This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Service and Repair Manual
Serial Number Range
S®-60 J
from S60JH-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. 1285305GT

Rev A
Decenber 2019
Service and Repair Manual Decenber 2019
Introduction
Introduction Introduction
Important Information
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills communications will be carefully considered for
are required to perform most procedures. future printings of this and all other manuals.
However, several procedures require specialized
skills, tools, lifting equipment and a suitable
workshop. In these instances, we strongly
recommend that maintenance and repair be Contact Us:
performed at an authorized Genie dealer service Internet: www.genielift.com
center. E-mail: awp.techpub@terex.com
Compliance Find a Manual for this Model

Go to http://www.genielift.com
Machine Classification
Use the links to locate Service Manuals,
Group B/Type 3 as defined by ISO 16368 Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2019 by Terex Corporation
1285305GT Rev A, Decenber 2019
First Edition, First Printing
Genie and "S" are registered trademarks of Terex South

Dakota, Inc. in the U.S.A. and many other countries.
ii S®-60 J Part No. 1285305GT

Decenber 2019 Service and Repair Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2019 Initial Release
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Part No. 1285305GT S®-60 J iii

Introduction
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)
iv S®-60 J Part No. 1285305GT

Safety Rules
General Safety Rules
Section 1 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 modify or alter a MEWP without prior
written permission from the manufacturer.
Do Not Perform Maintenance

Unless:
 You are trained and qualified to perform
maintenance on this machine.
 You read, understand and obey:
• manufacturer's instructions and safety
rules
• employer's safety rules and worksite
regulations
• applicable governmental regulations
 You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 1285305GT S®-60 J v

Safety Rules
Personal Safety Workplace Safety

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

hazards such as moving parts, free
swinging or unsecured components
when lifting or placing loads. Always
wear approved steel-toed shoes.
vi S®-60 J Part No. 1285305GT

Decenber 2019
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 1

Machine Specifications........................................................................................... 1
Performance Specifications.................................................................................... 1
Hydraulic Oil Specifications .................................................................................... 2
Hydraulic Component Specifications ..................................................................... 5
Deutz D2011 L03i Engine Specifications ............................................................... 6
Kubota D1105-E4B Engine Specifications ............................................................. 8
Kubota D1803-CR-TIE4 Engine Specifications...................................................... 9
Machine Torque Specifications ............................................................................ 10
Machine Component Weights .............................................................................. 10
Hydraulic Hose and Fitting Torque Specifications ............................................... 11
Torque Procedure ................................................................................................ 12
Part No. 1285305GT S®-60 J vii

Decenber 2019
Table of Contents
Section 3 Repair Procedures ............................................................................................. 14

Introduction .......................................................................................................... 14
Control System................................................................................................... 16
1-1 ALC-600 Platform Control Module ................................................................. 16
1-2 ALC-600 Service Mode.................................................................................. 16
1-3 Full Machine Calibration ................................................................................ 17
1-4 Machine Functions ......................................................................................... 18
How to Adjust the Machine Maximum Speed Setting..................................... 18
How to Adjust the Joystick Ramp Rate Setting .............................................. 19
How to Adjust the Joystick Threshold Setting ................................................ 20
1-5 How to Enter ALC600 Software Update Mode .............................................. 20
1-6 Display Module Menus .................................................................................. 21
1-7 How to Replace the Display Controller (DISCON) Module ........................... 25
1-8 How to Replace the Ground Control Overlay ................................................ 26
Platform Components ....................................................................................... 28

2-1 Platform Leveling Slave Cylinder ................................................................... 28
2-2 Platform Rotator ............................................................................................. 29
2-3 Platform Overload System ............................................................................. 31
How to Perform a Zero Load Platform Calibration.......................................... 31
How to Perform a Full Load Platform Calibration ........................................... 32
How to Replace the Platform Overload Load Cell .......................................... 34
2-4 Platform.......................................................................................................... 35
Jib Boom Components...................................................................................... 36

3-1 Jib Boom ........................................................................................................ 36
3-2 Jib Boom Lift Cylinder .................................................................................... 37
viii S®-60 J Part No. 1285305GT

Decenber 2019
Table of Contents
Boom Components ............................................................................................ 38

Boom Legend .................................................................................................. 38
Boom Components ............................................................................................ 39

4-1 Cable Track .................................................................................................... 39
How to Remove the Cable Track .................................................................... 39
How to Repair the Cable Track ....................................................................... 41
4-2 Primary Boom ................................................................................................ 42
4-3 Boom Lift Cylinder .......................................................................................... 43
4-4 Primary Boom Extension Cylinder ................................................................. 44
4-5 Platform Leveling Master Cylinder ................................................................. 45
4-6 Primary Boom Angle Sensor .......................................................................... 46
How to Repalce the Primary Boom Angle Sensor .......................................... 47
Engines................................................................................................................ 48
5-1 RPM Adjustment - Kubota D1105 and Deutz D2011 Models ........................ 48
5-2 Flex Plate ....................................................................................................... 48
How to Install the Flex Plate............................................................................ 49
How to install the Pump and Bell Housing Assembly ..................................... 50
5-3 Engine Fault Codes - Kubota D1803 Models................................................. 51
Hydraulic Pump .................................................................................................. 52

6-1 Function Pump ............................................................................................... 52
6-2 Drive Pump..................................................................................................... 52
How to Install the Drive Pump Coupler ........................................................... 53
6-3 How to Prime the Drive and Function Pumps ................................................ 53
6-4 Generator Pump ............................................................................................. 54
Part No. 1285305GT S®-60 J ix

Decenber 2019
Table of Contents
Manifolds ............................................................................................................ 56
7-1 Function Manifold Components ..................................................................... 56
7-2 Valve Adjustments - Function Manifold ......................................................... 60
How to Adjust the Boom Extend Relief Valve................................................. 60
7-3 Jib Boom / Platform Rotate Manifold Components........................................ 61
7-4 Turntable Rotation Manifold Components ..................................................... 62
7-5 Valve Adjustments - Oscillate Relief Valve.................................................... 63
How to Set Up the Oscillate Directional Valve................................................ 63
7-6 Traction Manifold Components, 4WD ............................................................ 66
7-7 Valve Adjustments, 4WD Traction Manifold .................................................. 68
7-8 Brake/Two-Speed Manifold Components ...................................................... 69
7-9 Generator Manifold Components .................................................................. 70
7-10 Turntable Rotation Manifold Components ................................................... 71
7-11 Valve Coils ................................................................................................... 72
Turntable Rotation Components ...................................................................... 73

8-1 Turntable Rotation Assembly......................................................................... 73
How to Adjust the Turntable Rotation Gear Backlash .................................... 74
8-2 Turntable Angle Sensor Replacement ........................................................... 75
How to Calibrate the Turntable Tilt Sensor..................................................... 76
Axle Components............................................................................................... 78
9-1 Oscillating Axle Cylinders .............................................................................. 78
x S®-60 J Part No. 1285305GT

Decenber 2019
Table of Contents
Section 4 Fault Codes ......................................................................................................... 79

Introduction ........................................................................................................... 79
Control System Fault Codes ............................................................................. 80

How to Retrieve Control System Fault Codes ................................................ 80
Control System Fault Codes ........................................................................... 81
Engine Fault Codes ............................................................................................ 98
Kubota D1803-CR-TIE4 Engine Fault Codes ................................................... 99
Part No. 1285305GT S®-60 J xi

Decenber 2019
Table of Contents
Section 5 Schematics ....................................................................................................... 102

Introduction ........................................................................................................ 102
Important Information ......................................................................................... 102
Electrical Symbol Legend .................................................................................. 103
Hydraulic Symbols Legend ................................................................................ 104
Limit Switch Location Legend ............................................................................ 105
Electrical Schematics – Options .................................................................... 107

Electrical Schematic, Generator Options ........................................................... 108
Electrical Schematic, Positive Air Shutdown ..................................................... 109
Electrical Schematics ...................................................................................... 111

Electrical Schematic, Turntable Controller ......................................................... 112
Electrical Schematic, Platform Controller .......................................................... 113
Electrical Schematic, Kubota D1803.................................................................. 116
Electrical Schematic, Kubota D1105.................................................................. 117
Electrical Schematic, Deutz D2011.................................................................... 120
Hydraulic Schematics...................................................................................... 121

Hydraulic Schematic .......................................................................................... 121
xii S®-60 J Part No. 1285305GT

Specifications
Performance Specifications
Performance Specifications
Section 2 Specifications
Machine Specifications
Machine Specifications
Tires and Wheels Boom function speeds, maximum from platform

controls
Tire size (Rough terrain) 315/55D20
Jib boom up 25 to 35 seconds
Tire weight (foam filled) 290 lbs
132 kg Jib boom down 15 to 25 seconds
Tire ply rating 12 Primary boom up 60 to 66 seconds
Overall tire diameter 32.5 in Primary boom down 60 to 66 seconds
82,5 cm Primary boom extend 30 to 33 seconds
Wheel diameter 20 in x 11 in Primary boom retract 30 to 33 seconds
50,8 cm x 28 cm
Turntable rotate, 360° 67 to 84 seconds
Wheel lugs 9 @ 5/8 -18 Boom stowed
Lug nut torque, dry 240 ft-lbs Turntable rotate, 360° 107 to 118 seconds
325 Nm Boom extended
Lug nut torque, lubricated 180 ft-lbs Platform rotate, 160° 18 to 22 seconds
244 Nm
Braking distance, maximum
Fuel capacities
High range on paved surface 3 to 6 ft
Fuel tank 30 gallons 0.9 to 1.8 m
114 liters
Drive speed, maximum stowed position
Hydraulic tank 21 gallons
80 liters 40 ft / 9.1 sec
12.2 m / 9.1 sec
Hydraulic system (including tank) 25 gallons
95 liters Drive speed, maximum raised or extended position
Drive hubs 24.5 fl oz 40 ft / 40 sec
724 cc Gradeability 12.2 m / 40 sec
Turntable rotation drive hub 8 fl oz See Operator's Manual
237 cc For operational specifications, refer to the
Drive hub oil type: SAE 90 multipurpose hypoid gear oil Operator's Manual.
API service classification GL5
For operational specifications, refer to the
Operator's Manual.
Part No. 1285305GT S®-60 J 1

Specifications
Hydraulic Oil Specifications

Hydraulic Oil Specifications
Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties. component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic Fluid Temperature
Hydraulic oil type Chevron Rando HD Premium
Range
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 Ambient air temperature
equipment and special installation instructions for
the approved optional fluids. Consult Genie 1 Chevron hydraulic oil 5606A
Product Support before use. 2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
Optional fluids may not have 4 Chevron Rando HD premium oil MV
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®-60 J Part No. 1285305GT

Specifications
Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310
Pour point -81°F / -63°C
Flash point 375°F / 190°C
Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
temperature Note: Use of Chevron 5606A hydraulic fluid, or
equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage
Part No. 1285305GT S®-60 J 3

Specifications
Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Fluid Properties Properties
ISO Grade 46 ISO Grade 46
Viscosity index 154 Viscosity index 192
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 8.0 cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Flash point 482°F / 250°C
Flash point None
temperature Maximum continuous operating 189°F / 87°C
temperature
Shell Tellus S4 VX Fluid

Properties
ISO Grade 32
Viscosity index 300
Kinematic Viscosity
cSt @ 200°F / 100°C 9
cSt @ 104°F / 40°C 33.8
Brookfield Viscosity
cSt @ -4°F / -20°C 481
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624
Flash point >100
temperature
4 S®-60 J Part No. 1285305GT

Specifications
Hydraulic Component
Hydraulic Component Specifications
Drive manifold
Specifications Hot oil relief valve pressure 280 psi

19,3 bar
Drive Pump Drive motor
Type: bi-directional variable displacement piston pump Displacement per revolution, 1.53 cu in
Flow rate @ 2500 rpm 21.1 gpm high speed 25 cc
80 L/min Displacement per revolution, .54 cu in
Drive pressure, maximum 3625 psi low speed 8.77 cc
250 bar Hydraulic Filters
Charge Pump High pressure filter: Beta 5
Type: gerotor High pressure filter bypass 102 psi
Displacement 0.85 cu in pressure 7 bar
13,9 cc Medium pressure filter Beta 6
Flow rate @ 2500 rpm 9.2 gpm Medium pressure filter bypass 51 psi
34,8 L/min pressure 3,5 bar
Charge pressure @ 2500 rpm 310 psi Hydraulic tank return filter 10 micron with 25 psi /
21,4 bar 1,7 bar bypass
Function Pump
Type: fixed displacement gear pump
Manifold Component
Displacement 1.52 cu in
25 cc Specifications
Flow rate @ 2500 rpm 16.5 gpm Plug torque
62,5 L/min
SAE No. 2 36 in-lbs / 4 Nm
Auxiliary Pump
SAE No. 4 10 ft-lbs / 13 Nm
Type: fixed displacement gear pump
SAE No. 6 14 ft-lbs / 19 Nm
Displacement 1.75 gpm
2,8 L/min SAE No. 8 38 ft-lbs / 51 Nm
Function manifold SAE No.10 41 ft-lbs / 55 Nm
System relief valve pressure, 3200 psi SAE No. 12 56 ft-lbs / 76 Nm

maximum 220 bar
Steer flow regulator 2 gpm
7,6 L/min
Oscillate relief valve pressure 650 psi
@ 2500 rpm 45 bar
Part No. 1285305GT S®-60 J 5

Specifications
Deutz D2011 L03i Engine

Deutz D2011 L03i Engine Specifications
Displacement 142 cu in
2.33 liters
Number of cylinders 3
Bore and Stroke 3.7 x 4.4 inches
94 x 112 mm
Horsepower 48 @ 2800 rpm
36 kW @ 2800 rpm
Firing order 1-2-3
Low idle 1500 rpm
313 Hz
High idle 2500 rpm
521.7 Hz
Compression ratio 19:01
Compression pressure 362 to 435 psi
25 to 30 bar
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in
0.3 mm
Exhaust 0.020 in
0.5 mm
Lubrication system
Oil pressure 40 to 60 psi
1.4 to 3 bar
Oil capacity 9.5 quarts
(including filter) 9 liters
Oil viscosity requirements
-22° F to 86° F/ -30° C to 30° C 5W-30 (synthetic)
-4° F to 90° F / -20° C to 32° C 10W-40
Above 23° F / -5° C 20W-50
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
Temperature switch point 220°F
104°C
Oil Pressure switch
Oil pressure switch point 22 psi
1.5 bar
6 S®-60 J Part No. 1285305GT

Specifications
Fuel injection system

Injection pump make Bosch
Injection pump pressure, 15000 psi
maximum 1034 bar
Injector opening pressure 3046 psi
210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator
Starter motor
Current draw, normal load 140A to 200A
Brush length, new 0.72 in
18.5 mm
Brush length, minimum 0.27 in
7 mm
Battery
Type 12V DC, Group 34/78
Quantity 1
Cold cranking ampere 1000A
Reserve capacity @ 25A rate 200 minutes
Alternator output 60A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
Part No. 1285305GT S®-60 J 7

Specifications
Kubota D1105-E4B Engine

Kubota D1105-E4B Engine Specifications

Injection pump make Bosch MD
1,123 liters Injection pump pressure, 1991 psi
maximum 137 bar
Number of cylinders 3
Injection timing 18° BTDC
78 x 78,4 mm Fuel requirement
Horsepower, gross 24.8 @ 3000 rpm
intermittent 18.5 kW @ 3000 rpm
Firing order 1-2-3 Starter motor
Cranking speed 200 - 300 RPM
Low idle 1500 rpm
250 Hz Current draw, normal load 155A
High idle 2700 rpm Battery
450 Hz Type 12V DC
Compression ratio 24:1 Group 31
Compression pressure 412 to 469 psi Quantity 1
28,4 to 32,3 bar
Ampere hour 120AH
Cold cranking ampere 1000A
Valve clearance, cold 0.0057 to 0.0072 in
0,145 to 0,185 mm Reserve capacity @ 25A rate 175 minutes
Lubrication system Alternator output 40A @ 12V DC
Oil pressure 28 to 64 psi Fan belt deflection 1/4 to 3/8 inch

1,9 to 4,4 bar 7 to 9 mm
Oil capacity (including filter) 5.4 quarts

5,1 liters
-4° F to 90° F / -20° C to 32° C 10W-40
Above 23° F / -5° C 20W-50
Engine coolant
Capacity 3.2 quarts
3 liters
8 S®-60 J Part No. 1285305GT

Specifications
Kubota D1803-CR-TIE4 Engine

Kubota D1803-CR-TIE4 Engine Specifications

Injection pump make Bosch MD
1,825 liters Injection pump pressure, maximum
Number of cylinders 3 Low idle 3700 - 4300 psi

