Terex Genie SX-135 XC Service And Repair Manual Download Page 77

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October 2016

Service and Repair Manual

Boom Components

Part No. 1263382

SX-135 XC

25 Fully retract the boom and lower the boom to

the horizontal position.

26 Stop the engine.
27 Re-measure the gap between boom tubes

#1 and #2 from points (8) and (9) (dimension

“A”) and boom tubes #2 and #3 from points

(10) and (11). (Illustration 1)

Result: The measurement is between 1 in /

2.6 cm and 1.5 in / 3.8 cm more than

dimension "A". The gap is in tolerance.

Proceed to step 28.

Result: The measurement is more than 1.5 in

/ 3.8 cm greater than dimension "A". Repeat

the procedure beginning with step 9.

Result: The measurement is less than 1 in /

2.6 cm greater than dimension "A". Repeat

the procedure beginning with step 20.

Result: The measurement is between 1 in /

2.6 cm and 1.5 in / 3.8 cm more than

dimension "A". The gap is in tolerance.

Proceed to step 28.

28 Install the red locking bracket over the cable

adjustment bolts. A flat edge of each bolt

head must be on top for the locking bracket to

secure the bolts (Illustration 2).

Bodily injury hazard. Failure to

install the red cable adjustment

locking bracket would allow the

cable mounting bolts to loosen

and fall out which could result

in death or serious injury.

29 Tighten the jam nut on the cable tension

retract bracket.

30 Lower the boom to the stowed position.

How to Replace the Boom Extend/Retract Cables

How to Replace the Boom

Extend/Retract Cables

Note: The cable sheaves must be inspected when

replacing the cables.
Remove the primary boom extension cylinder.

Refer to Repair Procedure,

How to Remove the

Primary Boom Extension Cylinder

Boom extend cables:

1 The boom extend cables remain attached to

the extension cylinder during removal.

Boom retract cables:

2 Loosen the retract adjustment bolt from the

boom retract cables at the platform end of the

#1 boom.

Illustration 1

1  retract cable
2  retract cable retaining bolts
3  retract cable adjustment bolt

3 Remove the retract cable retaining bolts and

attach an electrician's tape or rope to the

cable.

Summary of Contents for Genie SX-135 XC

Page 1: ...e SX 135 XC from SX135H 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 1263382 Rev A October 2016 ...

Page 2: ...degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Compliance Machine Classification Group B Type 3 ...

Page 3: ...ory Revision Date Section Procedure Page Description A 10 2016 Initial Release Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...e and Repair Manual October 2016 Introduction iv SX 135 XC Part No 1263382 Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label located under cover 5 Serial number stamped on chassis ...

Page 5: ... Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You ...

Page 6: ...ushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from flamm...

Page 7: ...ifications 8 Deutz TD 2 9 Engine Specifications 9 Perkins 1104D 44T Engine Specifications 10 Perkins 854F 34T Engine Specifications 12 Machine Torque Specifications 13 Hydraulic Hose and Fitting Torque Specifications 14 Torque Procedure 15 Section 3 Repair Procedures 18 Introduction 18 Platform Controls 20 1 1 Platform Circuit Board 20 How to Remove the LED Circuit Board 21 1 2 Joysticks 22 How to...

Page 8: ... the Jib Boom Bellcrank 46 3 6 Jib Boom Bellcrank Angle Sensor 47 Boom Components 50 4 1 Primary Boom Cable Track 51 4 2 Primary Boom 54 4 3 Primary Boom 55 How to Disassemble the Primary Boom 57 4 3 Primary Boom Lift Cylinder 60 4 4 Extension Cylinder 62 4 5 Boom Extend and Retract Cables 64 How to Replace the Boom Extend Retract Cables 67 4 6 Primary Boom Angle Sensor 69 4 7 Boom Length Sensor 7...

Page 9: ...old 106 8 5 Steer and Axle Manifold 108 8 6 Function Enable Manifold 112 8 7 Valve Adjustments Steer and Axle Manifold 113 8 8 Traction Manifold Components 114 8 9 Valve Adjustments Traction Manifold 118 8 10 Generator Manifold Component 119 8 11 Valve Coils 120 Turntable Rotation Components 122 9 1 Turntable Rotation Assembly 122 How to Adjust the Turntable Rotation Gear Backlash 123 9 2 Turntabl...

