Service and Repair Manual

Serial Number Range

S®-80 XC™
from S80XCH-101
to S80XCH-3100
This manual includes:
Repair procedures

S®-80 HF Fault Codes

Electrical and

S®-85 XC™
from S85XCH-101
to S85XCH-3090
Hydraulic Schematics

S®-85 HF
from S85XCD-101
to S85XCD-2001

For detailed maintenance

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

Original Instructions
Part No. 1280490GT
Rev E
April 2022
Service and Repair Manual April 2022

Introduction
Intro ductio n Intro ductio n

Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
maintenance procedure. Therefore, product specifications are subject to
change without notice.
This manual provides detailed scheduled
maintenance information for the machine owner Readers are encouraged to notify Genie of errors
and user. It also provides troubleshooting and and send in suggestions for improvement. All
repair procedures for qualified service communications will be carefully considered for
professionals. future printings of this and all other manuals.

Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.
However, several procedures require specialized Contact Us:
skills, tools, lifting equipment and a suitable Internet: www.genielift.com
workshop. In these instances, we strongly E-mail: awp.techpub@terex.com
recommend that maintenance and repair be
performed at an authorized Genie dealer service
center.
Find a Manual for this Model
Go to http://www.genielift.com
Compliance Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Machine Classification Manuals, Parts Manuals and Operator's Manuals.
Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and Copyright © 2017 by Terex Corporation
scheduled maintenance. 1280490GT Rev E, April 2022

First Edition, Fifth Printing

Genie and "S" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.

"XC" is a trademark of Terex South Dakota, Inc.

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April 2022 Service and Repair Manual

Introduction

Revision History
Revision Date Section Procedure / Page / Description
A 11/2017 New Release
B 12/2017 Schematics Electrical schematics
C 1/2018 Specifications Hydraulic Component Specifications
Schematics Electrical schematics
C1 4/2018 Repair 6-1
C2 7/2018 Repair Move Ground Controls to Control System
Schematics Electrical schematics
C3 10/2018 Specifications Machine Specifications
C4 5/2019 Specifications Machine Torque Specifications
Repair Display Menu
Fault Codes Control System Fault Codes
Schematics Electrical schematics
C5 6/2019 Fault Codes Control System Fault Codes
C6 7/2019 Repair Display Menu
C7 10/2019 Schematics Limit Switch Legend
D 5/2020 All Sections Add Deutz TCD 2.2 L3 Engine
Repair 2-4
E 4/2022 Front cover Add ending serial break

Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics

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Service and Repair Manual April 2022

Introduction

Serial Number Legend

1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

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Safety Rules
Secti on 1 Safety Rul es

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 modify or alter a MEWP without prior
written permission from the manufacturer.

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.

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Service and Repair Manual April 2022

Safety Rules

Personal Safety Workplace Safety

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

Read each procedure thoroughly. This Be sure to keep sparks, flames and
manual and the decals on the lighted tobacco away from flammable
machine, use signal words to identify and combustible materials like battery
the following: gases and engine fuels. Always have
an approved fire extinguisher within
Safety alert symbol—used to easy reach.
alert personnel to potential
personal injury hazards. Obey Be sure that all tools and working
all safety messages that follow areas are properly maintained and
this symbol to avoid possible ready for use. Keep work surfaces
injury or death. clean and free of debris that could get
into machine components and cause
Indicates a imminently damage.
hazardous situation which, if
not avoided, will result in death Be sure any forklift, overhead crane or
or serious injury. other lifting or supporting device is
fully capable of supporting and
Indicates a potentially stabilizing the weight to be lifted. Use
hazardous situation which, if only chains or straps that are in good
not avoided, could result in condition and of ample capacity.
death or serious injury.
Be sure that fasteners intended for
Indicates a potentially one time use (i.e., cotter pins and self-
hazardous situation which, if locking nuts) are not reused. These
not avoided, may cause minor components may fail if they are used
or moderate injury. a second time.
Indicates a potentially Be sure to properly dispose of old oil
hazardous situation which, if or other fluids. Use an approved
not avoided, may result in container. Please be environmentally
property damage. safe.
Be sure to wear protective eye wear Be sure that your workshop or work
and other protective clothing if the area is properly ventilated and well lit.
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.

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Table of Contents

Introduction Introduction ......................................................................................................ii

Important Information ......................................................................................... ii
Find a Manual for this Model............................................................................... ii
Revision History ................................................................................................ iii
Serial Number Legend ....................................................................................... iv

Section 1 Safety Rules......................................................................................................v

General Safety Rules ......................................................................................... v

Section 2 Specifications ...................................................................................................1

Machine Specifications ....................................................................................... 1
Performance Specifications ................................................................................ 2
Hydraulic Oil Specifications ................................................................................ 2
Hydraulic Component Specifications ................................................................... 5
Manifold Component Specifications .................................................................... 6
Deutz TD2011 L04i Engine Specifications .......................................................... 7
Deutz TCD 2.2 L3 Engine Specifications............................................................. 8
Deutz TD 2.9 Engine Specifications .................................................................... 9
Perkins 404D-22T Engine Specifications .......................................................... 10
Perkins 404F-E22TA Engine Specifications ...................................................... 11
Machine Torque Specifications ......................................................................... 12
Machine Component Weights ........................................................................... 12
Hydraulic Hose and Fitting Torque Specifications ............................................. 13
Torque Procedure ............................................................................................ 14

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Table of Contents

Section 3 Repair Procedures ......................................................................................... 16

Introduction ...................................................................................................... 16

Control System .............................................................................................. 18

1-1 ALC-600 Platform Control Module .............................................................. 18
1-2 ALC-600 Service Mode .............................................................................. 18
1-3 Full Machine Calibration ............................................................................. 19
1-4 Machine Functions ..................................................................................... 20
How to Adjust the Machine Maximum Speed Setting ................................... 20
How to Adjust the Joystick Ramp Rate Setting ............................................ 21
How to Adjust the Joystick Threshold Setting .............................................. 22
1-5 How to Enter ALC600 Software Update Mode ............................................ 22
1-6 Display Module Menus ............................................................................... 23
1-7 How to Replace the Display Controller (DISCON) Module .......................... 28
1-8 How to Replace the Ground Control Overlay .............................................. 29

Platform Components .................................................................................... 32

2-1 Platform ..................................................................................................... 32
2-2 Platform Leveling Slave Cylinder ................................................................ 33
How to Remove the Platform Leveling Slave Cylinder ................................. 33
How to Bleed the Slave Cylinder ................................................................. 33
2-3 Platform Rotator ......................................................................................... 34
How to Remove the Platform Rotator .......................................................... 34
How to Bleed the Platform Rotator .............................................................. 35
2-4 Platform Overload System.......................................................................... 36
How to Perform a Zero Load Platform Calibration ........................................ 36
How to Perform a Full Load Platform Calibration ......................................... 37
How to Replace the Platform Overload Load Cell ........................................ 39

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Table of Contents

Jib Boom Components .................................................................................. 40

3-1 Jib Boom .................................................................................................... 40
3-2 Jib Boom Lift Cylinder ................................................................................. 41

Boom Components ........................................................................................ 42

4-1 Cable Track ................................................................................................ 42
How to Remove the Cable Track, S-80 ........................................................ 42
How to Repair the Cable Track .................................................................... 44
4-2 Boom ......................................................................................................... 44
How to Shim the Boom ................................................................................ 44
How to Remove the Boom ........................................................................... 45
4-3 Boom Lift Cylinder ...................................................................................... 48
4-4 Boom Extension Cylinder............................................................................ 49
4-5 Boom Extend/Retract Cables ...................................................................... 51
How to Adjust the Extend/Retract Cables..................................................... 51
How to Replace the Boom Extend/Retract Cables ....................................... 53
4-6 Platform Leveling Master Cylinder .............................................................. 55
4-7 Primary Boom Angle Sensor Calibration ..................................................... 56
4-8 Boom Length Sensor .................................................................................. 57

Engines ........................................................................................................... 58
5-1 RPM Adjustment ........................................................................................ 58
5-2 Flex Plate ................................................................................................... 58
How to Remove the Flex Plate..................................................................... 58
How to Install the Flex Plate ........................................................................ 61
How to install the Pump and Bell Housing Assembly .................................... 62
_5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3 ............................. 63

Hydraulic Pump .............................................................................................. 64

6-1 Function Pump ........................................................................................... 64
6-2 Drive Pump ................................................................................................ 65
How to Prime the Drive Pump ...................................................................... 66

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Manifolds ........................................................................................................ 67
7-1 Function Manifold....................................................................................... 67
7-2 Valve Adjustments - Function Manifold ....................................................... 69
How to Adjust the System Relief Valve ........................................................ 69
How to Adjust the Boom Down Relief Valve ................................................ 69
How to Adjust the Boom Extend Relief Valve............................................... 70
7-3 Brake/Two-Speed Manifold Components.................................................... 71
7-4 Turntable Rotation Manifold Components ................................................... 72
7-5 Platform Rotate Manifold Components ....................................................... 73
7-6 Platform Manifold Components, S-80 XC ................................................... 74
7-7 Platform Manifold Components, S-85 XC ................................................... 75
7-8 4WD Traction Manifold Components .......................................................... 77
7-9 Valve Adjustments - Traction Manifold........................................................ 79
7-10 Generator Manifold Components .............................................................. 80
7-11 Valve Coils ............................................................................................... 81
Valve Coil Resistance Specifications ........................................................... 81

Fuel and Hydraulic Tanks .............................................................................. 83

8-1 Fuel Tank................................................................................................... 83
8-2 Hydraulic Tank ........................................................................................... 84

Turntable Rotation Components ................................................................... 86

9-1 Turntable Rotation Drive Hub Assembly ..................................................... 86
How to Remove the Turntable Rotation Drive Hub Assembly....................... 86
How to Remove the Turntable Rotation Hydraulic Motor .............................. 87
How to Adjust the Turntable Rotation Gear Backlash................................... 88
How to Calibrate the Turntable Tilt Sensor .................................................. 89

Steer Axle Components ................................................................................. 91

10-1 Yoke and Drive Hub ................................................................................. 91
10-2 Drive Motors ............................................................................................ 92
10-3 Drive Hubs ............................................................................................... 92

Generators...................................................................................................... 93
11-1 Hydraulic Generator ................................................................................. 93

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Table of Contents

Section 4 Fault Codes..................................................................................................... 94

Introduction ...................................................................................................... 94

Control System Fault Codes .......................................................................... 95

How to Retrieve Control System Fault Codes .............................................. 95
Control System Fault Codes - Models with Revision G Software or Lower.... 96
Control System Fault Codes - Models with Revision H Software or Higher . 113

Engine Fault Codes ...................................................................................... 130

Deutz TD 2.9 L4 Engine Fault Codes ........................................................... 131

Deutz TCD 2.2 L3 Engine Fault Codes ......................................................... 142

Perkins 404-22 Engine Fault Codes ............................................................. 152

GM 3.0L Engine Fault Codes........................................................................ 154

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Table of Contents

Section 5 Schematics ................................................................................................... 159

Introduction .................................................................................................... 159
Electrical Symbol Legend ............................................................................... 160
Hydraulic Symbols Legend ............................................................................. 161
Limit Switch Location Legend ......................................................................... 162
Engine Relay Layout - Deutz TD2.9 ............................................................... 163
Engine Relay Layout - Deutz TD2011L04i ...................................................... 164
Engine Relay Layout - Perkins 404D-22T ....................................................... 165
Engine Relay Layout - GM 3.0L...................................................................... 166
Connector Pin Legend.................................................................................... 167

Electrical Schematics .................................................................................. 169

Electrical Schematic, TCON
(to Serial number S80XCH-513, S85XCH- 518) ...................................... 170
Electrical Schematic, Platform Controller
(to Serial number S80XCH-513, S85XCH- 518) ...................................... 171
Electrical Schematic, Turntable Controller
(from S80XCH-514 to S80XCH-1393, S85XCH-519 to 1399) .................. 174
Electrical Schematic, Platform Controller
(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) ... 175
Electrical Schematic, Turntable Controller
(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ......... 178
Electrical Schematic, Platform Controller
(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) ......... 179
Electrical Schematic, Deutz TCD 2.2 L3 Engine ............................................. 182
Electrical Schematic, Deutz TD 2.9 L4 Engine ................................................ 186
Electrical Schematic, Deutz TD2011 L04i Engine ........................................... 187
Electrical Schematic, Perkins 404D-22T Engine ............................................. 190
Electrical Schematic, Perkins 404F-E22TA Engine ......................................... 191
Electrical Schematic, GM 3.0L Engine ............................................................ 194
Electrical Schematic, 12 kW Welder Generator and 3 kW Generator .............. 195

Hydraulic Schematics .................................................................................. 197

Hydraulic Schematic, S-80 XC Models ........................................................... 198
Hydraulic Schematic, S-85 XC Models......................................................... 199

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Specifications
Secti on 2 Specificatio ns

Machine Specifications Fluid capacities

Fuel tank, 35 gallons
Tires and wheels Diesel models 132,5 liters
Rough Terrain and Non Marking
Fuel tank, 30 gallons
Tire size 18-625 FF Gas models 113,5 liters
Tire ply rating 16 ply LPG tank 33.5 lbs
Overall tire diameter 40.7 in 15,2 kg
103,3 cm Hydraulic tank 40 gallons
Tire pressure foam filled 151 liters
Wheel diameter 24.5 in Hydraulic system (including tank) 64 gallons
62,2 cm 242 liters

Wheel width 15 in Turntable rotation drive hub 40 fl oz

38,1 cm (single fill port) 1183 cc
Tire weight, new foam filled 622 lbs Turntable rotation drive hub 43 fl oz
(minimum) 282 kg (dual fill port) 1262 cc

High Flotation Drive hubs 48 fl oz

four wheel drive 1420 cc
Tire size 41/18LL
Drive hub oil type: SAE 90 multipurpose hypoid
Tire ply rating 20 ply
gear oil API service classification GL5
Overall tire diameter 41.2 in
104,6 cm
Tire pressure 100 psi
6,89 bar
Wheel diameter 22.5 in
57,2 cm
Wheel width 14 in
35,6 cm
Tire weight 250 lbs
113,4 kg

Lugs and Lug Nut Torque

Wheel lugs 11 @ 3/4 - 16
Lug nut torque, dry 420 ft-lbs
569 Nm
Lug nut torque, lubricated 320 ft-lbs
434 Nm

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Service and Repair Manual April 2022

Specifications

Performance Specifications Hydraulic Oil Specifications

Drive speed, maximum Hydraulic Fluid Specifications
Stowed position, 40 ft / 9 - 11 sec Genie specifications require hydraulic oils which are
RT tires 12,2 m / 9 - 11 sec designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
Raised or extended 40 ft / 55 - 65 sec
temperature range, and the viscosity index should
12,2 m / 55 - 65 sec
exceed 140. They should provide excellent antiwear,
Braking distance, maximum oxidation prevention, corrosion inhibition, seal
High range on paved surface conditioning, and foam and aeration suppression
3 - 6 ft / 0,91 - 1,8 m
properties.
Gradeability Refer to Operator's Manual
Cleanliness level, ISO 15/13
Boom function speeds, maximum from platform minimum
controls Water content, 250 ppm
Jib boom up (S-85 XC) 25 - 35 sec maximum
Jib boom down (S-85 XC) 15 - 25 sec Recommended Hydraulic Fluid
Primary boom up 75 - 83 sec Hydraulic oil type Chevron Rando HD Premium
Primary boom down 110 - 115 sec Viscosity grade 32
Primary boom extend 59 - 67 sec Viscosity index 200
Primary boom retract 57 - 65 sec Optional Hydraulic Fluids
Turntable rotate stowed, (360°) 95 - 103 sec Mineral based Shell Tellus S2 V 32
Turntable rotate raised or extended, 210 - 250 sec Shell Tellus S2 V 46
(360°) Shell Tellus S4 VX 32
Shell Donax TG (Dexron III)
Platform rotate, 160° 40 - 50 sec Chevron 5606A
Platform level 20 - 22 sec Biodegradable Petro Canada Environ MV 46
(10° range of motion) Fire resistant UCON Hydrolube HP-5046

For operational specifications, refer to the Note: Genie specifications require additional
Operator's Manual. 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 its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

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Specifications

Do not top off with incompatible Chevron Rando HD Premium Oil

hydraulic fluids. Hydraulic fluids
may be incompatible due to the MV Fluid Properties
differences in base additive ISO Grade 32
chemistry. When incompatible
fluids are mixed, insoluble Viscosity index 200
materials may form and deposit Kinematic Viscosity
in the hydraulic system, cSt @ 200°F / 100°C 7.5
plugging hydraulic lines, filters, cSt @ 104°F / 40°C 33.5
control valves and may result in Brookfield Viscosity
component damage. cP @ -4°F / -20°C 1040
cP @ -22°F / -30°C 3310
Note: Do not operate the machine when the Flash point 375°F / 190°C
ambient air temperature is consistently above
120°F / 49°C. Pour point -58°F / -50°C
Maximum continuous operating 171°F / 77°C
Hydraulic Fluid Temperature temperature
Range
Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.
Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

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

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Specifications

Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46

Fluid Properties Fluid Properties
ISO Grade 15 ISO Grade 46
Viscosity index 300 Viscosity index 154
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 5.5 cSt @ 200°F / 100°C 8.0
cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C 44.4
cSt @ -40°F / -40°C 510 Flash point 482°F / 250°C
Flash point 180°F / 82°C Pour point -49°F / -45°C
Pour point -81°F / -63°C Maximum continuous operating 180°F / 82°C
Maximum continuous operating 124°F / 51°C temperature
temperature

Shell Tellus S4 VX Fluid

Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures Properties
are consistently below 0°F / -17°C unless an oil
ISO Grade 32
heating system is used.
Viscosity index 300
Continued use of Chevron Kinematic Viscosity
5606A hydraulic fluid, or cSt @ 200°F / 100°C 9
equivalent, when ambient cSt @ 104°F / 40°C 33.8
temperatures are consistently Brookfield Viscosity
above 32°F / 0°C may result in cSt @ -4°F / -20°C 481
component damage cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
Pour point -76°F / -60°C
Maximum continuous operating 103°F / 75°C
temperature

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Specifications

UCON Hydrolube HP-5046 Fluid Hydraulic Component

Properties Specifications
ISO Grade 46 Drive Pump
Viscosity index 192 Type: bi-directional variable displacement piston pump
Kinematic Viscosity Displacement per revolution 0 to 2.8 cu in
cSt @ 149°F / 65°C 22 0 to 46 cc
cSt @ 104°F / 40°C 46
Flow rate @ 2300 rpm 30.3 gpm
cSt @ 0°F / -18°C 1300
114,7 L/min
Flash point None
Drive pressure, maximum 3750 psi
Pour point -81°F / -63°C 259 bar
Maximum continuous operating 189°F / 87°C Charge Pump
temperature
Type gerotor
Displacement per revolution 0.85 cu in
13,9 cc
Flow rate @ 2300 rpm 9 gpm
34 L/min
Charge pressure @ 2300 rpm 310 psi
Neutral position 21,4 bar
Function Pump
Type: variable displacement piston pump
Displacement per revolution 0 to 2.3 cu in
0 to 38 cc
Flow rate @ 2300 rpm 0 to 23 gpm
0 to 87 L/min
Pressure, maximum 2900 psi
200 bar
Pressure compensator 2900 psi
200 bar
Standby pressure 250 psi
17,3 bar
Auxiliary Pump
Type: fixed displacement gear pump
Displacement per revolution 0.15 cu in
2,47 cc
Generator Pump
Displacement per revolution 1.4 cu in
23 cc

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Specifications

Function manifold Manifold Component

System relief valve pressure, 3200 psi Specifications
maximum 221 bar
Primary boom extend relief pressure 2400 psi Plug torque
(measured at PTEST port) 165 bar SAE No. 2 36 in-lbs / 4 Nm
Platform Manifold and Oscillate Valve SAE No. 4 10 ft-lbs / 13 Nm
Platform level flow regulator 0.6 gpm SAE No. 6 14 ft-lbs / 19 Nm
2,3 L/min
SAE No. 8 38 ft-lbs / 51 Nm
Platform rotate flow regulator 0.3 gpm
1,1 L/min SAE No. 10 41 ft-lbs / 55 Nm
Oscillate relief valve pressure 950 psi SAE No. 12 56 ft-lbs / 76 Nm
65,5 bar
Traction Manifold
Hot oil relief pressure 280 psi
19,3 bar
Brakes
Brake release pressure, 240 psi
Wheel drive hubs 16,5 bar
Drive Motors
Displacement per revolution 0.9 cu in
high speed: 14.7 cc
Displacement per revolution 2.7 cu in
low speed 45 cc
Hydraulic Filters
High pressure filter: Beta 3 ≥200
High pressure filter bypass pressure 102 psi
7 bar
Medium pressure filter Beta 3 ≥200
Medium pressure filter bypass 51 psi
pressure 3,5 bar
Hydraulic tank return filter 15 micron
hydraulic
10 micron air
breather
Drive motor case drain return filter Beta 10 ≥2
Accumulator
Relief pressure 1100 psi
Note: This component is 75,8 bar
not serviceable.

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Specifications

Deutz TD2011 L04i Engine Oil Temperature sender

Installation torque 8 - 18 ft-lbs
Displacement 220.9 cu. in 11 - 24 Nm
3,62 liters
Oil Pressure sender
Number of cylinders 4
Installation torque 8 - 18 ft-lbs
Bore and Stroke 3.78 x 4.92 inches 11 - 24 Nm
96 x 125 mm
Fuel injection system Motorpal
Horsepower net intermittent @ 74 hp
2400 rpm 55 kW Injection pump pressure, maximum 15,000 psi
1034 bar
Induction system turbocharged
Injector opening pressure 3046 psi
Firing order 1-3-4-2 210 bar
Low idle 1500 rpm Fuel requirement
High idle 2350 rpm For fuel requirements, refer to the engine Operator
Manual for your engine.
Compression ratio 17.5:1
Starter motor
Compression pressure (psi or bar) of the lowest
cylinder must be at least 75% of the highest cylinder Current draw, normal load 140 - 200A
Governor centrifugal Cranking speed 250 - 350 rpm
mechanical Battery – Engine starting and control system
Valve clearance, cold Type 12V DC, Group 31
Intake 0.012 in Quantity 2
0,3 mm
Battery capacity, maximum 1000A
Exhaust 0.020 in
0,5 mm Reserve capacity @ 25A rate 200 Minutes
Lubrication system Alternator output 80A @ 14V DC
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi Fan belt deflection 3/8 to 1/2 inch
2.8 to 4.1 bar 9 to 12 mm
Oil capacity (including filter) 12.8 quarts
12,1 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 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.

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Specifications

Deutz TCD 2.2 L3 Engine Oil temperature switch

Installation torque 8 - 18 ft-lbs
Displacement 134 cu. in 11 - 24 Nm
2,2 liters
Temperature switch point 257°F
Number of cylinders 3 125°C
Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch
92 x 110 mm
Installation torque 8 - 18 ft-lbs
Horsepower net intermittent @ 74 hp 11 - 24 Nm
2600 rpm 55 kW
Pressure switch point 17.4 psi
Induction system turbocharged 1,2 bar
Firing order 1-2-3 Fuel requirement
Low idle, standby 1000 rpm For fuel requirements, refer to the engine Operator
Manual for your engine.
Low idle, function enable 1500 rpm
Engine coolant capacity 2.5 gallons
High idle 2400 rpm
9,5 liters
Governor electronic Unit ships with Ethylene Glycol engine coolant. Consult
Lubrication system Low ash oil required your local supplier for compatibility before mixing
alternative engine coolants.
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2,8 to 4,1 bar Starter motor
Oil capacity (including filter) 8 quarts Current draw, normal load 140 - 200A
7,6 liters Cranking speed 250 - 350 rpm
Oil viscosity requirements
Battery – Engine starting and control system
-22°F to 86°F / -30°C to 30°C 5W-30 Type 12V DC, Group 31
(synthetic)
Quantity 1
-4°F to 104°F / -20°C to 40°C 10W-40
Battery capacity, maximum 1000A
Above 5°F / -15°C 15W-40
Reserve capacity @ 25A rate 200 Minutes
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative engine Alternator output 95A @ 14V DC
oils. For oil requirements, refer to the Engine Operator
Manual for your engine.

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Specifications

Deutz TD 2.9 L4 Engine Oil Temperature sender

Installation torque 8 - 18 ft-lbs
Displacement 177 cu. in 11 - 24 Nm
2,9 liters
Oil Pressure sender
Number of cylinders 4
Installation torque 8 - 18 ft-lbs
Bore and Stroke 3.6 x 4.3 inches 11 - 24 Nm
92 x 110 mm
Fuel injection system Motorpal
Horsepower net intermittent @ 74.2 hp
2600 rpm 55 kW Injection pump pressure, maximum 15,000 psi
1034 bar
Induction system turbocharged
Injector opening pressure 3046 psi
Firing order 1-3-4-2 210 bar
Low idle, standby 1000 rpm Fuel requirement
Low idle, function enable 1500 rpm For fuel requirements, refer to the engine Operator
Manual for your engine.
High idle 2500 rpm
Starter motor
Compression ratio 17.4:1
Current draw, normal load 140 - 200A
Compression pressure (psi or bar) of the lowest
cylinder must be at least 75% of the highest cylinder Cranking speed 250 - 350 rpm
Governor electronic Battery – Engine starting and control system
Valve clearance, cold Type 12V DC, Group 31
Intake 0.012 in Quantity 2
0,3 mm Battery capacity, maximum 1000A
Exhaust 0.020 in Reserve capacity @ 25A rate 200 Minutes
0,5 mm
Alternator output 95A @ 14V DC
Lubrication system
Fan belt deflection 3/8 to 1/2 inch
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 9 to 12 mm
2,8 to 4,1 bar
Oil capacity (including filter) 12.8 quarts
12,1 liters
Oil viscosity requirements Low ash oil required
-22°F to 86°F / -30°C to 30°C 5W-30
(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 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.

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Specifications

Perkins 404D-22T Engine Fuel injection system

Injection pump make Zexel
Displacement 134 cu in
2,2 liters Injection pressure 2133 psi
147 bar
Number of cylinders 4
Fuel requirement
Bore and Stroke 3.31 x 3.94 inches
84 x 100 mm For fuel requirements, refer to the engine Operator
Manual for your engine.
Horsepower 58 @ 2500 rpm
44 kW @ 2500 rpm Alternator output 55A @ 12V DC
Firing order 1-3-4-2 Fan belt deflection 3/8 in
Low idle, standby 1000 rpm 10 mm
Starter motor
Low idle, function enable 1500 rpm
Current draw, no load 140-200A
High idle 2500 rpm
Brush length, new 0.7480 in
Compression ratio 23.3:1
19 mm
Compression pressure 426 psi Brush length, minimum 0.5 in
29,4 bar 12,7 mm
Pressure (psi) of lowest cylinder must be within 50 psi /
Battery
3.45 bar of highest cylinder
Type 12V DC, Group 31
Governor centrifugal mechanical
Quantity 2
Valve clearance, cold
Cold cranking ampere 1000A
Intake 0.008 in
0,2 mm Reserve capacity @ 25A rate 200 minutes
Exhaust 0.008 in Engine coolant
0,2 mm Capacity 7.7 quarts
Lubrication system 7,3 liters
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 86°F / 30°C 5W-20
-4°F to 104°F / -20°C to 40°C 10W-30
Above 14°F / -10°C 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.

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Specifications

Perkins 404F-E22TA Engine Oil Pressure switch

Installation torque 8 - 18 ft-lbs
Displacement 134 cu. in 11 - 24 Nm
2,2 liters
Pressure switch point 14.2 psi
Number of cylinders 4 1 bar
Bore and Stroke 3.31 x 3.94 inches Fuel injection system
84 x 100 mm
Injection pump make Zexel
Horsepower net intermittent @ 55 hp / 41,1 kW
2800 rpm Injection pressure 2133 psi
Horsepower continuous 147 bar
52 hp / 38,8 kW
@ 2800 rpm Fuel requirement
Induction system turbocharged For fuel requirements, refer to the engine Operator
Firing order 1-3-4-2 Manual for your engine.

Low idle, standby 1100 rpm Starter motor

Current draw, normal load 140A - 200A
Low idle, function enable 1500 rpm
Cranking speed 200 - 250 rpm
High idle 2500 rpm
Battery – Engine starting and control system
Compression ratio 23.3:1
Type 12V DC, Group 31
Compression pressure (psi or bar) of the lowest
cylinder must be at least 75% of the highest cylinder Quantity 2
Governor electronic Battery capacity, maximum 1000A

Valve clearance, cold Reserve capacity @ 25A rate 200 Minutes

Intake 0.008 in Engine coolant
0,2 mm Capacity 13.3 quarts
Exhaust 0.018 in 12,6 liters
0,45 mm Coolant temperature switch
Lubrication system Installation torque 8 - 18 ft-lbs
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 11 - 24 Nm
2,8 to 4,1 bar Temperature switch point 221°F
Oil capacity (including filter) 9.4 - 11.2 quarts 105°C
8,9 - 10,6 liters Alternator output 85A @ 12V DC
Oil viscosity requirements Fan belt deflection 3/8 to 1/2 inch
-22°F to 86°F / -30°C to 30°C 5W-20 CJ4 9 to 12 mm
-4°F to 104°F / -20°C to 40°C 10W-40 CJ4
Above 5°F / -15°C 15W-40 CJ4
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.

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Specifications

Machine Torque Specifications Machine Component Weights

Platform Rotator Primary boom assembly 4808 lbs
1-8 center bolt, GR 5, dull gray, 500 ft-lbs (does not include jib assembly) 2181 kg
lubricated 678 Nm Turntable assembly 4441 lbs
1/2-13 bolts, GR 8, dull gray, 80 ft-lbs (does not include boom, jib or engine) 2015 kg
LOCTITE® 243™ threadlocker 108 Nm Counterweight, S-80 XC/HF 12300 lbs
Turntable rotate assembly 5580 kg
Rotate bearing mounting bolts, 180 ft-lbs Counterweight, S-85 XC/HF 14200 lbs
lubricated 244 Nm 6441 kg
Rotate drive hub mounting bolts, 80 ft-lbs Drive chassis assembly 8505 lbs
lubricated 108 Nm (does not include tire options) 3858 kg
Backlash plate mounting bolts, 280 ft-lbs Tire and wheel assembly 646 lbs
lubricated 379 Nm RT foam filled, max. 293 kg
Drive motors and hubs Tire and wheel assembly 258 lbs
High flotation, max. 117 kg
Drive hub mounting bolts, lubricated 180 ft-lbs
217 Nm Drive motor and hub 282 lbs
128 kg
Drive motor mounting bolts, dry 110 ft-lbs
149 Nm Engine assembly, max. 1300 lbs
Drive motor mounting bolts, 85 ft-lbs 590 kg
lubricated 115 Nm Primary boom lift cylinder 884 lbs
LOCTITE® 243™ threadlocker 401 kg
Function Pump Primary boom extend cylinder 1000 lbs
(includes cables and sheaves) 454 kg
Pump mounting bolts, 57 ft lbs
LOCTITE® 243™ threadlocker 77 Nm Jib boom assembly 363 lbs
(does not include platform) 165 kg
Engine vibration isolators
Compressed height 0.44 in - 0.56 in Jib boom cylinder 62 lbs
11 mm - 14 mm 28 kg
Oscillate cylinder 99 lbs
45 kg
Platform, 6 ft / 1,8 m 275 lbs
125 kg
Platform, 8 ft / 2,4 m 315 lbs
143 kg
Battery 63 lbs
29 kg

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Specifications

Hydraulic Hose and Fitting SAE O-ring Boss Port

Torque Specifications (tube fitting - installed into Aluminum)
(all types)
Your machine is equipped with Parker Seal-Lok™
SAE Dash Size Torque
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends -4 14 ft-lbs / 19 Nm
be torqued to specification when they are removed -6 23 ft-lbs / 31,2 Nm
and installed or when new hoses or fittings are -8 36 ft-lbs / 49 Nm
installed.
-10 62 ft-lbs / 84 Nm
-12 84 ft-lbs / 114 Nm
Seal-Lok™ Fittings -16 125 ft-lbs / 169,5 Nm
(hose end - ORFS)
-20 151 ft-lbs / 204,7 Nm
SAE Dash Size Torque
-24 184 ft-lbs / 249,5 Nm
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 41 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 81 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 150 ft-lbs / 205 Nm
Adjustable Fitting Non-adjustable fitting
-24 230 ft-lbs / 315 Nm
1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats (tube fitting - installed into Steel)
-4 7/16-20 2 SAE Dash Size Torque
-6 9/16-18 1 1/2 -4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm
-12 1 1/16-12 1 1/4
37° (Adj / Non-adj) 29 ft-lbs / 39,3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81,3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70,5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135,6 Nm
37° (Adj / Non-adj) 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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Service and Repair Manual April 2022

Specifications

Torque Procedure JIC 37° fittings

1 Align the tube flare (hex nut) against the nose
Seal-Lok™ fittings of the fitting body (body hex fitting) and
tighten the hex nut to the body hex fitting to
1 Replace the O-ring. The O-ring must be
hand tight, approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
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. Illustration 1

5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart 2 reference mark
in this section. 3 body hex fitting
6 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.

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Specifications

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.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 15

Service and Repair Manual April 2022

Repair Procedures

Machine Configuration:
Secti on 3 Repair P roce dur es

 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:
• Machine parked on a firm, level surface
• Key switch in the off position with the key
Observe and Obey: removed
 Repair procedures shall be completed by a • The red Emergency Stop button in the off
person trained and qualified on the repair of position at both the ground and platform
this machine. controls
 Immediately tag and remove from service a • Wheels chocked
damaged or malfunctioning machine.
• All external AC power supply disconnected
 Repair any machine damage or malfunction from the machine
before operating the machine.
• Boom in the stowed position

Before Repairs Start: • Turntable secured with the turntable rotation

lock
 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.

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Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to re-
assemble, perform the disassembly steps in
reverse order.

Symbols Legend
Safety alert symbol—used 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.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 17

Service and Repair Manual April 2022

Control System

1-1 1-2
ALC-600 Control Module How to Enter ALC-600 Service
Mode
Platform Controls
The platform control box contains the ALC-
600 platform Control Module. The platform Control
Module receives all signals from the platform
switches, joysticks and foot switch, and provides
operator feedback through an Indicator Module.
The joystick controllers at the platform controls
utilize Hall Effect technology and require no
calibration. Automatic calibration of center voltage
occurs on power up if the signal value is in the
valid range. Each joystick controller should
operate smoothly and provide proportional speed
control over its entire range of motion. The
remaining boom functions operate by on/off toggle
switches.

ALC-600 Control System Display

1 Number 1 or Escape
2 Number 2 or UP arrow
3 Number 3 or DOWN arrow
4 Number 4 or OK
1 ALC-600 platform control module 5 Settings menu
2 primary boom up/down and turntable 6 (not implemented)
rotate left/right joystick controller
7 Faults menu
3 LED indicator module
8 Fault LED Indicator
4 drive/steer joystick controller
9 Engine hours
10 Maintenance LED indicator
11 Maintenance menu
12 Home menu

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Control System

The Control System on this machine allows 1-3

access to calibrations through the Service Mode.
The procedures that follow will require the operator
Full Machine Calibration
to be in Service Mode. Service Mode can only be
Full machine calibration must be completed in the
entered at machine start up and requires a special
proper sequence when the ALC-600 controller
code. (TCON) in the ground control box has been
1 At the ground controls, select the ground replaced.
control mode using the key switch.
How to Fully Calibrate the
2 Push and hold buttons numbered 2 and
3 underneath the display screen. Machine
3 Pull out the red Emergency Stop button. Calibration procedures shall only be completed by
qualified technicians that have Genie factory
4 You will be prompted for a password. Enter 3 service training.
- 3 - 2 - 4.
Tip-over hazard. Failure to
5 Press the Gear button to access the settings
calibrate the machine in the
menu.
proper sequence could cause
Note: There will be a delay while the menu is the machine to tip over resulting
being loaded on the display screen. in death or serious injury.
6 The machine will now operate normally and Note: A digital level will be required to perform this
allow the viewing and modification of procedure.
calibrations and parameters.
Note: Start this procedure with the boom in the
Note: When a parameter is changed in Service stowed position.
Mode, the change is effective immediately when
button 4 (OK) is pushed. Machine restart is not Full machine calibration must be completed in the
required. A confirmation beep accompanies every following sequence:
save (button 4).
• Select model, engine, tires, and region,
Note: Pushing in the red Emergency Stop button then cycle power. Refer to Repair Section
will exit Service Mode. Display Module.
Note: If there has been no input for 10 minutes • Turntable level sensor. Refer to Repair
while in Service Mode, the ALC-600 will power Procedure, How to Calibrate the Turntable
down and Service Mode will be exited, unless the Level Sensor.
engine is running.
• Load cell sensor. Refer to Repair
Procedure, How to Calibrate the Load Cell
Sensor.
• Primary boom angle sensor. Refer to
Repair Procedure, How to Calibrate the
Primary Boom Angle Sensor.
• Primary boom length sensor. Refer to
Repair Procedure, How to Calibrate the
Primary Boom Length Sensor.
• Select option configuration. Refer to Repair
Section, Display Module, Options.

