exceeded

SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 (in

firing order); minimum value exceeded

523947 0 1159 Zerofuel calibration injector 2 (in firing order); maximum value exceeded

523947 1 1165 Zerofuel calibration injector 2 (in firing order); minimum value exceeded

523948 0 1160 Zerofuel calibration injector 3 (in firing order); maximum value exceeded

523948 1 1166 Zerofuel calibration injector 3 (in firing order); minimum value exceeded

523949 0 1161 Zerofuel calibration injector 4 (in firing order); maximum value exceeded

523949 1 1167 Zerofuel calibration injector 4 (in firing order); minimum value exceeded

523960 0 1011 Physical range check high for EGR cooler downstream temp.

523960 0 1458 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded

523960 1 1012 Physical range check low for EGR cooler downstream temp.

523960 1 1459 High exhaust gas temperature EGR cooler downstream; shut off threshold exceeded

523980 14 1187 Bad quality of reduction agent detected

523981 11 918 Urea-tank without heating function (heating phase)

523982 0 360 Powerstage diagnosis disabled; high battery voltage

523982 1 361 Powerstage diagnosis disabled; low battery voltage

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July 2017Service and Repair Manual

Deutz D 2.9 L4 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 127

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 523988 3 1245 Charging lamp; short circuit to

battery

523988 4 1246 Charging lamp; short circuit to ground

523988 5 1243 Charging lamp; open load

523988 12 1244 Charging lamp; over temp. 523998 4 1327 Injector cylinder bank 2 slave;

short circuit

523999 12 1328 Injector powerstage output Slave defect

524014 1 1254 Air pressure glow plug flush line; below limit

524016 2 1259 Amount of air is not plausible to pump speed

524016 2 1260 Calculated amount of air is not plausible to HFM reading

524016 11 1258 HFM sensor; electrical fault 524021 11 1263 Burner fuel line pipe leak behind

Shut Off Valve

524024 11 1302 Deviation of the exhaust gas temp. setpoint to actual value downstream (DOC) too high

524028 2 1431 CAN message PROEGRActr; plausibility error

524029 2 1432 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation positioner

524030 7 1440 EGR actuator; internal error 524031 13 1441 EGR actuator; calibration error

SPN FMI KWP Description 524032 2 1442 EGR actuator; status message

EGRCust is missing

524033 7 1443 EGR actuator; due to overload in Save Mode

524034 3 1438 Disc separator; short circuit to battery

524034 4 1439 Disc separator; short circuit to ground

524034 5 1436 Disc Separator; open load

524034 12 1437 Disc Separator; powerstage over temperature

524035 12 1341 Injector diagnostics; time out error in the SPI communication

524057 2 1505 Electric fuel pump; fuel pressure build up error

524097 9 1663 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl

524098 9 1664 Timeout error of CAN-Transmit-Frame ComDPFBrnPT

524099 9 1665 Timeout error of CAN-Transmit-Frame ComDPFC1

524100 9 1666 Timeout error of CAN-Transmit-Frame ComDPFHisDat

524101 9 1667 Timeout error of CAN-Transmit-Frame ComDPFTstMon

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Deutz D 2.9 L4 Engine Fault Codes

128 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol

SPN FMI KWP Description 524102 9 1674 Timeout error of

CAN-Receive-Frame ComRxDPFBrnAirPmpCtl

524103 9 1675 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp

524104 9 1676 Timeout error of CAN-Receive-Frame ComRxDPFCtl

524105 9 1668 Timeout error of CAN-Transmit-Frame ComEGRMsFlw

524106 9 1677 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1

524107 9 1678 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2

524108 9 1669 Timeout error of CAN-Transmit-Frame ComEGRTVActr

524109 9 1679 Timeout error of CAN-Receive-Frame ComRxEGRTVActr

524110 9 1670 Timeout error of CAN-Transmit-Frame ComETVActr

524111 9 1680 Timeout error of CAN-Receive-Frame ComRxETVActr

524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of

CAN-Receive-Frame ComRxITVActr

SPN FMI KWP Description 524114 9 1659 Timeout error of

CAN-Transmit-Frame A1DOC

524115 9 1660 Timeout error of CAN-Transmit-Frame AT1S

524116 9 1661 Timeout error of CAN-Transmit-Frame SCR2

524117 9 1662 Timeout error of CAN-Transmit-Frame SCR3

524118 9 1672 Timeout error of CAN-Receive-Frame ComRxCM1

524119 9 1673 Timeout error of CAN-Receive-Frame ComRxCustSCR3

524120 9 1682 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag

524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr

524122 9 1684 Timeout error of CAN-Receive-Frame ComRxUQSens

524123 9 1685 Timeout error of CAN-Receive-Frame ComSCRHtCtl

524124 9 1686 Timeout error of CAN-Receive-Frame ComTxAT1IMG

524125 9 1687 Timeout error of CAN-Receive-Frame ComTxTrbChActr

Page 149

July 2017Service and Repair Manual

Deutz D436 L3i Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 129

SPN = Suspect Parameter Number FMI = Failure Mode Identifier

SPN FMI Description Revolutions / Speed

190 8 Speed sensor 1: sensor fault; distance from gear; harness

190 8 Speed sensor 2: sensor fault; distance from gear; harness

84 8 Speed sensor: no tach; harness 190 0 Excess speed switch-off: speed i

excess of limit

Sensors 91 2 Set point sensor 1: short circuit;

harness

201 2 Set point sensor 2: short circuit; harness

102 2 Charge air pressure: short circuit; harness

100 2 Oil pressure: short circuit; harness 110 2 Coolant temp: short circuit; harness 105 2 Charge air temp: short circuit; harness 174 2 Fuel temp: short circuit; harness