Page 10: ...s 1104D 44T Models 218 VEC Module Deutz TD2 9 Models 219 VEC Module Perkins 854F Models 220 Telematics Connector Pin Legend 221 Electrical Symbols Legend 222 Hydraulic Symbols Legend 224 Generator Receptacle Wiring ANSI CSA 225 Generator Receptacle Wiring CE 226 Generator Receptacle Wiring AUX 227 Perkins 1104D 44T Engine Electrical Schematic 229 Perkins 1104D 44T Engine Electrical Schematic 230 P...

Page 11: ...heel lugs 10 3 4 16 Lug nut torque dry 320 ft lbs 434 Nm Fluid capacities Fuel tank 40 gal 151 liters Hydraulic tank 60 gal 227 liters Hydraulic system including tank 138 gal 522 liters Drive hubs 67 fl oz 1981 cc Turntable rotation drive hub 43 fl oz 1262 cc Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 For operational specifications refer to the Operator s...

Page 12: ... sec Primary boom extend retract 30 33 sec 0 100 in 254 cm Primary boom up down stowed 88 94 sec 75 Primary boom up down stringpot 138 in 351 cm 26 29 sec 10 Primary boom up down stringpot 202 in 513 cm 24 27 sec 10 Primary boom up down stringpot 268 in 681 cm 34 37 sec 10 Primary boom up down stringpot 357 in 907 cm 21 24 sec 5 Turntable rotate drive enable to drive enable 30 fully stowed 17 23 s...

Page 13: ...ube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the ...

Page 14: ... 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydraul...

Page 15: ...Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C cSt 1...

Page 16: ...8 cu in 0 to 45 cc Flow rate 2450 rpm 0 to 29 gpm 0 to 109 7 L min Pressure maximum 2900 psi 200 bar Pressure compensator 2900 psi 200 bar Standby pressure 350 psi 24 bar Auxiliary Pump Type fixed displacement gear pump Displacement per revolution 0 15 cu in 2 47 cc Function manifold System relief valve pressure maximum 3200 psi 221 bar Primary boom extend relief pressure measured at PTEST port 23...

Page 17: ...02 psi 7 bar Medium pressure filter Beta 3 200 Medium pressure filter bypass pressure 51 psi 3 5 bar Hydraulic tank return filter 10 micron with 25 psi 1 7 bar bypass Drive motor case drain return filter Beta 10 2 Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft...

Page 18: ...es may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 22 psi 1 5 bar Fuel injection system Motorpal Injection pump pressure maximum 15 000 psi 1034...

Page 19: ...h 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 22 psi 1 5 bar Fuel injection system Motorpal Injection ...

Page 20: ...bove 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 8 psi 0 55 bar Oil Sensor Settings 0 psi 10 ohms 50 psi 120 ohms Fuel injection system Transfer pump pressure 10 12 psi 0 ...

Page 21: ...t Engine coolant Capacity engine only 9 5 quarts 9 liters Coolant temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 230 F 110 C Temperature Sensor Settings 215 F 102 C 37 ohms 170 F 82 C 78 ohms Alternator output 85A 12V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm ...

Page 22: ...reme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil Pressure switch Installation torque 18 4 ft lbs 25 Nm Pressure switch point 12 psi 0 82 bar Oil Sensor Settings 0 psi 10 ohms 50 psi 120 ohms Fuel injection system Transfer pump pressure 10 12 psi 0 69 0 83 bar Injection pressure 23000 psi 1600 bar...

Page 23: ... ft lbs 834 Nm 1 2 13 bolts GR 8 dry use blue thread locking compound 90 ft lbs 122 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 5 8 11 SHC 180 ft lbs 244 Nm Rotate bearing mounting bolts lubricated 3 4 10 SHC 320 ft lbs 434 Nm Rotate drive hub mounting bolts dry 95 ft lbs 129 Nm Backlash plate mounting bolts lubricated 320 ft lbs 434 Nm Drive motors and hubs Drive hub mou...

Page 24: ... 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O rin...

Page 25: ... and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut ...

Page 26: ...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 fitti...

Page 27: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 17 This page intentionally left blank ...

Page 28: ... your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm l...

Page 29: ...t personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avo...