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Service and Repair Manual April 2022

Control System

1-4 10 Record the time it takes for that function to

complete a full cycle (ie; boom up).
Machine Functions
11 Compare the machine function time with the
function times listed in Refer to Specifications,
How to Adjust the Joystick
How to Adju st th e M achin e Ma ximu m Spe ed Set ting

Performance Specifications. Determine

whether the function time needs to increase
Maximum Speed Setting or decrease.
The maximum speed of a joystick controlled
12 Adjust the parameter in the ground display to
machine function can be modified from the ground
achieve the proper function cycle time.
controls display. Whenever a hydraulic cylinder,
drive motor or hydraulic pump is replaced, the
maximum speed setting should be adjusted to
maintain optimum performance. The maximum
speed 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 Enter the Service Mode. See Repair
Procedure, How to Enter the Service Mode.
2 Press the SETTINGS button above the
display screen.
3 Select SPEEDS from the display screen.
4 Navigate to the desired function's Maximum
Speed setting.
5 Select the desired setting to change and
press OK.
6 In the parameter adjustment screen, use the
display buttons to change the parameter.
Note that the factory default speed is
considered 100% for maximum speeds.
7 Scroll and press OK. The change is effective
immediately.
8 Start the engine from the ground controls.
9 Start a timer and activate the machine
function that needs to be adjusted. Using the
ground control functions is the same as
asking for full joystick deflection at the
platform.

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April 2022 Service and Repair Manual

Control System

How to Adjust the Joystick Ramp

How to Adju st th e Joys tick Ra mp Ra te Setti ng

8 Start the engine from the ground controls.

Rate Setting 9 Start a timer and activate the machine
function that needs to be adjusted. Using the
The ramp rate setting is an adjustment that
ground control functions is the same as
controls the way boom functions start and stop.
asking for full joystick deflection at the
There are two types of ramp rates to adjust on
platform.
separate menus:
10 Record the time it takes for that function to
Ramp Up Time -- the amount of time it takes to complete the ramp.
accelerate to speed.
11 Compare the machine function time with the
Ramp Down Time -- the amount of time it takes to function times listed in Specifications,
decelerate to a stop Performance Specifications. Determine
whether the ramp time needs to increase or
The ramp rate settings of a joystick can be
decrease.
changed to compensate for hydraulic pump wear
to maintain peak performance from the machine. 12 Adjust the parameter in the ground display to
achieve the proper ramp time.
Note: Perform this procedure with the boom in the
stowed position. Note: Refer to Repair Procedure, Display Module
Menus for ramp rates.
1 Enter the Service Mode. See Repair
Procedure, How to Enter the Service Mode.
2 Press the SETTINGS button above the
display screen.
3 Select SPEEDS from the display screen.
4 Navigate to the desired function's Ramp
setting.
5 Select the desired setting to change and
press OK.
6 In the parameter adjustment screen, use the
display buttons to change the parameter.
Note that the ramp rate is expressed in
seconds to complete the ramp.
7 Scroll and press OK. The change is effective
immediately.

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Service and Repair Manual April 2022

Control System

How to Adjust the Joystick 1-5

How to Adju st th e Joys tick T hres hold S etting

Threshold Setting How to Enter ALC600 Software

The threshold setting of a joystick is the minimum Update Mode
output at which a function proportional valve can
open and allow the function to operate. 1 Go to the Genie website
http://firmware.ghttps://www.genielift.com/en/s
The boom function threshold current should be upport/firmwareenielift.com/, select your
operating at near zero speed, smoothly with no Machine Model and select Search.
vibrations.
2 Download the software to a USB flash drive. If
Note: Perform this procedure with the boom in the zipped, extract the files to the USB flash drive.
stowed position. 3 With the machine off, open the GBOX (ground
1 Enter the Service Mode. box) lid and then remove the four Torx head
screws securing the Display Controller
2 Press the SETTINGS button above the (DISCON) door and remove the door to
display screen. expose the USB port.
3 Select SPEEDS from the display screen. 4 Insert the flash drive into the USB port.
4 Navigate to the desired function's Threshold 5 Set key switch to ground and pull out the red
setting. ground ESTOP while holding buttons 1 and 4.
5 Select the desired setting to change and 6 The Display Controller will go into the
press OK. bootloader mode.
6 In the parameter adjustment screen, use the 7 Browse and select the desired
display buttons to change the parameter. software. Follow the on-screen guidance to
Note that the factory default speed is start the update procedure.
considered 100% for threshold values.
8 When complete, turn off machine.
7 Scroll and press OK. The change is effective
immediately. 9 Remove USB flash drive, re-install the Display
Controller door and close the GBOX (ground
8 Switch the machine control to platform control box).
and start the engine from the platform
controls.. 10 Power up normally.

9 Using the joystick, verify that the function 11 As the display controller starts, operator shall
engages smoothly and without sudden verify on the start-up screen that the proper
movement or excessive joystick dead spots. software and revision are displayed.

10 Adjust the parameter in the ground display to 12 Perform a function check.

achieve a smooth function threshold.

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Control System

1-6
Display Module Menus
Screen or Menu Item Selection Default
Display Settings Backlight 0 - 100%
Contrast 0 - 100%
Display Inversion On • Off Off
Screen or Menu Item Selection Default
Model Configuration Model S-40 • S-45 • S-60 • S-65 • S-80 • S- Select Model
85 • S-60 J • S-80 J
Tires Rough Terrain • High Float • Trax Select Tires
(These are locked Engine Deutz D 2.9L T4 • Deutz TD 2.9L T4 Select Engine
unless factory • Deutz TCD 2.2L S5 • Deutz TCD
defaults are restored) 2.2L T4 • Deutz TD 2.2L S5 • Deutz
2011 L03i • Deutz TD2011 L04i •
Ford MSG425 EFI • GM 3.0L •
Kubota D1105 • Kubota D1803 •
Perkins 404D 22 • Perkins 404D 22T
• Perkins 404F E22T • Perkins 404F
E22TA
Region: ANSI/CSA • AUS • CE Select Region
(Platform Platform Width Standard Platform Standard Platform
configuration is not 4m Platform
locked)
Platform Level Hydraulic • eLevel Select Platform Level
Screen or Menu Item Selection Default
Options Footswitch Timeout 10 sec • 2 min • 30 min 2 min
Note: Some options Drive Priority On • Off Off
may not be visible Drive Cutout On • Off Off
with earlier software
revisions.
Platform Level Priority • Cutout Priority
Generator No Generator • Generator Installed No Generator
Contact Alarm Gen 2 • Gen 1 • Off Gen 2
Platform Recirculation On • Off Off
Units US Customary • Metric US Customary
Aircraft Proximity On • Off Off
Fuel Level Sensor Installed • Not Installed Installed
Low Fuel Threshold 10% - 100% 10%
Alarm Setting Off • Travel • Motion Travel
Standby RPM Default • High RPM Default
Power Save Timeout 10 min • 30 min • 60 min • 4 hrs • Off Off
Plat Level Threshold Cal On • Off On

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Control System

Screen or Menu Item Default

Sensor Calibration Chassis Tilt Select OK to calibrate
Load Sense Select OK to calibrate
Boom Angle Select OK to calibrate
Boom Length Select OK to calibrate
Platform Angle Select OK to calibrate
Screen or Menu Item Default
Drive Speeds Forward Threshold 1% - 128%, 100% = 800mA
Reverse Threshold 1% - 134%, 100% = 720mA
Forward Max 75% - 150%, 100% = 1665mA
Reverse Max 73% - 150%, 100% = 1575mA
Forward Out of Stowed High Max 82% - 150%, 100% = 1259mA
Reverse Out of Stowed High Max 80% - 150%, 100% = 1211mA
Screen or Menu Item Default
Drive Ramps Standard Acceleration 0.1 - 10 sec, 4 sec
Standard Deceleration 0.1 - 5 sec, 1 sec
Torque Switching Deceleration 0.5 - 5 sec, 4 sec
Screen or Menu Item Default
Deutz TD2011 L04i Threshold 2100 rpm
Anti-Stall Drive Minimum 50%
Range 100 rpm
Hysteresis 125 rpm
Screen or Menu Item Default
Deutz TD 2.9 T4 Threshold 2375 rpm
Anti-Stall Drive Minimum 50%
Range 125 rpm
Hysteresis 100 rpm

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Control System

Screen or Menu Item Default

Deutz TCD 2.2L T4 Threshold 2375 rpm
Anti-Stall Drive Minimum 50%
Range 125 rpm
Hysteresis 100 rpm
Screen or Menu Item Default
Deutz TCD 2.2L S5 Threshold 2275 rpm
Anti-Stall Drive Minimum 50%
Range 125 rpm
Hysteresis 100 rpm
Screen or Menu Item Default
Perkins 404D 22T Threshold 2375 rpm
Anti-Stall Drive Minimum 50%
Range 125 rpm
Hysteresis 100 rpm
Screen or Menu Item Default
Perkins 404F E22T Threshold 2400 rpm
Anti-Stall Drive Minimum 30%
Range 130 rpm
Hysteresis 100 rpm
Screen or Menu Item Default
GM 3.0L Threshold 2250 rpm
Anti-Stall Drive Minimum 50%
Range 400 rpm
Hysteresis 375 rpm
Screen or Menu Item Default
Primary Lift Speeds Extend Threshold 1% - 212%, 100% = 460mA
Retract Threshold 1% - 169%, 100% = 460mA
Up Threshold 1% - 186%, 100% = 560mA
Down Threshold 1% - 292%, 100% = 400mA
Extend Max 66% - 150%, 100% = 1499mA
Retract Max 71% - 150%, 100% = 1096mA
Retracted Up Max 32% - 150%, 100% = 1530mA
Retracted Down Max 32% - 150%, 100% = 1937mA

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Control System

Screen or Menu Item Default

Primary Lift Ramps Extend Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms
Extend Decelerating Rate 5000 ms max, 250 ms min, 1000 ms
Retract Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms
Retract Decelerating Rate 5000 ms max, 500 ms min, 1000 ms
Up Accelerating Rate 5000 ms max, 1000 ms min, 3000 ms
Up Decelerating Rate 5000 ms max, 500 ms min, 3000 ms
Down Accelerating Rate 5000 ms max, 1000 ms min, 3000 ms
Down Decelerating Rate 5000 ms max, 1000 ms min, 1000 ms
Screen or Menu Item Default
Turntable Speeds Rotate CW Threshold 1% - 105%, 100% = 800mA
Rotate CCW Threshold 1% - 105%, 100% = 800mA
Rotate CW Max 84% - 150%, 100% = 1210mA
Rotate CCW Max 84% - 150%, 100% = 1210mA
CW Out of Stow Max 96% - 150%, 100% = 881mA
CCW Out of Stow Max 96% - 150%, 100% = 881mA
Screen or Menu Item Default
Turntable Ramps CW Accelerating 1 - 10 sec, 3 sec
CW Decelerating 0.5 - 2 sec, 2 sec
CCW Accelerating 1 - 10 sec, 3 sec
CCW Decelerating 0.5 - 2 sec, 2 sec
Screen or Menu Item Default
Jib Boom and Jib Up Threshold 1% - 177%, 100% = 500mA
Platform Speeds Jib Down Threshold 1% - 173%, 100% = 500mA
Platform Level Up Threshold 1% - 144%, 100% = 690mA
Platform Level Down Threshold 1% - 146%, 100% = 680mA
Jib Up Max 62% - 150%. 100% = 1014mA
Jib Down Max 63% - 150%. 100% = 990mA
Platform Level Up Max 73% - 150%, 100% = 1100mA
Platform Level Down Max 72% - 150%, 100% = 1100mA

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April 2022 Service and Repair Manual

Control System

Screen or Menu Item Default

Jib and Platform Jib Up/Down Ramp 0.2 - 2 sec. 0.75 sec
Ramps
Platform Level Ramp 0.2 - 2 sec. 0.5 sec
Screen or Menu Item Default
Machine Disable Drive Disable On / Off
Options Machine Disable On / Off
Remote Disable Disable Engine Start • Drive Speed Cripple • Lift Speed
Cripple
Reset Defaults OK to reset Model Configuration and Options
Software Update OK to enter Software Update Mode

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Control System

1-7 3 Open the ground box lid (1) and disconnect

the wire harness going to the display
How to Replace the Display controller (DISCON).
Controller (DISCON) Module
4 Remove the DISCON door from the back by
1 Push in the red Emergency Stop button to the loosening the four Torx head screws (8) and
off position at both the ground and platform remove the two ribbon cables (6) connecting
controls. the ground box overlay to the DISCON.
2 Disconnect the negative terminal from the Note the orientation of the cables for reassembly.
start battery and auxiliary battery, if equipped.
5 Remove the DISCON from the ground control
box lid by removing the five hex nuts and
washers (4, 5). Discard the nuts and washers.
Note the lanyard attachment point for reassembly.
6 Remove the old DISCON gasket (2) from the
ground box lid and clean the lid surface from
any dirt, oil or old adhesive residue. Use a
99% solution of isopropyl alcohol to clean the
surface. Allow the surface to completely dry.
Note: Both the ground box lid and new gasket
must be 70° F / 21° C or higher at the time of
application. Application of the new gasket at lower
temperatures is not recommended.
7 Peel the adhesive protective film from the
back of the new gasket. Carefully line up the
new gasket over the ground box lid, making
sure the cutouts for the LCD screen, ribbon
cables and mounting studs are centered and
lining up with the gasket. Apply the new
gasket to the ground box lid and work from
the center out to eliminate air bubbles and
make sure all the gasket edges are securely
fixed.
Note: Once applied it is not recommended to lift
the gasket and attempt to reposition it.
Illustration 1
1 ground box lid
2 DISCON gasket
3 DISCON
4 8/32 nylock nuts
5 #8 flat washers
6 ribbon cable
7 DISCON door
8 Torx head screws

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Control System

8 Install the new DISCON onto the ground box 1-8

lid and fasten it using the new hex nuts and
washers. All five fastening points must be
How to Replace the Ground Box
used. Attach the DISCON door's lanyard to Control Overlay
the DISCON's mounting stud.
1 Push in the red Emergency Stop button to the
9 Evenly tighten the nuts, beginning with the off position at both the ground and platform
lower center nut, working out and then up. controls.
10 Install the new ribbon cables, connecting the 2 Disconnect the negative terminal from the
ground box overlay to the DISCON and start battery and auxiliary battery, if equipped.
reinstall the DISCON door, using the Torx
head screws removed in step 4. Be sure to 3 Open the ground control box and remove the
fully lock the tabs after the ribbon cables have switch contacts from the function enable
been fully inserted. switch, key switch and the red emergency
stop button. Do not disconnect the wires.
11 Reconnect the wire harness going to the Insert a small screwdriver into the loop at the
DISCON, then close and fasten the ground base of the contacts and engage the release
box lid. mechanism.
12 Reconnect the negative terminal to the start
battery and auxiliary batteries, if equipped.

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Control System

4 Unscrew the nut holding the buttons and key 7 Remove the ground box lid (1) from the
switch and remove the key switch and ground box.
buttons.
8 Remove the old overlay and clean the ground
Note the orientation of the key switch so it can be box lid surface from any dirt, oils or old
reassembled in the same position. adhesive residue. Clean the lid with 99%
isopropyl alcohol. Allow the surface to
5 Disconnect the wire harness connected to the completely dry.
DISCON and cut the zip ties securing the
harness to the ground box lid. Do not remove 9 Before placing the new overlay, make sure
the wire harness from the ground box. the temperature of the lid and overlay is
between 80-100° F / 26-38° C. Application
6 Remove the DISCON door (4) and disconnect below 80° F / 26° C is not recommended.
the ribbon cables (3) from the Display
Controller (DISCON) (2). Note the orientation 10 Peel the adhesive protective film from the
of the cables for reassembling. back of the overlay. Carefully align the
overlay, making sure the LCD screen cutout,
push buttons and key switch are centered.
Apply the overlay to the ground box, applying
pressure evenly to eliminate any air bubbles.
Note: Pay particular attention to the outside edges,
the LCD cutout edges and the area around the
ribbon cables, making sure there is complete
contact between the overlay and the ground box.
Note: It is not recommended peeling and
reapplying the overlay, so take time to align the
overlay before making contact with the ground
box.
11 Maintain the temperature of 80-100° F / 26-
38° C for a minimum of 20 minutes to allow
the adhesive to cure.
12 Install the provided ribbon cables, first to the
overlay and then the DISCON. Be sure the
connectors are applied evenly in the sockets
and the tabs are fully locked.
13 Reinstall the DISCON door using the Torx
head screws (5). Tighten, but do not
overtighten.
14 Reinstall the ground box door to the ground
box, using the fasteners removed in step 7.
1 ground box lid Tighten the fasteners securely.
2 DISCON
3 ribbon cables
4 DISCON door
5 Torx head screws

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Control System

15 Reinstall the E-Stop button, function enable

button and key switch and the contact
assemblies.
16 Reinstall the wire harness from the ground
box to the DISCON. Secure the harness to
the ground box lid using zip ties.
17 Close and fasten the ground box lid.
18 Reconnect the negative terminal to the start
battery and auxiliary batteries, if equipped.

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Platform Components

2-1
Platform

How to Remove the Platform

1 Remove the cable clamp from the top of the
platform mounting weldment.
2 Remove the mounting fasteners from the
power to platform outlet box bracket. Lay the
outlet box and bracket assembly off to the
side. Do not disconnect the wiring.
3 Remove the foot switch mounting fasteners.
4 Remove the cover plate from the bottom of
the foot switch to access the foot switch wire
terminals.
5 Tag and disconnect the foot switch wiring
from the foot switch. Remove the cable from
the back of the platform.
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

6 Remove the platform control box mounting

fasteners. Lower the control box and set it
aside.
Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

Note: If your machine is equipped with an airline to

platform option, the airline must be disconnected
from the platform before removal.
7 Support and secure the platform to an
appropriate lifting device.
8 Remove the platform mounting fasteners and
remove the platform from the machine.
Crushing hazard. The platform
could become unstable and fall
when it is removed from the
machine if not properly
supported.

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Platform Components

2-2 4 Remove the pin retaining fastener from the

slave cylinder rod-end pivot pin. Use a soft
Platform Leveling Cylinder metal drift to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the two Crushing hazard. The jib boom
primary supports for the platform. The slave could fall when the slave
cylinder keeps the platform level through the entire cylinder rod-end pivot pin is
range of boom motion. It operates in a closed- removed if not properly
circuit hydraulic loop with the master cylinder. The supported.
slave cylinder is equipped with counterbalance
valves to prevent movement in the event of a 5 Remove the external snap rings from the
hydraulic line failure. barrel-end pivot pin.
6 Use a soft metal drift to drive the barrel-end
How to Remove the Platform pivot pin out.
Leveling Cylinder 7 Carefully pull the cylinder out of the primary
Note: Before cylinder removal is considered, bleed boom to access the hydraulic hoses.
the leveling cylinder to be sure there is no air in 8 Tag, disconnect and plug the hydraulic hoses
the closed loop. from the slave cylinder. Cap the fittings on the
cylinder.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Bodily injury hazard. Spraying
end must be replaced. All connections must be hydraulic oil can penetrate and
torqued to specification during installation. Refer to burn skin. Loosen hydraulic
Specifications, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
gradually. Do not allow oil to
How to Re mov e th e Platfo rm Leveli ng Slave Cylind er

squirt or spray.
1 Extend the primary boom until the slave
cylinder barrel-end pivot pin is accessible.
How to Bleed the Slave Cylinder
How to Blee d th e Slave C ylinde r

2 Raise the primary boom slightly and place

blocks under the platform for support. Note: Do not start the engine. Use auxiliary power
3 Lower the primary boom until the platform is for all machine functions in this procedure.
resting on the blocks just enough to support
1 Raise the boom to a horizontal position.
the platform.
2 Move the platform level toggle switch up and
Note: Do not rest the entire weight of the boom on
down through two platform leveling cycles to
the blocks.
remove any air that might be in the system.

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Service and Repair Manual April 2022

Platform Components

2-3 2 Tag, disconnect and plug the hydraulic hoses

from the platform rotator manifold. Cap the
Platform Rotator fittings on the rotator.
The platform rotator is a hydraulically activated Bodily injury hazard. Spraying
helical gear assembly used to rotate the platform hydraulic oil can penetrate and
160 degrees. burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
How to Remove the Platform
How to Re mov e th e Platfo rm R otat or

gradually. Do not allow oil to

Rotator squirt or spray.

Component damage hazard. 3 S-85: Support the jib boom leveling arms and
Mark the platform mounting the platform mounting weldment with an
weldment and the rotator flange appropriate lifting device. Do not apply any
before removing the platform lifting pressure.
mounting weldment. The
platform mounting weldment 4 Remove the mounting bolts from the platform
must be replaced in the exact mounting weldment. Remove the center bolt
same position on the rotator and slide the platform mounting weldment off
flange as it was before removal. of the platform rotator.
If a new rotator is installed or Crushing hazard. The platform
the rotator is disassembled, mounting weldment may
proper alignment can be become unbalanced and fall if it
achieved by rotating the rotator is not properly supported.
all the way to the left and then
installing the platform mounting 5 Support the platform rotator with an
weldment all the way in the left appropriate lifting device. Do not apply any
position. lifting pressure.
Note: When removing a hose assembly or fitting, S-80:
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 6 Support the rod end of the platform leveling
torqued to specification during installation. Refer to slave cylinder. Protect the cylinder rod from
Specifications, Hydraulic Hose and Fitting Torque damage.
Specifications. 7 Remove the pivot pin retaining fasteners from
both the slave cylinder rod-end pivot pin and
1 Remove the platform. Refer to Repair
the rotator pivot pin.
Procedure, How to Remove the Platform.

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April 2022 Service and Repair Manual

Platform Components

How to Bleed the Platform

How to Blee d th e Platf orm Rota tor

8 Use a soft metal drift to remove both pivot

pins. Remove the platform rotator from the
machine.
Rotator
Note: This procedure will require two people. Do
Crushing hazard. The platform not start the engine. Use auxiliary power for this
rotator may become unbalanced procedure.
and fall if not properly
supported. 1 Move the function enable toggle switch to
either side and activate the platform rotate
Note: When installing the platform rotator toggle switch to the right then the left through
fasteners, torque the fasteners to specifications. two platform rotation cycles, then hold the
switch to the right position until the platform is
S-85:
fully rotated to the right.
9 Remove the pin retaining fasteners from the 2 Place a suitable container underneath the
jib boom and jib boom leveling arms to platform rotator.
platform rotator pivot pins. Do not remove the
pins. 3 Open the top bleed screw on the rotator, but
do not remove it.
10 Support the jib boom leveling arms.
Bodily injury hazard. Spraying
11 Use a soft metal drift to drive both pins out,
hydraulic oil can penetrate and
then remove the platform rotator from the
burn skin. Loosen hydraulic
machine.
connections very slowly to allow
Bodily injury hazard. The jib the oil pressure to dissipate
boom leveling arms may fall if gradually. Do not allow oil to
not properly supported. squirt or spray.

12 Lower the jib boom leveling arms. 4 Move the function enable button to either side
and hold the platform rotate toggle switch to
Crushing hazard. The platform the left position until the platform is fully
rotator could fall when removed rotated to the left. Continue holding the toggle
from the machine if not properly switch until air stops coming out of the bleed
supported. screw. Close the bleed screw.

Note: When installing the platform rotator Crushing hazard. Keep clear of
fasteners, torque the fasteners to specifications. the platform during rotation.

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Platform Components

5 Open the bottom bleed screw on the rotator, 2-4

but do not remove it.
Platform Overload System
Bodily injury hazard. Spraying
hydraulic oil can penetrate and Proper calibration of the platform overload system
burn skin. Loosen hydraulic is essential to safe machine operation. Continued
connections very slowly to allow use of an improperly calibrated platform overload
the oil pressure to dissipate system could result in the system failing to sense
gradually. Do not allow oil to an overloaded platform. The stability of the
squirt or spray. machine is compromised, and it could tip over.

6 Move the function enable toggle switch to

How to Perform a Zero Load
How to Pe rfor m a Ze ro Loa d Platfo rm C alibr ation

either side and hold the platform rotate toggle

switch to the right position until the platform is Platform Calibration
fully rotated to the right. Continue holding the
toggle switch until air stops coming out of the Perform this procedure when platform overload is
bleed screw. Close the bleed screw. not operating within the calibration parameters.
This procedure will re-calibrate the zero load point
Crushing hazard. Keep clear of without affecting a previous full load calibration. In
the platform during rotation. most cases the machine will maintain full load
capacity, however, in some situations the platform
7 Clean up any hydraulic oil that may have load capacity may be reduced until a full load
spilled. calibration has been performed.
8 Rotate the platform fully in both directions and Note: Perform this procedure with the machine on
inspect the bleed screws for leaks. a firm, level surface.
1 Fully retract and lower the boom. Level the
platform.
2 Remove all weight, tools, accessories and
equipment from the platform.
Note: Remove the welder (if equipped).

Tip-over hazard. Failure to

remove all non-integrated
factory and non-factory options
and accessories could result in
the machine tipping over,
causing death or serious injury.

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Platform Components

How to Perform a Full Load

How to Pe rfor m a Full Loa d Platf orm Calibr ation

3 Enter Service Mode. Refer to Repair

Procedure, How to Enter the Service Mode.
Platform Calibration
4 Press the settings button above the display
Perform this procedure if the platform support or
and select the Calibrations menu.
load cell sensor has been replaced, or if a zero
5 Navigate to the Sensor calibration screen. load platform calibration does not return the
machine to full load capacity.
6 Navigate to the Load Sense calibration
screen. Note: Perform this procedure with the machine on
7 Select and start the calibration procedure. a firm, level surface.

8 Follow the on-screen prompts to set the zero 1 Fully retract and lower the boom. Level the
load. platform.
9 Follow the prompts to accept the weight. 2 Remove all weight, tools, accessories and
equipment from the platform.
10 Calibration is now complete.
Note: Remove the welder (if equipped).
Exit Service Mode.
Tip-over hazard. Failure to
remove all non-integrated
factory and non-factory options
and accessories could result in
the machine tipping over,
causing death or serious injury.

3 Enter Service Mode. Refer to Repair

Procedure, How to Enter the Service Mode.
4 Press the settings button above the display
and select the Calibrations menu.
5 Navigate to the Sensor calibration screen.
6 Navigate to the Load Sense calibration
screen.
7 Select and start the calibration procedure.
8 Follow the on-screen prompts to set the zero
load.
9 Continue with the on screen prompts to set
the maximum load.

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Service and Repair Manual April 2022

Platform Components

10 Place a test weight on the platform floor using 11 Follow the prompts to accept the weight.
a suitable lifting device. Place the weight near
the center entry point of the platform, as far 12 Calibration is now complete.
away from the operator controls as possible. 13 Exit Service Mode.
Weight = 1,000 lbs / 454 kg 14 Push in the red Emergency Stop button to the
Note: If test weights are not available, you may off position.
use an industrial scale to weigh available objects Confirm calibration:
until it equals the platform’s maximum capacity.
15 Start the engine from the ground controls.
16 Add an additional 50 lbs / 23 kg of weight or
load to the platform.
Result: The alarm sounds. The engine turns
off. The platform overload indicator light
flashes at the platform controls and Platform
Overload is displayed on the LCD screen at
the ground controls.
Note: There may be a 2 second delay before the
Note: Alternate method for achieving rated load in overload indicator lights flash and the alarm
the platform is to attach a hanging scale to the sounds.
bottom of the platform and apply load using a
winch or chain hoist until the readout displays the 17 Test all machine functions from the ground
appropriate weight. controls.
Result: Engine does not start. Limited APU
functionality. Elevate and extend functions do
not operate.
18 Remove the weight or rated load from the
platform.

Platform hidden from illustration for clarity

1 platform support
2 sling
3 hanging scale
4 winch or chain hoist
5 anchoring device

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April 2022 Service and Repair Manual

Platform Components

How to Replace the Load Cell

How to Re place the Platfo rm O verlo ad Load Cell

Install the new Load Cell Sensor

Sensor 6 Screw the foot with jam nut into the top of the
Note: The preload adjustment should only be load cell sensor until the foot bolt extends out
performed after the load cell sensor has been of the bottom of the sensor.The foot should
not contact the flex plate when assembling
replaced.
onto the platform support.
1 Remove all equipment or tools from the 7 Assemble the load cell and foot assembly to
platform. Remove the welder if equipped. the platform and securely tighten the two
2 At the platform, remove the plastic instruction mounting screws. Torque the bolts to 101 ft-
holder from the document mount plate. lbs / 137 Nm.
3 Tag and disconnect the load cell sensor Set the Load Cell Sensor Preload
harness.
8 Rotate the foot screw counter clockwise until
4 Loosen the jam nut securing the load cell the foot just contacts the flex plate (finger
sensor foot and rotate the foot screw tight).
clockwise to remove the preload.
9 Using an open end wrench, continue to rotate
the foot counter clockwise an additional
1/2 turn (180°). Then, while holding the foot
bolt, securely tighten the jam nut. Torque the
jam nut to 55 ft-lbs / 75 Nm.
10 Attach the load cell sensor harness.
11 Install the plastic instruction holder.
12 Calibrate the platform overload system. Refer
to, How to Perform a Full Load Platform
Calibration.

1 flex plate
2 load cell sensor foot
3 jam nut
4 load cell sensor

5 Remove the fasteners securing the load cell

sensor and remove the sensor.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 39

Service and Repair Manual April 2022

Jib Boom Components

3-1 5 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on
Jib Boom the cylinder.
Bodily injury hazard. Spraying
How to Remove the Jib Boom hydraulic oil can penetrate and
Note: Perform this procedure with the boom in the burn skin. Loosen hydraulic
stowed position. connections very slowly to allow
the oil pressure to dissipate
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or hose squirt or spray.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 6 Attach a lifting strap from an overhead crane
Specifications, Hydraulic Hose and Fitting Torque to the jib boom assembly.
Specifications.
7 Place blocks under the platform leveling
1 Remove the platform. Refer to Repair cylinder for support. Protect the cylinder rod
Procedure, How to Remove the Platform. from damage.
Note: If the platform overload components are 8 Remove the pin retaining fastener from the
disassembled and/or removed from the platform slave cylinder rod-end pivot pin. Use a soft
support, the platform overload system will need to metal drift to remove the pin.
be calibrated. Refer to Repair Procedure, How to
Crushing hazard. The jib boom
Calibrate the Platform Overload System.
could fall when the slave
2 Tag and disconnect the electrical connector cylinder rod-end pivot pin is
from the platform load sense cell. removed if not properly attached
to the overhead crane.
3 Remove the hose and cable cover from the
side of the jib boom. 9 Remove the pin retaining fastener from the jib
4 Remove the hose and cable clamp from the boom bellcrank to primary boom pivot pin.
jib boom pivot pin. Lay all hoses and cables to 10 Use a soft metal drift to remove the pin and
the side. carefully remove the jib boom assembly from
the primary boom.
Component damage hazard.
Cables and hoses can be Crushing hazard. The jib boom
damaged if they are kinked or may become unbalanced and
pinched. fall when it is removed from the
machine if it is not properly
supported by the overhead lifting
device.

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April 2022 Service and Repair Manual

Jib Boom Components

3-2 4 Use a soft metal drift to tap the jib boom lift
cylinder rod-end pivot pin half way out. Then
Jib Boom Lift Cylinder lower one of the leveling arms to the ground.
Tap the pin the other direction and lower the
How to Remove the Jib Boom Lift opposite leveling arm. Do not remove the pin.
Cylinder 5 Support the jib boom lift cylinder with a lifting
device.
Note: Perform this procedure with the boom in the
stowed position. 6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin. Use a
Note: When removing a hose assembly or fitting, soft metal drift to remove the barrel-end pin
the O-ring (if equipped) on the fitting and/or hose and let the cylinder hang down.
end must be replaced. All connections must be
torqued to specification during installation. Refer to Crushing hazard. The platform
Specifications, Hydraulic Hose and Fitting Torque and jib boom could become
Specifications. unbalanced and fall when the jib
boom barrel-end pivot pin is
1 Raise the jib boom slightly and place blocks removed if not properly
under the platform mounting weldment. Then supported.
lower the jib boom until the platform is resting
on the blocks just enough to support the 7 Attach a lifting strap from an overhead lifting
platform. device to the lug on the rod end of the jib
boom lift cylinder.
Note: Do not rest the entire weight of the boom on
the blocks. 8 Use a soft metal drift to remove the jib boom
lift cylinder rod-end pin. Remove the cylinder
2 Tag, disconnect and plug the jib boom lift from the machine.
cylinder hydraulic hoses. Cap the fittings on
the cylinder. Crushing hazard. The jib boom
lift cylinder may become
Bodily injury hazard. Spraying unbalanced and fall when it is
hydraulic oil can penetrate and removed from the machine if it is
burn skin. Loosen hydraulic not properly supported by the
connections very slowly to allow suitable lifting device.
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

3 Remove the pin retaining fasteners from the

jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.

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4-1 6 S-80XC: Tag, disconnect and plug the

hydraulic hoses from the counterbalance
Cable Track valve manifold located on the platform rotator.
Cap the fittings on the manifold.
The boom cable track guides cables and hoses
running up the boom. It can be repaired link by link Bodily injury hazard. Spraying
without removing the cables and hoses that run hydraulic oil can penetrate and
through it. Removing the entire boom cable track burn skin. Loosen hydraulic
is necessary when performing major repairs that connections very slowly to allow
involve removing the boom. the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track
How to Re mov e th e Cabl e T rack, S-80

Note: When removing a hose assembly or fitting, 7 Tag, disconnect and plug the hydraulic hoses
the O-ring (if equipped) on the fitting and/or hose from the platform leveling slave cylinder at the
end must be replaced. All connections must be platform manifold and cap the fittings.
torqued to specification during installation. Refer to Bodily injury hazard. Spraying
Specifications, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
1 Open the platform control box. connections very slowly to allow
the oil pressure to dissipate
2 Tag and disconnect the foot switch wiring gradually. Do not allow oil to
from the terminal strip inside the platform squirt or spray.
control box.
8 Remove the timing link/timing link cam pin
3 Loosen the squeeze connector and remove
and gently rest the timing link against the
the foot switch cable from the control box.
counterweight.
4 Disconnect the wire connectors from the
9 S-85XC: Remove the hose and cable cover
bottom of the platform control box.
from the side of the jib boom.
Note: When installing the wire connectors to the
10 Tag, disconnect and plug the hydraulic hoses
bottom of the platform control box, match the color
from the jib boom/platform rotate select
of the connectors to those on the control box to be
manifold. Cap the fittings on the manifold.
sure they are installed in the correct location.
11 Tag, disconnect and plug the wiring from the
5 Remove the mounting fasteners from the jib boom/platform rotate select manifold.
power to platform outlet box bracket. Lay the
outlet box and bracket assembly off to the
side.

