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Genie S-60 S-65 S-60X S-60XC S-60 HC S-60TraX S-65 TraX Service Manual – PDF
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Genie S-60 S-65 S-60X S-60XC S-60 HC S-60TraX S-65 TraX Service & Repair Manual 1268492 – PDF DOWNLOAD
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Description
Genie S-60 S-65 S-60X S-60XC S-60 HC S-60TraX S-65 TraX Service & Repair Manual 1268492 – PDF DOWNLOAD
Language : English
Pages : 465
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-60 S-65 S-60X S-60XC S-60 HC S-60TraX S-65 TraX Service & Repair Manual 1268492 – PDF DOWNLOAD
Front Cover................................................................................................................... 1 Important Information......................................................................................................... 2 Find a Manual for this Model.................................................................................................. 2 Revision History.............................................................................................................. 3 Serial Number Legend.......................................................................................................... 4 General Safety Rules.......................................................................................................... 5 Table of Contents............................................................................................................. 7 Specifications................................................................................................................ 21 Machine Specifications.................................................................................................... 21 Performance Specifications................................................................................................ 22 Hydraulic Oil Specifications.............................................................................................. 23 Hydraulic Component Specifications........................................................................................ 26 Ford MSG-425 EFI Engine Specifications.................................................................................... 28 Deutz D436 L3i CN3 Engine Specifications.................................................................................. 29 Deutz D2011 L03i Engine Specifications.................................................................................... 31 Deutz TD2011L04i Engine Specifications.................................................................................... 33 Deutz D 2.9 L4 Engine Specifications...................................................................................... 35 Perkins 404D-22 Engine Specifications..................................................................................... 37 Perkins 404F-22 Engine Specifications..................................................................................... 38 Machine Torque Specifications............................................................................................. 40 Hydraulic Hose and Fitting Torque Specifications.......................................................................... 41 Torque Procedure.......................................................................................................... 42 Repair Procedures............................................................................................................. 44 Introduction.............................................................................................................. 44 Platform Controls......................................................................................................... 46 1-1 ALC-500 Circuit Board............................................................................................. 46 1-2 Joysticks......................................................................................................... 47 How to Adjust the Joystick Threshold Setting...................................................................... 47 How to Adjust the Joystick Max-out Setting........................................................................ 48 How to Adjust the Joystick Ramp Rate Setting...................................................................... 49 How to Calibrate the Boom Angle Sensor............................................................................ 51 Platform Components....................................................................................................... 52 2-1 Platform Leveling Slave Cylinder.................................................................................. 52 2-2 Platform Rotator.................................................................................................. 53 2-3 Platform Overload System, S-60, S-65, S-60 TRAX and S-65 TRAX (if equipped)....................................... 56 2-4 Platform Load Sense System, S-60 HC............................................................................... 58 How to Restore System Default Settings System..................................................................... 61 Jib Boom Components....................................................................................................... 62 3-1 Jib Boom.......................................................................................................... 62 3-2 Jib Boom Lift Cylinder............................................................................................ 63 Boom Components........................................................................................................... 64 4-1 Cable Track....................................................................................................... 64 How to Remove the Cable Track, S-60, S-60X, S-60XC, S-60 HC and S-60 TRAX......................................... 64 How to Remove the Cable Track, S-65 and S-65 TRAX................................................................. 65 How to Repair the Cable Track..................................................................................... 67 4-2 Boom.............................................................................................................. 69 4-3 Boom Lift Cylinder................................................................................................ 72 4-4 Boom Extension Cylinder........................................................................................... 73 4-5 Boom Extend/Retract Cables........................................................................................ 76 4-6 Platform Leveling Master Cylinder................................................................................. 79 4-7 Primary Boom Angle Sensor, S-60X and S-60XC....................................................................... 80 Engines................................................................................................................... 82 5-1 RPM Adjustment - Ford and Deutz Models............................................................................ 82 5-2 RPM Adjustment - Perkins 404D-22 Models........................................................................... 