255 - 296 bar
87 x 102,4 mm High idle 14500 - 15900 psi
1000 - 1096 bar
Horsepower, gross 49.6 @ 2700 rpm
Injection timing 18° BTDC
intermittent 37 kW @ 2700 rpm
Firing order 1-2-3 Fuel requirement
Low idle, standby 1200 rpm
200 Hz
Starter motor
Low idle, function enable 1500 rpm
250 Hz Cranking speed 200 - 300 RPM
High idle 2700 rpm Current draw, normal load 155A
450 Hz Battery
Compression ratio 16:0 Type 12V DC
Compression pressure 428 to 468 psi Group 31
29,5 to 32,3 bar
Quantity 1
Ampere hour 120AH
Valve clearance, cold 0.0071 to 0.0086 in
0,18 to 0,22 mm Cold cranking ampere 1000A
Reserve capacity @ 25A rate 175 minutes
Lubrication system
Oil pressure 35 to 64 psi Alternator output 40A @ 12V DC
2,4 to 4,4 bar Fan belt deflection 1/4 to 3/8 inch
Oil capacity (including filter) 8.6 quarts 7 to 9 mm
8,1 liters
-4° F to 90° F / -20° C to 32° C 10W-40
Above 23° F / -5° C 20W-50
Engine coolant
Capacity 10 quarts
9,5 liters
Part No. 1285305GT S®-60 J 9

Specifications
Machine Torque Specifications Machine Component Weights

Machine Torque Specifications Machine Component Weights
Note: All torque values are shown lubricated Lift structure 5300 lbs
unless otherwise noted. 2404 kg
Turntable assembly without lift structure, 6700 lbs
Platform Rotator
includes counterweights 3040 kg
1-8 center bolt, GR 5 483 ft-lbs
Counterweight, (x2) 1100 lbs
655 Nm
500 kg
1/2 -13 bolts, GR 8 80 ft-lbs
Drive chassis assembly 4800 lbs
108 Nm
2177 kg
Drive motor and hub
Tire and wheel assembly 290 lbs
Drive hub mounting bolts 159 ft-lbs 132 kg
216 Nm
Drive motor and hub 140 lbs
Drive motor mounting bolts 52 ft-lbs 64 kg
70.5 Nm
Engine assembly 475 lbs
Turntable bearing 215 kg
Rotate bearing mounting bolts 159 ft-lbs Primary boom 1920 lbs
216 Nm 871 kg
Turntable rotate assembly Primary boom lift cylinder 330 lbs
150 kg
Turntable rotate motor mounting bolts 170 ft-lbs
Removable threadlocker 230 Nm Primary boom extend cylinder 330 lbs
150 kg
Backlash plate mounting bolts 282 ft-lbs
382 Nm Jib boom assembly, with 6 ft / 1,8 m 800 lbs
platform 363 kg
Jib boom cylinder 106 lbs
48 kg
Oscillate cylinder 97 lbs
44 kg
Platform, 6 ft / 1,8 m 275 lbs
125 kg
Platform, 8 ft / 2,4 m 315 lbs
143 kg
Battery 63 lbs
29 kg
10 S®-60 J Part No. 1285305GT

Specifications
Hydraulic Hose and Fitting

Hydraulic Hose and Fitting Torque Specifications
SAE O-ring Boss Port

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

(swivel nut or hose connection)
SAE O-ring Boss Port
SAE Dash Size Thread Size Flats
(tube fitting - installed into Steel)
-4 7/16-20 2
-6 9/16-18 1 1/2
-4 ORFS / 37° (Adj) 15 ft-lbs / 20,3 Nm
-8 3/4-16 1 1/2 ORFS (Non-adj) 26 ft-lbs / 35,3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-10 7/8-14 1 1/2
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47,5 Nm
-12 1 1/16-12 1 1/4
37° (Adj / Non-adj) 29 ft-lbs / 39,3 Nm
-16 1 5/16-12 1
-8 ORFS (Adj / Non-adj) 60 ft-lbs / 81,3 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 52 ft-lbs / 70,5 Nm
-24 1 7/8-12 1 -10 ORFS (Adj / Non-adj) 100 ft-lbs / 135,6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115,3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271,2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413,5 Nm
Part No. 1285305GT S®-60 J 11

Specifications
Torque Procedure JIC 37° fittings

Torque Procedure
1 Align the tube flare (hex nut) against the nose

Seal-Lok™ fittings of the fitting body (body hex fitting) and
tighten the hex nut to the body hex fitting to
1 Replace the O-ring. The O-ring must be
hand tight, approximately 30 in-lbs / 3.4 Nm.
replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or 2 Using a permanent ink marker, make a
hose end has been tightened beyond finger reference mark on one the flats of the hex nut
tight. and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.
Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the O-
ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut
finger tight. Illustration 1
5 Tighten the nut or fitting to the appropriate 1 hex nut

torque. Refer to the appropriate torque chart 2 reference mark
in this section. 3 body hex fitting
6 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.
12 S®-60 J Part No. 1285305GT

Specifications
3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.
Note: Use the JIC 37° Fitting table in this section
to determine the correct number of flats, for the
proper tightening position.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Part No. 1285305GT S®-60 J 13

Repair Procedures
Machine Configuration:
Section 3 Repair Procedures
Introduction
 Unless otherwise specified, perform each

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

lock
 Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
 Be sure that all necessary tools and parts are
available and ready for use.
 Use only Genie approved replacement parts.
 Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
14 S®-60 J Part No. 1285305GT

Repair Procedures
About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.
Perform disassembly procedures to the point
where repairs can be completed. Then to re-
assemble, perform the disassembly steps in
reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected

after performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
Part No. 1285305GT S®-60 J 15

Control System
1-2
Control System 1-2 ALC-600 Service Mode
1-1
1-1 ALC-600 Platform Control Module
ALC-600 Control Module How to Enter ALC-600 Service

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

1 Number 1 or Escape
2 Number 2 or UP arrow
3 Number 3 or DOWN arrow
4 Number 4 or OK
1 ALC-600 platform control module
5 Settings menu
2 primary boom up/down and turntable
6 (not implemented)
rotate left/right joystick controller
7 Faults menu
3 LED indicator module
8 Fault LED Indicator
4 drive/steer joystick controller
9 Engine hours
10 Maintenance LED indicator
11 Maintenance menu
12 Home menu
16 S®-60 J Part No. 1285305GT

Control System
1-3
1-3 Full Machine Calibration
The Control System on this machine allows

access to calibrations through the Service Mode.
The procedures that follow will require the operator
Full Machine Calibration
to be in Service Mode. Service Mode can only be
Full machine calibration must be completed in the
entered at machine start up and requires a special
proper sequence when the ALC-600 controller
code.
(TCON) in the ground control box has been
1 At the ground controls, select the ground replaced.
control mode using the key switch.
2 Push and hold buttons numbered 2 and How to Fully Calibrate the
3 underneath the display screen. Machine
3 Pull out the red Emergency Stop button. Calibration procedures shall only be completed by
4 You will be prompted for a password. Enter 3 qualified technicians that have Genie factory
- 3 - 2 - 4. service training.
5 Press the Gear button to access the settings Tip-over hazard. Failure to
menu. calibrate the machine in the
Note: There will be a delay while the menu is proper sequence could cause
being loaded on the display screen. the machine to tip over resulting
in death or serious injury.
6 The machine will now operate normally and
allow the viewing and modification of Note: A digital level will be required to perform this
calibrations and parameters. procedure.
Note: When a parameter is changed in Service Note: Start this procedure with the boom in the
Mode, the change is effective immediately when stowed position.
button 4 (OK) is pushed. Machine restart is not
required. A confirmation beep accompanies every Full machine calibration must be completed in the
save (button 4). following sequence:
Note: Pushing in the red Emergency Stop button • Select model, engine, tires, and region,
will exit Service Mode. then cycle power. Refer to Repair Section
Display Module.
Note: If there has been no input for 10 minutes
while in Service Mode, the ALC-600 will power • Turntable level sensor. Refer to Repair
down and Service Mode will be exited, unless the Procedure, How to Calibrate the Turntable
engine is running. 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.
• Select option configuration. Refer to Repair
Section, Display Module, Options.
Part No. 1285305GT S®-60 J 17

Control System
1-4
1-4 Machine Functions
10 Record the time it takes for that function to

complete a full cycle (ie; boom up).
Machine Functions
11 Compare the machine function time with the
function times listed in Refer to Specifications,
Performance Specifications. Determine
How to Adjust the Joystick
How to Adjust the Machine Maximum Speed Setting
whether the function time needs to increase

or decrease.
Maximum Speed Setting
12 Adjust the parameter in the ground display to
The maximum speed of a joystick controlled achieve the proper function cycle time.
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.
18 S®-60 J Part No. 1285305GT

Control System
How to Adjust the Joystick Ramp

How to Adjust the Joystick Ramp Rate Setting
8 Start the engine from the ground controls.

Rate Setting 9 Start a timer and activate the machine
function that needs to be adjusted. Using the
The ramp rate setting is an adjustment that
ground control functions is the same as
controls the way boom functions start and stop.
asking for full joystick deflection at the
There are two types of ramp rates to adjust on
platform.
separate menus:
10 Record the time it takes for that function to
Ramp Up Time -- the amount of time it takes to complete the ramp.
accelerate to speed.
11 Compare the machine function time with the
Ramp Down Time -- the amount of time it takes to function times listed in Specifications,
decelerate to a stop Performance Specifications. Determine
whether the ramp time needs to increase or
The ramp rate settings of a joystick can be
decrease.
changed to compensate for hydraulic pump wear
to maintain peak performance from the machine. 12 Adjust the parameter in the ground display to
achieve the proper ramp time.
stowed position. Note: Refer to Repair Procedure, Display Module
Menus for ramp rates.
1 Enter the Service Mode. See Repair
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.
immediately.
Part No. 1285305GT S®-60 J 19

Control System
How to Adjust the Joystick 1-5

How to Adjust the Joystick Threshold Setting 1-5 How to Enter ALC600 Software Update Mode
Threshold Setting How to Enter ALC600 Software

The threshold setting of a joystick is the minimum Update Mode
output at which a function proportional valve can
open and allow the function to operate. 1 Go to the Genie website
http://firmware.genielift.com/
The boom function threshold current should be http://firmware.genielift.com, select your
operating at near zero speed, smoothly with no Machine Model and select Search.
vibrations.
2 Download the software to a USB flash drive. If
Note: Perform this procedure with the boom in the zipped, extract the files to the USB flash drive.
stowed position. 3 With the machine off, open the GBOX (ground
1 Enter the Service Mode. box) lid and then remove the four Torx head
screws securing the Display Controller
2 Press the SETTINGS button above the (DISCON) door and remove the door to
display screen. expose the USB port.
3 Select SPEEDS from the display screen. 4 Insert the flash drive into the USB port.
4 Navigate to the desired function's Threshold 5 Set key switch to ground and pull out the red
setting. ground ESTOP while holding buttons 1 and 4.
5 Select the desired setting to change and 6 The Display Controller will go into the
press OK. bootloader mode.
6 In the parameter adjustment screen, use the 7 Browse and select the desired
display buttons to change the parameter. software. Follow the on-screen guidance to
Note that the factory default speed is start the update procedure.
considered 100% for threshold values.
8 When complete, turn off machine.
immediately. 9 Remove USB flash drive, re-install the Display
Controller door and close the GBOX (ground
8 Switch the machine control to platform control box).
and start the engine from the platform
controls.. 10 Power up normally.
9 Using the joystick, verify that the function 11 As the display controller starts, operator shall
engages smoothly and without sudden verify on the start-up screen that the proper
movement or excessive joystick dead spots. software and revision are displayed.
10 Adjust the parameter in the ground display to 12 Perform a function check.

achieve a smooth function threshold.
20 S®-60 J Part No. 1285305GT

Control System
1-6
1-6 Display Module Menus
Display Module Menus

Screen or Menu Item Selection Default
Display Settings Backlight 0 - 100%
Contrast 0 - 100%
Display Inversion On / Off Off
Model Model S-40 / S-45 / S-60 / S-65 / S-80 / S- Select Model
Configuration 85 / S-60J / S-80J
Tires Rough Terrain / High Float / Trax Select Tires
(These are locked Engine Deutz 2.9L T4 / Deutz TD 2.9L T4 / Select Engine
unless factory Deutz TCD 2.2L S5 / Deutz TD
defaults are 2.2L S5 / Deutz D2011 L03i / Deutz
restored) TD2011 L04i / Ford MSG425 EFI /
GM 3.0L / Kubota D1105 / Kubota
D1803 / Perkins 404D 22 / Perkins
404D 22T / Perkins 404F E22T /
Perkins 404F E22TA
(Platform Platform Standard Platform Standard Platform
configuration is not 4m Platform
locked)
Region ANSI/CSA / AUS / CE Select Region
Options Footswitch Timeout 10 sec / 2 min / 30 min 2 min
Note: Some Drive Priority On / Off Off
options may not be Drive Cutout On / Off Off
visible with earlier
software revisions.
Platform Level On / Priority / Cutout On
Generator No Generator / Generator Installed No Generator
Contact Alarm On / Off On
Platform Recirculation On / Off Off
Units US Customary / Metric US Customary
Aircraft Proximity On / Off Off
Fuel Level Sensor Not Installed / Installed Installed
Glowplug Preglow Time 1 sec - 100 sec 12 sec
Lift Connect Not Installed / Installed Installed
Alarm Setting Off / Travel / Motion Off
Standby RPM Default / High RPM Default
Part No. 1285305GT S®-60 J 21

Control System
Screen or Menu Item Default

Sensor Calibration Chassis Tilt Select OK to calibrate
Load Sense Select OK to calibrate
Boom Angle Select OK to calibrate
Auto Threshold Boom Up / Down Threshold Select OK to calibrate
Calibration
Boom Extend / Retract Select OK to calibrate
Threshold
Drive Speeds Forward Threshold 122% max, 1% min, 100% = 755 mA
XC and HF
Reverse Threshold 122% max, 1% min, 100% = 731 mA
Forward Max 150% max, 78% min, 100% = 1365 mA
Reverse Max 150% max, 79% min, 100% = 1275 mA
Forward Out of Stow Max 150% max, 85% min, 100% = 1092 mA
Reverse Out of Stow Max 150% max, 85% min, 100% = 1059mA

Drive Ramps Standard Acceleration 5000 ms max, 100 ms min, 4000 ms
Standard Deceleration 5000 ms max, 100 ms min, 1000 ms
Torque Switching 5000 ms max, 500 ms min, 4000 ms
Deceleration
Kubota D1105 Threshold 2400 rpm
Anti-Stall
Drive Minimum 30%
Range 700 rpm
Hysteresis 200 rpm
Kubota D1803 Threshold 2400 rpm
Anti-Stall
Drive Minimum 30%
Range 700 rpm
Hysteresis 200 rpm
22 S®-60 J Part No. 1285305GT

Control System

Primary Lift Speeds Extend Thresholds 190% max, 1% min, 100% = 506 mA
Retract Threshold 179% max, 1% min, 100% = 513 mA
Up Threshold 250% max, 1% min, 100% = 450 mA
Down Threshold 253% max, 1% min, 100% = 443 mA
Extend Max 150% max, 68% min, 100% = 1425 mA
Retract Max 150% max, 70% min, 100% = 1325 mA
Up Max 150% max, 63% min, 100% = 1800 mA
Down Max 150% max, 63% min, 100% = 1800 mA

Primary Lift Ramps Extend Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms
Extend Decelerating Rate 5000 ms max, 250 ms min, 1000 ms
Retract Accelerating Rate 5000 ms max, 1000 ms min, 2500 ms
Retract Decelerating Rate 5000 ms max, 500 ms min, 1000 ms
Up Accelerating Rate 5000 ms max, 1000 ms min, 3000 ms
Up Decelerating Rate 5000 ms max, 500 ms min, 3000 ms
Down Accelerating Rate 5000 ms max, 1000 ms min, 3000 ms
Down Decelerating Rate 5000 ms max, 1000 ms min, 1000 ms
Turntable Speeds Rotate CW Max 150% max, 81% min, 100% = 1294 mA
Rotate CCW Max 150% max, 81% min, 100% = 1284 mA
Rotate CW Threshold 114% max, 1% min, 100% = 800 mA
Rotate CCW Threshold 114% max, 1% min, 100% = 800 mA
CW Out of Stow Max 150% max, 89% min, 100% = 1039 mA
CCW Out of Stow Max 150% max, 89% min, 100% = 1039 mA
Turntable Ramps CW Accelerating 5000 ms max, 1000 ms min, 3000 ms
CW Decelerating 5000 ms max, 500 ms min, 2000 ms
CCW Accelerating 5000 ms max, 1000 ms min, 3000 ms
CCW Decelerating 5000 ms max, 500 ms min, 2000 ms
Part No. 1285305GT S®-60 J 23