Page 30: ...alibrate a Joystick How to Remove the Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Locate the cables that connect to the bottom of the control box Number each cable and its location at the control box 3 Disconnect the cables from the bottom of the platform control box 4 Remove the control cable receptacle retaining fasteners f...

Page 31: ...ve the LED Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the circuit board mounted to the inside of the platform control box Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remov...

Page 32: ...e description of each LCD screen control button used in this procedure Plus Minus Previous Enter Drive functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter button twice 4 Use the scroll b...

Page 33: ... or neutral position Result The alarm at the ground controls should sound for a successful calibration Primary boom extend retract functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the minus button twice then press the enter but...

Page 34: ...n the down direction and hold for 5 seconds then return to the center or neutral position Result The alarm at the ground controls should sound for a successful calibration Jib boom up down functions 1 Turn the key switch to the off position 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 secon...

Page 35: ...ssful calibration How to Reset a Proportional Valve Coil Default How to Reset a Proportional Valve Coil Default Note Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter Note This procedure only needs to be performed if a proportional valve has been replaced Note After the valve coil defaults have been set each machi...

Page 36: ... While holding the joystick in position press the engine start button at the platform controls to set the joystick controller threshold 6 Slowly move the joystick off center in the opposite direction just until the machine function starts to move then move the joystick very slowly towards the neutral or center position just before the machine function stops Do not let go of the joystick 7 While ho...

Page 37: ...e until the alarm sounds Return the joystick to center Extend the boom approximately 4 ft 1 2 m then again move the joystick full stroke in the opposite direction until the alarm sounds Return the joystick to center Raise and extend the primary boom approximately 85 ft 26 m then again move the joystick full stroke in the opposite direction until the alarm sounds Return the joystick to center 15 On...

Page 38: ... control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the minus button twice 4 Press the previous button until the function to be adjusted is displayed 5 Press the plus button to increase the speed or press the minus button to decrease the speed 6 Press the enter button to save the setting in memo...

Page 39: ... screen control button used in this procedure Plus Minus Previous Enter 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Press and hold the enter button on the ground control panel while turning the key switch to platform controls Hold the enter button for approximately 5 seconds 3 Press the plus button twice then press the previous button twic...

Page 40: ...e electrical outlet box Do not disconnect the wiring Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 8 Remove the power to platform electrical outlet box from the platform and lay it to the side 9 Remove the weld cable from the platform if equipped Electrocution burn hazard Contact with electric...

Page 41: ... platform leveling cylinder barrel end pivot pin is accessible 2 Raise the jib boom slightly and place blocks under the platform 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Place a block under the platform leveling cylinder for support 5 Remove the external snap rings from the ba...

Page 42: ...ve the platform Refer to Repair Procedure How to Remove the Platform 2 Tag and disconnect the electrical connector from the platform angle sensor 3 Remove the platform angle sensor retaining fasteners Remove the platform angle sensor from the platform rotator Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if is dropped or sustains any ...

Page 43: ...rted when the jib boom leveling arm pivot pin is removed Component damage hazard The platform angle sensor is a very sensitive instrument It can be damaged internally if is dropped or sustains any physical shock even if the damage is not visible How to Bleed the Platform Rotator How to Bleed the Platform Rotator Note Do not start the engine Use auxiliary power for all machine functions in this pro...

Page 44: ...of the ground control box Activate calibration mode by moving the toggle switch in the left direction 5 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 6 Insert the key into the bypass recovery key switch and turn it to the bypass position Note The platform level calib...

Page 45: ...tform Overload System Proper calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over How to Calibrate the Platform Overload System Note Perform this procedure with the machi...

Page 46: ...S then press the enter button to accept 14 Press the enter or previous button on the LCD screen until CALIBRATE LOAD CELL ZERO is displayed 15 Press the plus button to select YES then press the enter button to accept 16 Add weight to the platform corresponding to the rated capacity of the machine determined in step 3 Place the weight near the center entry point of the platform farthest away from t...

Page 47: ...e overload indicator lights and alarm turn off 29 Add an additional test weight equal to 5 of the rated capacity onto the calibration weight to overload the platform Result The alarm should be sounding The platform overload indicator light should be flashing at the platform controls and platform overload should be displayed on the LCD screen at the ground controls Note There may be a 2 second dela...