Functional fault warning 100 1 Oil pressure warning: oil pressure

below speed 110 0 Coolant temperature warning:

exceeded warning level 105 0 Charge air temp: warning: exceeded

warning level 111 1 Coolant level warning: switch input

"Low coolant level" is active SID 190

14 Speed warning: revolutions above top revolution speed limit

174 0 Fuel temperature warning: exceeded level

SPN FMI Description Functional fault, switch off

100 1 Oil pressure switch: pressure below switch off limit

110 0 Coolant temperature switch: exceeded switch off limit

105 0 Charge air temp. switch: exceeded switch off limit

111 1 Coolant level switch: switch input "low coolant level" active

Actuator SID 24 12 Feedback: Actuator not connected.

Faulty actuator.

SID 24 13 Reference feedback: Actuator not connected. Faulty actuator.

SID 23 7 Control travel difference: Injector pump/actuator stuck or not connected. Difference between nominal/actual travel is >10%.

SID 23 13 Auto calibration, faulty operation: No automatic actuator equalization. Incorrect actuator input values.

Hardware inputs/outputs SID 51 2 Digital output 3. switch off solenoid, pin

M2: Short or open circuit at digital output.

SID 60 2 Digital output 6, pin M7: Short or open circuit at digital output.

SID 51 6 Excess voltage, switch off solenoid: Contact Genie product support.

91 11 Error Hand Setp1: Contact Genie product support.

898 2 Error CAN setp1: Contact Genie product support.

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Service and Repair ManualJuly 2017

Deutz D436 L3i Engine Fault Codes

130 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier

SPN FMI Description Communication

SID 231

12 CAN-Bus controller: CAN controller faulty.

SID 231

9 CAN interface. SAE J1939: Overflow in input buffer. Transmission cannot be placed on bus.

SID 231

14 Short or open circuit. Bus error: Open circuit.

Memory SID 253

12 Parameter programming: Fault in parameter programming in governor fixed memory.

SID 240

12 Cyclic program test: Monitoring of program memory shows error.

SID 254

2 Cyclic RAM test: Monitoring of working memory shows error.

Control unit hardware SID 254

2 Power supply, actuator: Actuator power supply out of range.

SID 254

2 Reference voltage 1: Actuator reference voltage out of range.

SID 254

2 Reference voltage 2: Actuator reference voltage out of range.

SID 254

2 Reference voltage 3: Actuator reference voltage out of range.

171 12 Internal temperature: Control unit internal temperature out of range.

108 12 Atmospheric pressure: Out of range.

Program logic SID 253

2 Parameter fault: No data found or checksum data faulty.

SID 240

2 Stack overflow: Internal calculation fault.

SID 254

2 Internal fault: Contact Genie product support.

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July 2017Service and Repair Manual

Perkins 404F-22 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 131

SPN = Suspect Parameter Number FMI = Failure Mode Identifier

SPN FMI Description 29 3 Accelerator Pedal Position 2: Voltage

Above Normal 29 4 Accelerator Pedal Position 2: Voltage

Below Normal 91 3 Accelerator Pedal Position 1: Voltage

Above Normal 91 4 Accelerator Pedal Position 1: Voltage

Below Normal 100 1 Engine Oil Pressure :Low- most

severe (3)

108 3 Barometric Pressure : Voltage Above Normal

108 4 Barometric Pressure : Voltage Below Normal

110 3 Engine Coolant Temperature : Voltage Above Normal

110 4 Engine Coolant Temperature : Voltage Below Normal

110 15 Engine Coolant Temperature : High -least severe (1)

168 0 Battery Potential/ Power Input 1 : High- most severe (3)

168 3 Battery Potential/ Power Input 1: Voltage Above Normal

168 4 Battery Potential/ Power Input 1: Voltage Below Normal

172 3 Engine Air Inlet Temperature: Voltage Above Normal

172 4 Engine Air Inlet Temperature: Voltage Below Normal

190 0 Engine Speed : High- most severe (3)

190 8 Engine Speed : Abnormal Frequency, Pulse Width or Period

558 3 Accelerator Pedal1 Low Idle Switch: Voltage Above Normal

558 4 Accelerator Pedal1 Low Idle Switch: Voltage Below Normal

638 6 Engine Fuel Rack Actuator: Current Above Normal

639 14 J1939 Network#1: Special Instruction

SPN FMI Description 723 3 Engine Speed Sensor #2: Voltage

Above Normal

723 4 Engine Speed Sensor #2: Voltage Below Normal

723 8 Engine Speed Sensor#2: Abnormal Frequency, Pulse Width or Period"

723 10 Engine Speed Sensor #2: Abnormal Rate of Change

733 3 Engine Rack Position Sensor: Voltage Above Normal

733 4 Engine Rack Position Sensor: Voltage Below Normal

1485 7 ECU Main Relay : Not Responding Property

2840 11 ECU Instance: Other Failure Mode

2840 12 ECU Instance: Failure 2840 13 ECU Instance: Out of Calibration 2970 3 Accelerator Pedal 2 Low Idle Switch:

Voltage Above Normal

2970 4 Accelerator Pedal 2 Low Idle Switch: Voltage Below Normal

3241 1 Exhaust Gas Temperature 1: Low- most severe (3)

3241 3 Exhaust Gas Temperature 1: Voltage Above Normal

241 4 Exhaust Gas Temperature 1: Voltage Below Normal

3241 15 Exhaust Gas Temperature 1: High- least severe (1)

3241 16 Exhaust Gas Temperature 1: High- moderate severity (2)

3242 1 Particulate Trap Intake Gas Temp: Low- most severe(3)"

3242 3 Particulate Trap Intake Gas Temp: Voltage Above Normal"

3242 4 Particulate Trap Intake Gas Temp: Voltage Below Normal"

3242 15 Particulate Trap Intake Gas Temp: High - least severe(1)"

3242 16 Particulate Trap Intake Gas Temp: High-moderate severity (2)

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Perkins 404F-22 Engine Fault Codes

132 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

SPN = Suspect Parameter Number FMI = Failure Mode Identifier

SPN FMI Description 3251 3 Particulate Trap Differential Pressure:

Voltage Above Normal

3251 4 Particulate Trap Differential Pressure: Voltage Below Normal

3473 7 Aftertreatmert #1 Failed to Ignite: Not Responding Properly

3473 11 Aftertreatmert #1 Failed to Ignite : Other Failure Mode

3484 0 Aftertreatmert #1 Ignition : High-most severe (3)

3484 3 Aftertreatmert #1 Ignition : Voltage Above Normal

3484 4 Aftertreatmert #1 Ignition : Voltage Below Normal

3556 6 Aftertreatmert 1 Hydrocarbon Doser 1: Current Above Normal

3610 3 Diesel Particulate Filter Outlet Pressure or 1: Voltage Above Normal"

3610 4 DieselParticulate Filter Outlet Pressure Sensor 1: Voltage Below Normal

3713 7 DPF Active Regeneration Inhibited Due to System Timeout: Not Responding Properly

3713 31 DPF Active Regeneration Inhibited Due to System Timeout

3719 0 Particulate Trap #1 Soot Load Percent: High- most severe (3)

3719 16 Particulate Trap #1 Soot Load Percent: High-moderate severity (2)

4016 6 High Current Auxiliary Power Relay 1: Current Above Normal

4201 3 Engine Speed Sensor #1: Voltage Above Normal

SPN FMI Description 4201 4 Engine Speed Sensor #1: Voltage

Below Normal

4201 8 Engine Speed Sensor #1: Abnormal Frequency, Pulse \Nidth, or Period

4201 10 Engine Speed Sensor #1: Abnormal Rate of Change

4765 1 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Low-most severe (3)

4765 3 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Above Normal

4765 4 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Below Normal

4765 15 Aftertreatmert #1Diesel Oxidation Catalyst Intake Gas Temperature: High-least severe (1)

4765 16 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: High-moderate severity (2)

5487 3 Aftertreatmert 1 Burner Unit Combustion Chamber Temperature: Voltage Above Normal

5487 4 Aftertreatmert 1 Burner Unit Combustion Chamber Temperature: Voltage Below Normal

6581 6 Aftertreatmert 1 Hydrocarbon Doser 2 : Current Above Normal

Page 153

July 2017Service and Repair Manual

Ford MSG-425 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 133

How to R etrieve For d M SG-425 Engine Fault C odes

How to Retrieve Ford 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 at its highest efficiency while at the same time keeping exhaust emissions to a minimum. When a sensor fails or returns signals that are outside of set parameters, the ECM will store a fault code in memory that relates to the appropriate sensor and will turn on the Check Engine Light.

Note: Perform this procedure with the key switch in the off position.

1 Open the ground controls side cover and locate the run/test toggle switch on the side of the ground control box.

2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls.

3 Move and hold the run/test toggle switch to the test position.

Result: The check engine light should turn on. The check engine light should begin to blink.

4 Continue to hold the run/test toggle switch in the test position and count the blinks.

Note: Before the fault codes are displayed, the check engine light will blink a code 1-6-5-4 three times. After the fault codes, the check engine light will blink a code 1-6-5-4 three times again indicating the end of the stored codes.

Note: If any fault codes are present, the ECM will blink a three digit code three times for each code stored in memory. It will blink the first digit of a three digit code, pause, blink the second digit, pause, and then blink the third digit. For example: the check engine light blinks 5 consecutive times, blinks 3 times and then 1 time. That would indicate code 531.

Note: Once a fault code has been retrieved and the repair has been completed, the ECM memory must be reset to clear the fault code from the ECM. Refer to Fault Codes Procedure, How to Clear Engine Fault Codes from the ECM.

How to Clear Engine Fault Codes from the ECM Note: Perform this procedure with the engine off and the key switch in the off position.