Control System

Jib Boom and Jib Up Threshold max 112% / min 1% / default 551 mA = 100%
Platform Speeds
Jib Down Threshold max 118% / min 1% / default 500 mA = 100%
Platform Level Up Threshold max 127% / min 1% / default 450 mA = 100%
Platform Level Down max 127% / min 1% / default 450 mA = 100%
Threshold
Platform Rotate CW max 114% / min 1% / default 510 mA = 100%
Threshold
Platform Rotate CCW max 126% / min 1% / default 521 mA = 100%
Threshold
Jib Up Max Output max 150% / min 90% / default 680 mA = 100%
Jib Down Max Output max 150% / min 87% / default 680 mA = 100%
Platform Level Up Max max 150% / min 83% / default 700 mA = 100%
Output
Platform Level Down Max max 150% / min 83% / default 700 mA = 100%
Output
Platform Rotate CW Max max 150% / min 89% / default 654 mA = 100%
Output
Platform Rotate CCW Max max 150% / min 83% / default 795 mA = 100%
Output
Jib and Platform Jib Up/Down Ramp max 2000 ms / min 200 ms / default 750 ms
Ramps
Platform Level Ramp max 2000 ms / min 200 ms / default 750 ms
Platform Rotate Ramp max 2000 ms / min 200 ms / default 600 ms
Machine Disable Drive Disable On / Off
Options
Machine Disable On / Off
Remote Disable Disable Engine Start / Drive Speed Cripple / Lift Speed Cripple
Reset to Defaults OK to reset Model Configuration and Options
Software Update OK to enter Software Update Mode
24 S®-60 J Part No. 1285305GT

Control System
1-7
1-7 How to Replace the Display Controller (DISCON) Module
6 Remove the old DISCON gasket (2) from the

ground box lid and clean the lid surface from
How to Replace the Display any dirt, oil or old adhesive residue. Use a
Controller (DISCON) Module 99% solution of isopropyl alcohol to clean the
surface. Allow the surface to completely dry.
1 Push in the red Emergency Stop button to the
off position at both the ground and platform Note: Both the ground box lid and new gasket
controls. must be 70° F / 21° C or higher at the time of
application. Application of the new gasket at lower
2 Disconnect the negative terminal from the temperatures is not recommended.
start battery and auxiliary battery, if equipped.
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.
8 Install the new DISCON onto the ground box
1 ground box lid lid and fasten it using the new hex nuts and
2 DISCON gasket washers. All five fastening points must be
3 flat washer used. Attach the DISCON door's lanyard to
4 hex nut the DISCON's mounting stud.
5 DISCON door
9 Evenly tighten the nuts, beginning with the
6 Torx head screws lower center nut, working out and then up.
7 ribbon cable
8 DISCON 10 Install the new ribbon cables, connecting the
ground box overlay to the DISCON and
3 Open the ground box lid (1) and disconnect reinstall the DISCON door, using the Torx
the wire harness going to the display head screws removed in step 4. Be sure to
controller (DISCON). fully lock the tabs after the ribbon cables have
been fully inserted.
4 Remove the DISCON door from the back by
loosening the four Torx head screws (8) and 11 Reconnect the wire harness going to the
remove the two ribbon cables (6) connecting DISCON, then close and fasten the ground
the ground box overlay to the DISCON. box lid.
Note the orientation of the cables for 12 Reconnect the negative terminal to the start
reassembly. battery and auxiliary batteries, if equipped.
5 Remove the DISCON from the ground control
box lid by removing the five hex nuts and
washers (4, 5). Discard the nuts and washers.
Note the lanyard attachment point for
reassembly.
Part No. 1285305GT S®-60 J 25

Control System
1-8
1-8 How to Replace the Ground Control Overlay
4 Unscrew the nut holding the buttons and key

switch and remove the key switch and
How to Replace the Ground Box buttons.
Control Overlay
Note the orientation of the key switch so it can be
1 Push in the red Emergency Stop button to the reassembled in the same position.
off position at both the ground and platform
5 Disconnect the wire harness connected to the
controls.
DISCON and cut the zip ties securing the
2 Disconnect the negative terminal from the harness to the ground box lid. Do not remove
start battery and auxiliary battery, if equipped. the wire harness from the ground box.
3 Open the ground box lid and remove the 6 Remove the DISCON door (4) and disconnect
switch contacts from the function enable and the ribbon cables (3) from the Display
E-Stop buttons and key switch. Do not Controller (DISCON) (2). Note the orientation
disconnect the wires. Insert a small of the cables for reassembling.
screwdriver into the loop at the base of the
contacts and engage the release mechanism.
Refer to Illustration 1.
1 DISCON
2 ribbon cables
3 DISCON door
4 Torx head screws
5 ground box lid
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.
26 S®-60 J Part No. 1285305GT

Control System
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 / 26-
38° C for a minimum of 20 minutes to allow
the adhesive to cure.
12 Install the provided ribbon cables, first to the
overlay and then the DISCON. Be sure the
connectors are applied evenly in the sockets
and the tabs are fully locked.
13 Reinstall the DISCON door using the Torx
head screws (5). Tighten, but do not
overtighten.
14 Reinstall the ground box door to the ground
box, using the fasteners removed in step 7.
Tighten the fasteners securely.
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.
Part No. 1285305GT S®-60 J 27

Platform Components
Platform Components
2-1
2-1 Platform Leveling Slave Cylinder
4 Remove the pin retaining fastener from the

slave cylinder rod-end pivot pin. Use a soft
Platform Leveling Slave Cylinder metal drift to drive the rod-end pivot pin out.
The slave cylinder and the rotator pivot are the two Crushing hazard. The platform
primary supports for the platform. The slave could fall when the slave
cylinder keeps the platform level through the entire cylinder rod-end pivot pin is
range of boom motion. It operates in a closed- removed if not properly
circuit hydraulic loop with the master cylinder. The supported.
slave cylinder is equipped with counterbalance
valves to prevent movement in the event of a 5 From the ground controls, use auxiliary power
hydraulic line failure. and activate platform level down to retract the
slave cylinder rod.
How to Remove the Platform 6 Tag, disconnect and plug the hydraulic hoses
Leveling Slave Cylinder from the slave cylinder.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
1 Extend the boom until the slave cylinder
barrel-end pivot pin is accessible. 7 Remove the external snap rings from the
barrel-end pivot pin.
2 Raise the jib boom slightly and place blocks
under the platform for support. 8 Use a soft metal drift to drive the barrel-end
pivot pin out.
3 Lower the jib boom until the platform is resting
on the blocks just enough to support the 9 Carefully pull the cylinder out of the boom.
platform.
Note: Do not rest the entire weight of the boom on How to Bleed the Platform
the blocks.
Leveling Cylinder
Note: Do not start the engine. Use auxiliary power
for this procedure.
1 Raise the jib boom to the horizontal position.
2 Simultaneously activate the boom up function
and the platform level up function until the
boom is fully raised.
3 Simultaneously activate the boom down
function and the platform level down function
until the boom is fully lowered.
28 S®-60 J Part No. 1285305GT

Platform Components
2-2
2-2 Platform Rotator
2 Tag, disconnect and plug the hydraulic hoses

from the platform rotator manifold. Cap the
Platform Rotator fittings on the rotator.
The platform rotator is a hydraulically activated 3 Tag, disconnect and plug the hydraulic hoses
helical gear assembly used to rotate the platform from the platform rotator manifold. Cap the
160 degrees. fittings on the rotator.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
Rotator burn skin. Loosen hydraulic
connections very slowly to allow
Component damage hazard. the oil pressure to dissipate
Mark the platform mounting gradually. Do not allow oil to
weldment and the rotator flange squirt or spray.
before removing the platform
mounting weldment. The 4 Support the jib boom leveling arms and the
platform mounting weldment platform mounting weldment with an
must be replaced in the exact appropriate lifting device. Do not apply any
same position on the rotator lifting pressure.
flange as it was before removal.
5 Remove the mounting bolts from the platform
If a new rotator is installed or
mounting weldment. Remove the center bolt
the rotator is disassembled,
and slide the platform mounting weldment off
proper alignment can be
of the platform rotator.
achieved by rotating the rotator
all the way to the left and then Crushing hazard. The platform
installing the platform mounting mounting weldment may
weldment all the way in the left become unbalanced and fall if it
position. is not properly supported.
Note: When removing a hose assembly or fitting, 6 Support the platform rotator with an
the O-ring (if equipped) on the fitting and/or hose appropriate lifting device. Do not apply any
end must be replaced. All connections must be lifting pressure.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.
1 Remove the platform and platform support.
Note: If the load sense components are
disassembled and/or removed from the platform
support, the platform load sense system will need
to be calibrated. Refer to Repair Procedure,
Platform Load Sense System.
Part No. 1285305GT S®-60 J 29

Platform Components
7 Remove the pin retaining fasteners from the How to Bleed the Platform
jib boom and jib boom leveling arms to
platform rotator pivot pins. Do not remove the
Rotator
pins. Note: This procedure will require two people. Do
not start the engine. Use auxiliary power for this
8 Support the jib boom leveling arms.
procedure.
9 Use a soft metal drift to drive both pins out,
then remove the platform rotator from the 1 Move the function enable toggle switch to
machine. either side and activate the platform rotate
toggle switch to the right then the left through
Bodily injury hazard. The jib two platform rotation cycles, then hold the
boom leveling arms may fall if switch to the right position until the platform is
not properly supported. fully rotated to the right.
2 Place a suitable container underneath the
10 Lower the jib boom leveling arms.
platform rotator.
Crushing hazard. The platform 3 Open the top bleed screw on the rotator, but
rotator could fall when removed do not remove it.
from the machine if not properly
supported. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Note: When installing the platform rotator burn skin. Loosen hydraulic
fasteners, torque the fasteners to specifications. connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.
4 Move the function enable toggle switch 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.
30 S®-60 J Part No. 1285305GT

Platform Components
2-3
2-3 Platform Overload System
5 Open the bottom bleed screw on the rotator,

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

How to Perform a Zero Load
How to Perform a Zero Load Platform Calibration
either side and hold the platform rotate toggle

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

remove all non-integrated
factory and non-factory options
and accessories could result in
the machine tipping over,
causing death or serious injury.
Part No. 1285305GT S®-60 J 31

Platform Components
How to Perform a Full Load

How to Perform a Full Load Platform Calibration
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 on a firm, level
1 Fully retract and lower the boom. Level the
platform.
Integrated Options and Accessories 2 Remove all weight, tools, accessories and
1 platform work lights
equipment from the platform.
2 auxiliary top rail Note: Options and accessories that are considered
3 platform full height mesh integrated components of the platform do not
4 platform half height mesh require removal to perform calibration. Refer to
5 swing gate latch guard Integrated Options and Accessories.
6 Contact alarm
7 control box cover
remove all non-integrated
3 Enter Service Mode. Refer to Repair factory and non-factory options
Procedure, How to Enter the Service Mode. and accessories could result in
the machine tipping over,
4 Press the settings button above the display causing death or serious injury.
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.
11 Exit Service Mode.
Integrated Options and Accessories
1 platform work lights
2 auxiliary top rail
3 platform full height mesh
4 platform half height mesh
5 swing gate latch guard
6 Contact alarm
7 control box cover
32 S®-60 J Part No. 1285305GT

Platform Components
3 Enter Service Mode. Refer to Repair 10 Place a test weight on the platform floor using
Procedure, How to Enter the Service Mode. a suitable lifting device. Place the weight near
the center entry point of the platform, as far
4 Press the settings button above the display
away from the operator controls as possible.
and select the Calibrations menu.
Weight = 660 lbs / 300 kg
5 Navigate to the Sensor calibration screen.
Note: If test weights are not available, you may
6 Navigate to the Load Sense calibration
use an industrial scale to weigh available objects
screen.
until it equals the platform’s maximum capacity.
8 Follow the on-screen prompts to set the zero
load.
9 Continue with the on screen prompts to set
the maximum load.
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 chain hoist until the readout displays the
appropriate weight.
Platform hidden from illustration for clarity

1 platform support
2 sling
3 hanging scale
4 winch or chain hoist
5 anchoring device
Part No. 1285305GT S®-60 J 33

Platform Components
How to Replace the Load Cell

How to Replace the Platform Overload Load Cell
11 Follow the prompts to accept the weight.

12 Calibration is now complete. Sensor
13 Exit Service Mode. Note: The preload adjustment should only be
performed after the load cell sensor has been
14 Push in the red Emergency Stop button to the replaced.
off position.
1 Remove all equipment or tools from the
Confirm calibration: platform. Remove the welder if equipped.
15 Start the engine from the ground controls. 2 At the platform, remove the plastic instruction
16 Add an additional 50 lbs / 23 kg of weight or holder from the document mount plate.
load to the platform. 3 Tag and disconnect the load cell sensor
Result: The alarm sounds. The engine turns harness.
off. The platform overload indicator light 4 Loosen the jam nut securing the load cell
flashes at the platform controls and Platform sensor foot and rotate the foot screw
Overload is displayed on the LCD screen at clockwise to remove the preload.
the ground controls.
5 Remove the fasteners securing the load cell
Note: There may be a 2 second delay before the sensor and remove the sensor.
overload indicator lights flash and the alarm
sounds. Install the new Load Cell Sensor
17 Test all machine functions from the ground 6 Screw the foot with jam nut into the top of the
controls. load cell sensor until the foot bolt extends out
of the bottom of the sensor.The foot should
Result: Engine does not start. Limited APU not contact the flex plate when assembling
functionality. Elevate and extend functions do onto the platform support.
not operate.
7 Assemble the load cell and foot assembly to
18 Remove the weight or rated load from the the platform and securely tighten the two
platform. mounting screws. Torque the bolts to 101 ft-
lbs / 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.
34 S®-60 J Part No. 1285305GT

Platform Components
2-4
2-4 Platform
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.
Part No. 1285305GT S®-60 J 35

Jib Boom Components

Jib Boom Components
3-1
3-1 Jib Boom
6 Attach a lifting strap from an overhead crane

to the jib boom assembly.
Jib Boom
7 Place blocks under the platform leveling
cylinder for support. Protect the cylinder rod
How to Remove the Jib Boom from damage.
Note: Perform this procedure with the boom in the 8 Remove the pin retaining fastener from the
stowed position. slave cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin.
Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose Crushing hazard. The jib boom
end must be replaced. All connections must be could fall when the slave
torqued to specification during installation. Refer to cylinder rod-end pivot pin is
Specifications, Hydraulic Hose and Fitting Torque removed if not properly attached
Specifications. to the overhead crane.
1 Remove the platform. 9 Remove the pin retaining fastener from the jib
2 Remove the platform mounting weldment. boom bellcrank to primary boom pivot pin.
3 Remove the hose and cable cover from the 10 Use a soft metal drift to remove the pin and
side of the jib boom. carefully remove the jib boom assembly from
the primary boom.
4 Remove the hose and cable clamp from the
jib boom pivot pin. Lay all hoses and cables to Crushing hazard. The jib boom
the side. may become unbalanced and
fall when it is removed from the
Component damage hazard. machine if it is not properly
Hoses and cables can be supported by the overhead
damaged if they are kinked or crane.
pinched.
5 Tag, disconnect and plug the jib boom lift

cylinder hydraulic hoses. Cap the fittings on
the cylinder.
burn skin. Loosen hydraulic
squirt or spray.
36 S®-60 J Part No. 1285305GT

Jib Boom Components
3-2
3-2 Jib Boom Lift Cylinder
4 Use a soft metal drift to tap the jib boom lift

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

jib boom lift cylinder rod-end pivot pin. Do not
remove the pin.
Part No. 1285305GT S®-60 J 37

Boom Components
Boom Components
Boom Legend
1 primary boom
2 mid-pivot
3 timing link
4 pivot lever
5 pivot link
6 lift cylinder
7 upper riser arm
8 lower riser arm
9 lower riser arm to turntable pivot pin
10 upper riser arm to turntable pivot pin
38 S®-60 J Part No. 1285305GT

Boom Components
Boom Components
4-1
4-1 Cable Track
7 Tag, disconnect and plug the platform leveling

slave cylinder hydraulic hoses from the
Cable Track bulkhead fittings on the side of the primary
boom. Cap the bulkhead fittings.
The primary boom cable track guides the cables
and hoses running up the boom. It can be repaired Bodily injury hazard. Spraying
link by link without removing the cables and hoses hydraulic oil can penetrate and
that run through it. Removing the entire primary burn skin. Loosen hydraulic
boom cable track is only necessary when connections very slowly to allow
performing major repairs that involve removing the the oil pressure to dissipate
primary boom. gradually. Do not allow oil to
squirt or spray.
How to Remove the Cable Track