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12 Tag, disconnect and plug the hydraulic hoses 17 Place blocks between the upper and lower
from the jib boom lift cylinder. Cap the fittings cable tracks and secure the upper and lower
on the cylinder. tracks together.
Bodily injury hazard. Spraying Crushing hazard. If the upper
hydraulic oil can penetrate and and lower cable tracks are not
burn skin. Loosen hydraulic properly secured together, the
connections very slowly to allow cable track could become
the oil pressure to dissipate unbalanced and fall when
gradually. Do not allow oil to removed from the machine.
squirt or spray.
18 Attach a lifting strap from an overhead crane
All models: to the cable track.
13 From the ground controls, raise the boom to a 19 Remove the mounting fasteners that attach
horizontal position. the lower cable track to the boom.
14 Remove the cotter pin from the upper cable 20 Remove the cable track from the machine and
track at the platform end of the boom. place it on a structure capable of supporting it.
Note: Always replace the cotter pin with a new Crushing hazard. The cable
one. track could become unbalanced
and fall if not properly attached
15 Remove the cable track guide fasteners from to the lifting device.
the cable track guides at the platform end of
the boom. Remove the cable track guides
from the boom. Component damage hazard.
Cables and hoses can be
16 Remove the cable clamp from the pivot end of damaged if they are kinked or
the boom. pinched.

Component damage hazard.

The cable track can be damaged
if it is twisted.

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How to Repair the Cable Track 4-2

How to Re pair the Cable Tr ack

Component damage hazard. Boom

The boom cable track can be
How to Shim the Boom
How to Shi m th e Boo m

damaged if it is twisted.

Note: A cable track repair kit is available through 1 Measure each wear pad.
Genie Service Parts, part no. 77896. The kit Boom wear pad specifications
includes a 4-link section of cable track.
Boom number one Minimum
1 Visually inspect the cable track and determine Bottom wear pads 0.50 inch
which 4-link section needs to be replaced. (extension end of boom) 12.7 mm
2 Carefully remove the snap rings from each Top and side wear pads 0.625 inch
end of the damaged section of cable track. (extension end of boom) 15.9 mm

3 Remove the retaining fasteners from the Boom number two

upper black rollers from the 4-link section of Top, bottom and side wear pads 0.50 inch
cable track to be replaced. Remove the (extension end of boom) 12.7 mm
rollers. Bottom wear pads 0.50 inch
(pivot end of boom) 12.7 mm
4 Lift up the hoses and cables and carefully
remove the damaged 4-link section of cable Top and side wear pads 0.625 inch
track. (pivot end of boom) 15.9 mm
Boom number three
Component damage hazard.
Hoses and cables can be Top, bottom and side wear pads 0.50 inch
damaged if they are kinked or (pivot end of boom) 12.7 mm
pinched. Note: Replace the pad if thickness is less than
minimum specification. If thickness is more than
5 Remove the upper rollers from the minimum specification, perform the following
replacement section of cable track. procedure.
6 Lift up the hoses and cables and carefully 2 Extend the boom until the wear pads are
insert the new 4-link section of cable track. accessible.
Component damage hazard. 3 Loosen the wear pad mounting fasteners.
Hoses and cables can be
damaged if they are kinked or 4 Install the new shims under the wear pad to
pinched. obtain zero clearance and zero drag.
5 Tighten the mounting fasteners.
7 Connect the ends of the replacement cable
track section to the existing cable track using 6 Extend and retract the boom through an entire
the snap rings. cycle. Check for tight spots that could cause
binding or scraping.
8 Install the rollers onto the new section of
cable track. Note: Always maintain squareness between the
outer and inner boom tubes.
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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How to Remove the Boom

How to Re mov e th e Boo m

1 Remove the jib boom. Refer to Repair

Procedure, How to Remove the Jib Boom.
Tip-over hazard. This procedure
requires the removal of the 2 Remove the cable track. Refer to Repair
turntable counterweight. Failure Procedure, How to Remove the Cable Track.
to remove the counterweight 3 Raise the boom until the short and long link
before removing the boom arm to boom pivot pins are above the
assembly will result in the turntable covers.
machine tipping over. Do not
remove the boom without first 4 Place a block of wood measuring 4 x 4 x
removing the counterweight. 60 inches / 10 x 10 x 152 cm under the long
link arm, across the turntable covers.
Tip-over hazard. When installing 5 Slowly lower the boom until the long link arm
the boom onto the machine, the contacts the wood block. Do not rest the
boom assembly must be first entire weight of the boom on the block. Turn
installed prior to the installation of the machine off.
the counterweight. If the
counterweight is installed before Component damage hazard. The
the boom assembly, the machine turntable covers can become
will tip over resulting in death or damaged if the weight of the
serious injury. boom is allowed to rest on the
block.
Tip-over hazard. The turntable
counterweight is essential for 6 Place wood blocks between the short link arm
machine stability. Failure to and the turntable weldment for support..
install the counterweight after 7 Securely attach shackles and lifting straps or
installing the boom assembly will chains with a minimum rating of 7.5 tons /
compromise machine stability 7000 kg to the lifting points on the top of the
resulting in the machine tipping turntable counterweight. Attach the lifting
over. Death or serious injury will straps or chains to a 7.5 ton / 7000 kg
result. overhead crane.
Note: A spreader bar and other hardware may be
Bodily injury hazard. This
needed to safely remove the counterweight.
procedure requires specific repair
skills, lifting equipment and a 8 Slowly operate the overhead crane to apply
suitable workshop. Attempting tension to the lifting straps. Do not attempt to
this procedure without these lift the machine with the overhead crane.
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

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9 Locate and remove the counterweight 15 Remove the hose and cable guide fasteners
retaining fastener at the center of the at the primary boom pivot pin. Remove the
counterweight. Carefully lift the counterweight hose and cable guide.
upwards and remove the counterweight from
16 Attach lifting straps from a 5 ton / 5000 kg
the machine. Set the counterweight on the
overhead crane to each end of the boom.
ground. Do not leave the counterweight
Support the boom. Do not apply any lifting
suspended above the ground.
pressure.
Crushing hazard. The turntable 17 Support and secure the rod end of the boom
counterweight will fall if not lift cylinder to a second overhead crane or
properly supported by the similar lifting device.
overhead crane resulting in
death or serious injury. Keep 18 Remove the lift cylinder rod-end pivot pin
personnel away from the area retaining fasteners. Use a soft metal drift to
when removing the remove the pin.
counterweight.
Crushing hazard. The boom
10 Remove the end cover from the pivot end of could fall if not properly
the primary boom. supported when the lift cylinder
rod-end pivot pin is removed.
11 Remove the limit switch mounting fasteners
from the limit switch on the ground controls 19 Using auxiliary power, activate the boom
side of the primary boom. Do not disconnect down function so the cylinder will retract.
the wiring. Remove the limit switch. Retract the cylinder just enough until the rod
end of the cylinder will clear the mounting
12 Disconnect the electrical connector from the
bracket on the boom. Turn the machine off.
string potentiometer.
13 Disconnect the electrical connector from the Crushing hazard. The boom lift
primary boom angle sensor. cylinder could fall if not properly
supported and secured to the
Note: The primary boom angle sensor is located lifting device.
on the pivot pin on the engine side of the boom.
20 Using the overhead crane, carefully lower the
14 Remove the primary boom angle sensor boom lift cylinder and allow it to rest on the
bracket mounting fasteners and remove the boom rest pad. Protect the cylinder rod from
primary boom angle sensor from the primary damage.
boom. Do not remove the angle sensor from
the bracket. 21 Remove the boom end cover retaining
fasteners and remove the cover.
Note: When the primary boom is installed, the
primary boom angle sensor will need to be
calibrated. Refer to Repair Procedure, How to
Calibrate the Primary Boom Angle Sensor.

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22 Tag, disconnect and plug the boom extension 28 Using the overhead crane, adjust the boom as
cylinder hydraulic hoses. Cap the fittings on necessary to relieve pressure from the pivot
the cylinder. pins.
Bodily injury hazard. Spraying 29 Use a soft metal drift to remove each boom
hydraulic oil can penetrate and pivot pin. Carefully remove the boom
burn skin. Loosen hydraulic assembly from the machine and place it on a
connections very slowly to allow structure capable of supporting it.
the oil pressure to dissipate
Crushing hazard. The boom
gradually. Do not allow oil to
could fall if not properly
squirt or spray.
supported by the overhead crane
23 Tag and disconnect the electrical connector when each boom pivot pin is
for the cable break limit switch. removed.

24 Tag and disconnect all boom wire harness Crushing hazard. The long and
electrical connectors located at the pivot end short link arms may fall if not
of the boom. properly supported when the
25 Support the platform leveling master cylinder. boom pivot pins are removed.
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.
26 Tag, disconnect and plug the hydraulic hoses
from the bulkhead fittings at the pivot end of
the boom. Cap the bulkhead fittings.
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.

27 Remove the external snap rings from both

boom pivot pins at the short and long link
arms. Do not remove the pins.

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4-3 5 Using auxiliary power, activate the boom

down function so the cylinder will retract.
Boom Lift Cylinder Retract the cylinder just enough until the rod
The boom lift cylinder raises and lowers the boom. end of the cylinder will clear the mounting
The boom lift cylinder is equipped with bracket on the boom. Turn the machine off.
counterbalance valves to prevent movement in the 6 Tag, disconnect and plug the boom lift
event of a hydraulic line failure. cylinder hydraulic hoses. Cap the fittings on
the cylinder.
How to Remove the Boom Lift
Bodily injury hazard. Spraying
Cylinder hydraulic oil can penetrate and
Bodily injury hazard. This burn skin. Loosen hydraulic
procedure requires specific repair connections very slowly to allow
skills, lifting equipment and a the oil pressure to dissipate
suitable workshop. Attempting gradually. Do not allow oil to
this procedure without these squirt or spray.
skills and tools could result in
death or serious injury and 7 Remove the pin retaining fasteners from the
significant component damage. boom lift cylinder barrel-end pivot pins. Do not
Dealer service is strongly remove the pins.
recommended. 8 Use a slide hammer to remove the barrel-end
pivot pins.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Crushing hazard. The lift
end must be replaced. All connections must be cylinder could become
torqued to specification during installation. Refer to unbalanced and fall if not
Specifications, Hydraulic Hose and Fitting Torque properly supported and secured
Specifications. to the lifting device.
1 Raise the boom to a horizontal position. 9 Move the boom lift cylinder towards the
2 Attach a 5 ton / 5000 kg overhead crane to counterweight end of the machine. Rotate the
the boom at the platform end for support. Do boom lift cylinder until the barrel-end pivot pin
not lift the boom. bores will clear the boom linkage.

3 Support and secure both ends of the boom lift 10 Carefully remove the boom lift cylinder from
cylinder to a second overhead crane or similar the machine.
lifting device. Crushing hazard. The lift
4 Remove the pin retaining fastener from the cylinder could become
boom lift cylinder rod-end pivot pin. Use a soft unbalanced and fall if not
metal drift to remove the pin. properly supported and secured
to the lifting device.
Crushing hazard. The boom will
fall if not properly supported
when the primary boom rod-
end pivot pin is removed.

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4-4 5 Fully loosen the lock nuts on the extend

cables. Do not remove the nuts.
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
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.
1 boom angle sensor
Note: When removing a hose assembly or fitting, 2 string potentiometer
the O-ring (if equipped) on the fitting and/or hose 3 cable guard
end must be replaced. All connections must be 4 cable guard retaining plate
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 6 Loosen the retract cable nut at the platform
Specifications. end of the boom. Pull the cable rod from the
support and let it hang down.
Note: Perform this procedure with the boom fully
retracted. 7 Remove the cable guard fasteners and
remove the cable guard.
1 Raise the boom to a horizontal position.
8 Locate the retaining plates that secure the
2 Remove the boom end cover retaining retract cables to the inside of the number
fasteners and remove the cover. 3 boom tube.
3 Remove the access covers from both sides of 9 Remove the cable retaining plates and pull
the boom at the pivot end. the retract cables off of the pulleys. Lay the
4 Remove the mounting plates and the string cables flat and out of the way.
potentiometer.

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10 Remove the fasteners from the retaining 14 Lift up the extend cable mounting plate and
blocks from the extension cylinder saddle. push the extend cables towards the platform
Remove the blocks. to create slack in the cables. Rest the cable
and bracket assembly on top of the extend
Note: Access the fasteners through the access
cylinder.
hole in the outer boom tube at the pivot end.
15 Locate the lower extend cable bracket on the
11 Disconnect the wire connector to the extend bottom of the number 3 boom tube.
cable break limit switch.
16 Remove the lower extend cable bracket
12 Remove the retaining fasteners that secure mounting fasteners and pull back on the
the extend cable mounting plates to the inside bracket to release it from the number 3 boom
of the number 1 boom tube. tube.
17 While pushing the lower extend cable bracket
towards the platform, pull the extend cable
mounting plate towards the pivot end of the
boom.
18 Secure the extend cable bracket and cables
to the cylinder to prevent them from falling off
when removing the cylinder.
19 Remove the external snap rings from the
extension cylinder pin at the pivot end of the
boom.
20 Use a soft metal drift to remove the pin.
21 Tag, disconnect and plug the boom extension
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
1 extend cable lock nuts the oil pressure to dissipate
2 extend cable mounting plate gradually. Do not allow oil to
3 extend cable mounting plate fastener squirt or spray.
4 extend cable bracket
22 Attach a lifting strap from a 5 ton / 5000 kg
13 Pull back on the extend cable mounting plate overhead crane to the lug at the rod end of
until it clears the blocks welded to the inside the boom extension cylinder.
of the number 1 boom tube.

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23 Lift the boom extension cylinder with the 4-5

crane until it clears the cylinder saddle inside
the number 2 boom tube.
Boom Extend and Retract Cables
How to Adjust the Boom
How to Adju st th e Exten d/Ret ract Cables

24 Carefully support and slide the extension

cylinder out of the boom.
Extend/Retract Cables
Crushing hazard. The extension
The boom extend/retract cables are responsible
cylinder could fall when removed
for the extension and retraction of the number
from the extension boom if not
3 boom tube. Proper adjustment of the boom
properly supported.
extend/retract cables and related components on a
regular basis is essential to good machine
Component damage hazard. Be performance and safe machine operation. The
careful not to damage the cable boom extend and retract functions should operate
break limit switch. smoothly and be free of hesitation, jerking and
unusual noise.
Component damage hazard. Be Note: Perform this procedure with the boom in a
careful not to damage the
horizontal position.
counterbalance valves on the
primary boom extension cylinder 1 Start the engine from the ground controls.
when removing the cylinder from
the primary boom. 2 Raise the boom to a horizontal position.
3 Fully retract the boom.
Note: During removal of the extension cylinder, the
overhead crane strap will need to be carefully 4 Stop the engine.
adjusted for proper balancing. 5 Remove the boom end cover retaining
fasteners and remove the cover.
6 Inspect the threaded ends of the boom extend
cables. The threads must be clean and in
good condition with no damaged threads.
7 Locate the retract cable adjustment nut on the
bottom of the number 1 boom tube at the
platform end of the boom. Loosen the nut, but
do not remove the nut.

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8 Locate the extend cable adjustment nuts on 11 Locate the retract cable adjustment nut on the
the counterweight end of boom tube #1. Refer bottom of the number 1 boom tube at the
to Illustration 1. Loosen the nylock nuts and platform end of the boom.
jam nuts on the cable tension equalizer 12 Using a dial type torque wrench, torque the
bracket. Do not remove the nuts. retract cable adjustment nut to 32-36 ft lbs /
9 Adjust the extend cable adjustment nut to 43-49 Nm using gentle and steady torque.
obtain 6 3/8 inches/16.2 cm to 6 13 Retract and extend the boom approximately
1/2 inches/16.5 cm between the platform end 3 feet / 1 m two times and stop during the
of boom tube #2 and boom tube #3. Refer to extension cycle. This will create slack in the
illustration 2. There should be approximately retract cables.
1/2 inch of exposed threads on the
adjustment bolts. Refer to Illustration 1. Note: Be sure to not fully extend the boom. Stop
when there is approximately 3 feet / 1 m of travel
Note: If the cables have been replaced, be sure left.
the adjustment nuts have been replaced. Do not
re-use the existing nuts. 14 Repeat steps 12 and 13 two to three times.

10 Extend the boom until there is approximately 15 Fully extend the boom then retract the boom
3 feet / 1 m of travel left. Do not fully extend approximately 12 inches / 30 cm.
the boom. 16 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.

Illustration 2
1 6.375 inches / 16.2 cm
Illustration 1
1 cable break limit switch
2 extend cable adjustment nut
3 extend cable pivot plate

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How to Replace the Boom

How to Re place the Boom Exten d/Ret ract C ables

17 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.
Extend/Retract Cables
Note: The cable pulleys must also be replaced
Note: If the boom extend cables are adjusted
when replacing the cables.
evenly, the wheel of the limit switch arm should be
centered in the notch of the pivot plate. 1 Remove the boom extension cylinder. Refer
to Repair Procedure, How to Remove the
18 Install the boom end cover at the pivot end of
Boom Extension Cylinder.
the boom.
Boom extend cables:
19 Fully retract and lower the boom to the
stowed position. 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.

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8 Install the boom extend cable clevis pins and 17 Repeat steps 14 through 19 for the other
rue rings to the pivot plate near the cable boom retract cable.
break limit switch.
18 At the platform end of the boom, install the
9 Install the boom extend cables to the lower retract cables, clevis pins and rue rings to the
extend cable bracket that mounts to the adjustment plate.
number 3 boom tube.
19 Remove and discard the old boom retract
Boom retract cables: pulleys from the pivot end of the boom
extension cylinder.
10 Remove the rue rings and clevis pins from the
boom retract cables at the platform end of the 20 Install the new boom retract pulleys to the
boom. pivot end of the boom extension cylinder.
11 Attach the cable pulling tool or a rope to one 21 Install the boom extension cylinder assembly
of the boom retract cables at the pivot end of into the boom.
the boom. Note: Before lowering the extension cylinder into
Note: A cable pulling tool is available through the saddles of the number 1 boom tube, wrap the
Genie Service Parts Department (Genie part no. boom retract cables around the pulleys.
94510)
22 Adjust the boom extend/retract cables. Refer
12 At the platform end of the boom, pull on the to Repair Procedure, How to Adjust the Boom
boom retract cable that has the rope attached Extend/Retract Cables.
to it.
13 Pull the old cable completely out of the boom
tube. Remove the rope. Discard the old boom
retract cable.
14 Securely attach the rope to the same end of
the new boom retract cable.
15 At the pivot end of the boom, carefully pull the
rope with the new retract cable attached.
16 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.

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5 Place a rod through the barrel-end pivot pin
4-6 and twist to remove the pin.
Platform Leveling Master
Cylinder
The master cylinder acts as a pump for the slave
cylinder. It is part of the closed loop hydraulic
circuit that keeps the platform level through the
entire range of boom motion. The master cylinder
is located inside the pivot end of the boom.

How to Remove the Platform

Leveling Master Cylinder 6 Attach a lifting strap from an overhead crane
to the lug on the rod end of the master
Note: When removing a hose assembly or fitting, cylinder.
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be 7 Remove the pin retaining fastener from the
torqued to specification during installation. Refer to rod-end pivot pin.
Specifications, Hydraulic Hose and Fitting Torque 8 Place a rod through the rod-end pivot pin and
Specifications. twist to remove the pin.
1 Raise the boom until the master cylinder rod- 9 Remove the master cylinder from the
end pivot pin is accessible. machine.
2 Remove the turntable end cover to access the Crushing hazard. The master
master cylinder. cylinder could become
3 Tag, disconnect and plug the master cylinder unbalanced and fall if not
hydraulic hoses. Cap the fittings on the properly attached to the lifting
cylinder. device.

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.

4 Remove the pin retaining fastener from the

master cylinder barrel-end pivot pin.

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Boom Components

4-7 8 Press OK on the display to continue with the

procedure to capture the maximum angle
Primary Boom Angle Sensor point.
The primary boom angle sensor is used to limit the 9 Operate the boom up function until the boom
angle of the primary boom relative to the angle of reaches its maximum angle. Continue holding
the turntable and gravity. the function enable and boom up buttons for
several seconds until the display indicates
How to Calibrate the Primary that the upper calibration point has been
Boom Angle Sensor obtained. This may require holding the
buttons for several seconds after the boom
Note: Perform this procedure with the machine on reaches its maximum angle.
a firm, level surface with the boom in the stowed
position. 10 Follow the on-screen prompts to lower the
boom until the display indicates the calibration
Note: The turntable level sensor and platform load is complete. If this step isn't done, the boom
sensor must be calibrated prior to calibrating the will be in the safety envelope when the
primary boom angle sensor. calibration procedure ends
Note: This procedure will establish the cross-check 11 The calibration is now complete.
angle with the boom limit switch LST3S. If LST3S 12 Exit the Service Mode.
does not switch its state properly during the
calibration, the calibration will be invalidated.
1 Fully retract and lower the boom. Ensure the
boom is in contact with the boom rest pad.
2 Enter Service Mode. Refer to Repair
Procedure, How to Enter the Service Mode.
3 Press the settings button above the display
and navigate to the Sensor Calibrations
menu.
4 Navigate to the Boom Angle Sensor
calibration screen.
5 Select and start the calibration procedure.
6 Start the engine.
7 When the display prompts the operator to
lower the boom, press and hold the function
enable button and the boom down buttons
until the display indicates that the lower
calibration point has been obtained. This may
require holding the buttons for several
seconds after the boom has touched the rest
pad.

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Boom Components

4-8 8 Press the OK button to continue to capture

the maximum extension point.
Boom Length Sensor
9 Press the function enable and boom extend
How to Calibrate the Primary buttons until the boom reaches its maximum
extension. Continue holding the buttons for
Boom Length Sensor several seconds after the boom reaches its
Note: The turntable level sensor and platform load maximum extension until the display indicates
sensor must be calibrated prior to calibrating the the calibration point has been captured.
primary boom angle sensor. 10 The calibration is complete.
Note: The turntable level sensor, platform load 11 Exit the Service Mode.
sensor and primary boom angle sensor must be
calibrated before calibrating the boom length
sensor.
Note: This procedure will establish the cross-check
angle with the boom limit switch LSB1RS. If
LSB1RS does not switch its state properly during
calibration, the calibration will be invalidated.
1 Fully retract the boom. Ensure the boom
angle is above 65°.
2 Enter Service Mode. See Repair Procedure,
How to Enter Service Mode.
3 Press the settings button above the display
and navigate to Sensor Calibrations.
4 Navigate to the Boom Length Sensor
calibration screen.
5 Select and start the calibration procedure.
6 Start the engine.
7 When the display prompts the operator to
retract the boom, press and hold the function
enable and boom retract buttons until the
display indicates the retracted calibration
point has been obtained. This may require
holding the buttons for several seconds after
the boom has fully retracted.

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Engines

5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the
Service or Maintenance Manual for your machine, engine and the pump. It is bolted to the engine
Check and Adjust the Engine RPM. flywheel and has a splined center to drive the
pump.
Type "B" flex plates combines the pump coupler,
as part of the flex plate, which is installed onto the
engine flywheel.

Type "B"
(flexplate with coupler combined)

How to Re mov e th e Fl ex Plate

How to Remove the Flex Plate

Note: Perform this procedure with the engine off
and cool to the touch.
1 Open the engine side turntable cover.
2 Tag and disconnect the battery cables from
the battery(s).
Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

3 Tag and disconnect the wiring plug at the

electronic displacement controller (EDC),
located on the drive pump.

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Engines

Deutz TD2011L04i models: Deutz TD 2.9, TCD 2.2 models:

1 Tag and disconnect the wiring from the bell 1 Tag and disconnect the wiring from the bell
housing. housing.
2 Remove the U-bolt from the exhaust flex pipe 2 Support the drive pump with an appropriate
at the muffler. lifting device. Remove all of the remaining bell
housing engine fasteners.
Burn hazard. Beware of hot
engine components. Contact 3 Carefully pull the pump and bell housing
with hot engine components assembly away from the engine and secure it
may result in severe burns. from moving.

3 Remove the muffler bracket retaining Component damage hazard.

Hoses can be damaged if they
fasteners from bell housing. Remove the
muffler and bracket assembly from the are kinked or pinched.
engine.
4 Remove the flex plate mounting fasteners,
4 Support the drive pump with an appropriate and remove the flex plate from the engine
lifting device. Remove all of the remaining bell flywheel.
housing engine 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,

and remove the flex plate from the engine
flywheel.

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Engines

Perkins models: GM model:

1 Tag and disconnect the wiring from the bell 1 Tag and disconnect the wire harness from the
housing. oxygen sensor.
2 Remove the fasteners supporting the muffler 2 Remove the exhaust pipe heat shield
assembly from the bell housing. fasteners from the top of the muffler.
Burn hazard. Beware of hot Burn hazard. Beware of hot
engine components. Contact engine components. Contact
with hot engine components with hot engine components
may result in severe burns. may result in severe burns.

3 Support the drive pump with an appropriate 3 Remove the muffler retainer bracket
lifting device. Remove all of the remaining bell fasteners.
housing engine fasteners.
4 Remove the muffler fasteners securing the
4 Carefully pull the pump and bell housing muffler to the exhaust manifold. Remove the
assembly away from the engine and secure it muffler from the bracket.
from moving.
5 Remove the relay housing from the muffler
Component damage hazard. mount. Do not disconnect the relays.
Hoses can be damaged if they 6 Disconnect and remove the ECM from the
are kinked or pinched. muffler mount.
5 Remove the flex plate mounting fasteners, 7 Close the shutoff valve on the Liquid
and remove the flex plate from the engine Petroleum Gas (LPG) tank by turning it
flywheel. clockwise (if equipped).
8 Unbolt the EPR valve from the muffler mount.
Leave the hoses attached to the EPR valve.
9 Remove the muffler mount.
10 Support the drive pump with an appropriate
lifting device. Remove all of pump plate
mounting fasteners.
11 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.

12 Remove the flex plate mounting fasteners,

and remove the flex plate from the engine
flywheel.

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Engines

How to Install the Flex Plate

How to I nstall t he Flex Plat e

3 Install the pump coupler onto the pump shaft

with the set screw toward the pump. Leave
1 Install the flex plate onto the engine flywheel the appropriate gap between coupler and
with the raised spline towards the pump. pump end plate for your engine.
Apply Loctite® removable thread locker to the
mounting fasteners. 4 Apply Loctite® removable thread locker to the
pump coupler set screw. Torque the set screw
Note: Torque the flex plate mounting fasteners in to 61 ft-lbs / 83 Nm.
two stages.
5 Install the pump onto the pump mounting
2 Torque the flex plate mounting bolts in plate. Apply Loctite® removable thread sealant
sequence to 28 ft-lbs / 38 Nm. Torque the flex to the pump retaining fasteners. Torque the
plate mounting bolts in sequence to 40 ft-lbs / pump retaining fasteners to 57 ft-lbs / 77 Nm.
54 Nm.
Component damage hazard. Do
not force the drive pump during
installation or the flex plate teeth
may become damaged.

6 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.
7 Install the pump and pump mounting plate
assembly onto the engine. Apply Loctite®
removable thread locker to the mounting
screws.

Deutz, Perkins

GM

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Engines

How to Install the Pump and Bell

How to ins tall th e Pum p a nd Bell Ho using Assem bly

Housing Assembly
1 Install the pump and bell housing assembly.
Deutz models: Torque the bell housing
mounting bolts in sequence to 28 ft-lbs / 38
Nm. Then torque the bell housing mounting
bolts in sequence to 40 ft-lbs / 54 Nm.
Perkins 404D 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. Perkins

GM 3.0L model: Torque the bell housing

mounting bolts in sequence to 28 ft-lbs / 38
Nm. Then torque the bell housing mounting in
sequence to 40 ft-lbs / 54 Nm bolts.
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. Do

not force the drive pump during
installation or the flex plate
teeth may become damaged. GM

Deutz

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Engines

5-3
Diesel Particle Filter
Regeneration - Deutz TCD 2.2 L3
Engine
The combustion of diesel fuel results in soot,
which is separated in the diesel particle filter
(DPF). This must be regenerated as the
contamination with soot increases. There are
3 types of regeneration.

Passive regeneration:
Under normal operating conditions when the
exhaust temperature is >482°F / 250°C the particle
filter contamination with soot remains in a
permissible range. This process is automatically
activated by the engine control unit, the operator
does not need to perform any actions.

Standstill regeneration:
If passive regeneration does not attain an
adequate reduction of the soot contamination, the
particle filter will continue to become contaminated
with soot and a standstill regeneration will be
required by the operator.
To perform standstill regeneration, refer to the
Operator's Manual on your machine.

Service regeneration:
If a fault occurs, the system reacts by reducing the
engine performance. This can include limited
machine functions, torque reduction, reduced
engine rpm and replacement of the DPF.
If standstill regeneration is prohibited by the
operator. Service regeneration must be performed
by a trained technician with the use of the DEUTZ
SerDia software tool and DeCom interface cable.
Available from Deutz.
If service regeneration is not performed,
replacement of the DPF will be required.

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Hydraulic Pump

6-1 2 Tag, disconnect and plug the function pump

hydraulic hoses. Cap the fittings on the pump.
Function Pump
Bodily injury hazard. Spraying
hydraulic oil can penetrate and
How to Remove the Function burn skin. Loosen hydraulic
Pump connections very slowly to allow
the oil pressure to dissipate
Note: When removing a hose assembly or fitting, gradually. Do not allow oil to
the O-ring (if equipped) on the fitting and/or hose squirt or spray.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 3 Support the pump with a suitable lifting
Specifications, Hydraulic Hose and Fitting Torque device.
Specifications.
4 Remove the pump mounting bolts. Carefully
1 Locate the two hydraulic tank valves at the remove the pump.
hydraulic tank. Close the valves.
Component damage hazard. Be
Component damage hazard. sure to open the two hydraulic
The engine must not be started tank valves and prime the pump
with the hydraulic tank shut-off after installing the pump.
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

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Hydraulic Pump

6-2 2 Locate the two hydraulic tank valves at the

hydraulic tank. Close the valves.
Drive Pump
The drive pump is a bi-directional variable
displacement piston pump. The pump output is
controlled by the electronic displacement controller
(EDC), 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 be performed at an authorized Sauer-
Danfoss service center. Contact Genie Product open closed
Support to locate your local authorized service
center. Component damage hazard.
The engine must not be started
with the hydraulic tank shut-off
How to Remove the Drive Pump valves in the closed position or
Component damage hazard. The component damage will occur. If
work area and surfaces where the tank valves are closed,
this procedure will be performed remove the key from the key
must be clean and free of debris switch and tag the machine to
that could get into the hydraulic inform personnel of the
system and cause severe condition.
component damage. Dealer
3 Tag, disconnect and plug the hydraulic hoses
service is recommended.
from the drive and function pumps. Cap the
Note: When removing a hose assembly or fitting, fittings on the pumps.
the O-ring (if equipped) on the fitting and/or hose Bodily injury hazard. Spraying
end must be replaced. All connections must be hydraulic oil can penetrate and
torqued to specification during installation. Refer to burn skin. Loosen hydraulic
Specifications, Hydraulic Hose and Fitting Torque connections very slowly to allow
Specifications. the oil pressure to dissipate
1 Disconnect the wiring plug at the electronic gradually. Do not allow oil to
displacement controller (EDC), located on the squirt or spray.
drive pump.
4 Support the pumps with a suitable lifting
device and remove the two drive pump
mounting fasteners.

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Hydraulic Pump

How to Prime the Drive Pump

How to Pri me t he D rive Pu mp

5 Carefully pull the drive pump out until the

pump coupler separates from the flex plate.
Component damage hazard.
6 Remove the drive pump from the machine. The engine must not be started
Component damage hazard. The with the hydraulic tank shut-off
pump(s) may become valves in the closed position or
unbalanced and fall if not component damage will occur. If
properly supported. the tank valves are closed,
remove the key from the key
switch and tag the machine to
Component damage hazard. inform personnel of the
The engine must not be started condition.
with the hydraulic tank shut-off
valves in the closed position or 1 Connect a 0 to 600 psi / 0 to 40 bar pressure
component damage will occur. If gauge to the diagnostic nipple on the drive
the tank valves are closed, pump.
remove the key from the key
switch and tag the machine to 2 GM models: If equipped, close the valve on
inform personnel of the the LPG tank, then disconnect the hose from
condition. the tank. Move the fuel select toggle switch to
the LPG position.
Deutz and Perkins models: Disconnect the
engine wiring harness from the fuel solenoid
at the injector pump.
3 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 300 psi / 20.7 bar.
4 GM models: If equipped, connect the LPG
hose to the LPG tank and open the valve on
the tank.
Deutz and Perkins models: Connect the
engine wiring harness to the fuel solenoid.
5 Start the engine from the ground controls.
Check for hydraulic leaks.

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Manifolds

7-1
Function Manifold Components
The function manifold assembly is located on the hydraulic tank side of the machine next to the batteries.

Index Schematic
Description Function Torque
No. Item
1 Solenoid Valve, 2 position 3 way SJ Boom up 50-55 ft-lbs / 68-75 Nm
2 Solenoid Valve, 2 position 3 way SK Boom down 30-35 ft-lbs / 41-47 Nm

3 Solenoid Valve, NO, Poppet SP Extend 33-37 ft-lbs / 45-50 Nm

4 Solenoid Valve, NO, Poppet SQ Retract 33-37 ft-lbs / 45-50 Nm

5 Proportional solenoid valve SR Extend proportional 20-25 ft-lbs / 27-34 Nm
6 Differential sensing valve SS Boom extend 30-35 ft-lbs / 41-47 Nm
7 Proportional solenoid valve SF Boom up/down proportional 33-37 ft-lbs / 45-50 Nm
8 Solenoid valve, 3 position 4 way SL Steering directional 20-25 ft-lbs / 27-34 Nm
9 Proportional solenoid valve SE Swing proportional 20-25 ft-lbs / 27-34 Nm
10 Solenoid valve, 3 position 4 way SI Swing directional 26-30 ft-lbs / 35-41 Nm
11 Flow regulator valve SD Oscillate flow control 20-25 ft-lbs / 27-34 Nm
12 Relief valve, 2600 psi / 179 bar SN Boom down relief 20-25 ft-lbs / 27-34 Nm
13 Relief valve, 2400 psi / 165 bar SO Boom extend relief 20-25 ft-lbs / 27-34 Nm
14 Check valve, 30 psi / 2.1 bar ST Return check valve 30-35 ft-lbs / 41-47 Nm
15 Differential sensing valve SH Primary lift 30-35 ft-lbs / 41-47 Nm
16 Check valve SA Back flow / check function 30-35 ft-lbs / 41-47 Nm
pump
17 Relief valve, 3200 psi / 221 bar SB System relief 20-25 ft-lbs / 27-34 Nm
18 Pressure reducing valve SC Oscillate pressure control 30-35 ft-lbs / 41-47 Nm
19 Differential sensing valve SG Differential sensing/turntable 30-35 ft-lbs / 41-47 Nm
rotate
20 Flow regulator valve SM Steering flow control 20-25 ft-lbs / 27-34 Nm

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Manifolds

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Manifolds

7-2 Valve Adjustments - Function How to Adjust the Boom Down

How to Adju st th e Boo m Down Relief V alve

Manifold Relief Valve

Note: Perform this procedure with the boom in the
How to Adjust the System Relief
How to Adju st th e Syste m Relie f Valve

stowed position.
Valve Note: Refer to Function Manifold Component list to
Note: Perform this procedure with the boom in the locate the boom down relief valve.
stowed position.
Note: Auxiliary power will be used to perform this
Note: Refer to Function Manifold Component list to procedure. Do not start the engine.
locate the system relief valve.
1 Connect a 0 to 5000 psi / 0 to 350 bar
Note: Auxiliary power will be used to perform this pressure gauge to the diagnostic nipple
procedure. Do not start the engine. located next to the auxiliary pump.
1 Connect a 0 to 5000 psi / 0 to 350 bar 2 Simultaneously activate and hold the auxiliary
pressure gauge to the diagnostic nipple power button and the primary boom down
(ptest) located next to the auxiliary pump. button with the boom fully lowered. Observe
the pressure reading on the pressure gauge.
2 Simultaneously activate and hold the auxiliary Refer to Specifications, Hydraulic
power button and the primary boom retract Specifications.
button with the primary boom fully retracted.
Observe the pressure reading on the pressure 3 Use a wrench to hold the relief valve and
gauge. Refer to Specifications, Hydraulic remove the cap on the function manifold.
Specifications. 4 Adjust the internal hex socket. Turn it
3 Locate the system relief valve on the function clockwise to increase the pressure or
manifold. Use a wrench to hold the relief valve counterclockwise to decrease the pressure.
and remove the cap. Install the relief valve cap.
4 Adjust the internal hex socket. Turn it Tip-over hazard. Do not adjust
clockwise to increase the pressure or the relief valve higher than
counterclockwise to decrease the pressure. specified.
Install the relief valve cap.
5 Repeat step 2 to confirm relief valve pressure.
Tip-over hazard. Do not adjust
the relief valve higher than 6 Remove the pressure gauge.
specified.