82 5-3 Flex Plate - Removal.............................................................................................. 82 How to Install a Type "A" Flex Plate.............................................................................. 84 How to Install a Type "B" Flex Plate.............................................................................. 85 How to install the Pump and Bell Housing Assembly................................................................. 86 5-4 Ford MSG-425 Engine Fault Codes................................................................................... 87 5-5 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models.................................................... 88 Hydraulic Pump............................................................................................................ 89 6-1 Lift/Steer Pump................................................................................................... 89 6-2 Drive Pump........................................................................................................ 90 Manifolds................................................................................................................. 92 7-1 Function Manifold Components (to serial number 26514)............................................................. 92 Function Manifold Components (from serial number 26515)............................................................... 95 7-2 Valve Adjustments - Function Manifold.............................................................................100 7-3 Jib Boom / Platform Rotate Manifold Components....................................................................101 7-4 Brake/Two-Speed Manifold Components...............................................................................102 7-5 Turntable Rotation Manifold Components............................................................................103 7-6 Oscillate Directional Valve Components............................................................................104 How to Set Up the Oscillate Directional Valve.....................................................................105 7-7 Valve Adjustments - Oscillate Relief Valve........................................................................106 7-8 Drive Oil Diverter Manifold Components (welder option)............................................................107 7-9 Traction Manifold Components, 2WD.................................................................................108 7-10 Valve Adjustments, 2WD Traction Manifold.........................................................................109 7-11 Traction Manifold Components, 4WD................................................................................110 7-12 Valve Adjustments, 4WD Traction Manifold.........................................................................112 7-13 Hydraulic Generator Manifold Components, 3kW.....................................................................113 7-14 Valve Coils......................................................................................................114 How to Test a Coil Diode..........................................................................................115 Turntable Rotation Components.............................................................................................116 8-1 Turntable Rotation Assembly.......................................................................................116 How to Adjust the Turntable Rotation Gear Backlash................................................................117 Axle Components...........................................................................................................119 9-1 Oscillating Axle Cylinders........................................................................................119 Track Components..........................................................................................................120 10-1 Track Assembly, S-60 TRAX and S-65 TRAX..........................................................................120 How to Replace a Track............................................................................................120 Fault Codes...................................................................................................................123 Introduction..............................................................................................................123 Control System Fault Codes................................................................................................124 How to Retrieve Control System Fault Codes............................................................................124 Control System Fault Codes............................................................................................125 Fault Code Display - Deutz and Perkins Models.............................................................................130 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4, D436 L3i and Perkins 404F-22 Models.........................130 Flashing and Solid LED's - Deutz D 2.9 L4 and Perkins 404F-22 Models..............................................131 Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-22 Models..........................................132 Main Menu Structure - Deutz D 2.9 L4 Models.......................................................................133 Main Menu Structure - Perkins 404F-22 Models......................................................................134 Deutz D436 L3i Display............................................................................................135 Main Menu Structure - Deutz D436 L3i Models.......................................................................136 Deutz D 2.9 L4 Engine Fault Codes.........................................................................................138 Deutz D436 L3i Engine Fault Codes.........................................................................................149 Perkins 404F-22 Engine Fault Codes........................................................................................151 Ford MSG-425 Engine Fault Codes...........................................................................................153 How to Retrieve Ford MSG-425 Engine Fault Codes.......................................................................153 Ford MSG-425 Engine Fault Codes.......................................................................................154 Load Sense System Fault Codes.............................................................................................159 Platform Load Sense System, S-60 HC...................................................................................159 Schematics....................................................................................................................167 Introduction..............................................................................................................167 Electrical Symbol Legend..................................................................................................168 Hydraulic Symbols Legend..................................................................................................169 Limit Switch Location Legend..............................................................................................170 