How to Remove the Cable Track

Note: When removing a hose assembly or fitting, from the "V1" and "V2" ports of the jib
the O-ring (if equipped) on the fitting and/or hose boom/platform rotate manifold. Cap the
end must be replaced. All connections must be fittings on the manifold.
torqued to specification during installation. Refer to Bodily injury hazard. Spraying
Specifications, Hydraulic Hose and Fitting Torque hydraulic oil can penetrate and
Specifications. burn skin. Loosen hydraulic
1 Open the platform control box. connections very slowly to allow
2 Tag and disconnect the foot switch wiring gradually. Do not allow oil to
from the terminal strip inside the platform squirt or spray.
control box. Pull the wiring out of the platform
control box. 9 Remove the hose and cable cover from the
side of the jib boom.
3 Raise the boom to a horizontal position.
10 Locate all electrical cables under the boom at
4 Disconnect the wire connectors from the
the pivot end that enter the cable track.
bottom of the platform control box.
11 Tag and disconnect the electrical connectors
Note: When installing the wire connectors to the
for all cables that enter the cable track.
bottom of the platform control box, match the color
of the connectors to those on the control box to be 12 Remove the retaining fasteners from the
sure they are installed in the correct location. electrical connector receptacles for the cables
that enter the cable track.
5 Remove the mounting fasteners from the
power to platform outlet box bracket. Lay the 13 Carefully pull the cables and connector
outlet box and bracket assembly off to the receptacles out of the primary boom.
side.
6 Remove the hose and cable clamps from the
platform support and jib boom.
Part No. 1285305GT S®-60 J 39

Boom Components
14 Tag, disconnect and plug all hydraulic hoses 21 Carefully remove the cable track from the
that enter the cable track from the bulkhead machine and place it on a structure capable of
fittings at the pivot end of the boom. supporting it.
Bodily injury hazard. Spraying Crushing hazard. The cable
hydraulic oil can penetrate and track could become unbalanced
burn skin. Loosen hydraulic and fall if not properly attached
connections very slowly to allow to the overhead crane.
gradually. Do not allow oil to Component damage hazard.
squirt or spray. Cables and hoses can be
damaged if they are kinked or
15 Pull the hydraulic hoses out of the primary pinched.
boom.
16 Remove the cotter pin from the upper cable Component damage hazard. The
track at the platform end of the boom. cable track can be damaged if it
Note: Always replace the cotter pin with a new is twisted.
one.
17 Remove the cable track pull tube guide
fasteners from the cable track guide at the
platform end of the boom. Remove the cable
track guide from the boom.
18 Place blocks in 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.

to the cable track.
20 Remove the mounting fasteners that attach
the lower cable track to the boom.
40 S®-60 J Part No. 1285305GT

Boom Components
How to Repair the Cable Track

How to Repair the Cable Track

The boom cable track can be
damaged if it is twisted.
Note: A 4 link repair section of cable track is

available through the Genie Service Parts
Department.
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.
Hoses and cables can be
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.
Hoses and cables can be
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.
Part No. 1285305GT S®-60 J 41

Boom Components
4-2
4-2 Primary Boom

from the boom extend cylinder. Cap the
Primary Boom fittings.Remove the cable tracks from both
sides of the boom. Set them onto the machine
How to Remove the Primary side covers.
Boom Bodily injury hazard. Spraying
Bodily injury hazard. This burn skin. Loosen hydraulic
procedure requires specific repair connections very slowly to allow
skills, lifting equipment and a the oil pressure to dissipate
suitable workshop. Attempting gradually. Do not allow oil to
this procedure without these squirt or spray.
skills and tools could result in
death or serious injury and 7 Using an overhead crane with a strap of
significant component damage. adequate capacity, support the platform end
Dealer service is strongly of the boom. Do not apply any lifting pressure.
recommended.
8 Using an overhead crane with a strap of
Note: Perform this procedure on a firm, level adequate capacity, support the barrel end of
surface with the machine in the stowed position the primary boom lift cylinder.
unless otherwise instructed. 9 Using a soft metal drift, remove the pivot pin
Note: When removing a hose assembly or fitting, securing the barrel end of the cylinder. Lower
the O-ring (if equipped) on the fitting and/or hose the cylinder onto the boom structure.
end must be replaced. All connections must be Crushing hazard. The cylinder
torqued to specification during installation. Refer to could fall if not properly
Specifications, Hydraulic Hose and Fitting Torque supported.
Specifications.
1 Remove the jib boom. Refer to Repair 10 Using an overhead crane with a strap of
Procedure, How to Remove the Jib Boom. adequate capacity, support the pivot end of
the boom. Do not apply any lifting pressure.
2 Raise the boom approximately 6 inches /
15 cm. 11 Tag, disconnect and plug the hydraulic hoses
from the platform level master cylinder at the
3 Place a block of wood 4x4x18 inches / pivot end of the boom. Cap the fittings.
10x10x45 cm across the boom rest and lower
the boom onto the block of wood. Bodily injury hazard. Spraying
4 Remove the covers from the pivot end of the burn skin. Loosen hydraulic
boom assembly and the mid-pivot. connections very slowly to allow
5 Working at the pivot end of the boom, remove the oil pressure to dissipate
the boom retract limit switch. gradually. Do not allow oil to
squirt or spray.
12 Using a soft metal drift, remove the pivot pin

securing the barrel end of the cylinder.
Note: Use the access hole on the right side of the
mid-pivot to remove the pivot pin.
42 S®-60 J Part No. 1285305GT

Boom Components
4-3
4-3 Boom Lift Cylinder
13 Remove the boom lower pivot pin retaining

fasteners. Use a soft metal drift to remove the
pin.
Boom Lift Cylinder
14 Remove the boom upper pivot pin retaining The primary boom lift cylinder raises and lowers
fasteners. Use a soft metal drift to remove the the primary boom. The primary boom lift cylinder is
pin. Remove the boom from the machine. equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure.
15 Using an overhead supporting device, support
one of the pivot levers.
16 Using a soft metal drift, push the pivot pin in
How to Remove the Boom Lift
far enough that it can be lowered onto the Cylinder
boom structure.
Bodily injury hazard. This
Crushing hazard. The pivot lever procedure requires specific repair
could fall if not properly skills, lifting equipment and a
supported. suitable workshop. Attempting
this procedure without these
17 Using an overhead supporting device, support skills and tools could result in
the other pivot lever. death or serious injury and
significant component damage.
18 Using a soft metal drift, finish removing the
Dealer service is strongly
pivot pin.
recommended.
Note: Do not remove the metal drift. Only pull it
back far enough to lower the pivot lever. Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
Crushing hazard. The timing end must be replaced. All connections must be
link will fall if the metal drift is torqued to specification during installation. Refer to
removed before it has been Specifications, Hydraulic Hose and Fitting Torque
properly supported. Specifications.
19 Using an overhead supporting device, support 1 Raise the boom until the lift cylinder rod-end
the timing link. pivot pin is above the side covers.
20 Remove the metal drift and lower the timing 2 Attach a 5 ton / 5000 kg overhead crane to
link onto the mid-pivot of the boom structure. the platform end of the boom for support. Do
not apply any lifting pressure.
21 Using a soft metal drift, remove the pivot pin
securing the boom to the mid-pivot. 3 Attach a 5 ton / 5000 kg overhead crane to
the two lifting eyes located at the top of the
Crushing hazard. The boom mid-pivot. Do not apply any lifting pressure.
assembly will fall if not properly
supported when removed from
the machine.
22 Remove the boom from the machine.
Part No. 1285305GT S®-60 J 43

Boom Components
4-4
4-4 Primary Boom Extension Cylinder
4 Tag, disconnect and plug the boom lift

the cylinder.
Primary Boom Extension
Cylinder
hydraulic oil can penetrate and The primary boom extension cylinder extends and
burn skin. Loosen hydraulic retracts the primary boom extension tube.The
connections very slowly to allow primary boom extension cylinder is equipped with
the oil pressure to dissipate counterbalance valves to prevent movement in the
gradually. Do not allow oil to event of a hydraulic line failure.
squirt or spray.
How to Remove the Primary
5 Using a suitable lifting device, secure the
barrel-end of lift cylinder.
Boom Extension Cylinder
6 Place a block of wood measuring Bodily injury hazard. This
4x4x24 inches / 10x10x50 cm across the top procedure requires specific repair
of the turntable bulkhead and below the skills, lifting equipment and a
cylinder. suitable workshop. Attempting
this procedure without these
7 Remove the pin retaining fastener from the skills and tools could result in
boom lift cylinder barrel-end pivot pin. death or serious injury and
8 Using a soft metal drift, remove the pivot pin. significant component damage.
Lower the cylinder onto the wooden block. Dealer service is strongly
recommended.
Crushing hazard. The lift
cylinder will fall if not properly Note: When removing a hose assembly or fitting,
supported when the pivot pin is the O-ring (if equipped) on the fitting and/or hose
removed. end must be replaced. All connections must be
9 Adjust the lifting strap to the center of the lift Specifications, Hydraulic Hose and Fitting Torque
cylinder. Specifications.
10 Remove the pin retaining fastener from the 1 Raise the jib boom to a horizontal position.
boom lift cylinder rod-end pivot pin.
2 Extend the boom until the extension cylinder
11 Using a soft metal drift, remove the pivot pin. rod-end pivot pins are accessible in the
Note: Apply slight lifting pressure to the mid-pivot extension tube.
to remove pressure from the pivot pin. 3 Raise the primary boom to a horizontal
position.
12 Carefully remove the boom lift cylinder from
the machine. 4 At the pivot end of the boom, remove the
cover from the end of the boom tube.
Crushing hazard. The lift
cylinder could become 5 Remove the boom extend limit switch.
unbalanced and fall if not
properly supported and secured
to the lifting device.
44 S®-60 J Part No. 1285305GT

Boom Components
4-5
4-5 Platform Leveling Master Cylinder
6 Tag, disconnect and plug the boom extension

the cylinder.
Platform Leveling Master
Cylinder
hydraulic oil can penetrate and The platform leveling master cylinder acts as a
burn skin. Loosen hydraulic pump for the slave cylinder. It is part of the closed-
connections very slowly to allow loop hydraulic circuit that keeps the platform level
the oil pressure to dissipate through the entire range of primary boom motion.
gradually. Do not allow oil to The platform leveling master cylinder is located
squirt or spray. inside the upper mid-pivot at the pivot end of the
primary boom.
Hoses and cables can be How to Remove the Platform
pinched. Leveling Master Cylinder
7 At the pivot end of the boom, remove the the O-ring (if equipped) on the fitting and/or hose
retaining fasteners and blocks securing the end must be replaced. All connections must be
extend cylinder to the boom tube. torqued to specification during installation. Refer to
8 At the platform end of the boom, remove the Specifications, Hydraulic Hose and Fitting Torque
external snap rings from the extension Specifications.
cylinder rod-end pivot pin. Use a soft metal 1 Remove the cover from the mid-pivot.
drift to remove the pin.
2 Tag, disconnect and plug the master cylinder
9 Support and slide the extension cylinder out hydraulic hoses. Cap the fittings on the
of the primary boom. cylinder.
Crushing hazard. The extension Bodily injury hazard. Spraying
cylinder could fall when removed hydraulic oil can penetrate and
from the extension boom if not burn skin. Loosen hydraulic
properly supported. connections very slowly to allow
Component damage hazard. Be gradually. Do not allow oil to
careful not to damage the squirt or spray.
counterbalance valves on the
primary boom extension cylinder
when removing the cylinder from
the primary boom.
Part No. 1285305GT S®-60 J 45

Boom Components
3 Remove the retaining fastener securing the 4-6
4-6 Primary Boom Angle Sensor
barrel end pivot pin.

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
4 Using a soft metal drift, remove the pivot pin. primary boom angle sensor.
Note: Use the access hole on the right side of the
1 Fully retract and lower the boom.
mid-pivot to remove the pivot pin.
2 Enter Service Mode. Refer to Repair
and navigate to the Sensor Calibrations
menu.
4 Navigate to the Boom Angle Sensor
calibration screen.
6 Start the engine.
7 When the display prompts the operator to
lower the boom, press and hold the function
1 pivot pin enable button and the boom down buttons
until the display indicates that the lower
5 Raise the boom until the rod end pivot pin of calibration point has been obtained. This may
the master cylinder is accessible. require holding the buttons for several
seconds.
6 Using an overhead supporting device, support
the master cylinder. 8 Press OK.
7 Remove the retaining fastener securing the 9 Exit Service Mode.
rod end pivot pin.
8 Using a soft metal drift, remove the pivot pin.
Crushing hazard. The cylinder
could fall if not properly
supported.
9 Remove the master cylinder from the

machine.
46 S®-60 J Part No. 1285305GT

Boom Components
How to Replace the Primary

How to Repalce the Primary Boom Angle Sensor
Boom Angle Sensor

1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls and turn the key switch to the off
position.
2 Locate the boom angle sensor at the platform
end of the upper riser arm.
3 Tag and disconnect the electrical connector
from the angle sensor.
4 Remove the retaining fasteners. Remove the
angle sensor from the machine.
5 Install the new angle sensor onto the
machine.
6 Securely connect the angle sensor harness to
the main harness.
7 Calibrate the angle sensor. Refer to Repair
Procedure, How to Calibrate the Primary
Boom Angle Sensor.
Part No. 1285305GT S®-60 J 47

Engines
5-2
Engines 5-2 Flex Plate
5-1
5-1 RPM Adjustment - Kubota D1105 and Deutz D2011 Models
RPM Adjustment - Kubota Flex Plate

D1105 and Deutz D2011Models The flex plate acts as a coupler between the
engine and the pump. It is bolted to the engine
Refer to Maintenance Procedure in the appropriate
flywheel and has a splined center to drive the
Service or Maintenance Manual for your machine,
pump.
Check and Adjust the Engine RPM.
How to Remove the Flex Plate
1 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
2 Carefully pull the pump away from the engine
and secure it from moving.
3 Remove the flex plate mounting fasteners.
4 Remove the flex plate from the engine.
48 S®-60 J Part No. 1285305GT

Engines
How to Install the Flex Plate

How to Install the Flex Plate
1 Install the flex plate onto the engine flywheel

with the raised spline towards the pump.
2 Apply Loctite® removable thread locker to the
flex plate mounting fasteners. Torque the flex
plate mounting fasteners in sequence.
Deutz D2011: Pre-torque to 15 ft-lbs / 20 Nm.
Then torque the flex plate mounting fasteners
in sequence to 42.5 ft-lbs / 57,5 Nm.
Kubota D1105: Pre-torque to 13 ft-lbs / 17,5
Nm. Then torque the flex plate mounting
fasteners in sequence to 36 ft-lbs / 49 Nm.
Kubota D1105
Kubota D1803: Pre-torque to 14 ft-lbs / 19
Nm. Then torque the flex plate mounting
fasteners in sequence to 40.5 ft-lbs / 55 Nm.
Kubota D1803
3 Apply high viscosity coupling grease to the

Deutz D2011 splines of the flex plate.
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
Part No. 1285305GT S®-60 J 49

Engines
How to Install the Pump and Bell

How to install the Pump and Bell Housing Assembly
Housing Assembly
1 Install the pump and bell housing assembly.
Apply Loctite® removable threadlocker to the
bell housing mounting fasteners. Torque the
bell housing mounting fasteners in sequence.
Deutz D2011: Pre-torque the bell housing
mounting fasteners labeled "C" in sequence
to 17.5 ft-lbs / 24 Nm. Then torque the bell
housing mounting fasteners in sequence to
50 ft-lbs / 67,5 Nm.
Kubota D1105: Pre-torque the bell housing
mounting fasteners labeled "A" in sequence to Deutz D2011
5 ft-lbs / 7 Nm. Pre-torque the bell housing
mounting fasteners labeled "B" in sequence to
10 ft-lbs / 13 Nm.
Then torque the bell housing mounting
fasteners labeled "A" in sequence to 15 ft-lbs /
20 Nm.
Then torque the bell housing mounting
fasteners labeled "B" in sequence to 29 ft-lbs /
40 Nm.
Kubota D1803: Pre-torque the bell housing
mounting fasteners in sequence to 17 ft-lbs /
23 Nm. Then torque the bell housing
mounting fasteners in sequence to 49 ft-lbs /
Kubota D1105
66 Nm.
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.
Kubota D1803
50 S®-60 J Part No. 1285305GT

Engines
5-3
5-3 Engine Fault Codes - Kubota D1803 Models
Engine Fault Codes - Kubota

D1803 Models
How to Retrieve Engine Fault
Codes
The ECM constantly monitors the engine by the
use of sensors on the engine. The ECM also uses
signals from the sensors to initiate sequential fuel
injection and make constant and instantaneous
changes to ignition timing, fuel delivery and throttle
position to maintain the engine's running condition
at its highest efficiency while at the same time
keeping exhaust emissions to a minimum. When a
sensor fails or returns signals that are outside of
set parameters, the ECM will store a fault code in
memory that relates to the appropriate sensor.
One or more fault LED's will illuminate on the
display located at the ground control box. The
active fault code will also be displayed on the LCD
screen.
If a fault occurs that does not result in an engine
shutdown, the engine rpm will go into limp home
mode resulting in the loss of high rpm.
Refer to Fault Codes Section, How to Retrieve
Kubota D1803 Engine Fault Codes. Use the Fault
Code Charts to aid in identifying the fault.
Part No. 1285305GT S®-60 J 51