5 Repeat step 2 to confirm relief valve pressure.

6 Remove the pressure gauge.

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Manifolds

How to Adjust the Boom Extend

How to Adju st th e Boo m Exten d Relie f Valve

Relief Valve
Note: Perform this procedure with the machine on
a firm, level surface that is free of obstructions.
Note: Refer to Function Manifold Component list to
locate the boom extend relief valve.
1 From the ground controls, start the engine
and raise the boom to the horizontal position.
2 Fully extend the boom. Turn the engine off.
3 Connect a 0 to 3000 psi / 0 to 200 bar
pressure gauge to the diagnostic nipple
located next to the auxiliary pump.
4 Simultaneously activate and hold the auxiliary
power button and the primary boom extend
button with the boom fully extended. Observe
the pressure reading on the pressure gauge.
Refer to Specifications, Hydraulic
Specifications.
5 Locate the boom extend relief valve on the
function manifold. Use a wrench to hold the
relief valve and remove the cap.
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 step 2 to confirm relief valve pressure.

8 Remove the pressure gauge.

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Manifolds

7-3
Brake / Two Speed Manifold Components
The brake/two speed manifold is mounted on the engine side of the machine above the hydraulic filters.

Index Schematic
Description Function Torque
No. Item
1 Orifice, 0.025 inch / 0,635 mm BE Brake release circuit
2 Check valve BF Brake release circuit 20-25 ft-lbs / 27-34 Nm
3 Solenoid Valve, 2 position 3 way BG Brake release 20-25 ft-lbs / 27-34 Nm
4 Solenoid Valve, 2 position 3 way BH Two-speed drive motor shift 20-25 ft-lbs / 27-34 Nm

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Manifolds

7-4
Turntable Rotation Manifold Components
The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the
machine.

Index Schematic
Description Function Torque
No. Item
1 Counterbalance valve, 1000 psi / RA Turntable rotate left 25-30 ft-lbs / 34-41 Nm
69 bar
2 Counterbalance valve, 1000 psi / RB Turntable rotate right 25-30 ft-lbs / 34-41 Nm
69 bar
3 Shuttle valve, 2 position 3 way RD Turntable rotation brake 8-10 ft-lbs / 10-15 Nm
release
4 Orifice, 0.030 inch / 0,8 mm RC Turntable rotate brake circuit

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Manifolds

7-5
Platform Rotate Manifold Components
The platform rotate manifold is mounted on the platform rotator.

Index
Description Schematic Item Function Torque
No.
1 Counterbalance valve, 3300 psi / PA Platform rotate right 37-44 ft-lbs / 50-60 Nm
227 bar
2 Counterbalance valve, 3300 psi / PB Platform rotate left 37-44 ft-lbs / 50-60 Nm
227 bar

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Manifolds

7-6
Platform Manifold Components, S-80 XC
The jib boom / platform rotate manifold is mounted to the platform support.

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 3 position 4 way EF Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 3 position 4 way EB Platform level up/down 30-35 ft-lbs / 41-47 Nm
3 Counterbalance valve, 3500 psi EC Platform level CB valve 26-30 ft-lbs / 35-41 Nm
4 Counterbalance valve, 3500 psi ED Platform level CB valve 26-30 ft-lbs / 35-41 Nm
5 Needle valve EA Platform level 20-25 ft-lbs / 27-34 Nm
6 Pressure comp., flow control EE Platform rotate flow control 33-37 ft-lbs / 45-50 Nm
valve

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Manifolds

7-7
Platform Manifold Components, S-85 XC
The jib boom / platform rotate manifold is mounted to the platform support.

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 3 position 4 way EF Platform rotate CW/CCW 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 3 position 4 way EB Platform level up/down 30-35 ft-lbs / 41-47 Nm
3 Solenoid valve, 3 position 4 way EH Jib boom up/down 30-35 ft-lbs / 41-47 Nm
4 Counterbalance valve, 3500 psi EC Platform level CB valve 26-30 ft-lbs / 35-41 Nm
5 Counterbalance valve, 3500 psi ED Platform level CB valve 26-30 ft-lbs / 35-41 Nm
6 Needle valve EA Platform level 20-25 ft-lbs / 27-34 Nm
7 Pressure comp., flow control valve EE Platform rotate flow control 33-37 ft-lbs / 45-50 Nm
8 Pressure comp., flow control valve EG Jib up/down flow control 33-37 ft-lbs / 45-50 Nm

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Manifolds

7-8
Traction Manifold Components, 4WD
The drive manifold is mounted inside the drive chassis at the non-steer end of the machine.

Index Schematic
Description Function Torque
No. Item
1 Relief valve, 280 psi / 19.3 bar DE Charge pressure circuit 35-40 ft-lbs / 48-54 Nm
2 Flow divider/combiner valve DB Controls flow to non-steer end 80-90 ft-lbs / 108-122 Nm
drive motors in forward and
reverse
3 Check valve DF Steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
4 Check valve DC Non-steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
5 Flow divider/combiner valve DK Controls flow to flow 80-90 ft-lbs / 108-122 Nm
divider/combiner valves 2 and 13
6 Check valve DD Non-steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm
7 Orifice, 0.040 inch / 1 mm DL Equalizes pressure on both sides
of flow divider/combiner valve 5
8 Orifice, 0.040 inch / 1 mm DA Equalizes pressure on both sides
of flow divider/combiner valve 2
9 Orifice, 0.040 inch / 1 mm DN Equalizes pressure on both sides
of flow divider/combiner valve 13
10 Check valve DG Steer end drive motor circuit 60-70 ft-lbs / 81-95 Nm
11 Check valve DH Steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm
12 Shuttle Valve, 3 position 3 way DJ Charge pressure circuit that 80-90 ft-lbs / 108-122 Nm
directs hot oil out of low pressure
side of drive pump
13 Flow divider/combiner valve DM Controls flow to steer end drive 80-90 ft-lbs / 108-122 Nm
motors in forward and reverse
14 Check valve DP Non-steer end drive motor circuit 35-40 ft-lbs / 48-54 Nm

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Manifolds

7-9
Valve Adjustments - Traction
Manifold
How to Adjust the Hot Oil Relief
Valve
Note: The pressure differential between the charge
pump relief valve (located in the drive pump) and
the hot oil shuttle relief valve (located in the
traction manifold) is necessary to return hot oil
from the closed loop drive circuit to the hydraulic
tank for cooling. This pressure differential must be
maintained at 40 psi / 3 bar.
Note: Two people will be required to perform this
procedure.
1 Open the engine side turntable cover and
connect a 0 to 600 psi / 0 to 40 bar pressure
gauge to the diagnostic nipple on the drive
pump.
2 Start the engine from the platform controls
and allow the engine to run at low idle. Note
the pressure reading on the pressure gauge.
3 Turn the engine off and connect a 0 to 600 psi
/ 0 to 40 bar pressure gauge to the diagnostic
nipple located on the traction manifold.
4 Start the engine from the platform controls
and drive the machine slowly in the forward
direction. Note the pressure reading on the
pressure gauge.
5 Turn the engine off, and remove the hot oil
shuttle relief valve cap. Adjust the internal hex
socket clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the valve cap.
6 Repeat steps 4 and 5 until a pressure
differential (between the charge pump reading
and the hot oil shuttle relief valve) of 40 psi /
3 bar is obtained.

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Manifolds

7-10
Generator Manifold
The generator manifold is mounted on the turntable tray by the fuel tank.

Index Schematic
Description Function Torque
No. Item
1 Relief valve GA Generator relief valve 50 ft-lbs / 67 Nm
2 Solenoid Valve GB Charge pressure circuit 60-65 ft lbs / 81-88 Nm
3 Needle valve GD Charge pressure circuit 50 ft-lbs / 67 Nm
4 Differential sensing valve GC Pilot valve to diverter valve 50 ft-lbs / 67 Nm
5 Counterbalance valve GF Adds backpressure to generator
circuit
6 Check valve GE Prevents oil to generator 24-26 ft-lbs / 32,5-35,3 Nm

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Manifolds

7-11 Valve Coil Resistance

Valve Coil Resist anc e Specific ations

Valve Coils Specification

Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromotive force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil that provides this force field. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification
resistance values outside specification can
produce erratic operation. When coil resistance Proportional solenoid valve (schematic 4.8Ω
items SE, SF and SR)
decreases below specification, amperage
increases. As resistance rises above specification, 2 position 3 way solenoid valve 6.3Ω
voltage increases. (schematic items SJ and SK)
2 position 2 way solenoid valve 5.9Ω
While valves may operate when coil resistance is (schematic items SP and SQ)
outside specification, maintaining coils within
specification will help ensure proper valve function 3 position 4 way solenoid valve 6.3Ω
(schematic items EB, EF, EH, SI and
over a wide range of operating temperatures. SL)
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.

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How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. 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 multimeter
1 Test the coil for resistance. Refer to Repair
Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative 4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
Genie part number 27287 Note: The multimeter, when set to read DC
current, should be capable of reading up to
Note: The battery should read 9V DC or more 800 mA.
when measured across the terminals.
4 Connect the negative lead to the other
terminal on 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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Fuel and Hydraulic Tanks

8-1 4 Tag, disconnect, drain and plug the supply

and return fuel hoses. Cap the fittings on the
Fuel Tank fuel tank.
5 Remove the fuel tank retaining fasteners.
How to Remove the Fuel Tank
6 Remove the fuel tank from the machine.
Explosion and fire hazard.
Engine fuels are combustible. Component damage hazard.
Perform this procedure in an The fuel tank is plastic and may
open, well-ventilated area away become damaged if allowed to
from heaters, sparks, flames and fall.
lighted tobacco. Always have an
approved fire extinguisher within Component damage hazard.
easy reach. When installing the plastic fuel
tank, do not overtighten the
Explosion and fire hazard. When retaining fasteners.
transferring fuel, connect a
Note: Clean the fuel tank and inspect for damage
grounding wire between the
before installing it onto the machine.
machine and pump or container.

Explosion and fire hazard. Never

drain or store fuel in an open
container due to the possibility of
fire.

1 Turn the manual fuel shutoff valve to the

closed position (if equipped).
2 Remove the fuel filler cap from the tank.
3 Using an approved hand-operated pump,
drain the fuel tank into a suitable container.
Refer to Specifications, Machine
Specifications.
Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.

Note: Be sure to only use a hand operated pump

suitable for use with gasoline and diesel fuel.

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Fuel and Hydraulic Tanks

8-2 2 Close the two hydraulic tank valves located at

the hydraulic tank (if equipped).
Hydraulic Tank
Component damage hazard.
The primary functions of the hydraulic tank are to The engine must not be started
cool, clean and de-aerate the hydraulic fluid during with the hydraulic tank shut-off
operation. The tank utilizes internal suction valves in the closed position or
strainers for the pump supply hoses and has an component damage will occur. If
external return filter equipped with a filter condition the tank valves are closed,
indicator. remove the key from the key
switch and tag the machine to
How to Remove the Hydraulic inform personnel of the
condition.
Tank
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.
open closed
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
3 Remove the drain plug from the hydraulic tank
end must be replaced. All connections must be
and completely drain the tank into a container
torqued to specification during installation. Refer to
of suitable capacity. Refer to Specifications,
Specifications, Hydraulic Hose and Fitting Torque
Machine Specifications.
Specifications.
4 Tag, disconnect and plug the two suction
1 Remove the fuel tank. Refer to Repair hoses that are attached to the hydraulic tank.
Procedure, How to Remove the Fuel Tank.
5 Tag and disconnect and plug the hose from
the return filter. Cap the fitting on the return
filter housing.
6 Tag and disconnect and plug the supply hose
for the auxiliary power unit. Cap the fitting on
the hydraulic tank.
7 Support the hydraulic tank with 2 lifting straps.
Place one lifting strap at each end of the tank
and attach the lifting straps to an overhead
crane.
8 Remove the four fasteners securing the tank
to the chassis bulkhead.

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Fuel and Hydraulic Tanks

9 Remove the hydraulic tank from the machine. 17 Clean up any oil that may have spilled.
Crushing hazard. The hydraulic 18 Open the hydraulic tank shutoff valves (if
tank could become unbalanced equipped).
and fall if not properly supported
when removed from the Component damage hazard. Be
machine. sure to open the two hydraulic
tank shutoff valves (if equipped)
10 Remove the suction strainers from the tank and prime the pump after
and clean them using a mild solvent. installing the hydraulic tank.
11 Rinse out the inside of the tank using a mild Note: Always use pipe thread sealant when
solvent. installing the drain plug and strainers.
12 Install the suction strainers using pipe thread
sealant on the threads.
13 Install the drain plug using pipe thread sealant
on the threads.
14 Install the hydraulic tank onto the machine.
15 Install the two suction hoses and the supply
hose for the auxiliary power unit.
16 Fill the tank with hydraulic oil until the level is
within the top 2 inches / 5 cm of the sight
gauge. Do not overfill.

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Turntable Rotation Components

9-1 4 Attach a suitable lifting device to the lifting

eyes on the drive hub assembly.
Turntable Rotation Drive Hub
Assembly
How to Re mov e th e T urnt able R otati on D rive Hu b Asse mbly

How to Remove the Turntable

Rotation Drive Hub Assembly
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Secure the turntable from rotating with the
turntable rotation lock pin.
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the
motor.
Bodily injury hazard. Spraying
hydraulic oil can penetrate and 1 backlash pivot plate
burn skin. Loosen hydraulic 2 adjustment bolt with lock nut
connections very slowly to allow 3 backlash pivot plate mounting bolts
the oil pressure to dissipate
gradually. Do not allow oil to 5 Remove the backlash pivot plate mounting
squirt or spray. bolts. Carefully remove the drive hub
assembly from the machine.
3 Loosen the backlash pivot plate and
adjustment bolts. Crushing hazard. The turntable
rotate drive hub assembly could
become unbalanced and fall
when removed from the machine
if not properly supported by the
lifting device.

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Turntable Rotation Components

When installing the drive hub assembly: How to Remove the Turntable
How to Re mov e th e T urnt able R otati on Hy dra ulic Mo tor

6 Install the drive hub. Apply removable thread Rotation Hydraulic Motor
locking compound to fastener threads.Torque
the backlash pivot plate mounting fasteners to Note: When removing a hose assembly or fitting,
specification. Refer to Specifications, Machine the O-ring (if equipped) on the fitting and/or hose
Torque Specifications. end must be replaced. All connections must be
torqued to specification during installation. Refer to
7 Install the brake and then the motor onto the Specifications, Hydraulic Hose and Fitting Torque
drive hub. Apply removable thread locking Specifications.
compound to fastener threads.Torque the
motor/brake mounting fasteners to 1 Secure the turntable from rotating with the
specification. Refer to Specifications, Machine turntable rotation lock pin.
Torque Specifications. 2 Tag, disconnect and plug the hydraulic hoses
8 Adjust turntable rotation gear backlash. Refer from the drive motor. Cap the fittings on the
to Repair Procedure, How to Adjust the motor.
Turntable Rotation Gear Backlash.
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.

3 Remove the hydraulic tube that connects from

the counterbalance manifold to the brake.
Cap the fittings on the brake and manifold.
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.

4 Remove the motor/brake mounting fasteners.

Carefully remove the motor from the brake.

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Turntable Rotation Components

5 Clean up any oil that may have spilled. How to Adjust the Turntable
How to Adju st th e T urn table Rota tion G ear Backlas h

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 motor
2 drive hub mounting bolts
3 drive hub with brake

1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts

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Turntable Rotation Components

How to Calibrate the Turntable

How to Cali brat e th e T urn table Tilt Se nso r

3 Push the backlash pivot plate towards the

turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
Tilt Sensor
gear). Note: Perform this procedure on a firm, level
surface with the machine in the stowed position.
4 Loosen the lock nut on the adjustment bolt.
5 Turn the adjustment bolt clockwise until it Note: A digital level will be required to perform this
contacts the backlash pivot plate. procedure.

6 Turn the adjustment bolt one half turn 1 Enter Service Mode. Refer to Repair
counterclockwise. Tighten the lock nut on the Procedure, How to Enter the Service Mode.
adjustment bolt. 2 Press the settings button above the display
7 Rotate the backlash pivot plate away from the and navigate to the Sensor Calibrations
turntable until it contacts the adjustment bolt. menu.
Then torque the mounting fasteners on the 3 Navigate to the Chassis Tilt Sensor calibration
backlash pivot plate. Refer to Specifications, screen.
Machine Torque Specifications.
4 Select and start the calibration procedure.
8 Rotate the turntable through an entire
rotation. Check for tight spots that could 5 If the machine is not sufficiently level, the
cause binding. Readjust if necessary. procedure will fail with the message that the
chassis no not sufficiently level. Move the
machine to a more level location if this occurs.
6 The first calibration is machine pitch. This is
the pitch of the machine from the platform end
to the counterweight end of the machine.
7 Place the digital level onto the swing chassis
bearing plate, which is located to the left of
the fuel tank. Orient the level along the pitch
axis of the machine.
8 Enter the value as seen on the digital level
into the ground control display. If the digital
level is showing a negative value, enter it as a
positive number. Press OK when the value on
the ground control display matches the value
of the digital level (excluding the plus/minus
sign).

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Turntable Rotation Components

9 A graphic of the machine pitch will now be 13 A graphic of the machine roll will now be
shown on the display. By pressing the UP or shown on the display. By pressing the UP and
DOWN buttons, the graphic will change to DOWN buttons, the graphic will change to
show the counterweight being uphill or show whether the operator is on the uphill or
downhill. Select the image that corresponds to downhill side of the machine.. Select the
the current pitch of the machine and press image that corresponds to the current roll of
OK. the machine and press OK.

Turntable Pitch
1 uphill
2 downhill Turntable Roll

10 The next calibration of the machine is the 1 uphill

machine roll. This is the angle of the machine 2 downhill
from side to side.
14 The calibration is now complete.
11 Place the digital level onto the swing chassis
15 Exit the Service Mode.
bearing plate, which is located to the left of
the fuel tank. Orient the level along the roll
axis of the machine.
12 Enter the value as seen on the digital level
onto the ground control display. If the level is
showing a negative value, enter it as a
positive number. Press OK when the value on
the ground control display matches the value
of the digital level sensor (excluding the
plus/minus sign).

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Steer Axle Components

10-1 6 Remove the lug nuts. Remove the tire and

wheel assembly.
Yoke and Drive Hub
7 Remove the hydraulic hose clamp retaining
fastener from the top of the yoke pivot pin.
How to Remove the Yoke and
8 Remove the drive motor mounting fasteners.
Drive Hub Assembly
9 Slide the drive motor shaft out of the drive hub
Note: When removing a hose assembly or fitting, and remove the drive motor from the
the O-ring (if equipped) on the fitting and/or hose machine.
end must be replaced. All connections must be
torqued to specification during installation. Refer to 10 Remove the pin retaining fasteners from the
Specifications, Hydraulic Hose and Fitting Torque upper and lower yoke pivot pins.
Specifications. 11 Support and secure the yoke and drive hub
assembly to a lifting jack.
1 Remove the pin retaining fasteners from both
the steer cylinder and the tie rod cylinder pivot 12 Use a slide hammer to remove the upper
pins. Remove the pins. yoke pivot pin. Use a soft metal drift to drive
the lower yoke pivot pin down and out.
2 Tag, disconnect and plug the hydraulic hoses
from the drive motor. Cap the fittings on the Crushing hazard. The yoke and
drive motor. drive hub assembly could
become unbalanced and fall
Bodily injury hazard. Spraying
when the yoke pivot pins are
hydraulic oil can penetrate and
removed if not properly
burn skin. Loosen hydraulic
supported and secured to the
connections very slowly to allow
lifting jack.
the oil pressure to dissipate
gradually. Do not allow oil to
13 Place the yoke and drive hub assembly on a
squirt or spray.
flat surface with the drive hub facing down.
3 Loosen the wheel lug nuts. Do not remove 14 Remove the drive hub mounting fasteners
them. that attach the drive hub to the yoke. Remove
the yoke from the drive hub. Refer to
4 Block the non-steer wheels, and center a
lifting jack of ample capacity under the steer Specifications, Machine Torque
axle. Specifications.

5 Raise the machine approximately 6 inches / Note: Replace the thrust washer when installing
15 cm and place blocks under the chassis for the yoke and drive hub assembly onto the axle.
support.

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Steer Axle Components

10-2 10-3
Drive Motors Drive Hub

How to Remove a Drive Motor How to Remove a Drive Hub

Component damage hazard. Note: When removing a hose assembly or fitting,
Repairs to the motor should only the O-ring (if equipped) on the fitting and/or hose
be performed by an authorized end must be replaced. All connections must be
dealer. torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
Component damage hazard. The
work area and surfaces where 1 Remove the drive motor. Refer to Repair
this procedure will be performed Procedure, How to Remove a Drive Motor.
must be clean and free of debris
that could get into the hydraulic 2 Loosen the wheel lug nuts. Do not remove
system and cause severe them.
component damage. Dealer 3 Center a lifting jack of ample capacity under
service is recommended. the non-steer axle.
Note: When removing a hose assembly or fitting, 4 Raise the machine approximately 6 inches /
the O-ring (if equipped) on the fitting and/or hose 15 cm and place blocks under the chassis for
end must be replaced. All connections must be support.
torqued to specification during installation. Refer to 5 Remove the wheel lug nuts, then the tire and
Specifications, Hydraulic Hose and Fitting Torque wheel assembly.
Specifications.
6 Place a second lifting jack under the drive hub
1 Remove the drive motor access covers from for support and secure the drive hub to the
both sides of the inner axle. lifting jack.
2 Tag, disconnect and plug the hydraulic hoses 7 Remove the drive hub mounting fasteners
from the drive motor. Cap the fittings on the that attach the drive hub to the axle. Remove
drive motor. the drive hub.
Bodily injury hazard. Spraying Crushing hazard. The drive hub
hydraulic oil can penetrate and could become unbalanced and
burn skin. Loosen hydraulic fall if not properly supported by
connections very slowly to allow an overhead crane or lifting
the oil pressure to dissipate device when removed from the
gradually. Do not allow oil to machine.
squirt or spray.
Note: Do not re-use the drive hub mounting
3 Remove the drive motor mounting fasteners. fasteners. Genie specifications require the use of
4 Slide the drive motor shaft out of the drive new fasteners.
hub, and remove the drive motor from the
machine.

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Generators

11-1 4 Adjust the valve counter-clockwise to increase

the frequency and clockwise to decrease the
Hydraulic Generator frequency, until the correct value is reached
according to the table below.
How to Adjust the Generator ANSI 12 kW Generator 61 Hz +/- 0.5 Hz
Frequency ANSI 3 kW Generator 61 Hz +/- 0.5 Hz
Electrocution/burn hazard. CE / ROW 3 kW Generator 51 Hz +/- 0.5 Hz
Contact with electrically charged 5 Once the correct frequency is set, tighten the
circuits could result in death or jam nut.
serious injury. Remove all rings,
watches and other jewelry.

Note: Perform this procedure with the machine on

a firm, level surface.
Note: This procedure will require a digital
multimeter (DMM) with a frequency counter.
1 Set the multimeter to read frequency and
110 vac and connect the leads to the 110 vac
receptacle.
2 Start the engine and then start the generator.
The engine will go to high idle.
3 Locate the generator manifold on the
turntable tray by the fuel tank and loosen the
jam nut on the needle valve identified in the
illustration.

Generator Manifold
1 needle valve

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Fault Codes

Before Troubleshooting:
Secti on 4 Fault C odes

 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.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and conditions.
qualified on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
serious injury. Remove all rings,
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• 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)

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Control System Fault Codes

Control System
How to Re triev e Con trol Syst em Fa ult Cod es

How to Retrieve Control System

Fault Codes
The machine control system contains two different
types of fault codes
Active Faults: These faults have been detected in
the current operating session. The presence of an
active fault will be reflected by the System Fault
Indicator lights and the alarm.
Logged Faults: The faults contained in the fault log
have occurred in the past and may or may not still
be in effect.
Both faults may be viewed by pressing the Fault
Button above the ground display and navigating to
either the Active Machine Faults screen or the
Machine Fault Log screen. The list of faults will by
shown by fault code and the hour meter of when it
occurred.
The fault lists can be browsed. To learn more
about a fault entry, select it and press OK. A
screen will be shown that describes the fault in
more detail.

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Control System Fault Codes

Contr ol System Fa ult Co des - M odels wit h Revisi on G S oftwa re o r L ower

Models with Revision G Software or Lower

ID Component ID Name Cause Effect Solution
6 Keyswitch 19 Fault Signals Machine will not Verify with a voltmeter that signals switch
C134PLT be functional. properly.
and * With the keyswitch in the Ground
C174GND position, C174GND (WH, TCON J5-12)
from KS1 are should be 12 V and C134PLT (GR/BK,
both HIGH TCON J5-8) should be 0 V.
for at least * With the keyswitch in the Platform
1 second, position, C174GND (WH, TCON J5-12)
causing both should be 0 V and C134PLT (GR/BK,
control TCON J5-8) should be 12 V.
stations to
Cycle power to allow the machine to re-
be selected.
test the fault.
11 Engine Start 19 Stuck ON Toggle Engine start Verify with a voltmeter that the Engine
Toggle at power switch input switch will not Start Toggle Switch (TS2) is operating
Switch up. was detected operate. properly.
as HIGH at * C33STR (BK, PCON J16-3) should be 0
start-up. V with the switch OFF and 12 V with the
switch ON.
Cycle power to allow the machine to re-
test the fault.
12 CAN Bus 29 System not CAN bus Machine will not Verify CAN bus is functional. Pull out
functioning system is not be functional. connector J5 from the TCON and with a
functioning voltmeter set to resistance verify that pins
properly. 3 and 4 on the harness connector
measure between 55 and 65 Ohms and
that neither pin has a short to power or
ground. Check wiring and boom cable
for open or short circuits if resistance
check fails.
13 Jib Up/Down 19 Stuck ON Toggle The Jib Up or Verify with a voltmeter that the Jib
Toggle at power switch input Down functions Up/Down Toggle Switch (TS8) is
Switch up. was detected will not operate. operating properly.
as HIGH at * C43JU (BL, PCON J17-6) should be 0 V
start-up. with the switch OFF and 12 V with the
switch held in the UP position.
* C44JD (BL/BK, PCON J17-8) should be
0 V with the switch OFF and 12 V with the
switch held in the DOWN position.
Cycle power to allow the machine to re-
test the fault.
14 Battery 15 Voltage is Battery Advisory fault. Verify with a voltmeter that the alternator
Voltage low. voltage is too Machine is fully is operating properly.
low while functional. * With the engine running, battery voltage
engine is should be above 12.3 V.
running. * Verify alternator and power wiring.
* Replace alternator if necessary.
* Replace battery if necessary.

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April 2022 Service and Repair Manual

Control System Fault Codes

ID Component ID Name Cause Effect Solution

15 Foot Switch 19 Stuck ON Foot switch Machine will not * Release foot switch and cycle power.
at power input was be functional. * If problem persists, with a voltmeter
up, or detected as verify that C24FS (WH, PCON J12-2) is
timeout HIGH at LOW when foot switch is released and 12
occurred. start-up, or V when held down.
the
footswitch
was held for
too long and
caused the
foot switch
timer to
elapse.
19 APU 12 Solenoid TCON Machine will not Check C27AUX (RD, TCON J3-3) wiring.
Solenoid and output detected that be functional. * With a voltmeter verify that C27AUX
Switch shorted to C27AUX (RD, TCON J3-3) is 0 V when the
V+ circuit is Auxiliary Power toggle switch is OFF and
shorted to 12 12 V when switch is ON.
V. * Verify the terminals of the APU solenoid
15 Solenoid TCON Auxiliary Power have a resistance greater than 5 ohms.
output detected that function will not If not, replace the solenoid.
shorted to C27AUX operate.
GND circuit is
shorted to
GND.
19 Stuck ON Toggle Auxiliary Power Verify with a voltmeter that the AUX
at power switch input function will not Power Switch (TS1) is operating properly.
up. was detected operate from * C47AUX (RD, PCON J17-10) should be
as HIGH at platform. 0 V with the switch OFF and 12 V with the
start-up. switch ON.
Cycle power to allow the machine to re-
test the fault.
20 Primary 12 Joystick Circuit Boom Extend * Leave joystick in neutral position and
Boom voltage too C163PER is and Retract cycle power.
Extend / high. above 4.5 V. functions will not * If fault persists, with a voltmeter check
Retract operate. that C163PER (BL/WH, PCON J18-4) is
Joystick at 2. 5V +/- 0.2 V at startup and does not
15 Joystick Circuit go above 4.5 V or below 0.5 V when fully
voltage too C163PER is stroked in each direction.
low. below 0.5 V. * Replace joystick if voltage check fails.
19 Joystick Circuit
held at C163PER
startup. voltage was
not within the
startup
voltage
range of 2.5
V +/- 0.2 V.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

21 Primary 12 Joystick Circuit Boom Up and * Leave joystick in neutral position and
Boom Up / voltage too C164PUD is Down functions cycle power.
Down high. above 4.5 V. will not operate. * If fault persists, with a voltmeter check
Joystick that C164PUD (RD/WH, PCON J18-3) is
15 Joystick Circuit at 2. 5V +/- 0.2 V at startup and does not
voltage too C164PUD is go above 4.5 V or below 0.5 V when fully
low. below 0.5 V. stroked in each direction.
* Replace joystick if voltage check fails.
19 Joystick Circuit
held at C164PUD
startup. voltage was
not within the
startup
voltage
range of 2.5
V +/- 0.2 V.
22 Primary 12 Circuit TCON Boom Up * With a voltmeter, measure Y22.
Boom Up shorted to detected that function will not Proper resistance should be between 5 -
Valve V+ C1PBU operate. Boom 60 ohms. Replace Y22 if resistance is
circuit is Down will also outside of those values.
shorted to 12 not operate if * Verify wiring for C1PBU (RD, TCON J4-
V. short is to 12 V. 10) and check for open or short circuits.
15 Circuit TCON
shorted to detected that
GND C1PBU
circuit is
shorted to
GND.
23 Primary 12 Circuit TCON Boom Up and * With a voltmeter, measure Y21.
Boom Down shorted to detected that Down functions Proper resistance should be between 5 -
Valve V+ C2PBD will not operate. 60 ohms. Replace Y21 if resistance is
circuit is outside of those values.
shorted to 12 * Verify wiring for C2PBD (RD/BK, TCON
V. J4-9) and check for open or short circuits.
15 Circuit TCON * Verify resistance between Recovery
shorted to detected that Module pins J37-2 and J37-11 is zero
GND C2PBD ohms.
circuit is
shorted to
GND.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

24 Boom Angle 13 No signal No CAN Boom Up, * Verify sensor power P85PWR (GR,
Sensor messages have Extend and TCON J6-7) is at 12 V while the system is
been received by Turntable running.
the TCON from Rotate * Verify the sensor is receiving power.
the Angle functions will Unplug the sensor and verify 12 V across
Sensor. not operate. pins 2 (+) and 1 (-) on the harness
connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure
resistance across harness connector pins
3 and 4. If resistance is not between
55 and 65 ohms, check CAN
wire harnesses.* Replace sensor if
necessary.
17 Invalid Sensor has been Run the boom angle calibration process
calibration replaced and and verify fault is no longer active.
requires
calibration, or
calibration in
memory has
been erased.
19 Out of Sensor disagrees * Run the boom angle calibration process
range with boom and verify fault is no longer active.
position sensed * If fault persists, verify LST3S (C68LS,
by LST3S, or RD, TCON J7-3) operates properly. The
boom exceeded signal should be 12 V when the boom is
the calibrated stowed and 0 V when the boom is up.
minimum or
maximum values.
36 Internal The two internal * Run the boom angle calibration process
check sensing channels and verify fault is no longer active.
inside the Angle * If fault persists, replace the sensor.
Sensor have
registered a
significant
difference.
25 Cable 21 Loose Boom cable Boom Up * Return boom to stowed position as
tension cable tension limit and Extend quickly as possible.
switch LSB2S functions will * Verify both boom cables are properly
indicates that the not operate. tensioned and that LST3S is properly
tension is loose centered in the bracket.
on the boom * Verify LSB2S (C59CNK, BL/WH, TCON
cables. J7-5) operates properly. Signal should
normally by 12 V. If cable tension is
loose, signal should be 0 V.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

26 Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y26.
Boom shorted to that C7PBE Extend and Proper resistance should be between 5 -
Extend Valve V+ circuit is shorted Retract 60 ohms. Replace Y26 if resistance is
to 12 V. functions will outside of those values.
not operate. * Verify wiring for C7PBE (BK, TCON J4-
15 Circuit TCON detected 7) and check for open or short circuits.
shorted to that C7PBE
GND circuit is shorted
to GND.
27 Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y25.
Boom shorted to that C8PBR Extend and Proper resistance should be between 5 -
Retract V+ circuit is shorted Retract 60 ohms. Replace Y25 if resistance is
Valve to 12 V. functions will outside of those values.
not operate. * Verify wiring for C8PBR (BK/WH, TCON
15 Circuit TCON detected J4-8) and check for open or short circuits.
shorted to that C8PBR * Verify resistance between Recovery
GND circuit is shorted Module pins J37-5 and J37-8 is zero
to GND. ohms.

