operating instructions in the appropriate Operator's. Manual on your ... equipment and special installation instructions for ... DPF reporting fast channel 2 signal.
manual and the decals on the the following: 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
Service and Repair Manual July 2020 Introduction ii S -80 XC™ • S -85 XC™ • S -80 HF • S -85 HF Part No. 1280490GT Introduction Introduction Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure.
Service and Repair Manual Serial Number Range S®-80 XCTM S®-80 HF S®-85 XCTM S®-85 HF from S80XCH-101 from S80XCD-101 from S85XCH-101 from S85XCD-101 This manual includes: Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1280490GT Rev D July 2020 Service and Repair Manual Introduction July 2020 Intro ductio n Intro ductio n Important Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure. This manual provides detailed scheduled maintenance information for the machine owner and user. It also provides troubleshooting and repair procedures for qualified service professionals. Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center. Compliance Machine Classification Group B/Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals. Contact Us: Internet: www.genielift.com E-mail: awp.techpub@terex.com Find a Manual for this Model Go to http://www.genielift.com Use the links to locate Service Manuals, Maintenance Manuals, Service and Repair Manuals, Parts Manuals and Operator's Manuals. Copyright © 2017 by Terex Corporation 1280490 Rev D, July 2020 First Edition, Fourth Printing Genie and "Z" 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. ii S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Revision History Revision A B C Date 11/2017 12/2017 1/2018 C1 4/2018 C2 7/2018 C3 10/2018 C4 5/2019 C5 6/2019 C6 7/2019 C7 10/2019 D 5/2020 Section Schematics Specifications Schematics Repair Repair Schematics Specifications Specifications Repair Fault Codes Schematics Fault Codes Repair Schematics All Sections Repair Service and Repair Manual Introduction Procedure / Page / Description New Release Electrical schematics Hydraulic Component Specifications Electrical schematics 6-1 Move Ground Controls to Control System Electrical schematics Machine Specifications Machine Torque Specifications Display Menu Control System Fault Codes Electrical schematics Control System Fault Codes Display Menu Limit Switch Legend Add Deutz TCD 2.2 L3 Engine 2-4 Reference Examples: Section Repair Procedure, 4-2 Section Fault Codes, All charts Section Schematics, Legends and schematics Electronic Version Click on any content or procedure in the Table of Contents to view the update. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF iii Service and Repair Manual Introduction Serial Number Legend July 2020 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on drive chassis) iv S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Sectio n 1 Safety Rul es Service and Repair Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine. You read, understand and obey: manufacturer's instructions and safety rules employer's safety rules and worksite regulations applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF v Service and Repair Manual Safety Rules July 2020 Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following: Safety alert 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. Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. Workplace Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use. Keep work surfaces clean and free of debris that could get into machine components and cause damage. Be sure any forklift, overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted. Use only chains or straps that are in good condition and of ample capacity. Be sure that fasteners intended for one time use (i.e., cotter pins and selflocking nuts) are not reused. These components may fail if they are used a second time. Be sure to properly dispose of old oil or other fluids. Use an approved container. Please be environmentally safe. Be sure that your workshop or work area is properly ventilated and well lit. vi S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Table of Contents Introduction Section 1 Section 2 Introduction ......................................................................................................ii Important Information ......................................................................................... ii Find a Manual for this Model............................................................................... ii Revision History ................................................................................................ iii Serial Number Legend....................................................................................... iv Safety Rules......................................................................................................v General Safety Rules ......................................................................................... v 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 Hydraulic Hose and Fitting Torque Specifications .............................................13 Torque Procedure ............................................................................................ 14 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF vii Table of Contents July 2020 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 .......................... 27 1-8 How to Replace the Ground Control Overlay .............................................. 28 Platform Components.................................................................................... 31 2-1 Platform ..................................................................................................... 31 2-2 Platform Leveling Slave Cylinder ................................................................ 32 How to Remove the Platform Leveling Slave Cylinder ................................. 32 How to Bleed the Slave Cylinder ................................................................. 32 2-3 Platform Rotator......................................................................................... 33 How to Remove the Platform Rotator .......................................................... 33 How to Bleed the Platform Rotator .............................................................. 34 2-4 Platform Overload System.......................................................................... 35 How to Perform a Zero Load Platform Calibration........................................ 35 How to Perform a Full Load Platform Calibration ......................................... 36 How to Replace the Platform Overload Load Cell ........................................ 38 viii S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Table of Contents Jib Boom Components ..................................................................................39 3-1 Jib Boom ....................................................................................................39 3-2 Jib Boom Lift Cylinder.................................................................................40 Boom Components ........................................................................................41 4-1 Cable Track................................................................................................41 How to Remove the Cable Track, S-80 ........................................................41 How to Repair the Cable Track ....................................................................43 4-2 Boom .........................................................................................................43 How to Shim the Boom ................................................................................43 How to Remove the Boom ...........................................................................44 4-3 Boom Lift Cylinder ......................................................................................47 4-4 Boom Extension Cylinder............................................................................48 4-5 Boom Extend/Retract Cables......................................................................50 How to Adjust the Extend/Retract Cables.....................................................50 How to Replace the Boom Extend/Retract Cables .......................................52 4-6 Platform Leveling Master Cylinder ..............................................................54 4-7 Primary Boom Angle Sensor Calibration .....................................................55 4-8 Boom Length Sensor ..................................................................................56 Engines ........................................................................................................... 57 5-1 RPM Adjustment ........................................................................................57 5-2 Flex Plate ...................................................................................................57 How to Remove the Flex Plate.....................................................................57 How to Install the Flex Plate ........................................................................60 How to install the Pump and Bell Housing Assembly....................................61 _5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3 .............................62 Hydraulic Pumps ............................................................................................ 63 7-1 Function Pump ...........................................................................................63 7-2 Drive Pump ................................................................................................64 How to Prime the Drive Pump......................................................................65 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF ix Table of Contents July 2020 Manifolds........................................................................................................ 66 8-1 Function Manifold....................................................................................... 66 8-2 Valve Adjustments - Function Manifold....................................................... 68 How to Adjust the System Relief Valve........................................................ 68 How to Adjust the Boom Down Relief Valve ................................................ 68 How to Adjust the Boom Extend Relief Valve............................................... 69 8-3 Brake/Two-Speed Manifold Components.................................................... 70 8-4 Turntable Rotation Manifold Components................................................... 71 8-5 Platform Rotate Manifold Components ....................................................... 72 8-6 Platform Manifold Components, S-80 XC ................................................... 73 8-7 Platform Manifold Components, S-85 XC ................................................... 74 8-8 4WD Traction Manifold Components .......................................................... 76 8-9 Valve Adjustments - Traction Manifold........................................................ 78 8-10 Generator Manifold Components.............................................................. 79 8-11 Valve Coils............................................................................................... 80 Valve Coil Resistance Specifications........................................................... 80 Fuel and Hydraulic Tanks .............................................................................. 82 9-1 Fuel Tank................................................................................................... 82 9-2 Hydraulic Tank ........................................................................................... 83 Turntable Rotation Components ................................................................... 85 10-1 Turntable Rotation Drive Hub Assembly ................................................... 85 How to Remove the Turntable Rotation Drive Hub Assembly....................... 85 How to Remove the Turntable Rotation Hydraulic Motor.............................. 86 How to Adjust the Turntable Rotation Gear Backlash................................... 87 How to Calibrate the Turntable Tilt Sensor .................................................. 88 Steer Axle Components................................................................................. 90 11-1 Yoke and Drive Hub ................................................................................. 90 11-2 Drive Motors ............................................................................................ 91 11-3 Drive Hubs ............................................................................................... 91 Generators...................................................................................................... 92 12-1 Hydraulic Generator ................................................................................. 92 x S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Section 4 Section 5 Table of Contents 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 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 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF xi Table of Contents July 2020 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 xii S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Sectio n 2 Specificatio ns Machine Specifications Tires and wheels Rough Terrain and Non Marking Tire size Tire ply rating Overall tire diameter Tire pressure Wheel diameter Wheel width Tire weight, new foam filled (minimum) High Flotation Tire size Tire ply rating Overall tire diameter Tire pressure Wheel diameter Wheel width Tire weight 18-625 FF 16 ply 40.7 in 103,3 cm foam filled 24.5 in 62,2 cm 15 in 38,1 cm 622 lbs 282 kg 41/18LL 20 ply 41.2 in 104,6 cm 100 psi 6,89 bar 22.5 in 57,2 cm 14 in 35,6 cm 250 lbs 113,4 kg Fluid capacities Fuel tank, Diesel models 35 gallons 132,5 liters Fuel tank, Gas models 30 gallons 113,5 liters LPG tank 33.5 lbs 15,2 kg Hydraulic tank 40 gallons 151 liters Hydraulic system (including tank) 64 gallons 242 liters Turntable rotation drive hub (single fill port) 40 fl oz 1183 cc Turntable rotation drive hub (dual fill port) 43 fl oz 1262 cc Drive hubs four wheel drive 48 fl oz 1420 cc Drive hub oil type: SAE 90 multipurpose hypoid gear oil API service classification GL5 Lugs and Lug Nut Torque Wheel lugs Lug nut torque, dry Lug nut torque, lubricated 11 @ 3/4 - 16 420 ft-lbs 569 Nm 320 ft-lbs 434 Nm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 1 Service and Repair Manual Specifications July 2020 Performance Specifications Drive speed, maximum Stowed position, RT tires 40 ft / 9 - 11 sec 12,2 m / 9 - 11 sec Raised or extended 40 ft / 55 - 65 sec 12,2 m / 55 - 65 sec Braking distance, maximum High range on paved surface 3 - 6 ft / 0,91 - 1,8 m Gradeability Refer to Operator's Manual Boom function speeds, maximum from platform controls Jib boom up (S-85 XC) 25 - 35 sec Jib boom down (S-85 XC) 15 - 25 sec Primary boom up 75 - 83 sec Primary boom down 110 - 115 sec Primary boom extend 59 - 67 sec Primary boom retract 57 - 65 sec Turntable rotate stowed, (360°) 95 - 103 sec Turntable rotate raised or extended, (360°) 210 - 250 sec Platform rotate, 160° 40 - 50 sec Platform level (10° range of motion) 20 - 22 sec For operational specifications, refer to the Operator's Manual. Hydraulic Oil Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems, have the ability to perform over a wide temperature range, and the viscosity index should exceed 140. They should provide excellent antiwear, oxidation prevention, corrosion inhibition, seal conditioning, and foam and aeration suppression properties. Cleanliness level, minimum ISO 15/13 Water content, maximum 250 ppm Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Mineral based Shell Tellus S2 V 32 Shell Tellus S2 V 46 Shell Tellus S4 VX 32 Shell Donax TG (Dexron III) Chevron 5606A Biodegradable Petro Canada Environ MV 46 Fire resistant UCON Hydrolube HP-5046 Note: Genie specifications require additional equipment and special installation instructions for the approved optional fluids. Consult Genie Product Support before use. Optional fluids may not have the same hydraulic lifespan and may result in component damage. Note: Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range. If the hydraulic fluid temperature consistently exceeds 200°F / 90°C an optional oil cooler may be required. 2 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the differences in base additive chemistry. When incompatible fluids are mixed, insoluble materials may form and deposit in the hydraulic system, plugging hydraulic lines, filters, control valves and may result in component damage. Note: Do not operate the machine when the ambient air temperature is consistently above 120°F / 49°C. Hydraulic Fluid Temperature Range Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C Brookfield Viscosity cP @ -4°F / -20°C cP @ -22°F / -30°C Flash point Pour point Maximum continuous operating temperature 32 200 7.5 33.5 1040 3310 375°F / 190°C -58°F / -50°C 171°F / 77°C 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 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 3 Service and Repair Manual Specifications July 2020 Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ -40°F / -40°C Flash point Pour point Maximum continuous operating temperature 15 300 5.5 15.0 510 180°F / 82°C -81°F / -63°C 124°F / 51°C Petro-Canada Environ MV 46 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C Flash point Pour point Maximum continuous operating temperature 46 154 8.0 44.4 482°F / 250°C -49°F / -45°C 180°F / 82°C Note: Use of Chevron 5606A hydraulic fluid, or equivalent, is required when ambient temperatures are consistently below 0°F / -17°C unless an oil heating system is used. Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage Shell Tellus S4 VX Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C Brookfield Viscosity cSt @ -4°F / -20°C cSt @ -13°F / -25°C cSt @ -40°F / -40°C Flash point Pour point Maximum continuous operating temperature 32 300 9 33.8 481 702.4 2624 >100 -76°F / -60°C 103°F / 75°C 4 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 0°F / -18°C Flash point Pour point Maximum continuous operating temperature 46 192 22 46 1300 None -81°F / -63°C 189°F / 87°C Hydraulic Component Specifications Drive Pump Type: bi-directional variable displacement piston pump Displacement per revolution 0 to 2.8 cu in 0 to 46 cc Flow rate @ 2300 rpm Drive pressure, maximum 30.3 gpm 114,7 L/min 3750 psi 259 bar Charge Pump 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 Neutral position 310 psi 21,4 bar Function Pump Type: variable displacement piston pump Displacement per revolution Flow rate @ 2300 rpm 0 to 2.3 cu in 0 to 38 cc 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 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 5 Service and Repair Manual Specifications July 2020 Function manifold System relief valve pressure, maximum Primary boom extend relief pressure (measured at PTEST port) Platform Manifold and Oscillate Valve Platform level flow regulator Platform rotate flow regulator Oscillate relief valve pressure Traction Manifold Hot oil relief pressure Brakes Brake release pressure, Wheel drive hubs Drive Motors Displacement per revolution high speed: Displacement per revolution low speed Hydraulic Filters High pressure filter: High pressure filter bypass pressure Medium pressure filter Medium pressure filter bypass pressure Hydraulic tank return filter Drive motor case drain return filter Accumulator Relief pressure Note: This component is not serviceable. 3200 psi 221 bar 2400 psi 165 bar 0.6 gpm 2,3 L/min 0.3 gpm 1,1 L/min 950 psi 65,5 bar 280 psi 19,3 bar 240 psi 16,5 bar 0.9 cu in 14.7 cc 2.7 cu in 45 cc Beta 3 200 102 psi 7 bar Beta 3 200 51 psi 3,5 bar 15 micron hydraulic 10 micron air breather Beta 10 2 1100 psi 75,8 bar Manifold Component Specifications Plug torque SAE No. 2 SAE No. 4 SAE No. 6 SAE No. 8 SAE No. 10 SAE No. 12 36 in-lbs / 4 Nm 10 ft-lbs / 13 Nm 14 ft-lbs / 19 Nm 38 ft-lbs / 51 Nm 41 ft-lbs / 55 Nm 56 ft-lbs / 76 Nm 6 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Deutz TD2011 L04i Engine Displacement 220.9 cu. in 3,62 liters Number of cylinders 4 Bore and Stroke 3.78 x 4.92 inches 96 x 125 mm Horsepower net intermittent @ 2400 rpm 74 hp 55 kW Induction system turbocharged Firing order 1 - 3 - 4 - 2 Low idle 1500 rpm High idle 2350 rpm Compression ratio 17.5:1 Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder Governor centrifugal mechanical Valve clearance, cold Intake 0.012 in 0,3 mm Exhaust 0.020 in 0,5 mm Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2.8 to 4.1 bar 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. Oil Temperature sender Installation torque 8 - 18 ft-lbs 11 - 24 Nm Oil Pressure sender Installation torque 8 - 18 ft-lbs 11 - 24 Nm Fuel injection system Motorpal Injection pump pressure, maximum 15,000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140 - 200A Cranking speed 250 - 350 rpm Battery Engine starting and control system Type 12V DC, Group 31 Quantity 2 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Alternator output 80A @ 14V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 7 Service and Repair Manual Specifications July 2020 Deutz TCD 2.2 L3 Engine Displacement 134 cu. in 2,2 liters Number of cylinders 3 Bore and Stroke 3.6 x 4.3 inches 92 x 110 mm Horsepower net intermittent @ 2600 rpm 74 hp 55 kW Induction system turbocharged Firing order 1 - 2 - 3 Low idle, standby 1000 rpm Low idle, function enable 1500 rpm High idle 2400 rpm Governor electronic Lubrication system Low ash oil required Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2,8 to 4,1 bar Oil capacity (including filter) 8 quarts 7,6 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. Oil temperature switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Temperature switch point 257°F 125°C Oil Pressure switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Pressure switch point 17.4 psi 1,2 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Engine coolant capacity 2.5 gallons 9,5 liters Unit ships with Ethylene Glycol engine coolant. Consult your local supplier for compatibility before mixing alternative engine coolants. Starter motor Current draw, normal load 140 - 200A Cranking speed 250 - 350 rpm Battery Engine starting and control system Type 12V DC, Group 31 Quantity 1 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Alternator output 95A @ 14V DC 8 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Deutz TD 2.9 L4 Engine Displacement 177 cu. in 2,9 liters Number of cylinders 4 Bore and Stroke 3.6 x 4.3 inches 92 x 110 mm Horsepower net intermittent @ 2600 rpm 74.2 hp 55 kW Induction system turbocharged Firing order 1 - 3 - 4 - 2 Low idle, standby 1000 rpm Low idle, function enable 1500 rpm High idle 2500 rpm Compression ratio 17.4:1 Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder Governor electronic Valve clearance, cold Intake 0.012 in 0,3 mm Exhaust 0.020 in 0,5 mm Lubrication system Oil pressure, hot (@ 2000 rpm) Oil capacity (including filter) 40 to 60 psi 2,8 to 4,1 bar 12.8 quarts 12,1 liters Oil viscosity requirements -22°F to 86°F / -30°C to 30°C Low ash oil required 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. Oil Temperature sender Installation torque 8 - 18 ft-lbs 11 - 24 Nm Oil Pressure sender Installation torque 8 - 18 ft-lbs 11 - 24 Nm Fuel injection system Motorpal Injection pump pressure, maximum 15,000 psi 1034 bar Injector opening pressure 3046 psi 210 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140 - 200A Cranking speed 250 - 350 rpm Battery Engine starting and control system Type 12V DC, Group 31 Quantity 2 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Alternator output 95A @ 14V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 9 Service and Repair Manual Specifications July 2020 Perkins 404D-22T Engine Displacement 134 cu in 2,2 liters Number of cylinders 4 Bore and Stroke 3.31 x 3.94 inches 84 x 100 mm Horsepower 58 @ 2500 rpm 44 kW @ 2500 rpm Firing order 1 - 3 - 4 - 2 Low idle, standby 1000 rpm Low idle, function enable 1500 rpm High idle 2500 rpm Compression ratio 23.3:1 Compression pressure 426 psi 29,4 bar Pressure (psi) of lowest cylinder must be within 50 psi / 3.45 bar of highest cylinder Governor centrifugal mechanical Valve clearance, cold Intake 0.008 in 0,2 mm Exhaust 0.008 in 0,2 mm Lubrication system Oil pressure, cold (at 2500 rpm) 60 psi 4,1 bar Oil capacity (including filter) 9.3 quarts 8,8 liters Oil viscosity requirements Below 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. Fuel injection system Injection pump make Zexel Injection pressure 2133 psi 147 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Alternator output 55A @ 12V DC Fan belt deflection 3/8 in 10 mm Starter motor Current draw, no load Brush length, new Brush length, minimum 140-200A 0.7480 in 19 mm 0.5 in 12,7 mm Battery Type Quantity 12V DC, Group 31 2 Cold cranking ampere 1000A Reserve capacity @ 25A rate 200 minutes Engine coolant Capacity 7.7 quarts 7,3 liters 10 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Perkins 404F-E22TA Engine Displacement 134 cu. in 2,2 liters Number of cylinders 4 Bore and Stroke 3.31 x 3.94 inches 84 x 100 mm Horsepower net intermittent @ 2800 rpm Horsepower continuous @ 2800 rpm 55 hp / 41,1 kW 52 hp / 38,8 kW Induction system turbocharged Firing order 1 - 3 - 4 - 2 Low idle, standby 1100 rpm Low idle, function enable 1500 rpm High idle 2500 rpm Compression ratio 23.3:1 Compression pressure (psi or bar) of the lowest cylinder must be at least 75% of the highest cylinder Governor electronic Valve clearance, cold Intake 0.008 in 0,2 mm Exhaust 0.018 in 0,45 mm Lubrication system Oil pressure, hot (@ 2000 rpm) 40 to 60 psi 2,8 to 4,1 bar Oil capacity (including filter) 9.4 - 11.2 quarts 8,9 - 10,6 liters Oil viscosity requirements -22°F to 86°F / -30°C to 30°C 5W-20 CJ4 -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. Oil Pressure switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Pressure switch point 14.2 psi 1 bar Fuel injection system Injection pump make Zexel Injection pressure 2133 psi 147 bar Fuel requirement For fuel requirements, refer to the engine Operator Manual for your engine. Starter motor Current draw, normal load 140A - 200A Cranking speed 200 - 250 rpm Battery Engine starting and control system Type 12V DC, Group 31 Quantity 2 Battery capacity, maximum 1000A Reserve capacity @ 25A rate 200 Minutes Engine coolant Capacity 13.3 quarts 12,6 liters Coolant temperature switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Temperature switch point 221°F 105°C Alternator output 85A @ 12V DC Fan belt deflection 3/8 to 1/2 inch 9 to 12 mm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 11 Service and Repair Manual Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5, dull gray, lubricated 1/2-13 bolts, GR 8, dull gray, LOCTITE® 243TM threadlocker Turntable rotate assembly Rotate bearing mounting bolts, lubricated Rotate drive hub mounting bolts, lubricated Backlash plate mounting bolts, lubricated Drive motors and hubs Drive hub mounting bolts, lubricated Drive motor mounting bolts, dry Drive motor mounting bolts, lubricated LOCTITE® 243TM threadlocker Function Pump Pump mounting bolts, LOCTITE® 243TM threadlocker Engine vibration isolators Compressed height 500 ft-lbs 678 Nm 80 ft-lbs 108 Nm 180 ft-lbs 244 Nm 80 ft-lbs 108 Nm 280 ft-lbs 379 Nm 180 ft-lbs 217 Nm 110 ft-lbs 149 Nm 80 ft-lbs 108 Nm 57 ft lbs 77 Nm 0.44 in - 0.56 in 11 mm - 14 mm July 2020 12 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal-LokTM ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed. Seal-LokTM Fittings (hose end - ORFS) SAE Dash Size Torque -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 -24 230 ft-lbs / 315 Nm JIC 37° Fittings (swivel nut or hose connection) SAE Dash Size Thread Size -4 7/16-20 -6 9/16-18 -8 3/4-16 -10 7/8-14 -12 1 1/16-12 -16 1 5/16-12 -20 1 5/8-12 -24 1 7/8-12 Flats 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 SAE O-ring Boss Port (tube fitting - installed into Aluminum) (all types) SAE Dash Size Torque -4 14 ft-lbs / 19 Nm -6 23 ft-lbs / 31,2 Nm -8 36 ft-lbs / 49 Nm -10 62 ft-lbs / 84 Nm -12 84 ft-lbs / 114 Nm -16 125 ft-lbs / 169,5 Nm -20 151 ft-lbs / 204,7 Nm -24 184 ft-lbs / 249,5 Nm Adjustable Fitting 1 jam nut Non-adjustable fitting SAE O-ring Boss Port (tube fitting - installed into Steel) SAE Dash Size Torque -4 ORFS / 37° (Adj) ORFS (Non-adj) 37° (Non-adj) 15 ft-lbs / 20,3 Nm 26 ft-lbs / 35,3 Nm 22 ft-lbs / 30 Nm -6 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 35 ft-lbs / 47,5 Nm 29 ft-lbs / 39,3 Nm -8 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 60 ft-lbs / 81,3 Nm 52 ft-lbs / 70,5 Nm -10 ORFS (Adj / Non-adj) 37° (Adj / Non-adj) 100 ft-lbs / 135,6 Nm 85 ft-lbs / 115,3 Nm -12 (All types) 135 ft-lbs / 183 Nm -16 (All types) 200 ft-lbs / 271,2 Nm -20 (All types) 250 ft-lbs / 339 Nm -24 (All types) 305 ft-lbs / 413,5 Nm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 13 Service and Repair Manual Specifications July 2020 Torque Procedure Seal-LokTM fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight. Note: The O-ring in Parker Seal LokTM fittings and hose end are custom-size O-rings. They are not standard size O-rings. They are available in the Oring field service kit (Genie part number 49612). 2 Lubricate the O-ring before installation. 3 Be sure the O-ring face seal is seated and retained properly. 4 Position the tube and nut squarely on the face seal end of the fitting, and tighten the nut finger tight. 5 Tighten the nut or fitting to the appropriate torque. Refer to the appropriate torque chart in this section. 6 Operate all machine functions and inspect the hose, fittings and related components to confirm there are no leaks. JIC 37° fittings 1 Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, approximately 30 in-lbs / 3.4 Nm. 2 Using a permanent ink marker, make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting. Refer to Illustration 1. Illustration 1 1 hex nut 2 reference mark 3 body hex fitting 14 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 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. Service and Repair Manual Specifications 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 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 15 Service and Repair Manual Repair Procedures July 2020 Sectio n 3 Repair P roce dur es Observe and Obey: Repair procedures shall be completed by a person trained and qualified on the repair of this machine. Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Repairs Start: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and parts are available and ready for use. Use only Genie approved replacement parts. Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions. Machine Configuration: Unless otherwise specified, perform each repair procedure with the machine in the following configuration: Machine parked on a firm, level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both the ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock 16 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 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 reassemble, 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. Service and Repair Manual Repair Procedures Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 17 Service and Repair Manual Control System July 2020 1-1 ALC-600 Control Module Platform Controls The platform control box contains the ALC600 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. 1-2 How to Enter ALC-600 Service Mode 1 ALC-600 platform control module 2 primary boom up/down and turntable rotate left/right joystick controller 3 LED indicator module 4 drive/steer joystick controller 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 5 Settings menu 6 (not implemented) 7 Faults menu 8 Fault LED Indicator 9 Engine hours 10Maintenance LED indicator 11Maintenance menu 12Home menu 18 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System The Control System on this machine allows access to calibrations through the Service Mode. The procedures that follow will require the operator to be in Service Mode. Service Mode can only be entered at machine start up and requires a special code. 1 At the ground controls, select the ground control mode using the key switch. 2 Push and hold buttons numbered 2 and 3 underneath the display screen. 3 Pull out the red Emergency Stop button. 4 You will be prompted for a password. Enter 3 - 3 - 2 - 4. 5 Press the Gear button to access the settings menu. Note: There will be a delay while the menu is being loaded on the display screen. 6 The machine will now operate normally and allow the viewing and modification of calibrations and parameters. Note: When a parameter is changed in Service Mode, the change is effective immediately when button 4 (OK) is pushed. Machine restart is not required. A confirmation beep accompanies every save (button 4). Note: Pushing in the red Emergency Stop button will exit Service Mode. Note: If there has been no input for 10 minutes while in Service Mode, the ALC-600 will power down and Service Mode will be exited, unless the engine is running. 1-3 Full Machine Calibration Full machine calibration must be completed in the proper sequence when the ALC-600 controller (TCON) in the ground control box has been replaced. How to Fully Calibrate the Machine Calibration procedures shall only be completed by qualified technicians that have Genie factory service training. Tip-over hazard. Failure to calibrate the machine in the proper sequence could cause the machine to tip over resulting in death or serious injury. Note: A digital level will be required to perform this procedure. Note: Start this procedure with the boom in the stowed position. Full machine calibration must be completed in the following sequence: Select model, engine, tires, and region, then cycle power. Refer to Repair Section Display Module. Turntable level sensor. Refer to Repair Procedure, How to Calibrate the Turntable Level Sensor. 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 19 Service and Repair Manual Control System July 2020 1-4 Machine Functions How to Adju st th e M achin e Ma ximu m Spe ed Set ting How to Adjust the Joystick Maximum Speed Setting The maximum speed of a joystick controlled machine function can be modified from the ground 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. 10 Record the time it takes for that function to complete a full cycle (ie; boom up). 11 Compare the machine function time with the function times listed in Refer to Specifications, Performance Specifications. Determine whether the function time needs to increase or decrease. 12 Adjust the parameter in the ground display to achieve the proper function cycle time. 20 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System How to Adju st th e Joys tick Ra mp Ra te Setti ng How to Adjust the Joystick Ramp Rate Setting The ramp rate setting is an adjustment that controls the way boom functions start and stop. There are two types of ramp rates to adjust on separate menus: Ramp Up Time -- the amount of time it takes to accelerate to speed. Ramp Down Time -- the amount of time it takes to decelerate to a stop The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine. Note: Perform this procedure with the boom in the stowed position. 1 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. 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. 10 Record the time it takes for that function to complete the ramp. 11 Compare the machine function time with the function times listed in Specifications, Performance Specifications. Determine whether the ramp time needs to increase or decrease. 12 Adjust the parameter in the ground display to achieve the proper ramp time. Note: Refer to Repair Procedure, Display Module Menus for ramp rates. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 21 Service and Repair Manual Control System July 2020 How to Adju st th e Joys tick T hres hold S etting How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate. The boom function threshold current should be operating at near zero speed, smoothly with no vibrations. Note: Perform this procedure with the boom in the stowed position. 1 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 Threshold 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 threshold values. 7 Scroll and press OK. The change is effective immediately. 8 Switch the machine control to platform control and start the engine from the platform controls. 9 Using the joystick, verify that the function engages smoothly and without sudden movement or excessive joystick dead spots. 10 Adjust the parameter in the ground display to achieve a smooth function threshold. 1-5 How to Enter ALC600 Software Update Mode 1 Go to the Genie website http://firmware.genielift.com, select your Machine Model and select Search. 2 Download the software to a USB flash drive. If zipped, extract the files to the USB flash drive. 3 With the machine off, open the GBOX (ground box) lid and then remove the four Torx head screws securing the Display Controller (DISCON) door and remove the door to expose the USB port. 4 Insert the flash drive into the USB port. 5 Set key switch to ground and pull out the red ground ESTOP while holding buttons 1 and 4. 6 The Display Controller will go into the bootloader mode. 7 Browse and select the desired software. Follow the on-screen guidance to start the update procedure. 8 When complete, turn off machine. 9 Remove USB flash drive, re-install the Display Controller door and close the GBOX (ground box). 10 Power up normally. 11 As the display controller starts, operator shall verify on the start-up screen that the proper software and revision are displayed. 12 Perform a function check. 22 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System 1-6 Display Module Menus Screen or Menu Display Settings Screen or Menu Model Configuration (These are locked unless factory defaults are restored) Backlight Contrast Item Display Inversion Model Item Tires Engine (Platform configuration is not locked) Platform Region Screen or Menu Item Options Footswitch Timeout Note: Some options may not be visible with earlier software revisions. Drive Priority Drive Cutout Platform Level Generator Contact Alarm Platform Recirculation Units Aircraft Proximity Fuel Level Sensor Glowplug Preglow Time Lift Connect Alarm Setting Standby RPM 0 - 100% 0 - 100% Selection Default On / Off Off Selection Default S-40 / S-45 / S-60 / S-65 / S-80 / S- Select Model 85 / S-60J / S-80J Rough Terrain / High Float / Trax Select Tires Deutz 2.9L T4 / Deutz TD 2.9L T4 / Select Engine Deutz TCD 2.2L S5 / Deutz TD 2.2L S5 / Deutz D2011 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 Standard Platform 4m Platform Standard Platform ANSI/CSA / AUS / CE Selection 10 sec / 2 min / 30 min On / Off On / Off Select Region 2 min Off Off Default On / Priority / Cutout On No Generator / Generator Installed No Generator On / Off On On / Off Off US Customary / Metric US Customary On / Off Off Not Installed / Installed Installed 1 sec - 100 sec 12 sec Not Installed / Installed Installed Off / Travel / Motion Off Default / High RPM Default Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 23 Service and Repair Manual Control System Screen or Menu Sensor Calibration Item Chassis Tilt Load Sense Select OK to calibrate Select OK to calibrate Default Load Sense Select OK to calibrate Boom Length Select OK to calibrate Screen or Menu Auto Threshold Calibration Screen or Menu Drive Speeds XC or HF Item Boom Up / Down Threshold Select OK to calibrate Default Boom Extend / Retract Threshold Item Forward Threshold Select OK to calibrate Default 128% max, 1% min, 100% = 800mA Reverse Threshold 134% max, 1% min, 100% = 720mA Forward Max 150% max, 75% min, 100% = 1665mA Reverse Max 150% max, 73% min, 100% = 1575mA Screen or Menu Drive Ramps Forward Out of Stow High Max Reverse Out of Stow High Max Item Standard Acceleration Standard Deceleration 150% max, 83% min, 100% = 1147mA 150% max, 80% min, 100% = 1211mA Default 5000 ms max, 100 ms min, 4000 ms 5000 ms max, 100 ms min, 1000 ms Screen or Menu Deutz TD2.9 Anti-Stall Torque Switching Deceleration Item Threshold Drive Minimum 5000 ms max, 500 ms min, 4000 ms 2375 rpm Default 50% Range 125 rpm Hysteresis 100 rpm Screen or Menu Deutz TD2011 Anti-Stall Item Threshold Drive Minimum 2350 rpm 50% Default Range 100 rpm Hysteresis 125 rpm July 2020 24 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Screen or Menu Perkins 404F Anti-Stall Screen or Menu Perkins 404D Anti-Stall Screen or Menu GM 3.0L Anti-Stall Screen or Menu Primary Boom Lift Speeds Item Threshold Drive Minimum Range Hysteresis Item Threshold Drive Minimum Range Hysteresis Item Threshold Drive Minimum Range Hysteresis Item Extend Threshold Retract Threshold Up Threshold Down Threshold Extend Max Retract Max Up Max Down Max Service and Repair Manual Control System 2350 rpm Default 50% 125 rpm 100 rpm 2350 rpm Default 50% 125 rpm 100 rpm 2190 rpm Default 70% 125 rpm 125 rpm Default 212% max, 1% min, 100% = 460mA 169% max, 1% min, 100% = 460mA 186% max, 1% min, 100% = 560mA 292% max, 1% min, 100% = 400mA 150% max, 66% min, 100% = 1499mA 150% max, 71% min, 100% = 1096mA 150% max, 69% min, 100% = 1530mA 150% max, 61% min, 100% = 1937mA Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 25 Service and Repair Manual Control System July 2020 Screen or Menu Item Primary Lift Ramps Extend Accelerating Rate Extend Decelerating Rate Retract Accelerating Rate Retract Decelerating Rate Up Accelerating Rate Up Decelerating Rate Down Accelerating Rate Down Decelerating Rate Screen or Menu Turntable Speeds Item Rotate CW Max Rotate CCW Max Rotate CW Threshold Rotate CCW Threshold CW Out of Stow Max CCW Out of Stow Max Screen or Menu Turntable Ramps Item CW Accelerating CW Decelerating CCW Accelerating CCW Decelerating Screen or Menu Machine Disable Options Item Drive Disable Machine Disable Remote Disable Reset to Defaults Software Update Default 5000 ms max, 1000 ms min, 2500 ms 5000 ms max, 250 ms min, 1000 ms 5000 ms max, 1000 ms min, 2500 ms 5000 ms max, 500 ms min, 1000 ms 5000 ms max, 1000 ms min, 3000 ms 5000 ms max, 500 ms min, 3000 ms 5000 ms max, 1000 ms min, 3000 ms 5000 ms max, 1000 ms min, 1000 ms Default 150% max, 84% min, 100%= 1210mA 150% max, 84% min, 100%= 1210mA 105% max, 1% min, 100%= 800mA 105% max, 1% min, 100%= 800mA 150% max, 96% min, 100%= 881mA 150% max, 96% min, 100%= 881mA Default 5000 ms max, 1000 ms min, 3000 ms 5000 ms max, 500 ms min, 2000 ms 5000 ms max, 1000 ms min, 3000 ms 5000 ms max, 500 ms min, 2000 ms On / Off Default On / Off Disable Engine Start / Drive Speed Cripple / Lift Speed Cripple OK to reset Model Configuration and Options OK to enter Software Update Mode 26 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System 1-7 How to Replace the Display Controller (DISCON) Module 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the negative terminal from the start battery and auxiliary battery, if equipped. 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 3 Open the ground box lid (1) and disconnect the wire harness going to the display controller (DISCON). 4 Remove the DISCON door from the back by loosening the four Torx head screws (8) and remove the two ribbon cables (6) connecting the ground box overlay to the DISCON. Note the orientation of the cables for reassembly. 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 27 Service and Repair Manual Control System July 2020 8 Install the new DISCON onto the ground box lid and fasten it using the new hex nuts and washers. All five fastening points must be used. Attach the DISCON door's lanyard to the DISCON's mounting stud. 9 Evenly tighten the nuts, beginning with the lower center nut, working out and then up. 10 Install the new ribbon cables, connecting the ground box overlay to the DISCON and reinstall the DISCON door, using the Torx head screws removed in step 4. Be sure to fully lock the tabs after the ribbon cables have been fully inserted. 11 Reconnect the wire harness going to the DISCON, then close and fasten the ground box lid. 12 Reconnect the negative terminal to the start battery and auxiliary batteries, if equipped. 1-8 How to Replace the Ground Box Control Overlay 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls. 2 Disconnect the negative terminal from the start battery and auxiliary battery, if equipped. 3 Open the ground control box and remove the switch contacts from the function enable switch, key switch and the red emergency stop button. Do not disconnect the wires. Insert a small screwdriver into the loop at the base of the contacts and engage the release mechanism. 28 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System 4 Unscrew the nut holding the buttons and key switch and remove the key switch and buttons. Note the orientation of the key switch so it can be reassembled in the same position. 5 Disconnect the wire harness connected to the DISCON and cut the zip ties securing the harness to the ground box lid. Do not remove the wire harness from the ground box. 6 Remove the DISCON door (4) and disconnect the ribbon cables (3) from the Display Controller (DISCON) (2). Note the orientation of the cables for reassembling. 1 ground box lid 2 DISCON 3 ribbon cables 4 DISCON door 5 Torx head screws 7 Remove the ground box lid (1) from the ground box. 8 Remove the old overlay and clean the ground box lid surface from any dirt, oils or old adhesive residue. Clean the lid with 99% isopropyl alcohol. Allow the surface to completely dry. 9 Before placing the new overlay, make sure the temperature of the lid and overlay is between 80-100° F / 26-38° C. Application below 80° F / 26° C is not recommended. 10 Peel the adhesive protective film from the 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 / 2638° 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. Tighten the fasteners securely. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 29 Service and Repair Manual 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. July 2020 30 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 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. Service and Repair Manual Platform Components Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 31 Service and Repair Manual Platform Components July 2020 2-2 Platform Leveling Cylinder The slave cylinder and the rotator pivot are the two primary supports for the platform. The slave cylinder keeps the platform level through the entire range of boom motion. It operates in a closedcircuit hydraulic loop with the master cylinder. The slave cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. How to Remove the Platform Leveling Cylinder Note: Before cylinder removal is considered, bleed the slave cylinder to be sure there is no air in the closed loop. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. How to Re mov e th e Platfo rm Leveli ng Slave Cylind er 1 Extend the primary boom until the slave cylinder barrel-end pivot pin is accessible. 2 Raise the primary boom slightly and place blocks under the platform for support. 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks. 4 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to drive the rod-end pivot pin out. Crushing hazard. The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly supported. 5 Remove the external snap rings from the barrel-end pivot pin. 6 Use a soft metal drift to drive the barrel-end pivot pin out. 7 Carefully pull the cylinder out of the primary boom to access the hydraulic hoses. 8 Tag, disconnect and plug the hydraulic hoses from the slave cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. How to Blee d th e Slave C ylinde r How to Bleed the Slave Cylinder Note: Do not start the engine. Use auxiliary power for all machine functions in this procedure. 1 Raise the boom to a horizontal position. 2 Move the platform level toggle switch up and down through two platform leveling cycles to remove any air that might be in the system. 32 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Platform Components 2-3 Platform Rotator The platform rotator is a hydraulically activated helical gear assembly used to rotate the platform 160 degrees. How to Re mov e th e Platfo rm R otat or How to Remove the Platform Rotator Component damage hazard. Mark the platform mounting weldment and the rotator flange before removing the platform mounting weldment. The platform mounting weldment must be replaced in the exact same position on the rotator flange as it was before removal. If a new rotator is installed or the rotator is disassembled, proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position. 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 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. 2 Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the fittings on the rotator. 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 S-85: Support the jib boom leveling arms and the platform mounting weldment with an appropriate lifting device. Do not apply any lifting pressure. 4 Remove the mounting bolts from the platform mounting weldment. Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Crushing hazard. The platform mounting weldment may become unbalanced and fall if it is not properly supported. 5 Support the platform rotator with an appropriate lifting device. Do not apply any lifting pressure. S-80: 6 Support the rod end of the platform leveling slave cylinder. Protect the cylinder rod from damage. 7 Remove the pivot pin retaining fasteners from both the slave cylinder rod-end pivot pin and the rotator pivot pin. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 33 Service and Repair Manual Platform Components July 2020 8 Use a soft metal drift to remove both pivot pins. Remove the platform rotator from the machine. Crushing hazard. The platform rotator may become unbalanced and fall if not properly supported. Note: When installing the platform rotator fasteners, torque the fasteners to specifications. S-85: 9 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to platform rotator pivot pins. Do not remove the pins. 10 Support the jib boom leveling arms. 11 Use a soft metal drift to drive both pins out, then remove the platform rotator from the machine. Bodily injury hazard. The jib boom leveling arms may fall if not properly supported. 12 Lower the jib boom leveling arms. Crushing hazard. The platform rotator could fall when removed from the machine if not properly supported. Note: When installing the platform rotator fasteners, torque the fasteners to specifications. How to Blee d th e Platf orm Rotat or How to Bleed the Platform Rotator Note: This procedure will require two people. Do not start the engine. Use auxiliary power for this procedure. 1 Move the function enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles, then hold the switch to the right position until the platform is fully rotated to the right. 2 Place a suitable container underneath the platform rotator. 3 Open the top bleed screw on the rotator, but do not remove it. 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 Move the function enable button to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. 34 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Platform Components 5 Open the bottom bleed screw on the rotator, but do not remove it. 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. 6 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the bleed screw. Close the bleed screw. Crushing hazard. Keep clear of the platform during rotation. 7 Clean up any hydraulic oil that may have spilled. 8 Rotate the platform fully in both directions and inspect the bleed screws for leaks. 2-4 Platform Overload System Proper calibration of the platform overload system is essential to safe machine operation. Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform. The stability of the machine is compromised, and it could tip over. How to Pe rfor m a Ze ro Loa d Platfo rm C alibr ation How to Perform a Zero Load Platform Calibration Perform this procedure when platform overload is not operating within the calibration parameters. This procedure will re-calibrate the zero load point without affecting a previous full load calibration. In most cases the machine will maintain full load capacity, however, in some situations the platform load capacity may be reduced until a full load calibration has been performed. Note: Perform this procedure with the machine on 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 factory and nonfactory accessories could result in the machine tipping over, causing death or serious injury. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 35 Service and Repair Manual Platform Components July 2020 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 Follow the prompts to accept the weight. 10 Calibration is now complete. Exit Service Mode. How to Pe rfor m a Full Loa d Platfo rm Calibr ation How to Perform a Full Load Platform Calibration Perform this procedure if the platform support or load cell sensor has been replaced, or if a zero load platform calibration does not return the machine to full load capacity. Note: Perform this procedure with the machine on 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 factory and nonfactory 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. 36 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Platform Components 10 Place a test weight on the platform floor using a suitable lifting device. Place the weight near the center entry point of the platform, as far away from the operator controls as possible. Weight = 1,000 lbs / 454 kg Note: If test weights are not available, you may use an industrial scale to weigh available objects until it equals the platform's maximum capacity. Note: Alternate method for achieving rated load in the platform is to attach a hanging scale to the bottom of the platform and apply load using a winch or ratchet until the readout displays the appropriate weight. 11 Follow the prompts to accept the weight. 12 Calibration is now complete. 13 Exit Service Mode. 14 Push in the red Emergency Stop button to the off position. Confirm calibration: 15 Start the engine from the ground controls. 16 Place an additional 50 lbs / 23 kg of weight in 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 overload indicator lights flash and the alarm sounds. 17 Test all machine functions from the ground 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 hanging scale 3 winch or ratchet 4 anchoring device Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 37 Service and Repair Manual Platform Components July 2020 How to Re place the Platfo rm Ov erlo ad Load Cell How to Replace the Load Cell Sensor Note: The preload adjustment should only be performed after the load cell sensor has been replaced. 1 Remove all equipment or tools from the platform. Remove the welder if equipped. 2 At the platform, remove the plastic instruction holder from the document mount plate. 3 Tag and disconnect the load cell sensor harness. 1 flex plate 2 load cell sensor foot 3 jam nut 4 load cell sensor 4 Loosen the jam nut securing the load cell sensor foot and rotate the foot screw clockwise to remove the preload. 5 Remove the fasteners securing the load cell sensor and remove the sensor. Install the new Load Cell Sensor 6 Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out of the bottom of the sensor. The foot should not contact the flex plate when assembling onto the platform support. 7 Assemble the load cell and foot assembly to the platform and securely tighten the two mounting screws. Torque the bolts to 101 ftlbs / 137 Nm. Set the Load Cell Sensor Preload 8 Rotate the foot screw counter clockwise until the foot just contacts the flex plate (finger tight). 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 Place a 1,000 lb / 454 kg test weight on the platform floor using a suitable lifting device. Place the weight near the center entry point of the platform, farthest away from the operator controls as possible, as shown in Illustration 2 13 Lift the weight off the platform and place it back on in the same position two more times to settle the platform overload assembly. 14 Perform a full platform overload system calibration. Refer to Repair Procedure, How to Calibrate the Platform Overload System. 38 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Jib Boom Components 3-1 Jib Boom How to Remove the Jib Boom Note: Perform this procedure with the boom in the stowed position. 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 Remove the platform. Refer to Repair Procedure, How to Remove the Platform. Note: If the platform overload components are disassembled and/or removed from the platform support, the platform overload system will need to be calibrated. Refer to Repair Procedure, How to Calibrate the Platform Overload System. 2 Tag and disconnect the electrical connector from the platform load sense cell. 3 Remove the hose and cable cover from the side of the jib boom. 4 Remove the hose and cable clamp from the jib boom pivot pin. Lay all hoses and cables to the side. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. 5 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 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. 6 Attach a lifting strap from an overhead crane to the jib boom assembly. 7 Place blocks under the platform leveling cylinder for support. Protect the cylinder rod from damage. 8 Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The jib boom could fall when the slave cylinder rod-end pivot pin is removed if not properly attached to the overhead crane. 9 Remove the pin retaining fastener from the jib boom bellcrank to primary boom pivot pin. 10 Use a soft metal drift to remove the pin and carefully remove the jib boom assembly from the primary boom. Crushing hazard. The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 39 Service and Repair Manual Jib Boom Components July 2020 3-2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note: Perform this procedure with the boom in the stowed position. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the jib boom slightly and place blocks under the platform mounting weldment. Then lower the jib boom until the platform is resting on the blocks just enough to support the platform. Note: Do not rest the entire weight of the boom on the blocks. 2 Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 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 pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Do not remove the pin. 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm. Do not remove the pin. 5 Support the jib boom lift cylinder with a lifting device. 6 Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down. Crushing hazard. The platform and jib boom could become unbalanced and fall when the jib boom barrel-end pivot pin is removed if not properly supported. 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder. 8 Use a soft metal drift to remove the jib boom lift cylinder rod-end pin. Remove the cylinder from the machine. Crushing hazard. The jib boom lift cylinder may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane. 40 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 4-1 Cable Track The boom cable track guides cables and hoses running up the boom. It can be repaired link by link without removing the cables and hoses that run through it. Removing the entire boom cable track is necessary when performing major repairs that involve removing the boom. How to Re mov e th e Cabl e T rack, S -80 How to Remove the Cable Track Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Open the platform control box. 2 Tag and disconnect the foot switch wiring from the terminal strip inside the platform control box. 3 Loosen the squeeze connector and remove the foot switch cable from the control box. 4 Disconnect the wire connectors from the bottom of the platform control box. Note: When installing the wire connectors to the bottom of the platform control box, match the color of the connectors to those on the control box to be sure they are installed in the correct location. 5 Remove the mounting fasteners from the power to platform outlet box bracket. Lay the outlet box and bracket assembly off to the side. 6 S-80XC: Tag, disconnect and plug the hydraulic hoses from the counterbalance valve manifold located on the platform rotator. Cap the fittings on the 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. 7 Tag, disconnect and plug the hydraulic hoses from the platform leveling slave cylinder at the platform manifold and cap the 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. 8 Remove the timing link/timing link cam pin and gently rest the timing link against the counterweight. 9 S-85XC: Remove the hose and cable cover from the side of the jib boom. 10 Tag, disconnect and plug the hydraulic hoses from the jib boom/platform rotate select manifold. Cap the fittings on the manifold. 11 Tag, disconnect and plug the wiring from the jib boom/platform rotate select manifold. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 41 Service and Repair Manual Boom Components July 2020 12 Tag, disconnect and plug the hydraulic hoses from the jib boom lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. All models: 13 From the ground controls, raise the boom to a horizontal position. 14 Remove the cotter pin from the upper cable track at the platform end of the boom. Note: Always replace the cotter pin with a new one. 15 Remove the cable track guide fasteners from the cable track guides at the platform end of the boom. Remove the cable track guides from the boom. 16 Remove the cable clamp from the pivot end of the boom. 17 Place blocks between the upper and lower cable tracks and secure the upper and lower tracks together. Crushing hazard. If the upper and lower cable tracks are not properly secured together, the cable track could become unbalanced and fall when removed from the machine. 18 Attach a lifting strap from an overhead crane to the cable track. 19 Remove the mounting fasteners that attach the lower cable track to the boom. 20 Remove the cable track from the machine and place it on a structure capable of supporting it. Crushing hazard. The cable track could become unbalanced and fall if not properly attached to the overhead crane. Component damage hazard. Cables and hoses can be damaged if they are kinked or pinched. Component damage hazard. The cable track can be damaged if it is twisted. 42 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components How to Re pair the C able Tr ack How to Repair the Cable Track Component damage hazard. The boom cable track can be damaged if it is twisted. Note: A cable track repair kit is available through Genie Service Parts, part no. 77896. The kit includes a 4-link section of cable track. 1 Visually inspect the cable track and determine which 4-link section needs to be replaced. 2 Carefully remove the snap rings from each end of the damaged section of cable track. 3 Remove the retaining fasteners from the upper black rollers from the 4-link section of cable track to be replaced. Remove the rollers. 4 Lift up the hoses and cables and carefully remove the damaged 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 5 Remove the upper rollers from the replacement section of cable track. 6 Lift up the hoses and cables and carefully insert the new 4-link section of cable track. Component damage hazard. Hoses and cables can be damaged if they are kinked or pinched. 7 Connect the ends of the replacement cable track section to the existing cable track using the snap rings. 8 Install the rollers onto the new section of cable track. 9 Operate the boom extend/retract function through a full cycle to ensure smooth operation of the new section of cable track. 4-2 Boom How to Shi m th e Boo m How to Shim the Boom 1 Measure each wear pad. Boom wear pad specifications Boom number one Minimum Bottom wear pads (extension end of boom) 0.50 inch 12.7 mm Top and side wear pads (extension end of boom) 0.625 inch 15.9 mm Boom number two Top, bottom and side wear pads (extension end of boom) 0.50 inch 12.7 mm Bottom wear pads (pivot end of boom) 0.50 inch 12.7 mm Top and side wear pads (pivot end of boom) 0.625 inch 15.9 mm Boom number three Top, bottom and side wear pads (pivot end of boom) 0.50 inch 12.7 mm Note: Replace the pad if thickness is less than minimum specification. If thickness is more than minimum specification, perform the following procedure. 2 Extend the boom until the wear pads are accessible. 3 Loosen the wear pad mounting fasteners. 4 Install the new shims under the wear pad to obtain zero clearance and zero drag. 5 Tighten the mounting fasteners. 6 Extend and retract the boom through an entire cycle. Check for tight spots that could cause binding or scraping. Note: Always maintain squareness between the outer and inner boom tubes. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 43 Service and Repair Manual Boom Components July 2020 How to Re mov e th e Boo m How to Remove the Boom Tip-over hazard. This procedure requires the removal of the turntable counterweight. Failure to remove the counterweight before removing the boom assembly will result in the machine tipping over. Do not remove the boom without first removing the counterweight. Tip-over hazard. When installing the boom onto the machine, the boom assembly must be first installed prior to the installation of the counterweight. If the counterweight is installed before the boom assembly, the machine will tip over resulting in death or serious injury. Tip-over hazard. The turntable counterweight is essential for machine stability. Failure to install the counterweight after installing the boom assembly will compromise machine stability resulting in the machine tipping over. Death or serious injury will result. Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. 1 Remove the jib boom. Refer to Repair Procedure, How to Remove the Jib Boom. 2 Remove the cable track. Refer to Repair Procedure, How to Remove the Cable Track. 3 Raise the boom until the short and long link arm to boom pivot pins are above the turntable covers. 4 Place a block of wood measuring 4 x 4 x 60 inches / 10 x 10 x 152 cm under the long link arm, across the turntable covers. 5 Slowly lower the boom until the long link arm contacts the wood block. Do not rest the entire weight of the boom on the block. Turn the machine off. Component damage hazard. The turntable covers can become damaged if the weight of the boom is allowed to rest on the block. 6 Place wood blocks between the short link arm and the turntable weldment for support. 7 Securely attach shackles and lifting straps or chains with a minimum rating of 7.5 tons / 7000 kg to the lifting points on the top of the turntable counterweight. Attach the lifting straps or chains to a 7.5 ton / 7000 kg overhead crane. Note: A spreader bar and other hardware may be needed to safely remove the counterweight. 8 Slowly operate the overhead crane to apply tension to the lifting straps. Do not attempt to lift the machine with the overhead crane. 44 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 9 Locate and remove the counterweight retaining fastener at the center of the counterweight. Carefully lift the counterweight upwards and remove the counterweight from the machine. Set the counterweight on the ground. Do not leave the counterweight suspended above the ground. Crushing hazard. The turntable counterweight will fall if not properly supported by the overhead crane resulting in death or serious injury. Keep personnel away from the area when removing the counterweight. 10 Remove the end cover from the pivot end of the primary boom. 11 Remove the limit switch mounting fasteners from the limit switch on the ground controls side of the primary boom. Do not disconnect the wiring. Remove the limit switch. 12 Disconnect the electrical connector from the string potentiometer. 13 Disconnect the electrical connector from the primary boom angle sensor. Note: The primary boom angle sensor is located on the pivot pin on the engine side of the boom. 14 Remove the primary boom angle sensor bracket mounting fasteners and remove the primary boom angle sensor from the primary boom. Do not remove the angle sensor from the bracket. 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. 15 Remove the hose and cable guide fasteners at the primary boom pivot pin. Remove the hose and cable guide. 16 Attach lifting straps from a 5 ton / 5000 kg overhead crane to each end of the boom. Support the boom. Do not apply any lifting pressure. 17 Support and secure the rod end of the boom lift cylinder to a second overhead crane or similar lifting device. 18 Remove the lift cylinder rod-end pivot pin retaining fasteners. Use a soft metal drift to remove the pin. Crushing hazard. The boom could fall if not properly supported when the lift cylinder rod-end pivot pin is removed. 19 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off. Crushing hazard. The boom lift cylinder could fall if not properly supported and secured to the lifting device. 20 Using the overhead crane, carefully lower the boom lift cylinder and allow it to rest on the boom rest pad. Protect the cylinder rod from damage. 21 Remove the boom end cover retaining fasteners and remove the cover. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 45 Service and Repair Manual Boom Components July 2020 22 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 the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 23 Tag and disconnect the electrical connector for the cable break limit switch. 24 Tag and disconnect all boom wire harness electrical connectors located at the pivot end of the boom. 25 Support the platform leveling master cylinder. Remove the master cylinder rod-end pivot pin retaining fasteners. Place a rod through the pin and twist to remove. Carefully lower the master cylinder down. 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. 28 Using the overhead crane, adjust the boom as necessary to relieve pressure from the pivot pins. 29 Use a soft metal drift to remove each boom pivot pin. Carefully remove the boom assembly from the machine and place it on a structure capable of supporting it. Crushing hazard. The boom could fall if not properly supported by the overhead crane when each boom pivot pin is removed. Crushing hazard. The long and short link arms may fall if not properly supported when the boom pivot pins are removed. 46 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 4-3 Boom Lift Cylinder The boom lift cylinder raises and lowers the boom. The boom lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. How to Remove the Boom Lift Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom to a horizontal position. 2 Attach a 5 ton / 5000 kg overhead crane to the boom at the platform end for support. Do not lift the boom. 3 Support and secure both ends of the boom lift cylinder to a second overhead crane or similar lifting device. 4 Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Crushing hazard. The boom will fall if not properly supported when the primary boom rodend pivot pin is removed. 5 Using auxiliary power, activate the boom down function so the cylinder will retract. Retract the cylinder just enough until the rod end of the cylinder will clear the mounting bracket on the boom. Turn the machine off. 6 Tag, disconnect and plug the boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. 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. 7 Remove the pin retaining fasteners from the boom lift cylinder barrel-end pivot pins. Do not remove the pins. 8 Use a slide hammer to remove the barrel-end pivot pins. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. 9 Move the boom lift cylinder towards the counterweight end of the machine. Rotate the boom lift cylinder until the barrel-end pivot pin bores will clear the boom linkage. 10 Carefully remove the boom lift cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 47 Service and Repair Manual Boom Components July 2020 4-4 Boom Extension Cylinder The boom extension cylinder is located inside the boom assembly and incorporates cables and pulleys that are responsible for extending the number 3 boom tube. The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure. How to Remove the Boom Extension Cylinder Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage. Dealer service is strongly recommended. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. Note: Perform this procedure with the boom fully retracted. 1 Raise the boom to a horizontal position. 2 Remove the boom end cover retaining fasteners and remove the cover. 3 Remove the access covers from both sides of the boom at the pivot end. 4 Remove the mounting plates and the string potentiometer. 5 Fully loosen the lock nuts on the extend cables. Do not remove the nuts. 1 boom angle sensor 2 string potentiometer 3 cable guard 4 cable guard retaining plate 6 Loosen the retract cable nut at the platform end of the boom. Pull the cable rod from the support and let it hang down. 7 Remove the cable guard fasteners and remove the cable guard. 8 Locate the retaining plates that secure the retract cables to the inside of the number 3 boom tube. 9 Remove the cable retaining plates and pull the retract cables off of the pulleys. Lay the cables flat and out of the way. 48 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 10 Remove the fasteners from the retaining blocks from the extension cylinder saddle. Remove the blocks. Note: Access the fasteners through the access hole in the outer boom tube at the pivot end. 11 Disconnect the wire connector to the extend cable break limit switch. 12 Remove the retaining fasteners that secure the extend cable mounting plates to the inside of the number 1 boom tube. 1 extend cable lock nuts 2 extend cable mounting plate 3 extend cable mounting plate fastener 4 extend cable bracket 13 Pull back on the extend cable mounting plate until it clears the blocks welded to the inside of the number 1 boom tube. 14 Lift up the extend cable mounting plate and push the extend cables towards the platform to create slack in the cables. Rest the cable and bracket assembly on top of the extend cylinder. 15 Locate the lower extend cable bracket on the bottom of the number 3 boom tube. 16 Remove the lower extend cable bracket mounting fasteners and pull back on the bracket to release it from the number 3 boom 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 the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 22 Attach a lifting strap from a 5 ton / 5000 kg overhead crane to the lug at the rod end of the boom extension cylinder. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 49 Service and Repair Manual Boom Components July 2020 23 Lift the boom extension cylinder with the crane until it clears the cylinder saddle inside the number 2 boom tube. 24 Carefully support and slide the extension cylinder out of the boom. Crushing hazard. The extension cylinder could fall when removed from the extension boom if not properly supported. Component damage hazard. Be careful not to damage the cable break limit switch. Component damage hazard. Be careful not to damage the counterbalance valves on the primary boom extension cylinder when removing the cylinder from the primary boom. Note: During removal of the extension cylinder, the overhead crane strap will need to be carefully adjusted for proper balancing. 4-5 Boom Extend and Retract Cables How to Adju st th e Exten d/Ret ract Cables How to Adjust the Boom Extend/Retract Cables The boom extend/retract cables are responsible for the extension and retraction of the number 3 boom tube. Proper adjustment of the boom extend/retract cables and related components on a regular basis is essential to good machine performance and safe machine operation. The boom extend and retract functions should operate smoothly and be free of hesitation, jerking and unusual noise. Note: Perform this procedure with the boom in a horizontal position. 1 Start the engine from the ground controls. 2 Raise the boom to a horizontal position. 3 Fully retract the boom. 4 Stop the engine. 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. 50 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 8 Locate the extend cable adjustment nuts on the counterweight end of boom tube #1. Refer to Illustration 1. Loosen the nylock nuts and jam nuts on the cable tension equalizer bracket. Do not remove the nuts. 9 Adjust the extend cable adjustment nut to obtain 6 3/8 inches/16.2 cm to 6 1/2 inches/16.5 cm between the platform end of boom tube #2 and boom tube #3. Refer to illustration 2. There should be approximately 1/2 inch of exposed threads on the adjustment bolts. Refer to Illustration 1. Note: If the cables have been replaced, be sure the adjustment nuts have been replaced. Do not re-use the existing nuts. 10 Extend the boom until there is approximately 3 feet / 1 m of travel left. Do not fully extend the boom. 11 Locate the retract cable adjustment nut on the bottom of the number 1 boom tube at the platform end of the boom. 12 Using a dial type torque wrench, torque the retract cable adjustment nut to 32-36 ft lbs / 43-49 Nm using gentle and steady torque. 13 Retract and extend the boom approximately 3 feet / 1 m two times and stop during the extension cycle. This will create slack in the retract cables. Note: Be sure to not fully extend the boom. Stop when there is approximately 3 feet / 1 m of travel left. 14 Repeat steps 12 and 13 two to three times. 15 Fully extend the boom then retract the boom approximately 12 inches / 30 cm. 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 1 1 cable break limit switch 2 extend cable adjustment nut 3 extend cable pivot plate Illustration 2 1 6.375 inches / 16.2 cm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 51 Service and Repair Manual Boom Components July 2020 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. Note: If the boom extend cables are adjusted evenly, the wheel of the limit switch arm should be centered in the notch of the pivot plate. 18 Install the boom end cover at the pivot end of the boom. 19 Fully retract and lower the boom to the stowed position. How to Re place the Boom Exten d/Ret ract C ables How to Replace the Boom Extend/Retract Cables Note: The cable pulleys must also be replaced when replacing the cables. 1 Remove the boom extension cylinder. Refer to Repair Procedure, How to Remove the Boom Extension Cylinder. Boom extend cables: 2 Remove the cables from the lower boom extend cable bracket that attaches to the number 3 boom tube. 3 Remove the rue rings and clevis pins from the boom extend cables located near the extend cable break limit switch. 4 Remove the external snap rings from the boom extend cable pulley pivot pin. Use a soft metal drift to remove the pin. Note: When driving the pivot pin out, be sure to drive it from the shaped end of the pin. 5 Remove the pulley and boom extend cables from the extension cylinder assembly. Discard the old cables and pulleys. 6 Route the new boom extend cables through the boom extend pulley bracket. 7 Install the new boom extend cable pulley, pivot pin and snap rings. Note: Be sure the boom extend cables are routed through the grooves of the pulley and the upper wear pad on the extension cylinder. 52 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 8 Install the boom extend cable clevis pins and rue rings to the pivot plate near the cable break limit switch. 9 Install the boom extend cables to the lower extend cable bracket that mounts to the number 3 boom tube. Boom retract cables: 10 Remove the rue rings and clevis pins from the boom retract cables at the platform end of the boom. 11 Attach the cable pulling tool or a rope to one of the boom retract cables at the pivot end of the boom. Note: A cable pulling tool is available through Genie Service Parts Department (Genie part no. 94510) 12 At the platform end of the boom, pull on the boom retract cable that has the rope attached 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. 17 Repeat steps 14 through 19 for the other boom retract cable. 18 At the platform end of the boom, install the retract cables, clevis pins and rue rings to the adjustment plate. 19 Remove and discard the old boom retract pulleys from the pivot end of the boom extension cylinder. 20 Install the new boom retract pulleys to the pivot end of the boom extension cylinder. 21 Install the boom extension cylinder assembly into the boom. Note: Before lowering the extension cylinder into the saddles of the number 1 boom tube, wrap the boom retract cables around the pulleys. 22 Adjust the boom extend/retract cables. Refer to Repair Procedure, How to Adjust the Boom Extend/Retract Cables. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 53 Service and Repair Manual Boom Components July 2020 4-6 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 Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Raise the boom until the master cylinder rodend pivot pin is accessible. 2 Remove the turntable end cover to access the master cylinder. 3 Tag, disconnect and plug the master 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 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. 5 Place a rod through the barrel-end pivot pin and twist to remove the pin. 6 Attach a lifting strap from an overhead crane to the lug on the rod end of the master cylinder. 7 Remove the pin retaining fastener from the rod-end pivot pin. 8 Place a rod through the rod-end pivot pin and twist to remove the pin. 9 Remove the master cylinder from the machine. Crushing hazard. The master cylinder could become unbalanced and fall if not properly attached to the overhead crane. 54 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Boom Components 4-7 Primary Boom Angle Sensor The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the turntable and gravity. How to Calibrate the Primary Boom Angle Sensor Note: Perform this procedure with the machine on a firm, level surface with the boom in the stowed position. Note: The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor. Note: This procedure will establish the cross-check angle with the boom limit switch LST3S. If LST3S 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. 8 Press OK on the display to continue with the procedure to capture the maximum angle point. 9 Operate the boom up function until the boom reaches its maximum angle. Continue holding the function enable and boom up buttons for several seconds until the display indicates that the upper calibration point has been obtained. This may require holding the buttons for several seconds after the boom reaches its maximum angle. 10 Follow the on-screen prompts to lower the boom until the display indicates the calibration is complete. If this step isn't done, the boom will be in the safety envelope when the calibration procedure ends 11 The calibration is now complete. 12 Exit the Service Mode. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 55 Service and Repair Manual Boom Components July 2020 4-8 Boom Length Sensor How to Calibrate the Primary Boom Length Sensor Note: The turntable level sensor and platform load sensor must be calibrated prior to calibrating the primary boom angle sensor. Note: The turntable level sensor, platform load 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. 8 Press the OK button to continue to capture the maximum extension point. 9 Press the function enable and boom extend buttons until the boom reaches its maximum extension. Continue holding the buttons for several seconds after the boom reaches its maximum extension until the display indicates the calibration point has been captured. 10 The calibration is complete. 11 Exit the Service Mode. 56 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Engines 5-1 RPM Adjustment Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine, Check and Adjust the Engine RPM. 5-2 Flex Plate The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the pump. 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 57 Service and Repair Manual Engines July 2020 Deutz TD2011L04i models: 1 Tag and disconnect the wiring from the bell housing. 2 Remove the U-bolt from the exhaust flex pipe at the muffler. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 3 Remove the muffler bracket retaining fasteners from bell housing. Remove the muffler and bracket assembly from the engine. 4 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell 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. Deutz TD 2.9, TCD 2.2 models: 1 Tag and disconnect the wiring from the bell housing. 2 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners. 58 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Engines 3 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. 4 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel. Perkins models: 1 Tag and disconnect the wiring from the bell housing. 2 Remove the fasteners supporting the muffler assembly from the bell housing. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 3 Support the drive pump with an appropriate lifting device. Remove all of the remaining bell housing engine fasteners. 4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving. Component damage hazard. Hoses can be damaged if they are kinked or pinched. 5 Remove the flex plate mounting fasteners, and remove the flex plate from the engine flywheel. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 59 Service and Repair Manual Engines July 2020 GM model: 1 Tag and disconnect the wire harness from the oxygen sensor. 2 Remove the exhaust pipe heat shield fasteners from the top of the muffler. Burn hazard. Beware of hot engine components. Contact with hot engine components may result in severe burns. 3 Remove the muffler retainer bracket fasteners. 4 Remove the muffler fasteners securing the muffler to the exhaust manifold. Remove the muffler from the bracket. 5 Remove the relay housing from the muffler mount. Do not disconnect the relays. 6 Disconnect and remove the ECM from the muffler mount. 7 Close the shutoff valve on the Liquid Petroleum Gas (LPG) tank by turning it 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. How to I nstall t he Flex Plat e How to Install the Flex Plate 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. Apply Loctite® removable thread locker to the mounting fasteners. Note: Torque the flex plate mounting fasteners in two stages. 2 Torque the flex plate mounting bolts in sequence to 28 ft-lbs / 38 Nm. Torque the flex plate mounting bolts in sequence to 40 ft-lbs / 54 Nm. Deutz, Perkins GM 60 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Engines 3 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine. 4 Apply Loctite® removable thread locker to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. 5 Install the pump onto the pump mounting plate. Apply Loctite® removable thread sealant to the pump retaining fasteners. Torque the pump retaining fasteners to 57 ftlbs / 77 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. How to ins tall th e Pum p a nd Bell Ho using Assem bly How to Install the Pump and Bell Housing Assembly 1 Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C" in sequence to 28 ft-lbs / 38 Nm. Then torque the bell housing mounting bolts labeled "C" in sequence to 40 ft-lbs / 54 Nm. 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. 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. Deutz Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 61 Service and Repair Manual Engines Perkins GM July 2020 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. 62 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Hydraulic Pumps 7-1 Function Pump How to Remove the Function Pump Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced. All connections must be torqued to specification during installation. Refer to Specifications, Hydraulic Hose and Fitting Torque Specifications. 1 Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 2 Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. 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 Support the pump with a suitable lifting device. 4 Remove the pump mounting bolts. Carefully remove the pump. Component damage hazard. Be sure to open the two hydraulic tank valves and prime the pump after installing the pump. open closed Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 63 Service and Repair Manual Hydraulic Pumps July 2020 7-2 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 SauerDanfoss service center. Contact Genie Product Support to locate your local authorized service center. How to Remove the Drive Pump Component damage hazard. The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage. Dealer service is recommended. 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 Disconnect the wiring plug at the electronic displacement controller (EDC), located on the drive pump. 2 Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. open closed Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 3 Tag, disconnect and plug the hydraulic hoses from the drive and function pumps. Cap the fittings on the pumps. 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 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners. 64 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Hydraulic Pumps 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate. 6 Remove the drive pump from the machine. Component damage hazard. The pump(s) may become unbalanced and fall if not properly supported. Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. How to Pri me t he Driv e Pu mp How to Prime the Drive Pump Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. 1 Connect a 0 to 600 psi / 0 to 40 bar pressure gauge to the diagnostic nipple on the drive pump. 2 GM models: If equipped, close the valve on the LPG tank, then disconnect the hose from 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 65 Service and Repair Manual Manifolds July 2020 8-1 Function Manifold Components The function manifold assembly is located on the tank side tray, behind the ground control box. Index No. Description 1 Solenoid Valve, 2 position 3 way 2 Solenoid Valve, 2 position 3 way 3 Solenoid Valve, NO, Poppet 4 Solenoid Valve, NO, Poppet 5 Proportional solenoid valve 6 Differential sensing valve 7 Proportional solenoid valve 8 Solenoid valve, 3 position 4 way 9 Proportional solenoid valve 10 Solenoid valve, 3 position 4 way 11 Flow regulator valve 12 Relief valve, 2600 psi / 179 bar 13 Relief valve, 2400 psi / 165 bar 14 Check valve, 30 psi / 2.1 bar 15 Differential sensing valve 16 Check valve 17 Relief valve, 3200 psi / 221 bar 18 Pressure reducing valve 19 Differential sensing valve 20 Flow regulator valve Schematic Item SJ Boom up Function SK Boom down SP Extend SQ Retract SR Extend proportional SS Boom extend SF Boom up/down proportional SL Steering directional SE Swing proportional SI Swing directional SD Oscillate flow control SN Boom down relief SO Boom extend relief ST Return check valve SH Primary lift SA Back flow / check function pump SB System relief SC Oscillate pressure control SG Differential sensing/turntable rotate SM Steering flow control Torque 50-55 ft-lbs / 68-75 Nm 30-35 ft-lbs / 41-47 Nm 33-37 ft-lbs / 45-50 Nm 33-37 ft-lbs / 45-50 Nm 20-25 ft-lbs / 27-34 Nm 30-35 ft-lbs / 41-47 Nm 33-37 ft-lbs / 45-50 Nm 20-25 ft-lbs / 27-34 Nm 20-25 ft-lbs / 27-34 Nm 26-30 ft-lbs / 35-41 Nm 20-25 ft-lbs / 27-34 Nm 20-25 ft-lbs / 27-34 Nm 20-25 ft-lbs / 27-34 Nm 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 20-25 ft-lbs / 27-34 Nm 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 20-25 ft-lbs / 27-34 Nm 66 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 67 Service and Repair Manual Manifolds July 2020 8-2 Valve Adjustments Function Manifold How to Adju st th e Syste m Relief Valve How to Adjust the System Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the system relief valve. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the diagnostic nipple (ptest) located next to the auxiliary pump. 2 Simultaneously activate and hold the auxiliary power button and the primary boom retract button with the primary boom fully retracted. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 3 Locate the system relief valve on the function manifold. Use a wrench to hold the relief valve and remove the cap. 4 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. 5 Repeat step 2 to confirm relief valve pressure. 6 Remove the pressure gauge. How to Adju st th e Boo m Down Relief V alve How to Adjust the Boom Down Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the boom down relief valve. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the diagnostic nipple located next to the auxiliary pump. 2 Simultaneously activate and hold the auxiliary power button and the primary boom down button with the boom fully lowered. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Specifications. 3 Use a wrench to hold the relief valve and remove the cap on the function manifold. 4 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. 5 Repeat step 2 to confirm relief valve pressure. 6 Remove the pressure gauge. 68 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 How to Adju st th e Boo m Exten d Relie f Valve How to Adjust the Boom Extend Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Refer to Function Manifold Component list to locate the boom extend relief valve. Note: Auxiliary power will be used to perform this procedure. Do not start the engine. 1 Connect a 0 to 3000 psi / 0 to 200 bar pressure gauge to the diagnostic nipple located next to the auxiliary pump. 2 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. 3 Locate the boom extend relief valve on the function manifold. Use a wrench to hold the relief valve and remove the cap. 4 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. 5 Repeat step2 to confirm relief valve pressure. 6 Remove the pressure gauge. Service and Repair Manual Manifolds Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 69 Service and Repair Manual Manifolds July 2020 8-3 Brake / Two Speed Manifold Components The brake/two speed manifold is mounted inside the drive chassis. Index No. Description 1 Orifice, 0.025 inch / 0.63 mm 2 Check valve 3 Solenoid Valve, 2 position 3 way 4 Solenoid Valve, 2 position 3 way Schematic Item Function BE Turntable rotation brake release BF Brake release circuit BG Brake release BH Two-speed motor shift Torque 20-25 ft-lbs / 27-34 Nm 20-25 ft-lbs / 27-34 Nm 20-25 ft-lbs / 27-34 Nm 70 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds 8-4 Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor at the ground control side of the machine. Index No. Description 1 Counterbalance valve, 1000 psi 2 Counterbalance valve, 1000 psi 3 Shuttle valve, 2 position 3 way 4 Orifice, 0.030 inch / 0.8 mm Schematic Item Function RA Turntable rotate left RB Turntable rotate right RD Turntable rotation brake release RC Brake release circuit Torque 25-30 ft-lbs / 34-41 Nm 25-30 ft-lbs / 34-41 Nm 8-10 ft-lbs / 10-15 Nm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 71 Service and Repair Manual Manifolds 8-5 Platform Rotate Manifold Components The platform rotate manifold is mounted on the platform rotator. Index No. Description 1 Counterbalance valve, 3300 psi 2 Counterbalance valve, 3300 psi Schematic Item Function PA Platform rotate right PB Platform rotate left July 2020 Torque 37-44 ft-lbs / 50-60 Nm 37-44 ft-lbs / 50-60 Nm 72 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds 8-6 Platform Manifold Components, S-80 XC The jib boom / platform rotate manifold is mounted to the platform support. Index No. Description 1 Solenoid valve, 3 position 4 way 2 Solenoid valve, 3 position 4 way 3 Counterbalance valve, 3500 psi 4 Counterbalance valve, 3500 psi 5 Needle valve 6 Pressure comp., flow control valve Schematic Item Function EF Platform rotate CW/CCW EB Platform level up/down EC Platform level CB valve ED Platform level CB valve EA Platform level EE Platform rotate flow control Torque 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 26-30 ft-lbs / 35-41 Nm 26-30 ft-lbs / 35-41 Nm 20-25 ft-lbs / 27-34 Nm 33-37 ft-lbs / 45-50 Nm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 73 Service and Repair Manual Manifolds 8-7 Platform Manifold Components, S-85 XC The jib boom / platform rotate manifold is mounted to the platform support. Index No. Description 1 Solenoid valve, 3 position 4 way 2 Solenoid valve, 3 position 4 way 3 Solenoid valve, 3 position 4 way 4 Counterbalance valve, 3500 psi 5 Counterbalance valve, 3500 psi 6 Needle valve 7 Pressure comp., flow control valve 8 Pressure comp., flow control valve Schematic Item Function EF Platform rotate CW/CCW EB Platform level up/down EH Jib boom up/down EC Platform level CB valve ED Platform level CB valve EA Platform level EE Platform rotate flow control EG Jib up/down flow control July 2020 Torque 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 30-35 ft-lbs / 41-47 Nm 26-30 ft-lbs / 35-41 Nm 26-30 ft-lbs / 35-41 Nm 20-25 ft-lbs / 27-34 Nm 33-37 ft-lbs / 45-50 Nm 33-37 ft-lbs / 45-50 Nm 74 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual This page intentionally left blank. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 75 Service and Repair Manual Manifolds July 2020 8-8 Traction Manifold Components, 4WD The drive manifold is mounted inside the drive chassis at the non-steer end of the machine. Index No. Description 1 Relief valve, 280 psi / 19.3 bar 2 Flow divider/combiner valve 3 Check valve 4 Check valve 5 Flow divider/combiner valve 6 Check valve 7 Orifice, 0.040 inch / 1 mm 8 Orifice, 0.040 inch / 1 mm 9 Orifice, 0.040 inch / 1 mm 10 Check valve 11 Check valve 12 Shuttle Valve, 3 position 3 way 13 Flow divider/combiner valve 14 Check valve Schematic Item Function DE Charge pressure circuit DB Controls flow to non-steer end drive motors in forward and reverse DF Steer end drive motor circuit DC Non-steer end drive motor circuit CK Controls flow to flow divider/combiner valves 2 and 13 DD Non-steer end drive motor circuit DL Equalizes pressure on both sides of flow divider/combiner valve 5 DA Equalizes pressure on both sides of flow divider/combiner valve 2 DN Equalizes pressure on both sides of flow divider/combiner valve 13 DG Steer end drive motor circuit DH Steer end drive motor circuit DJ Charge pressure circuit that directs hot oil out of low pressure side of drive pump DM Controls flow to steer end drive motors in forward and reverse DP Non-steer end drive motor circuit Torque 35-40 ft-lbs / 48-54 Nm 80-90 ft-lbs / 108-122 Nm 35-40 ft-lbs / 48-54 Nm 35-40 ft-lbs / 48-54 Nm 80-90 ft-lbs / 108-122 Nm 60-70 ft-lbs / 81-95 Nm 60-70 ft-lbs / 81-95 Nm 35-40 ft-lbs / 48-54 Nm 80-90 ft-lbs / 108-122 Nm 80-90 ft-lbs / 108-122 Nm 35-40 ft-lbs / 48-54 Nm 76 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 77 Service and Repair Manual Manifolds 8-9 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 (item BJ). 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. July 2020 78 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds 8-10 Generator Manifold The generator manifold is mounted on the turntable tray by the fuel tank. Index No. Description 1 Relief valve 2 Solenoid Valve 3 Needle valve 4 Differential sensing valve 5 Counterbalance valve 6 Check valve Schematic Item Function GA Generator relief valve GB Charge pressure circuit GD Charge pressure circuit GC Pilot valve to diverter valve CF Adds backpressure to generator circuit GE Prevents oil to generator Torque 50 ft-lbs / 67 Nm 60-65 ft lbs / 81-88 Nm 50 ft-lbs / 67 Nm 50 ft-lbs / 67 Nm 24-26 ft-lbs / 32.5-35.3 Nm Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 79 Service and Repair Manual Manifolds July 2020 8-11 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve. Critical to normal operation is continuity within the coil that provides this force field. Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases. While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 1 Tag and disconnect the wiring from the coil to be tested. 2 Test the coil resistance. Result: The resistance should be within specification, plus or minus 30%. Result: If the resistance is not within specification, plus or minus 30%, replace the coil. Valve Coil Resist anc e Specific ations Valve Coil Resistance Specification Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 10°C that your air temperature increases or decreases from 68°F / 20°C. Valve Coil Resistance Specification Proportional solenoid valve (schematic items SE, SF and SR) 2 position 3 way solenoid valve (schematic items SJ and SK) 2 position 2 way solenoid valve (schematic items SP and SQ) 3 position 4 way solenoid valve (schematic items EB, EF, EH, SI and SL) 4.8 6.3 5.9 6.3 80 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Manifolds 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 Test the coil for resistance. Refer to Repair Procedure, How to Test a Coil. 2 Connect a 10W resistor to the negative terminal of a known good 9V DC battery. Connect the other end of the resistor to a terminal on the coil. Resistor 10 Genie part number 27287 Note: The battery should read 9V DC or more when measured across the terminals. 1 multimeter 2 9v DC battery 3 10 resistor 4 coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6. 3 Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA. 4 Connect the negative lead to the other terminal on the coil. 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 81 Service and Repair Manual Fuel and Hydraulic Tanks July 2020 9-1 Fuel Tank How to Remove the Fuel Tank Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, well-ventilated area away from heaters, sparks, flames and lighted tobacco. Always have an approved fire extinguisher within easy reach. Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container. 4 Tag, disconnect, drain and plug the supply and return fuel hoses. Cap the fittings on the fuel tank. 5 Remove the fuel tank retaining fasteners. 6 Remove the fuel tank from the machine. Component damage hazard. The fuel tank is plastic and may become damaged if allowed to fall. Component damage hazard. When installing the plastic fuel tank, do not overtighten the retaining fasteners. Note: Clean the fuel tank and inspect for damage before installing it onto the machine. 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. 82 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Fuel and Hydraulic Tanks 9-2 Hydraulic Tank The primary functions of the hydraulic tank are to cool, clean and de-aerate the hydraulic fluid during operation. The tank utilizes internal suction strainers for the pump supply hoses and has an external return filter equipped with a filter condition indicator. How to Remove the Hydraulic 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. 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 Remove the fuel tank. Refer to Repair Procedure, How to Remove the Fuel Tank. 2 Close the two hydraulic tank valves located at the hydraulic tank (if equipped). Component damage hazard. The engine must not be started with the hydraulic tank shut-off valves in the closed position or component damage will occur. If the tank valves are closed, remove the key from the key switch and tag the machine to inform personnel of the condition. open closed 3 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to Specifications, Machine Specifications. 4 Tag, disconnect and plug the two suction hoses that are attached to the hydraulic 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 83 Service and Repair Manual Fuel and Hydraulic Tanks July 2020 8 Remove the four fasteners securing the tank to the chassis bulkhead. 9 Remove the hydraulic tank from the machine. Crushing hazard. The hydraulic tank could become unbalanced and fall if not properly supported when removed from the machine. 10 Remove the suction strainers from the tank and clean them using a mild solvent. 11 Rinse out the inside of the tank using a mild solvent. 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. 17 Clean up any oil that may have spilled. 18 Open the hydraulic tank shutoff valves (if equipped). Component damage hazard. Be sure to open the two hydraulic tank shutoff valves (if equipped) and prime the pump after installing the hydraulic tank. Note: Always use pipe thread sealant when installing the drain plug and strainers. 84 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Turntable Rotation Components 10-1 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 burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Loosen the backlash pivot plate and adjustment bolts. 4 Attach a suitable lifting device to the lifting eyes on the drive hub assembly. 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts 5 Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub assembly from the machine. 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. When installing the drive hub assembly: 6 Install the drive hub. Apply removable thread locking compound to fastener threads. Torque the backlash pivot plate mounting fasteners to specification. Refer to Specifications, Machine Torque Specifications. 7 Install the brake and then the motor onto the drive hub. Apply removable thread locking compound to fastener threads. Torque the motor/brake mounting fasteners to Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 85 Service and Repair Manual Turntable Rotation Components July 2020 specification. Refer to Specifications, Machine Torque Specifications. 8 Adjust turntable rotation gear backlash. Refer to Repair Procedure, How to Adjust the Turntable Rotation Gear Backlash. How to Re mov e th e T urnt able R otati on Hy dra ulic Mo tor How to Remove the Turntable Rotation Hydraulic Motor 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 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. 86 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Turntable Rotation Components 5 Clean up any oil that may have spilled. How to Adju st th e T urn table Rota tion G ear Backlas h How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear. Note: Perform this procedure with the boom between the non-steer end tires and with the machine on a firm and level surface. 1 Secure the turntable from rotating with the turntable rotation lock pin. Note: The turntable rotation lock pin is located next to the boom rest pad. 2 Loosen the backlash pivot plate mounting fasteners. 1 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 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 87 Service and Repair Manual Turntable Rotation Components July 2020 3 Push the backlash pivot plate towards the turntable as far as possible (this will push the rotation gear into the turntable bearing ring gear). 4 Loosen the lock nut on the adjustment bolt. 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate. 6 Turn the adjustment bolt one half turn counterclockwise. Tighten the lock nut on the adjustment bolt. 7 Rotate the backlash pivot plate away from the turntable until it contacts the adjustment bolt. Then torque the mounting fasteners on the backlash pivot plate. Refer to Specifications, Machine Torque Specifications. 8 Rotate the turntable through an entire rotation. Check for tight spots that could cause binding. Readjust if necessary. How to Cali brat e th e T urn table Tilt Se nso r How to Calibrate the Turntable Tilt Sensor Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Note: A digital level will be required to perform this procedure. 1 Enter Service Mode. Refer to Repair Procedure, How to Enter the Service Mode. 2 Press the settings button above the display and navigate to the Sensor Calibrations menu. 3 Navigate to the Chassis Tilt Sensor calibration screen. 4 Select and start the calibration procedure. 5 If the machine is not sufficiently level, the 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). 88 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Turntable Rotation Components 9 A graphic of the machine pitch will now be shown on the display. By pressing the UP or DOWN buttons, the graphic will change to show the counterweight being uphill or downhill. Select the image that corresponds to the current pitch of the machine and press OK. 13 A graphic of the machine roll will now be shown on the display. By pressing the UP and DOWN buttons, the graphic will change to show whether the operator is on the uphill or downhill side of the machine.. Select the image that corresponds to the current roll of the machine and press OK. Turntable Pitch 1 uphill 2 downhill 10 The next calibration of the machine is the machine roll. This is the angle of the machine from side to side. 11 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 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). Turntable Roll 1 uphill 2 downhill 14 The calibration is now complete. 15 Exit the Service Mode. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 89 Service and Repair Manual Steer Axle Components July 2020 11-1 Yoke and Drive Hub How to Remove the Yoke and 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 Remove the pin retaining fasteners from both the steer cylinder and the tie rod cylinder pivot pins. Remove the pins. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. 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 Loosen the wheel lug nuts. Do not remove them. 4 Block the non-steer wheels, and center a lifting jack of ample capacity under the steer axle. 5 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 6 Remove the lug nuts. Remove the tire and wheel assembly. 7 Remove the hydraulic hose clamp retaining fastener from the top of the yoke pivot pin. 8 Remove the drive motor mounting fasteners. 9 Slide the drive motor shaft out of the drive hub and remove the drive motor from the machine. 10 Remove the pin retaining fasteners from the upper and lower yoke pivot pins. 11 Support and secure the yoke and drive hub assembly to a lifting jack. 12 Use a slide hammer to remove the upper yoke pivot pin. Use a soft metal drift to drive the lower yoke pivot pin down and out. Crushing hazard. The yoke and drive hub assembly could become unbalanced and fall when the yoke pivot pins are removed if not properly supported and secured to the lifting jack. 13 Place the yoke and drive hub assembly on a flat surface with the drive hub facing down. 14 Remove the drive hub mounting fasteners that attach the drive hub to the yoke. Remove the yoke from the drive hub. Refer to Specifications, Machine Torque Specifications. Note: Replace the thrust washer when installing the yoke and drive hub assembly onto the axle. 90 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Steer Axle Components 11-2 Drive Motors 11-3 Drive Hub How to Remove a Drive Motor Component damage hazard. Repairs to the motor should only be performed by an authorized dealer. 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. 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 Remove the drive motor access covers from both sides of the inner axle. 2 Tag, disconnect and plug the hydraulic hoses from the drive motor. Cap the fittings on the drive motor. 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 drive motor mounting fasteners. 4 Slide the drive motor shaft out of the drive hub, and remove the drive motor from the machine. How to Remove a Drive Hub 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 Remove the drive motor. Refer to Repair Procedure, How to Remove a Drive Motor. 2 Loosen the wheel lug nuts. Do not remove them. 3 Center a lifting jack of ample capacity under the non-steer axle. 4 Raise the machine approximately 6 inches / 15 cm and place blocks under the chassis for support. 5 Remove the wheel lug nuts, then the tire and wheel assembly. 6 Place a second lifting jack under the drive hub for support and secure the drive hub to the lifting jack. 7 Remove the drive hub mounting fasteners that attach the drive hub to the axle. Remove the drive hub. Crushing hazard. The drive hub could become unbalanced and fall if not properly supported by an overhead crane or lifting device when removed from the machine. Note: Do not re-use the drive hub mounting fasteners. Genie specifications require the use of new fasteners. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 91 Service and Repair Manual Generators July 2020 12-1 Hydraulic Generator How to Adjust the Generator Frequency Electrocution/burn hazard. Contact with electrically charged circuits could result in death or 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. 4 Adjust the valve counter-clockwise to increase the frequency and clockwise to decrease the frequency, until the correct value is reached according to the table below. ANSI 12 kW Generator 61 Hz +/- 0.5 Hz ANSI 3 kW Generator 61 Hz +/- 0.5 Hz CE / ROW 3 kW Generator 51 Hz +/- 0.5 Hz Once the correct frequency is set, tighten the jam nut. Generator Manifold 1 needle valve 92 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual This page intentionally left blank. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 93 Service and Repair Manual Fault Codes July 2020 Sectio n 4 Fault C odes Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Unless otherwise specified, perform each procedure with the machine in the following configuration: Machine parked on a firm, level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both the ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine (if equipped with the weld cable to platform option) Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Read each appropriate fault code thoroughly. Attempting short cuts may produce hazardous conditions. Be aware of the following hazards and follow generally accepted safe workshop practices. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: Two persons will be required to safely perform some troubleshooting procedures. 94 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes How to Re triev e Con trol Syst em Fa ult Cod es Control System 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 95 Service and Repair Manual Control System Fault Codes July 2020 Control 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 C134PLT be functional. and C174GND from KS1 are both HIGH for at least 1 second, causing both control stations to be selected. Verify with a voltmeter that signals switch properly. * With the keyswitch in the Ground position, C174GND (WH, TCON J5-12) should be 12 V and C134PLT (GR/BK, TCON J5-8) should be 0 V. * With the keyswitch in the Platform position, C174GND (WH, TCON J5-12) should be 0 V and C134PLT (GR/BK, TCON J5-8) should be 12 V. Cycle power to allow the machine to retest the fault. 11 Engine Start 19 Stuck ON Toggle at power Switch up. Toggle Engine start switch input switch will not was detected operate. as HIGH at start-up. Verify with a voltmeter that the Engine Start Toggle Switch (TS2) is operating properly. * 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 retest the fault. 12 CAN Bus 29 System not CAN bus Machine will not functioning system is not be functional. functioning properly. 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 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 at power Switch up. Toggle The Jib Up or switch input Down functions was detected will not operate. as HIGH at start-up. Verify with a voltmeter that the Jib Up/Down Toggle Switch (TS8) is 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 retest the fault. 14 Battery Voltage 15 Voltage is low. Battery Advisory fault. voltage is too Machine is fully low while functional. engine is running. Verify with a voltmeter that the alternator is operating properly. * With the engine running, battery voltage should be above 12.3 V. * Verify alternator and power wiring. * Replace alternator if necessary. * Replace battery if necessary. 96 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 15 Foot Switch 19 Stuck ON at power up, or timeout occurred. Foot switch input was detected as HIGH at start-up, or the footswitch was held for too long and caused the foot switch timer to elapse. Machine will not be functional. * Release foot switch and cycle power. * If problem persists, with a voltmeter verify that C24FS (WH, PCON J12-2) is LOW when foot switch is released and 12 V when held down. 19 APU 12 Solenoid Solenoid and output Switch shorted to V+ 15 Solenoid output shorted to GND TCON Machine will not detected that be functional. C27AUX circuit is shorted to 12 V. TCON Auxiliary Power detected that function will not C27AUX operate. circuit is shorted to GND. Check C27AUX (RD, TCON J3-3) wiring. * With a voltmeter verify that C27AUX (RD, TCON J3-3) is 0 V 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 Stuck ON at power up. Toggle Auxiliary Power switch input function will not was detected operate from as HIGH at platform. start-up. Verify with a voltmeter that the AUX Power Switch (TS1) is operating properly. * C47AUX (RD, PCON J17-10) should be 0 V with the switch OFF and 12 V with the switch ON. Cycle power to allow the machine to retest the fault. 20 Primary Boom Extend / Retract Joystick 12 Joystick voltage too high. 15 Joystick voltage too low. Circuit C163PER is above 4.5 V. Boom Extend and Retract functions will not operate. Circuit C163PER is below 0.5 V. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C163PER (BL/WH, PCON J18-4) is at 2. 5V +/- 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. 19 Joystick held at startup. Circuit C163PER voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 97 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 21 Primary Boom Up / Down Joystick 12 Joystick Circuit Boom Up and voltage too C164PUD is Down functions high. above 4.5 V. will not operate. 15 Joystick voltage too low. 19 Joystick held at startup. Circuit C164PUD is below 0.5 V. Circuit C164PUD voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C164PUD (RD/WH, PCON J18-3) is at 2. 5V +/- 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. 22 Primary Boom Up Valve 12 Circuit shorted to V+ TCON Boom Up detected that function will not C1PBU operate. Boom circuit is Down will also shorted to 12 not operate if V. short is to 12 V. * With a voltmeter, measure Y22. Proper resistance should be between 5 60 ohms. Replace Y22 if resistance is outside of those values. * Verify wiring for C1PBU (RD, TCON J410) and check for open or short circuits. 15 Circuit shorted to GND TCON detected that C1PBU circuit is shorted to GND. 23 Primary 12 Circuit Boom Down shorted to Valve V+ 15 Circuit shorted to GND TCON Boom Up and detected that Down functions C2PBD will not operate. circuit is shorted to 12 V. TCON detected that C2PBD circuit is shorted to GND. * With a voltmeter, measure Y21. Proper resistance should be between 5 60 ohms. Replace Y21 if 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. 98 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 24 Boom Angle 13 No signal Sensor No CAN messages have been received by the TCON from the Angle Sensor. Boom Up, Extend and Turntable Rotate functions will not operate. * Verify sensor power P85PWR (GR, TCON J6-7) is at 12 V while the system is running. * Verify the sensor is receiving power. 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. 17 Invalid calibration Sensor has been replaced and requires calibration, or calibration in memory has been erased. Run the boom angle calibration process and verify fault is no longer active. 19 Out of range Sensor disagrees with boom position sensed by LST3S, or boom exceeded the calibrated minimum or maximum values. * Run the boom angle calibration process and verify fault is no longer active. * If fault persists, verify LST3S (C68LS, RD, TCON J7-3) operates properly. The signal should be 12 V when the boom is stowed and 0 V when the boom is up. 36 Internal check The two internal sensing channels inside the Angle Sensor have registered a significant difference. * Run the boom angle calibration process and verify fault is no longer active. * If fault persists, replace the sensor. 25 Cable tension 21 Loose cable Boom cable tension limit switch LSB2S indicates that the tension is loose on the boom cables. Boom Up and Extend functions will not operate. * Return boom to stowed position as quickly as possible. * Verify both boom cables are properly tensioned and that LST3S is properly centered in the bracket. * 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 99 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 26 Primary 12 Circuit Boom shorted to Extend Valve V+ 27 Primary Boom Retract Valve 15 Circuit shorted to GND 12 Circuit shorted to V+ 15 Circuit shorted to GND Cause TCON detected that C7PBE circuit is shorted to 12 V. TCON detected that C7PBE circuit is shorted to GND. TCON detected that C8PBR circuit is shorted to 12 V. TCON detected that C8PBR circuit is shorted to GND. Effect Solution Boom Extend and Retract functions will not operate. * With a voltmeter, measure Y26. Proper resistance should be between 5 60 ohms. Replace Y26 if resistance is outside of those values. * Verify wiring for C7PBE (BK, TCON J47) and check for open or short circuits. Boom Extend and Retract functions will not operate. * With a voltmeter, measure Y25. Proper resistance should be between 5 60 ohms. Replace Y25 if 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 Buttons 19 Held at startup 36 Jib Up Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND 37 Jib Down Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND Buttons were held at system start, or are shorted on the ground control panel. The function associated with the stuck button will not operate. PCON detected Jip Up that V43JU circuit function will is shorted to 12 not operate. V. PCON detected that V43JU circuit is shorted to GND. PCON detected Jib Down that V44JD circuit function will is shorted to 12 not operate. V. PCON detected that V44JD circuit is shorted to GND. * Release the ground control buttons and cycle power. * If problem persists, open ground control box and open the Display 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. * With a voltmeter, measure Y68. Proper resistance should be between 5 60 ohms. Replace Y68 if resistance is outside of those values. * Verify wiring for V43JU (BL, PCON J128) and check for open or short circuits. * With a voltmeter, measure Y69. Proper resistance should be between 5 60 ohms. Replace Y69 if resistance is outside of those values. * Verify wiring for V44JD (BL/BK, PCON J12-9) and check for open or short circuits. 