Hydraulic Pump
6-2
Hydraulic Pump 6-2 Drive Pump
6-1
6-1 Function Pump
Function Pump Drive Pump

How to Remove the Function How to Remove the Drive Pump
Pump Note: When removing a hose assembly or fitting,
Specifications.
Specifications. 1 Remove the fasteners securing the function
pump to the drive pump.
1 Remove the fasteners securing the generator
pump to the function pump. 2 With hoses attached, remove the function
pump (and generator pump, if equipped) from
2 With hoses attached, remove the generator
the drive pump.
pump from the function pump.
3 Tag, disconnect and plug the drive pump
3 Tag, disconnect and plug the function pump
hydraulic hoses. Cap the fittings on the pump.
squirt or spray.
squirt or spray.
4 Support the generator pump with a strap and
4 Support the function pump with a strap and
appropriate lifting device. Do not apply any
lifting pressure.
lifting pressure.
5 Remove the pump mounting bolts. Carefully
remove the pump.
remove the pump.
NOTE: When installing a new pump, it is
NOTE: When installing a new pump, it is
necessary to prime the pump. Refer to Repair
necessary to prime the pump. Refer to Repair
Procedure How to Prime the Pump.
Procedure How to Prime the Pump.
52 S®-60 J Part No. 1285305GT

Hydraulic Pump
How to Install the Drive Pump 6-3

How to Install the Drive Pump Coupler 6-3 How to Prime the Drive and Function Pumps
Coupler How to Prime the Drive and

1 Install the coupler onto the pump shaft with Function Pumps
the set screw towards the pump. Leave a
1/32 inch / 0.8 mm gap between the coupler 1 Fill the tank with hydraulic oil until the fluid
and pump end plate. level is in the center of the sight glass at the
rear of the tank. Do not overfill.
2 If any of the pumps are new and have not
been previously used, they must be primed.
Drive Pump: After the pump is installed,
fasteners torqued and all hoses connected,
remove one of the hoses at the top of the
pump (port E or port F) and add a minimum of
0.75 liter / 25 ounces of hydraulic oil to the
pump. Install and torque the hose to
specification.
Function Pump: After the pump is installed,
1 drive pump fasteners torqued and all hoses connected,
2 coupler spacing remove the plug at the uppermost port of the
3 pump coupler pump and add a minimum of 0.375 liter /
13 ounces of hydraulic oil to the pump. Install
2 Apply Loctite® removable thread locker to the
and torque the port plug to 77 Nm / 57 ft-lbs.
coupler set screw. Torque the set screw to
70 ft-lbs / 95 Nm. 3 Locate the quick-disconnect port at the top of
the siphon riser hydraulic oil supply line from
tank to the pumps.
4 Use a clear line to connect an air-powered
vacuum pump to the test port.
5 Activate the pump until no bubbles are seen
in the clear vacuum pump hose while the
pump is running. Disconnect the vacuum
pump from the quick-disconnect port.
6 Start the engine from the ground controls and
check for hydraulic leaks.
Part No. 1285305GT S®-60 J 53

Hydraulic Pump
6-4
6-4 Generator Pump
Generator Pump
How to Remove the Generator
Pump
Specifications.
1 Tag, disconnect and plug the generator pump
squirt or spray.
2 Support the pump with a strap and

lifting pressure.
remove the pump.
54 S®-60 J Part No. 1285305GT

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Part No. 1285305GT S®-60 J 55

Manifolds
Manifolds
7-1
7-1 Function Manifold Components
Function Manifold Components

Index Schematic
Description Function Torque
No. Item
1 Solenoid valve, 2 position 2 way AA Function enable valve 15-20 ft-lbs / 20-27
Nm
2 Proportional directional valve, 3 position AB Platform rotate left/right and jib 25-30 ft-lbs / 34-41
4 way boom up/down Nm
3 Proportional directional valve, 3 position AC Platform level up/down 25-30 ft-lbs / 34-41
4 way Nm
4 Relief valve, 3000 psi / 207 bar AD Platform level circuit 25-30 ft-lbs / 34-41
Nm
5 Solenoid valve, 3 position 4 way AE Primary boom up/down 20-25 ft-lbs / 27-34
Nm
6 Solenoid valve, 2 position 2 way AF Primary boom extend 30-35 ft-lbs / 41-47
Nm
7 Solenoid valve, 3 position 4 way AG Steer left/right 20-25 ft-lbs / 27-34
Nm
8 Relief valve, 2000 psi / 138 bar AH Primary boom extend 25-30 ft-lbs / 34-41
Nm
9 Flow regulator valve, 2 GPM / 7,6 L/min AI Steer left/right 25-30 ft-lbs / 34-41
Nm
10 Proportional solenoid valve, 2 position AJ Primary boom extend/retract 30-35 ft-lbs / 41-47
2 way Nm
11 Solenoid valve, 2 position 2 way AK Primary boom extend/retract 30-35 ft-lbs / 41-47
Nm
12 Check valve AL Primary boom extend/retract circuit 8-10 ft-lbs / 11-13
Nm
13 Proportional solenoid valve, 2 position AM Primary boom up/down 30-35 ft-lbs / 41-47
2 way Nm
14 Differential sensing valve AO Primary boom up/down 30-35 ft-lbs / 41-47
Nm
15 Check valve AP Platform level down 20-25 ft-lbs / 27-34
Nm
16 Piston, not shown AAD Platform level up/down
17 Shuttle valve AQ Platform level circuit 25-30 ft-lbs / 34-41
Nm
18 Check valve AR Platform level circuit 8-10 ft-lbs / 11-13
Nm
19 Check valve AS Primary boom up/down circuit 8-10 ft-lbs / 11-13
Nm
20 Check valve AT Turntable rotate circuit 8-10 ft-lbs / 11-13
Nm
56 S®-60 J Part No. 1285305GT

Manifolds
Part No. 1285305GT S®-60 J 57

Manifolds
Function Manifold Components, continued

Index Schematic
No. Item
21 Flow regulator valve, 0.1 GPM / 0,37 AU Differential sensing circuit 25-30 ft-lbs / 34-41
L\mon Nm
22 Relief valve, 3200 psi / 221 bar AV System relief 20-25 ft-lbs / 27-34
Nm
23 Differential sensing valve AW Turntable rotate 30-35 ft-lbs / 41-47
Nm
24 Check valve, 30 psi / 2,1 bar AX Platform rotate left/right and jib 20-25 ft-lbs / 27-34
boom up/down Nm
25 Check valve AY Platform level up 8-10 ft-lbs / 11-13
Nm
26 Check valve AZ Platform level up 20-25 ft-lbs / 27-34
Nm
27 Differential sensing valve AAA Primary boom extend/retract 50-55 ft-lbs / 68-74
Nm
28 Sequence valve, 850 psi / 59 bar AAB Oscillate circuit 30-35 ft-lbs / 41-47
Nm
29 Pressure reducing valve, 650 psi / AAC Oscillate circuit 30-35 ft-lbs / 41-47
45 bar Nm
30 Check valve AAE Steer circuit 8-10 ft-lbs / 11-13
Nm
31 Orifice, 0.031 in / 0.79 mm AAF Primary boom extend/retract circuit
32 Check valve AAG Oscillate circuit 8-10 ft-lbs / 11-13
Nm
33 Check valve, 30 psi / 2,1 bar AAH Platform level up/down 20-25 ft-lbs / 27-34
Nm
34 Check valve, 30 psi / 2,1 bar AAI Platform rotate right and jib boom 20-25 ft-lbs / 27-34
down Nm
35 Proportional solenoid valve, 2 position AAJ Turntable rotate 20-25 ft-lbs / 27-34
2 way Nm
36 Check valve, 30 psi / 2,1 bar AAK Platform rotate left and jib boom up 20-25 ft-lbs / 27-34
Nm
37 Solenoid valve, 3 position 4 way AAL Turntable rotate 25-30 ft-lbs / 34-41
Nm
58 S®-60 J Part No. 1285305GT

Manifolds
Part No. 1285305GT S®-60 J 59

Manifolds
7-2 Valve Adjustments - Function How to Adjust the Boom Extend

7-2 Valve Adjustments - Function Manifold How to Adjust the Boom Extend Relief Valve
Manifold Relief Valve

How to Adjust the System Relief stowed position.
Valve Note: Refer to Function Manifold Component list to
locate the boom extend relief valve.
stowed position. Note: Auxiliary power will be used to perform this
procedure. Do not start the engine.
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
1 Connect a 0 to 5000 psi / 0 to 350 bar
located next to the auxiliary pump.
pressure gauge to the ptest port on the
function manifold. 2 Simultaneously activate and hold the auxiliary
power button and the primary boom extend
2 Simultaneously activate and hold the auxiliary
button with the boom fully extended. Observe
power button and the primary boom retract
the pressure reading on the pressure gauge.
button with the primary boom fully retracted.
Refer to Specifications, Hydraulic
3 Observe the pressure reading on the pressure Specifications.
gauge. Refer to Specifications, Hydraulic
3 Locate the boom extend relief valve on the
Specifications.
function manifold. Use a wrench to hold the
4 Locate the system relief valve on the function relief valve and remove the cap.
manifold. Use a wrench to hold the relief valve
4 Adjust the internal hex socket. Turn it
and remove the cap.
clockwise to increase the pressure or
5 Adjust the internal hex socket. Turn it counterclockwise to decrease the pressure.
clockwise to increase the pressure or Install the relief valve cap.
counterclockwise to decrease the pressure.
Install the relief valve cap.. Tip-over hazard. Do not adjust
the relief valve higher than
Tip-over hazard. Do not adjust specified.
specified. 5 Repeat step2 to confirm relief valve pressure.
6 Remove the pressure gauge.
6 Repeat step 2 to confirm relief valve pressure.
7 Remove the pressure gauge.
60 S®-60 J Part No. 1285305GT

Manifolds
7-3
7-3 Jib Boom / Platform Rotate Manifold Components
Jib Boom / Platform Rotate Manifold Components

The jib boom / platform rotate manifold is mounted to the platform support.
Index Schematic
No. Item
1 Solenoid valve, 2 position 3 way FF Platform rotate/jib boom select 20-25 ft-lbs / 27-34 Nm
Part No. 1285305GT S®-60 J 61

Manifolds
7-4
7-4 Turntable Rotation Manifold Components
Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
No. Item
1 Counterbalance valve MM Turntable rotate right 35-40 ft-lbs / 47-54 Nm
2 Counterbalance valve NN Turntable rotate left 35-40 ft-lbs / 47-54 Nm
3 Shuttle valve, 2 position 3 way OO Turntable rotation brake release 10-13 ft-lbs / 14-18 Nm
4 Orifice, 0.030 inch / 0.76 mm PP Brake release circuit(located
inside port)
62 S®-60 J Part No. 1285305GT

Manifolds
7-5
7-5 Valve Adjustments - Oscillate Relief Valve How to Set Up the Oscillate Directional Valve
Valve Adjustments - Oscillate How to Set Up the Oscillate

Relief Valve Directional Valve Linkage
Note: Adjustment of the oscillate directional valve
How to Adjust the Oscillate Relief linkage is only necessary when the linkage or
valve has been replaced.
Valve Pressure
Note: Two people will be required to perform this
1 Connect a 0 to 1500 psi / 0 to 100 bar
procedure.
pressure gauge to the diagnostic nipple
located on the OSC-TEST port on the function Note: Perform this procedure on a firm, level
manifold. surface with the machine in the stowed position.
2 Start the engine from the Ground Control box 1 Use a "bubble type" level to verify the floor is
and press the enable button. completely level.
3 Continue pressing the enable button and
observe the pressure reading on the pressure
perform this procedure on a
gauge. Refer to Specifications, Hydraulic
level floor could compromise the
Specifications
stability of the machine resulting
4 Loosen the nut of the oscillate valve (BC) on in the machine tipping over.
the function manifold.
2 Remove the drive chassis cover and the non-
5 Adjust the hex screw. Turn it clockwise to steer axle covers.
increase the pressure or counterclockwise to
decrease the pressure. Tighten the nut. 3 Place a "bubble type" level across the drive
chassis non-steer end. Verify the drive
Tip-over hazard. Do not adjust chassis is completely level.
specified. 4 Remove the heim joint retaining fastener from
the axle.
6 Repeat step 3 to confirm the valve pressure. 5 To level the drive chassis, start the engine.
7 Turn the engine off, remove the pressure Press the function enable button and push up
gauge and assemble the directional valve or pull down on the threaded rod until the
linkage. machine is completely level.
6 Verify that the ground and drive chassis are
completely level.
Part No. 1285305GT S®-60 J 63

Manifolds
7 Adjust the heim joint until the hole lines up

with the retaining fastener hole in the axle.
8 Install the heim joint to the axle and tighten
the jam nut.
9 Verify the drive chassis is completely level.
10 Measure the distance between the drive
chassis and the non-steer axle on both sides
(from the inside of the drive chassis).
Note: If the distance is not within 0.15in / 3.8mm to
0.17in / 4.3mm and the adjustment to the linkage
was completed with the ground and drive chassis
level, repeat steps 6 through 11 OR consult Genie
Product Support.
64 S®-60 J Part No. 1285305GT

Part No. 1285305GT S®-60 J 65

Manifolds
7-6
7-6 Traction Manifold Components, 4WD
Traction Manifold Components, 4WD

The traction manifold is mounted inside the drive chassis at the non-steer end.
Index Schematic
No. Item
1 Flow divider/combiner valve DK Divides flow between diagonal pairs of 80-90 ft-lbs / 108-122
motors Nm
2 Check valve, 5 psi DC Prevents cavitation in LF motor 35-40 ft-lbs / 14-16
Nm
3 Orifice, 0.040 inch / 1 mm DA Prevents scrub at high steer angles by
allowing some bypass flow around the left
flow divider
4 Check valve, 5 psi DF Prevents cavitation in RF motor 35-40 ft-lbs / 14-16
Nm
5 Orifice, 0.040 inch / 1 mm DN Prevents scrub at high steer angles by
allowing some bypass flow around the
right flow divider
6 Relief valve, 280 psi / 19.3 bar DI Hot oil shuttle relief 35-40 ft-lbs / 14-16
Nm
7 Flow divider/combiner valve, DM Combines return flow from RF and RR 80-90 ft-lbs / 108-122
24 gpm motors Nm
8 Flow divider/combiner valve, DB Combines return flow from LF and RR 80-90 ft-lbs / 108-122
24 gpm motors Nm
9 Check valve, 5 psi DD Prevents cavitation in LF and RR 55-60 ft-lbs / 75-81
motors Nm
10 Check valve, 5 psi DH Prevents cavitation in RR motor 35-40 ft-lbs / 14-16

Nm
11 Check valve, 5 psi DE Prevents cavitation in LR motor 35-40 ft-lbs / 14-16
Nm
12 Check valve, 5 psi DG Prents cavitation in RF and LR motor 55-60 ft-lbs / 75-81
Nm
13 Shuttle valve, fixed DJ Directs oil from low pressure side to hot 55-60 ft-lbs / 75-81
oil relief valve Nm
14 Orifice, 0.040 inch / 1 mm DL Prevents scrub at high steer angles by
allowing some bypass flow around the
right flow divider
66 S®-60 J Part No. 1285305GT

Manifolds
Part No. 1285305GT S®-60 J 67

Manifolds
7-7
7-7 Valve Adjustments, 4WD Traction Manifold
8 Hold the charge pressure relief valve and

remove the cap (item DI).
Valve Adjustments, 4WD Traction
Manifold 9 Adjust the internal hex socket until the
pressure reading on the gauge is 30 psi /
2 bar less than the pressure reading on the
How to Adjust the Charge pump. Turn it clockwise to increase the
pressure or counterclockwise to decrease the
Pressure Relief Valve pressure. Install the valve cap.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure 10 Repeat steps 7 through 9 until the pressure
gauge to the test port on the drive pump. reading at the drive manifold is 30 psi / 2 bar
2 Hold the charge pressure relief valve and less than the pressure reading at the pump.
remove the cap (item DI). 11 Turn the engine off and remove the pressure
3 Turn the internal hex socket clockwise fully gauge.
until it stops. Install the cap.
4 Start the engine and move and hold the
function enable/rpm select toggle switch to
the high rpm (rabbit symbol) position. Note
the reading on the pressure gauge.
5 Turn the engine off.
6 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
7 Start the engine from the platform controls.
Press down the foot switch and slowly move
the drive control handle off center just until the
machine begins to move. Note the reading on
the pressure gauge. Turn the machine off.
68 S®-60 J Part No. 1285305GT

Manifolds
7-8
7-8 Brake/Two-Speed Manifold Components
Brake / Two Speed Manifold Components