35 Ground 19 Held at Buttons were The function * Release the ground control buttons and
Buttons startup held at system associated cycle power.
start, or are with the * If problem persists, open ground control
shorted on the stuck button box and open the Display Controller
ground control will not access door, being careful to keep water
panel. operate. out. Verify the ribbon cables are
properly seated and dry.
* Re-seat and/or replace ribbon cables if
necessary.
* Replace ground control overlay.
36 Jib Up Valve 12 Circuit PCON detected Jip Up * With a voltmeter, measure Y68.
shorted to that V43JU circuit function will Proper resistance should be between 5 -
V+ is shorted to 12 not operate. 60 ohms. Replace Y68 if resistance is
V. outside of those values.
15 Circuit PCON detected * Verify wiring for V43JU (BL, PCON J12-
shorted to that V43JU circuit 8) and check for open or short circuits.
GND is shorted to
GND.
37 Jib Down 12 Circuit PCON detected Jib Down * With a voltmeter, measure Y69.
Valve shorted to that V44JD circuit function will Proper resistance should be between 5 -
V+ is shorted to 12 not operate. 60 ohms. Replace Y69 if resistance is
V. outside of those values.
15 Circuit PCON detected * Verify wiring for V44JD (BL/BK, PCON
shorted to that V44JD circuit J12-9) and check for open or short
GND is shorted to circuits.
GND.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

41 Turntable 12 Joystick Circuit C165TTR Turntable * Leave joystick in neutral position and
Rotate voltage too is above 4.5 V. Rotate cycle power.
Joystick high. functions will * If fault persists, with a voltmeter check
not operate. that C165TTR (WH/RD, PCON J18-2) is
15 Joystick Circuit C165TTR at 2. 5V +/- 0.2 V at startup and does not
voltage too is below 0.5 V. go above 4.5 V or below 0.5 V when fully
low. stroked in each direction.
* Replace joystick if voltage check fails.
19 Joystick Circuit C165TTR
held at voltage was not
startup. within the startup
voltage range of
2.5 V +/- 0.2 V.
42 Turntable 12 Circuit TCON detected Turntable * With a voltmeter, measure Y24.
Rotate CW shorted to that C4TRL Rotate Proper resistance should be between 5 -
Valve V+ circuit is shorted functions will 60 ohms. Replace Y24 if resistance is
to 12 V. not operate. outside of those values.
15 Circuit TCON detected * Verify wiring for C4TRL (WH, TCON J3-
shorted to that C4TRL 12) and check for open or short circuits.
GND circuit is shorted
to GND.
43 Turntable 12 Circuit TCON detected Turntable * With a voltmeter, measure Y23.
Rotate CCW shorted to that C5TRR Rotate Proper resistance should be between 5 -
Valve V+ circuit is shorted functions will 60 ohms. Replace Y23 if resistance is
to 12 V. not operate. outside of those values.
15 Circuit TCON detected * Verify wiring for C5TRR (WH/BK, TCON
shorted to that C5TRR J3-1) and check for open or short circuits.
GND circuit is shorted
to GND.
44 Drive Enable 19 Stuck ON Toggle switch Drive Enable Verify with a voltmeter that the Drive
Switch at power input was switch will Enable Toggle Switch (TS15) is operating
up. detected as not operate, properly.
HIGH at start-up. possibly * C143DEL (BL/RD, PCON J16-7) should
preventing be 0 V with the switch OFF and 12 V with
drive while the switch held in the ON position.
the turntable Cycle power to allow the machine to re-
is rotated. test the fault.
45 Platform 19 Stuck ON Toggle switch Platform Verify with a voltmeter that the Platform
Level at power input was Level Up or Level Up/Down Toggle Switch (TS9) is
Up/Down up. detected as Down operating properly.
Switch HIGH at start-up. functions * C14PLU (OR, PCON J17-2) should be 0
may not V with the switch OFF and 12 V with the
operate, switch held in the UP position.
depending * C15PLD (OR/BK, PCON J17-3) should
on which be 0 V with the switch OFF and 12 V with
direction the the switch held in the DOWN position.
switch fault
occurred. Cycle power to allow the machine to re-
test the fault.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

46 Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y70.
Rotate CW shorted to that V17PRL Rotate CW Proper resistance should be between 5 -
Valve V+ circuit is shorted function will 60 ohms. Replace Y70 if resistance is
to 12 V. not operate. outside of those values.
15 Circuit PCON detected * Verify wiring for V17PRL (GR, PCON
shorted to that V17PRL J12-5) and check for open or short
GND circuit is shorted circuits.
to GND.
47 Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y71.
Rotate CCW shorted to that V18PRR Rotate CCW Proper resistance should be between 5 -
Valve V+ circuit is shorted function will 60 ohms. Replace Y71 if resistance is
to 12 V. not operate. outside of those values.
15 Circuit PCON detected * Verify wiring for V18PRR (GR/BK,
shorted to that V18PRR PCON J12-4) and check for open or short
GND circuit is shorted circuits.
to GND.
51 Drive 12 Joystick Circuit C160DRV Drive * Leave joystick in neutral position and
Forward / voltage too is above 4.5 V. Forward and cycle power.
Reverse high. Reverse * If fault persists, with a voltmeter check
Joystick functions will that C160DRV (WH/RD, PCON J18-10) is
not operate. at 2. 5V +/- 0.2 V at startup and does not
15 Joystick Circuit C160DRV go above 4.5 V or below 0.5 V when fully
voltage too is below 0.5 V. stroked in each direction.
low. * Replace joystick if voltage check fails.
19 Joystick Circuit C160DRV
held at voltage was not
startup. within the startup
voltage range of
2.5 V +/- 0.2 V.
52 Drive 12 Circuit TCON detected Drive * With a voltmeter, measure Y6. Proper
Forward shorted to that C30FWD Forward, resistance should be between 5 -
Valve V+ circuit is shorted Brake 60 ohms. Replace Y6 if resistance is
to 12 V. Release and outside of those values.
possibly * Verify wiring for C30FWD (WH, TCON
15 Circuit TCON detected
shorted to that C30FWD Engine will J2-6) and check for open or short circuits.
not operate.
GND circuit is shorted
to GND.
53 Drive 12 Circuit TCON detected Drive * With a voltmeter, measure Y5. Proper
Reverse shorted to that C31REV Reverse, resistance should be between 5 -
Valve V+ circuit is shorted Brake 60 ohms. Replace Y5 if resistance is
to 12 V. Release and outside of those values.
15 Circuit TCON detected possibly * Verify wiring for C31REV (WH/BK,
Engine will TCON J2-7) and check for open or short
shorted to that C31REV
GND circuit is shorted not operate. circuits.
to GND.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

54 Brake 12 Circuit TCON detected Machine will * With a voltmeter, measure Y2. Proper
Release shorted to that C32BRK not be resistance should be between 5 -
Valve V+ circuit is shorted functional. 60 ohms. Replace Y2 if resistance is
to 12 V. outside of those values.
15 Circuit TCON detected * Verify wiring for C32BRK (WH/RD,
shorted to that C32BRK TCON J2-9) and check for open or short
GND circuit is shorted circuits.
to GND.
55 Motor Stroke 12 Circuit TCON detected Drive * With a voltmeter, measure Y27.
Valve shorted to that C29MS functions will Proper resistance should be between 5 -
V+ circuit is shorted not operate. 60 ohms. Replace Y27 if resistance is
to 12 V. outside of those values.
15 Circuit TCON detected * Verify wiring for C29MS (RD/WH, TCON
shorted to that C29MS J2-8) and check for open or short circuits.
GND circuit is shorted
to GND.
61 Steer 12 Joystick Circuit C159STD Drive and * Leave joystick in neutral position and
Joystick voltage too or C159STA is steer cycle power.
high. above 4.5 V. functions will * If fault persists, identify which circuit is
not operate. the steer circuit. Check C159STA
15 Joystick Circuit C159STD (BL/WH, PCON J18-11) for a joystick
voltage too or C159STA is steer option. Check C159STD (BL/RD,
low. below 0.5 V. PCON J18-9) for the rocker joystick steer
option. With a voltmeter check that the
19 Joystick Circuit C159STD circuit is at 2. 5V +/- 0.2 V at startup and
held at or C159STA does not go above 4.5 V or below 0.5 V
startup. voltage was not when fully stroked in each direction.
within the startup
* Replace joystick if voltage check fails.
voltage range of
2.5 V +/- 0.2 V.
68 Safety 21 Out of The system has All functions Use Auxiliary Power and the boom retract
Envelope range determined that will not and/or down functions to bring the
Fault the platform operate platform back within the operational
position has except for envelope.
exceeded the the recovery
safety envelope procedure.
boundary.
69 Generator 12 Circuit TCON detected Generator * With a voltmeter, measure Y29.
Control shorted to that C45GEN function will Proper resistance should be between 5 -
Circuit V+ circuit is shorted not operate. 60 ohms. Replace Y29 if resistance is
to 12 V. outside of those values.
15 Circuit TCON detected * Verify wiring for C45GEN (GR/WH,
shorted to that C45GEN TCON J3-2) and check for open or short
GND circuit is shorted circuits.
to GND.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 103
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Control System Fault Codes

ID Component ID Name Cause Effect Solution

71 ESTOP 15 ESTOP Mistmatched ESTOP * Inspect PCON J15 pins 11 and 12 for
Circuit Return signals detected circuit cannot open or short circuits. Using a voltmeter,
circuit on ESTOP complete, set to diode test mode and make sure the
shorted to Return circuits. preventing diode tests ok with the anode at pin
GND Either: machine 12 and cathode at pin 11. If test fails,
* PCON ESTOP functions. replace the PCON.
2 and ESTOP * Inspect TCON J5 pins 11 and 12 for
4 do not match, open or short circuits. Using a voltmeter,
or set to diode test mode and make sure the
* TCON ESTOP diode tests ok with the anode at pin
2 and ESTOP 12 and cathode at pin 11. If test fails,
4 do not match. replace the PCON.
* Check P23RET (BK) for shorts to
ground or power.
16 ESTOP TCON detected Check P56PWR (RD, TCON J5-7) for
Power that P56PWR is open or short circuits. Verify power is
circuit shorted to GND, reaching the P1 ESTOP contact block.
shorted to thereby When ESTOP is pulled out, verify power
GND preventing the is reaching the KS1 keyswitch contact
ESTOP circuit blocks.
from functioning.
21 ESTOP TCON detected * Check for open and short circuits in the
Return that ESTOP boom cable.
circuit Return circuits * Verify that there is low resistance (less
mismatch are not matching, than five ohms) on the cabling between
indicating a fault TCON J5-11 and PCON J15-11 (BK wire
with either in harness and boom cable). An open
P23PWR or circuit between these pins indicates a
P23RET. harness or cable fault.
* Verify that there is low resistance (less
than five ohms) on the cabling between
TCON J5-10 and PCON J15-10 (RD wire
in harness and boom cable). An open
circuit between these pins indicates a
harness or cable fault.
22 ESTOP TCON detected * Using a voltmeter and with the system
Source that ESTOP 1 is turned OFF, check the resistance
circuit is at 12 V but between TCON J5 pins 9 and 10.
shorted to ESTOP 3 is at 0 Replace TCON if resistance is more than
GND V. 5 ohms.
31 ESTOP TCON detected * Check P79PWR (BK, TCON J5-9) and
Source that ESTOP 1 is P23PWR (RD, TCON J5-10) for open or
circuit at 0 V but short circuits.
mismatch ESTOP 3 is at 12
V.

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April 2022 Service and Repair Manual

Control System Fault Codes

ID Component ID Name Cause Effect Solution

72 Contact 36 Switch PCON detected Boom Up * Using a voltmeter, verify that the voltage on
Alarm state that inputs from and Extend C248CA (OR/BK, PCON J12-1) is always the
mismatch SW30 (contact functions will opposite of C247CA (OR, PCON J12-11).
alarm proximity not operate. * Check wiring for open or short circuits.
sensor) are the * Verify SW30 is receiving power and ground
same voltage. by verifying 12 V across C31 pins 1 and 3.
* Replace SW30 if necessary.
75 TCON 34 Incorrect The TCON's Boom Up Reprogram the machine with latest software.
Secondary software secondary and Extend Check http://firmware.genielift.com/ for the
Processor version processor functions will latest software version.
Software software version not operate.
does not match
the system
software revision
level.
76 Platform 13 No signal No CAN Boom Up, * Verify sensor power P26PWR (BK, PCON
Load Sensor messages have Extend and J13-9) is at 12 V while the system is running.
been received by Turntable * Verify 12 V across pins on C27-2 (+) and
the TCON from Rotate C27-3 (-) on the harness connector.
the platform load functions will * Measure resistance across C27 pins 4 and
sensor. not operate. 5 on the harness connector. If resistance is
not between 55 and 65 ohms, check CAN wire
harnesses.
* Replace sensor if necessary.
15 Reverse The sensor has * Make sure the platform is not touching the
loading reported a ground or an overhead obstruction. Cycle
reversed or power and check that fault is no longer
reported.
negative load
condition. This * Perform the platform overload calibration
procedure.
fault is triggered
when the boom * Replace sensor if necessary.
up function has
operated for at
least 10 seconds
and the platform
load is
consistently
detected as less
than -220 lbs.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 105
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Control System Fault Codes

ID Component ID Name Cause Effect Solution

76 17 Invalid The platform load * Run the platform overload calibration process
calibration sensor has no and verify fault is no longer active.
valid calibration
data, either
because the
sensor was
replaced or the
prior calibration
was cleared from
memory or was
unsuccessful.
21 Internal The two internal * Run the platform overload calibration process
check sensing channels and verify fault is no longer active.
inside the Angle * If fault persists, replace the sensor.
Sensor have
registered a
significant
difference.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

77 Platform 21 Internal The secondary All functions * Cycle power and verify condition clears itself.
Overload check platform overload will not * If problem persists, run the platform overload
Detection check detected operate calibration procedure.
overload before except for * If problem persists, replace the sensor.
the operational the recovery
platform overload procedure.
check.
78 Platform 13 Not TCON has not Controls * Verify PCON is receiving power. Check for
Controller detected detected the from the 12 V on J15-2 (+) and J15-1 (-).
(PCON) PCON primary platform will * Verify PCON is receiving ESTOP signals.
processor on the not operate. With ground ESTOP pulled out and keyswitch
communications set to Platform, verify 12 V is reaching PCON
J15-10.
bus.
* Verify CAN bus is functional. Pull out
connector J15 from the PCON and with a
voltmeter set to resistance verify that pins
3 and 4 on the harness connector measure
between 110 and 130 Ohms. Check wiring
and boom cable for open or short circuits if
resistance check fails.
* Replace PCON if necessary.
34 Incorrect PCON software Boom Up Reprogram the machine with latest software.
software revision does not and Extend Check http://firmware.genielift.com/ for the
version match the system functions will latest software version.
revision level. not operate.
36 Secondary TCON has not Controls Reprogram the machine with latest software.
processor detected the from the Check http://firmware.genielift.com/ for the
not PCON secondary platform will latest software version.
detected. processor on the not operate.
communications
bus.
79 Display 13 Not TCON has not Controls * Verify DISCON is operating by checking that
Controller detected detected the from the the display on the front is operating properly.
(DISCON) DISCON on the ground will * If there is no display, try to power up the
communications not operate. DISCON by setting the keyswitch to Ground,
bus. pull out the ground ESTOP and press the
Ground Function Enable button. The display
should start.
* If there is still no display, check DISCON
power on J10 pins 2 (+) and 1 (-).
* If DISCON operates but fault persists, check
the CAN bus wiring. Disconnect J10 and with
a voltmeter set to resistance verify that the
resistance between pins 3 and 4 on the
harness connector are between 55 and
65 ohms. Check CAN wiring if resistance
check fails.
* Replace DISCON if required.
34 Incorrect DISCON Boom Up Reprogram the machine with latest software.
software software revision and Extend Check http://firmware.genielift.com/ for the
version does not match functions will latest software version.
the system not operate.
revision level.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 107
Service and Repair Manual April 2022

Control System Fault Codes

ID Component ID Name Cause Effect Solution

80 Turntable 13 Not The DISCON has Machine will * Verify TCON is receiving power. Check for
Controller detected not detected the not be 12 V on J5-2 (+) and J5-1 (-).
(TCON) TCON on the functional. * Verify TCON is receiving ESTOP signals.
CAN bus. With ground ESTOP pulled out and keyswitch
set to Ground, verify 12 V is reaching TCON
J5-9 and J5-12.
* Verify CAN bus is functional. Pull out
connector J5 from the TCON and with a
voltmeter set to resistance verify that pins
3 and 4 on the harness connector measure
between 55 and 65 Ohms. Check wiring and
boom cable for open or short circuits if
resistance check fails.
* Replace TCON if necessary.
36 Incorrect TCON's Reprogram the machine with latest software.
software secondary Check http://firmware.genielift.com/ for the
version processor latest software version.
software revision
does not match
the system
revision level.
83 Telematics 21 Remote The telematics Machine will Call machine owner to re-enable machine
disable module has not be functions.
locked out functional, or
machine have limited
operation. functionality,
depending
on the
telematics
option.
84 Turntable Tilt 13 Not The tilt sensors Boom Up, * Verify S8O is receiving power. Disconnect
Sensor detected (S8O and/or Extend and sensor connector and verify harness connector
S8S) have not Drive pins 1 and 2 measure 12 V.
been detected on functions will * Verify S8S is receiving power. Disconnect
the CAN bus. not operate. sensor connector and verify harness connector
pins 1 and 2 measure 12 V.
* Verify CAN bus wiring. With a voltmeter set to
resistance, check the resistance between pins
3 and 4 on the harness connector (not the
sensor's integrated connector). Resistance
should be between 55 and 65 ohms. Check
CAN wiring if resistance check fails.
* Replace sensor if required.
17 Invalid The tilt sensors Boom Up Perform the tilt sensor calibration process.
calibration have no valid and Extend
calibration data, functions will
either because not operate.
the sensor(s)
were replaced or
the prior
calibration was
cleared from
memory or was
unsuccessful.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

88 Function 12 Circuit TCON detected Only * With a voltmeter, measure Y74.
Enable Valve shorted to that C155PCE Auxiliary Proper resistance should be between 5 -
V+ circuit is shorted Power is 60 ohms. Replace Y74 if resistance is
to 12 V. available. outside of those values.
15 Circuit TCON detected * Verify wiring for C155PCE (OR/RD,
shorted to that C155PCE TCON J2-5) and check for open or short
GND circuit is shorted circuits.
to GND.
92 Turntable 12 Circuit TCON detected Turntable * With a voltmeter, measure Y13.
Rotate Flow shorted to that C6TRF Rotate Proper resistance should be between 5 -
Valve V+ circuit is shorted functions will 60 ohms. Replace Y13 if resistance is
to 12 V. not operate. outside of those values.
15 Circuit TCON detected * Verify wiring for C6TRF (WH/RD, TCON
shorted to that C6TRF J4-1) and check for open or short circuits.
GND circuit is shorted
to GND.
94 Boom 13 No signal No CAN Boom Up, * Verify sensor power P85PWR (GR, TCON
Length messages have Extend and J6-7) is at 12 V while the system is running.
Sensor been received by Turntable * Verify the sensor is receiving power.
the TCON from Rotate Unplug the sensor and verify 12 V across
the Length functions will pins 1 (+) and 2 (-) on the harness
Sensor. not operate. connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure resistance
across harness connector pins 3 and 4. If
resistance is not between 55 and 65 ohms,
check CAN wire harnesses.
* Replace sensor if necessary.
17 Invalid Sensor has been Run the boom length calibration process
calibration replaced and and verify fault is no longer active.
requires
calibration, or
calibration in
memory has
been erased.
19 Out of Sensor disagrees * Run the boom length calibration process
range with boom and verify fault is no longer active.
position sensed * If fault persists, verify LSB1RS C42LS,
by LSB1RS, or OR/RD, Recovery Module J36-4 and J36-
boom exceeded 9, TCON J7-4) operates properly. The
the calibrated signal should be 12 V when the boom is
minimum or fully retracted and 0 V when the boom is
maximum values. extended at least 24 inches.
36 Internal The two internal * Run the boom length calibration process
check sensing channels and verify fault is no longer active.
inside the Length * If fault persists, replace the sensor.
Sensor have
registered a
significant
difference.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

96 Engine Oil 21 Value too The engine oil Engine may * Stop engine as soon as possible.
Pressure low pressure is not attempt * Verify the engine oil level.
measured as too to start until * Verify the engine oil pump.
low, potentially system
damaging the power cycle. * Power on the machine and start the
engine. At the ground controls display,
engine. Engine may
be turned off view the engine oil pressure gauge for
by control proper operation.
system * If engine uses an analog oil pressure
immediately. sensor, verify it is sending an analog
voltage on C25PSR (WH/BK, TCON J6-
9).
100 Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y20.
Level Up shorted to that V14PLU Level Up and Proper resistance should be between 5 -
Valve V+ circuit is shorted possibly 60 ohms. Replace Y20 if resistance is
to 12 V. Level Down outside of those values.
functions will * Verify wiring for V14PLU (OR, PCON
15 Circuit PCON detected
not operate. J12-6) and check for open or short
shorted to that V14PLU
GND circuit is shorted circuits.
to GND.
101 Platform 12 Circuit PCON detected Platform * With a voltmeter, measure Y19.
Level Down shorted to that V15PLD Level Down Proper resistance should be between 5 -
Valve V+ circuit is shorted and possibly 60 ohms. Replace Y19 if resistance is
to 12 V. Level Up outside of those values.
15 Circuit PCON detected functions will * Verify wiring for V15PLD (OR/BK,
not operate. PCON J12-7) and check for open or short
shorted to that V15PLD
GND circuit is shorted circuits.
to GND.
150 Platform 21 Condition This is a flag that Advisory Power up the machine in service mode
Overload occurred indicates that the condition. and clear the flag in the service menu on
Recovery platform was Machine is the ground control display.
overloaded and fully
that auxiliary functional.
function enable
was used while
overloaded.
152 Primary 12 Circuit TCON detected Boom Up * With a voltmeter, measure Y12.
Boom shorted to that C3PBF and Down Proper resistance should be between 5 -
Up/Down V+ circuit is shorted functions will 60 ohms. Replace Y12 if resistance is
Flow Valve to 12 V. not operate. outside of those values.
15 Circuit TCON detected * Verify wiring for C3PBF (RD/WH, TCON
shorted to that C3PBF J4-4) and check for open or short circuits.
GND circuit is shorted * Verify resistance between Recovery
to GND. Module pins J37-3 and J37-10 is zero
ohms.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

160 Steer Left 12 Circuit TCON detected Steer Left * With a voltmeter, measure Y3. Proper
Valve shorted to that C37STL function will resistance should be between 5 -
V+ circuit is shorted not operate. 60 ohms. Replace Y3 if resistance is
to 12 V. outside of those values.
15 Circuit TCON detected * Verify wiring for C37STL (BL/BK, TCON
shorted to that C37STL J4-11) and check for open or short
GND circuit is shorted circuits.
to GND.
161 Steer Right 12 Circuit TCON detected Steer Right * With a voltmeter, measure Y4. Proper
Valve shorted to that C36STR function will resistance should be between 5 -
V+ circuit is shorted not operate. 60 ohms. Replace Y4 if resistance is
to 12 V. outside of those values.
15 Circuit TCON detected * Verify wiring for C36STR (BL, TCON J4-
shorted to that C36STR 12) and check for open or short circuits.
GND circuit is shorted
to GND.
169 Primary 12 Circuit TCON detected Boom * With a voltmeter, measure Y15.
Boom shorted to that C9PEF Extend and Proper resistance should be between 5 -
Extend / V+ circuit is shorted Retract 60 ohms. Replace Y15 if resistance is
Retract Flow to 12 V. functions will outside of those values.
Valve not operate. * Verify wiring for C9PEF (BK/RD, TCON
15 Circuit TCON detected J4-5) and check for open or short circuits.
shorted to that C9PEF * Verify resistance between Recovery
GND circuit is shorted Module pins J37-6 and J37-7 is zero
to GND. ohms.

174 Platform 19 Stuck ON Toggle switch Platform Verify with a voltmeter that the Platform
Rotate at power input was Rotate Left Rotate Toggle Switch (TS7) is operating
Toggle up. detected as or Right will properly.
Switch HIGH at start-up. not operate, * C17PRL (GR, PCON J16-4) and
depending C18PRR (GR/BK, PCON J17-5) should
on which be 12 V when the switch is pressed in
side of the their respective directions.
switch was Cycle power to allow the machine to re-
faulted. test the fault.
177 Engine 12 Value too The engine Engine will * Stop engine as soon as possible.
Coolant high coolant not restart * Verify the engine coolant level.
Temperature temperature is until machine * Verify the engine coolant/water pump.
measured as too power is
high, potentially cycled. * Power on the machine and start the
engine. At the ground controls display,
damaging the Engine may
engine. stop itself, view the engine temperature gauge for
depending proper operation.
on the * If engine uses an analog temperature
engine sensor, verify it is sending an analog
option. voltage on C26TSR (WH/RD, TCON J6-
10).

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

178 Engine 21 Fault The engine has Machine will * Check the engine fault codes with an
Warning triggered the function as engine diagnostic tool.
Lamp Engine Warning normal.
Lamp condition.
179 Engine Stop 21 Fault The engine has Control * Stop engine immediately.
Lamp triggered the system will * Check the engine fault codes with an
Engine Stop not allow engine diagnostic tool.
Lamp condition. engine
restart until
power cycle.
Engine may
stop itself,
depending
on the
engine
option.
240 Sensor 12 Circuit TCON detected Boom Up * Turn on machine and verify sensor
Power shorted to that P85PWR and Extend power P85PWR (GR, TCON J6-7) is at
P85PWR V+ circuit is shorted functions will 12 V.
to 12 V. not operate. * Inspect wiring for open or shorts circuits.
15 Circuit TCON detected
shorted to that P85PWR
GND circuit is shorted
to GND.
241 Sensor 12 Circuit TCON detected Boom Up * Turn on machine and verify sensor
Power shorted to that P109PWR and Extend power P109PWR (GR/WH, TCON J7-7)
P109PWR V+ circuit is shorted functions will is at 12 V.
to 12 V. not operate. * Inspect wiring for open or shorts circuits.
15 Circuit TCON detected
shorted to that P109PWR
GND circuit is shorted
to GND.
242 Sensor 12 Circuit PCON detected Boom Up * Turn on machine and verify sensor
Power shorted to that P26PWR and Extend power P26PWR (BK, PCON J13-9) is at
P26PWR V+ circuit is shorted functions will 12 V.
to 12 V. not operate. * Inspect wiring for open or shorts circuits.
15 Circuit PCON detected
shorted to that P26PWR
GND circuit is shorted
to GND.
243 Proximity 19 Stuck ON Toggle switch Operator will Verify with a voltmeter that the Proximity
Override at power input was be unable to Override Toggle Switch (TS46) is
Toggle up. detected as override the operating properly.
Switch HIGH at start-up. proximity * C90PRX (RD/BK, PCON J17-9) should
cutoff be 12 V when the switch is pressed.
feature. Cycle power to allow the machine to re-
test the fault.

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Control System Fault Codes

Contr ol System Fa ult Co des - M odels wit h Revisi on H Sof twar e o r High er

Models with Revision H software or higher

ID Component ID Name Cause Effect Solution
1 Engine Can 13 Not Engine CANBUS Disable engine start *Verify with a voltmeter that CAN+
Bus detected CAN+ or CAN- for tier 4F engines and CAN- lines are not shorted.*
shorted to supply. Measure the resistance between
D228CAN+ (YL, TCON J9-3) and
D228CAN- (GR, TCON J9-4); should
be between 55 and 65 ohms.
* D228CAN+ (YL, TCON J9-3) should
be between 1V and 5V.
* D228CAN- (GR, TCON J9-4) should
be between 1V and 5V. Remove
short(s) and cycle power.
7 Engine 21 Fault The engine has Machine will function * Check the engine fault codes with
Warning triggered the as normal. an engine diagnostic tool.
Engine Warning
Lamp condition.
8 Engine Stop 21 Fault The engine has Control system will * Check the engine fault codes with
triggered the not allow engine an engine diagnostic tool.
Engine Stop Lamp restart until power Note: The control system shuts off the
condition. cycle. Engine may engine immediately upon receiving
stop itself, depending this fault from the engine.
on the engine option.
9 Engine 21 Fault Engine is reporting This is a generic Refer to the engine fault codes in the
an engine-specific engine warning fault. menu system.
fault Engine may enforce
power reduction.
Other effects vary
depending on the
fault.
10 Ground 27 Active at Engine start button Engine start is Release engine start button, check
Controls startup held at startup. disabled DISCON overlay and ribbon cable if
Engine Start issue persists.
Switch
11 Platform 27 Active at Platform controls Engine start switch *Verify with a voltmeter that the
Controls startup engine start switch will not operate. Engine Start Toggle Switch (TS2) is
Engine Start active at startup. operating properly.
Switch * C33STR (BK, PCON J16-3) should
be 0 V with the switch OFF and 12 V
with the switch ON.
*Cycle power to allow the machine to
re-test the fault.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

12 Machine 13 Not Machine CANBUS Machine will not be *Verify with a voltmeter that CAN+
CAN Bus detected CAN+ or CAN- functional. and CAN- lines are not shorted.
shorted to supply *Measure the resistance between
D82CAN+ (YL, TCON J5-3) and
D81CAN- (GR, TCON J5-4); should
be between 55 and 65 ohms.
*D81CAN+ (YL, TCON J5-3) should
be between 1V and 5V.
*D81CAN- (GR, TCON J5-4) should
be between 1V and 5V.
*Remove short(s) and cycle power.
13 Jib 27 Active at Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib
Up/Down startup was detected as functions will not Up/Down Toggle Switch (TS8) is
Switch HIGH at start-up. operate. operating properly.
* C43JU (BL, PCON J17-6) should be
0 V with the switch OFF and 12 V with
the switch held in the UP position.
* C44JD (BL/BK, PCON J17-8)
should be 0 V with the switch OFF
and 12 V with the switch held in the
DOWN position.
*Cycle power to allow the machine to
re-test the fault.
15 Foot Switch 27 Active at Foot switch input Machine will not be * Release foot switch and cycle
startup was detected as functional. power.
HIGH at start-up, * If problem persists, with a voltmeter
or the footswitch verify that C24FS (WH, PCON J12-2)
was held for too is LOW when foot switch is released
long and caused and 12 V when held down.
the footswitch timer
to elapse.
28 Timeout Foot switch Machine will not be
depressed too long functional.
without action
17 Aux Pump 11 Shorted TCON detected Machine will not be *Check C27AUX (RD, TCON J3-3)
Coil to that C27AUX functional. wiring. *With a voltmeter verify that
supply circuit is shorted to C27AUX (RD, TCON J3-3) is 0 V
voltage 12V. when the Auxiliary Power toggle
switch is OFF and 12 V when switch
is ON.
*Verify the terminals of the APU
solenoid have a resistance greater
than 5 ohms. If not, replace the
solenoid.
19 Aux Enable 27 Active at Aux button held at Machine will not be Release Aux button, check DISCON
Switch startup startup. functional. overlay and ribbon cable if issue
persists.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

20 Pri Boom 11 Shorted Circuit C163PER is Boom Extend and * Leave joystick in neutral position
Ext / Ret to above 4.5 V. Retract functions will and cycle power.
Joystick supply not operate. * If fault persists, with a voltmeter
voltage check that C163PER (BL/WH, PCON
27 Active Circuit C163PER J18-4) is at 2. 5V +/- 0.2 V at startup
at voltage was not and does not go above 4.5 V or below
startup within the startup 0.5 V when fully stroked in each
voltage range of 2.5 direction.
V +/- 0.2 V. * Replace joystick if voltage check
fails.
Pri Boom 11 Shorted Circuit C164PUD is Boom Up and Down * Leave joystick in neutral position
21 Up / Down to above 4.5 V. functions will not and cycle power.
Joystick supply operate. * If fault persists, with a voltmeter
voltage check that C164PUD (RD/WH, PCON
27 Active Circuit C164PUD J18-3) is at 2. 5V +/- 0.2 V at startup
at voltage was not and does not go above 4.5 V or below
28 0.5 V when fully stroked in each
startup within the startup
voltage range of 2.5 direction.
V +/- 0.2 V. * Replace joystick if voltage check
fails.
22 Pri Boom 11 Shorted TCON detected that Boom Up function will * With a voltmeter, measure Y22.
Up coil to C1PBU circuit is not operate. Boom Proper resistance should be between
supply shorted to 12 V. Down will also not 5 - 60 ohms. Replace Y22 if
voltage operate if short is to resistance is outside of those values.
12 V. * Verify wiring for C1PBU (RD, TCON
J4-10) and check for open or short
circuits.
23 Pri Boom 11 Shorted TCON detected that Boom Up and Down * With a voltmeter, measure Y21.
Down Coil to C2PBD circuit is functions will not Proper resistance should be between
supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y21 if
voltage GND. resistance is outside of those values.
* Verify wiring for C2PBD (RD/BK,
TCON J4-9) and check for open or
short circuits.
* Verify resistance between Recovery
Module pins J37-2 and J37-11 is zero
ohms.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

24 Pri Boom 13 Not No CAN messages Machine limited to * Verify sensor power P85PWR (GR,
Angle detected have been recovery functions TCON J6-7) is at 12 V while the system
received by the is running.
TCON from the * Verify the sensor is receiving power.
Angle Sensor. Unplug the sensor and verify 12 V
across pins 2 (+) and 1 (-) on the
harness connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure
resistance across harness connector
pins 3 and 4. If resistance is not
between 55 and 65 ohms, check CAN
wire harnesses.
* Replace sensor if necessary.
14 Cross The two internal * Calibrate boom angle sensor.
check sensing channels * Check boom angle sensor mount,
failed inside the Angle ensure all fasteners are tightened to
Sensor have spec.
registered a * Replace sensor if issue persists.
significant
difference.
17 Not Sensor has been Run the boom angle calibration
calibrated replaced and process and verify fault is no longer
requires active.
calibration, or
calibration in
memory has been
erased.
19 Value out Min or max boom Machine limited to * Verify that with the boom stowed
of angle out of recovery functions. C68LS (BL, TCON J7-3) is 12V and
expected expected range. that the boom is making contact with
range Crosscheck limit the LST3S limit switch arm.
switch disagrees * Verify that with the boom above
with boom angle 12 degrees C68LS (BL, TCON J7-3) is
sensor. 0V and that the boom is not making
contact with the LST3S limit switch arm.
* Check LST3S limit switch for physical
damage.
* Check bearings in rotary base
housing.
* Calibrate boom angle sensor.
25 Cable 21 Fault Boom cable Boom Up and * Return boom to stowed position as
tension tension limit switch Extend functions will quickly as possible.
LSB2S indicates not operate. * Verify both boom cables are
that the tension is properly tensioned and that LST3S is
loose on the boom properly centered in the bracket.
cables. * Verify LSB2S (C59CNK, BL/WH,
TCON J7-5) operates properly.
Signal should normally by 12 V. If
cable tension is loose, signal should
be 0 V.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

26 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y26.
Ext Coil to C7PBE circuit is Retract functions will Proper resistance should be between
supply shorted to 12 V or not operate. 5 - 60 ohms. Replace Y26 if
voltage GND. resistance is outside of those values.
* Verify wiring for C7PBE (BK, TCON
J4-7) and check for open or short
circuits.
27 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y25.
Ret Coil to C8PBR circuit is Retract functions will Proper resistance should be between
supply shorted to 12 V or not operate. 5 - 60 ohms. Replace Y25 if
voltage GND. resistance is outside of those values.
* Verify wiring for C8PBR (BK/WH,
TCON J4-8) and check for open or
short circuits.
* Verify resistance between Recovery
Module pins J37-5 and J37-8 is zero
ohms.
35 Ground 27 Active Buttons were held The function *Release the ground control buttons
Control at at system start, or associated with the and cycle power.
Button startup are shorted on the stuck button will not *If problem persists, open ground
ground control operate. control box and open the Display
panel. Controller access door, being careful
to keep water out. Verify the ribbon
cables are properly seated and dry.
*Re-seat and/or replace ribbon cables
if necessary.
*Replace ground control overlay.
36 Jib Up Coil 11 Shorted PCON detected that Jip Up function will * With a voltmeter, measure Y68.
to V43JU circuit is not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y68 if
voltage GND. resistance is outside of those values.
* Verify wiring for V43JU (BL, PCON
J12-8) and check for open or short
circuits.
37 Jib Down 11 Shorted PCON detected that Jib Down function will * With a voltmeter, measure Y69.
Coil to V44JD circuit is not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y69 if
voltage GND. resistance is outside of those values.
* Verify wiring for V44JD (BL/BK,
PCON J12-9) and check for open or
short circuits.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

40 Jib Select 11 Shorted PCON detected Jib and platform *With a voltmeter, measure Y18.
Coil to V18PRR is short to functions will not Proper resistance should be between
supply supply operate 5 - 60 ohms. Replace Y18 if
voltage resistance is outside of those values.
*Verify wiring for V18PRR (GR/BK,
PCON J12-4) and check for short
circuits.
41 Turntable 11 Shorted Circuit C165TTR is Turntable Rotate * Leave joystick in neutral position
Rotate to above 4.5 V. functions will not and cycle power.
Joystick supply operate. * If fault persists, with a voltmeter
voltage check that C165TTR (WH/RD, PCON
27 Active Circuit C165TTR J18-2) is at 2. 5V +/- 0.2 V at startup
at voltage was not and does not go above 4.5 V or below
startup within the startup 0.5 V when fully stroked in each
voltage range of 2.5 direction.
V +/- 0.2 V. * Replace joystick if voltage check
fails.