1 Open the engine side turntable cover and locate the battery.

2 Disconnect the negative battery cable from the battery for a minimum of 5 minutes.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

3 Connect the negative battery cable to the battery.

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Ford MSG-425 Engine Fault Codes

134 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Ford M SG- 425 Engi ne Fault Codes

Code Description 16 Never crank synced at start 91 FP low voltage 92 FP high voltage 107 MAP Low Voltage

108 MAP High Pressure 111 IAT higher than expected 1 112 IAT low voltage 113 IAT high voltage 116 ECT higher than expected 1

117 ECT/CHT Low Voltage 118 ECT/CHT High Voltage 121 TPS1 lower than TPS2 122 TPS1 low voltage

123 TPS1 high voltage 127 IAT higher than expected 2 129 BP low pressure 134 EGO open/lazy pre-cat 1 140 EGO open/lazy post-cat 1

154 EGO open/lazy pre-cat 2/post-cat 1 160 EGO open/lazy post-cat 2 171 AL high gasoline bank1 172 AL low gasoline bank1

174 AL high gasoline bank2 175 AL low gasoline bank2 182 FT Gasoline Low Voltage 183 FT Gasoline High Voltage 187 FT Gaseaous fuel low voltage

188 FT Gaseaous fuel high voltage 217 ECT higher than expected 2 219 Max govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage

223 TPS2 high voltage 236 TIP Active

Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low-side short to

Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low-side short to

Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low-side short to

Ground 268 Injector Coil Shorted

270 Injector Loop Open or Low-side short to Ground

271 Injector Coil Shorted 273 Injector Loop Open or Low-side short to

Ground

274 Injector Coil Shorted 276 Injector Loop Open or Low-side short to

Ground

277 Injector Coil Shorted 279 Injector Loop Open or Low-side short to

Ground

280 Injector Coil Shorted 282 Injector Loop Open or Low- side short to

Ground 283 Injector Coil Shorted 285 Injector Loop Open or Low-side short to

Ground 286 Injector Coil Shorted

288 Injector Loop Open or Low-side short to Ground

289 Injector Coil Shorted

For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030).

Ford MSG-425 EFI Diagnostic Manual Genie part number 162067

Page 155

July 2017Service and Repair Manual

Ford MSG-425 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 135

Code Description 301 Emissions/catalyst damaging misfire 302 Emissions/catalyst damaging misfire 303 Emissions/catalyst damaging misfire 304 Emissions/catalyst damaging misfire

305 Emissions/catalyst damaging misfire 306 Emissions/catalyst damaging misfire 307 Emissions/catalyst damaging misfire 308 Emissions/catalyst damaging misfire 326 Knock 1 Excessive Signal

327 Knock 1 sensor Open 331 Knock 2 Excessive Signal 332 Knock 2 sensor Open 336 Crank sync noise

337 Crank loss 341 Cam sync noise 342 Cam loss 420 Gasoline cat monitor 430 Gasoline cat monitor

524 Oil pressure low 562 Battery Voltage Low 563 Battery Voltage High 601 Flash checksum invalid

604 RAM failure 606 COP failure 615 Start relay coil open 616 Start relay control ground short 617 Start relay coil short to power

627 Fpump relay coil open 628 FPump motor loop open or high-side shorted

to ground

628 Fpump relay control ground short 629 FPump motor high-side shorted to power 629 Fpump relay coil short to power

Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage

653 5VE2 high voltage 685 Relay Coil Open 686 Relay Control ground short 687 Relay coil short to power 1111 Fuel rev limit

1112 Spark rev limit 1121 FPP1/2 simultaneous voltages out of range 1122 FPP1/2 do not match each other or the IVS 1151 CL high LPG

1152 CL low LPG 1153 CL high NG 1154 CL low NG 1155 CL high gasoline bank1 1156 CL low gasoline bank1

1157 CL high gasoline bank2 1158 CL low gasoline bank2 1161 AL high LPG 1162 AL low LPG

1163 AL high NG 1164 AL low NG 1165 LPG cat monitor 1166 NG cat monitor 1171 Megajector delivery pressure higher than

expected 1172 Megajector delivery pressure lower than

expected

For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030).

Ford MSG-425 EFI Diagnostic Manual Genie part number 162067

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Ford MSG-425 Engine Fault Codes

136 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Code Description 1173 Megajector comm lost 1174 Megajector voltage supply high 1175 Megajector voltage supply low 1176 Megajector internal actuator fault detection

1177 Megajector internal circuitry fault detection 1178 Megajector internal comm fault detection 1311 Misfire detected 1312 Misfire detected 1313 Misfire detected

1314 Misfire detected 1315 Misfire detected 1316 Misfire detected 1317 Misfire detected

1318 Misfire detected 1511 AUX analog PU1 high 1512 AUX analog PU1 low 1513 AUX analog PU2 high 1514 AUX analog PU2 low

1515 AUX analog PD1 high 1516 AUX analog PD1 low 1517 AUX analog PU3 high 1518 AUX analog PU3 low

1521 CHT higher than expected 1 1522 CHT higher than expected 2 1531 IVS/Brake/Trans-Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low

1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high

Code Description 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low

1555 AUX DIG3 high 1556 AUX DIG3 low 1561 AUX analog PD2 high 1562 AUX analog PD2 low 1563 AUX analog PD3 high

1564 AUX analog PD3 low 1611 5VE 1/2 simultaneous out of range 1612 RTI 1 loss 1613 RTI 2 loss

1614 RTI 3 loss 1615 A/D loss 1616 Invalid interrupt 1621 Rx Inactive 1622 Rx Noise

1623 Invalid Packet Format 1624 Shutdown Request 1625 Shutdown Request 1626 CAN Tx failure

1627 CAN Rx failure 1628 CAN addresss conflict failure

For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030).