The brake/two speed manifold is mounted inside the drive chassis.
Index Schematic
No. Item
1 Orifice, 0.025 inch / 0.63 mm BE Turntable rotation brake release
2 Check valve BF Brake release circuit 20-25 ft-lbs / 27-34 Nm
3 Solenoid Valve, 2 position 3 way BG Brake release 20-25 ft-lbs / 27-34 Nm
4 Solenoid Valve, 2 position 3 way BH Two-speed motor shift 20-25 ft-lbs / 27-34 Nm
Part No. 1285305GT S®-60 J 69

Manifolds
7-9
7-9 Generator Manifold Components
12 Kw Generator Manifold
The generator manifold is mounted on the turntable tray by the fuel tank.
Index Schematic
No. Item
1 Relief valve GA Generator relief valve 50 ft-lbs / 67 Nm
2 Solenoid Valve GB Charge pressure circuit 60-65 ft lbs / 81-88 Nm
3 Needle valve GD Charge pressure circuit 50 ft-lbs / 67 Nm
4 Differential sensing valve GC Pilot valve to diverter valve 50 ft-lbs / 67 Nm
5 Counterbalance valve GF Adds backpressure to generator
circuit
6 Check valve GE Prevents oil to generator 24-26 ft-lbs / 32.5-35.3 Nm
70 S®-60 J Part No. 1285305GT

Manifolds
7-10
7-10 Turntable Rotation Manifold Components
Turntable Rotation Manifold Components

The turntable rotation manifold is mounted to the turntable rotation motor.
Index Schematic
No. Item
1 Counterbalance valve MM Turntable rotate right 35-40 ft-lbs / 47-54 Nm
2 Counterbalance valve NN Turntable rotate left 35-40 ft-lbs / 47-54 Nm
3 Shuttle valve. 2 position, 3 way OO Turntable rotation brake release 10-13 ft-lbs / 14-18 Nm
4 Orifice, 0.030 inch / 0.76 mm PP Brake release circuit
Part No. 1285305GT S®-60 J 71

Manifolds
7-11 Valve Coil Resistance

7-11 Valve Coils
Valve Coils Specification

Note: The following coil resistance specifications
How to Test a Coil are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
A properly functioning coil provides an temperature, the coil resistance will typically
electromagnetic force which operates the solenoid increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil. Zero resistance or infinite from 68°F / 20°C.
resistance indicates the coil has failed.
Description Specification
Since coil resistance is sensitive to temperature,
Solenoid Valve, 10V DC (schematic items BE 5.5 to 7.5
resistance values outside specification can
and BF) Ω
produce erratic operation. When coil resistance
decreases below specification, amperage Solenoid Valve, 10V DC (schematic item GB) 4 to 6 Ω
increases. As resistance rises above specification, Solenoid Valve, 10V DC (schematic item FF) 5 to 7 Ω
voltage increases.
Proportional solenoid valve, 12V DC 7.6 to 9.6
While valves may operate when coil resistance is (schematic items AB, AC) Ω
outside specification, maintaining coils within Proportional solenoid valve, 12V DC 6.2 to 8.2
specification will help ensure proper valve function (schematic item AAJ) Ω
over a wide range of operating temperatures. Proportional solenoid valve, 12V DC 4.9 to 6.9
(schematic item AJ and AM) Ω
Solenoid Valve, 12V DC (schematic item AA, 7.6 to 9.6
Contact with electrically charged AE, AG and AAL) Ω
circuits could result in death or
serious injury. Remove all rings, Solenoid Valve, 12V DC (schematic item AF, 4.9 to 6.9
watches and other jewelry. AK) Ω
Note: If the machine has been in operation, allow

the coil to cool at least 3 hours before performing
this test.
1 Tag and disconnect the wiring from the coil to
be tested.
2 Test the coil resistance using a multimeter set
to resistance (W). Refer to the Valve Coil
Resistance Specification table.
Result: If the resistance is not within the
adjusted specification, plus or minus 10%,
replace the coil.
72 S®-60 J Part No. 1285305GT

Turntable Rotation Components

8-1
8-1 Turntable Rotation Assembly
3 Loosen the backlash pivot plate mounting

bolts and adjustment bolts. Pull the turntable
Turntable Rotation Assembly rotation assembly away from the turntable
bearing.
How to Remove the Turntable
Rotation Assembly
Specifications.
Note: Perform this procedure with the machine on
a firm and level surface.
1 Secure the turntable from rotating with the
turntable rotation lock pin. 1 backlash pivot plate
Note: The turntable rotation lock pin is located next 2 adjustment bolt with lock nut
to the boom rest pad. 3 backlash pivot plate mounting bolts
4 drive hub mounting bolts
from the turntable rotation drive motor. Cap 4 Attach a suitable lifting device to the lifting
the fittings on the drive motor. eyes on the drive hub assembly.
squirt or spray.
Part No. 1285305GT S®-60 J 73

How to Adjust the Turntable

How to Adjust the Turntable Rotation Gear Backlash
5 Remove the drive hub mounting bolts.

Carefully remove the drive hub assembly from
the machine.
Rotation Gear Backlash
The turntable rotation drive hub is mounted on an
Crushing hazard. The turntable adjustable plate that controls the gap between the
could rotate unexpectedly when rotation motor pinion gear and the turntable
the rotation drive hub assembly bearing ring gear.
is removed if the turntable is not
secured with the turntable Note: Perform this procedure with the boom
rotation lock pin. between the non-steer end tires and with the
machine on a firm and level surface.
Crushing hazard. The turntable
rotation assembly could become 1 Secure the turntable from rotating with the
unbalanced and fall when turntable rotation lock pin.
removed from the machine if not Note: The turntable rotation lock pin is located next
properly supported by the to the boom rest pad.
overhead crane.
2 Loosen the backlash pivot plate mounting
When installing the drive hub assembly: fasteners.
6 Install the drive hub. Torque the drive hub

mounting bolts to specification. Refer to
Specifications, Machine Torque
Specifications.
7 Adjust turntable rotation gear backlash. Refer
to Repair Procedure, How to Adjust the
Turntable Rotation Gear Backlash.
1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts
74 S®-60 J Part No. 1285305GT

8-2
8-2 Turntable Angle Sensor Replacement
3 Push the backlash pivot plate towards the

turntable as far as possible (this will push the
rotation gear into the turntable bearing ring
How to Replace the Turntable
gear). Angle Sensor
4 Loosen the lock nut on the adjustment bolt. 1 Push in the red Emergency Stop button to the
5 Turn the adjustment bolt clockwise until it off position at both the ground and platform
contacts the backlash pivot plate. controls and turn the key switch to the off
position.
6 Turn the adjustment bolt 1/2 turn
counterclockwise. Tighten the lock nut on the 2 Locate the turntable angle sensor behind the
adjustment bolt. function manifold.
7 Rotate the backlash pivot plate away from the 3 Tag and disconnect the electrical connector
turntable until it contacts the adjustment bolt. from the angle sensor.
Then torque the mounting fasteners on the 4 Remove the retaining fasteners. Remove the
backlash pivot plate to specification. Refer to angle sensor from the machine.
Specifications, Machine Torque
Specifications. 5 Install the new angle sensor onto the
machine.
8 Rotate the turntable through an entire
rotation. Check for tight spots that could 6 Securely connect the angle sensor harness to
cause binding. Readjust if necessary. the main harness.
7 Calibrate the angle sensor. Refer to Repair
Procedure, How to Calibrate the Turntable Tilt
Sensor.
Part No. 1285305GT S®-60 J 75

How to Calibrate the Turntable

How to Calibrate the Turntable Tilt Sensor
9 A graphic of the machine pitch will now be

shown on the display. By pressing the UP or
Tilt Sensor DOWN buttons, the graphic will change to
Note: Perform this procedure on a firm, level show the counterweight being uphill or
surface with the machine in the stowed position. downhill. Select the image that corresponds to
the current pitch of the machine and press
Note: A digital level will be required to perform this OK.
procedure.
1 Enter Service Mode. Refer to Repair
and navigate to the Sensor Calibrations
menu. Turntable Pitch
3 Navigate to the Chassis Tilt Sensor calibration 1 uphill
screen. 2 downhill
4 Select and start the calibration procedure. 10 The next calibration of the machine is the
5 If the machine is not sufficiently level, the machine roll. This is the angle of the machine
procedure will fail with the message that the from side to side.
chassis no not sufficiently level. Move the 11 Place the digital level onto the swing chassis
machine to a more level location if this occurs. bearing plate, which is located to the left of
6 The first calibration is machine pitch. This is the fuel tank. Orient the level along the roll
the pitch of the machine from the platform end axis of the machine.
to the counterweight end of the machine. 12 Enter the value as seen on the digital level
7 Place the digital level onto the swing chassis onto the ground control display. If the level is
bearing plate, which is located to the left of showing a negative value, enter it as a
the fuel tank. Orient the level along the pitch positive number. Press OK when the value on
axis of the machine. the ground control display matches the value
of the digital level sensor (excluding the
8 Enter the value as seen on the digital level plus/minus sign).
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).
76 S®-60 J Part No. 1285305GT

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 Roll
1 uphill
2 downhill
14 The calibration is now complete.

15 Exit the Service Mode.
Part No. 1285305GT S®-60 J 77

Axle Components
Axle Components
9-1
9-1 Oscillating Axle Cylinders

to the barrel end of the oscillating cylinder.
Oscillating Axle Cylinders
The oscillate system is designed so that all four barrel-end pivot pin. Use a soft metal drift to
tires maintain firm contact to the ground on unlevel remove the pin.
terrain improving traction and machine stability.
6 Remove the cylinder from the machine.
The oscillating axle cylinders extend and retract
between the drive chassis and the oscillating axle. Crushing hazard. The oscillate
The cylinders are equipped with counterbalance cylinder may become
valves to prevent movement in the event of a unbalanced and fall when
hydraulic line failure. The valves are not removed from the machine if not
adjustable. properly attached to the
overhead crane.
How to Remove the Oscillate
Cylinder
Note: Perform this procedure on a firm, level
Specifications.
1 Rotate the turntable until the boom is between
the steer tires or tracks.
2 Tag, disconnect and plug the oscillating axle
the cylinder.
squirt or spray.

rod-end pivot pin. Use a soft metal drift to
remove the pin.
78 S®-60 J Part No. 1285305GT

Fault Codes
Before Troubleshooting:
Section 4 Fault Codes
Introduction
 Read, understand and obey the safety rules

 Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:  Read each appropriate fault code thoroughly.
 Troubleshooting and repair procedures shall Attempting short cuts may produce hazardous
be completed by a person trained and conditions.
qualified on the repair of this machine  Be aware of the following hazards and follow
 Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine. Electrocution/burn hazard.
 Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
 Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
• Machine parked on a firm, level surface
• Key switch in the off position with the key
removed
• The red Emergency Stop button in the off
position at both the ground and platform
controls
• Wheels chocked
• All external AC power supply disconnected
from the machine
• Boom in the stowed position
• Turntable secured with the turntable rotation
lock
• Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
Part No. 1285305GT S®-60 J 79

Control System Fault Codes

Control System
How to Retrieve Control System Fault Codes
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.
80 S®-60 J Part No. 1285305GT


ID Component ID Name Cause Effect Solution

1 Engine Can 13 Not Engine CANBUS Disable engine start *Verify with a voltmeter that CAN+
Bus detected CAN+ or CAN- for tier 4F engines and CAN- lines are not shorted.*
shorted to supply. Measure the resistance between
D228CAN+ (YL, TCON J9-3) and
D228CAN- (GR, TCON J9-4); should
be between 55 and 65 ohms.
* D228CAN+ (YL, TCON J9-3) should
be between 1V and 5V.
* D228CAN- (GR, TCON J9-4) should
be between 1V and 5V. Remove
short(s) and cycle power.
7 Engine 21 Fault The engine has Machine will function * Check the engine fault codes with
Warning triggered the as normal. an engine diagnostic tool.
Engine Warning
Lamp condition.
8 Engine Stop 21 Fault The engine has Control system will * Check the engine fault codes with
triggered the not allow engine an engine diagnostic tool.
Engine Stop Lamp restart until power Note: The control system shuts off the
condition. cycle. Engine may engine immediately upon receiving
stop itself, depending this fault from the engine.
on the engine option.
10 Ground 27 Active at Engine start button Engine start is Release engine start button, check
Controls startup held at startup. disabled DISCON overlay and ribbon cable if
Engine Start issue persists.
Switch
11 Platform 27 Active at Platform controls Engine start switch *Verify with a voltmeter that the
Controls startup engine start switch will not operate. Engine Start Toggle Switch (TS2) is
Engine Start active at startup. operating properly.
Switch * C33STR (BK, PCON J16-3) should
be 0 V with the switch OFF and 12 V
with the switch ON.
*Cycle power to allow the machine to
re-test the fault.
12 Machine 13 Not Machine CANBUS Machine will not be *Verify with a voltmeter that CAN+
CAN Bus detected CAN+ or CAN- functional. and CAN- lines are not shorted.
shorted to supply *Measure the resistance between
D82CAN+ (YL, TCON J5-3) and
D81CAN- (GR, TCON J5-4); should
be between 55 and 65 ohms.
*D81CAN+ (YL, TCON J5-3) should
*D81CAN- (GR, TCON J5-4) should

*Remove short(s) and cycle power.
Part No. 1285305GT S®-60 J 81


13 Jib 27 Active Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib
Up/Down at was detected as functions will not Up/Down Toggle Switch (TS8) is
Switch startup HIGH at start-up. operate. operating properly.
* C43JU (BL, PCON J17-6) should be
0 V with the switch OFF and 12 V with
the switch held in the UP position.
* C44JD (BL/BK, PCON J17-8)
should be 0 V with the switch OFF
and 12 V with the switch held in the
DOWN position.
re-test the fault.
15 Foot Switch 27 Active Foot switch input Machine will not be * Release foot switch and cycle
at was detected as functional. power.
startup HIGH at start-up, or * If problem persists, with a voltmeter
the footswitch was verify that C24FS (WH, PCON J12-2)
held for too long is LOW when foot switch is released
and caused the and 12 V when held down.
footswitch timer to
elapse.
28 Timeout Foot switch Machine will not be
depressed too long functional.
without action
17 Aux Pump 11 Shorted TCON detected that Machine will not be *Check C27AUX (RD, TCON J3-3)
Coil to C27AUX circuit is functional. wiring. *With a voltmeter verify that
supply shorted to 12V. C27AUX (RD, TCON J3-3) is 0 V
voltage when the Auxiliary Power toggle
switch is OFF and 12 V when switch
is ON.
*Verify the terminals of the APU
solenoid have a resistance greater
than 5 ohms. If not, replace the
solenoid.
19 Aux Enable 27 Active Aux button held at Machine will not be Release Aux button, check DISCON
Switch at startup. functional. overlay and ribbon cable if issue
startup persists.
20 Pri Boom 11 Shorted Circuit C163PER is Boom Extend and * Leave joystick in neutral position
Ext / Ret to above 4.5 V. Retract functions will and cycle power.
Joystick supply not operate. * If fault persists, with a voltmeter
voltage check that C163PER (BL/WH, PCON
27 Active Circuit C163PER J18-4) is at 2. 5V +/- 0.2 V at startup
at voltage was not and does not go above 4.5 V or below
startup within the startup 0.5 V when fully stroked in each
voltage range of 2.5 direction.
V +/- 0.2 V. * Replace joystick if voltage check
fails.
82 S®-60 J Part No. 1285305GT


21 Pri Boom 11 Shorted Circuit C164PUD is Boom Up and Down * Leave joystick in neutral position
Up / Down to above 4.5 V. functions will not and cycle power.
Joystick supply operate. * If fault persists, with a voltmeter
voltage check that C164PUD (RD/WH, PCON
28 Active Circuit C164PUD J18-3) is at 2. 5V +/- 0.2 V at startup
fails.
22 Pri Boom 11 Shorted TCON detected that Boom Up function will * With a voltmeter, measure Y22.
Up coil to C1PBU circuit is not operate. Boom Proper resistance should be between
supply shorted to 12 V. Down will also not 5 - 60 ohms. Replace Y22 if
voltage operate if short is to resistance is outside of those values.
12 V. * Verify wiring for C1PBU (RD, TCON
J4-10) and check for open or short
circuits.
23 Pri Boom 11 Shorted TCON detected that Boom Up and Down * With a voltmeter, measure Y21.
Down Coil to C2PBD circuit is functions will not Proper resistance should be between
supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y21 if
voltage GND. resistance is outside of those values.
* Verify wiring for C2PBD (RD/BK,
TCON J4-9) and check for open or
short circuits.
* Verify resistance between Recovery
Module pins J37-2 and J37-11 is zero
ohms.
Part No. 1285305GT S®-60 J 83