42 Turntable 11 Shorted TCON detected that Turntable Rotate * With a voltmeter, measure Y24.
Rotate CW to C4TRL circuit is functions will not Proper resistance should be between
Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y24 if
voltage GND. resistance is outside of those values.
* Verify wiring for C4TRL (WH, TCON
J3-12) and check for open or short
circuits.
43 Turntable 11 Shorted TCON detected that Turntable Rotate * With a voltmeter, measure Y23.
Rotate to C5TRR circuit is functions will not Proper resistance should be between
CCW Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y23 if
voltage GND. resistance is outside of those values.
* Verify wiring for C5TRR (WH/BK,
TCON J3-1) and check for open or
short circuits.
44 Drive 27 Active Toggle switch input Drive Enable switch *Verify with a voltmeter that the Drive
Enable at was detected as will not operate, Enable Toggle Switch (TS15) is
Toggle startup HIGH at start-up. possibly preventing operating properly.
Switch drive while the * C143DEL (BL/RD, PCON J16-7)
turntable is rotated. should be 0 V with the switch OFF
and 12 V with the switch held in the
ON position.
*Cycle power to allow the machine to
re-test the fault.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

45 Platform 27 Active Toggle switch input Platform Level Up or *Verify with a voltmeter that the
Level at was detected as Down functions may Platform Level Up/Down Toggle
Toggle startup HIGH at start-up. not operate, Switch (TS9) is operating properly.
Switch depending on which * C14PLU (OR, PCON J17-2) should
direction the switch be 0 V with the switch OFF and 12 V
fault occurred. with the switch held in the UP
position.
* C15PLD (OR/BK, PCON J17-3)
should be 0 V with the switch OFF
and 12 V with the switch held in the
DOWN position.
*Cycle power to allow the machine to
re-test the fault.
46 Platform 11 Shorted PCON detected that Platform Rotate CW * With a voltmeter, measure Y70.
Rotate CW to V17PRL circuit is function will not Proper resistance should be between
Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y70 if
voltage GND. resistance is outside of those values.
* Verify wiring for V17PRL (GR,
PCON J12-5) and check for open or
short circuits.
47 Platform 11 Shorted PCON detected that Platform Rotate CCW * With a voltmeter, measure Y71.
Rotate to V18PRR circuit is function will not Proper resistance should be between
CCW Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y71 if
voltage GND. resistance is outside of those values.
* Verify wiring for V18PRR (GR/BK,
PCON J12-4) and check for open or
short circuits.
51 Drive 11 Shorted Circuit C160DRV is Drive Forward and * Leave joystick in neutral position
Joystick to above 4.5 V. Reverse functions and cycle power.
supply will not operate. * If fault persists, with a voltmeter
voltage check that C160DRV (WH/RD, PCON
27 Active Circuit C160DRV J18-10) is at 2. 5V +/- 0.2 V at startup
at voltage was not and does not go above 4.5 V or below
startup within the startup 0.5 V when fully stroked in each
voltage range of 2.5 direction.
V +/- 0.2 V. * Replace joystick if voltage check
fails.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

52 Drive 11 Shorted TCON detected Drive Forward, Brake * With a voltmeter, measure Y6.
Forward to that C30FWD Release and possibly Proper resistance should be between
Pump Coil supply circuit is shorted to Engine will not 5 - 60 ohms. Replace Y6 if resistance
voltage 12 V or GND. operate. is outside of those values.
* Verify wiring for C30FWD (WH,
TCON J2-6) and check for open or
short circuits.
53 Drive 11 Shorted TCON detected Drive Reverse, Brake * With a voltmeter, measure Y5.
Reverse to that C31REV Release and possibly Proper resistance should be between
Pump Coil supply circuit is shorted to Engine will not 5 - 60 ohms. Replace Y5 if resistance
voltage 12 V or GND. operate. is outside of those values.
* Verify wiring for C31REV (WH/BK,
TCON J2-7) and check for open or
short circuits.
54 Brake 11 Shorted TCON detected Machine will not be * With a voltmeter, measure Y2.
Release to that C32BRK functional. Proper resistance should be between
Coil supply circuit is shorted to 5 - 60 ohms. Replace Y2 if resistance
voltage 12 V or GND. is outside of those values.
* Verify wiring for C32BRK (WH/RD,
TCON J2-9) and check for open or
short circuits.
55 High Drive 11 Shorted TCON detected Drive functions will * With a voltmeter, measure Y27.
Speed Coil to that C29MS circuit not operate. Proper resistance should be between
supply is shorted to 12 V 5 - 60 ohms. Replace Y27 if
voltage or GND. resistance is outside of those values.
* Verify wiring for C29MS (RD/WH,
TCON J2-8) and check for open or
short circuits.
56 Telematics 13 Not M7 telematics Information only Cycle power. If fault persists, check
Device detected device not telematics ready connector wiring. If
detected. there are no wiring issues replace M7.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

61 Steer 11 Shorted Circuit C159STD or Drive and steer * Leave joystick in neutral position
Joystick to C159STA is above functions will not and cycle power.
supply 4.5 V. operate. * If fault persists, identify which circuit
voltage is the steer circuit. Check C159STA
27 Active Circuit C159STD or (BL/WH, PCON J18-11) for a joystick
at C159STA voltage steer option. Check C159STD
startup was not within the (BL/RD, PCON J18-9) for the rocker
startup voltage joystick steer option. With a voltmeter
range of 2.5 V +/- check that the circuit is at 2. 5V +/-
0.2 V. 0.2 V at startup and does not go
above 4.5 V or below 0.5 V when fully
stroked in each direction.
* Replace joystick if voltage check
fails.

62 Prox 27 Active Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib
Override at was detected as functions will not Up/Down Toggle Switch (TS8) is
Togggle startup HIGH at start-up. operate. operating properly.
Switch * C43JU (BL, PCON J17-6) should be
0 V with the switch OFF and 12 V with
the switch held in the UP position.
* C44JD (BL/BK, PCON J17-8)
should be 0 V with the switch OFF
and 12 V with the switch held in the
DOWN position.
Cycle power to allow the machine to
re-test the fault.
68 Ground 27 Active Button was held at The function * Release the ground control buttons
Function at system start, or is associated with the and cycle power. * If problem persists,
Enable startup shorted on the stuck button will not open ground control box and open the
Button ground control operate. Display Controller access door, being
panel. careful to keep water out. Verify the
ribbon cables are properly seated and
dry.
* Re-seat and/or replace ribbon
cables if necessary.
* Replace ground control overlay.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

69 AC 11 Shorted TCON detected that Generator function * With a voltmeter, measure Y29.
Generator to C45GEN circuit is will not operate. Proper resistance should be between
Output supply shorted to 12 V. 5 - 60 ohms. Replace Y29 if
voltage resistance is outside of those values.
* Verify wiring for C45GEN (GR/WH,
TCON J3-2) and check for open or
short circuits.
72 Lift Guard 14 Cross PCON detected that Boom Up and Extend * Using a voltmeter, verify that the
Contact check inputs from SW30 functions will not voltage on C248CA (OR/BK, PCON
Alarm failed (contact alarm operate. J12-1) is always the opposite of
Switch proximity sensor) C247CA (OR, PCON J12-11).
are the same * Check wiring for open or short
voltage. circuits.
* Verify SW30 is receiving power and
ground by verifying 12 V across
C31 pins 1 and 3.
* Replace SW30 if necessary.
21 Fault
73 Engine Oil 12 Sensor Engine oil pressure Engine will not * With a voltmeter, check that
Pressure value sender is shorted to operate. C25PSR ( WH/BK, TCON J6P9) is
too 12V. not shorted to 12V and voltage is
high between 0.1-11.5V
* Replace sender if necessary
24 Too low The engine oil Engine may not * Stop engine as soon as possible.
pressure is attempt to start until * Verify the engine oil level.
measured as too system power cycle. * Verify the engine oil pump.
low, potentially Engine may be
damaging the turned off by control * Power on the machine and start the
engine. At the ground controls
engine. system immediately.
display, view the engine oil pressure
gauge for proper operation.
* If engine uses an analog oil
pressure sensor, verify it is sending
an analog voltage on C25PSR
(WH/BK, TCON J6-9).

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

74 Engine 15 Sensor Engine Engine will not * With a voltmeter, check that
Temperature value too temperature operate C26TSR ( WH/RD, TCON J6P8) is
low sensor is shorted not shorted to ground and voltage is
to ground between 0.1-11.5V
* Replace sensor if necessary
23 Too high The engine coolant Engine will not * Stop engine as soon as possible.
temperature is restart until machine * Verify the engine coolant level.
measured as too power is cycled. * Verify the engine coolant/water pump.
high, potentially Engine may stop * Power on the machine and start the
damaging the itself, depending on engine. At the ground controls display,
engine. the engine option. view the engine temperature gauge for
proper operation.
* If engine uses an analog temperature
sensor, verify it is sending an analog
voltage on C26TSR (WH/RD, TCON
J6-10).
76 Platform 13 Not Load sensor not Boom Up, Extend * Verify sensor power P26PWR (BK,
Load Sensor detected detected on the and Turntable Rotate PCON J13-9) is at 12 V while the
communications functions will not system is running.
bus. operate. * Verify 12 V across pins on C27-2
(+) and C27-3 (-) on the harness
connector.
* Measure resistance across
C27 pins 4 and 5 on the harness
connector. If resistance is not
between 55 and 65 ohms, check
CAN wire harnesses.
* Replace sensor if necessary.
14 Cross The two internal Boom Up, Extend * Check that the load sensor is
check sensing channels and Turntable Rotate mounted correctly and all fasteners
failed inside the Load functions will not are tightened to spec.
Sensor have operate. * Calibrate load sensor.
registered a * Replace sensor if issue persists.
significant
difference.
15 Value to Platform load Machine limited to * Make sure the platform is not
low sensor out of recovery functions touching the ground or an overhead
calibration obstruction. Cycle power and check
that fault is no longer reported.
* Perform the platform overload
calibration procedure.
* Replace sensor if necessary.
17 Not Platform load * Calibrate load sensor.
calibrated sensor out of * Replace sensor if issue persists.
calibration
21 Fault Platform load * Check that the load sensor is
sensor out of mounted correctly and all fasteners
calibration are tightened to spec.
* Calibrate load sensor.
* Replace sensor if issue persists.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

78 Platform 13 Not TCON has not Controls from the * Verify PCON is receiving power.
Controller detected detected the platform will not Check for 12 V on J15-2 (+) and J15-
(PCON) PCON primary operate. 1 (-).
processor on the * Verify PCON is receiving ESTOP
communications signals. With ground ESTOP pulled
bus. out and keyswitch set to Platform,
verify 12 V is reaching PCON J15-10.
* Verify CAN bus is functional. Pull
out connector J15 from the PCON
and with a voltmeter set to resistance
verify that pins 3 and 4 on the
harness connector measure between
110 and 130 Ohms. Check wiring and
boom cable for open or short circuits
if resistance check fails.
* Replace PCON if necessary.
29 Software PCON software is Machine limited to Download latest software from
version out of date. recovery functions firmware site and update machine.
mismatch
79 Display 13 Not TCON has not Controls from the * Verify DISCON is operating by
Controller detected detected the ground will not checking that the display on the front
(DISCON) DISCON on the operate. is operating properly.
communications * If there is no display, try to power up
bus. the DISCON by setting the keyswitch
to Ground, pull out the ground
ESTOP and press the Ground
Function Enable button. The display
should start.
* If there is still no display, check
DISCON power on J10 pins 2 (+) and
1 (-).
* If DISCON operates but fault
persists, check the CAN bus wiring.
Disconnect J10 and with a voltmeter
set to resistance verify that the
resistance between pins 3 and 4 on
the harness connector are between
55 and 65 ohms. Check CAN wiring if
resistance check fails.
* Replace DISCON if required.
29 Software DISCON software Machine limited to Download latest software from
version is out of date. recovery functions firmware site and update machine.
mismatch

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

80 Turntable 13 Not The DISCON has Machine limited to * Verify TCON is receiving power.
Controller detected not detected the recovery functions Check for 12 V on J5-2 (+) and J5-1
(TCON) TCON on the CAN (-).
bus. * Verify TCON is receiving ESTOP
signals. With ground ESTOP pulled
out and keyswitch set to Ground,
verify 12 V is reaching TCON J5-
9 and J5-12.
* Verify CAN bus is functional. Pull
out connector J5 from the TCON and
with a voltmeter set to resistance
verify that pins 3 and 4 on the
harness connector measure between
55 and 65 Ohms. Check wiring and
boom cable for open or short circuits
if resistance check fails.
* Replace TCON if necessary.
29 Software TCON software is Download latest software from
version out of date firmware site and update machine.
mismatch
82 Overload 21 Recovery This is a flag that Advisory condition. Power up the machine in service
indicates that the Machine is fully mode and clear the flag in the service
platform was functional. menu on the ground control display.
overloaded and
that auxiliary
function enable
was used while
overloaded.
83 Disabled 21 By owner The telematics Machine will not be Call machine owner to re-enable
module has locked functional, or have machine functions.
out machine limited functionality,
operation. depending on the
telematics option.
84 Chassis 13 Not The tilt sensor Boom Up, Extend * Verify S8O is receiving power.
Angle detected S80 has not been and Drive functions Disconnect sensor connector and
detected on the will not operate. verify harness connector pins 1 and
CAN bus. 2 measure 12 V.
* Verify CAN bus wiring. With a
voltmeter set to resistance, check the
resistance between pins 3 and 4 on
the harness connector (not the
sensor's integrated connector).
Resistance should be between
55 and 65 ohms. Check CAN wiring if
resistance check fails.
* Replace sensor if required.
17 Not Tilt sensor not Machine limited to Calibrate tilt sensor.
calibrated calibrated recovery functions

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

85 Chassis 13 Not Tilt sensor not Machine limited to Calibrate tilt sensor.
Angle detected calibrated recovery functions
Safety
88 Function 11 Shorted TCON detected Only Auxiliary Power * With a voltmeter, measure Y74.
Enable Coil to that C155PCE is available. Proper resistance should be between
supply circuit is shorted to 5 - 60 ohms. Replace Y74 if
voltage 12 V or GND. resistance is outside of those values.
* Verify wiring for C155PCE (OR/RD,
TCON J2-5) and check for open or
short circuits.
89 Fuel Level 12 Value to Fuel sensor Information only With a voltmeter, check voltage on
Sensor high shorted to B+ C65FLI (BL/WH, TCON J7-11). The
voltage should be between 1V and
5V. Check for shorts to B+.
15 Value to Fuel sensor With a voltmeter, check voltage on
low shorted to GND C65FLI (BL/WH, TCON J7-11). The
voltage should be between 1V and
5V. Check for shorts to ground.
92 Turntable 11 Shorted TCON detected Turntable Rotate * With a voltmeter, measure Y13.
Rotate Flow to that C6TRF circuit functions will not Proper resistance should be between
Coil supply is shorted to 12 V operate. 5 - 60 ohms. Replace Y13 if
voltage or GND. resistance is outside of those values.
* Verify wiring for C6TRF (WH/RD,
TCON J4-1) and check for open or
short circuits.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

94 Primary 13 Not No CAN messages Boom Up, Extend * Verify sensor power P85PWR (GR,
Boom detected have been and Turntable Rotate TCON J6-7) is at 12 V while the
Length received by the functions will not system is running.
TCON from the operate. * Verify the sensor is receiving power.
Length Sensor. Unplug the sensor and verify 12 V
across pins 1 (+) and 2 (-) on the
harness connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure
resistance across harness connector
pins 3 and 4. If resistance is not
between 55 and 65 ohms, check
CAN wire harnesses.
* Replace sensor if necessary.
14 Cross The two internal Machine limited to * Ensure that the boom angle sensor
check sensing channels recovery functions cord is hooked up to the bracket on
failed inside the Length the boom and that the cord extends
Sensor have and retracts smoothly.
registered a * Calibrate boom length sensor.
significant * Replace sensor if necessary.
difference.
17 Not Boom length Calibrate boom length sensor.
calibrated sensor not
calibrated.
19 Value out Min or max length * Verify that with the boom retracted
of out of expected C24LS (OR/RD TCON J7-4) is 12V
expected range. and that the boom is making contact
range Crosscheck limit with the LSB1RS limit switch arm.
switch disagrees * Verify that when the boom is
with length sensor. extended at least 10" C24LS
(OR/RD, TCON J7-4) is OV and that
the boom is not making contact with
the LSB1RS limit switch arm.
* Check LSB1RS limit switch for
physical damage.
* Calibrate length sensor.
99 Primary 11 Shorted TCON detected Boom Extend and * With a voltmeter, measure Y15.
Boom to supply that C9PEF circuit Retract functions will Proper resistance should be between
Extend / voltage is shorted to 12 V not operate. 5 - 60 ohms. Replace Y15 if
Retract or GND. resistance is outside of those values.
Flow Coil * Verify wiring for C9PEF (BK/RD,
TCON J4-5) and check for open or
short circuits.
* Verify resistance between Recovery
Module pins J37-6 and J37-7 is zero
ohms.

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Service and Repair Manual April 2022

Control System Fault Codes

ID Component ID Name Cause Effect Solution

100 Platform 11 Shorted PCON detected Platform Level Up * With a voltmeter, measure Y20.
Level Up Coil to supply that V14PLU circuit and possibly Level Proper resistance should be between
voltage is shorted to 12 V Down functions will 5 - 60 ohms. Replace Y20 if resistance
or GND. not operate. is outside of those values.
* Verify wiring for V14PLU (OR, PCON
J12-6) and check for open or short
circuits.
101 Platform 11 Shorted PCON detected Platform Level * With a voltmeter, measure Y19.
Level Down to supply that V15PLD circuit Down and possibly Proper resistance should be between
Coil voltage is shorted to 12 V Level Up functions 5 - 60 ohms. Replace Y19 if resistance
or GND. will not operate. is outside of those values.
* Verify wiring for V15PLD (OR/BK,
PCON J12-7) and check for open or
short circuits.
110 Platform 27 Active at Toggle switch input Platform Rotate Left *Verify with a voltmeter that the
Rotate startup was detected as or Right will not Platform Rotate Toggle Switch (TS7)
Toggle HIGH at start-up. operate, depending is operating properly.
Switch @PC on which side of the * C17PRL (GR, PCON J16-4) and
switch was faulted. C18PRR (GR/BK, PCON J17-5)
should be 12 V when the switch is
pressed in their respective directions.
*Cycle power to allow the machine to
re-test the fault.
116 Model 31 Setup Machine is not fully Machine will not Navigate to Settings -> Model
Configuration invalid. configured or set to operate. Configuration and ensure model,
wrong model. engine, tires, and region are set and
correct.
141 Boom 10 Safety The system has All functions will not Use Auxiliary Power and the boom
Envelope determined that operate except for retract and/or down functions to bring
Exceeded the platform the recovery the platform back within the
position has procedure. operational envelope.
exceeded the
safety envelope
boundary.
150 Sensor 11 Shorted PCON detected Boom Up and * Turn on machine and verify sensor
Power to supply that P26PWR Extend functions power P26PWR (BK, PCON J13-9) is
P26PWR voltage circuit is shorted to will not operate. at 12 V.
12 V or GND. * Inspect wiring for open or shorts
circuits.
152 Primary 11 Shorted TCON detected Boom Up and Down * With a voltmeter, measure Y12.
Boom to supply that C3PBF circuit functions will not Proper resistance should be between
Up/Down voltage is shorted to 12 V operate. 5 - 60 ohms. Replace Y12 if resistance
Flow Coil or GND. is outside of those values.
* Verify wiring for C3PBF (RD/WH,
TCON J4-4) and check for open or
short circuits.
* Verify resistance between Recovery
Module pins J37-3 and J37-10 is zero
ohms.

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Control System Fault Codes

ID Component ID Name Cause Effect Solution

160 LF Steer (L 11 Shorted TCON detected Steer Left function * With a voltmeter, measure Y3.
or R) Coil to that C37STL circuit will not operate. Proper resistance should be between
supply is shorted to 12 V 5 - 60 ohms. Replace Y3 if resistance
voltage or GND. is outside of those values.
* Verify wiring for C37STL (BL/BK,
TCON J4-11) and check for open or
short circuits.
161 RF Steer (L 11 Shorted TCON detected Steer Right function * With a voltmeter, measure Y4.
or R) Coil to that C36STR will not operate. Proper resistance should be between
supply circuit is shorted to 5 - 60 ohms. Replace Y4 if resistance
voltage 12 V or GND. is outside of those values.
* Verify wiring for C36STR (BL,
TCON J4-12) and check for open or
short circuits.
185 ESTOP 11 Shorted TCON detected ESTOP circuit * Using a voltmeter and with the
Source to that ESTOP 1 is at cannot complete, system turned OFF, check the
supply 12 V but ESTOP preventing machine resistance between TCON J5 pins
voltage 3 is at 0 V. functions. 9 and 10. Replace TCON if
resistance is more than 5 ohms.
* Check P79PWR (BK, TCON J5-9)
and P23PWR (RD, TCON J5-10) for
open or short circuits.
186 ESTOP 11 Shorted Mismatched ESTOP circuit * Inspect PCON J15 pins 11 and
Return to signals detected cannot complete, 12 for open or short circuits. Using a
supply on ESTOP Return preventing machine voltmeter, set to diode test mode and
voltage circuits. Either: functions. make sure the diode tests ok with the
* PCON ESTOP anode at pin 12 and cathode at pin
2 and ESTOP 4 do 11. If test fails, replace the PCON.
not match, or * Inspect TCON J5 pins 11 and 12 for
* TCON ESTOP open or short circuits. Using a
2 and ESTOP 4 do voltmeter, set to diode test mode and
not match. make sure the diode tests ok with the
anode at pin 12 and cathode at pin
11. If test fails, replace the PCON.
* Check P23RET (BK) for shorts to
ground or power.
187 TCON Bank 13 Not Power plug not TCON outputs will * Check J1, Bank Power, on TCON is
power detected connected or not turn on. making a good connection.
loose. * Verify pin 1 is grounded
Internal TCON * Verify pins 2, 3, 4 are 12V
component failure. * Replace TCON
188 PCON Bank 13 Not Power plug not PCON outputs will * Check J11, Bank Power, on PCON
power detected connected or not turn on. is making a good connection.
loose. * Verify pin 1 is grounded
Internal TCON * Verify pins 3, 4 are 12V
component failure. * Replace PCON

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Engine Fault Codes

Engine Fault Codes

Some engine options have their own Electronic
Control Module that contains more detailed fault
information that is specific to the engine. This
system can be accessed by using the engine's
dedicated service tool. This service tool may be
connected to the Engine Service Connector,
located to the right of the battery tray.
The ground controls display and fault menu will
show basic engine faults, such as low oil pressure
and high coolant temperature. It will also show
faults for engine warning and engine stop, which
correspond to the engine warning lamp and engine
stop lamp indicators that the engine may require.
More advanced faults specific to the engine will
require the use of a corresponding engine service
tool.

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 51 11 1231 Actuator error EGR-Valve;
KWP = Keyword Protocol Power stage over temp due to
SPN FMI KWP Description high current

51 3 1019 EGR-Valve, short circuit to 51 12 1018 Actuator EGR-Valve;

battery powerstage over temperature

51 3 1024 Position sensor error of actuator 51 12 1021 Mechanical actuator defect

EGR-Valve; signal range check EGR-Valve
high 51 12 1225 Actuator EGR-Valve; over
51 3 1226 EGR-Valve; short circuit to temperature
battery (A02) 94 1 474 Low fuel pressure; warning
51 3 1227 EGR-Valve; short circuit to threshold exceeded
battery (A67) 94 1 475 Low fuel pressure; shut off
51 4 1020 EGR-Valve; short circuit to threshold exceeded
ground 94 3 472 Sensor error low fuel pressure;
51 4 1025 Position sensor error actuator signal range check high
EGR-Valve; signal range check 94 4 473 Sensor error low fuel pressure;
low signal range check low
51 4 1228 EGR-Valve; short circuit to 97 3 464 Sensor error water in fuel; signal
ground (A02) range check high
51 4 1229 EGR-Valve; short circuit to 97 4 465 Sensor error water in fuel; signal
ground (A67) range check low
1 4 1232 Actuator error EGR-Valve; 97 12 1157 Water in fuel level prefilter;
Voltage below threshold maximum value exceeded
51 5 1015 Actuator error EGR-Valve; signal 100 0 734 High oil pressure; warning
range check low threshold exceeded
51 5 1017 Actuator EGR-Valve; open load 100 0 735 High oil pressure; shut off
51 5 1023 Actuator error EGR-Valve; signal threshold exceeded
range check low 100 1 736 Low oil pressure; warning
51 5 1223 Actuator EGR-Valve; open load threshold exceeded

51 6 1014 Actuator error EGR-Valve; signal 100 1 737 Low oil pressure; shut off
range check high threshold exceeded

51 6 1022 Actuator error EGR-Valve; signal 100 3 732 Sensor error oil pressure; signal
range check high range check high

51 6 1224 Actuator EGR-Valve; over 100 4 733 Sensor error oil pressure sensor;
current signal range check low

51 6 1230 Actuator error EGR-Valve; 102 2 88 Charged air pressure above

Overload by short-circuit warning threshold

51 7 1016 Actuator position for EGR-Valve 102 2 89 Charged air pressure above shut
not plausible off threshold
102 4 777 Sensor error charged air press.;
signal range check low

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 168 0 1180 Physical range check high for
KWP = Keyword Protocol battery voltage
SPN FMI KWP Description 168 1 1181 Physical range check low for
105 0 996 High charged air cooler battery voltage
temperature; warning threshold 168 2 47 High battery voltage; warning
exceeded threshold exceeded
105 0 997 High charged air cooler 168 2 48 Low battery voltage; warning
temperature; shut off threshold threshold exceeded
exceeded
168 3 45 Sensor error battery voltage;
105 3 994 Sensor error charged air signal range check high
temperature; signal range check
high 168 4 46 Sensor error battery voltage;
signal range check low
105 4 995 Sensor error charged air
temperature; signal range check 171 3 417 Sensor error environment
low temperature; signal range check
high
108 3 412 Sensor error ambient air press.;
signal range check high 171 4 418 Sensor error environment
temperature; signal range check
108 4 413 Sensor error ambient air press.; low
signal range check low
172 0 1182 Physical range check high for
110 0 98 High coolant temperature; intake air temperature
warning threshold exceeded
172 1 1183 Physical range check low for
110 0 99 High coolant temperature; shut intake air temperature
off threshold exceeded
172 2 9 Sensor ambient air temperature;
110 3 96 Sensor error coolant temp.; plausibility error
signal range check high
172 2 983 Intake air sensor; plausibility
110 4 97 Sensor error coolant temp.; error
signal range check low
172 3 981 Sensor error intake air; signal
111 1 101 Coolant level too low range check high
132 11 1 Air flow sensor load correction 172 4 982 Sensor error intake air sensor;
factor exceeding the maximum signal range check low
drift limit; plausibility error
174 0 481 High low fuel temperature;
132 11 2 Air flow sensor load correction warning threshold exceeded
factor exceeding drift limit;
plausibility error 174 0 482 High Low fuel temperature; shut
off threshold exceeded
132 11 3 Air flow sensor low idle
correction factor exceeding the 175 0 740 Physical range check high for oil
maximum drift limit temperature

132 11 4 Air flow sensor load correction 175 0 745 High oil temperature; warning
factor exceeding the maximum threshold exceeded
drift limit 175 0 746 High oil temperature; shut off
157 3 877 Sensor error rail pressure; signal threshold exceeded
range check high 175 1 741 Physical range check low for oil
157 4 878 Sensor error rail pressure; signal temperature
range check low

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 412 3 1007 Sensor error EGR cooler
KWP = Keyword Protocol downstream temperature; signal
SPN FMI KWP Description range check high

175 2 738 Sensor oil temperature; 412 4 1008 Sensor error EGR cooler
plausibility error downstream temperature; signal
range check low
175 2 739 Sensor oil temperature;
plausibility error oil temperature 520 9 306 Timeout Error of CAN-Receive-
too high Frame TSC1TR; Setpoint

175 3 743 Sensor error oil temperature; 597 2 49 Break lever mainswitch and
signal range check high break lever redundancy switch
status not plausible
175 4 744 Sensor error oil temperature;
signal range check low 624 3 971 SVS lamp; short circuit to batt.

190 0 389 Engine speed above warning 624 4 972 SVS lamp; short circuit to grd.
threshold (FOC-Level 1) 624 5 969 SVS lamp; open load
190 2 421 Offset angle between crank- and 624 12 970 SVS lamp; powerstage over
camshaft sensor is too large temperature
190 8 419 Sensor camshaft speed; 630 12 376 Access error EEPROM memory
disturbed signal (delete)
190 8 422 Sensor crankshaft speed; 630 12 377 Access error EEPROM memory
disturbed signal (read)
190 11 390 Engine speed above warning 630 12 378 Access error EEPROM memory
threshold (FOC-Level 2) (write)
190 12 420 Sensor camshaft speed; no 639 14 84 CAN-Bus 0 "BusOff-Status"
signal
651 3 580 Injector 1 (in firing order); short
190 12 423 Sensor crankshaft speed; no circuit
signal
651 4 586 High side to low side short circuit
190 14 391 Engine speed above warning in the injector 1 (in firing order)
threshold (Overrun Mode)
651 5 568 Injector 1 (in firing order);
190 14 1222 Camshaft- and Crankshaft speed interruption of electric connection
sensor signal not available on
CAN 652 3 581 Injector 2 (in firing order); short
circuit
411 0 791 Physical range check high for
differential pressure Venturiunit 652 4 587 High side to low side short circuit
(EGR) in the injector 2 (in firing order)

411 1 792 Physical range check low for 652 5 569 Injector 2 (in firing order);
differential pressure Venturiunit interruption of electric connection
(EGR) 653 3 582 Injector 3 (in firing order); short
411 3 795 Sensor error differential pressure circuit
Venturiunit (EGR); signal range 653 4 588 High side to low side short circuit
check high in the injector 3 (in firing order)
411 4 381 Physical range check low for 653 5 570 Injector 3 (in firing order);
EGR differential pressure interruption of electric connection
411 4 796 Sensor error differential pressure
Venturiunit (EGR); signal range
check low

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 1109 2 121 Engine shut off demand ignored
KWP = Keyword Protocol
1136 0 1398 Physikal range check high for
SPN FMI KWP Description ECU temperature
654 3 583 Injector 4 (in firing order); short 1136 1 1399 Physikal range check low for
circuit ECU temperature
654 4 589 High side to low side short circuit 1136 3 1400 Sensor error ECU temperature;
in the injector 4 (in firing order) signal range check high
654 5 571 Injector 4 (in firing order); 1136 4 1401 Sensor error ECU temperature;
interruption of electric connection signal range check low
676 11 543 Cold start aid relay error. 1176 3 849 Sensor error pressure sensor
676 11 544 Cold start aid relay open load upstream turbine; signal range
check high
677 3 956 Starter relay high side; short
circuit to battery 1176 4 850 Sensor error pressure sensor
downstream turbine; signal
677 3 960 Starter relay low side; short range check high
circuit to battery
1180 0 1193 Physical range check high for
677 4 957 Starter relay high side; short exhaust gas temperature
circuit to ground upstream turbine
677 4 961 Starter relay low side; short 1180 0 1460 Turbocharger Wastegate CAN
circuit to ground feedback; warning threshold
677 5 958 Starter relay; no load error exceeded
677 12 959 Starter relay; powerstage over 1180 0 1462 Exhaust gas temperature
temperature upstream turbine; warning
threshold exceeded
703 3 426 Engine running lamp; short
circuit to battery 1180 1 1194 Physical range check low for
exhaust gas temperature
703 4 427 Engine running lamp; short upstream turbine
circuit to ground
1180 1 1461 Turbocharger Wastegate CAN
703 5 424 Engine running lamp; open load feedback; shut off threshold
703 12 425 Engine running lamp; exceeded
powerstage over temperature 1180 1 1463 Exhaust gas temperature
729 5 545 Cold start aid relay open load upstream turbine; shut off
threshold exceeded
729 12 547 Cold start aid relay; over
temperature error 1180 3 1067 Sensor error exhaust gas
temperature upstream turbine;
898 9 305 Timeout Error of CAN-Receive- signal range check high
Frame TSC1TE; Setpoint
1180 11 1066 Sensor exhaust gas temperature
1079 13 946 Sensor supply voltage monitor upstream turbine; plausibility
1 error (ECU) error
1080 13 947 Sensor supply voltage monitor 1188 2 1414 Wastegate; status message from
2 error (ECU) ECU missing

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature
KWP = Keyword Protocol exhaust gas mass flow;
SPN FMI KWP Description plausibility error

1188 7 1415 Wastegate actuator; blocked 2659 12 1526 Exhaust gas recirculation; AGS
sensor has "burn off" not
1188 11 1411 Wastegate actuator; internal performed
error
2797 4 1337 Injector diagnostics; timeout
1188 11 1412 Wastegate actuator; EOL error of short circuit to ground
calibration not performed measurement cyl. Bank 0
correctly
2798 4 1338 Injector diagnostics; timeout
1188 11 1416 Wastegate actuator; over error of short circuit to ground
temperature (> 145øC) measurement cyl. Bank 1
1188 11 1417 Wastegate actuator; over 2798 4 1339 Injector diagnostics; short circuit
temperature (> 135øC) to ground monitoring Test in Cyl.
1188 11 1418 Wastegate actuator; operating Bank 0
voltage error 2798 4 1340 Injector diagnostics; short circuit
1188 13 1413 Wastegate actuator calibration to ground monitoring Test in Cyl.
deviation too large, recalibration Bank 1
required 3224 2 127 DLC Error of CAN-Receive-
1231 14 85 CAN-Bus 1 "BusOff-Status" Frame AT1IG1 NOX Sensor
(SCR-system upstream cat;
1235 14 86 CAN-Bus 2 "BusOff-Status" DPF-system downstream cat);
1237 2 747 Override switch; plausibility error length of frame incorrect
1322 12 610 Too many recognized misfires in 3224 9 128 Timeout Error of CAN-Receive-
more than one cylinder Frame AT1IG1; NOX sensor
upstream
1323 12 604 Too many recognized misfires in
cylinder 1 (in firing order) 3248 4 1047 Sensor error particle filter
downstream temperature; signal
1324 12 605 Too many recognized misfires in range check low
cylinder 2 (in firing order)
3699 2 1616 DPF differential pressure sensor
1325 12 606 Too many recognized misfires in and a further sensor or actuator
cylinder 3 (in firing order) CRT system defective
1326 12 607 Too many recognized misfires in 3699 2 1617 Temperature sensor us. and ds.
cylinder 4 (in firing order) DOC simultaneously defect
2659 0 1524 Physical range check high for 3699 14 1615 Maximum stand-still-duration
EGR exhaust gas mass flow reached; oil exchange required
2659 1 1525 Physical range check low for 4765 0 1039 Physical range check high for
EGR exhaust gas mass flow exhaust gas temperature
2659 2 1523 Exhaust gas recirculation AGS upstream (DOC)
sensor; plausibility error 4765 1 1042 Physical range check low for
exhaust gas temperature
upstream (DOC)

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523212 9 171 Timeout Error of CAN-Receive-
KWP = Keyword Protocol Frame ComEngPrt; Engine
SPN FMI KWP Description Protection

4766 0 1029 Physical range check high for 523216 9 198 Timeout Error of CAN-Receive-
exhaust gas temperature Frame PrHtEnCmd; pre-heat
downstream (DOC) command, engine command

4766 1 1032 Physical range check low for 523240 9 179 Timeout CAN-message
exhaust gas temperature FunModCtl; Function Mode
downstream (DOC) Control

4768 2 1036 Sensor exhaust gas temperature 523350 4 565 Injector cylinder-bank 1; short
upstream (DOC); plausibility circuit
error 523352 4 566 Injector cylinder-bank 2; short
4768 3 1044 Sensor error exhaust gas circuit
temperature upstream (DOC); 523354 12 567 Injector powerstage output
signal range check high defect
4768 4 1045 Sensor error exhaust gas 523470 2 826 Pressure Relief Valve (PRV)
temperature upstream (DOC) forced to open; performed by
signal range check low pressure increase
4769 2 1026 Sensor exhaust gas temperature 523470 2 827 Pressure Relief Valve (PRV)
downstream (DOC); plausibility forced to open; performed by
error pressure shock
4769 3 1034 Sensor error exhaust gas 523470 7 876 Maximum rail pressure in limp
temperature downstream (DOC); home mode exceeded (PRV)
signal range check high
523470 11 831 The PRV can not be opened at
4769 4 1035 Sensor error exhaust gas this operating point with a
temperature downstream (DOC); pressure shock
signal range check low
523470 11 832 Rail pressure out of tolerance
523006 3 34 Controller mode switch; short range
circuit to battery
523470 12 828 Open Pressure Relief Valve
523006 4 35 Controller mode switch; short (PRV); shut off condition
circuit to ground
523470 12 829 Open Pressure Relief Valve
523008 1 648 Manipulation control was (PRV); warning condition
triggered
523470 14 830 Pressure Relief Valve (PRV) is
523008 2 649 Timeout error in Manipulation open
control
523550 12 980 T50 start switch active for too
523009 9 825 Pressure Relief Valve (PRV) long
reached maximun allowed
opening count 523601 13 948 Sensor supply voltage monitor
3 error (ECU)
523009 10 833 Pressure relief valve (PRV)
reached maximun allowed open 523603 9 126 Timeout Error of CAN-Receive-
time Frame AMB; Ambient
Temperature Sensor

