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Genie S-60 XC S-60 HF S-60 TraX S-65 XC S-65 HF S-65 TraX Service & Repair 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 & Repair Manual 1288652 – 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 & Repair Manual 1288652 – PDF DOWNLOAD
Language : English
Pages : 235
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 & Repair Manual 1288652 – 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 TD 2.9 Engine Specifications........................................................................................ 24 Deutz D436 L3i Engine Specifications...................................................................................... 25 Perkins 404D-22 Engine Specifications..................................................................................... 27 Perkins 404F-E22T Engine Specifications................................................................................... 28 Weichai WP3.2 Engine Specifications....................................................................................... 29 Machine Torque Specifications............................................................................................. 30 Machine Component Weights................................................................................................. 31 Hydraulic Hose and Fitting Torque Specifications.......................................................................... 32 Torque Procedure.......................................................................................................... 33 Repair Procedures............................................................................................................. 35 Introduction.............................................................................................................. 35 Control System............................................................................................................ 37 1-1 ALC-600 Platform Control Module................................................................................... 37 1-2 ALC-600 Service Mode.............................................................................................. 37 1-3 Full Machine Calibration.......................................................................................... 38 1-4 Machine Functions................................................................................................. 39 How to Adjust the Machine Maximum Speed Setting................................................................... 39 How to Adjust the Joystick Ramp Rate Setting...................................................................... 40 How to Adjust the Joystick Threshold Setting...................................................................... 41 1-5 How to Enter ALC600 Software Update Mode.......................................................................... 41 1-6 Display Module Menus.............................................................................................. 42 1-7 How to Replace the Display Controller (DISCON) Module............................................................. 48 1-8 How to Replace the Ground Control Overlay......................................................................... 49 Platform Components....................................................................................................... 52 2-1 Platform Leveling Slave Cylinder.................................................................................. 52 2-2 Platform Rotator.................................................................................................. 53 2-3 Platform Overload System.......................................................................................... 56 How to Perform a Zero Load Platform Calibration................................................................... 56 How to Perform a Full Load Platform Calibration................................................................... 57 How to Replace the Platform Overload Load Cell.................................................................... 58 2-4 Platform.......................................................................................................... 59 Jib Boom Components....................................................................................................... 60 3-1 Jib Boom.......................................................................................................... 60 3-2 Jib Boom Lift Cylinder............................................................................................ 61 Boom Components........................................................................................................... 62 Boom Components........................................................................................................... 63 4-1 Cable Track....................................................................................................... 63 How to Remove the Cable Track, S-60 XC and S-60 TRAX.............................................................. 63 How to Remove the Cable Track, S-65 XC and S-65 XC TRAX........................................................... 64 How to Repair the Cable Track..................................................................................... 66 4-2 Boom Assembly..................................................................................................... 66 4-3 Boom Lift Cylinder................................................................................................ 69 4-4 Boom Extension Cylinder........................................................................................... 70 4-5 Boom Extend/Retract Cables........................................................................................ 72 4-6 Platform Leveling Master Cylinder................................................................................. 75 4-7 Primary Boom Angle Sensor Calibration............................................................................. 76 4-8 Primary Boom Angle Sensor Replacement............................................................................. 77 4-9 Boom Length Sensor Calibration.................................................................................... 79 Engines................................................................................................................... 81 5-1 RPM Adjustment - Ford and Deutz Models............................................................................ 81 5-2 RPM Adjustment - Perkins 404D-22 Models........................................................................... 81 5-3 Flex Plate........................................................................................................ 81 How to Install a Type "A" Flex Plate.............................................................................. 83 How to Install a Type "B" Flex Plate.............................................................................. 84 How to install the Pump and Bell Housing Assembly................................................................. 85 5-4 Engine Fault Codes................................................................................................ 86 5-5 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3............................................................. 87 Hydraulic Pump............................................................................................................ 88 6-1 Lift/Steer Pump................................................................................................... 88 6-2 Drive Pump........................................................................................................ 89 Manifolds................................................................................................................. 