Page 48: ...d hold the enter button on the ground control panel while turning the key switch to ground controls Hold the enter button for approximately 5 seconds 3 Press the buttons on the ground controls in the following sequence plus minus minus plus 4 Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed 5 Press the plus button or the minus button to select YES The...

Page 49: ...boom 5 3 boom 4 4 bellcrank 5 jib angle sensor 6 bellcrank leveling cylinder 7 bellcrank vertical link 8 bellcrank lower link 9 jib lift cylinder 10platform leveling cylinder 11platform vertical link 12platform lower link 13jib rest pad 14platform level sensor 15jib cable track 16jib cable tray 17jib manifold ...

Page 50: ... the platform rotator Refer to Repair Procedure How to Remove the Platform Rotator 3 Tag disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to the platform manifold Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not all...

Page 51: ...om angle sensor Remove the cover 13 Remove the jib boom angle sensor mounting bracket fasteners from the side of the primary extension boom 14 Carefully remove the bracket and sensor assembly Note the location of the springs Do not lose the springs Note There is one spring inside the jib boom pivot pin and one inside the angle sensor Note When the jib boom is installed the jib boom angle sensor wi...

Page 52: ...anced and fall when it is removed from the machine if it is not properly supported by the overhead crane 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specificat...

Page 53: ...w to Remove the Jib Boom Level Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Extend the primary boom until the ...

Page 54: ...orted 3 4 Jib Boom Extension Cylinder How to Remove the Jib Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the ...

Page 55: ...he lower cable track 9 Remove the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 10 Pull the electrical cables out of the lower cable track that lead to the primary boom 11 Attach a lifting strap from a second overhead crane to the pivot end of the jib boom for support Do not apply any lifting pressure 12 Place a block under the j...

Page 56: ...adjusted for proper balancing 3 5 How to Remove the Jib Boom Bellcrank Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Rem...

Page 57: ...system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion If a jib boom bellcrank angle sensor is replaced it must be calibrated prior to machine operation The jib boom bellcrank angle sensor is mounted to the bellcrank pivot pin on the engine side of the machine How to Calibrate the Jib Boom Bellcrank Angle Sensor Note If the primary boom an...

Page 58: ...ection 6 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine 7 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key ...

Page 59: ...ss and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings Note Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved 18 Press the enter or previous button on the LCD screen until EXIT is displayed 19 Press the plus button to select YES then press the enter b...

Page 60: ...omponents 50 SX 135 XC Part No 1263382 1 boom tube 1 2 boom tube 2 3 boom tube 3 4 boom lift cylinder 5 bellcrank level cylinder 6 bellcrank vertical link 7 bellcrank lower link 8 boom angle sensor 9 lower cable track 10cable track 11jib manifold ...

Page 61: ...move the hose and cable clamp retaining fasteners from lower cable track at the pivot end of the jib boom Remove the clamps 4 Pull the electrical cables out of the lower cable track that lead to the primary boom Component damage hazard Cables can be damaged if they are kinked or pinched 5 Tag and disconnect the electrical connectors from the jib boom manifold located at the platform end of the pri...

Page 62: ...econdary boom lower end cover could become unbalanced and fall when removed from the secondary boom if not properly supported and secured to the lifting device 15 Locate the two hydraulic hoses inside the end of the secondary boom that lead to the primary boom cable track 16 Tag disconnect and plug the hydraulic hoses from the unions Cap the fittings on the unions Bodily injury hazard Spraying hyd...

Page 63: ...ables and hoses can be damaged if they are kinked or pinched How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A cable track repair kit is available through the Genie Service Parts Department 1 Visually inspect the cable track and determine which 4 link section needs to be replaced 2 Support the cable track assembly above t...

Page 64: ...to ensure smooth operation of the new section of cable track 4 2 Primary Boom How to Shim the Boom 1 Measure each upper side and lower wear pad Note If a wear pad is not less than specification perform the following procedure Platform end wear pads 2 Extend the boom until the wear pads are accessible at the platform end of the machine 3 Loosen the wear pad mounting fasteners 4 Add shims by hand un...

Page 65: ... injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connec...

Page 66: ...s at the primary boom pivot pin Remove the hose and cable guide 9 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Place support blocks und...