Ford MSG-425 EFI Diagnostic Manual Genie part number 162067

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Ford MSG-425 Engine Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 137

Code Description 1629 J1939 TSC1 message receipt lost 1630 J1939 ETC message receipt lost 1631 PWM1-Gauge1 open / ground short 1632 PWM1-Gauge1 short to power

1633 PWM2-Gauge2 open /ground short 1634 PWM2-Gauge2 short to power 1635 PWM3-Gauge3 open / ground short 1636 PWM3-Gauge3 short to power 1641 Buzzer control ground short

1642 Buzzer open 1643 Buzzer control short to power 1644 MIL control ground short 1645 MIL control short to power

2111 Unable to reach lower TPS 2112 Unable to reach higher TPS 2115 FPP1 higher than IVS limit 2116 FPP2 higher than IVS limit 2120 FPP1 invalid voltage and FPP2 disagrees

with IVS 2121 FPP1 lower than FPP2

2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees

with IVS

2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage

Code Description 2130 IVS stuck at-idle, FPP1/2 match 2131 IVS stuck off-idle, FPP1/2 match 2135 TPS1/2 simultaneous voltages out of range 2139 FPP1 lower than IVS limit

2140 FPP2 lower than IVS limit 2229 BP high pressure 2300 Primary Loop Open or Low-side Short to

Ground

2301 Primary Coil Shorted 2303 Primary Loop Open or Low-side Short to

Ground 2304 Primary Coil Shorted 2306 Primary Loop Open or Low-side Short to

Ground 2307 Primary Coil Shorted

For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030).

Ford MSG-425 EFI Diagnostic Manual Genie part number 162067

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Service and Repair ManualJuly 2017

Ford MSG-425 Engine Fault Codes

138 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Code Description 2309 Primary Loop Open or Low-side Short to

Ground

2310 Primary Coil Shorted 2312 Primary Loop Open or Low-side Short to

Ground

2313 Primary Coil Shorted 2315 Primary Loop Open or Low-side Short to

Ground

2316 Primary Coil Shorted 2318 Primary Loop Open or Low-side Short to

Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low-side Short to

Ground 2322 Primary Coil Shorted 2618 Tach output ground short

2619 Tach output short to power

For further engine fault code troubleshooting and diagnostic information, refer to the Ford MSG-425 EFI Diagnostic Manual (EDI part number 1080030).

Ford MSG-425 EFI Diagnostic Manual Genie part number 162067

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Load Sense System Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 139

Platform Load Sense System, S-60 HC

How to Retrieve Platform Load Sense System Fault Codes Note: Perform this procedure with the engine off, the key switch turned to ground controls and the red Emergency Stop buttons pulled out to the on position at both the ground and platform controls.

1 Open the ground controls side turntable cover.

2 Locate the operational and safety controllers near the ground control box.

3 Determine whether a safety or operational fault exists by visually inspecting which controller has flashing LEDs.

Note: If the LEDs are flashing on both controllers, determine the fault code on one controller at a time.

4 Determine the error source: The red LED indicates the error source and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second.

5 Determine the error type: The green LED indicates the error type and will flash two separate codes. The first code will indicate the first digit of the two digit code, flashing once per second. It will then pause for 1.5 seconds and flash the second digit once per 0.5 second.

6 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected.

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Fault Codes

140 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source 12, System Checks

Error Type Condition Solution

ID Name

11 Safety envelope reached Power relays disengaged. Use recovery switch and APU from the ground controls to recover the machine to stowed position or within the operating envelope.

12 Platform load greater 1200 lbs/544 kg or less.

Power relays disengaged. Remove weight from platform until load is than 1250 lbs/567 kg

13 CAN communication failure Power relays disengaged. Repair CAN bus wiring and/or connections.

14 Sensor power failure Power relays disengaged. Use recovery switch and APU from the ground controls to recover the machine to stowed position or within the operating envelope.

21 Angle sensor not active Power relays disengaged. Inspect boom angle sensor for proper operation and be sure it is connected to boom properly OR replace boom angle sensor.

22 String potentiometer not active Power relays disengaged. Inspect string potentiometer for proper operation and be sure it is connected to boom properly OR replace string potentiometer.

23 Power relay output short high Power relays disengaged. Repair system wiring and/or connections.Relay wiring open or shorted to voltage.

24 Power relay output short low Power relays disengaged. Repair system wiring and/or connections.Relay wiring open or shorted to ground.

25 Directional relay output short high Boom up/down and extend/retract inoperative. Relay wiring open or shorted to voltage.

Repair system wiring and/or connections.

26 Output short low Boom up/down and extend/retract inoperative. Relay wiring open or shorted to ground.

Repair system wiring and/or connections.

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Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 141

Error Source 21, String Potentiometer Operational Sensor (C167PSL)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

11 Output short high Power relays disengaged. String potentiometer wiring open or shorted to voltage.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

12 Value too high Power relays disengaged. String potentiometer wiring open or shorted to voltage.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

15 Value too low Power relays disengaged. String potentiometer wiring open or shorted to ground.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

16 Output short low Power relays disengaged. String potentiometer wiring open or shorted to ground.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

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Fault Codes

142 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source 22, String Potentiometer Safety Sensor (C167PSL)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

11 Output short high Power relays disengaged. String potentiometer wiring open or shorted to voltage.

Repair wiring and/or connections OR String potentiometer replace string potentiometer and calibrate overload system.to voltage.