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523612 12 637 Internal ECU monitoring
KWP = Keyword Protocol detection reported error
SPN FMI KWP Description 523612 12 1170 Internal software error ECU
523605 9 300 Timeout Error of CAN-Receive- 523612 14 973 Softwarereset CPU SWReset_0
Frame TSC1AE; Traction
Control 523612 14 974 Softwarereset CPU SWReset_1

523606 9 301 Timeout Error of CAN-Receive- 523612 14 975 Softwarereset CPU SWReset_2
Frame TSC1AR; Retarder 523613 0 856 Maximum positive deviation of
523612 12 387 Internal software error ECU; rail pressure exceeded
injection cut off (RailMeUn0)

523612 12 612 Internal ECU monitoring 523613 0 857 Maximum positive deviation of
detection reported error rail pressure in metering unit
exceeded (RailMeUn1)
523612 12 613 Internal ECU monitoring
detection reported error 523613 0 858 Railsystem leakage detected
(RailMeUn10)
523612 12 614 Internal ECU monitoring
detection reported error 523613 0 859 Maximum negative deviation of
rail pressure in metering unit
523612 12 615 Internal ECU monitoring exceeded (RailMeUn2)
detection reported error
523613 0 860 Negative deviation of rail
523612 12 616 Internal ECU monitoring pressure second stage
detection reported error (RailMeUn22)
523612 12 617 Internal ECU monitoring 523613 0 862 Maximum rail pressure
detection reported error exceeded (RailMeUn4)
523612 12 618 Internal ECU monitoring 523613 1 861 Minimum rail pressure exceeded
detection reported error (RailMeUn3)
523612 12 619 Internal ECU monitoring 523613 2 864 Setpoint of metering unit in
detection reported error overrun mode not plausible
523612 12 620 Internal ECU monitoring 523615 3 594 Metering unit (Fuel-System);
detection reported error short circuit to battery highside
523612 12 621 Internal ECU monitoring 523615 3 596 Metering unit (Fuel-System);
detection reported error short circuit to battery low side
523612 12 623 Internal ECU monitoring 523615 4 595 Metering unit (Fuel-System);
detection reported error short circuit to ground high side
523612 12 624 Internal ECU monitoring 523615 4 597 Metering Unit (Fuel-System);
detection reported error short circuit to ground low side
523612 12 625 Internal ECU monitoring 523615 5 592 Metering unit (Fuel-System);
detection reported error open load
523612 12 627 Internal ECU monitoring 523615 12 593 Metering unit (Fuel-System);
detection reported error powerstage over temperature
523612 12 628 Internal ECU monitoring 523619 2 488 Physical range check high for
detection reported error exhaust gas temperature
upstrem (SCR-CAT)
523698 11 122 Shut off request from
supervisory monitoring function

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI SPN Description

FMI = Failure Mode Identifier 523788 12 299 Timeout Error of CAN-Transmit-
KWP = Keyword Protocol Frame TrbCH; Status Wastegate
SPN FMI KWP Description 523793 9 202 Timeout Error of CAN-Receive-
523717 12 125 Timeout Error of CAN-Transmit- Frame UAA10; AGS sensor
Frame AmbCon; Weather service message
environments 523794 9 203 Timeout Error of CAN-Receive-
523718 3 1488 SCR mainrelay; short circuit to Frame UAA11; AGS sensor data
battery (only CV56B) 523895 13 559 Check of missing injector
523718 4 1489 SCR mainrelay; short circuit to adjustment value programming
ground (only CV56B) (IMA) injector 1 (in firing order)

523718 5 1486 SCR mainrelay; open load (only 523896 13 560 check of missing injector
CV56B) adjustment value programming
(IMA) injector 2 (in firing order)
523718 12 1487 SCR mainrelay; powerstage over
temperature (only CV56B) 523897 13 561 check of missing injector
adjustment value programming
523766 9 281 Timeout Error of CAN-Receive- (IMA) injector 3 (in firing order)
Frame Active TSC1AE
523898 13 562 check of missing injector
523767 9 282 Timeout Error of CAN-Receive- adjustment value programming
Frame Passive TSC1AE (IMA) injector 4 (in firing order)
523768 9 283 Timeout Error of CAN-Receive- 523910 6 1261 Air Pump; over current
Frame Active TSC1AR
523913 3 74 Sensor error glow plug control
523769 9 284 Timeout Error of CAN-Receive- diagnostic line voltage; signal
Frame Passive TSC1AR range check high
523770 9 285 Timeout Error of CAN-Receive- 523913 4 75 Sensor error glow plug control
Frame Passive TSC1DE diagnostic line voltage; signal
523776 9 291 Timeout Error of CAN-Receive- range check low
Frame TSC1TE - active 523914 3 78 Glow plug control; short circuit to
523777 9 292 Passive Timeout Error of CAN- battery
Receive-Frame TSC1TE; 523914 4 79 Glow plug control; short circuit to
Setpoint ground
523778 9 293 Active Timeout Errorof CAN- 523914 5 76 Glow plug control; open load
Receive-Frame TSC1TR
523914 5 1216 Glow plug control release line;
523779 9 294 Passive Timeout Error of CAN- short circuit error
Receive-Frame TSC1TR
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

138 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 523946 1 1164 Zero fuel calibration injector 1 (in
KWP = Keyword Protocol firing order); minimum value
SPN FMI KWP Description exceeded

523922 7 1262 Burner Shut Off Valve; blocked 523947 0 1159 Zerofuel calibration injector 2 (in
closed firing order); maximum value
exceeded
523922 7 1264 Burner Shut Off Valve; blocked
closed 523947 1 1165 Zerofuel calibration injector 2 (in
firing order); minimum value
523929 0 109 Fuel Balance Control integrator exceeded
injector 1 (in firing order);
maximum value exceeded 523948 0 1160 Zerofuel calibration injector 3 (in
firing order); maximum value
523929 1 115 Fuel Balance Control integrator exceeded
injector 1 (in firing order);
minimum value exceeded 523948 1 1166 Zerofuel calibration injector 3 (in
firing order); minimum value
523930 0 110 Fuel Balance Control integrator exceeded
injector 2 (in firing order);
maximum value exceeded 523949 0 1161 Zerofuel calibration injector 4 (in
firing order); maximum value
523930 1 116 Fuel Balance Control integrator exceeded
injector 2 (in firing order);
minimum value exceeded 523949 1 1167 Zerofuel calibration injector 4 (in
firing order); minimum value
523931 0 111 Fuel Balance Control integrator exceeded
injector 3 (in firing order);
maximum value exceeded 523960 0 1011 Physical range check high for
EGR cooler downstream temp.
523931 1 117 Fuel Balance Control integrator
injector 3 (in firing order); 523960 0 1458 High exhaust gas temperature
minimum value exceeded EGR cooler downstream;
warning threshold exceeded
523932 0 112 Fuel Balance Control integrator
injector 4 (in firing order); 523960 1 1012 Physical range check low for
maximum value exceeded EGR cooler downstream temp.
523932 1 118 Fuel Balance Control integrator 523960 1 1459 High exhaust gas temperature
injector 4 (in firing order); EGR cooler downstream; shut
minimum value exceeded off threshold exceeded
523935 12 168 Timeout Error of CAN-Transmit- 523980 14 1187 Bad quality of reduction agent
Frame EEC3VOL1; Engine send detected
messages 523981 11 918 Urea-tank without heating
523936 12 169 Timeout Error of CAN-Transmit- function (heating phase)
Frame EEC3VOL2; Engine send 523982 0 360 Powerstage diagnosis disabled;
messages high battery voltage
523946 0 1158 Zero fuel calibration injector 1 (in 523982 1 361 Powerstage diagnosis disabled;
firing order); maximum value low battery voltage
exceeded

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 139
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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 524032 2 1442 EGR actuator; status message
KWP = Keyword Protocol EGRCust is missing
SPN FMI KWP Description 524033 7 1443 EGR actuator; due to overload in
523988 3 1245 Charging lamp; short circuit to Save Mode
battery 524034 3 1438 Disc separator; short circuit to
523988 4 1246 Charging lamp; short circuit to battery
ground 524034 4 1439 Disc separator; short circuit to
523988 5 1243 Charging lamp; open load ground

523988 12 1244 Charging lamp; over temp. 524034 5 1436 Disc Separator; open load

523998 4 1327 Injector cylinder bank 2 slave; 524034 12 1437 Disc Separator; powerstage over
short circuit temperature

523999 12 1328 Injector powerstage output Slave 524035 12 1341 Injector diagnostics; time out
defect error in the SPI communication

524014 1 1254 Air pressure glow plug flush line; 524057 2 1505 Electric fuel pump; fuel pressure
below limit build up error

524016 2 1259 Amount of air is not plausible to 524097 9 1663 Timeout error of CAN-Transmit-
pump speed Frame DPFBrnAirPmpCtl

524016 2 1260 Calculated amount of air is not 524098 9 1664 Timeout error of CAN-Transmit-
plausible to HFM reading Frame ComDPFBrnPT

524016 11 1258 HFM sensor; electrical fault 524099 9 1665 Timeout error of CAN-Transmit-
Frame ComDPFC1
524021 11 1263 Burner fuel line pipe leak behind
Shut Off Valve 524100 9 1666 Timeout error of CAN-Transmit-
Frame ComDPFHisDat
524024 11 1302 Deviation of the exhaust gas
temp. setpoint to actual value 524101 9 1667 Timeout error of CAN-Transmit-
downstream (DOC) too high Frame ComDPFTstMon

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

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Deutz TD 2.9 L4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 524114 9 1659 Timeout error of CAN-Transmit-
KWP = Keyword Protocol Frame A1DOC
SPN FMI KWP Description 524115 9 1660 Timeout error of CAN-Transmit-
524102 9 1674 Timeout error of CAN-Receive- Frame AT1S
Frame ComRxDPFBrnAirPmpCtl 524116 9 1661 Timeout error of CAN-Transmit-
524103 9 1675 Timeout error of CAN-Receive- Frame SCR2
Frame ComRxDPFBrnAirPmp 524117 9 1662 Timeout error of CAN-Transmit-
524104 9 1676 Timeout error of CAN-Receive- Frame SCR3
Frame ComRxDPFCtl 524118 9 1672 Timeout error of CAN-Receive-
524105 9 1668 Timeout error of CAN-Transmit- Frame ComRxCM1
Frame ComEGRMsFlw 524119 9 1673 Timeout error of CAN-Receive-
524106 9 1677 Timeout error of CAN-Receive- Frame ComRxCustSCR3
Frame ComRxEGRMsFlw1 524120 9 1682 Timeout error of CAN-Receive-
524107 9 1678 Timeout error of CAN-Receive- Frame ComRxSCRHtDiag
Frame ComRxEGRMsFlw2 524121 9 1683 Timeout error of CAN-Receive-
524108 9 1669 Timeout error of CAN-Transmit- Frame ComRxTrbChActr
Frame ComEGRTVActr 524122 9 1684 Timeout error of CAN-Receive-
524109 9 1679 Timeout error of CAN-Receive- Frame ComRxUQSens
Frame ComRxEGRTVActr 524123 9 1685 Timeout error of CAN-Receive-
524110 9 1670 Timeout error of CAN-Transmit- Frame ComSCRHtCtl
Frame ComETVActr 524124 9 1686 Timeout error of CAN-Receive-
524111 9 1680 Timeout error of CAN-Receive- Frame ComTxAT1IMG
Frame ComRxETVActr 524125 9 1687 Timeout error of CAN-Receive-
524112 9 1671 Timeout ComITVActr Frame ComTxTrbChActr

524113 9 1681 Timeout error of CAN-Receive-

Frame ComRxITVActr

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 1077 411 3 Engine exhaust gas recirculation.
SPN = Suspect Parameter Number Signal value above maximum limit.
DTC SPN FMI Description 1078 411 4 Engine exhaust gas recirculation.
1000 98 2 Engine oil level sensor internal Signal value below maximum limit.
error. Sensor reports error. 1079 108 0 Ambient air pressure sensor above
Open/short transducer. normal operational range.
1001 98 31 Engine oil level out of range. Level 1080 108 1 Ambient air pressure sensor below
low, high, foaming. normal operational range.
1002 98 31 Oil sensor voltage out of range. 1081 108 15 Fault check max signal range
<8,5V ±0,5V; >16,5V ±0,5V. violated for ambient air pressure
1003 98 2 Oil sensor invalid sensor status. sensor.

1004 98 31 Oil sensor temperature out of 1082 108 17 Fault check min signal range
range. violated for ambient air pressure
sensor.
1005 98 14 Oil sensor is broken or
disconnected. 1083 108 2 Ambient air pressure sensor error
by component self diagnosis.
1021 100 3 Oil pressure voltage above normal
or shorted to high. 1084 3720 0 DPF ash load above normal
operational range.
1022 100 4 Oil pressure voltage below normal
or shorted to low. 1086 3734 0 DPF soot load exceeded. Remove
filter level.
1025 100 1 Low oil pressure. Warning
threshold exceeded. 1087 4781 14 DPF soot load exceeded shut off
level.
1026 100 1 Low oil pressure. Shut off threshold
exceeded. 1088 4781 0 DPF soot load exceeded warning
level.
1043 107 0 Air filter differential pressure. Air
filter clogged. 1089 4781 16 DPF. Too much standstill time in
short time interval.
1071 411 2 Engine exhaust gas recirculation.
Pressure does not change 1090 10156 0 DPF. The standstill-regeneration
between engine operating points. mode time exceeds the short-limit.

1072 411 0 Engine exhaust gas recirculation. 1091 3735 16 DPF. Standstill required and no
Pressure above normal operational successful standstill longer than
range. escalation threshold. Moderately
severe.
1073 411 1 Engine exhaust gas recirculation.
Pressure below normal operational 1092 3735 0 DPF. Standstill required and no
range. successful standstill longer than
escalation threshold. Most severe.
1074 411 2 Engine exhaust gas recirculation.
Negative measured differential 1093 4766 1 DOC. Regeneration temperature in
pressure. standstill main phase not reached.

1075 411 2 Engine exhaust gas recirculation. 1102 171 2 Ambient air temperature shows a
Positive measured differential deviation from expected value at
pressure. cold start conditions.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 1134 3251 3 DPF voltage above normal or
SPN = Suspect Parameter Number shorted to high.
DTC SPN FMI Description 1135 3251 4 DPF voltage below normal or
111 102 0 Engine intake manifold pressure shorted to low.
above normal operational range. 1136 3251 14 DPF reporting communication
1114 102 1 Engine intake manifold pressure error.
below normal operational range. 1137 3251 14 DPF reporting data error.
1115 102 3 Intake manifold pressure sensor 1138 3251 14 DPF reporting fast channel 1 error.
voltage above normal or shorted to
high. 1139 3251 14 DPF reporting fast channel 2 signal
range error.
1116 102 4 Intake manifold pressure sensor
voltage below normal or shorted to 1149 3251 2 DPF difference pressure value not
low. plausible.

1118 102 1 Intake manifold pressure below 1150 3251 0 DPF difference pressure above
normal operational range. shut off threshold.

1121 102 2 DFC for signal variation check for 1151 3251 16 DPF difference pressure above
pressure sensor of the intake warning threshold.
manifold. 1152 3251 1 DPF difference pressure below
1122 102 0 Intake air pressure valve sensor, shut off threshold.
warning condition exceeded. 1153 3251 18 DPF difference pressure below
1123 102 1 Intake air pressure valve sensor, warning threshold.
shutoff condition exceeded. 1161 5571 16 Rail fuel pressure relief valve
1124 1209 2 Engine exhaust pressure turbine above normal operational range.
upstream differs from ambient 1162 5571 2 Rail fuel pressure relief valve is
pressure while engine not running. forced to open, perform pressure
1125 1209 15 Engine exhaust pressure turbine increase.
upstream above upper limit. 1163 5571 2 Rail fuel pressure relief valve is
1126 1176 1 Engine turbocharger compressor forced to open. Performed by
intake pressure below normal pressure increase.
operational range. 1164 5571 16 Rail fuel pressure relief valve is
1127 1209 2 Engine exhaust pressure turbine forced to open. Shutoff conditions.
upstream tuck check failed. 1165 5571 15 Rail fuel pressure relief valve is
Pressure does not change forced to open. Warning
between engine operating points. conditions.
1130 1209 3 Engine exhaust pressure sensor 1166 5571 0 Open rail fuel pressure relief valve
voltage above normal or shorted to was detected.
high.
1167 5571 2 Unexpected opening of the rail fuel
1131 1209 4 Engine exhaust pressure sensor pressure relief valve.
voltage below normal or shorted to
1168 5571 2 Successful rail fuel pressure relief
low.
valve opening cannot be ensured.
1169 5571 13 Averaged rail fuel pressure after
valve opening is outside the
expected tolerance range.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 1209 157 4 Engine fuel injector metering rail
SPN = Suspect Parameter Number pressure voltage below normal
DTC SPN FMI Description or shorted to low.

1170 5571 16 Open time of rail fuel pressure 121 520252 2 Wrong checksum in the CAN
relief valve for wear out monitoring message EAT Control.
had exceeded. 1212 629 12 ECU. Keep alive error during
1171 94 1 Fuel pressure build up during runtime at an external device.
engine start not successful. 1213 629 12 ECU. Keep alive error during
1172 1347 5 Electrical fuel pump current below initialization phase at an external
normal or open circuit. device.

1174 1347 3 Electrical fuel pump voltage above 1215 629 12 ECU. Read diagnosis error for
normal or shorted to high. non volatile memory.

1175 1347 4 Electrical fuel pump voltage below 1216 629 12 ECU. Write diagnosis error for
normal or shorted to low. non volatile memory.

119 1231 14 CAN Bus 2 off Error for Application 1218 629 12 ECU. Stack memory threshold
CAN. overrun.

1190 7103 13 Rail fuel pressure below set point, 1219 629 12 ECU. Observation counter
speed-dependent threshold irregular switch off counter
exceeded. triggered by engine running.

1191 7103 13 Rail fuel pressure metering unit. 122 4207 2 TSC1 message checksum fault.
Fuel quantity balance is disrupted. 123 4207 2 TSC1 message checksum fault.
1194 7103 13 Negative rail fuel pressure 1233 5826 15 Emission control system
governor deviation at zero delivery operator inducement level
by metering unit. 1 severity above normal
1195 7103 1 Rail fuel pressure value is below operational range.
minimum rail pressure threshold. 1235 5826 0 Emission control system
1197 7103 0 Maximum rail fuel pressure operator inducement level
exceeded. 2 severity above normal
operational range.
1198 7103 2 Set point of fuel metering unit in
overrun mode not plausible. 1236 5826 14 Emission control system
operator pre-trigger inducement
120 639 14 CAN Bus 1 off Error for Power train level 2 severity.
CAN.
124 4207 2 TSC1 message checksum fault.
1200 5357 14 Shut-off due to undershoot of
minimum rail pressure. 125 4207 2 TSC1 message checksum fault.

1202 157 0 Maximum rail pressure exceeded 1274 91 3 Accelerator pedal sensor
in limp home mode. position 1 voltage above normal
or shorted to high.
1208 157 3 Engine fuel injector metering rail
pressure voltage above normal or 1275 2623 3 Accelerator pedal 1, channel
shorted to high. 2 voltage above normal or
shorted to high.
1276 29 3 Accelerator pedal 2 voltage
above normal or shorted to high.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 1308 677 5 Engine starter motor relay current
SPN = Suspect Parameter Number below normal or shorted to low.
DTC SPN FMI Description 1310 677 3 Engine starter motor relay voltage
1277 2625 3 Accelerator pedal 2, channel above normal or shorted to high.
2 voltage above normal or shorted 1311 677 4 Engine starter motor relay voltage
to high. below normal or shorted to low.
1280 91 4 Accelerator pedal sensor position 1323 91 11 Accelerator pedal position 1.
1 voltage below normal or shorted Possible error between APP1 and
to low. APP2 or APP1 and idle switch.
1281 2623 4 Accelerator pedal 1, channel 1326 29 11 Accelerator Pedal 2 Position.
2 voltage below normal or shorted Possible error between APP1 and
to low. idle switch.
1282 29 4 Accelerator pedal 2 voltage below 1346 1041 14 Start signal indicator. Terminal
normal or shorted to low. 50 was operated too long.
1283 2625 4 Accelerator pedal 2, channel 1354 105 0 Engine intake manifold
2 voltage below normal or shorted 1 temperature data above normal
to low. operational range. Warning
1289 3509 14 Failure of sensor supply voltage threshold exceeded.
1 from ECU. 1355 105 0 Engine intake manifold
1290 3509 0 Sensor supply voltage 1 from ECU 1 temperature above normal
above normal operational range. operational range. Shutoff
threshold exceeded.
1291 3509 6 Sensor supply voltage 1 from ECU
current above normal or grounded 1357 1136 0 Engine ECU temperature above
circuit. normal operational range. Most
severe.
1292 3509 1 Sensor supply voltage 1 from ECU
below normal operational range. 1358 1136 1 Engine ECU temperature below
normal operational range. Most
1293 3510 14 Failure of sensor supply voltage severe.
2 from ECU.
1359 1136 15 Engine ECU temperature above
1294 3510 0 Sensor supply voltage 2 from ECU normal operational range. Least
above normal operational range. severe.
1295 3510 6 Sensor supply voltage 2 from ECU 1360 1136 17 Engine ECU temperature below
current above normal or grounded normal operational range. Least
circuit. severe.
1296 3510 1 Sensor supply voltage 2 from ECU 1361 1136 2 Engine ECU temperature fault
below normal operational range. check.
1306 677 3 Engine starter motor relay voltage 1362 412 15 Engine exhaust gas recirculation
above normal or shorted to high. temperature above normal
1307 677 4 Engine starter motor relay voltage operational range.
below normal or shorted to low.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 1392 51 4 Engine throttle valve 1, position
SPN = Suspect Parameter Number 1 voltage below normal or
DTC SPN FMI Description shorted to low.

1363 412 17 Engine exhaust gas recirculation 1397 105 0 Engine intake manifold
temperature below normal 1 temperature above normal
operational range. operational range.

1364 412 3 Engine exhaust gas recirculation 1398 105 1 Engine intake manifold
temperature voltage above normal 1 temperature below normal
or shorted to high. operational range.

1365 412 4 Engine exhaust gas recirculation 1399 4766 2 DOC temperature too high.
temperature voltage below normal 1400 4766 2 DOC temperature too low.
or shorted to low.
1401 4766 15 DOC outlet temperature above
1372 51 5 Engine throttle valve 1, position normal operational range.
1 current below normal or open
circuit. 1402 4766 3 DOC outlet temperature voltage
above normal or shorted to high.
1375 51 3 Engine throttle valve 1, position
1 voltage above normal or shorted 1403 4766 4 DOC outlet temperature voltage
to high. Short circuit to battery 1. below normal or shorted to low.

1376 51 3 Engine throttle valve 1, position 1404 4766 2 DOC intake temperature error.
1 voltage above normal or shorted 1405 4766 15 DOC Intake temperature above
to high. Short circuit to battery 2. normal operational range.
1377 51 4 Engine throttle valve 1, position 1406 4766 3 DOC intake temperature voltage
1 voltage below normal or shorted above normal or shorted to high.
to low. Short circuit to ground 1.
1407 4766 4 DOC intake temperature voltage
1378 51 4 Engine throttle valve 1, position below normal or shorted to low.
1 voltage below normal or shorted
1408 4766 2 DOC intake temperature does
to low. Short circuit to ground 2.
not change.
1379 51 6 Engine throttle valve 1, position
142 520256 9 Timeout of EAT control receive
1 current above normal or
message. CAN message is not
grounded circuit.
received.
1382 51 7 Engine throttle valve 1 position
144 523211 9 Timeout error of CAN receive
1 mechanical system not
frame EBC1.
responding or out of adjustment.
Valve stuck closed. 154 523212 9 Timeout error of CAN receive
frame engine protection.
1383 51 7 Engine throttle valve 1 position
1 mechanical system not 1540 520254 8 The stand still regeneration
responding or out of adjustment. mode time exceeds the long limit
Valve stuck open. threshold.
1391 51 3 Engine throttle valve 1, position 1541 520255 2 Hoses connected to the dp DPF
1 voltage above normal or shorted SENT sensor inverted. Swap
to high. hoses.
155 523741 14 Engine shutdown request via
CAN.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 367 3349 0 Timeout Error of CAN receive
SPN = Suspect Parameter Number frame TSC1TR; control signal.
DTC SPN FMI Description 38 1485 3 ECM main relay voltage above
1587 97 0 Water in fuel level prefilter; normal or shorted to high.
maximum value exceeded. 39 1485 3 ECM main relay voltage above
188 523240 9 Timeout CAN message function normal or shorted to high of
mode control. actuator relay 2.

219 520253 2 Rolling counter fault CAN 40 1485 3 ECM main relay voltage above
message EAT Control. normal or shorted to high of
actuator relay 3.
220 4206 2 Fault check for Rolling Counter
of TSC1AE. 41 1485 4 ECM main relay voltage below
normal or shorted to low.
221 4206 2 Fault check for Rolling Counter
of TSC1AR. 42 1485 4 ECM main relay voltage below
normal or shorted to low of
222 4206 2 Fault check for Rolling Counter actuator relay 2.
of TSC1TE.
43 1485 4 ECM main relay voltage below
223 4206 2 Fault check for Rolling Counter normal or shorted to low of
of TSC1TR. actuator relay 3.
349 3349 0 Timeout error of CAN receive 48 168 0 Battery voltage above normal
frame active TSC1AE. operational range.
350 3349 0 Timeout error of CAN receive 49 168 1 Battery voltage low normal
frame passive TSC1AE. operational range.
351 3349 0 Timeout error of CAN receive 50 168 3 Battery voltage above normal or
frame active TSC1AR. shorted to high.
352 3349 0 Timeout error of CAN receive 51 168 4 Battery voltage above normal or
frame passive TSC1AR. shorted to low.
353 3349 0 Timeout error of CAN receive 516 523982 0 Power stage diagnosis disabled.
frame TSC1TE active. High battery voltage.
354 3349 0 TSC1 receive timeout error. 517 523982 1 Power stage diagnosis disabled.
Short circuit to ground error. Low battery voltage.
355 3349 0 Timeout error of CAN receive 52 168 0 High battery voltage. Warning
frame TSC1TR. threshold is exceeded.
356 3349 0 Passive timeout error of CAN 567 27 5 Engine exhaust gas recirculation
receive frame TSC1TR. 1 valve position current below
361 3349 0 Timeout error of CAN receive normal or open circuit.
frame TSC1AE. Traction Control. 570 27 3 Engine exhaust gas recirculation
363 3349 0 Timeout error of CAN receive 1 valve position voltage above
frame TSC1AR. Retarder. normal or shorted to battery 1.
365 3349 0 Timeout error of CAN receive 571 27 3 Engine exhaust gas recirculation
frame TSC1TE. Setpoint. 1 valve position voltage above
normal or shorted to battery 2.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 613 171 3 Ambient air temperature sensor
SPN = Suspect Parameter Number voltage above normal or shorted to
DTC SPN FMI Description high.

572 27 4 Engine exhaust gas recirculation 614 171 4 Ambient air temperature sensor
1 valve position voltage below voltage below normal or shorted to
normal or shorted to ground 1. low.

573 27 4 Engine exhaust gas recirculation 615 723 8 Camshaft speed sensor abnormal
1 valve position voltage below frequency or pulse width or period.
normal or shorted to ground 2. 616 723 14 Camshaft sensor detection. Out of
574 27 6 Engine exhaust gas recirculation range, signal disrupted, no signal.
1 valve position current above 617 723 13 Offset angle between crank and
normal or grounded circuit. camshaft sensor is too large.
577 27 7 Engine exhaust gas recirculation 618 4201 8 Crankshaft sensor detection. Out
1 valve position. Mechanical of range, signal disrupted, no
system not responding or out of signal.
adjustment. Valve stuck closed.
619 4201 14 Crankshaft speed sensor. Speed
578 27 7 Engine exhaust gas recirculation detection, out of range, signal
1 valve position. Mechanical disrupted or no signal.
system not responding or out of
adjustment. Valve stuck open. 68 1669 14 CAN Bus ID-5. CAN Hardware
registers are not updated within the
582 5763 3 Engine exhaust gas recirculation 1, expected time.
actuator 1 voltage above normal or
shorted to high. 70 110 2 Engine Coolant Temperature. Data
erratic, intermittent or incorrect.
583 5763 4 Engine exhaust gas recirculation 1,
actuator 1 voltage below normal or 709 97 3 Water in fuel indicator 1. Voltage
shorted to low. above normal or shorted to high.

586 3055 14 Internal software error ECU. 710 97 4 Water in fuel indicator 1. Voltage
Injection cut off. below normal or shorted to low.

587 190 0 Engine speed above warning 721 94 15 Low fuel pressure system, max.
threshold. Over speed detection in physical range exceeded.
component engine protection. 723 94 3 Engine fuel pressure sensor
588 190 0 Engine speed above warning voltage above normal or shorted to
threshold. FOC-Level 1. high.

589 190 0 Engine speed above warning 724 94 4 Engine fuel pressure sensor
threshold. FOC-Level 2. voltage below normal or shorted to
low.
590 190 0 Engine speed above warning
threshold. Overrun Mode. 725 94 1 Low fuel pressure system, warning
threshold exceeded.
610 171 15 Environment temperature sensor,
temperature above upper physical 726 94 1 Low fuel pressure, shut off
threshold. threshold exceeded.
75 110 3 Engine coolant temperature
voltage above normal or shorted to
high.
76 110 4 Engine coolant temperature
voltage below normal or shorted to
low.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 821 5363 5 Engine cylinder 6 fuel injection
SPN = Suspect Parameter Number quantity current below normal or
DTC SPN FMI Description open circuit.

77 110 0 High coolant temperature. Warning 822 2797 6 Engine fuel 1 injector, Group
threshold exceeded. 1 current above normal or
grounded circuit.
78 110 0 Coolant temperature. System
reaction initiated. 823 2798 6 Engine fuel 1 injector, Group
2 current above normal or
797 676 12 Engine cold start aid relay error. grounded circuit.
798 676 5 Engine cold start aid relay current 824 5358 6 Engine cylinder 1 fuel injection
below normal or open circuit. quantity above normal or grounded
799 676 5 Engine cold start aid relay current circuit. Short circuit of the power
below normal or open circuit. stage low-side.
80 411 2 Intake air massflow not in expected 825 5359 6 Engine cylinder 2 fuel injection
range. quantity above normal or grounded
circuit. Short circuit of the power
803 676 3 Engine cold start aid relay voltage stage low-side.
above normal or shorted to high.
826 5360 6 Engine cylinder 3 fuel injection
805 676 4 Engine cold start aid relay voltage quantity above normal or grounded
below normal or shorted to low. circuit. Short circuit of the power
807 2797 14 Engine fuel 1 injector, Group 1. stage low-side.
Number of possible injections 827 5361 6 Engine cylinder 4 fuel injection
limited by the injection valve. quantity above normal or grounded
815 2797 4 Engine fuel 1 injector, Group circuit. Short circuit of the power
1 voltage below normal or shorted stage low-side.
to low. 828 5362 6 Engine cylinder 5 fuel injection
816 5358 5 Engine cylinder 1 fuel injection quantity above normal or grounded
quantity current below normal or circuit. Short circuit of the power
open circuit. stage low-side.
817 5359 5 Engine cylinder 2 fuel injection 829 5363 6 Engine cylinder 6 fuel injection
quantity current below normal or quantity above normal or grounded
open circuit. circuit. Short circuit of the power
stage low-side.
818 5360 5 Engine cylinder 3 fuel injection
quantity current below normal or 83 111 1 Coolant level too low.
open circuit. 830 5358 6 Engine cylinder 1 fuel injection
819 5361 5 Engine cylinder 4 fuel injection quantity above normal or grounded
quantity current below normal or circuit. Short circuit between high-
open circuit. side and low-side of the power
stage.
820 5362 5 Engine cylinder 5 fuel injection
quantity current below normal or
open circuit.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 840 4257 14 Engine fuel 1 injector, group
SPN = Suspect Parameter Number 3 missing injector adjustment value
DTC SPN FMI Description programming injector 3.

831 5359 6 Engine cylinder 2 fuel injection 854 7103 5 Engine fuel metering rail pump
quantity above normal or grounded current below normal or open
circuit. Short circuit between high- circuit.
side and low-side of the power 855 7103 3 Engine fuel metering rail pump
stage. voltage above normal or shorted to
832 5360 6 Engine cylinder 3 fuel injection high. Short circuit to battery on the
quantity above normal or grounded high side power stage.
circuit. Short circuit between high- 856 7103 3 Engine fuel metering rail pump
side and low-side of the power voltage above normal or shorted to
stage. high. Short circuit to battery on the
833 5361 6 Engine cylinder 4 fuel injection low side power stage.
quantity above normal or grounded 857 7103 4 Engine fuel metering rail pump
circuit. Short circuit between high- voltage below normal or shorted to
side and low-side of the power low. Short circuit to battery on the
stage. high side power stage.
834 5362 6 Engine cylinder 5 fuel injection 858 7103 4 Engine fuel metering rail pump
quantity above normal or grounded voltage below normal or shorted to
circuit. Short circuit between high- low. Short circuit to battery on the
side and low-side of the power low side power stage.
stage.
859 7103 6 Engine fuel metering rail pump
835 5363 6 Engine cylinder 6 fuel injection current above normal or grounded
quantity above normal or grounded circuit.
circuit. Short circuit between high-
side and low-side of the power 868 629 12 Function monitoring: fault of ECU
stage. ADC. Null load test pulse.

836 105 3 Engine intake manifold 869 629 12 Function monitoring: fault of ECU
temperature voltage above normal ADC. Test voltage.
or shorted to high. 870 629 12 ECU. DFC to indicate ICO request
837 105 4 Engine intake manifold from MoCSOP module.
temperature voltage below normal 871 91 14 Function monitoring: Monitoring of
or shorted to low. accelerator pedal position.
838 2797 14 Engine fuel 1 injector, group 875 190 2 Function monitoring: Fault of
1 missing injector adjustment value engine speed check.
programming injector 1.
876 5357 2 Engine fuel injection error for
839 2798 14 Engine fuel 1 injector, group multiple cylinders. Diagnostic fault
2 missing injector adjustment value check error between level
programming injector 2. 1 energizing time and level
2 information.

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Deutz TCD 2.2 L3 Engine Fault Codes

DTC = Diagnostic Trouble Code DTC SPN FMI Description

FMI = Failure Mode Identifier 887 513 2 Actual engine percent torque.
SPN = Suspect Parameter Number DFC to report the fault in
DTC SPN FMI Description energizing time comparison.