Page 67: ...er to Repair Procedure How to Remove the Jib Boom Lift Cylinder 6 Remove the jib boom bellcrank Refer to Repair Procedure How to Remove the Jib Boom Bellcrank 7 Remove the boom primary extension cylinder Refer to Repair Procedure How to Remove the Boom Primary Extension Cylinder 8 The boom tubes can be disassembled without removing the cable track assembly If you choose to remove the cable track a...

Page 68: ...port and slide the 3 boom tube from the boom assembly Remove the 2 boom tube 18 Tag and disconnect the harness to limit switch 3RS and 4EOS Remove the bracket and limit switch from the 1 boom tube Tip over hazard Failure to install the correct proximity and or limit switches in the correct location will result in the machine tipping over resulting in death or serious injury 19 At the pivot end of ...

Page 69: ...ake sure the tube remains parallel to the 1 boom tube while removing 26 When approximately 10 feet of the 2 boom tube remains in the 1 boom tube attach a strap from a suitable overhead lifting device and slightly lift the tube Crushing hazard The number 2 boom tube may become unbalanced and fall when it is removed from the number 1 boom tube if it is not properly supported and attached to the over...

Page 70: ... 2 m between the turntable and boom rest pad 2 Attach a lifting strap from an overhead crane or other suitable lifting device to the rod end of the the boom lift cylinder 3 Attach an overhead 10 ton 9071 kg crane to the platform end of the boom for support Do not lift the boom Note Place the lifting strap between the cable track assembly and the boom 4 Remove the boom storage area cover retaining ...

Page 71: ...chor hole to secure the engine pivot plate from moving Crushing hazard Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury 14 Remove the pin retaining fastener from the barrel end pivot pin Do not remove the pin 15 Support the boom lift cylinder with an overhead crane 16 Use a slide hammer to remove the boom lift cylinder barrel ...

Page 72: ...orqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the boom to a horizontal position and fully retract the primary extension cylinder 2 Remove the retaining fasteners from the boom end cover at the pivot end of the boom Remove the cover from the machine 3 Tag and disconnect the limit switch harnesses Remove the fasteners to ...

Page 73: ...d allow the cable mounting bolts to loosen and fall out which could result in death or serious injury 2 Loosen the 3 extend cable adjustment bolts 10 turns about 1 in 2 54 cm Note Do not over loosen the extend cables 3 Remove the locking plates securing the extend cylinder to boom 1 1 Illustration 1 4 Remove the locking plates securing the extend cylinder to boom 2 2 Illustration 1 5 Remove the lo...

Page 74: ...m Extend and Retract Cables How to Adjust the Boom Extend Retract Cables Properly adjusted extend retract cables are essential to safe machine operation Failure to maintain proper adjustment of the cables could result in unsafe operating conditions and may cause component damage The boom extend and retract functions should operate smoothly and be free of hesitation jerking and unusual noise 1 Star...

Page 75: ...e gap should be 1 in 2 6 cm to 1 5 in 3 8 cm greater than dimension A Result The measurement is between 1 in 2 6 cm and 1 5 in 3 8 cm more than dimension A The gap is in tolerance Proceed to step 28 Result The measurement is more than 1 5 in 3 8 cm greater than dimension A Proceed to step 7 Result The measurement is less than 1 in 2 6 cm greater than dimension A Proceed to step 20 7 Remove the boo...

Page 76: ...m 16 Start the engine and fully raise and extend the boom approximately 15 ft 4 6 m 17 Fully retract the boom and lower the boom to the horizontal position 18 Stop the engine 19 Re measure the gap between boom tubes 1 and 2 from points 11 and 12 dimension A and boom tubes 2 and 3 from points 9 and 10 Illustration 1 Result The measurement is between 1 in 2 6 cm and 1 5 in 3 8 cm more than dimension...

Page 77: ...flat edge of each bolt head must be on top for the locking bracket to secure the bolts Illustration 2 Bodily injury hazard Failure to install the red cable adjustment locking bracket would allow the cable mounting bolts to loosen and fall out which could result in death or serious injury 29 Tighten the jam nut on the cable tension retract bracket 30 Lower the boom to the stowed position How to Rep...

Page 78: ... 2 retract cable retaining plate 3 retract cable 6 Remove the fasteners securing the retract cable retaining plate and lay the retract cable on the bottom of the boom 7 At the pivot end pull the retract cable out of the boom tubes 8 Repeat the procedure for the other retract cable 9 Reverse the procedure to install the new retract cable 10 Adjust the boom extend retract cables Refer to Repair Proc...

