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Genie S-60 XC S-60 HF S-60 TraX S-65 XC S-65 HF S-65 TraX Service Manual – PDF
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Genie S-60 XC S-60 HF S-60 TraX S-65 XC S-65 HF S-65 TraX Service Manual 1316494 – PDF DOWNLOAD
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Description
Genie S-60 XC S-60 HF S-60 TraX S-65 XC S-65 HF S-65 TraX Service Manual 1316494 – PDF DOWNLOAD
Language : English
Pages : 211
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie S-60 XC S-60 HF S-60 TraX S-65 XC S-65 HF S-65 TraX Service Manual 1316494 – 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......................................................................... 13 Machine Specifications............................................................. 13 Performance Specifications......................................................... 14 Hydraulic Oil Specifications....................................................... 14 Hydraulic Component Specifications................................................. 17 Manifold Component Specifications.................................................. 18 Ford MSG-425 EFI Engine Specifications............................................. 19 Deutz D2011 L03i Engine Specifications............................................. 20 Deutz TD2011L04i Engine Specifications............................................. 21 Deutz TD 2.2 L3 Engine Specifications.............................................. 22 Deutz D 2.9 L4 Engine Specifications............................................... 23 Deutz D 2.9 L4 Engine Specifications............................................... 24 Deutz TD 2.9 Engine Specifications................................................. 25 Deutz D436 L3i Engine Specifications............................................... 26 Perkins 404D-22 Engine Specifications.............................................. 28 Perkins 404F-E22T Engine Specifications............................................ 29 Weichai WP3.2 Engine Specifications................................................ 30 Machine Torque Specifications...................................................... 31 Machine Component Weights.......................................................... 32 Hydraulic Hose and Fitting Torque Specifications................................... 33 Torque Procedure................................................................... 34 Repair Procedures...................................................................... 36 Introduction....................................................................... 36 Control System..................................................................... 38 1-1 ALC-600 Platform Control Module............................................ 38 1-2 ALC-600 Service Mode....................................................... 38 1-3 Full Machine Calibration................................................... 39 1-4 Machine Functions.......................................................... 40 How to Adjust the Machine Maximum Speed Setting............................ 40 How to Adjust the Joystick Ramp Rate Setting............................... 41 How to Adjust the Joystick Threshold Setting............................... 42 1-5 How to Enter ALC600 Software Update Mode................................... 43 1-6 Display Module Menus....................................................... 44 1-7 How to Replace the Display Controller (DISCON) Module...................... 50 1-8 How to Replace the Ground Control Overlay.................................. 51 Platform Components................................................................ 54 2-1 Platform................................................................... 54 2-2 Platform Leveling Cylinder................................................. 55 How to Remove the Platform Leveling Cylinder............................... 55 2-3 Platform Rotator........................................................... 56 How to Bleed the Platform Rotator.......................................... 57 2-4 Platform Overload System................................................... 58 How to Perform a Zero Load Platform Calibration............................ 58 How to Perform a Full Load Platform Calibration............................ 59 How to Replace the Platform Overload Load Cell............................. 60 2-5 Platform Level Sensor...................................................... 61 Jib Boom Components................................................................ 63 3-1 Jib Boom................................................................... 63 3-2 Jib Boom Lift Cylinder..................................................... 64 Boom Components.................................................................... 65 Boom Components.................................................................... 66 4-1 Cable Track................................................................ 66 How to Remove the Cable Track.............................................. 66 How to Repair the Cable Track.............................................. 68 4-2 Boom Assembly.............................................................. 68 4-3 Boom Lift Cylinder......................................................... 71 4-4 Boom Extension Cylinder.................................................... 72 4-5 Boom Extend/Retract Cables................................................. 74 4-6 Primary Boom Angle Sensor Calibration...................................... 77 4-7 Primary Boom Angle Sensor Replacement...................................... 78 4-8 Boom Length Sensor Calibration............................................. 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................................................................. 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 Engine Fault Codes......................................................... 87 5-5 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3...................... 88 Hydraulic Pump..................................................................... 89 6-1 Lift/Steer Pump............................................................ 89 6-2 Drive Pump................................................................. 90 Manifolds.......................................................................... 94 7-1 Function Manifold Components............................................... 94 7-2 Valve Adjustments - Function Manifold...................................... 96 How to Adjust the Boom Extend Relief Valve................................. 96 7-3 Platform Manifold Components, S-60 XC, S-60 HF, S-60 TraX.................. 97 7-4 Platform Manifold Components, S-65 XC, S-65 HF, S-65 TraX.................. 98 7-5 Turntable Rotation Manifold Components..................................... 99 7-6 Valve Adjustments - Oscillate Relief Valve.................................100 How to Set Up the Oscillate Directional Valve..............................100 7-7 Traction Manifold Components...............................................103 7-8 Valve Adjustments - Traction Manifold......................................105 7-9 Generator Manifold Components..............................................106 7-10 Hydraulic Generator.......................................................107 7-11 Valve Coils...............................................................108 How to Test a Coil Diode...................................................108 Turntable Rotation Components......................................................110 8-1 Turntable Rotation Assembly................................................110 How to Adjust the Turntable Rotation Gear Backlash.........................111 How to Calibrate the Turntable Tilt Sensor.................................112 Axle Components....................................................................114 9-1 Oscillating Axle Cylinders.................................................114 Track Components...................................................................115 10-1 Track Assembly, S-60 TRAX and S-65 TRAX...................................115 How to Replace the Track...................................................115 Fault Codes............................................................................119 Introduction.......................................................................119 Control System Fault Codes.........................................................120 How to Retrieve Control System Fault Codes.....................................120 Control System Fault Codes.....................................................121 Engine Fault Codes.................................................................138 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes...........................139 Deutz D/TD 2.9 L4 Tier IV Engine Fault Codes.......................................149 Deutz D436 L3i Engine Fault Codes..................................................160 Perkins 404-22 Engine Fault Codes..................................................162 Ford MSG-425 Engine Fault Codes....................................................164 Weichai WP3.2 Engine Fault Codes...................................................169 Schematics.............................................................................172 Introduction.......................................................................172 Electrical Symbol Legend...........................................................173 Hydraulic Symbols Legend...........................................................174 Limit Switch Location Legend.......................................................175 Electrical Schematics..............................................................177 Electrical Schematic, Turntable Controller - Models without Recovery Module....178 Electrical Schematic, Turntable Controller - Models with Recovery Module.......179 Electrical Schematic, Platform Controller......................................182 Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Engine.....................183 Electrical Schematic, Deutz TD 2.2 L3 Engine...................................186 Electrical Schematic, Deutz D436 Engine........................................190 Electrical Schematic, Deutz D/TD 2.9 L4 Tier IV Engine.........................191 Electrical Schematic, Deutz D/TD 2.9 L4 Stage IV Engine........................194 Electrical Schematic, Perkins 404D-22 Engine...................................198 Electrical Schematic, Perkins 404F-E22T Engine.................................199 Electrical Schematic, Ford MSG-425 EFI Engine..................................202 Electrical Schematic, Weichai WP3.2 Engine.....................................203 Electrical Schematic, Generator Options........................................206 Hydraulic Schematics...............................................................207 Hydraulicl Schematic, S-60 XC, S-60 HF Models..................................208 Hydraulic Schematic, S-65 XC, S-65 HF Models...................................209 Back Cover.............................................................................211
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