Ford Engine Relay Layout..................................................................................................171 Engine Relay Layout - Deutz D 2.9 L4 and Perkins 404F-22..................................................................172 Electrical Schematics – Options...........................................................................................173 Ford MSG-425 EFI Engine Wire Harness..................................................................................174 Deutz D 2.9 L4 Engine Wire Harness....................................................................................175 Perkins 404F-22 Engine Wire Harness...................................................................................178 Deutz D436 L3i Engine Wire Harness....................................................................................179 Electrical Schematic, Options - Deutz D436 L3i........................................................................182 Electrical Schematic, Options - Deutz D2011L03i, TD2011L04i and Perkins 404D-22.......................................183 Electrical Schematic, Options - Deutz D 2.9 L4........................................................................186 Electrical Schematic, Options - Perkins 404F-22.......................................................................187 Wiring Diagram, 3kW Hydraulic Generator...............................................................................190 Wiring Diagram, 12kW Hydraulic Generator - Welder Option..............................................................191 Electrical Schematic, 12kW Hydraulic Generator - Welder Option........................................................194 Hydraulic Schematic, 12kW Hydraulic Generator - Welder Option.........................................................195 Hydraulic Schematics......................................................................................................197 Hydraulic Schematic, 2WD Models.......................................................................................198 Hydraulic Schematic, 4WD Models.......................................................................................199 Electrical Schematics – ANSI and CSA Models...............................................................................201 Electrical Schematic, Ford MSG-425 EFI Models (ANSI • CSA)............................................................202 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (ANSI • CSA)................................206 Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI • CSA)..................................207 Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (ANSI • CSA).............................................210 Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (ANSI • CSA)................................211 Electrical Schematic, Deutz D2011L03i Models (ANSI • CSA).............................................................214 Electrical Schematic, Deutz TD2011L04i Models (ANSI • CSA)............................................................218 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)....................222 Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)......................223 Platform Control Box Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).................................226 Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)....................227 Electrical Schematic, Deutz D 2.9 L4 Models (ANSI • CSA)..............................................................230 Ground Control Box Terminal Strip Wiring Diagram, Deutz D 2.9 L4 Models (ANSI • CSA)..................................234 Ground Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI • CSA)....................................235 Platform Control Box Wiring Diagram, Deutz D 2.9 L4 Models (ANSI • CSA)...............................................238 Platform Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 Models (ANSI • CSA)..................................239 Electrical Schematic, Deutz D436 L3i Models (ANSI • CSA)..............................................................242 Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................246 Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)....................................247 Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)...............................................250 Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................251 Electrical Schematic, Perkins 404D-22 Models (ANSI • CSA).............................................................254 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (ANSI • CSA).................................258 Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (ANSI • CSA)...................................259 Platform Control Box Wiring Diagram, Perkins 404D-22 Models (ANSI • CSA)..............................................262 Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (ANSI • CSA).................................263 Electrical Schematic, Perkins 404F-22 Models (ANSI • CSA).............................................................266 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404F-22 Models (ANSI • CSA).................................270 Ground Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI • CSA)...................................271 Platform Control Box Wiring Diagram, Perkins 404F-22 Models (ANSI • CSA)..............................................274 Platform Control Box Switch Panel Wiring Diagram, Perkins 404F-22 Models (ANSI • CSA).................................275 Electrical Schematic, S-60X • S-60XC Ford MSG-425 EFI Models (ANSI • CSA).............................................278 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Ford MSG-425 EFI Models (ANSI • CSA)................282 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Ford MSG-425 EFI Models (ANSI • CSA)................283 Platform Control Box Wiring Diagram, S-60X • S-60XC, Ford MSG-425 EFI Models (ANSI • CSA).............................286 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Ford MSG-425 EFI Models (ANSI • CSA)................287 Electrical Schematic, S-60X • S-60XC, Deutz D2011L03i Models (ANSI • CSA).............................................290 Electrical Schematic, S-60X • S-60XC, Deutz TD2011L04i Models (ANSI • CSA)............................................294 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)....................298 Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)......299 Platform Control Box Wiring Diagram, S-60X • S-60XC, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA).................302 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Deutz D2011L03i • TD2011L04i Models (ANSI • CSA)....303 Electrical Schematic, S-60X • S-60XC, Deutz D 2.9 L4 Models (ANSI • CSA)..............................................306 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Deutz D 2.9 L4 Models (ANSI • CSA)..................310 Ground Control Box Switch Panel Wiring Diagram,S-60X • S-60XC, Deutz D 2.9 L4 (ANSI • CSA)............................311 Platform Control Box Wiring Diagram, S-60X • S-60XC, Deutz D 2.9 L4 Models (ANSI • CSA)...............................314 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Deutz