12 Value too high Power relays disengaged. String potentiometer wiring open or shorted to voltage.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

15 Value too low Power relays disengaged. String potentiometer wiring open OR shorted to ground OR string potentiometer is faulty.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

16 Output short low Power relays disengaged. String potentiometer wiring open OR shorted to ground.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

21 Inconsistent Checks operational and safety sensor values against each other.

Repair wiring and/or connections OR replace string potentiometer and calibrate overload system.

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July 2017Service and Repair Manual

Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 143

Error Source 31, Boom Angle Operational Sensor (C123PBS)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

11 Output short high Power relays disengaged. Boom angle sensor wiring open or shorted to voltage.

Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

12 Value too high Power relays disengaged. Boom angle sensor wiring open or shorted to voltage OR sensor is out of operating range

Repair wiring and/or connections OR adjust or replace boom angle sensor and calibrate overload system.

15 Value too low Power relays disengaged. Boom angle sensor wiring open OR shorted to ground OR sensor is out of operating range.

Repair wiring and/or connections OR adjust or replace boom angle sensor and calibrate overload system.

16 Output short low Power relays disengaged. Boom angle sensor wiring open OR shorted to ground.

Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

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Service and Repair ManualJuly 2017

Fault Codes

144 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source 32, Boom Angle Safety Sensor (C141PBS)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR 11 Output short high Power relays disengaged.

Boom angle sensor wiring open or shorted to voltage.

Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

12 Value too high Power relays disengaged. Boom angle sensor wiring open or shorted to voltage OR sensor is out of operating range.

Repair wiring and/or connections OR adjust or replace boom angle sensor and calibrate overload system.

15 Value too low Power relays disengaged. Boom angle sensor wiring open OR shorted to ground OR sensor is out of operating range.

Repair wiring and/or connections OR adjust or replace boom angle sensor and calibrate overload system.

16 Output short low Power relays disengaged. Boom angle sensor wiring open OR shorted to ground.

Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

21 Inconsistent Checks operational and safety sensor values against each other.

Repair wiring and/or connections OR replace boom angle sensor and calibrate overload system.

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July 2017Service and Repair Manual

Fault Codes

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 145

Error Source 41, Load Cell Operational (C175LDS)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

11 Output short high Power relays disengaged. Load cell wiring open OR shorted to voltage. Platform may be overloaded.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

12 Value too high Power relays disengaged. Load cell wiring open OR shorted to voltage. Platform may be reverse loaded.

Repair wiring and/or connections OR replace platform load cell OR remove excess weight from platform.

15 Value too low Power relays disengaged. Load cell wiring open OR shorted to ground.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system. Check for binding of the overload component linkage and be sure platform is NOT on the ground OR supported from underneath.

16 Output short low Power relays disengaged. Load cell wiring open OR shorted to ground.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

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Service and Repair ManualJuly 2017

Fault Codes

146 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Error Source 42, Load Cell Safety (C94LDS)

Error Type Condition Solution

ID Name

5 Sensor tolerance fault Power relays disengaged. Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

11 Output short high Power relays disengaged. Load cell wiring open OR shorted to voltage.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

12 Value too high Power relays disengaged. Load cell wiring open OR shorted to voltage. Platform may be overloaded.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system OR remove excess weight from platform.

15 Value too low Power relays disengaged. Load cell wiring open OR shorted to ground. Platform may be reverse loaded.

16 Output short low Power relays disengaged. Load cell wiring open OR shorted to ground.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

17 Not calibrated Boom range of motion is limited.

Calibrate the platform load sense system.

18 Just calibrated Used to clear diagnostic codes.

Self-clearing.

21 Inconsistent Checks operational and safety sensor values against each other.

Repair wiring and/or connections OR replace platform load cell and calibrate overload system.

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July 2017Service and Repair Manual

Schematics

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 147

Section 5 Schem atics

Observe and Obey: Troubleshooting and repair procedures shall

be completed by a person trained and qualified on the repair of this machine

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Before Troubleshooting: Read, understand and obey the safety rules

and operating instructions in the appropriate operator's manual on your machine.

Be sure that all necessary tools and test equipment are available and ready for use.

About This Section There are two groups of schematics in this section.

Electrical Schematics

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Hydraulic Schematics

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Service and Repair ManualJuly 2017

Electrical Symbol Legend

148 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge

Diode Hour meter LED Fuse with amperage Foot switch

T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid

Connection - no terminal T-circuits connect at terminal

Circuits crossing no connection

Quick disconnect terminal

Circuit breaker with amperage

Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor

Horn button - normally open

Emergency Stop button - normally closed Resistor with ohm value Battery separator Gauge sending unit

Oil temperature switch normally open

Coolant temperature switch - normally open

Oil pressure switch normally closed

Control relay contact normally open

Diode starting aid, glow plug or flame ignitor

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July 2017Service and Repair Manual

Hydraulic Symbols Legend

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 149

Orifice with size Check valve Shut off valve Brake

Pump, fixed displacement Pump, bi-directional variable displacement Motor, bi-directional Motor, 2 speed

bi-directional

Cylinder, double acting Pump, prime mover (engine or motor)

Shuttle valve. 2 position, 3 way Differential sensing valve

Filter with bypass relief valve

Relief valve with pressure setting Priority flow regulator valve Solenoid operated

proportional valve

Directional valve (mechanically activated) Flow divider/combiner valve Pilot operated 3 position, 3

way shuttle valve

Solenoid operated 2 position, 3 way directional

valve

Counterbalance valve with pressure and pilot ratio

Solenoid operated 3 position 4 way directional

valve

Solenoid operated 3 position, 4 way proportional

directional valve

Solenoid valve, 2 position 2 way

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Limit Switch Location Legend