Page 79: ...l will be required to perform this procedure Note A kit is available through Genie Product Support Genie part number 58351 This kit includes a digital level with a magnetic base and cable harnesses Note Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter 1 Push in the ground controls red Emergency Stop button to the...

Page 80: ...tton to change the angle and then change back to the measured value The system must detect a change in displayed value to record the calibrated value 13 Press and hold a function enable speed select button and the primary boom button until the boom stops at the end of the lift cylinder stroke 14 At the PRIMARY BOOM ANGLE TO GRAVITY 75 0 DEG screen press the plus or minus button to adjust the displ...

Page 81: ...position Be sure there are no calibration faults shown on the display 4 7 Boom Length Sensor How to Calibrate the Primary Boom Length Sensor Note Perform this procedure with the machine on a firm level surface with the axles extended Note The turntable level sensor must be calibrated prior to calibrating the primary boom Note LTB1LO and LTB1LS are calibrated at the same time Note Primary boom angl...

Page 82: ...s position Note The length sensor calibration values will not be saved correctly unless the key switch is in the bypass recovery position 8 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position Hold the enter button for approximately 5 seconds and then release it 9 Enter sensor calibration mode by pressing the...

Page 83: ... to accept 21 Turn the key back to the run position and remove the key from the bypass recovery key switch Insert the key into the main key switch and turn it to ground controls 22 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 23 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fastene...

Page 84: ...t is bolted to the engine flywheel and has a splined center to drive the pump How to Remove the Flex Plate 1 Disconnect the wiring plug at the electronic displacement controller EDC located on the drive pump 2 Support the drive pump with an appropriate lifting device Then remove all of the pump mounting plate to engine bell housing bolts 3 Carefully pull the pump away from the engine and secure it...

Page 85: ...p shaft and flex plate 4 Install the pump plate and pump assembly onto the engine Grease Specification Shell Alvania Grease CG NLGI 0 1 or equivalent Deutz and Perkins models How to Install the Pump Plate 1 Using a suitable lifting device install the pump plate and pump assembly onto the engine 2 Deutz engines Torque the pump plate mounting bolts in sequence to 23 ft lbs 31 Nm Then torque the pump...

Page 86: ...n 2 Bypass Recovery 3 Recovery How to Use the Bypass Mode Tip over hazard Operating the machine outside of the operating envelope while in Bypass mode will result in death or serious injury if proper operating procedures and safety precautions are not followed Do not use this mode if you are not trained and familiar with the operating envelope of the machine Note Before using the Bypass mode make ...

Page 87: ...ns Bodily injury hazard When using recovery mode the platform may not fully lower to the ground when the recovery mode is completed Failure to use only suitable equipment and or practices to allow the operator to safely exit the platform could result in death or serious injury Bodily injury hazard Platform leveling is not active when using recovery mode The platform could reach high out of level c...

Page 88: ...placeable membrane decal with touch sensitive buttons for various machine functions The ground control box also contains two printed circuit boards The LCD Liquid Crystal Display circuit board is mounted to the inside of the control box lid which controls the LCD display screen The ECM circuit board is the main circuit board for the machine All operating parameters and configuration of options for...

Page 89: ...ush in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the ground control box lid fasteners 3 Open the ground control box 4 Tag and disconnect the harnesses from the ground control box 5 Remove the control cable receptacle retaining fasteners from the side of the control box 6 Attach a grounded wrist strap to the ground screw inside the control b...

Page 90: ...remove the circuit board from the control box 6 3 Membrane Decal The membrane decal is a special decal that consists of a decal with an electronic membrane on the backside The membrane contains touch sensitive areas that when pushed activate the machine functions The membrane contains touch sensitive areas that activate the machine functions How to Replace the Membrane Decal 1 Turn the key switch ...

Page 91: ... Close the control box lid and install the retaining fasteners 6 4 Full Machine Calibration Full machine calibration must be completed in the proper sequence when the ALC 1000 circuit board TCON in the ground control box has been replaced or the turntable level sensor SCON has been replaced How to Fully Calibrate the Machine Calibration procedures shall only be completed by qualified technicians t...