93 7-1 Function Manifold Components - from S60XCH-45010 to 45345, S65XCH-45001 to 45345, S65XCM-101 to 302............... 93 7-1.1 Function Manifold Components - from S60XCH-45345, S65XCH-45345, S65SCM-303, S65XCD-101.......................... 96 7-2 Valve Adjustments - Function Manifold.............................................................................101 How to Adjust the Boom Extend Relief Valve........................................................................101 7-3 Jib Boom / Platform Rotate Manifold Components....................................................................102 7-4 Turntable Rotation Manifold Components............................................................................103 7-5 Valve Adjustments - Oscillate Relief Valve........................................................................104 How to Set Up the Oscillate Directional Valve.....................................................................104 7-6 Traction Manifold Components, 4WD.................................................................................107 7-7 Valve Adjustments, 4WD Traction Manifold..........................................................................109 7-8 Generator Manifold Components.....................................................................................110 7-9 Hydraulic Generator...............................................................................................110 7-10 Valve Coils......................................................................................................112 How to Test a Coil Diode..........................................................................................113 Turntable Rotation Components.............................................................................................114 8-1 Turntable Rotation Assembly.......................................................................................114 How to Adjust the Turntable Rotation Gear Backlash................................................................115 How to Calibrate the Turntable Tilt Sensor........................................................................116 Axle Components...........................................................................................................118 9-1 Oscillating Axle Cylinders........................................................................................118 Track Components..........................................................................................................119 10-1 Track Assembly, S-60 TRAX and S-65 TRAX..........................................................................119 How to Replace the Track..........................................................................................119 Fault Codes...................................................................................................................123 Introduction..............................................................................................................123 Control System Fault Codes................................................................................................124 How to Retrieve Control System Fault Codes............................................................................124 Control System Fault Codes - Models with Revision G Software or Lower.................................................125 Control System Fault Codes - Models with Revision H Software or Higher................................................142 Engine Fault Codes........................................................................................................159 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes..................................................................160 Deutz TD 2.9 L4 Teir IV Engine Fault Codes................................................................................170 Deutz D436 L3i Engine Fault Codes.........................................................................................181 Perkins 404-22 Engine Fault Codes.........................................................................................183 Ford MSG-425 Engine Fault Codes...........................................................................................185 Weichai WP3.2 Engine Fault Codes..........................................................................................190 Schematics....................................................................................................................193 Introduction..............................................................................................................193 Electrical Symbol Legend..................................................................................................194 Hydraulic Symbols Legend..................................................................................................195 Limit Switch Location Legend..............................................................................................196 Electrical Schematics.....................................................................................................197 Electrical Schematic, Turntable Controller (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101 to 1290)....198 Electrical Schematic, Platform Controller (from S60XCH-45010 to 45353, S65XCH-45001 to 45353, S65XCM-101 to 1290).....199 Electrical Schematic, Turntable Controller (from S60XCH-45354, S65XCH-45354, S65XCD-101, S65XCM-1291).................202 Electrical Schematic, Platform Controller (from S60XCH-45354, S65XCH-45354, S65XCD-101, S65XCM-1291)..................203 Electrical Schematic, Deutz TD 2.2 L3 Engine..........................................................................206 Electrical Schematic, Deutz TD 2.9 L4 Stage IV Engine.................................................................210 Electrical Schematic, Deutz D/TD 2.9 L4 Tier IV Engine................................................................214 Electrical Schematic, Deutz D2011 L03i, TD2011 L04i Engine............................................................215 Electrical Schematic, Deutz D436 L3i Engine...........................................................................218 Electrical Schematic, Weichai WP3.2 Engine............................................................................219 Electrical Schematic, Perkins 404F-E22T Engine........................................................................222 Electrical Schematic, Perkins 404D-22T Engine.........................................................................223 Electrical Schematic, Ford MSG-425 EFI Engine.........................................................................226 Electrical Schematic, Generator Options...............................................................................227 Hydraulic Schematics......................................................................................................229 Hydraulic Schematic, (from S65XCM-101 to S65XCM-302)..................................................................230 Hydraulic Schematic, (from S60XCH-45010 to 45344, S65XCH-45001 to 45344)..............................................231 Hydraulic Schematic, (from S60XCH-45345, S65XCH-45345, S65XCD-101)....................................................233 Back Cover....................................................................................................................235
S.S 05/24