150 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

All models except as noted

1 LSB1RO 2 LSB2S 3 Primary boom angle sensor (excludes the

S-60 HC)

4 LST3O 5 LST2O 6 LST1O

S-60 HC, S-60X and S-60XC as noted

1 String pot (S-60 HC MODELS) 2 LST3S (S-60X / S-60XC) 3 LSB1ES (S-60X / S-60XC)

4 LS18 / LS18A (CE MODELS) 5 LSB1EO (S-60X / S-60XC) 6 Primary boom angle sensor (S-60 HC

Page 171

July 2017Service and Repair Manual

Ford Engine Relay Layout

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 151

Ford MSG-425 EFI

1 Power Relay 2 Fuel Pump Relay 3 Starter Relay 4 Starter - 20A 5 Empty 6 Fuse 1 - 10A 7 Fuse 2 - 5A 8 Fuse 3 - 10A 9 Fuse 4 - 15A 10 Fuse 5 - 15A

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Service and Repair ManualJuly 2017

Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22

152 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Deutz D 2.9 L4

Fuses

F7 20A Horn, Hydraulic Oil Cooler F8 30A ECU Power F17 15A Ignition F19 10A Engine accessory F20 20A Fuel Pump

Diode

D22 6A Alternator Ext.

Relays

CR2B Ignition on CR5B Horn CR6 Fuel pump

CR17B Hydraulic oil cooler (option) CR23B Engine accessory CR39B Auxiliary pump

Perkins 404F-22 Fuses

F10 15A Relay power F11A 15A ARD Injector 1 F11B 15A ARD Injector 2 F11C 5A Linear solenoid F12 7.5A Engine start F17 10A Fuel, Alternator Ext. F22A 15A Glow plug 1 F22B 20A Glow plug 2 F22C 20A ARD Glow plug

Diode

D22 6A Alternator Ext.

Relays

CR1B Engine start CR6 Fuel, Alternator Ext. CR15A Glow plug 1 CR15B Glow plug 2 CR15C ARD Glow plug CR79 Burner air pump

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153

Ford MSG-425 Engine Wire Harness

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Service and Repair ManualJuly 2017

154 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Ford MSG-425 EFI Engine Wire Harness

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 155

Deutz D 2.9 L4 Engine Wire Harness

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156

Deutz D 2.9 L4 Engine Wire Harness

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157

Perkins 404F-22 Engine Wire Harness

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158 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Perkins 404F-22 Engine Wire Harness

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 159

Deutz D436 L3i Engine Wire Harness

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160

Deutz D436 L3i Engine Wire Harness

Page 181

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161

Electrical Schematic, Options - Deutz D436 L3i

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162 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Options - Deutz D436 L3i

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 163

Electrical Schematic, Options Deutz D2011L03i, TD2011L04i and Perkins 404D-22

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164

Electrical Schematic, Options Deutz D2011L03i, TD2011L04i and Perkins 404D-22

Page 185

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165

Electrical Schematic, Options - Deutz D 2.9 L4

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166 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Options - Deutz D 2.9 L4

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 167

Electrical Schematic, Options - Perkins 404F-22

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168

Electrical Schematic, Options - Perkins 404F-22

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169

Wiring Diagram, 3kW Hydraulic Generator

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170 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Wiring Diagram, 3kW Hydraulic Generator

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 171

Wiring Diagram, 12kW Hydraulic Generator - Welder Option

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172

Wiring Diagram, 12kW Hydraulic Generator - Welder Option

Page 193

July 2017Service and Repair Manual

173

Electrical Schematic, 12kW Hydraulic Generator - Welder Option

Page 194

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174 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, 12kW Hydraulic Generator - Welder Option

Page 195

July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 175

Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option

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Service and Repair ManualJuly 2017

176

Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option

Page 197

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177

Hydraulic Schematic, 2WD Models

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178 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Hydraulic Schematic, 2WD Models

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 179

Hydraulic Schematic, 4WD Models

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180

Hydraulic Schematic, 4WD Models

Page 201

July 2017Service and Repair Manual

181

Electrical Schematic, Ford MSG-425 EFI Models (ANSI CSA)

Page 202

Service and Repair ManualJuly 2017

182 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Ford MSG-425 EFI Models (ANSI / CSA)

Page 203

July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 183

Electrical Schematic, Ford MSG-425 EFI Models (ANSI / CSA)

Page 204

Service and Repair ManualJuly 2017

184

Electrical Schematic, Ford MSG-425 EFI Models (ANSI CSA)

Page 205

July 2017Service and Repair Manual

185

Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 206

Service and Repair ManualJuly 2017

186 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 207

July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 187

Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 208

Service and Repair ManualJuly 2017

188

Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 209

July 2017Service and Repair Manual

189

Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 210

Service and Repair ManualJuly 2017

190 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 211

July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 191

Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 212

Service and Repair ManualJuly 2017

192

Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI CSA)

Page 213

July 2017Service and Repair Manual

193

Electrical Schematic, Deutz D2011L03i Models (ANSI CSA)

Page 214

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194 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Deutz D2011L03i Models (ANSI CSA)

Page 215

July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 195

Electrical Schematic, Deutz D2011L03i Models (ANSI CSA)