D 2.9 L4 Models (ANSI • CSA)..................315 Electrical Schematic, S-60X • S-60XC, Deutz D436 L3i Models (ANSI • CSA)..............................................318 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Deutz D436 L3i Models (ANSI • CSA)..................322 Ground Control Box Switch Panel Wiring Diagram,S-60X • S-60XC, Deutz D436 L3i (ANSI • CSA)............................323 Platform Control Box Wiring Diagram, S-60X • S-60XC, Deutz D436 L3i Models (ANSI • CSA)...............................326 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Deutz D436 L3i Models (ANSI • CSA)..................327 Electrical Schematic, S-60X • S-60XC, Perkins 404D-22 Models (ANSI • CSA).............................................330 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Perkins 404D-22 Models (ANSI • CSA).................334 Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Perkins 404D-22 Models (ANSI • CSA)...................335 Platform Control Box Wiring Diagram, S-60X • S-60XC, Perkins 404D-22 Models (ANSI • CSA)..............................338 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Perkins 404D-22 Models (ANSI • CSA).................339 Electrical Schematic, S-60X • S-60XC, Perkins 404F-22 Models (ANSI • CSA).............................................342 Ground Control Box Terminal Strip Wiring Diagram, S-60X • S-60XC, Perkins 404F-22 Models (ANSI • CSA).................346 Ground Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Perkins 404F-22 Models (ANSI • CSA)...................347 Platform Control Box Wiring Diagram, S-60X • S-60XC, Perkins 404F-22 Models (ANSI • CSA)..............................350 Platform Control Box Switch Panel Wiring Diagram, S-60X • S-60XC, Perkins 404F-22 Models (ANSI • CSA).................351 Electrical Schematics – CE Models.........................................................................................353 Electrical Schematic, Ford MSG-425 EFI Models (CE)....................................................................354 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (CE)........................................358 Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE)..........................................359 Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (CE).....................................................362 Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (CE)........................................363 Electrical Schematic, Deutz D2011L03i Models (CE).....................................................................366 Electrical Schematic, Deutz TD2011L04i Models (CE)....................................................................370 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (CE)............................374 Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (CE)..............................375 Platform Control Box Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (CE).........................................378 Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (CE)............................379 Electrical Schematic, Deutz D436 L3i Models (CE)......................................................................382 Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................386 Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)....................................387 Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)...............................................390 Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................391 Electrical Schematic, Perkins 404D-22 Models (CE).....................................................................394 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (CE).........................................398 Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE)...........................................399 Platform Control Box Wiring Diagram, Perkins 404D-22 Models (CE)......................................................402 Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (CE).........................................403 Electrical Schematic, S-60 HC (CE)....................................................................................406 Chassis Wiring Diagram, S-60 HC (CE)..................................................................................407 Ground Control Box Terminal Strip Wiring Diagram, S-60 HC (CE)........................................................410 Platform Control Box Wiring Diagram, S-60 HC (CE).....................................................................411 Electrical Schematics – AS Models.........................................................................................413 Electrical Schematic, Ford MSG-425 EFI Models (AS)....................................................................414 Ground Control Box Terminal Strip Wiring Diagram, Ford MSG-425 EFI Models (AS)........................................418 Ground Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)..........................................419 Platform Control Box Wiring Diagram, Ford MSG-425 EFI Models (AS).....................................................422 Platform Control Box Switch Panel Wiring Diagram, Ford MSG-425 EFI Models (AS)........................................423 Electrical Schematic, Deutz D2011L03i Models (AS).....................................................................426 Electrical Schematic, Deutz TD2011L04i Models (AS)....................................................................430 Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (AS)............................434 Ground Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (AS)..............................435 Platform Control Box Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (AS).........................................438 Platform Control Box Switch Panel Wiring Diagram, Deutz D2011L03i • TD2011L04i Models (AS)............................439 Electrical Schematic, Deutz D436 L3i Models (CE)......................................................................442 Ground Control Box Terminal Strip Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................446 Ground Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)....................................447 Platform Control Box Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)...............................................450 Platform Control Box Switch Panel Wiring Diagram, Deutz D436 L3i Models (ANSI • CSA)..................................451 Electrical Schematic, Perkins 404D-22 Models (AS).....................................................................454 Ground Control Box Terminal Strip Wiring Diagram, Perkins 404D-22 Models (AS).........................................458 Ground Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS)...........................................459 Platform Control Box Wiring Diagram, Perkins 404D-22 Models (AS)......................................................462 Platform Control Box Switch Panel Wiring Diagram, Perkins 404D-22 Models (AS).........................................463 Back Cover....................................................................................................................465
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