100 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 41 Turntable Rotate Joystick 12 Joystick voltage too high. 15 Joystick voltage too low. 19 Joystick held at startup. Circuit C165TTR is above 4.5 V. Circuit C165TTR is below 0.5 V. Circuit C165TTR voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. Turntable Rotate functions will not operate. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C165TTR (WH/RD, PCON J18-2) is at 2. 5V +/- 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. 42 Turntable Rotate CW Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND TCON detected that C4TRL circuit is shorted to 12 V. TCON detected that C4TRL circuit is shorted to GND. Turntable Rotate functions will not operate. * With a voltmeter, measure Y24. Proper resistance should be between 5 60 ohms. Replace Y24 if resistance is outside of those values. * Verify wiring for C4TRL (WH, TCON J312) and check for open or short circuits. 43 Turntable 12 Circuit Rotate CCW shorted to Valve V+ 15 Circuit shorted to GND TCON detected that C5TRR circuit is shorted to 12 V. TCON detected that C5TRR circuit is shorted to GND. Turntable Rotate functions will not operate. * With a voltmeter, measure Y23. Proper resistance should be between 5 60 ohms. Replace Y23 if resistance is outside of those values. * Verify wiring for C5TRR (WH/BK, TCON J3-1) and check for open or short circuits. 44 Drive Enable 19 Stuck ON Switch at power up. Toggle switch input was detected as HIGH at start-up. Drive Enable switch will not operate, possibly preventing drive while the turntable is rotated. Verify with a voltmeter that the Drive Enable Toggle Switch (TS15) is operating properly. * C143DEL (BL/RD, PCON J16-7) 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 retest the fault. 45 Platform Level Up/Down Switch 19 Stuck ON at power up. Toggle switch input was detected as HIGH at start-up. Platform Level Up or Down functions may not operate, depending on which direction the switch fault occurred. Verify with a voltmeter that the Platform Level Up/Down Toggle Switch (TS9) is operating properly. * C14PLU (OR, PCON J17-2) should be 0 V with the switch OFF and 12 V 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 retest the fault. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 101 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 46 Platform Rotate CW Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND PCON detected that V17PRL circuit is shorted to 12 V. PCON detected that V17PRL circuit is shorted to GND. Platform Rotate CW function will not operate. * With a voltmeter, measure Y70. Proper resistance should be between 5 60 ohms. Replace Y70 if resistance is outside of those values. * Verify wiring for V17PRL (GR, PCON J12-5) and check for open or short circuits. 47 Platform 12 Circuit Rotate CCW shorted to Valve V+ 15 Circuit shorted to GND PCON detected that V18PRR circuit is shorted to 12 V. PCON detected that V18PRR circuit is shorted to GND. Platform Rotate CCW function will not operate. * With a voltmeter, measure Y71. Proper resistance should be between 5 60 ohms. Replace Y71 if resistance is outside of those values. * Verify wiring for V18PRR (GR/BK, PCON J12-4) and check for open or short circuits. 51 Drive Forward / Reverse Joystick 12 Joystick voltage too high. 15 Joystick voltage too low. Circuit C160DRV is above 4.5 V. Circuit C160DRV is below 0.5 V. Drive Forward and Reverse functions will not operate. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C160DRV (WH/RD, PCON J18-10) is at 2. 5V +/- 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. 19 Joystick held at startup. Circuit C160DRV voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. 52 Drive Forward Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND TCON detected that C30FWD circuit is shorted to 12 V. TCON detected that C30FWD circuit is shorted to GND. Drive Forward, Brake Release and possibly Engine will not operate. * With a voltmeter, measure Y6. Proper resistance should be between 5 60 ohms. Replace Y6 if resistance is outside of those values. * Verify wiring for C30FWD (WH, TCON J2-6) and check for open or short circuits. 53 Drive Reverse Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND TCON detected that C31REV circuit is shorted to 12 V. TCON detected that C31REV circuit is shorted to GND. Drive Reverse, Brake Release and possibly Engine will not operate. * With a voltmeter, measure Y5. Proper resistance should be between 5 60 ohms. Replace Y5 if resistance is outside of those values. * Verify wiring for C31REV (WH/BK, TCON J2-7) and check for open or short circuits. 102 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 54 Brake Release Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND TCON detected that C32BRK circuit is shorted to 12 V. TCON detected that C32BRK circuit is shorted to GND. Machine will not be functional. * With a voltmeter, measure Y2. Proper resistance should be between 5 60 ohms. Replace Y2 if resistance is outside of those values. * Verify wiring for C32BRK (WH/RD, TCON J2-9) and check for open or short circuits. 55 Motor Stroke 12 Circuit Valve shorted to V+ 15 Circuit shorted to GND TCON detected that C29MS circuit is shorted to 12 V. TCON detected that C29MS circuit is shorted to GND. Drive functions will not operate. * With a voltmeter, measure Y27. Proper resistance should be between 5 60 ohms. Replace Y27 if resistance is outside of those values. * Verify wiring for C29MS (RD/WH, TCON J2-8) and check for open or short circuits. 61 Steer Joystick 12 Joystick voltage too high. 15 Joystick voltage too low. 19 Joystick held at startup. Circuit C159STD or C159STA is above 4.5 V. Circuit C159STD or C159STA is below 0.5 V. Circuit C159STD or C159STA voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. Drive and steer functions will not operate. * Leave joystick in neutral position and cycle power. * If fault persists, identify which circuit is the steer circuit. Check C159STA (BL/WH, PCON J18-11) for a joystick steer option. Check C159STD (BL/RD, PCON J18-9) for the rocker joystick steer option. With a voltmeter check that the circuit is at 2. 5V +/- 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. 68 Safety Envelope Fault 21 Out of range The system has determined that the platform position has exceeded the safety envelope boundary. All functions will not operate except for the recovery procedure. Use Auxiliary Power and the boom retract and/or down functions to bring the platform back within the operational envelope. 69 Generator Control Circuit 12 Circuit shorted to V+ 15 Circuit shorted to GND TCON detected that C45GEN circuit is shorted to 12 V. TCON detected that C45GEN circuit is shorted to GND. Generator function will not operate. * With a voltmeter, measure Y29. Proper resistance should be between 5 60 ohms. Replace Y29 if resistance is outside of those values. * Verify wiring for C45GEN (GR/WH, TCON J3-2) and check for open or short circuits. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 103 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 71 ESTOP Circuit 15 ESTOP Return circuit shorted to GND 16 ESTOP Power circuit shorted to GND 21 ESTOP Return circuit mismatch 22 ESTOP Source circuit is shorted to GND 31 ESTOP Source circuit mismatch Cause Effect Solution Mistmatched signals detected on ESTOP Return circuits. Either: * PCON ESTOP 2 and ESTOP 4 do not match, or * TCON ESTOP 2 and ESTOP 4 do not match. ESTOP * Inspect PCON J15 pins 11 and 12 for circuit cannot open or short circuits. Using a voltmeter, complete, set to diode test mode and make sure the preventing diode tests ok with the anode at pin machine 12 and cathode at pin 11. If test fails, functions. replace the PCON. * Inspect TCON J5 pins 11 and 12 for open or short circuits. Using a voltmeter, set to diode test mode and 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. TCON detected that P56PWR is shorted to GND, thereby preventing the ESTOP circuit from functioning. Check P56PWR (RD, TCON J5-7) for open or short circuits. Verify power is reaching the P1 ESTOP contact block. When ESTOP is pulled out, verify power is reaching the KS1 keyswitch contact blocks. TCON detected that ESTOP Return circuits are not matching, indicating a fault with either P23PWR or P23RET. * Check for open and short circuits in the boom cable. * Verify that there is low resistance (less than five ohms) on the cabling between TCON J5-11 and PCON J15-11 (BK wire in harness and boom cable). An open circuit between these pins indicates a 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. TCON detected that ESTOP 1 is at 12 V but ESTOP 3 is at 0 V. TCON detected that ESTOP 1 is at 0 V but ESTOP 3 is at 12 V. * Using a voltmeter and with the system turned OFF, check the resistance between TCON J5 pins 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. 104 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name 72 Contact Alarm 36 Switch state mismatch 75 TCON Secondary Processor Software 34 Incorrect software version 76 Platform 13 No signal Load Sensor 15 Reverse loading Cause Effect Solution PCON detected that inputs from SW30 (contact alarm proximity sensor) are the same voltage. Boom Up and Extend functions will not operate. * Using a voltmeter, verify that the voltage on C248CA (OR/BK, PCON J12-1) is always the opposite of C247CA (OR, PCON J12-11). * Check wiring for open or short circuits. * Verify SW30 is receiving power and ground by verifying 12 V across C31 pins 1 and 3. * Replace SW30 if necessary. The TCON's secondary processor software version does not match the system software revision level. Boom Up and Extend functions will not operate. Reprogram the machine with latest software. Check http://firmware.genielift.com/ for the latest software version. No CAN messages have been received by the TCON from the platform load sensor. Boom Up, Extend and Turntable Rotate functions will not operate. * Verify sensor power P26PWR (BK, PCON J13-9) is at 12 V while the system is running. * 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. The sensor has reported a reversed or negative load condition. This fault is triggered when the boom up function has operated for at least 10 seconds and the platform load is consistently detected as less than -220 lbs. * Make sure the platform is not touching the ground or an overhead obstruction. Cycle power and check that fault is no longer reported. * Perform the platform overload calibration procedure. * Replace sensor if necessary. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 105 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect 76 17 Invalid The platform load calibration sensor has no valid calibration data, either because the sensor was replaced or the prior calibration was cleared from memory or was unsuccessful. 21 Internal check The two internal sensing channels inside the Angle Sensor have registered a significant difference. July 2020 Solution * Run the platform overload calibration process and verify fault is no longer active. * Run the platform overload calibration process and verify fault is no longer active. * If fault persists, replace the sensor. 106 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 77 Platform Overload Detection 21 Internal check The secondary platform overload check detected overload before the operational platform overload check. All functions will not operate except for the recovery procedure. * Cycle power and verify condition clears itself. * If problem persists, run the platform overload calibration procedure. * If problem persists, replace the sensor. 78 Platform Controller (PCON) 13 Not detected TCON has not detected the PCON primary processor on the communications bus. Controls from the platform will not operate. * Verify PCON is receiving power. Check for 12 V on J15-2 (+) and J15-1 (-). * Verify PCON is receiving ESTOP signals. With ground ESTOP pulled 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. 34 Incorrect software version PCON software revision does not match the system revision level. Boom Up and Extend functions will not operate. Reprogram the machine with latest software. Check http://firmware.genielift.com/ for the latest software version. 36 Secondary processor not detected. TCON has not Controls detected the from the PCON secondary platform will processor on the not operate. communications bus. Reprogram the machine with latest software. Check http://firmware.genielift.com/ for the latest software version. 79 Display Controller (DISCON) 13 Not detected TCON has not detected the DISCON on the communications bus. Controls from the ground will not operate. * Verify DISCON is operating by checking that the display on the front is operating properly. * If there is no display, try to power up 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. 34 Incorrect software version DISCON software revision does not match the system revision level. Boom Up and Extend functions will not operate. Reprogram the machine with latest software. Check http://firmware.genielift.com/ for the latest software version. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 107 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 80 Turntable Controller (TCON) 13 Not detected The DISCON has Machine will not detected the not be TCON on the functional. CAN bus. * Verify TCON is receiving power. Check for 12 V on J5-2 (+) and J5-1 (-). * 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. 36 Incorrect software version TCON's secondary processor software revision does not match the system revision level. Reprogram the machine with latest software. Check http://firmware.genielift.com/ for the latest software version. 83 Telematics 21 Remote disable The telematics module has locked out machine operation. Machine will not be functional, or have limited functionality, depending on the telematics option. Call machine owner to re-enable machine functions. 84 Turntable Tilt 13 Not Sensor detected The tilt sensors (S8O and/or S8S) have not been detected on the CAN bus. Boom Up, Extend and Drive functions will not operate. * Verify S8O is receiving power. Disconnect sensor connector and verify harness connector pins 1 and 2 measure 12 V. * Verify S8S is receiving power. Disconnect 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 calibration The tilt sensors have no valid calibration data, either because the sensor(s) were replaced or the prior calibration was cleared from memory or was unsuccessful. Boom Up and Extend functions will not operate. Perform the tilt sensor calibration process. 108 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 88 Function 12 Circuit Enable Valve shorted to V+ 15 Circuit shorted to GND TCON detected that C155PCE circuit is shorted to 12 V. TCON detected that C155PCE circuit is shorted to GND. Only Auxiliary Power is available. * With a voltmeter, measure Y74. Proper resistance should be between 5 60 ohms. Replace Y74 if resistance is outside of those values. * Verify wiring for C155PCE (OR/RD, TCON J2-5) and check for open or short circuits. 92 Turntable 12 Circuit Rotate Flow shorted to Valve V+ 15 Circuit shorted to GND TCON detected that C6TRF circuit is shorted to 12 V. TCON detected that C6TRF circuit is shorted to GND. Turntable Rotate functions will not operate. * With a voltmeter, measure Y13. Proper resistance should be between 5 60 ohms. Replace Y13 if resistance is outside of those values. * Verify wiring for C6TRF (WH/RD, TCON J4-1) and check for open or short circuits. 94 Boom Length Sensor 13 No signal No CAN messages have been received by the TCON from the Length Sensor. Boom Up, Extend and Turntable Rotate functions will not operate. * Verify sensor power P85PWR (GR, TCON J6-7) is at 12 V while the system is running. * Verify the sensor is receiving power. 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. 17 Invalid calibration Sensor has been replaced and requires calibration, or calibration in memory has been erased. Run the boom length calibration process and verify fault is no longer active. 19 Out of range Sensor disagrees with boom position sensed by LSB1RS, or boom exceeded the calibrated minimum or maximum values. * Run the boom length calibration process and verify fault is no longer active. * If fault persists, verify LSB1RS C42LS, OR/RD, Recovery Module J36-4 and J369, TCON J7-4) operates properly. The signal should be 12 V when the boom is fully retracted and 0 V when the boom is extended at least 24 inches. 36 Internal check The two internal sensing channels inside the Length Sensor have registered a significant difference. * Run the boom length calibration process and verify fault is no longer active. * If fault persists, replace the sensor. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 109 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 96 Engine Oil 21 Value too Pressure low 100 Platform Level Up Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND 101 Platform 12 Circuit Level Down shorted to Valve V+ 15 Circuit shorted to GND 150 Platform Overload Recovery 21 Condition occurred 152 Primary Boom Up/Down Flow Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND Cause Effect Solution The engine oil pressure is measured as too low, potentially damaging the engine. Engine may not attempt to start until system power cycle. Engine may be turned off by control system immediately. * Stop engine as soon as possible. * Verify the engine oil level. * Verify the engine oil pump. * Power on the machine and start the engine. At the ground controls 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 J69). PCON detected that V14PLU circuit is shorted to 12 V. PCON detected that V14PLU circuit is shorted to GND. Platform * With a voltmeter, measure Y20. Level Up and Proper resistance should be between 5 - possibly 60 ohms. Replace Y20 if resistance is Level Down outside of those values. functions will * Verify wiring for V14PLU (OR, PCON not operate. J12-6) and check for open or short circuits. PCON detected that V15PLD circuit is shorted to 12 V. PCON detected that V15PLD circuit is shorted to GND. Platform Level Down and possibly Level Up functions will not operate. * With a voltmeter, measure Y19. Proper resistance should be between 5 60 ohms. Replace Y19 if resistance is outside of those values. * Verify wiring for V15PLD (OR/BK, PCON J12-7) and check for open or short circuits. This is a flag that indicates that the platform was overloaded and that auxiliary function enable was used while overloaded. Advisory condition. Machine is fully functional. Power up the machine in service mode and clear the flag in the service menu on the ground control display. TCON detected that C3PBF circuit is shorted to 12 V. TCON detected that C3PBF circuit is shorted to GND. Boom Up and Down functions will not operate. * With a voltmeter, measure Y12. Proper resistance should be between 5 60 ohms. Replace Y12 if resistance 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. 110 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name 160 Steer Left Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND 161 Steer Right Valve 12 Circuit shorted to V+ 15 Circuit shorted to GND 169 Primary 12 Circuit Boom shorted to Extend / V+ Retract Flow Valve 15 Circuit shorted to GND Cause TCON detected that C37STL circuit is shorted to 12 V. TCON detected that C37STL circuit is shorted to GND. TCON detected that C36STR circuit is shorted to 12 V. TCON detected that C36STR circuit is shorted to GND. TCON detected that C9PEF circuit is shorted to 12 V. TCON detected that C9PEF circuit is shorted to GND. Effect Steer Left function will not operate. Solution * With a voltmeter, measure Y3. Proper resistance should be between 5 60 ohms. Replace Y3 if resistance is outside of those values. * Verify wiring for C37STL (BL/BK, TCON J4-11) and check for open or short circuits. Steer Right function will not operate. * With a voltmeter, measure Y4. Proper resistance should be between 5 60 ohms. Replace Y4 if resistance is outside of those values. * Verify wiring for C36STR (BL, TCON J412) and check for open or short circuits. Boom Extend and Retract functions will not operate. * With a voltmeter, measure Y15. Proper resistance should be between 5 60 ohms. Replace Y15 if resistance is outside of those values. * 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. 174 Platform Rotate Toggle Switch 19 Stuck ON at power up. 177 Engine 12 Value too Coolant high Temperature Toggle switch input was detected as HIGH at start-up. The engine coolant temperature is measured as too high, potentially damaging the engine. Platform Rotate Left or Right will not operate, depending on which side of the switch was faulted. Verify with a voltmeter that the Platform Rotate Toggle Switch (TS7) is operating properly. * C17PRL (GR, PCON J16-4) and 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 retest the fault. Engine will * Stop engine as soon as possible. not restart * Verify the engine coolant level. until machine * Verify the engine coolant/water pump. power is cycled. Engine may stop itself, depending * Power on the machine and start the engine. At the ground controls display, view the engine temperature gauge for 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). Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 111 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 178 Engine Warning Lamp 21 Fault 179 Engine Stop 21 Fault Lamp 240 Sensor Power P85PWR 12 Circuit shorted to V+ 15 Circuit shorted to GND 241 Sensor Power P109PWR 12 Circuit shorted to V+ 15 Circuit shorted to GND 242 Sensor Power P26PWR 12 Circuit shorted to V+ 15 Circuit shorted to GND 243 Proximity Override Toggle Switch 19 Stuck ON at power up. Cause Effect Solution The engine has triggered the Engine Warning Lamp condition. Machine will * Check the engine fault codes with an function as engine diagnostic tool. normal. The engine has triggered the Engine Stop Lamp condition. Control system will not allow engine restart until power cycle. Engine may stop itself, depending on the engine option. * Stop engine immediately. * Check the engine fault codes with an engine diagnostic tool. TCON detected that P85PWR circuit is shorted to 12 V. TCON detected that P85PWR circuit is shorted to GND. Boom Up and Extend functions will not operate. * Turn on machine and verify sensor power P85PWR (GR, TCON J6-7) is at 12 V. * Inspect wiring for open or shorts circuits. TCON detected that P109PWR circuit is shorted to 12 V. TCON detected that P109PWR circuit is shorted to GND. Boom Up and Extend functions will not operate. * Turn on machine and verify sensor power P109PWR (GR/WH, TCON J7-7) is at 12 V. * Inspect wiring for open or shorts circuits. PCON detected that P26PWR circuit is shorted to 12 V. PCON detected that P26PWR circuit is shorted to GND. Boom Up and Extend functions will not operate. * Turn on machine and verify sensor power P26PWR (BK, PCON J13-9) is at 12 V. * Inspect wiring for open or shorts circuits. Toggle switch input was detected as HIGH at start-up. Operator will be unable to override the proximity cutoff feature. Verify with a voltmeter that the Proximity Override Toggle Switch (TS46) is operating properly. * C90PRX (RD/BK, PCON J17-9) should be 12 V when the switch is pressed. Cycle power to allow the machine to retest the fault. 112 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes Control 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 Bus detected CAN+ or CAN- shorted to supply. Disable engine start for tier 4F engines *Verify with a voltmeter that CAN+ and CAN- lines are not shorted.* 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 Warning 21 Fault The engine has triggered the Engine Warning Lamp condition. Machine will function * Check the engine fault codes with as normal. an engine diagnostic tool. 8 Engine Stop 21 Fault The engine has triggered the Engine Stop Lamp condition. Control system will not allow engine restart until power cycle. Engine may stop itself, depending on the engine option. * Check the engine fault codes with an engine diagnostic tool. Note: The control system shuts off the engine immediately upon receiving this fault from the engine. 9 Engine 21 Fault Engine is reporting an engine-specific fault This is a generic engine warning fault. Engine may enforce power reduction. Other effects vary depending on the fault. Refer to the engine fault codes in the menu system. 10 Ground 27 Active at Engine start button Controls startup held at startup. Engine Start Switch Engine start is disabled Release engine start button, check DISCON overlay and ribbon cable if issue persists. 11 Platform 27 Active at Platform controls Controls startup engine start switch Engine Start active at startup. Switch Engine start switch will not operate. *Verify with a voltmeter that the Engine Start Toggle Switch (TS2) is operating properly. * 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 113 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause 12 Machine CAN Bus 13 Not Machine CANBUS detected CAN+ or CAN- shorted to supply Effect Machine will not be functional. 13 Jib Up/Down Switch 27 Active at Toggle switch input The Jib Up or Down startup was detected as functions will not HIGH at start-up. operate. 15 Foot Switch 27 Active at Foot switch input Machine will not be startup was detected as functional. HIGH at start-up, or the footswitch was held for too long and caused the footswitch timer to elapse. 28 Timeout Foot switch Machine will not be depressed too long functional. without action 17 Aux Pump Coil 11 Shorted to supply voltage TCON detected that C27AUX circuit is shorted to 12V. Machine will not be functional. 19 Aux Enable 27 Active at Aux button held at Machine will not be Switch startup startup. functional. Solution *Verify with a voltmeter that CAN+ and CAN- lines are not shorted. *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. *Verify with a voltmeter that the Jib Up/Down Toggle Switch (TS8) is 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. * Release foot switch and cycle power. * If problem persists, with a voltmeter verify that C24FS (WH, PCON J12-2) is LOW when foot switch is released and 12 V when held down. *Check C27AUX (RD, TCON J3-3) wiring. *With a voltmeter verify that C27AUX (RD, TCON J3-3) is 0 V 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. Release Aux button, check DISCON overlay and ribbon cable if issue persists. 114 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 20 Pri Boom Ext / Ret Joystick 11 Shorted Circuit C163PER is to above 4.5 V. supply voltage Boom Extend and Retract functions will not operate. 27 Active at startup Circuit C163PER voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C163PER (BL/WH, PCON J18-4) is at 2. 5V +/- 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. Pri Boom 21 Up / Down Joystick 11 Shorted Circuit C164PUD is to above 4.5 V. supply voltage Boom Up and Down functions will not operate. 27 Active 28 at startup Circuit C164PUD voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C164PUD (RD/WH, PCON J18-3) is at 2. 5V +/- 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. 22 Pri Boom Up coil 11 Shorted TCON detected that Boom Up function will * With a voltmeter, measure Y22. 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 Down Coil 11 Shorted TCON detected that Boom Up and Down to C2PBD circuit is functions will not supply shorted to 12 V or operate. voltage GND. * With a voltmeter, measure Y21. Proper resistance should be between 5 - 60 ohms. Replace Y21 if 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 115 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 24 Pri Boom Angle 13 Not detected Cause Effect No CAN messages Machine limited to have been recovery functions received by the TCON from the Angle Sensor. 14 Cross check failed The two internal sensing channels inside the Angle Sensor have registered a significant difference. 17 Not Sensor has been calibrated replaced and requires calibration, or calibration in memory has been erased. 19 Value out Min or max boom of angle out of expected expected range. range Crosscheck limit switch disagrees with boom angle sensor. Machine limited to recovery functions. 25 Cable tension 21 Fault Boom cable tension limit switch LSB2S indicates that the tension is loose on the boom cables. Boom Up and Extend functions will not operate. Solution * Verify sensor power P85PWR (GR, TCON J6-7) is at 12 V while the system is running. * Verify the sensor is receiving power. 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. * Calibrate boom angle sensor. * Check boom angle sensor mount, ensure all fasteners are tightened to spec. * Replace sensor if issue persists. Run the boom angle calibration process and verify fault is no longer active. * Verify that with the boom stowed C68LS (BL, TCON J7-3) is 12V and that the boom is making contact with the LST3S limit switch arm. * Verify that with the boom above 12 degrees C68LS (BL, TCON J7-3) is 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. * Return boom to stowed position as quickly as possible. * Verify both boom cables are properly tensioned and that LST3S is properly centered in the bracket. * 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. 116 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 26 Pri Boom Ext Coil 11 Shorted TCON detected that Boom Extend and to C7PBE circuit is Retract functions will supply shorted to 12 V or not operate. voltage GND. * With a voltmeter, measure Y26. Proper resistance should be between 5 - 60 ohms. Replace Y26 if resistance is outside of those values. * Verify wiring for C7PBE (BK, TCON J4-7) and check for open or short circuits. 27 Pri Boom Ret Coil 11 Shorted TCON detected that Boom Extend and to C8PBR circuit is Retract functions will supply shorted to 12 V or not operate. voltage GND. * With a voltmeter, measure Y25. Proper resistance should be between 5 - 60 ohms. Replace Y25 if 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 Control Button 27 Active at startup Buttons were held at system start, or are shorted on the ground control panel. The function associated with the stuck button will not operate. *Release the ground control buttons and cycle power. *If problem persists, open ground control box and open the Display 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 to V43JU circuit is not operate. supply shorted to 12 V or voltage GND. * With a voltmeter, measure Y68. Proper resistance should be between 5 - 60 ohms. Replace Y68 if resistance is outside of those values. * Verify wiring for V43JU (BL, PCON J12-8) and check for open or short circuits. 