877 5441 2 Engine fuel injection timing error 888 513 2 Actual engine percent torque.
for multiple cylinders. DFC to report in torque
comparison error.
878 5357 2 Engine fuel injection error for
multiple cylinders. Diagnostic 889 520250 2 Function monitoring: Error in the
fault check to report the error post-build selectable monitoring.
due to non plausibility in ZFC. 890 629 12 ECU. Status of the EMM alarm
879 523612 12 Internal recovery. Diagnosis fault FCCU0 which is read out of the
check to report the error to FCCU hardware module.
demand for an ICO due to an 91 1109 2 Engine protection system
error in the PoI2 shut-off. approaching shutdown. Engine
88 598 10 Clutch switch. Abnormal rate of shut off demand ignored.
change. 92 1109 14 Engine protection system
880 523612 12 Internal recovery. Diagnosis fault approaching shutdown. Shut off
check to report the error to request from supervisory
demand for an ICO due to an monitoring function.
error in the PoI3 efficiency factor. 996 629 12 ECU. Diagnostic fault check to
881 523612 12 Internal recovery. Diagnosis fault report ABE active state.
check to report the error to 997 629 12 Function monitoring: Fault of
demand for an ICO due to an ECU, WDA active by
error in change of EOM. inquiry/response communication.
882 5357 2 Engine fuel injection error for 998 629 12 Function monitoring: Fault of
multiple cylinders. Diagnosis ECU, Error Pin active suspision
fault check to report the error to of HW fault.
demand for an ICO due to an
error in total torque relevant 999 629 12 Function monitoring: Fault of
quantity. ECU, WDA active by overvoltage
detection.
883 5357 2 Engine fuel injection error for
multiple cylinders. Diagnostic The following DTC fault code range shares the same
fault check to report the error description. Replace the ECU.
due to injection quantity DTC 891 - 945 Description
correction.
SPN 629 Internal ECU error.
884 5442 2 Engine fuel injection pressure
error for multiple cylinders. FMI 12

885 29 2 Accelerator pedal 2 position.

886 677 2 Engine starter motor relay.
Function monitoring: Fault of
ECU power train active.

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Perkins 404-22 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI Description

FMI = Failure Mode Identifier 723 3 Engine Speed Sensor #2: Voltage
SPN FMI Description Above Normal
29 3 Accelerator Pedal Position 2: Voltage 723 4 Engine Speed Sensor #2: Voltage
Above Normal Below Normal
29 4 Accelerator Pedal Position 2: Voltage 723 8 Engine Speed Sensor#2: Abnormal
Below Normal Frequency, Pulse Width or Period"
91 3 Accelerator Pedal Position 1: Voltage 723 10 Engine Speed Sensor #2: Abnormal
Above Normal Rate of Change
91 4 Accelerator Pedal Position 1: Voltage 733 3 Engine Rack Position Sensor: Voltage
Below Normal Above Normal
100 1 Engine Oil Pressure :Low- most 733 4 Engine Rack Position Sensor: Voltage
severe (3) Below Normal
108 3 Barometric Pressure : Voltage Above 1485 7 ECU Main Relay : Not Responding
Normal Property
108 4 Barometric Pressure : Voltage Below 2840 11 ECU Instance: Other Failure Mode
Normal 2840 12 ECU Instance: Failure
110 3 Engine Coolant Temperature : 2840 13 ECU Instance: Out of Calibration
Voltage Above Normal
2970 3 Accelerator Pedal 2 Low Idle Switch:
110 4 Engine Coolant Temperature : Voltage Above Normal
Voltage Below Normal
2970 4 Accelerator Pedal 2 Low Idle Switch:
110 15 Engine Coolant Temperature : High Voltage Below Normal
-least severe (1)
3241 1 Exhaust Gas Temperature 1: Low-
168 0 Battery Potential/ Power Input 1 : most severe (3)
High- most severe (3)
3241 3 Exhaust Gas Temperature 1: Voltage
168 3 Battery Potential/ Power Input 1: Above Normal
Voltage Above Normal
241 4 Exhaust Gas Temperature 1: Voltage
168 4 Battery Potential/ Power Input 1: Below Normal
Voltage Below Normal
3241 15 Exhaust Gas Temperature 1: High-
172 3 Engine Air Inlet Temperature: Voltage least severe (1)
Above Normal
3241 16 Exhaust Gas Temperature 1: High-
172 4 Engine Air Inlet Temperature: Voltage moderate severity (2)
Below Normal
3242 1 Particulate Trap Intake Gas Temp:
190 0 Engine Speed : High- most severe (3) Low- most severe(3)"
190 8 Engine Speed : Abnormal Frequency, 3242 3 Particulate Trap Intake Gas Temp:
Pulse Width or Period Voltage Above Normal"
558 3 Accelerator Pedal1 Low Idle Switch: 3242 4 Particulate Trap Intake Gas Temp:
Voltage Above Normal Voltage Below Normal"
558 4 Accelerator Pedal1 Low Idle Switch: 3242 15 Particulate Trap Intake Gas Temp:
Voltage Below Normal High - least severe(1)"
638 6 Engine Fuel Rack Actuator: Current 3242 16 Particulate Trap Intake Gas Temp:
Above Normal High-moderate severity (2)
639 14 J1939 Network#1: Special Instruction

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Perkins 404-22 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI Description

FMI = Failure Mode Identifier 4201 4 Engine Speed Sensor #1: Voltage
SPN FMI Description Below Normal
3251 3 Particulate Trap Differential Pressure: 4201 8 Engine Speed Sensor #1: Abnormal
Voltage Above Normal Frequency, Pulse \Nidth, or Period
3251 4 Particulate Trap Differential Pressure: 4201 10 Engine Speed Sensor #1: Abnormal
Voltage Below Normal Rate of Change
3473 7 Aftertreatmert #1 Failed to Ignite: Not 4765 1 Aftertreatmert #1 Diesel Oxidation
Responding Properly Catalyst Intake Gas Temperature:
Low-most severe (3)
3473 11 Aftertreatmert #1 Failed to Ignite :
Other Failure Mode 4765 3 Aftertreatmert #1 Diesel Oxidation
Catalyst Intake Gas Temperature:
3484 0 Aftertreatmert #1 Ignition : High-most Voltage Above Normal
severe (3)
4765 4 Aftertreatmert #1 Diesel Oxidation
3484 3 Aftertreatmert #1 Ignition : Voltage
Catalyst Intake Gas Temperature:
Above Normal Voltage Below Normal
3484 4 Aftertreatmert #1 Ignition : Voltage
4765 15 Aftertreatmert #1Diesel Oxidation
Below Normal
Catalyst Intake Gas Temperature:
3556 6 Aftertreatmert 1 Hydrocarbon Doser High-least severe (1)
1: Current Above Normal 4765 16 Aftertreatmert #1 Diesel Oxidation
3610 3 Diesel Particulate Filter Outlet Catalyst Intake Gas Temperature:
Pressure or 1: Voltage Above High-moderate severity (2)
Normal" 5487 3 Aftertreatmert 1 Burner Unit
3610 4 DieselParticulate Filter Outlet Combustion Chamber Temperature:
Pressure Sensor 1: Voltage Below Voltage Above Normal
Normal 5487 4 Aftertreatmert 1 Burner Unit
3713 7 DPF Active Regeneration Inhibited Combustion Chamber Temperature:
Due to System Timeout: Not Voltage Below Normal
Responding Properly 6581 6 Aftertreatmert 1 Hydrocarbon Doser
3713 31 DPF Active Regeneration Inhibited 2 : Current Above Normal
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

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GM 3.0L Engine Fault Codes

DTC Set 2 DTC Set 2

Description Description
SPN-2/FMI-2 SPN-2/FMI-2
DTC 11: Intake cam / distributor position DTC 221: TPS1-2 higher than expected
520800 / 7 653/6
error
DTC 16: Crank and/or cam no sync during DTC 222: TPS2 voltage low
636 / 8 520251 / 4
start
DTC 24: Exhaust cam position error 520801 / 7 DTC 223: TPS2 voltage high 520251 / 3
DTC 87 Fuel pressure lower than expected 94 / 1 DTC 234: Boost control overboost failure 1692 / 0
DTC 88 Fuel pressure higher than expected 94 / 0 DTC 236: TIP active 1692 / 2
DTC 91: FP low voltage 94 / 4 DTC 237: TIP low voltage 1127 / 4
DTC 92: FP high voltage 94 / 3 DTC 238: TIP high voltage 1127 / 3
DTC 107: MAP voltage low 106 / 4 DTC 261: Injector 1 open or short to ground 651 / 5
DTC 108: MAP pressure high 106 / 16 DTC 262: Injector 1 coil shorted 651 / 6
DTC 111: IAT higher than expected stage 1 105 / 15 DTC 264: Injector 2 open or short to ground 652 / 5
DTC 112: IAT voltage low 105 / 4 DTC 265: Injector 2 coil shorted 652 / 6
DTC 113: IAT voltage high 105 / 3 DTC 267: Injector 3 open or short to ground 653 / 5
DTC 116: ECT higher than expected stage 1 110 / 15 DTC 268: Injector 3 coil shorted 653/6
DTC 117: ECT voltage low 110 / 4 DTC 270: Injector 4 open or short to ground 654 / 5
DTC 118: ECT voltage high 110 / 3 DTC 271: Injector 4 coil shorted 654 / 6
DTC 121: TPS1-2 lower than expected 51 / 1 DTC 273: Injector 5 open or short to ground 655 / 5
DTC 122: TPS1 voltage low 51 / 4 DTC 274: Injector 5 coil shorted 655 / 6
DTC 123: TPS1 voltage high 51 / 3 DTC 276: Injector 6 open or short to ground 656 / 5
DTC 127: IAT higher than expected stage 2 105 / 0 DTC 277: Injector 6 coil shorted 656 / 6
DTC 129: BP pressure low 108 / 1 DTC 279: Injector 7 open or short to ground 657 / 5
DTC 134: EGO1 open / lazy 724 / 10 DTC 280: Injector 7 coil shorted 657 / 6
DTC 140: EGO3 open / lazy 520209 / 10 DTC 282: Injector 8 open or short to ground 658 / 5
DTC 154: EGO2 open / lazy 520208 / 10 DTC 283: Injector 8 coil shorted 658 / 6
DTC 160: EGO4 open / lazy 520210 / 10 DTC 285: Injector 9 open or short to ground 659 / 5
DTC 171: Adaptive-learn gasoline DTC 308: Cylinder 8 emissions/catalyst damaging
520200 / 0 1330 / 31
bank1 high misfire
DTC 172: Adaptive-learn gasoline bank1 low 520200 / 1 DTC 326: Knock1 excessive or erratic signal 731 / 2
DTC 174: Adaptive-learn gasoline DTC 327: Knock1 sensor open or not present
520201 / 0 731 / 4
bank2 high
DTC 175: Adaptive-learn gasoline bank2 low 520201 / 1 DTC 331: Knock2 excessive or erratic signal 520241 / 2
DTC 182: FT low voltage 174 / 4 DTC 332: Knock2 sensor open or not present 520241 / 4
DTC 183: FT high voltage 174 / 3 DTC 336: CRANK input signal noise 636 / 2
DTC 187: Gaseous fuel temp sender low DTC 337: Crank signal loss
520240 / 4 636 / 4
voltage
DTC 188: Gaseous fuel temp sendr high DTC 341: CAM input signal noise
520240 / 3 723 / 2
voltage
DTC 217: ECT higher than expected stage 2 110 / 0 DTC 342: Loss of CAM input signal 723 / 4
DTC 219: RPM higher than max allowed DTC 359: Fuel run-out longer than expected
515 / 15 1239 / 7
govern speed

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GM 3.0L Engine Fault Codes

DTC Set 2 DTC Set 2

Description SPN-2 / FMI- Description SPN-2 / FMI-
2 2
DTC 420: Catalyst inactive on gasoline (Bank DTC 1111: RPM above fuel rev limit level
520211 / 10 515 / 16
1)
DTC 430: Catalyst inactive on gasoline (Bank DTC 1112: RPM above spark rev limit level
520212 / 10 515 / 0
2)
DTC 502: Roadspeed input loss of signal 84 / 1 DTC 1121: FPP1/2 simultaneous voltages out-of-range 91 / 31
DTC 508: IAC ground short 520252 / 6 DTC 1122: FPP1/2 do not match each other or IVS 520250 / 31
DTC 509: IAC coil open/short 520252 / 5 DTC 1131: WGP voltage high 1192 / 3
DTC 520: Oil pressure sndr low prssure stage DTC 1132: WGP voltage low
100 / 18 1192 / 4
1
DTC 521: Oil pressure sender high pressure 100/ 0 DTC 1151: Closed-loop LPG high 520206 / 0
DTC 522: Oil pressure sender low voltage 651 / 5 DTC 1152: Closed-loop LPG low 520206 / 1
DTC 523: Oil pressure sender high voltage 100 / 3 DTC 1153: Closed-loop NG high 520207 / 0
DTC 524: Oil pressure low 100 / 1 DTC 1154: Closed-loop NG low 520207 / 1
DTC 562: Vbat voltage low 168 / 17 DTC 1155: Closed-loop gasoline bank1 high 520204 / 0
DTC 563: Vbat voltage high 168 / 15 DTC 1156: Closed-loop gasoline bank1 low 520204 /
DTC 601: Microprocessor failure - FLASH 628 / 13 DTC 1157: Closed-loop gasoline bank2 high 520205 / 0
DTC 604: Microprocessor failure - RAM 630 / 12 DTC 1158: Closed-loop gasoline bank2 low 520205 / 1
DTC 606: Microprocessor failure - COP 629 / 31 DTC 1161: Adaptive-learn LPG high 520202 / 0
DTC 615: Start relay coil open 1321 / 5 DTC 1162: Adaptive-learn LPG low 520202 / 1
DTC 616: Start relay ground short 1321 / 4 DTC 1163: Adaptive-learn NG high 520203 / 0
DTC 617: Start relay coil short to power 1321 / 3 DTC 1164: Adaptive-learn NG low 520203 / 1
DTC 627: Fuel pump relay coil open 1348 / 5 DTC 1165: Catalyst inactive on LPG 520213 / 10
DTC 628: Fuel-pump high-side open or short DTC 1166: Catalyst inactive on NG 520214 / 0
1347 / 5
to ground
DTC 628: Fuel pump relay control ground DTC 1171: MegaJector delivery pressure higher than 520260 / 0
1348 / 4
short expected
DTC 629: Fuel-pump high-side short to power DTC 1172: MegaJector delivery pressure lower than 520260 / 1
1347 / 6
expected
DTC 629: Fuel pump relay coil short to power 1348 / 3 DTC 1173: MegaJector comm lost 520260 / 31
DTC 642: Sensor supply voltage 1 low 1079 / 4 DTC 1174: MegaJector voltage supply high 520260 / 3
DTC 643: Sensor supply voltage 1 high 1079 / 3 DTC 1175: MegaJector voltage supply low 520260 / 4
DTC 650: MIL open 1213 / 5 DTC 1176: MegaJector internal actuator fault detection 520260 / 12
DTC 652: Sensor supply voltage 2 low 1080 / 4 DTC 1177: MegaJector internal circuitry fault detection 520260 / 12
DTC 653: Sensor supply voltage 2 high 1080 / 3 DTC 1178: MegaJector internal comm fault detection 520260 / 12
DTC 685: Power relay coil open 1485 / 5 DTC 1182: Fuel impurity level high 520401 / 0
DTC 686: Power relay ground short 1485 / 4 DTC 1183: MegaJector autozero / lockoff failure 520803 / 31
DTC 687: Power relay coil short to power 1485 / 3 DTC 1311: Cylinder 1 misfire detected 1323 / 11
DTC 916: Shift actuator feedback out-of-range 520226 / 3 DTC 1312: Cylinder 2 misfire detected 1324 / 11
DTC 919: Shift unable to reach desired gear 520226 / 7 DTC 1313: Cylinder 3 misfire detected 1325 / 11
DTC 920: Shift actuator or drive circuit failed 520226 / 31 DTC 1314: Cylinder 4 misfire detected 1326 / 11

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GM 3.0L Engine Fault Codes

DTC Set 2
DTC Set 2
Description Description SPN-2 / FMI-
SPN-2 / FMI-2
2
DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage 520220 / 3
DTC 1316: Cylinder 6 misfire detected 1328 / 11 DTC 1544: AUX analog Pull-Up/Down 2 low voltage 520220 / 4
DTC 1317: Cylinder 7 misfire detected 1329 / 11 DTC 1545: AUX analog Pull-Up/Down 3 high voltage 520221 / 3
DTC 1318: Cylinder 8 misfire detected 1330 / 11 DTC 1546: AUX analog Pull-Up/Down 3 low voltage 520221 / 4
DTC 1411: EMWT1 voltage high 441 / 3 DTC 1547: AUX analog Pull-Up/Down 4 high voltage 713 / 3
DTC 1412: EMWT2 voltage high 442 / 3 DTC 1548: AUX analog Pull-Up/Down 4 low voltage 713 / 4
DTC 1413: EMWT1 voltage low 441 / 4 DTC 1551: AUX digital 1 high voltage 520222 / 3
DTC 1414: EMWT2 voltage low 442 / 4 DTC 1552: AUX digital 1 low voltage 520222 / 4
DTC 1415: EMWT1 higher than expected DTC 1553: AUX digital 2 high voltage 520223 / 3
441 / 15
stage 1
DTC 1416: EMWT2 higher than expected DTC 1554: AUX digital 2 low voltage 520223 / 4
442 / 15
stage 1
DTC 1417: EMWT1 higher than expected DTC 1555: AUX digital 3 high voltage 520224 / 3
441 / 0
stage 2
DTC 1418: EMWT2 higher than expected DTC 1555: Water Intrusion Detection 520224 / 3
442 / 0
stage 2
DTC 1419: ERWT1 voltage high 443 / 3 DTC 1556: AUX digital 3 low voltage 520224 / 4
DTC 1420: ERWT2 voltage high 444 / 3 DTC 1561: AUX analog Pull-Down 2 high voltage 0/3
DTC 1421: ERWT1 voltage low 443 / 4 DTC 1561: AUX analog Pull-Down 3 high voltage 0/4
DTC 1422: ERWT2 voltage low 444 / 4 DTC 1561: AUX analog Pull-Down 2 low voltage 0/4
DTC 1423: ERWT1 higher than expected DTC 1611: Sensor supply voltage 1 and 2 out-of-range 1079 / 31
443 / 15
stage 1
DTC 1424: ERWT2 higher than expected DTC 1612: Microprocessor failure - RTI 1 629 / 31
444 / 15
stage 1
DTC 1425: ERWT1 higher than expected DTC 1613: Microprocessor failure - RTI 2 629 / 31
443 / 0
stage 2
DTC 1426: ERWT2 higher than expected DTC 1614: Microprocessor failure - RTI 3 629 / 31
444 / 0
stage 2
DTC 1511: AUX analog Pull-Up 1 high DTC 1615: Microprocessor failure - A/D 629 / 31
520216 / 3
voltage
DTC 1511: AUX analog Pull-Up 1 high DTC 1616: Microprocessor failure - Interrupt 629 / 31
520216 / 3
voltage
DTC 1512: AUX analog Pull-Up 1 low voltage 520216 / 4 DTC 1621: RS-485 Rx inactive 0 / 31
DTC 1513: AUX analog Pull-Up 2 high DTC 1622: RS-485 Rx noise 0 / 31
520217 / 3
voltage
DTC 1514: AUX analog Pull-Up 2 low voltage 520217 / 4 DTC 1623: RS-485 Rx bad packet format 0 / 31
DTC 1515: AUX analog Pull-Down 1 high DTC 1624: RS-485 remote shutdown request
520215 / 3 0 / 31
voltage
DTC 1516: AUX analog Pull-Down 1 low DTC 1625: J1939 shutdown request
520215 / 4 1384 / 31
voltagee

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GM 3.0L Engine Fault Codes

DTC Set 2
DTC Set 2
Description SPN-2 / FMI- Description
SPN-2 / FMI-2
2
DTC 1517: AUX analog Pull-Up 3 high voltage 520218 / 3 DTC 1626: CAN-J1939 Tx fault 639 / 12
DTC 1518: AUX analog Pull-Up 3 low voltage 520218 / 4 DTC 1627: CAN-J1939 Rx fault 639 / 12
DTC 1521: CHT higher than expected stage 1 DTC 1628: J1939 CAN address / engine-number
110 / 16 639 /13
conflict
DTC 1522: CHT higher than expected stage 2 110 / 0 DTC 1629: J1939 TSC1 message receipt loss 639 / 9
DTC 1531: Gov1/2/3 interlock failure 520270 / 31 DTC 1630: J1939 ETC message receipt loss 91 / 2
DTC 1541: AUX analog Pull-Up/Down 1 high DTC 1632: PWM1-Gauge1 short to power
520219 / 3 697 / 6
voltage
DTC 1542: AUX analog Pull-Up/Down 1 low DTC 1633: PWM2-Gauge2 open / ground short
520219 / 4 698 / 5
voltage
DTC 1634: PWM2-Gauge2 short to power 698 / 6 DTC 2126: FPP1-2 higher than expected 91 / 16
DTC 1635: PWM3-Gauge3 open / ground DTC 2127: FPP2 voltage low
699 / 6 29 / 4
short
DTC 1636: PWM3-Gauge3 short to power 700 / 5 DTC 2128: FPP2 voltage high 29 / 3
DTC 1637: PWM4 open / ground short 700 / 6 DTC 2130: IVS stuck at-idle, FPP1/2 match 558 / 5
DTC 1638: PWM4 short to power 520230 / 5 DTC 2131: IVS stuck off-idle, FPP1/2 match 558 / 6
DTC 1639: PWM5 open / ground short 520230 / 5 DTC 2135: TPS1/2 simultaneous voltages out-of-range 51 / 31
DTC 1640: PWM5 short to power 520230 / 6 DTC 2139: FPP1 lower than IVS 91 / 1
DTC 1641: Buzzer control ground short 920 / 4 DTC 2140: FPP2 lower than IVS 29 / 1
DTC 1642: Buzzer open 920 / 5 DTC 2229: BP pressure high 108 / 0
DTC 1643: Buzzer control short to power 920 / 3 DTC 2300: Spark coil 1 primary open or short to ground 1268 / 5
DTC 1644: MIL control ground short 1213 / 4 DTC 2301: Spark coil 1 primary shorted 1268 / 6
DTC 1645: MIL control short to power 1213 / 3 DTC 2303: Spark coil 2 primary open or short to ground 1269 / 5
DTC 1651: J1939 ETC message receipt loss DTC 2304: Spark coil 2 primary shorted
91 / 9 1269 / 6
while in-gear
DTC 1661: PWM6 open / ground short 925 / 5 DTC 2306: Spark coil 3 primary open or short to ground 1270 / 5
DTC 1662: PWM6 short to power 925 / 3 DTC 2307: Spark coil 3 primary shorted 1270 / 6
DTC 1663: PWM7 open / ground short 926 / 5 DTC 2309: Spark coil 4 primary open or short to ground 1271 / 5
DTC 1664: PWM7 short to power 926 / 3 DTC 2310: Spark coil 4 primary shorted 1271 / 6
DTC 1665: PWM8 open / ground short 2646 / 5 DTC 2312: Spark coil 5 primary open or short to ground 1272 / 5
DTC 1666: PWM8 short to power 2646 / 3 DTC 2313: Spark coil 5 primary shorted 1272 / 6
DTC 1669: PWM9 open / ground short 2647 / 5 DTC 2315: Spark coil 6 primary open or short to ground 1273 / 5
DTC 1670: PWM9 short to power 2647 / 3 DTC 2316: Spark coil 6 primary shorted 1273 / 6
DTC 2111: Unable to reach lower TPS 51 / 7 DTC 2318: Spark coil 7 primary open or short to ground 1274 / 5
DTC 2112: Unable to reach higher TPS 51 / 7 DTC 2319: Spark coil 7 primary shorted 1274 / 6
DTC 2115: FPP1 higher than IVS 91 / 0 DTC 2321: Spark coil 8 primary open or short to ground 1275 / 5
DTC 2116: FPP2 higher than IVS 29 / 0 DTC 2322: Spark coil 8 primary shorted 1275 / 6
DTC 2120: FPP1 invalid voltage and DTC 2324: Spark coil 9 primary open or short to ground
520250 / 31 1276 / 5
FPP2 disagrees with IVS
DTC 2121: FPP1-2 lower than expected 91 / 18 DTC 2325: Spark coil 9 primary shorted 1276 / 6
DTC 2122: FPP1 voltage high DTC 2327: Spark coil 10 primary open or short to
91 / 3 1277 / 5
ground

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 157
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GM 3.0L Engine Fault Codes

DTC Set 2
DTC Set 2
Description SPN-2 / FMI- Description
SPN-2 / FMI-2
2
DTC 2123: FPP1 voltage low 91 / 4 DTC 2328: Spark coil 10 primary shorted 1277 / 6
DTC 2125: FPP2 invalid voltage and 520250 / 31 DTC 2428: EGT temperature high
173 / 0
FPP1 disagrees with IVS
DTC 2618: Tach output ground short 645 / 4 DTC 8909: UEGO pump voltage shorted low 3218 / 3
DTC 2619: Tach output short to power 645 / 3 DTC 8910: UEGO sense cell voltage high 3218 / 3
DTC 8901: UEGO microprocessor internal 3221 / 1 DTC 8911: UEGO sense cell voltage low
3218 / 4
fault
DTC 8902: UEGO heater supply high voltage 3222 / 3 DTC 8912: UEGO pump voltage at high drive limi 3217 / 3
DTC 8903: UEGO heater supply low voltage 3222 / 4 DTC 8913: UEGO pump voltage at low drive limit 3217 / 3
DTC 8904: UEGO cal resistor voltage high 3221 / 3 DTC 8914: UEGO sense cell slow to warm up 3225 / 4
DTC 8905: UEGO cal resistor voltage low 3221 / 4 DTC 8915: UEGO pump cell slow to warm up 3222 / 4
DTC 8906: UEGO return voltage shorted high 3056 / 3 DTC 8916: UEGO sense cell impedance high 3225 / 10
DTC 8907: UEGO return voltage shorted low 3056 / 4 DTC 8917: UEGO pump cell impedance high 3225 / 0
DTC 8908: UEGO pump voltage shorted high 3218 / 3 DTC 8918: UEGO pump cell impedance low 3225 / 1

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Schematics

About This Section

Secti on 5 Schematic s

There are two groups of schematics in this section.

Electrical Schematics
Electrocution/burn hazard.
Contact with electrically charged
Observe and Obey: circuits could result in death or
serious injury. Remove all rings,
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and
qualified on the repair of this machine
 Immediately tag and remove from service a Hydraulic Schematics
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction hydraulic oil can penetrate and
before operating the machine. burn skin. Loosen hydraulic
connections very slowly to allow
Before Troubleshooting: the oil pressure to dissipate
gradually. Do not allow oil to
 Read, understand and obey the safety rules squirt or spray.
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.

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 159
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Electrical Symbol Legend

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

T-circuits connect at Circuits crossing no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage

Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor

Horn button - normally Emergency Stop button

Resistor with ohm value Battery separator Gauge sending unit
open - normally closed

Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor

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Hydraulic Symbols Legend

Orifice with size Check valve Shut off valve Brake

Pump, bi-directional Motor, 2 speed bi-

Pump, fixed displacement Motor, bi-directional
variable displacement directional

Pump, prime mover Shuttle valve. 2 position,

Cylinder, double acting Differential sensing valve
(engine or motor) 3 way

Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve

Solenoid operated
Directional valve Flow divider/combiner Pilot operated 3 position,
2 position, 3 way
(mechanically activated) valve 3 way shuttle valve
directional valve

Solenoid operated
Solenoid operated
Counterbalance valve with 3 position, 4 way Solenoid valve, 2 position
3 position 4 way directional
pressure and pilot ratio proportional directional 2 way
valve
valve

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 161
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Limit Switch Location Legend

1 S17 5 LST3S
2 S22 6 S8O, S8S
3 LSB2S 7 LST1O
4 LSB1RS 8 S24

Limit Switches and Sensors

S17 Boom angle sensor

S22 Boom length sensor
LSB2S Limit switch cable tension- safety
LSB1RS Limit switch boom fully retracted- safety
LST3S Limit switch boom angle- safety
S8O Universal tilt sensor - operational
S8S Universal tilt sensor - safety
LST1O Limit switch turntable - operational
S24 Load cell - platform overload

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Engine Relay Layout - Deutz TD2.9

Deutz TD 2.9 L4
Fuses

CB8A 30A See Elec Schem for circuits

CB8B 30A See Elec Schem for circuits
F19 15A See Elec Schem for circuits
F21 10A See Elec Schem for circuits
CB9 30A See Elec Schem for circuits
CB10 20A See Elec Schem for circuits
CB1 30A See Elec Schem for circuits
CB2 15A See Elec Schem for circuits

Diode

D22 6A Alternator Ext.

Relays

CR1 Ignition on
CR5 Horn
CR6 Fuel pump
CR15A Glow plugs
CR15B Glow plugs
CR17 Hydraulic oil cooler
CR27 Auxiliary
CR41 R21IGN

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 163
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Engine Relay Layout - Deutz TD2011L04i

Deutz TD2011L04i
Fuses

CB8A 30A See Elec Schem for circuits

CB8B 30A See Elec Schem for circuits
F19 5A See Elec Schem for circuits
F21 5A See Elec Schem for circuits
CB9 30A See Elec Schem for circuits
CB10 20A See Elec Schem for circuits
CB1 30A See Elec Schem for circuits
CB2 15A See Elec Schem for circuits

Diode

D22 6A Alternator Ext.

Relays

CR1 Engine start

CR3 High RPM.

CR15A Glow plug 1

CR15B Glow plug 2

CR17 Hydraulic Oil Cooler

CR23 Drive

CR41 R21IGN

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Engine Relay Layout - Perkins 404D-22T

Perkins 404D-22T
Circuit
Breakers
CB1 30A See Elec Schem for circuits
CB2 15A See Elec Schem for circuits
CB9 30A See Elec Schem for circuits
CB10 20A See Elec Schem for circuits
CB8A 30A See Elec Schem for circuits
CB8B 30A See Elec Schem for circuits
Fuses
F19 5A See Elec Schem for circuits
F21 5A See Elec Schem for circuits
Diode

D22 6A Alternator Ext.

Relays

CR1 Start

CR3 High RPM

CR4 Low RPM

CR5 Horn
CR17 Hydraulic oil cooler (option)
CR15A Glow plugs
CR15B Glow Plugs

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 165
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Engine Relay Layout - GM 3.0L

GM 3.0L
Fuses

CB8A 30A See Elec Schem for circuits

CB8B 30A See Elec Schem for circuits
F19 5A See Elec Schem for circuits
F21 5A See Elec Schem for circuits
CB9 30A See Elec Schem for circuits
CB10 20A See Elec Schem for circuits
CB1 30A See Elec Schem for circuits
CB2 15A See Elec Schem for circuits

Diode

D22 6A Alternator Ext.

Relays

CR1 Engine start

CR3 High RPM.

CR5 Horn

CR17 Hydraulic OIl Cooler

CR23 Drive

CR41 R21IGN

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Connector Pin Legend

Number Description C43 VEC - blue - 8 pin

C1 Boom cable - Controls C44 VEC - green - 8 pin
C2 Boom cable - Power C45 VEC- gray - 2 pin
C3 Boom sensors C46 VEC - black - 2 pin
C4 Function manifold C47 Function enable
C5 Function manifold C48 Brake
C6 Engine C49 Motor stroke
C7 Engine C50 Drive pump
C8 Engine - Power C51 Engine ECG
C9 Foot switch C52 Engine ECG
C10 Platform options C53 Platform recirculation valve
C11 Platform manifold C56 Telematics
C12 Boom cable (platform) - Controls C57 ACP
C13 Drive lights C72 ECU
C14 Hydraulic oil cooler
C15 Flashing beacons
C16 Engine diagnostic port
C17 Boom cable (platform) - power
C18 D2.9 engine connector
C19 LST3S
C20 LST1O
C21 LSB1RS
C22 LSB2S
C23 Generator from engine harness
C24 Welder encloser
C25 GM3.0 vehicle interface conn. 1
C26 GM3.0 vehicle interface conn. 2
C27 Load sense
C28 Boom angle sensor
C29 Boom extension string pot
C30 Canbus terminating resistor
C31 Crew alarm proximity switch
C32 Crew alarm lights
C33 GBOX service port
C34 PBOX service port
C35 404D speed sensor
C36 404D fuel solenoid
C37 Work lights
C41 VEC - black - 8 pin
C42 VEC - gray - 8 pin

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 167
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Connector Pin Legend

Number Description
J1 TCON power
J2 TCON engine
J3 TCON functions
J4 TCON functions
J5 TCON logic
J6 TCON limit switches
J7 TCON limit switches
J8 TCON unused
J9 TCON communication
J10 DISCON
J12 PCON power
J13 PCON functions
J14 PCON functions
J15 PCON logic
J16 PCON toggles
J17 PCON toggles
J18 PCON joysticks
J19 PCON unused
J20 Boom angle sensor operational- not used
J21 Boom angle sensor safety- not used
J22 Fuel level sensor
J23 Platform level sensor operational- not used
J24 Platform level sensor safety- not used
J25 Boom function- joystick
J26 Drive function- joystick
J27 404D ECG - black
J28 404D ECG - gray
J29 D2.9 ECU 1
J30 D2.9 ECU 2
J31 D2.9 engine interface
J32 Chassis tilt sensor operational
J33 Chassis tilt sensor safety
J34 D2011 engine interface
J35 LED PCB
J36 Recovery module power
J37 Recovery module I/O

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Electrical Schematic, Turntable Controller

(to serial number S80XCH-513, S85XCH- 518)

169
Service and Repair Manual April 2022

Electrical Schematic, Turntable Controller

(to serial number S80XCH-513, S85XCH- 518)

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Electrical Schematic, Platform Controller

(to serial number S80XCH-513, S85XCH- 518)

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 171
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Electrical Schematic, Platform Controller

(to serial number S80XCH-513, S85XCH- 518)

172
 April 2022 Service and Repair Manual

Electrical Schematic, Turntable Controller

(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)

173
Service and Repair Manual April 2022

Electrical Schematic, Turntable Controller

(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)

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Electrical Schematic, Platform Controller

(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 175
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Electrical Schematic, Platform Controller

(from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399)

176
 April 2022 Service and Repair Manual

Electrical Schematic, Turntable Controller

(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)

177
Service and Repair Manual April 2022

Electrical Schematic, Turntable Controller

(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)

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Electrical Schematic, Platform Controller

(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 179
Service and Repair Manual April 2022

Electrical Schematic, Platform Controller

(from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400)

180
 April 2022 Service and Repair Manual

Electrical Schematic, Deutz TCD 2.2 L3 Engine

181
Service and Repair Manual April 2022

Electrical Schematic, Deutz TCD 2.2 L3 Engine

182 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
April 2022 Service and Repair Manual

Electrical Schematic, Deutz TCD 2.2 L3 Engine

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 183
Service and Repair Manual April 2022

Electrical Schematic, Deutz TCD 2.2 L3 Engine

184
 April 2022 Service and Repair Manual

Electrical Schematic, Deutz TD 2.9 L4 Engine

185
Service and Repair Manual April 2022

Electrical Schematic, Deutz TD 2.9 L4 Engine

186 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
April 2022 Service and Repair Manual

Electrical Schematic, Deutz TD2011 L04i Engine

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 187
Service and Repair Manual April 2022

Electrical Schematic, Deutz TD2011 L04i Engine

188
 April 2022 Service and Repair Manual

Electrical Schematic, Perkins 404D-22T Engine

189
Service and Repair Manual April 2022

Electrical Schematic, Perkins 404D-22T Engine

190 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
April 2022 Service and Repair Manual

Electrical Schematic, Perkins 404F-E22TA Engine

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 191
Service and Repair Manual April 2022

Electrical Schematic, Perkins 404F-E22TA Engine

192
 April 2022 Service and Repair Manual

Electrical Schematic, GM 3.0L Engine

193
Service and Repair Manual April 2022

Electrical Schematic, GM 3.0L Engine

194 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
April 2022 Service and Repair Manual

Electrical Schematic,
12 kW Welder Generator and 3 kW Generator

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 195
Service and Repair Manual April 2022

Electrical Schematic,
12 Kw Welder Generator and 3 kW Generator

196
 April 2022 Service and Repair Manual

Hydraulic Schematic, S-80 XC Models

197
Service and Repair Manual April 2022

Hydraulic Schematic, S-80 XC Models

198 S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF Part No. 1280490GT
April 2022 Service and Repair Manual

Hydraulic Schematic, S-85 XC Models

Part No. 1280490GT S®-80 XC™ • S®-80 HF • S®-85 XC™ • S®-85 HF 199
Service and Repair Manual April 2022

Hydraulic Schematic, S-85 XC Models

S®-80 XC™ • S®-8 0 HF • S®- 85 XC™ • S®-8 5 HF Part No. 128 049 0GT Service a nd Re pair Ma nual April 202 2

200