24 Pri Boom 13 Not No CAN messages Machine limited to * Verify sensor power P85PWR (GR,
Angle detected have been recovery functions TCON J6-7) is at 12 V while the
received by the system is running.
TCON from the * Verify the sensor is receiving power.
Angle Sensor. Unplug the sensor and verify 12 V
across pins 2 (+) and 1 (-) on the
harness connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure
resistance across harness connector
pins 3 and 4. If resistance is not
between 55 and 65 ohms, check
CAN wire harnesses.
* Replace sensor if necessary.
14 Cross Boom stowed *Verify that with the boom stowed
check crosscheck switch C68LS (BL, TCON J7-3) is 12V and
failed value not as that the boom is making contact with
expected 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.
17 Not Sensor has been Run the boom angle calibration
calibrated replaced and process and verify fault is no longer
requires active.
calibration, or
calibration in
memory has been
erased.
19 Value out Min or max boom Machine limited to * Calibrate boom angle snesor.
of angle out of recovery functions * Check boom angle sensor mount,
expected expected range. ensure all fasteners are tightened to
range spec.
* Replace sensor if issue persists.
25 Cable 21 Fault Boom cable Boom Up and * Return boom to stowed position as
tension tension limit switch Extend functions will quickly as possible.
LSB2S indicates not operate. * Verify both boom cables are
that the tension is properly tensioned and that LST3S is
loose on the boom properly centered in the bracket.
cables. * Verify LSB2S (C59CNK, BL/WH,
TCON J7-5) operates properly.
Signal should normally by 12 V. If
cable tension is loose, signal should
be 0 V.
84 S®-60 J Part No. 1285305GT


26 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y26.
Ext Coil to C7PBE circuit is Retract functions will Proper resistance should be between
supply shorted to 12 V or not operate. 5 - 60 ohms. Replace Y26 if
* Verify wiring for C7PBE (BK, TCON
circuits.
27 Pri Boom 11 Shorted TCON detected that Boom Extend and * With a voltmeter, measure Y25.
Ret Coil to C8PBR circuit is Retract functions will Proper resistance should be between
supply shorted to 12 V or not operate. 5 - 60 ohms. Replace Y25 if
* Verify wiring for C8PBR (BK/WH,
short circuits.
ohms.
35 Ground 27 Active Buttons were held The function *Release the ground control buttons
Control at at system start, or associated with the and cycle power.
Button startup are shorted on the stuck button will not *If problem persists, open ground
ground control operate. control box and open the Display
panel. Controller access door, being careful
to keep water out. Verify the ribbon
cables are properly seated and dry.
*Re-seat and/or replace ribbon cables
if necessary.
*Replace ground control overlay.
36 Jib Up Coil 11 Shorted PCON detected that Jip Up function will * With a voltmeter, measure Y68.
to V43JU circuit is not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y68 if
* Verify wiring for V43JU (BL, PCON
circuits.
37 Jib Down 11 Shorted PCON detected that Jib Down function will * With a voltmeter, measure Y69.
Coil to V44JD circuit is not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y69 if
* Verify wiring for V44JD (BL/BK,
PCON J12-9) and check for open or
short circuits.
Part No. 1285305GT S®-60 J 85


40 Jib Select 11 Shorted PCON detected Jib and platform *With a voltmeter, measure Y18.
Coil to V18PRR is short to functions will not Proper resistance should be between
supply supply operate 5 - 60 ohms. Replace Y18 if
voltage resistance is outside of those values.
*Verify wiring for V18PRR (GR/BK,
PCON J12-4) and check for short
circuits.
41 Turntable 11 Shorted Circuit C165TTR is Turntable Rotate * Leave joystick in neutral position
Rotate to above 4.5 V. functions will not and cycle power.
Joystick supply operate. * If fault persists, with a voltmeter
voltage check that C165TTR (WH/RD, PCON
27 Active Circuit C165TTR J18-2) is at 2. 5V +/- 0.2 V at startup
fails.
42 Turntable 11 Shorted TCON detected that Turntable Rotate * With a voltmeter, measure Y24.
Rotate CW to C4TRL circuit is functions will not Proper resistance should be between
Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y24 if
* Verify wiring for C4TRL (WH, TCON
circuits.
43 Turntable 11 Shorted TCON detected that Turntable Rotate * With a voltmeter, measure Y23.
Rotate to C5TRR circuit is functions will not Proper resistance should be between
CCW Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y23 if
* Verify wiring for C5TRR (WH/BK,
short circuits.
44 Drive 27 Active Toggle switch input Drive Enable switch *Verify with a voltmeter that the Drive
Enable at was detected as will not operate, Enable Toggle Switch (TS15) is
Toggle startup HIGH at start-up. possibly preventing operating properly.
Switch drive while the * C143DEL (BL/RD, PCON J16-7)
turntable is rotated. should be 0 V with the switch OFF
ON position.
re-test the fault.
86 S®-60 J Part No. 1285305GT


45 Platform 27 Active Toggle switch input Platform Level Up or *Verify with a voltmeter that the
Level at was detected as Down functions may Platform Level Up/Down Toggle
Toggle startup HIGH at start-up. not operate, Switch (TS9) is operating properly.
Switch depending on which * C14PLU (OR, PCON J17-2) should
direction the switch be 0 V with the switch OFF and 12 V
fault occurred. with the switch held in the UP
position.
* C15PLD (OR/BK, PCON J17-3)
DOWN position.
re-test the fault.
46 Platform 11 Shorted PCON detected that Platform Rotate CW * With a voltmeter, measure Y70.
Rotate CW to V17PRL circuit is function will not Proper resistance should be between
Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y70 if
* Verify wiring for V17PRL (GR,
short circuits.
47 Platform 11 Shorted PCON detected that Platform Rotate CCW * With a voltmeter, measure Y71.
Rotate to V18PRR circuit is function will not Proper resistance should be between
CCW Coil supply shorted to 12 V or operate. 5 - 60 ohms. Replace Y71 if
* Verify wiring for V18PRR (GR/BK,
short circuits.
51 Drive 11 Shorted Circuit C160DRV is Drive Forward and * Leave joystick in neutral position
Joystick to above 4.5 V. Reverse functions and cycle power.
supply will not operate. * If fault persists, with a voltmeter
voltage check that C160DRV (WH/RD, PCON
27 Active Circuit C160DRV J18-10) is at 2. 5V +/- 0.2 V at startup
fails.
Part No. 1285305GT S®-60 J 87


52 Drive 11 Shorted TCON detected Drive Forward, Brake * With a voltmeter, measure Y6.
Forward to that C30FWD Release and possibly Proper resistance should be between
Pump Coil supply circuit is shorted to Engine will not 5 - 60 ohms. Replace Y6 if resistance
voltage 12 V or GND. operate. is outside of those values.
* Verify wiring for C30FWD (WH,
short circuits.
53 Drive 11 Shorted TCON detected Drive Reverse, Brake * With a voltmeter, measure Y5.
Reverse to that C31REV Release and possibly Proper resistance should be between
Pump Coil supply circuit is shorted to Engine will not 5 - 60 ohms. Replace Y5 if resistance
voltage 12 V or GND. operate. is outside of those values.
* Verify wiring for C31REV (WH/BK,
short circuits.
54 Brake 11 Shorted TCON detected Machine will not be * With a voltmeter, measure Y2.
Release to that C32BRK functional. Proper resistance should be between
Coil supply circuit is shorted to 5 - 60 ohms. Replace Y2 if resistance
voltage 12 V or GND. is outside of those values.
* Verify wiring for C32BRK (WH/RD,
short circuits.
55 High Drive 11 Shorted TCON detected Drive functions will * With a voltmeter, measure Y27.
Speed Coil to that C29MS circuit not operate. Proper resistance should be between
supply is shorted to 12 V 5 - 60 ohms. Replace Y27 if
voltage or GND. resistance is outside of those values.
* Verify wiring for C29MS (RD/WH,
short circuits.
56 Telematics 13 Not M7 telematics Information only Cycle power. If fault persists, check
Device detected device not telematics ready connector wiring. If
detected. there are no wiring issues replace M7.
88 S®-60 J Part No. 1285305GT


61 Steer 11 Shorted Circuit C159STD or Drive and steer * Leave joystick in neutral position
Joystick to C159STA is above functions will not and cycle power.
supply 4.5 V. operate. * If fault persists, identify which circuit
voltage is the steer circuit. Check C159STA
27 Active Circuit C159STD or (BL/WH, PCON J18-11) for a joystick
at C159STA voltage steer option. Check C159STD
startup was not within the (BL/RD, PCON J18-9) for the rocker
startup voltage joystick steer option. With a voltmeter
range of 2.5 V +/- check that the circuit is at 2. 5V +/-
0.2 V. 0.2 V at startup and does not go
above 4.5 V or below 0.5 V when fully
stroked in each direction.
* Replace joystick if voltage check
fails.
62 Prox 27 Active Toggle switch input The Jib Up or Down *Verify with a voltmeter that the Jib
Override at was detected as functions will not Up/Down Toggle Switch (TS8) is
Togggle startup HIGH at start-up. operate. operating properly.
Switch * C43JU (BL, PCON J17-6) should be
0 V with the switch OFF and 12 V with
the switch held in the UP position.
* C44JD (BL/BK, PCON J17-8)
DOWN position.
Cycle power to allow the machine to
re-test the fault.
68 Ground 27 Active Button was held at The function * Release the ground control buttons
Function at system start, or is associated with the and cycle power. * If problem persists,
Enable startup shorted on the stuck button will not open ground control box and open the
Button ground control operate. Display Controller access door, being
panel. careful to keep water out. Verify the
ribbon cables are properly seated and
dry.
* Re-seat and/or replace ribbon
cables if necessary.
* Replace ground control overlay.
Part No. 1285305GT S®-60 J 89


69 AC 11 Shorted TCON detected that Generator function * With a voltmeter, measure Y29.
Generator to C45GEN circuit is will not operate. Proper resistance should be between
Output supply shorted to 12 V. 5 - 60 ohms. Replace Y29 if
voltage resistance is outside of those values.
* Verify wiring for C45GEN (GR/WH,
short circuits.
72 Lift Guard 14 Cross PCON detected that Boom Up and Extend * Using a voltmeter, verify that the
Contact check inputs from SW30 functions will not voltage on C248CA (OR/BK, PCON
Alarm failed (contact alarm operate. J12-1) is always the opposite of
Switch proximity sensor) C247CA (OR, PCON J12-11).
are the same * Check wiring for open or short
voltage. circuits.
* Verify SW30 is receiving power and
ground by verifying 12 V across
C31 pins 1 and 3.
* Replace SW30 if necessary.
21 Fault
73 Engine Oil 12 Sensor Engine oil pressure Engine will not * With a voltmeter, check that
Pressure value sender is shorted to operate. C25PSR ( WH/BK, TCON J6P9) is
too 12V. not shorted to 12V and voltage is
high between 0.1-11.5V
* Replace sender if necessary
24 Too low The engine oil Engine may not * Stop engine as soon as possible.
pressure is attempt to start until * Verify the engine oil level.
measured as too system power cycle. * Verify the engine oil pump.
low, potentially Engine may be
damaging the turned off by control * Power on the machine and start the
engine. system immediately. 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).
90 S®-60 J Part No. 1285305GT


74 Engine 15 Sensor Engine Engine will not * With a voltmeter, check that
Temperature value too temperature operate C26TSR ( WH/RD, TCON J6P8) is
low sensor is shorted not shorted to ground and voltage is
to ground between 0.1-11.5V
* Replace sensor if necessary
23 Too high The engine coolant Engine will not * Stop engine as soon as possible.
temperature is restart until machine * Verify the engine coolant level.
measured as too power is cycled. * Verify the engine coolant/water
high, potentially Engine may stop pump.
damaging the itself, depending on
engine. the engine option. * 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 TCON has not Boom Up, Extend * Verify sensor power P26PWR (BK,
Load Sensor detected detected the and Turntable Rotate PCON J13-9) is at 12 V while the
DISCON on the functions will not system is running.
communications operate. * Verify 12 V across pins on C27-2
bus. (+) and C27-3 (-) on the harness
connector.
* Measure resistance across
C27 pins 4 and 5 on the harness
connector. If resistance is not
CAN wire harnesses.
14 Cross TCON has not Boom Up, Extend * Check that the load sensor is
check detected the and Turntable Rotate mounted correctly and all fasteners
failed DISCON on the functions will not are tightened to spec.
communications operate. * Calibrate load sensor.
bus. * Replace sensor if issue persists.
15 Value to Platform load Machine limited to * Make sure the platform is not
low sensor out of recovery functions touching the ground or an overhead
calibration obstruction. Cycle power and check
that fault is no longer reported.
* Perform the platform overload
calibration procedure.
17 Not Platform load * Calibrate load sensor.
calibrated sensor out of * Replace sensor if issue persists.
calibration
21 Fault Platform load * Check that the load sensor is
sensor out of mounted correctly and all fasteners
calibration are tightened to spec.
* Calibrate load sensor.
* Replace sensor if issue persists.
Part No. 1285305GT S®-60 J 91


78 Platform 13 Not TCON has not Controls from the * Verify PCON is receiving power.
Controller detected detected the platform will not Check for 12 V on J15-2 (+) and J15-
(PCON) PCON primary operate. 1 (-).
processor on the * Verify PCON is receiving ESTOP
communications signals. With ground ESTOP pulled
bus. out and key switch set to Platform,
verify 12 V is reaching PCON J15-10.
* Verify CAN bus is functional. Pull
out connector J15 from the PCON
and with a voltmeter set to resistance
verify that pins 3 and 4 on the
harness connector measure between
110 and 130 Ohms. Check wiring and
boom cable for open or short circuits
if resistance check fails.
* Replace PCON if necessary.
29 Software PCON software is Machine limited to Download latest software from
version out of date. recovery functions firmware site and update machine.
mismatch
79 Display 13 Not TCON has not Controls from the * Verify DISCON is operating by
Controller detected detected the ground will not checking that the display on the front
(DISCON) DISCON on the operate. is operating properly.
communications * If there is no display, try to power up
bus. the DISCON by setting the key switch
to Ground, pull out the ground
ESTOP and press the Ground
Function Enable button. The display
should start.
* If there is still no display, check
DISCON power on J10 pins 2 (+) and
1 (-).
* If DISCON operates but fault
persists, check the CAN bus wiring.
Disconnect J10 and with a voltmeter
set to resistance verify that the
resistance between pins 3 and 4 on
the harness connector are between
55 and 65 ohms. Check CAN wiring if
resistance check fails.
* Replace DISCON if required.
29 Software DISCON software Machine limited to Download latest software from
version is out of date. recovery functions firmware site and update machine.
mismatch
92 S®-60 J Part No. 1285305GT


80 Turntable 13 Not The DISCON has Machine limited to * Verify TCON is receiving power.
Controller detected not detected the recovery functions Check for 12 V on J5-2 (+) and J5-1
(TCON) TCON on the CAN (-).
bus. * Verify TCON is receiving ESTOP
signals. With ground ESTOP pulled
out and key switch set to Ground,
verify 12 V is reaching TCON J5-
9 and J5-12.
* Verify CAN bus is functional. Pull
out connector J5 from the TCON and
with a voltmeter set to resistance
verify that pins 3 and 4 on the
harness connector measure between
55 and 65 Ohms. Check wiring and
boom cable for open or short circuits
if resistance check fails.
* Replace TCON if necessary.
29 Software TCON software is Download latest software from
version out of date firmware site and update machine.
mismatch
82 Overload 21 Recovery This is a flag that Advisory condition. Power up the machine in service
indicates that the Machine is fully mode and clear the flag in the service
platform was functional. menu on the ground control display.
overloaded and
that auxiliary
function enable
was used while
overloaded.
83 Disabled 21 By owner The telematics Machine will not be Call machine owner to re-enable
module has locked functional, or have machine functions.
out machine limited functionality,
operation. depending on the
telematics option.
84 Chassis 13 Not The tilt sensor Boom Up, Extend * Verify S8O is receiving power.
Angle detected S80 has not been and Drive functions Disconnect sensor connector and
detected on the will not operate. verify harness connector pins 1 and
CAN bus. 2 measure 12 V.
* Verify CAN bus wiring. With a
voltmeter set to resistance, check the
resistance between pins 3 and 4 on
the harness connector (not the
sensor's integrated connector).
Resistance should be between
55 and 65 ohms. Check CAN wiring if
resistance check fails.
* Replace sensor if required.
17 Not Tilt sensor not Machine limited to Calibrate tilt sensor.
calibrated calibrated recovery functions
Part No. 1285305GT S®-60 J 93