Page 216

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196

Electrical Schematic, Deutz D2011L03i Models (ANSI CSA)

Page 217

July 2017Service and Repair Manual

197

Electrical Schematic, Deutz TD2011L04i Models (ANSI CSA)

Page 218

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198 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Electrical Schematic, Deutz TD2011L04i Models (ANSI CSA)

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July 2017Service and Repair Manual

Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 199

Electrical Schematic, Deutz TD2011L04i Models (ANSI CSA)

Page 220

Service and Repair ManualJuly 2017

200

Electrical Schematic, Deutz TD2011L04i Models (ANSI CSA)

Page 221

July 2017Service and Repair Manual

201

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA)

Page 222

Service and Repair ManualJuly 2017

202 S-60/65 S-60/65 TRAX S-60 HC S-60X/XC Part No. 1268492GT

Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA)

Page 223

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Part No. 1268492GTS-60/65 S-60/65 TRAX S-60 HC S-60X/XC 203

Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Ford MSG-425 EFI Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Deutz D 2.9 L4 Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Deutz D 2.9 L4 Models (ANSI CSA)

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Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC Deutz D 2.9 L4 Models (ANSI CSA)

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Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC Deutz D 2.9 L4 Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Deutz D436 L3i Models (ANSI CSA)

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Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC Deutz D436 L3i Models (ANSI CSA)

Page 329

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Electrical Schematic, S-60X S-60XC Perkins 404D-22 Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Perkins 404D-22 Models (ANSI CSA)

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Ground Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA)

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Platform Control Box Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA)

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Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404D-22 Models (ANSI CSA)

Page 341

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Electrical Schematic, S-60X S-60XC Perkins 404F-22 Models (ANSI CSA)

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Electrical Schematic, S-60X S-60XC Perkins 404F-22 Models (ANSI CSA)

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Ground Control Box Terminal Strip Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA)

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Ground Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA)

Page 349

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Platform Control Box Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA)

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Platform Control Box Switch Panel Wiring Diagram, S-60X S-60XC, Perkins 404F-22 Models (ANSI CSA)

Page 353

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Electrical Schematic, Ford MSG-425 EFI Models (CE)

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Electrical Schematic, Ford MSG-425 EFI Models (CE)

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Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE)

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Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE)

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Electrical Schematic, Deutz D2011L03i Models (CE)

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Electrical Schematic, Deutz TD2011L04i Models (CE)

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Electrical Schematic, Deutz TD2011L04i Models (CE)

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Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (CE)

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Electrical Schematic, Deutz D436 L3i Models (CE)

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Electrical Schematic, Deutz D436 L3i Models (CE)

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Electrical Schematic, Deutz D436 L3i Models (CE)

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Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (CE)

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Platform Control Box Wiring Diagram, Deutz D436 L3i Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (CE)

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Electrical Schematic, Perkins 404D-22 Models (CE)

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Electrical Schematic, Perkins 404D-22 Models (CE)

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Electrical Schematic, Perkins 404D-22 Models (CE)

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Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE)

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Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE)

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Platform Control Box Wiring Diagram, Perkins 404D-22 Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE)

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Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE)

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Electrical Schematic, S-60 HC (CE)

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Electrical Schematic, S-60 HC (CE)

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Chassis Wiring Diagram, S-60 HC (CE)

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Service and Repair ManualJuly 2017

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Chassis Wiring Diagram, S-60 HC (CE)

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Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (CE)

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Platform Control Box Wiring Diagram, S-60 HC (CE)

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Platform Control Box Wiring Diagram, S-60 HC (CE)

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Electrical Schematic, Ford MSG-425 EFI Models (AS)

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Service and Repair ManualJuly 2017

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Electrical Schematic, Ford MSG-425 EFI Models (AS)

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Electrical Schematic, Ford MSG-425 EFI Models (AS)

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Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (AS)

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Service and Repair ManualJuly 2017

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July 2017Service and Repair Manual

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Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)

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Service and Repair ManualJuly 2017

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Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)

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Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (AS)

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July 2017Service and Repair Manual

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Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)

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Service and Repair ManualJuly 2017

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Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)

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Electrical Schematic, Deutz D2011L03i Models (AS)

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Electrical Schematic, Deutz D2011L03i Models (AS)

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Electrical Schematic, Deutz D2011L03i Models (AS)

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Electrical Schematic, Deutz TD2011L04i Models (AS)

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Electrical Schematic, Deutz TD2011L04i Models (AS)

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Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Service and Repair ManualJuly 2017

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Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Platform Control Box Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i TD2011L04i Models (AS)

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Electrical Schematic, Deutz D436 L3i Models (AS)

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Electrical Schematic, Deutz D436 L3i Models (AS)

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Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (AS)

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Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (AS)

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Service and Repair ManualJuly 2017

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Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (AS)

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Platform Control Box Wiring Diagram, Deutz D436 L3i Models (AS)

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Platform Control Box Wiring Diagram, Deutz D436 L3i Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (AS)

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Electrical Schematic, Perkins 404D-22 Models (AS)

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Electrical Schematic, Perkins 404D-22 Models (AS)

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Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (AS)

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Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (AS)

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July 2017Service and Repair Manual

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Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS)

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Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS)

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Platform Control Box Wiring Diagram, Perkins 404D-22 Models (AS)

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Platform Control Box Wiring Diagram, Perkins 404D-22 Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS)

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Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS) S-60/65 S- 60/65 TR AX S-60 HC S-60X/XC Part No. 1268492GT Service and R epair M anual July 2017

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References