37 Jib Down Coil 11 Shorted PCON detected that Jib Down function will * With a voltmeter, measure Y69. 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 117 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause 40 Jib Select Coil 11 Shorted PCON detected to V18PRR is short to supply supply voltage Effect Jib and platform functions will not operate 41 Turntable Rotate Joystick 11 Shorted Circuit C165TTR is to above 4.5 V. supply voltage Turntable Rotate functions will not operate. 27 Active at startup Circuit C165TTR voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. Solution *With a voltmeter, measure Y18. Proper resistance should be between 5 - 60 ohms. Replace Y18 if resistance is outside of those values. *Verify wiring for V18PRR (GR/BK, PCON J12-4) and check for short circuits. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C165TTR (WH/RD, PCON J18-2) is at 2. 5V +/- 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. 42 Turntable Rotate CW Coil 43 Turntable Rotate CCW Coil 44 Drive Enable Toggle Switch 11 Shorted TCON detected that Turntable Rotate to C4TRL circuit is functions will not supply shorted to 12 V or operate. voltage GND. 11 Shorted TCON detected that Turntable Rotate to C5TRR circuit is functions will not supply shorted to 12 V or operate. voltage GND. 27 Active at startup Toggle switch input was detected as HIGH at start-up. Drive Enable switch will not operate, possibly preventing drive while the turntable is rotated. * With a voltmeter, measure Y24. Proper resistance should be between 5 - 60 ohms. Replace Y24 if resistance is outside of those values. * Verify wiring for C4TRL (WH, TCON J3-12) and check for open or short circuits. * With a voltmeter, measure Y23. Proper resistance should be between 5 - 60 ohms. Replace Y23 if resistance is outside of those values. * Verify wiring for C5TRR (WH/BK, TCON J3-1) and check for open or short circuits. *Verify with a voltmeter that the Drive Enable Toggle Switch (TS15) is operating properly. * C143DEL (BL/RD, PCON J16-7) 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. 118 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 45 Platform Level Toggle Switch 27 Active at startup Toggle switch input was detected as HIGH at start-up. Platform Level Up or Down functions may not operate, depending on which direction the switch fault occurred. *Verify with a voltmeter that the Platform Level Up/Down Toggle Switch (TS9) is operating properly. * C14PLU (OR, PCON J17-2) should be 0 V with the switch OFF and 12 V 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 Rotate CW Coil 11 Shorted PCON detected that Platform Rotate CW to V17PRL circuit is function will not supply shorted to 12 V or operate. voltage GND. * With a voltmeter, measure Y70. Proper resistance should be between 5 - 60 ohms. Replace Y70 if resistance is outside of those values. * Verify wiring for V17PRL (GR, PCON J12-5) and check for open or short circuits. 47 Platform Rotate CCW Coil 11 Shorted PCON detected that Platform Rotate CCW * With a voltmeter, measure Y71. to V18PRR circuit is function will not Proper resistance should be between 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 Joystick 11 Shorted Circuit C160DRV is to above 4.5 V. supply voltage Drive Forward and Reverse functions will not operate. 27 Active at startup Circuit C160DRV voltage was not within the startup voltage range of 2.5 V +/- 0.2 V. * Leave joystick in neutral position and cycle power. * If fault persists, with a voltmeter check that C160DRV (WH/RD, PCON J18-10) is at 2. 5V +/- 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 119 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 52 Drive Forward Pump Coil 11 Shorted to supply voltage TCON detected that C30FWD circuit is shorted to 12 V or GND. Drive Forward, Brake Release and possibly Engine will not operate. * With a voltmeter, measure Y6. Proper resistance should be between 5 - 60 ohms. Replace Y6 if resistance is outside of those values. * Verify wiring for C30FWD (WH, TCON J2-6) and check for open or short circuits. 53 Drive Reverse Pump Coil 11 Shorted to supply voltage TCON detected that C31REV circuit is shorted to 12 V or GND. Drive Reverse, Brake Release and possibly Engine will not operate. * With a voltmeter, measure Y5. Proper resistance should be between 5 - 60 ohms. Replace Y5 if resistance is outside of those values. * Verify wiring for C31REV (WH/BK, TCON J2-7) and check for open or short circuits. 54 Brake Release Coil 11 Shorted to supply voltage TCON detected that C32BRK circuit is shorted to 12 V or GND. Machine will not be functional. * With a voltmeter, measure Y2. Proper resistance should be between 5 - 60 ohms. Replace Y2 if resistance is outside of those values. * Verify wiring for C32BRK (WH/RD, TCON J2-9) and check for open or short circuits. 55 High Drive Speed Coil 11 Shorted to supply voltage TCON detected that C29MS circuit is shorted to 12 V or GND. Drive functions will not operate. * With a voltmeter, measure Y27. Proper resistance should be between 5 - 60 ohms. Replace Y27 if resistance is outside of those values. * Verify wiring for C29MS (RD/WH, TCON J2-8) and check for open or short circuits. 56 Telematics Device 13 Not M7 telematics detected device not detected. Information only Cycle power. If fault persists, check telematics ready connector wiring. If there are no wiring issues replace M7. 120 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause 61 Steer Joystick 11 Shorted Circuit C159STD or to C159STA is above supply 4.5 V. voltage 27 Active at startup Circuit C159STD or C159STA voltage was not within the startup voltage range of 2.5 V +/0.2 V. Effect Drive and steer functions will not operate. Solution * Leave joystick in neutral position and cycle power. * If fault persists, identify which circuit is the steer circuit. Check C159STA (BL/WH, PCON J18-11) for a joystick steer option. Check C159STD (BL/RD, PCON J18-9) for the rocker joystick steer option. With a voltmeter check that the circuit is at 2. 5V +/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 Override Togggle Switch 68 Ground Function Enable Button 27 Active Toggle switch input The Jib Up or Down at was detected as functions will not startup HIGH at start-up. operate. 27 Active at startup Button was held at system start, or is shorted on the ground control panel. The function associated with the stuck button will not operate. *Verify with a voltmeter that the Jib Up/Down Toggle Switch (TS8) is 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. * Release the ground control buttons and cycle power. * If problem persists, open ground control box and open the Display 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 121 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 69 AC Generator Output 11 Shorted TCON detected that Generator function to C45GEN circuit is will not operate. supply shorted to 12 V. voltage * With a voltmeter, measure Y29. Proper resistance should be between 5 - 60 ohms. Replace Y29 if 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 Contact Alarm Switch 14 Cross check failed PCON detected that inputs from SW30 (contact alarm proximity sensor) are the same voltage. Boom Up and Extend functions will not operate. * Using a voltmeter, verify that the voltage on C248CA (OR/BK, PCON J12-1) is always the opposite of C247CA (OR, PCON J12-11). * Check wiring for open or short 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 Pressure 12 Sensor value too high Engine oil pressure sender is shorted to 12V. Engine will not operate. * With a voltmeter, check that C25PSR ( WH/BK, TCON J6P9) is not shorted to 12V and voltage is between 0.1-11.5V * Replace sender if necessary 24 Too low The engine oil pressure is measured as too low, potentially damaging the engine. Engine may not attempt to start until system power cycle. Engine may be turned off by control system immediately. * Stop engine as soon as possible. * Verify the engine oil level. * Verify the engine oil pump. * Power on the machine and start the engine. At the ground controls 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). 122 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 74 Engine 15 Sensor Engine Temperature value too temperature low sensor is shorted to ground Engine will not operate * With a voltmeter, check that C26TSR ( WH/RD, TCON J6P8) is not shorted to ground and voltage is between 0.1-11.5V * Replace sensor if necessary 23 Too high The engine coolant Engine will not temperature is restart until machine measured as too power is cycled. high, potentially Engine may stop damaging the itself, depending on engine. the engine option. * Stop engine as soon as possible. * Verify the engine coolant level. * Verify the engine coolant/water pump. * Power on the machine and start the engine. At the ground controls display, 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 detected Load sensor not detected on the communications bus. Boom Up, Extend * Verify sensor power P26PWR (BK, and Turntable Rotate PCON J13-9) is at 12 V while the system functions will not is running. 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 check failed The two internal sensing channels inside the Load Sensor have registered a significant difference. Boom Up, Extend * Check that the load sensor is and Turntable Rotate mounted correctly and all fasteners functions will not are tightened to spec. operate. * Calibrate load sensor. * Replace sensor if issue persists. 15 Value to Platform load low sensor out of calibration Machine limited to recovery functions * Make sure the platform is not touching the ground or an overhead 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 calibrated sensor out of calibration * Calibrate load sensor. * Replace sensor if issue persists. 21 Fault Platform load sensor out of calibration * Check that the load sensor is mounted correctly and all fasteners are tightened to spec. * Calibrate load sensor. * Replace sensor if issue persists. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 123 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name 78 Platform Controller (PCON) 13 Not detected Cause TCON has not detected the PCON primary processor on the communications bus. Effect Controls from the platform will not operate. 79 Display Controller (DISCON) 29 Software PCON software is version out of date. mismatch 13 Not detected TCON has not detected the DISCON on the communications bus. Machine limited to recovery functions Controls from the ground will not operate. 29 Software DISCON software Machine limited to version is out of date. recovery functions mismatch Solution * Verify PCON is receiving power. Check for 12 V on J15-2 (+) and J151 (-). * Verify PCON is receiving ESTOP signals. With ground ESTOP pulled 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. Download latest software from firmware site and update machine. * Verify DISCON is operating by checking that the display on the front is operating properly. * If there is no display, try to power up 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. Download latest software from firmware site and update machine. 124 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name 80 Turntable Controller (TCON) 13 Not detected Cause Effect The DISCON has not detected the TCON on the CAN bus. Machine limited to recovery functions 82 Overload 83 Disabled 84 Chassis Angle 29 Software TCON software is version out of date mismatch 21 Recovery This is a flag that indicates that the platform was overloaded and that auxiliary function enable was used while overloaded. Advisory condition. Machine is fully functional. 21 By owner The telematics module has locked out machine operation. Machine will not be functional, or have limited functionality, depending on the telematics option. 13 Not detected The tilt sensor S80 has not been detected on the CAN bus. Boom Up, Extend and Drive functions will not operate. 17 Not Tilt sensor not calibrated calibrated Machine limited to recovery functions Solution * Verify TCON is receiving power. Check for 12 V on J5-2 (+) and J5-1 (-). * Verify TCON is receiving ESTOP signals. With ground ESTOP pulled out and keyswitch set to Ground, verify 12 V is reaching TCON J59 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. Download latest software from firmware site and update machine. Power up the machine in service mode and clear the flag in the service menu on the ground control display. Call machine owner to re-enable machine functions. * Verify S8O is receiving power. Disconnect 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. Calibrate tilt sensor. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 125 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause 85 Chassis Angle Safety 13 Not Tilt sensor not detected calibrated 88 Function Enable Coil 11 Shorted to supply voltage TCON detected that C155PCE circuit is shorted to 12 V or GND. 89 Fuel Level 12 Value to Fuel sensor Sensor high shorted to B+ 15 Value to Fuel sensor low shorted to GND 92 Turntable Rotate Flow Coil 11 Shorted to supply voltage TCON detected that C6TRF circuit is shorted to 12 V or GND. Effect Machine limited to recovery functions Only Auxiliary Power is available. Information only Turntable Rotate functions will not operate. Solution Calibrate tilt sensor. * With a voltmeter, measure Y74. Proper resistance should be between 5 - 60 ohms. Replace Y74 if resistance is outside of those values. * Verify wiring for C155PCE (OR/RD, TCON J2-5) and check for open or short circuits. With a voltmeter, check voltage on C65FLI (BL/WH, TCON J7-11). The voltage should be between 1V and 5V. Check for shorts to B+. With a voltmeter, check voltage on C65FLI (BL/WH, TCON J7-11). The voltage should be between 1V and 5V. Check for shorts to ground. * With a voltmeter, measure Y13. Proper resistance should be between 5 - 60 ohms. Replace Y13 if resistance is outside of those values. * Verify wiring for C6TRF (WH/RD, TCON J4-1) and check for open or short circuits. 126 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 94 Primary Boom Length 13 Not detected No CAN messages have been received by the TCON from the Length Sensor. Boom Up, Extend and Turntable Rotate functions will not operate. * Verify sensor power P85PWR (GR, TCON J6-7) is at 12 V while the system is running. * Verify the sensor is receiving power. 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 check failed The two internal sensing channels inside the Length Sensor have registered a significant difference. Machine limited to recovery functions * Ensure that the boom angle sensor cord is hooked up to the bracket on the boom and that the cord extends and retracts smoothly. * Calibrate boom length sensor. * Replace sensor if necessary. 17 Not Boom length calibrated sensor not calibrated. Calibrate boom length sensor. 19 Value out Min or max length of out of expected expected range. range Crosscheck limit switch disagrees with length sensor. * Verify that with the boom retracted C24LS (OR/RD TCON J7-4) is 12V and that the boom is making contact with the LSB1RS limit switch arm. * Verify that when the boom is 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 Boom Extend / Retract Flow Coil 11 Shorted to supply voltage TCON detected that C9PEF circuit is shorted to 12 V or GND. Boom Extend and Retract functions will not operate. * With a voltmeter, measure Y15. Proper resistance should be between 5 - 60 ohms. Replace Y15 if resistance is outside of those values. * 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 127 Service and Repair Manual Control System Fault Codes July 2020 ID Component ID Name Cause Effect Solution 100 Platform 11 Shorted Level Up Coil to supply voltage PCON detected Platform Level Up that V14PLU circuit and possibly Level is shorted to 12 V Down functions will or GND. not operate. * With a voltmeter, measure Y20. Proper resistance should be between 5 60 ohms. Replace Y20 if resistance is outside of those values. * Verify wiring for V14PLU (OR, PCON J12-6) and check for open or short circuits. 101 Platform Level Down Coil 11 Shorted to supply voltage PCON detected Platform Level that V15PLD circuit Down and possibly is shorted to 12 V Level Up functions or GND. will not operate. * With a voltmeter, measure Y19. Proper resistance should be between 5 60 ohms. Replace Y19 if resistance is outside of those values. * Verify wiring for V15PLD (OR/BK, PCON J12-7) and check for open or short circuits. 110 Platform Rotate Toggle Switch @PC 27 Active at startup Toggle switch input was detected as HIGH at start-up. Platform Rotate Left or Right will not operate, depending on which side of the switch was faulted. *Verify with a voltmeter that the Platform Rotate Toggle Switch (TS7) is operating properly. * C17PRL (GR, PCON J16-4) and 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 retest the fault. 116 Model 31 Setup Configuration invalid. Machine is not fully Machine will not configured or set to operate. wrong model. Navigate to Settings -> Model Configuration and ensure model, engine, tires, and region are set and correct. 141 Boom 10 Safety The system has Envelope determined that Exceeded the platform position has exceeded the safety envelope boundary. All functions will not operate except for the recovery procedure. Use Auxiliary Power and the boom retract and/or down functions to bring the platform back within the operational envelope. 150 Sensor Power P26PWR 11 Shorted to supply voltage PCON detected that P26PWR circuit is shorted to 12 V or GND. Boom Up and Extend functions will not operate. * Turn on machine and verify sensor power P26PWR (BK, PCON J13-9) is at 12 V. * Inspect wiring for open or shorts circuits. 152 Primary Boom Up/Down Flow Coil 11 Shorted to supply voltage TCON detected that C3PBF circuit is shorted to 12 V or GND. Boom Up and Down * With a voltmeter, measure Y12. functions will not Proper resistance should be operate. between 5 - 60 ohms. Replace Y12 if resistance 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. 128 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect 160 LF Steer (L or R) Coil 11 Shorted to supply voltage TCON detected Steer Left function that C37STL circuit will not operate. is shorted to 12 V or GND. 161 RF Steer (L or R) Coil 11 Shorted to supply voltage TCON detected that C36STR circuit is shorted to 12 V or GND. Steer Right function will not operate. 185 ESTOP Source 11 Shorted to supply voltage TCON detected that ESTOP 1 is at 12 V but ESTOP 3 is at 0 V. ESTOP circuit cannot complete, preventing machine functions. 186 ESTOP Return 11 Shorted to supply voltage Mismatched signals detected on ESTOP Return circuits. Either: * PCON ESTOP 2 and ESTOP 4 do not match, or * TCON ESTOP 2 and ESTOP 4 do not match. ESTOP circuit cannot complete, preventing machine functions. 187 TCON Bank power 13 Not Power plug not detected connected or loose. Internal TCON component failure. TCON outputs will not turn on. 188 PCON Bank 13 Not Power plug not power detected connected or loose. Internal TCON component failure. PCON outputs will not turn on. Solution * With a voltmeter, measure Y3. Proper resistance should be between 5 - 60 ohms. Replace Y3 if resistance is outside of those values. * Verify wiring for C37STL (BL/BK, TCON J4-11) and check for open or short circuits. * With a voltmeter, measure Y4. Proper resistance should be between 5 - 60 ohms. Replace Y4 if resistance is outside of those values. * Verify wiring for C36STR (BL, TCON J4-12) and check for open or short circuits. * Using a voltmeter and with the system turned OFF, check the resistance between TCON J5 pins 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. * Inspect PCON J15 pins 11 and 12 for open or short circuits. Using a voltmeter, set to diode test mode and make sure the diode tests ok with the anode at pin 12 and cathode at pin 11. If test fails, replace the PCON. * Inspect TCON J5 pins 11 and 12 for open or short circuits. Using a voltmeter, set to diode test mode and 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. * Check J1, Bank Power, on TCON is making a good connection. * Verify pin 1 is grounded * Verify pins 2, 3, 4 are 12V * Replace TCON * Check J11, Bank Power, on PCON is making a good connection. * Verify pin 1 is grounded * Verify pins 3, 4 are 12V * Replace PCON Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 129 Service and Repair Manual 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. July 2020 130 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 51 3 1019 EGR-Valve, short circuit to battery 51 3 1024 Position sensor error of actuator EGR-Valve; signal range check high 51 3 1226 EGR-Valve; short circuit to battery (A02) 51 3 1227 EGR-Valve; short circuit to battery (A67) 51 4 1020 EGR-Valve; short circuit to ground 51 4 1025 Position sensor error actuator EGR-Valve; signal range check low 51 4 1228 EGR-Valve; short circuit to ground (A02) 51 4 1229 EGR-Valve; short circuit to ground (A67) 1 4 1232 Actuator error EGR-Valve; Voltage below threshold 51 5 1015 Actuator error EGR-Valve; signal range check low 51 5 1017 Actuator EGR-Valve; open load 51 5 1023 Actuator error EGR-Valve; signal range check low 51 5 1223 Actuator EGR-Valve; open load 51 6 1014 Actuator error EGR-Valve; signal range check high 51 6 1022 Actuator error EGR-Valve; signal range check high 51 6 1224 Actuator EGR-Valve; over current 51 6 1230 Actuator error EGR-Valve; Overload by short-circuit 51 7 1016 Actuator position for EGR-Valve not plausible SPN FMI KWP 51 11 1231 51 12 1018 51 12 1021 51 12 1225 94 1 474 94 1 475 94 3 472 94 4 473 97 3 464 97 4 465 97 12 1157 100 0 734 100 0 735 100 1 736 100 1 737 100 3 732 100 4 733 102 2 88 102 2 89 102 4 777 Description Actuator error EGR-Valve; Power stage over temp due to high current Actuator EGR-Valve; powerstage over temperature Mechanical actuator defect EGR-Valve Actuator EGR-Valve; over temperature Low fuel pressure; warning threshold exceeded Low fuel pressure; shut off threshold exceeded Sensor error low fuel pressure; signal range check high Sensor error low fuel pressure; signal range check low Sensor error water in fuel; signal range check high Sensor error water in fuel; signal range check low Water in fuel level prefilter; maximum value exceeded High oil pressure; warning threshold exceeded High oil pressure; shut off threshold exceeded Low oil pressure; warning threshold exceeded Low oil pressure; shut off threshold exceeded Sensor error oil pressure; signal range check high Sensor error oil pressure sensor; signal range check low Charged air pressure above warning threshold Charged air pressure above shut off threshold Sensor error charged air press.; signal range check low Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 131 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 105 0 996 High charged air cooler temperature; warning threshold exceeded 105 0 997 High charged air cooler temperature; shut off threshold exceeded 105 3 994 Sensor error charged air temperature; signal range check high 105 4 995 Sensor error charged air temperature; signal range check low 108 3 412 Sensor error ambient air press.; signal range check high 108 4 413 Sensor error ambient air press.; signal range check low 110 0 98 High coolant temperature; warning threshold exceeded 110 0 99 High coolant temperature; shut off threshold exceeded 110 3 96 Sensor error coolant temp.; signal range check high 110 4 97 Sensor error coolant temp.; signal range check low 111 1 101 Coolant level too low 132 11 1 Air flow sensor load correction factor exceeding the maximum drift limit; plausibility error 132 11 2 Air flow sensor load correction factor exceeding drift limit; plausibility error 132 11 3 Air flow sensor low idle correction factor exceeding the maximum drift limit 132 11 4 Air flow sensor load correction factor exceeding the maximum drift limit 157 3 877 Sensor error rail pressure; signal range check high 157 4 878 Sensor error rail pressure; signal range check low SPN FMI KWP 168 0 1180 168 1 1181 168 2 47 168 2 48 168 3 45 168 4 46 171 3 417 171 4 418 172 0 172 1 172 2 172 2 172 3 172 4 174 0 174 0 175 0 175 0 175 0 175 1 1182 1183 9 983 981 982 481 482 740 745 746 741 Description Physical range check high for battery voltage Physical range check low for battery voltage High battery voltage; warning threshold exceeded Low battery voltage; warning threshold exceeded Sensor error battery voltage; signal range check high Sensor error battery voltage; signal range check low Sensor error environment temperature; signal range check high Sensor error environment temperature; signal range check low Physical range check high for intake air temperature Physical range check low for intake air temperature Sensor ambient air temperature; plausibility error Intake air sensor; plausibility error Sensor error intake air; signal range check high Sensor error intake air sensor; signal range check low High low fuel temperature; warning threshold exceeded High Low fuel temperature; shut off threshold exceeded Physical range check high for oil temperature High oil temperature; warning threshold exceeded High oil temperature; shut off threshold exceeded Physical range check low for oil temperature 132 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 175 2 738 Sensor oil temperature; plausibility error 175 2 739 Sensor oil temperature; plausibility error oil temperature too high 175 3 743 Sensor error oil temperature; signal range check high 175 4 744 Sensor error oil temperature; signal range check low 190 0 389 Engine speed above warning threshold (FOC-Level 1) 190 2 421 Offset angle between crank- and camshaft sensor is too large 190 8 419 Sensor camshaft speed; disturbed signal 190 8 422 Sensor crankshaft speed; disturbed signal 190 11 390 Engine speed above warning threshold (FOC-Level 2) 190 12 420 Sensor camshaft speed; no signal 190 12 423 Sensor crankshaft speed; no signal 190 14 391 Engine speed above warning threshold (Overrun Mode) 190 14 1222 Camshaft- and Crankshaft speed sensor signal not available on CAN 411 0 791 Physical range check high for differential pressure Venturiunit (EGR) 411 1 792 Physical range check low for differential pressure Venturiunit (EGR) 411 3 795 Sensor error differential pressure Venturiunit (EGR); signal range check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit (EGR); signal range check low SPN FMI KWP 412 3 1007 412 4 1008 520 9 306 597 2 49 624 3 971 624 4 972 624 5 969 624 12 970 630 12 376 630 12 377 630 12 378 639 14 84 651 3 580 651 4 586 651 5 568 652 3 581 652 4 587 652 5 569 653 3 582 653 4 588 653 5 570 Description Sensor error EGR cooler downstream temperature; signal range check high Sensor error EGR cooler downstream temperature; signal range check low Timeout Error of CAN-ReceiveFrame TSC1TR; Setpoint Break lever mainswitch and break lever redundancy switch status not plausible SVS lamp; short circuit to batt. SVS lamp; short circuit to grd. SVS lamp; open load SVS lamp; powerstage over temperature Access error EEPROM memory (delete) Access error EEPROM memory (read) Access error EEPROM memory (write) CAN-Bus 0 "BusOff-Status" Injector 1 (in firing order); short circuit High side to low side short circuit in the injector 1 (in firing order) Injector 1 (in firing order); interruption of electric connection Injector 2 (in firing order); short circuit High side to low side short circuit in the injector 2 (in firing order) Injector 2 (in firing order); interruption of electric connection Injector 3 (in firing order); short circuit High side to low side short circuit in the injector 3 (in firing order) Injector 3 (in firing order); interruption of electric connection Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 133 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI KWP = Keyword Protocol SPN FMI KWP Description 654 3 583 Injector 4 (in firing order); short circuit 654 4 589 High side to low side short circuit in the injector 4 (in firing order) 654 5 571 Injector 4 (in firing order); interruption of electric connection 676 11 543 Cold start aid relay error. 