85 Chassis 13 Not Tilt sensor not Machine limited to Calibrate tilt sensor.
Angle detected calibrated recovery functions
Safety
88 Function 11 Shorted TCON detected Only Auxiliary Power * With a voltmeter, measure Y74.
Enable Coil to that C155PCE is available. Proper resistance should be between
supply circuit is shorted to 5 - 60 ohms. Replace Y74 if
voltage 12 V or GND. resistance is outside of those values.
* Verify wiring for C155PCE (OR/RD,
short circuits.
89 Fuel Level 12 Value to Fuel sensor Information only With a voltmeter, check voltage on
Sensor high shorted to B+ C65FLI (BL/WH, TCON J7-11). The
voltage should be between 1V and
5V. Check for shorts to B+.
15 Value to Fuel sensor With a voltmeter, check voltage on
low shorted to GND C65FLI (BL/WH, TCON J7-11). The
voltage should be between 1V and
5V. Check for shorts to ground.
92 Turntable 11 Shorted TCON detected Turntable Rotate * With a voltmeter, measure Y13.
Rotate Flow to that C6TRF circuit functions will not Proper resistance should be between
Coil supply is shorted to 12 V operate. 5 - 60 ohms. Replace Y13 if
voltage or GND. resistance is outside of those values.
* Verify wiring for C6TRF (WH/RD,
short circuits.
94 S®-60 J Part No. 1285305GT


94 Primary 13 Not No CAN messages Boom Up, Extend * Verify sensor power P85PWR (GR,
Boom detected have been and Turntable Rotate TCON J6-7) is at 12 V while the
Length received by the functions will not system is running.
TCON from the operate. * Verify the sensor is receiving power.
Length Sensor. Unplug the sensor and verify 12 V
across pins 1 (+) and 2 (-) on the
harness connector.
* Verify the CAN bus wiring. With the
sensor still unplugged, measure
resistance across harness connector
pins 3 and 4. If resistance is not
CAN wire harnesses.
14 Cross The two internal Machine limited to * Ensure that the boom angle sensor
check sensing channels recovery functions cord is hooked up to the bracket on
failed inside the Length the boom and that the cord extends
Sensor have and retracts smoothly.
registered a * Calibrate boom length sensor.
significant * Replace sensor if necessary.
difference.
17 Not Boom length Calibrate boom length sensor.
calibrated sensor not
calibrated.
19 Value out Min or max length * Verify that with the boom retracted
of out of expected C24LS (OR/RD TCON J7-4) is 12V
expected range. and that the boom is making contact
range 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.
99 Primary 11 Shorted TCON detected Boom Extend and * With a voltmeter, measure Y15.
Boom to supply that C9PEF circuit Retract functions will Proper resistance should be between
Extend / voltage is shorted to 12 V not operate. 5 - 60 ohms. Replace Y15 if
Retract or GND. resistance is outside of those values.
Flow Coil * Verify wiring for C9PEF (BK/RD,
short circuits.
ohms.
Part No. 1285305GT S®-60 J 95


100 Platform 11 Shorted PCON detected Platform Level Up * With a voltmeter, measure Y20. Proper
Level Up Coil to supply that V14PLU circuit and possibly Level resistance should be between 5 -
voltage is shorted to 12 V Down functions will 60 ohms. Replace Y20 if resistance is
outside of those values.
or GND. not operate.
* Verify wiring for V14PLU (OR, PCON
circuits.
101 Platform 11 Shorted PCON detected Platform Level * With a voltmeter, measure Y19. Proper
Level Down to supply that V15PLD circuit Down and possibly resistance should be between 5 -
Coil voltage is shorted to 12 V Level Up functions 60 ohms. Replace Y19 if resistance is
outside of those values.
or GND. will not operate.
* Verify wiring for V15PLD (OR/BK,
short circuits.
110 Platform 27 Active at Toggle switch input Platform Rotate Left *Verify with a voltmeter that the Platform
Rotate startup was detected as or Right will not Rotate Toggle Switch (TS7) is operating
Toggle HIGH at start-up. operate, depending properly.
Switch @PC on which side of the * C17PRL (GR, PCON J16-4) and
switch was faulted. C18PRR (GR/BK, PCON J17-5) should
be 12 V when the switch is pressed in
their respective directions.
*Cycle power to allow the machine to re-
test the fault.
116 Model 31 Setup Machine is not fully Machine will not Navigate to Settings -> Model
Configuration invalid. configured or set to operate. Configuration and ensure model,
wrong model. engine, tires, and region are set and
correct.
141 Boom 10 Safety The system has All functions will not Use Auxiliary Power and the boom
Envelope determined that operate except for retract and/or down functions to
Exceeded the platform the recovery bring the platform back within the
position has procedure. operational envelope.
exceeded the
safety envelope
boundary.
150 Sensor 11 Shorted PCON detected Boom Up and * Turn on machine and verify sensor
Power to supply that P26PWR Extend functions power P26PWR (BK, PCON J13-9)
P26PWR voltage circuit is shorted to will not operate. is at 12 V.
12 V or GND. * Inspect wiring for open or shorts
circuits.
152 Primary 11 Shorted TCON detected Boom Up and Down * With a voltmeter, measure Y12.
Boom to supply that C3PBF circuit functions will not Proper resistance should be
Up/Down voltage is shorted to 12 V operate. between 5 - 60 ohms. Replace
Flow Coil or GND. Y12 if resistance is outside of those
values.
* Verify wiring for C3PBF (RD/WH,
short circuits.
* Verify resistance between
Recovery Module pins J37-3 and
J37-10 is zero ohms.
96 S®-60 J Part No. 1285305GT

ID Component ID Cause Effect Solution
160 LF Steer (L 11 Shorted TCON detected that Steer Left function * With a voltmeter, measure Y3.
or R) Coil to C37STL circuit is will not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y3 if resistance
voltage GND. is outside of those values.
* Verify wiring for C37STL (BL/BK,
short circuits.
161 RF Steer (L 11 Shorted TCON detected that Steer Right function * With a voltmeter, measure Y4.
or R) Coil to C36STR circuit is will not operate. Proper resistance should be between
supply shorted to 12 V or 5 - 60 ohms. Replace Y4 if resistance
voltage GND. is outside of those values.
* Verify wiring for C36STR (BL,
short circuits.
185 ESTOP 11 Shorted TCON detected that ESTOP circuit * Using a voltmeter and with the
Source to ESTOP 1 is at 12 V cannot complete, system turned OFF, check the
supply but ESTOP 3 is at 0 preventing machine resistance between TCON J5 pins
voltage V. functions. 9 and 10. Replace TCON if
resistance is more than 5 ohms.
* Check P79PWR (BK, TCON J5-9)
and P23PWR (RD, TCON J5-10) for
open or short circuits.
186 ESTOP 11 Shorted Mismatched signals ESTOP circuit * Inspect PCON J15 pins 11 and
Return to detected on ESTOP cannot complete, 12 for open or short circuits. Using a
supply Return circuits. preventing machine voltmeter, set to diode test mode and
voltage Either: functions. make sure the diode tests ok with the
* PCON ESTOP anode at pin 12 and cathode at pin
2 and ESTOP 4 do 11. If test fails, replace the PCON.
not match, or * Inspect TCON J5 pins 11 and 12 for
* TCON ESTOP open or short circuits. Using a
2 and ESTOP 4 do voltmeter, set to diode test mode and
not match. make sure the diode tests ok with the
anode at pin 12 and cathode at pin
11. If test fails, replace the PCON.
* Check P23RET (BK) for shorts to
ground or power.
Part No. 1285305GT S®-60 J 97

Engine Fault Codes
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.
98 S®-60 J Part No. 1285305GT

Kubota D1803-CR-TIE4 Engine Fault Codes

SPN = Suspect Parameter Number SPN FMI Description

FMI = Failure Mode Identifier
171 3 Intake Air Temperature Built-in MAF
SPN FMI Description Sensor Abnormality
29 3 Accelerator Position Sensor 2 171 4
Abnormality
172 3 Intake Air Temperature Error
29 4
172 4
91 2 Accelerator Position Sensor
190 0 Engine Overrun
Correlation Errorl
628 2 ECU Flash ROM and CPU
91 3 Accelerator Position Sensor 1
Abnormality
Abnormality
633 7 Pressure Limiter Emergency Open
91 4
636 2 Crankshaft Position Sensor (NE
100 1 Oil Pressure Error
Sensor) Abnormality
102 3 Boost Pressure Sensor Abnormality
636 8
102 4
636 7 NE-G Phase Shift
108 3 Barometric Pressure Sensor Error
651 3
108 4
652 3 Open Circuit of Harness / Coil
110 0 Engine Overheat
653 3
110 3 Coolant Temperature Sensor
654 3
Abnormality
676 0 Glow Plug Abnormality
110 4
676 5
132 1 Intake Air Volume Low
677 4 Ground Short of Starter Relay Driving
132 3 MAF Sensor Abnormality
Circuit
132 4
679 7 Pressure Limiter Abnormality
132 15 Boost Pressure Low
679 16
157 0 High Rail Pressure
723 2 Camshaft Position Sensor (G Sensor)
157 3 Rail Pressure Sensor Abnormality Abnormality
157 4 723 8
168 3 Battery Voltage Abnormality
168 4
Part No. 1285305GT S®-60 J 99


3509 3 Sensor Supply Voltage 1 Abnormality
SPN FMI Description
3509 4
3510 3 Sensor Supply Voltage 2 Abnormality
Abnormality
3510 4
1077 12 Internal Injector Drive Circuit
Abnormality 3511 3 Sensor Supply Voltage 3 Abnormality
1239 1 Fuel Leak in High Pressured Fuel 3511 4
Sysytem
3701 0 Excessive PM5
1347 3
1347 4 SCV (MPROP) Drive System
Abnormality
4765 0 Exhaust Gas Temperature Sensor 0:
1347 5
Emergency High
1347 7 SCV (MPROP) Stuck
4765 3 Exhaust Gas Temperature Sensor 0
1485 2 Main Relay Locked in Closed Position (T0) Abnormality
3242 0 Exhaust Gas Temperature Sensor 1: 4765 4
Emergency High
523523 3 Injector Short
523524 3
(T1) Abnormality
523525 1 Injector Charge Voltage Abnormality
3242 4
3246 0 Exhaust Gas Temperature Sensor 2:
Abnormality
Emergency High
523535 0 Injector Charge Voltage High
(T@) Abnormality
3246 4
3251 3 Differential Pressure Sensor 1
Abnormality
3251 4
3252 0 Emission Deterioration
100 S®-60 J Part No. 1285305GT


523589 17 Low Coolant Temperature in Parked
SPN FMI Description Regeneration
523538 2 QR (IQA) Data Abnormality 523590 16 Parked Regeneration Tmi OUY
523538 7 523591 2
523543 2 Accelerator Position Sensor Error 523592 2
(CAN)
523595 2 CAN2 Frame Error
523544 3 Glow Relay Abnormality 523596 2
523544 4 523598 2
523547 2 CAN2 Bus Off 523599 0 All Exhaust Gas temperature Sensor
523548 2 CAN2 Frame Error Failure
523572 4 523601 0 High Exhaust Gas Temperature After
523574 3 EGR Actuator Abnormality Emergency High Temperature DTC
523574 4 523602 0 High Frequency of Regeneration.
523575 7 523603 15 Over Heat pre-caution
523576 2 EGR (DC Motor) Abnormality 523604 2 CAN1 Bus Off

523577 2 523605 6 Internal Injector drive Circuit
Abnormality
523578 2 No Communication with EGR
523700 13 EEPROM Check Sum Error
523580 2 Intake Throttle Feedback Error
523582 3 Intake Throttle Lift Sensor
Abnormality
523582 4
Part No. 1285305GT S®-60 J 101

Schematics
About This Section

Section 5 Schematics
Introduction
There are two groups of schematics in this section.
Electrical Schematics
Contact with electrically charged
Observe and Obey: circuits could result in death or
 Troubleshooting and repair procedures shall watches and other jewelry.
be completed by a person trained and
qualified on the repair of this machine
 Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
 Repair any machine damage or malfunction
before operating the machine. burn skin. Loosen hydraulic
Before Troubleshooting: the oil pressure to dissipate
 Read, understand and obey the safety rules squirt or spray.
 Be sure that all necessary tools and test Important Information
equipment are available and ready for use.

Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual 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.
102 S®-60 J Part No. 1285305GT

Electrical Symbol Legend

Electrical Symbol Legend
Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge
Diode Hour meter LED Fuse with amperage Foot switch
T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid
T-circuits connect at Circuits crossing no Quick disconnect Circuit breaker with

Connection - no terminal
terminal connection terminal amperage
Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor
Horn button - normally Emergency Stop button

Resistor with ohm value Battery separator Gauge sending unit
open - normally closed
Oil temperature switch Coolant temperature Oil pressure switch Control relay contact Diode starting aid, glow
normally open switch - normally open normally closed normally open plug or flame ignitor
Part No. 1285305GT S®-60 J 103

Hydraulic Symbols Legend

Hydraulic Symbols Legend
Orifice with size Check valve Shut off valve Brake
Pump, bi-directional Motor, 2 speed bi-

Pump, fixed displacement Motor, bi-directional
variable displacement directional
Pump, prime mover Shuttle valve. 2 position,

Cylinder, double acting Differential sensing valve
(engine or motor) 3 way
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator valve
valve setting proportional valve
Solenoid operated
Directional valve Flow divider/combiner Pilot operated 3 position,
2 position, 3 way
(mechanically activated) valve 3 way shuttle valve
directional valve
Solenoid operated
Solenoid operated
Counterbalance valve with 3 position, 4 way Solenoid valve, 2 position
3 position 4 way directional
pressure and pilot ratio proportional directional 2 way
valve
valve
104 S®-60 J Part No. 1285305GT

Limit Switch Location Legend

Limit Switch Location Legend
S-60 J
1 LSB1RO
2 LST1O
3 UTS
4 PBAS
5 LSB1DO
Limit Switches and Sensors
LSB1RO Limit switch boom fully retracted - operational

LST1O Limit switch drive turntable - operational
UTS Universal tilt sensors
PBAS Primary boom angle sensor
LSB1DO Limit switch boom down - operational
Part No. 1285305GT S®-60 J 105

106 S®-60 J Part No. 1285305GT

Electrical Schematic, Generator Options

Electrical Schematics – Options
107

108 S®-60 J Part No. 1285305GT

Electrical Schematic, Positive Air Shutdown

Part No. 1285305GT S®-60 J 109

110
Electrical Schematic, Turntable Controller

Electrical Schematics
111

112 S®-60 J Part No. 1285305GT

Electrical Schematic, Platform Controller

Part No. 1285305GT S®-60 J 113

114
Electrical Schematic, Kubota D1803
115

116 S®-60 J Part No. 1285305GT


Part No. 1285305GT S®-60 J 117

118
Electrical Schematic, Deutz D2011
119

120 S®-60 J Part No. 1285305GT

Hydraulic Schematic
Hydraulic Schematic
Part No. 1285305GT S®-60 J 121

Hydraulic Schematic
S®-60 J Part No. 1285305GT Service and Repair Manual Decenber 2019
122

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What is the purpose of this manual?

What is the purpose of this manual?

What safety rules should be followed when performing maintenance?

What safety rules should be followed when performing maintenance?

Service and Repair Manual

Serial Number Range

For detailed maintenance

Part No. 1285305GT

Important Technical Publications

Compliance Find a Manual for this Model

1285305GT Rev A, Decenber 2019

First Edition, First Printing

Genie and "S" are registered trademarks of Terex South

ii S®-60 J Part No. 1285305GT

Part No. 1285305GT S®-60 J iii

Serial Number Legend

iv S®-60 J Part No. 1285305GT

Do Not Perform Maintenance

Part No. 1285305GT S®-60 J v

Personal Safety Workplace Safety

Be aware of potential crushing

vi S®-60 J Part No. 1285305GT

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

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

Part No. 1285305GT S®-60 J vii

Section 3 Repair Procedures ............................................................................................. 14

Platform Components ....................................................................................... 28

Jib Boom Components...................................................................................... 36

viii S®-60 J Part No. 1285305GT

Boom Components ............................................................................................ 38

Boom Components ............................................................................................ 39

Hydraulic Pump .................................................................................................. 52

Part No. 1285305GT S®-60 J ix

Turntable Rotation Components ...................................................................... 73

x S®-60 J Part No. 1285305GT

Section 4 Fault Codes ......................................................................................................... 79

Control System Fault Codes ............................................................................. 80

Engine Fault Codes ............................................................................................ 98

Kubota D1803-CR-TIE4 Engine Fault Codes ................................................... 99

Part No. 1285305GT S®-60 J xi

Section 5 Schematics ....................................................................................................... 102

Electrical Schematics – Options .................................................................... 107

Electrical Schematics ...................................................................................... 111

Hydraulic Schematics...................................................................................... 121

xii S®-60 J Part No. 1285305GT

Tires and Wheels Boom function speeds, maximum from platform

Part No. 1285305GT S®-60 J 1

Hydraulic Oil Specifications

Do not top off with incompatible

Note: Extended machine operation can cause the

2 S®-60 J Part No. 1285305GT

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

Part No. 1285305GT S®-60 J 3

Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid

Shell Tellus S4 VX Fluid

4 S®-60 J Part No. 1285305GT

Specifications Hot oil relief valve pressure 280 psi

Function manifold SAE No.10 41 ft-lbs / 55 Nm

System relief valve pressure, 3200 psi SAE No. 12 56 ft-lbs / 76 Nm