676 11 544 Cold start aid relay open load 677 3 956 Starter relay high side; short circuit to battery 677 3 960 Starter relay low side; short circuit to battery 677 4 957 Starter relay high side; short circuit to ground 677 4 961 Starter relay low side; short circuit to ground 677 5 958 Starter relay; no load error 677 12 959 Starter relay; powerstage over temperature 703 3 426 Engine running lamp; short circuit to battery 703 4 427 Engine running lamp; short circuit to ground 703 5 424 Engine running lamp; open load 703 12 425 Engine running lamp; powerstage over temperature 729 5 545 Cold start aid relay open load 729 12 547 Cold start aid relay; over temperature error 898 9 305 Timeout Error of CAN-ReceiveFrame TSC1TE; Setpoint 1079 13 946 Sensor supply voltage monitor 1 error (ECU) 1080 13 947 Sensor supply voltage monitor 2 error (ECU) SPN FMI 1109 2 1136 0 KWP 121 1398 1136 1 1399 1136 3 1400 1136 4 1401 1176 3 849 1176 4 850 1180 0 1193 1180 0 1460 1180 0 1462 1180 1 1194 1180 1 1461 1180 1 1463 1180 3 1067 1180 11 1066 1188 2 1414 Description Engine shut off demand ignored Physikal range check high for ECU temperature Physikal range check low for ECU temperature Sensor error ECU temperature; signal range check high Sensor error ECU temperature; signal range check low Sensor error pressure sensor upstream turbine; signal range check high Sensor error pressure sensor downstream turbine; signal range check high Physical range check high for exhaust gas temperature upstream turbine Turbocharger Wastegate CAN feedback; warning threshold exceeded Exhaust gas temperature upstream turbine; warning threshold exceeded Physical range check low for exhaust gas temperature upstream turbine Turbocharger Wastegate CAN feedback; shut off threshold exceeded Exhaust gas temperature upstream turbine; shut off threshold exceeded Sensor error exhaust gas temperature upstream turbine; signal range check high Sensor exhaust gas temperature upstream turbine; plausibility error Wastegate; status message from ECU missing 134 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 1188 7 1415 Wastegate actuator; blocked 1188 11 1411 Wastegate actuator; internal error 1188 11 1412 Wastegate actuator; EOL calibration not performed correctly 1188 11 1416 Wastegate actuator; over temperature (> 145øC) 1188 11 1417 Wastegate actuator; over temperature (> 135øC) 1188 11 1418 Wastegate actuator; operating voltage error 1188 13 1413 Wastegate actuator calibration deviation too large, recalibration required 1231 14 85 CAN-Bus 1 "BusOff-Status" 1235 14 86 CAN-Bus 2 "BusOff-Status" 1237 2 747 Override switch; plausibility error 1322 12 610 Too many recognized misfires in more than one cylinder 1323 12 604 Too many recognized misfires in cylinder 1 (in firing order) 1324 12 605 Too many recognized misfires in cylinder 2 (in firing order) 1325 12 606 Too many recognized misfires in cylinder 3 (in firing order) 1326 12 607 Too many recognized misfires in cylinder 4 (in firing order) 2659 0 1524 Physical range check high for EGR exhaust gas mass flow 2659 1 1525 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor; plausibility error SPN FMI KWP 2659 2 1527 2659 12 1526 2797 4 1337 2798 4 1338 2798 4 1339 2798 4 1340 3224 2 127 3224 9 128 3248 4 1047 3699 2 1616 3699 2 1617 3699 14 1615 4765 0 1039 4765 1 1042 Description AGS sensor temperature exhaust gas mass flow; plausibility error Exhaust gas recirculation; AGS sensor has "burn off" not performed Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 0 Injector diagnostics; timeout error of short circuit to ground measurement cyl. Bank 1 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 0 Injector diagnostics; short circuit to ground monitoring Test in Cyl. Bank 1 DLC Error of CAN-ReceiveFrame AT1IG1 NOX Sensor (SCR-system upstream cat; DPF-system downstream cat); length of frame incorrect Timeout Error of CAN-ReceiveFrame AT1IG1; NOX sensor upstream Sensor error particle filter downstream temperature; signal range check low DPF differential pressure sensor and a further sensor or actuator CRT system defective Temperature sensor us. and ds. DOC simultaneously defect Maximum stand-still-duration reached; oil exchange required Physical range check high for exhaust gas temperature upstream (DOC) Physical range check low for exhaust gas temperature upstream (DOC) Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 135 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 4766 0 1029 Physical range check high for exhaust gas temperature downstream (DOC) 4766 1 1032 Physical range check low for exhaust gas temperature downstream (DOC) 4768 2 1036 Sensor exhaust gas temperature upstream (DOC); plausibility error 4768 3 1044 Sensor error exhaust gas temperature upstream (DOC); signal range check high 4768 4 1045 Sensor error exhaust gas temperature upstream (DOC) signal range check low 4769 2 1026 Sensor exhaust gas temperature downstream (DOC); plausibility error 4769 3 1034 Sensor error exhaust gas temperature downstream (DOC); signal range check high 4769 4 1035 Sensor error exhaust gas temperature downstream (DOC); signal range check low 523006 3 34 Controller mode switch; short circuit to battery 523006 4 35 Controller mode switch; short circuit to ground 523008 1 648 Manipulation control was triggered 523008 2 649 Timeout error in Manipulation control 523009 9 825 Pressure Relief Valve (PRV) reached maximun allowed opening count 523009 10 833 Pressure relief valve (PRV) reached maximun allowed open time SPN 523212 523216 523240 523350 523352 523354 523470 523470 523470 523470 523470 523470 523470 523470 523550 523601 523603 FMI KWP Description 9 171 Timeout Error of CAN-ReceiveFrame ComEngPrt; Engine Protection 9 198 Timeout Error of CAN-ReceiveFrame PrHtEnCmd; pre-heat command, engine command 9 179 Timeout CAN-message FunModCtl; Function Mode Control 4 565 Injector cylinder-bank 1; short circuit 4 566 Injector cylinder-bank 2; short circuit 12 567 Injector powerstage output defect 2 826 Pressure Relief Valve (PRV) forced to open; performed by pressure increase 2 827 Pressure Relief Valve (PRV) forced to open; performed by pressure shock 7 876 Maximum rail pressure in limp home mode exceeded (PRV) 11 831 The PRV can not be opened at this operating point with a pressure shock 11 832 Rail pressure out of tolerance range 12 828 Open Pressure Relief Valve (PRV); shut off condition 12 829 Open Pressure Relief Valve (PRV); warning condition 14 830 Pressure Relief Valve (PRV) is open 12 980 T50 start switch active for too long 13 948 Sensor supply voltage monitor 3 error (ECU) 9 126 Timeout Error of CAN-ReceiveFrame AMB; Ambient Temperature Sensor 136 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 523605 9 300 Timeout Error of CAN-ReceiveFrame TSC1AE; Traction Control 523606 9 301 Timeout Error of CAN-ReceiveFrame TSC1AR; Retarder 523612 12 387 Internal software error ECU; injection cut off 523612 12 612 Internal ECU monitoring detection reported error 523612 12 613 Internal ECU monitoring detection reported error 523612 12 614 Internal ECU monitoring detection reported error 523612 12 615 Internal ECU monitoring detection reported error 523612 12 616 Internal ECU monitoring detection reported error 523612 12 617 Internal ECU monitoring detection reported error 523612 12 618 Internal ECU monitoring detection reported error 523612 12 619 Internal ECU monitoring detection reported error 523612 12 620 Internal ECU monitoring detection reported error 523612 12 621 Internal ECU monitoring detection reported error 523612 12 623 Internal ECU monitoring detection reported error 523612 12 624 Internal ECU monitoring detection reported error 523612 12 625 Internal ECU monitoring detection reported error 523612 12 627 Internal ECU monitoring detection reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail pressure exceeded (RailMeUn0) 523613 0 857 Maximum positive deviation of rail pressure in metering unit exceeded (RailMeUn1) 523613 0 858 Railsystem leakage detected (RailMeUn10) 523613 0 859 Maximum negative deviation of rail pressure in metering unit exceeded (RailMeUn2) 523613 0 860 Negative deviation of rail pressure second stage (RailMeUn22) 523613 0 862 Maximum rail pressure exceeded (RailMeUn4) 523613 1 861 Minimum rail pressure exceeded (RailMeUn3) 523613 2 864 Setpoint of metering unit in overrun mode not plausible 523615 3 594 Metering unit (Fuel-System); short circuit to battery highside 523615 3 596 Metering unit (Fuel-System); short circuit to battery low side 523615 4 595 Metering unit (Fuel-System); short circuit to ground high side 523615 4 597 Metering Unit (Fuel-System); short circuit to ground low side 523615 5 592 Metering unit (Fuel-System); open load 523615 12 593 Metering unit (Fuel-System); powerstage over temperature 523619 2 488 Physical range check high for exhaust gas temperature upstrem (SCR-CAT) 523698 11 122 Shut off request from supervisory monitoring function Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 137 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 523717 12 125 Timeout Error of CAN-TransmitFrame AmbCon; Weather environments 523718 3 1488 SCR mainrelay; short circuit to battery (only CV56B) 523718 4 1489 SCR mainrelay; short circuit to ground (only CV56B) 523718 5 1486 SCR mainrelay; open load (only CV56B) 523718 12 1487 SCR mainrelay; powerstage over temperature (only CV56B) 523766 9 281 Timeout Error of CAN-ReceiveFrame Active TSC1AE 523767 9 282 Timeout Error of CAN-ReceiveFrame Passive TSC1AE 523768 9 283 Timeout Error of CAN-ReceiveFrame Active TSC1AR 523769 9 284 Timeout Error of CAN-ReceiveFrame Passive TSC1AR 523770 9 285 Timeout Error of CAN-ReceiveFrame Passive TSC1DE 523776 9 291 Timeout Error of CAN-ReceiveFrame TSC1TE - active 523777 9 292 Passive Timeout Error of CANReceive-Frame TSC1TE; Setpoint 523778 9 293 Active Timeout Errorof CANReceive-Frame TSC1TR 523779 9 294 Passive Timeout Error of CANReceive-Frame TSC1TR SPN 523788 523793 523794 523895 523896 523897 523898 523910 523913 523913 523914 523914 523914 523914 523914 523914 523919 523920 FMI SPN Description 12 299 Timeout Error of CAN-TransmitFrame TrbCH; Status Wastegate 9 202 Timeout Error of CAN-ReceiveFrame UAA10; AGS sensor service message 9 203 Timeout Error of CAN-ReceiveFrame UAA11; AGS sensor data 13 559 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order) 13 560 check of missing injector adjustment value programming (IMA) injector 2 (in firing order) 13 561 check of missing injector adjustment value programming (IMA) injector 3 (in firing order) 13 562 check of missing injector adjustment value programming (IMA) injector 4 (in firing order) 6 1261 Air Pump; over current 3 74 Sensor error glow plug control diagnostic line voltage; signal range check high 4 75 Sensor error glow plug control diagnostic line voltage; signal range check low 3 78 Glow plug control; short circuit to battery 4 79 Glow plug control; short circuit to ground 5 76 Glow plug control; open load 5 1216 Glow plug control release line; short circuit error 11 1217 Glow plug control; internal error 12 77 Glow plug control; powerstage over temperature 2 1378 Sensor air pump airpressure; plausibility error 2 1379 Sensor exhaust gas back pressure burner; plausibility error 138 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 523922 7 1262 Burner Shut Off Valve; blocked closed 523922 7 1264 Burner Shut Off Valve; blocked closed 523929 0 109 Fuel Balance Control integrator injector 1 (in firing order); maximum value exceeded 523929 1 115 Fuel Balance Control integrator injector 1 (in firing order); minimum value exceeded 523930 0 110 Fuel Balance Control integrator injector 2 (in firing order); maximum value exceeded 523930 1 116 Fuel Balance Control integrator injector 2 (in firing order); minimum value exceeded 523931 0 111 Fuel Balance Control integrator injector 3 (in firing order); maximum value exceeded 523931 1 117 Fuel Balance Control integrator injector 3 (in firing order); minimum value exceeded 523932 0 112 Fuel Balance Control integrator injector 4 (in firing order); maximum value exceeded 523932 1 118 Fuel Balance Control integrator injector 4 (in firing order); minimum value exceeded 523935 12 168 Timeout Error of CAN-TransmitFrame EEC3VOL1; Engine send messages 523936 12 169 Timeout Error of CAN-TransmitFrame EEC3VOL2; Engine send messages 523946 0 1158 Zero fuel calibration injector 1 (in firing order); maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 (in firing order); minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 (in firing order); maximum value exceeded 523947 1 1165 Zerofuel calibration injector 2 (in firing order); minimum value exceeded 523948 0 1160 Zerofuel calibration injector 3 (in firing order); maximum value exceeded 523948 1 1166 Zerofuel calibration injector 3 (in firing order); minimum value exceeded 523949 0 1161 Zerofuel calibration injector 4 (in firing order); maximum value exceeded 523949 1 1167 Zerofuel calibration injector 4 (in firing order); minimum value exceeded 523960 0 1011 Physical range check high for EGR cooler downstream temp. 523960 0 1458 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded 523960 1 1012 Physical range check low for EGR cooler downstream temp. 523960 1 1459 High exhaust gas temperature EGR cooler downstream; shut off threshold exceeded 523980 14 1187 Bad quality of reduction agent detected 523981 11 918 Urea-tank without heating function (heating phase) 523982 0 360 Powerstage diagnosis disabled; high battery voltage 523982 1 361 Powerstage diagnosis disabled; low battery voltage Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 139 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 523988 3 1245 Charging lamp; short circuit to battery 523988 4 1246 Charging lamp; short circuit to ground 523988 5 1243 Charging lamp; open load 523988 12 1244 Charging lamp; over temp. 523998 4 1327 Injector cylinder bank 2 slave; short circuit 523999 12 1328 Injector powerstage output Slave defect 524014 1 1254 Air pressure glow plug flush line; below limit 524016 2 1259 Amount of air is not plausible to pump speed 524016 2 1260 Calculated amount of air is not plausible to HFM reading 524016 11 1258 HFM sensor; electrical fault 524021 11 1263 Burner fuel line pipe leak behind Shut Off Valve 524024 11 1302 Deviation of the exhaust gas temp. setpoint to actual value downstream (DOC) too high 524028 2 1431 CAN message PROEGRActr; plausibility error 524029 2 1432 Timeout Error of CAN-ReceiveFrame ComEGRActr - exhaust gas recirculation positioner 524030 7 1440 EGR actuator; internal error 524031 13 1441 EGR actuator; calibration error SPN 524032 524033 524034 524034 524034 524034 524035 524057 524097 524098 524099 524100 524101 FMI KWP Description 2 1442 EGR actuator; status message EGRCust is missing 7 1443 EGR actuator; due to overload in Save Mode 3 1438 Disc separator; short circuit to battery 4 1439 Disc separator; short circuit to ground 5 1436 Disc Separator; open load 12 1437 Disc Separator; powerstage over temperature 12 1341 Injector diagnostics; time out error in the SPI communication 2 1505 Electric fuel pump; fuel pressure build up error 9 1663 Timeout error of CAN-TransmitFrame DPFBrnAirPmpCtl 9 1664 Timeout error of CAN-TransmitFrame ComDPFBrnPT 9 1665 Timeout error of CAN-TransmitFrame ComDPFC1 9 1666 Timeout error of CAN-TransmitFrame ComDPFHisDat 9 1667 Timeout error of CAN-TransmitFrame ComDPFTstMon 140 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol SPN FMI KWP Description 524102 9 1674 Timeout error of CAN-ReceiveFrame ComRxDPFBrnAirPmpCtl 524103 9 1675 Timeout error of CAN-ReceiveFrame ComRxDPFBrnAirPmp 524104 9 1676 Timeout error of CAN-ReceiveFrame ComRxDPFCtl 524105 9 1668 Timeout error of CAN-TransmitFrame ComEGRMsFlw 524106 9 1677 Timeout error of CAN-ReceiveFrame ComRxEGRMsFlw1 524107 9 1678 Timeout error of CAN-ReceiveFrame ComRxEGRMsFlw2 524108 9 1669 Timeout error of CAN-TransmitFrame ComEGRTVActr 524109 9 1679 Timeout error of CAN-ReceiveFrame ComRxEGRTVActr 524110 9 1670 Timeout error of CAN-TransmitFrame ComETVActr 524111 9 1680 Timeout error of CAN-ReceiveFrame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN-ReceiveFrame ComRxITVActr SPN FMI 524114 9 524115 9 524116 9 524117 9 524118 9 524119 9 524120 9 524121 9 524122 9 524123 9 524124 9 524125 9 KWP Description 1659 Timeout error of CAN-TransmitFrame A1DOC 1660 Timeout error of CAN-TransmitFrame AT1S 1661 Timeout error of CAN-TransmitFrame SCR2 1662 Timeout error of CAN-TransmitFrame SCR3 1672 Timeout error of CAN-ReceiveFrame ComRxCM1 1673 Timeout error of CAN-ReceiveFrame ComRxCustSCR3 1682 Timeout error of CAN-ReceiveFrame ComRxSCRHtDiag 1683 Timeout error of CAN-ReceiveFrame ComRxTrbChActr 1684 Timeout error of CAN-ReceiveFrame ComRxUQSens 1685 Timeout error of CAN-ReceiveFrame ComSCRHtCtl 1686 Timeout error of CAN-ReceiveFrame ComTxAT1IMG 1687 Timeout error of CAN-ReceiveFrame ComTxTrbChActr Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 141 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes July 2020 DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 1000 98 2 Engine oil level sensor internal error. Sensor reports error. Open/short transducer. 1001 98 31 Engine oil level out of range. Level low, high, foaming. 1002 98 31 Oil sensor voltage out of range. <8,5V ±0,5V; >16,5V ±0,5V. 1003 98 2 Oil sensor invalid sensor status. 1004 98 31 Oil sensor temperature out of range. 1005 98 14 Oil sensor is broken or disconnected. 1021 100 3 Oil pressure voltage above normal or shorted to high. 1022 100 4 Oil pressure voltage below normal or shorted to low. 1025 100 1 Low oil pressure. Warning threshold exceeded. 1026 100 1 Low oil pressure. Shut off threshold exceeded. 1043 107 0 Air filter differential pressure. Air filter clogged. 1071 411 2 Engine exhaust gas recirculation. Pressure does not change between engine operating points. 1072 411 0 Engine exhaust gas recirculation. Pressure above normal operational range. 1073 411 1 Engine exhaust gas recirculation. Pressure below normal operational range. 1074 411 2 Engine exhaust gas recirculation. Negative measured differential pressure. 1075 411 2 Engine exhaust gas recirculation. Positive measured differential pressure. DTC SPN FMI Description 1077 411 3 Engine exhaust gas recirculation. Signal value above maximum limit. 1078 411 4 Engine exhaust gas recirculation. Signal value below maximum limit. 1079 108 0 Ambient air pressure sensor above normal operational range. 1080 108 1 Ambient air pressure sensor below normal operational range. 1081 108 15 Fault check max signal range violated for ambient air pressure sensor. 1082 108 17 Fault check min signal range violated for ambient air pressure sensor. 1083 108 2 Ambient air pressure sensor error by component self diagnosis. 1084 3720 0 DPF ash load above normal operational range. 1086 3734 0 DPF soot load exceeded. Remove filter level. 1087 4781 14 DPF soot load exceeded shut off level. 1088 4781 0 DPF soot load exceeded warning level. 1089 4781 16 DPF. Too much standstill time in short time interval. 1090 10156 0 DPF. The standstill-regeneration mode time exceeds the short-limit. 1091 3735 16 DPF. Standstill required and no successful standstill longer than escalation threshold. Moderately severe. 1092 3735 0 DPF. Standstill required and no successful standstill longer than escalation threshold. Most severe. 1093 4766 1 DOC. Regeneration temperature in standstill main phase not reached. 1102 171 2 Ambient air temperature shows a deviation from expected value at cold start conditions. 142 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 111 102 0 Engine intake manifold pressure above normal operational range. 1114 102 1 Engine intake manifold pressure below normal operational range. 1115 102 3 Intake manifold pressure sensor voltage above normal or shorted to high. 1116 102 4 Intake manifold pressure sensor voltage below normal or shorted to low. 1118 102 1 Intake manifold pressure below normal operational range. 1121 102 2 DFC for signal variation check for pressure sensor of the intake manifold. 1122 102 0 Intake air pressure valve sensor, warning condition exceeded. 1123 102 1 Intake air pressure valve sensor, shutoff condition exceeded. 1124 1209 2 Engine exhaust pressure turbine upstream differs from ambient pressure while engine not running. 1125 1209 15 Engine exhaust pressure turbine upstream above upper limit. 1126 1176 1 Engine turbocharger compressor intake pressure below normal operational range. 1127 1209 2 Engine exhaust pressure turbine upstream tuck check failed. Pressure does not change between engine operating points. 1130 1209 3 Engine exhaust pressure sensor voltage above normal or shorted to high. 1131 1209 4 Engine exhaust pressure sensor voltage below normal or shorted to low. DTC SPN FMI 1134 3251 3 1135 3251 4 1136 3251 14 1137 3251 14 1138 3251 14 1139 3251 14 1149 3251 2 1150 3251 0 1151 3251 16 1152 3251 1 1153 3251 18 1161 5571 16 1162 5571 2 1163 5571 2 1164 5571 16 1165 5571 15 1166 5571 0 1167 5571 2 1168 5571 2 1169 5571 13 Description DPF voltage above normal or shorted to high. DPF voltage below normal or shorted to low. DPF reporting communication error. DPF reporting data error. DPF reporting fast channel 1 error. DPF reporting fast channel 2 signal range error. DPF difference pressure value not plausible. DPF difference pressure above shut off threshold. DPF difference pressure above warning threshold. DPF difference pressure below shut off threshold. DPF difference pressure below warning threshold. Rail fuel pressure relief valve above normal operational range. Rail fuel pressure relief valve is forced to open, perform pressure increase. Rail fuel pressure relief valve is forced to open. Performed by pressure increase. Rail fuel pressure relief valve is forced to open. Shutoff conditions. Rail fuel pressure relief valve is forced to open. Warning conditions. Open rail fuel pressure relief valve was detected. Unexpected opening of the rail fuel pressure relief valve. Successful rail fuel pressure relief valve opening cannot be ensured. Averaged rail fuel pressure after valve opening is outside the expected tolerance range. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 143 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes July 2020 DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 1170 5571 16 Open time of rail fuel pressure relief valve for wear out monitoring had exceeded. 1171 94 1 Fuel pressure build up during engine start not successful. 1172 1347 5 Electrical fuel pump current below normal or open circuit. 1174 1347 3 Electrical fuel pump voltage above normal or shorted to high. 1175 1347 4 Electrical fuel pump voltage below normal or shorted to low. 119 1231 14 CAN Bus 2 off Error for Application CAN. 1190 7103 13 Rail fuel pressure below set point, speed-dependent threshold exceeded. 1191 7103 13 Rail fuel pressure metering unit. Fuel quantity balance is disrupted. 1194 7103 13 Negative rail fuel pressure governor deviation at zero delivery by metering unit. 1195 7103 1 Rail fuel pressure value is below minimum rail pressure threshold. 1197 7103 0 Maximum rail fuel pressure exceeded. 1198 7103 2 Set point of fuel metering unit in overrun mode not plausible. 120 639 14 CAN Bus 1 off Error for Power train CAN. 1200 5357 14 Shut-off due to undershoot of minimum rail pressure. 1202 157 0 Maximum rail pressure exceeded in limp home mode. 1208 157 3 Engine fuel injector metering rail pressure voltage above normal or shorted to high. DTC SPN FMI 1209 157 4 121 520252 2 1212 629 12 1213 629 12 1215 629 12 1216 629 12 1218 629 12 1219 629 12 122 4207 2 123 4207 2 1233 5826 15 1235 5826 0 1236 5826 14 124 4207 2 125 4207 2 1274 91 3 1275 2623 3 1276 29 3 Description Engine fuel injector metering rail pressure voltage below normal or shorted to low. Wrong checksum in the CAN message EAT Control. ECU. Keep alive error during runtime at an external device. ECU. Keep alive error during initialization phase at an external device. ECU. Read diagnosis error for non volatile memory. ECU. Write diagnosis error for non volatile memory. ECU. Stack memory threshold overrun. ECU. Observation counter irregular switch off counter triggered by engine running. TSC1 message checksum fault. TSC1 message checksum fault. Emission control system operator inducement level 1 severity above normal operational range. Emission control system operator inducement level 2 severity above normal operational range. Emission control system operator pre-trigger inducement level 2 severity. TSC1 message checksum fault. TSC1 message checksum fault. Accelerator pedal sensor position 1 voltage above normal or shorted to high. Accelerator pedal 1, channel 2 voltage above normal or shorted to high. Accelerator pedal 2 voltage above normal or shorted to high. 144 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 1277 2625 3 Accelerator pedal 2, channel 2 voltage above normal or shorted to high. 1280 91 4 Accelerator pedal sensor position 1 voltage below normal or shorted to low. 1281 2623 4 Accelerator pedal 1, channel 2 voltage below normal or shorted to low. 1282 29 4 Accelerator pedal 2 voltage below normal or shorted to low. 1283 2625 4 Accelerator pedal 2, channel 2 voltage below normal or shorted to low. 1289 3509 14 Failure of sensor supply voltage 1 from ECU. 1290 3509 0 Sensor supply voltage 1 from ECU above normal operational range. 1291 3509 6 Sensor supply voltage 1 from ECU current above normal or grounded circuit. 1292 3509 1 Sensor supply voltage 1 from ECU below normal operational range. 1293 3510 14 Failure of sensor supply voltage 2 from ECU. 1294 3510 0 Sensor supply voltage 2 from ECU above normal operational range. 1295 3510 6 Sensor supply voltage 2 from ECU current above normal or grounded circuit. 1296 3510 1 Sensor supply voltage 2 from ECU below normal operational range. 1306 677 3 Engine starter motor relay voltage above normal or shorted to high. 1307 677 4 Engine starter motor relay voltage below normal or shorted to low. DTC SPN FMI 1308 677 5 1310 677 3 1311 677 4 1323 91 11 1326 29 11 1346 1041 14 1354 105 0 1355 105 0 1357 1136 0 1358 1136 1 1359 1136 15 1360 1136 17 1361 1136 2 1362 412 15 Description Engine starter motor relay current below normal or shorted to low. Engine starter motor relay voltage above normal or shorted to high. Engine starter motor relay voltage below normal or shorted to low. Accelerator pedal position 1. Possible error between APP1 and APP2 or APP1 and idle switch. Accelerator Pedal 2 Position. Possible error between APP1 and idle switch. Start signal indicator. Terminal 50 was operated too long. Engine intake manifold 1 temperature data above normal operational range. Warning threshold exceeded. Engine intake manifold 1 temperature above normal operational range. Shutoff threshold exceeded. Engine ECU temperature above normal operational range. Most severe. Engine ECU temperature below normal operational range. Most severe. Engine ECU temperature above normal operational range. Least severe. Engine ECU temperature below normal operational range. Least severe. Engine ECU temperature fault check. Engine exhaust gas recirculation temperature above normal operational range. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 145 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes July 2020 DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 1363 412 17 Engine exhaust gas recirculation temperature below normal operational range. 1364 412 3 Engine exhaust gas recirculation temperature voltage above normal or shorted to high. 1365 412 4 Engine exhaust gas recirculation temperature voltage below normal or shorted to low. 1372 51 5 Engine throttle valve 1, position 1 current below normal or open circuit. 1375 51 3 Engine throttle valve 1, position 1 voltage above normal or shorted to high. Short circuit to battery 1. 1376 51 3 Engine throttle valve 1, position 1 voltage above normal or shorted to high. Short circuit to battery 2. 1377 51 4 Engine throttle valve 1, position 1 voltage below normal or shorted to low. Short circuit to ground 1. 1378 51 4 Engine throttle valve 1, position 1 voltage below normal or shorted to low. Short circuit to ground 2. 1379 51 6 Engine throttle valve 1, position 1 current above normal or grounded circuit. 1382 51 7 Engine throttle valve 1 position 1 mechanical system not responding or out of adjustment. Valve stuck closed. 1383 51 7 Engine throttle valve 1 position 1 mechanical system not responding or out of adjustment. Valve stuck open. 1391 51 3 Engine throttle valve 1, position 1 voltage above normal or shorted to high. DTC SPN FMI 1392 51 4 1397 105 0 1398 105 1 1399 4766 2 1400 4766 2 1401 4766 15 1402 4766 3 1403 4766 4 1404 4766 2 1405 4766 15 1406 4766 3 1407 4766 4 1408 4766 2 142 520256 9 144 523211 9 154 523212 9 1540 520254 8 1541 520255 2 155 523741 14 Description Engine throttle valve 1, position 1 voltage below normal or shorted to low. Engine intake manifold 1 temperature above normal operational range. Engine intake manifold 1 temperature below normal operational range. DOC temperature too high. DOC temperature too low. DOC outlet temperature above normal operational range. DOC outlet temperature voltage above normal or shorted to high. DOC outlet temperature voltage below normal or shorted to low. DOC intake temperature error. DOC Intake temperature above normal operational range. DOC intake temperature voltage above normal or shorted to high. DOC intake temperature voltage below normal or shorted to low. DOC intake temperature does not change. Timeout of EAT control receive message. CAN message is not received. Timeout error of CAN receive frame EBC1. Timeout error of CAN receive frame engine protection. The stand still regeneration mode time exceeds the long limit threshold. Hoses connected to the dp DPF SENT sensor inverted. Swap hoses. Engine shutdown request via CAN. 146 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 1587 97 0 Water in fuel level prefilter; maximum value exceeded. 188 523240 9 Timeout CAN message function mode control. 219 520253 2 Rolling counter fault CAN message EAT Control. 220 4206 2 Fault check for Rolling Counter of TSC1AE. 221 4206 2 Fault check for Rolling Counter of TSC1AR. 222 4206 2 Fault check for Rolling Counter of TSC1TE. 223 4206 2 Fault check for Rolling Counter of TSC1TR. 349 3349 0 Timeout error of CAN receive frame active TSC1AE. 350 3349 0 Timeout error of CAN receive frame passive TSC1AE. 351 3349 0 Timeout error of CAN receive frame active TSC1AR. 352 3349 0 Timeout error of CAN receive frame passive TSC1AR. 353 3349 0 Timeout error of CAN receive frame TSC1TE active. 354 3349 0 TSC1 receive timeout error. Short circuit to ground error. 355 3349 0 Timeout error of CAN receive frame TSC1TR. 356 3349 0 Passive timeout error of CAN receive frame TSC1TR. 361 3349 0 Timeout error of CAN receive frame TSC1AE. Traction Control. 363 3349 0 Timeout error of CAN receive frame TSC1AR. Retarder. 365 3349 0 Timeout error of CAN receive frame TSC1TE. Setpoint. DTC SPN FMI 367 3349 0 38 1485 3 39 1485 3 40 1485 3 41 1485 4 42 1485 4 43 1485 4 48 168 0 49 168 1 50 168 3 51 168 4 516 523982 0 517 523982 1 52 168 0 567 27 5 570 27 3 571 27 3 Description Timeout Error of CAN receive frame TSC1TR; control signal. ECM main relay voltage above normal or shorted to high. ECM main relay voltage above normal or shorted to high of actuator relay 2. ECM main relay voltage above normal or shorted to high of actuator relay 3. ECM main relay voltage below normal or shorted to low. ECM main relay voltage below normal or shorted to low of actuator relay 2. ECM main relay voltage below normal or shorted to low of actuator relay 3. Battery voltage above normal operational range. Battery voltage low normal operational range. Battery voltage above normal or shorted to high. Battery voltage above normal or shorted to low. Power stage diagnosis disabled. High battery voltage. Power stage diagnosis disabled. Low battery voltage. High battery voltage. Warning threshold is exceeded. Engine exhaust gas recirculation 1 valve position current below normal or open circuit. Engine exhaust gas recirculation 1 valve position voltage above normal or shorted to battery 1. Engine exhaust gas recirculation 1 valve position voltage above normal or shorted to battery 2. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 147 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes July 2020 DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 572 27 4 Engine exhaust gas recirculation 1 valve position voltage below normal or shorted to ground 1. 573 27 4 Engine exhaust gas recirculation 1 valve position voltage below normal or shorted to ground 2. 574 27 6 Engine exhaust gas recirculation 1 valve position current above normal or grounded circuit. 577 27 7 Engine exhaust gas recirculation 1 valve position. Mechanical system not responding or out of adjustment. Valve stuck closed. 578 27 7 Engine exhaust gas recirculation 1 valve position. Mechanical system not responding or out of adjustment. Valve stuck open. 582 5763 3 Engine exhaust gas recirculation 1, actuator 1 voltage above normal or shorted to high. 583 5763 4 Engine exhaust gas recirculation 1, actuator 1 voltage below normal or shorted to low. 586 3055 14 Internal software error ECU. Injection cut off. 587 190 0 Engine speed above warning threshold. Over speed detection in component engine protection. 588 190 0 Engine speed above warning threshold. FOC-Level 1. 589 190 0 Engine speed above warning threshold. FOC-Level 2. 590 190 0 Engine speed above warning threshold. Overrun Mode. 610 171 15 Environment temperature sensor, temperature above upper physical threshold. DTC SPN FMI 613 171 3 614 171 4 615 723 8 616 723 14 617 723 13 618 4201 8 619 4201 14 68 1669 14 70 110 2 709 97 3 710 97 4 721 94 15 723 94 3 724 94 4 725 94 1 726 94 1 75 110 3 76 110 4 Description Ambient air temperature sensor voltage above normal or shorted to high. Ambient air temperature sensor voltage below normal or shorted to low. Camshaft speed sensor abnormal frequency or pulse width or period. Camshaft sensor detection. Out of range, signal disrupted, no signal. Offset angle between crank and camshaft sensor is too large. Crankshaft sensor detection. Out of range, signal disrupted, no signal. Crankshaft speed sensor. Speed detection, out of range, signal disrupted or no signal. CAN Bus ID-5. CAN Hardware registers are not updated within the expected time. Engine Coolant Temperature. Data erratic, intermittent or incorrect. Water in fuel indicator 1. Voltage above normal or shorted to high. Water in fuel indicator 1. Voltage below normal or shorted to low. Low fuel pressure system, max. physical range exceeded. Engine fuel pressure sensor voltage above normal or shorted to high. Engine fuel pressure sensor voltage below normal or shorted to low. Low fuel pressure system, warning threshold exceeded. Low fuel pressure, shut off threshold exceeded. Engine coolant temperature voltage above normal or shorted to high. Engine coolant temperature voltage below normal or shorted to low. 148 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 77 110 0 High coolant temperature. Warning threshold exceeded. 78 110 0 Coolant temperature. System reaction initiated. 797 676 12 Engine cold start aid relay error. 798 676 5 Engine cold start aid relay current below normal or open circuit. 799 676 5 Engine cold start aid relay current below normal or open circuit. 80 411 2 Intake air massflow not in expected range. 803 676 3 Engine cold start aid relay voltage above normal or shorted to high. 805 676 4 Engine cold start aid relay voltage below normal or shorted to low. 807 2797 14 Engine fuel 1 injector, Group 1. Number of possible injections limited by the injection valve. 815 2797 4 Engine fuel 1 injector, Group 1 voltage below normal or shorted to low. 816 5358 5 Engine cylinder 1 fuel injection quantity current below normal or open circuit. 817 5359 5 Engine cylinder 2 fuel injection quantity current below normal or open circuit. 818 5360 5 Engine cylinder 3 fuel injection quantity current below normal or open circuit. 819 5361 5 Engine cylinder 4 fuel injection quantity current below normal or open circuit. 820 5362 5 Engine cylinder 5 fuel injection quantity current below normal or open circuit. DTC SPN FMI 821 5363 5 822 2797 6 823 2798 6 824 5358 6 825 5359 6 826 5360 6 827 5361 6 828 5362 6 829 5363 6 83 111 1 830 5358 6 Description Engine cylinder 6 fuel injection quantity current below normal or open circuit. Engine fuel 1 injector, Group 1 current above normal or grounded circuit. Engine fuel 1 injector, Group 2 current above normal or grounded circuit. Engine cylinder 1 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Engine cylinder 2 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Engine cylinder 3 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Engine cylinder 4 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Engine cylinder 5 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Engine cylinder 6 fuel injection quantity above normal or grounded circuit. Short circuit of the power stage low-side. Coolant level too low. Engine cylinder 1 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 149 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes July 2020 DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 831 5359 6 Engine cylinder 2 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. 832 5360 6 Engine cylinder 3 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. 833 5361 6 Engine cylinder 4 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. 834 5362 6 Engine cylinder 5 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. 835 5363 6 Engine cylinder 6 fuel injection quantity above normal or grounded circuit. Short circuit between highside and low-side of the power stage. 836 105 3 Engine intake manifold temperature voltage above normal or shorted to high. 837 105 4 Engine intake manifold temperature voltage below normal or shorted to low. 838 2797 14 Engine fuel 1 injector, group 1 missing injector adjustment value programming injector 1. 839 2798 14 Engine fuel 1 injector, group 2 missing injector adjustment value programming injector 2. DTC SPN FMI 840 4257 14 854 7103 5 855 7103 3 856 7103 3 857 7103 4 858 7103 4 859 7103 6 868 629 12 869 629 12 870 629 12 871 91 14 875 190 2 876 5357 2 Description Engine fuel 1 injector, group 3 missing injector adjustment value programming injector 3. Engine fuel metering rail pump current below normal or open circuit. Engine fuel metering rail pump voltage above normal or shorted to high. Short circuit to battery on the high side power stage. Engine fuel metering rail pump voltage above normal or shorted to high. Short circuit to battery on the low side power stage. Engine fuel metering rail pump voltage below normal or shorted to low. Short circuit to battery on the high side power stage. Engine fuel metering rail pump voltage below normal or shorted to low. Short circuit to battery on the low side power stage. Engine fuel metering rail pump current above normal or grounded circuit. Function monitoring: fault of ECU ADC. Null load test pulse. Function monitoring: fault of ECU ADC. Test voltage. ECU. DFC to indicate ICO request from MoCSOP module. Function monitoring: Monitoring of accelerator pedal position. Function monitoring: Fault of engine speed check. Engine fuel injection error for multiple cylinders. Diagnostic fault check error between level 1 energizing time and level 2 information. 150 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code FMI = Failure Mode Identifier SPN = Suspect Parameter Number DTC SPN FMI Description 877 5441 2 Engine fuel injection timing error for multiple cylinders. 878 5357 2 Engine fuel injection error for multiple cylinders. Diagnostic fault check to report the error due to non plausibility in ZFC. 879 523612 12 Internal recovery. Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off. 88 598 10 Clutch switch. Abnormal rate of change. 880 523612 12 Internal recovery. Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor. 881 523612 12 Internal recovery. Diagnosis fault check to report the error to demand for an ICO due to an error in change of EOM. 882 5357 2 Engine fuel injection error for multiple cylinders. Diagnosis fault check to report the error to demand for an ICO due to an error in total torque relevant quantity. 883 5357 2 Engine fuel injection error for multiple cylinders. Diagnostic fault check to report the error due to injection quantity correction. 884 5442 2 Engine fuel injection pressure error for multiple cylinders. 885 29 2 Accelerator pedal 2 position. 886 677 2 Engine starter motor relay. Function monitoring: Fault of ECU power train active. DTC SPN FMI Description 887 513 2 Actual engine percent torque. DFC to report the fault in energizing time comparison. 888 513 2 Actual engine percent torque. DFC to report in torque comparison error. 889 520250 2 Function monitoring: Error in the post-build selectable monitoring. 890 629 12 ECU. Status of the EMM alarm FCCU0 which is read out of the FCCU hardware module. 91 1109 2 Engine protection system approaching shutdown. Engine shut off demand ignored. 92 1109 14 Engine protection system approaching shutdown. Shut off request from supervisory monitoring function. 996 629 12 ECU. Diagnostic fault check to report ABE active state. 997 629 12 Function monitoring: Fault of ECU, WDA active by inquiry/response communication. 998 629 12 Function monitoring: Fault of ECU, Error Pin active suspision of HW fault. 999 629 12 Function monitoring: Fault of ECU, WDA active by overvoltage detection. The following DTC fault code range shares the same description. Replace the ECU. DTC 891 - 945 Description SPN 629 Internal ECU error. FMI 12 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 151 Service and Repair Manual Perkins 404-22 Engine Fault Codes July 2020 SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN FMI Description 29 3 Accelerator Pedal Position 2: Voltage Above Normal 29 4 Accelerator Pedal Position 2: Voltage Below Normal 91 3 Accelerator Pedal Position 1: Voltage Above Normal 91 4 Accelerator Pedal Position 1: Voltage Below Normal 100 1 Engine Oil Pressure :Low- most severe (3) 108 3 Barometric Pressure : Voltage Above Normal 108 4 Barometric Pressure : Voltage Below Normal 110 3 Engine Coolant Temperature : Voltage Above Normal 110 4 Engine Coolant Temperature : Voltage Below Normal 110 15 Engine Coolant Temperature : High -least severe (1) 168 0 Battery Potential/ Power Input 1 : High- most severe (3) 168 3 Battery Potential/ Power Input 1: Voltage Above Normal 168 4 Battery Potential/ Power Input 1: Voltage Below Normal 172 3 Engine Air Inlet Temperature: Voltage Above Normal 172 4 Engine Air Inlet Temperature: Voltage Below Normal 190 0 Engine Speed : High- most severe (3) 190 8 Engine Speed : Abnormal Frequency, Pulse Width or Period 558 3 Accelerator Pedal1 Low Idle Switch: Voltage Above Normal 558 4 Accelerator Pedal1 Low Idle Switch: Voltage Below Normal 638 6 Engine Fuel Rack Actuator: Current Above Normal 639 14 J1939 Network#1: Special Instruction SPN FMI Description 723 3 Engine Speed Sensor #2: Voltage Above Normal 723 4 Engine Speed Sensor #2: Voltage Below Normal 723 8 Engine Speed Sensor#2: Abnormal Frequency, Pulse Width or Period" 723 10 Engine Speed Sensor #2: Abnormal Rate of Change 733 3 Engine Rack Position Sensor: Voltage Above Normal 733 4 Engine Rack Position Sensor: Voltage Below Normal 1485 7 ECU Main Relay : Not Responding Property 2840 11 ECU Instance: Other Failure Mode 2840 12 ECU Instance: Failure 2840 13 ECU Instance: Out of Calibration 2970 3 Accelerator Pedal 2 Low Idle Switch: Voltage Above Normal 2970 4 Accelerator Pedal 2 Low Idle Switch: Voltage Below Normal 3241 1 Exhaust Gas Temperature 1: Lowmost severe (3) 3241 3 Exhaust Gas Temperature 1: Voltage Above Normal 241 4 Exhaust Gas Temperature 1: Voltage Below Normal 3241 15 Exhaust Gas Temperature 1: Highleast severe (1) 3241 16 Exhaust Gas Temperature 1: Highmoderate severity (2) 3242 1 Particulate Trap Intake Gas Temp: Low- most severe(3)" 3242 3 Particulate Trap Intake Gas Temp: Voltage Above Normal" 3242 4 Particulate Trap Intake Gas Temp: Voltage Below Normal" 3242 15 Particulate Trap Intake Gas Temp: High - least severe(1)" 3242 16 Particulate Trap Intake Gas Temp: High-moderate severity (2) 152 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Perkins 404-22 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier SPN FMI Description 3251 3 Particulate Trap Differential Pressure: Voltage Above Normal 3251 4 Particulate Trap Differential Pressure: Voltage Below Normal 3473 7 Aftertreatmert #1 Failed to Ignite: Not Responding Properly 3473 11 Aftertreatmert #1 Failed to Ignite : Other Failure Mode 3484 0 Aftertreatmert #1 Ignition : High-most severe (3) 3484 3 Aftertreatmert #1 Ignition : Voltage Above Normal 3484 4 Aftertreatmert #1 Ignition : Voltage Below Normal 3556 6 Aftertreatmert 1 Hydrocarbon Doser 1: Current Above Normal 3610 3 Diesel Particulate Filter Outlet Pressure or 1: Voltage Above Normal" 3610 4 DieselParticulate Filter Outlet Pressure Sensor 1: Voltage Below Normal 3713 7 DPF Active Regeneration Inhibited Due to System Timeout: Not Responding Properly 3713 31 DPF Active Regeneration Inhibited Due to System Timeout 3719 0 Particulate Trap #1 Soot Load Percent: High- most severe (3) 3719 16 Particulate Trap #1 Soot Load Percent: High-moderate severity (2) 4016 6 High Current Auxiliary Power Relay 1: Current Above Normal 4201 3 Engine Speed Sensor #1: Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor #1: Voltage Below Normal 4201 8 Engine Speed Sensor #1: Abnormal Frequency, Pulse \Nidth, or Period 4201 10 Engine Speed Sensor #1: Abnormal Rate of Change 4765 1 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Low-most severe (3) 4765 3 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Above Normal 4765 4 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: Voltage Below Normal 4765 15 Aftertreatmert #1Diesel Oxidation Catalyst Intake Gas Temperature: High-least severe (1) 4765 16 Aftertreatmert #1 Diesel Oxidation Catalyst Intake Gas Temperature: High-moderate severity (2) 5487 3 Aftertreatmert 1 Burner Unit Combustion Chamber Temperature: Voltage Above Normal 5487 4 Aftertreatmert 1 Burner Unit Combustion Chamber Temperature: Voltage Below Normal 6581 6 Aftertreatmert 1 Hydrocarbon Doser 2 : Current Above Normal Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 153 Service and Repair Manual GM 3.0L Engine Fault Codes July 2020 Description DTC Set 2 SPN-2/FMI-2 Description DTC 11: Intake cam / distributor position error 520800 / 7 DTC 221: TPS1-2 higher than expected DTC 16: Crank and/or cam no sync during start 636 / 8 DTC 222: TPS2 voltage low DTC 24: Exhaust cam position error 520801 / 7 DTC 223: TPS2 voltage high DTC 87 Fuel pressure lower than expected 94 / 1 DTC 234: Boost control overboost failure DTC 88 Fuel pressure higher than expected 94 / 0 DTC 236: TIP active DTC 91: FP low voltage 94 / 4 DTC 237: TIP low voltage DTC 92: FP high voltage 94 / 3 DTC 238: TIP high voltage DTC 107: MAP voltage low 106 / 4 DTC 261: Injector 1 open or short to ground DTC 108: MAP pressure high 106 / 16 DTC 262: Injector 1 coil shorted DTC 111: IAT higher than expected stage 1 105 / 15 DTC 264: Injector 2 open or short to ground DTC 112: IAT voltage low 105 / 4 DTC 265: Injector 2 coil shorted DTC 113: IAT voltage high 105 / 3 DTC 267: Injector 3 open or short to ground DTC 116: ECT higher than expected stage 1 110 / 15 DTC 268: Injector 3 coil shorted DTC 117: ECT voltage low 110 / 4 DTC 270: Injector 4 open or short to ground DTC 118: ECT voltage high 110 / 3 DTC 271: Injector 4 coil shorted DTC 121: TPS1-2 lower than expected 51 / 1 DTC 273: Injector 5 open or short to ground DTC 122: TPS1 voltage low 51 / 4 DTC 274: Injector 5 coil shorted DTC 123: TPS1 voltage high 51 / 3 DTC 276: Injector 6 open or short to ground DTC 127: IAT higher than expected stage 2 105 / 0 DTC 277: Injector 6 coil shorted DTC 129: BP pressure low 108 / 1 DTC 279: Injector 7 open or short to ground DTC 134: EGO1 open / lazy 724 / 10 DTC 280: Injector 7 coil shorted DTC 140: EGO3 open / lazy 520209 / 10 DTC 282: Injector 8 open or short to ground DTC 154: EGO2 open / lazy 520208 / 10 DTC 283: Injector 8 coil shorted DTC 160: EGO4 open / lazy 520210 / 10 DTC 285: Injector 9 open or short to ground DTC 171: Adaptive-learn gasoline bank1 high 520200 / 0 DTC 308: Cylinder 8 emissions/catalyst damaging misfire DTC 172: Adaptive-learn gasoline bank1 low 520200 / 1 DTC 326: Knock1 excessive or erratic signal DTC 174: Adaptive-learn gasoline bank2 high 520201 / 0 DTC 327: Knock1 sensor open or not present DTC 175: Adaptive-learn gasoline bank2 low 520201 / 1 DTC 331: Knock2 excessive or erratic signal DTC 182: FT low voltage 174 / 4 DTC 332: Knock2 sensor open or not present DTC 183: FT high voltage 174 / 3 DTC 336: CRANK input signal noise DTC 187: Gaseous fuel temp sender low voltage 520240 / 4 DTC 337: Crank signal loss DTC 188: Gaseous fuel temp sendr high voltage 520240 / 3 DTC 341: CAM input signal noise DTC 217: ECT higher than expected stage 2 110 / 0 DTC 342: Loss of CAM input signal DTC 219: RPM higher than max allowed govern speed 515 / 15 DTC 359: Fuel run-out longer than expected DTC Set 2 SPN-2/FMI-2 653/6 520251 / 4 520251 / 3 1692 / 0 1692 / 2 1127 / 4 1127 / 3 651 / 5 651 / 6 652 / 5 652 / 6 653 / 5 653/6 654 / 5 654 / 6 655 / 5 655 / 6 656 / 5 656 / 6 657 / 5 657 / 6 658 / 5 658 / 6 659 / 5 1330 / 31 731 / 2 731 / 4 520241 / 2 520241 / 4 636 / 2 636 / 4 723 / 2 723 / 4 1239 / 7 154 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual GM 3.0L Engine Fault Codes Description DTC Set 2 SPN-2 / FMI2 Description DTC Set 2 SPN-2 / FMI2 DTC 420: Catalyst inactive on gasoline (Bank 1) 520211 / 10 DTC 1111: RPM above fuel rev limit level 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank 2) 520212 / 10 DTC 1112: RPM above spark rev limit level 515 / 0 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 1 100 / 18 DTC 1132: WGP voltage low 1192 / 4 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 to ground 1347 / 5 DTC 1166: Catalyst inactive on NG 520214 / 0 DTC 628: Fuel pump relay control ground short 1348 / 4 DTC 1171: MegaJector delivery pressure higher than expected 520260 / 0 DTC 629: Fuel-pump high-side short to power 1347 / 6 DTC 1172: MegaJector delivery pressure lower than expected 520260 / 1 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 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 155 Service and Repair Manual GM 3.0L Engine Fault Codes July 2020 Description DTC Set 2 SPN-2 / FMI-2 Description DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage DTC 1316: Cylinder 6 misfire detected 1328 / 11 DTC 1544: AUX analog Pull-Up/Down 2 low voltage DTC 1317: Cylinder 7 misfire detected 1329 / 11 DTC 1545: AUX analog Pull-Up/Down 3 high voltage DTC 1318: Cylinder 8 misfire detected 1330 / 11 DTC 1546: AUX analog Pull-Up/Down 3 low voltage DTC 1411: EMWT1 voltage high 441 / 3 DTC 1547: AUX analog Pull-Up/Down 4 high voltage DTC 1412: EMWT2 voltage high 442 / 3 DTC 1548: AUX analog Pull-Up/Down 4 low voltage DTC 1413: EMWT1 voltage low 441 / 4 DTC 1551: AUX digital 1 high voltage DTC 1414: EMWT2 voltage low 442 / 4 DTC 1552: AUX digital 1 low voltage DTC 1415: EMWT1 higher than expected stage 1 441 / 15 DTC 1553: AUX digital 2 high voltage DTC 1416: EMWT2 higher than expected stage 1 442 / 15 DTC 1554: AUX digital 2 low voltage DTC 1417: EMWT1 higher than expected stage 2 441 / 0 DTC 1555: AUX digital 3 high voltage DTC 1418: EMWT2 higher than expected stage 2 442 / 0 DTC 1555: Water Intrusion Detection DTC 1419: ERWT1 voltage high 443 / 3 DTC 1556: AUX digital 3 low voltage DTC 1420: ERWT2 voltage high 444 / 3 DTC 1561: AUX analog Pull-Down 2 high voltage DTC 1421: ERWT1 voltage low 443 / 4 DTC 1561: AUX analog Pull-Down 3 high voltage DTC 1422: ERWT2 voltage low 444 / 4 DTC 1561: AUX analog Pull-Down 2 low voltage DTC 1423: ERWT1 higher than expected stage 1 443 / 15 DTC 1611: Sensor supply voltage 1 and 2 out-of-range DTC 1424: ERWT2 higher than expected stage 1 444 / 15 DTC 1612: Microprocessor failure - RTI 1 DTC 1425: ERWT1 higher than expected stage 2 443 / 0 DTC 1613: Microprocessor failure - RTI 2 DTC 1426: ERWT2 higher than expected stage 2 444 / 0 DTC 1614: Microprocessor failure - RTI 3 DTC 1511: AUX analog Pull-Up 1 high voltage 520216 / 3 DTC 1615: Microprocessor failure - A/D DTC 1511: AUX analog Pull-Up 1 high voltage 520216 / 3 DTC 1616: Microprocessor failure - Interrupt DTC 1512: AUX analog Pull-Up 1 low voltage 520216 / 4 DTC 1621: RS-485 Rx inactive DTC 1513: AUX analog Pull-Up 2 high voltage 520217 / 3 DTC 1622: RS-485 Rx noise DTC 1514: AUX analog Pull-Up 2 low voltage 520217 / 4 DTC 1623: RS-485 Rx bad packet format DTC 1515: AUX analog Pull-Down 1 high voltage 520215 / 3 DTC 1624: RS-485 remote shutdown request DTC 1516: AUX analog Pull-Down 1 low voltagee 520215 / 4 DTC 1625: J1939 shutdown request DTC Set 2 SPN-2 / FMI- 2 520220 / 3 520220 / 4 520221 / 3 520221 / 4 713 / 3 713 / 4 520222 / 3 520222 / 4 520223 / 3 520223 / 4 520224 / 3 520224 / 3 520224 / 4 0 / 3 0 / 4 0 / 4 1079 / 31 629 / 31 629 / 31 629 / 31 629 / 31 629 / 31 0 / 31 0 / 31 0 / 31 0 / 31 1384 / 31 156 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual GM 3.0L Engine Fault Codes Description DTC Set 2 SPN-2 / FMI2 Description DTC Set 2 SPN-2 / FMI-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 1 110 / 16 DTC 1628: J1939 CAN address / engine-number conflict 639 /13 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 voltage 520219 / 3 DTC 1632: PWM1-Gauge1 short to power 697 / 6 DTC 1542: AUX analog Pull-Up/Down 1 low voltage 520219 / 4 DTC 1633: PWM2-Gauge2 open / ground short 698 / 5 DTC 1634: PWM2-Gauge2 short to power 698 / 6 DTC 2126: FPP1-2 higher than expected 91 / 16 DTC 1635: PWM3-Gauge3 open / ground short 699 / 6 DTC 2127: FPP2 voltage low 29 / 4 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 while in-gear 91 / 9 DTC 2304: Spark coil 2 primary shorted 1269 / 6 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 FPP2 disagrees with IVS 520250 / 31 DTC 2324: Spark coil 9 primary open or short to ground 1276 / 5 DTC 2121: FPP1-2 lower than expected 91 / 18 DTC 2325: Spark coil 9 primary shorted 1276 / 6 DTC 2122: FPP1 voltage high 91 / 3 DTC 2327: Spark coil 10 primary open or short to ground 1277 / 5 Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 157 Service and Repair Manual GM 3.0L Engine Fault Codes July 2020 Description DTC Set 2 SPN-2 / FMI2 Description DTC 2123: FPP1 voltage low 91 / 4 DTC 2328: Spark coil 10 primary shorted DTC 2125: FPP2 invalid voltage and FPP1 disagrees with IVS 520250 / 31 DTC 2428: EGT temperature high DTC 2618: Tach output ground short 645 / 4 DTC 8909: UEGO pump voltage shorted low DTC 2619: Tach output short to power 645 / 3 DTC 8910: UEGO sense cell voltage high DTC 8901: UEGO microprocessor internal fault 3221 / 1 DTC 8911: UEGO sense cell voltage low DTC 8902: UEGO heater supply high voltage 3222 / 3 DTC 8912: UEGO pump voltage at high drive limi DTC 8903: UEGO heater supply low voltage 3222 / 4 DTC 8913: UEGO pump voltage at low drive limit DTC 8904: UEGO cal resistor voltage high 3221 / 3 DTC 8914: UEGO sense cell slow to warm up DTC 8905: UEGO cal resistor voltage low 3221 / 4 DTC 8915: UEGO pump cell slow to warm up DTC 8906: UEGO return voltage shorted high 3056 / 3 DTC 8916: UEGO sense cell impedance high DTC 8907: UEGO return voltage shorted low 3056 / 4 DTC 8917: UEGO pump cell impedance high DTC 8908: UEGO pump voltage shorted high 3218 / 3 DTC 8918: UEGO pump cell impedance low DTC Set 2 SPN-2 / FMI-2 1277 / 6 173 / 0 3218 / 3 3218 / 3 3218 / 4 3217 / 3 3217 / 3 3225 / 4 3222 / 4 3225 / 10 3225 / 0 3225 / 1 158 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Sectio n 5 Schematic s Observe and Obey: Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine. Repair any machine damage or malfunction before operating the machine. Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Service and Repair Manual Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Hydraulic Schematics 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. Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 159 Service and Repair Manual Electrical Symbol Legend July 2020 Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter LED Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no terminal T-circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button - normally open Emergency Stop button - normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch Coolant temperature normally open switch - normally open Oil pressure switch normally closed Control relay contact normally open Diode starting aid, glow plug or flame ignitor 160 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, fixed displacement Pump, bi-directional variable displacement Motor, bi-directional Motor, 2 speed bidirectional Cylinder, double acting Pump, prime mover (engine or motor) Shuttle valve. 2 position, 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve (mechanically activated) Flow divider/combiner valve Pilot operated 3 position, 3 way shuttle valve Solenoid operated 2 position, 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid operated 3 position 4 way directional valve Solenoid operated 3 position, 4 way proportional directional valve Solenoid valve, 2 position 2 way Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 161 Service and Repair Manual Limit Switch Location Legend July 2020 1 S17 2 S22 3 LSB2S 4 LSB1RS S17 S22 LSB2S LSB1RS LST3S S8O S8S LST1O S24 5 LST3S 6 S8O, S8S 7 LST1O 8 S24 Limit Switches and Sensors Boom angle sensor Boom length sensor Limit switch cable tension- safety Limit switch boom fully retracted- safety Limit switch boom angle- safety Universal tilt sensor - operational Universal tilt sensor - safety Limit switch turntable - operational Load cell - platform overload 162 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Engine Relay Layout - Deutz TD2.9 Deutz TD 2.9 L4 Fuses CB8A CB8B F19 F21 CB9 CB10 CB1 CB2 30A 30A 15A 10A 30A 20A 30A 15A See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits See Elec Schem for circuits Diode D22 Relays CR1 CR5 CR6 CR15A CR15B CR17 CR27 CR41 6A Alternator Ext. Ignition on Horn Fuel pump Glow plugs Glow plugs Hydraulic oil cooler Auxiliary R21IGN Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 163 Service and Repair Manual Engine Relay Layout - Deutz TD2011L04i July 2020 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 Relays CR1 CR3 CR15A CR15B CR17 CR23 CR41 6A Alternator Ext. Engine start High RPM. Glow plug 1 Glow plug 2 Hydraulic Oil Cooler Drive R21IGN 164 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Engine Relay Layout - Perkins 404D-22T Perkins 404D-22T Circuit Breakers CB1 CB2 CB9 CB10 CB8A CB8B Fuses 30A See Elec Schem for circuits 15A See Elec Schem for circuits 30A See Elec Schem for circuits 20A See Elec Schem for circuits 30A See Elec Schem for circuits 30A See Elec Schem for circuits F19 F21 Diode 5A See Elec Schem for circuits 5A See Elec Schem for circuits D22 Relays 6A Alternator Ext. CR1 Start CR3 High RPM CR4 Low RPM CR5 CR17 CR15A CR15B Horn Hydraulic oil cooler (option) Glow plugs Glow Plugs Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 165 Service and Repair Manual Engine Relay Layout - GM 3.0L July 2020 GM 3.0L Fuses CB8A CB8B F19 F21 CB9 CB10 CB1 CB2 30A See Elec Schem for circuits 30A See Elec Schem for circuits 5A See Elec Schem for circuits 5A See Elec Schem for circuits 30A See Elec Schem for circuits 20A See Elec Schem for circuits 30A See Elec Schem for circuits 15A See Elec Schem for circuits Diode D22 Relays CR1 CR3 CR5 CR17 CR23 CR41 6A Alternator Ext. Engine start High RPM. Horn Hydraulic OIl Cooler Drive R21IGN 166 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Number Description C1 Boom cable - Controls C2 Boom cable - Power C3 Boom sensors C4 Function manifold C5 Function manifold C6 Engine C7 Engine C8 Engine - Power C9 Foot switch C10 Platform options C11 Platform manifold C12 Boom cable (platform) - Controls C13 Drive lights 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 C43 VEC - blue - 8 pin Service and Repair Manual Connector Pin Legend C44 VEC - green - 8 pin C45 VEC- gray - 2 pin C46 VEC - black - 2 pin C47 Function enable C48 Brake C49 Motor stroke C50 Drive pump C51 Engine ECG C52 Engine ECG C53 Platform recirculation valve C56 Telematics C57 ACP C72 ECU Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 167 Service and Repair Manual 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 July 2020 168 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518) 169 Service and Repair Manual Electrical Schematic, Turntable Controller (to serial number S80XCH-513, S85XCH- 518) July 2020 170 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518) Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 171 Service and Repair Manual Electrical Schematic, Platform Controller (to serial number S80XCH-513, S85XCH- 518) July 2020 172 July 2020 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) 173 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) July 2020 174 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 175 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCH-514 to S80XCH-1393, S85XCH-519 to S85XCH-1399) July 2020 176 July 2020 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) 177 Service and Repair Manual Electrical Schematic, Turntable Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) July 2020 178 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 179 Service and Repair Manual Electrical Schematic, Platform Controller (from S80XCD-101, S85XCD-101, S80XCH-1394, S85XCH-1400) July 2020 180 July 2020 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine 181 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine July 2020 182 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 183 Service and Repair Manual Electrical Schematic, Deutz TCD 2.2 L3 Engine July 2020 184 July 2020 Service and Repair Manual Electrical Schematic, Deutz TD 2.9 L4 Engine 185 Service and Repair Manual Electrical Schematic, Deutz TD 2.9 L4 Engine July 2020 186 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Deutz TD2011 L04i Engine Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 187 Service and Repair Manual Electrical Schematic, Deutz TD2011 L04i Engine July 2020 188 July 2020 Service and Repair Manual Electrical Schematic, Perkins 404D-22T Engine 189 Service and Repair Manual Electrical Schematic, Perkins 404D-22T Engine July 2020 190 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, Perkins 404F-E22TA Engine Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 191 Service and Repair Manual Electrical Schematic, Perkins 404F-E22TA Engine July 2020 192 July 2020 Service and Repair Manual Electrical Schematic, GM 3.0L Engine 193 Service and Repair Manual Electrical Schematic, GM 3.0L Engine July 2020 194 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Electrical Schematic, 12 kW Welder Generator and 3 kW Generator Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 195 Service and Repair Manual Electrical Schematic, 12 Kw Welder Generator and 3 kW Generator July 2020 196 July 2020 Service and Repair Manual Hydraulic Schematic, S-80 XC Models 197 Service and Repair Manual Hydraulic Schematic, S-80 XC Models July 2020 198 S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF Part No. 1280490GT July 2020 Service and Repair Manual Hydraulic Schematic, S-85 XC Models Part No. 1280490GT S®-80 XCTM · S®-85 XCTM · S®-80 HF · S®-85 HF 199 Service and Repair Manual July 2020 Hydraulic Schematic, S-85 XC Models S®-80 XCTM · S ®-8 5 XCTM · S® -80 HF · S®-8 5 HF Part No. 128 049 0GT Service a nd Re pair Ma nual July 20 20 200Microsoft Word 2016