Page 92: ...e angle sensors Refer to Repair Procedure How to Calibrate the Axle Angle Sensors Steer sensors Refer to Repair Procedure How to Calibrate All Steer Sensors Primary boom angle sensor Refer to Repair Procedure How to Calibrate the Primary Boom Angle Sensor Primary boom length sensor Refer to Repair Procedure How to Calibrate the Primary Boom Length Sensor Jib boom bellcrank angle sensor Refer to Re...

Page 93: ...nus Previous Enter Activation of the enter or previous buttons scrolls through the screens To change parameter values or select a setting use the plus button to increase or scroll forward and the minus button to decrease or scroll backwards Then press the enter button to save the new value to memory An audible beep will indicate a save to memory Use the enter and previous buttons to scroll to the ...

Page 94: ...switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press plus minus minus plus Metric English measurement units English German French Spanish Portuguese Italian Dutch and Swedish Deutz 2 9L Turbo D2 9T Set engine Deutz TD2011L04i DL04i Perkins 1104D 44T P1104 Perkins 854F P854T Start Glow Time 30s max 0s min 6s default Display Faults as Text ...

Page 95: ... 100 default 50 min Forward not stowed drive speed 120 max 100 default 50 min Forward low drive speed 120 max 100 default 50 min Forward high drive speed 120 max 100 default 50 min Reverse extended drive speed 120 max 100 default 50 min Reverse not stowed drive speed 120 max 100 default 50 min Reverse low drive speed 120 max 100 default 50 min Reverse high drive speed 120 max 100 default 50 min Dr...

Page 96: ...ft Primary boom up speed 80ft Primary boom up speed 120ft Primary boom up speed 150ft Primary boom up speed 170ft Primary boom down speed stowed Primary boom down speed 80ft Primary boom down speed 80ft 120 max 50 min Primary boom down speed 120ft 100 default Primary boom down speed 150ft Primary boom down speed 170ft Primary boom extend speed Primary boom retract speed Turntable rotate speed retr...

Page 97: ... Jib up down ramp acceleration Jib up down ramp deceleration Jib extend ramp acceleration Jib retract ramp deceleration Screen or Menu Procedure Description Range or Selection Valve Calibration With key switch OFF press and hold the enter button and turn key switch to on position Release the enter button and press minus minus enter enter Delete drive valve calibration Delete boom extend retract va...

Page 98: ...sensors calibration YES NO Axle angle fully retracted YES NO Axle angle fully extended YES NO Delete all steer sensors calibrations YES NO Delete blue end blue side steer sensor LF calibration YES NO Delete yellow end blue side steer sensor LR calibration YES NO Delete blue end yellow side steer sensor RF calibration YES NO Delete yellow end yellow side steer sensor RR calibration YES NO Use butto...

Page 99: ... NO AL Motion MO AL Travel TR AL Descent DE AL Travel and Descent TD AL Lift Drive options No NO CO Drive cut out while not stowed DCONS Lifting or driving LORDR Proximity Switch NONE PROX Platform Overload sensing NONE PLFTS Flashing Beacon NO YES Disable Steer Mode Change while Driving NO YES Rocker Switch steering NO YES Foot Switch Lockout 0 30 minutes 30 0 max and 0 0 min 10 0 default Holding...

Page 100: ...o hydraulic tank valves at the hydraulic tank Close the valves Component damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition 2 Tag disconnect and plug the function pump hydraulic hoses Cap th...

Page 101: ... drain port of the function pump install the function pump case drain hose 4 Clean up any oil that may have spilled Properly discard the used oil 5 Start the engine from the ground controls 6 Check for hydraulic leaks How to Adjust the Function Pump Standby Pressure How to Adjust the Function Pump Standby Pressure 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the functi...

Page 102: ...an 350 psi 25 bar Once the gauge reads higher than 350 psi 25 bar turn the adjustment screw counterclockwise until the gauge reads 350 psi 25 bar Tighten the set screw Proceed to step 11 Pressure reads less than 350 psi 25 bar 6 Loosen the set screw for the standby pressure adjustment screw on the rear function pump Turn the adjustment screw clockwise higher pressure until the pressure reads 350 p...

Page 103: ...st the Function Pump Pressure Compensator How to Adjust the Function Pump Pressure Compensator Note Two people will be required to perform this procedure 1 Confirm the system relief pressure is set to specification Refer to Repair Procedure Valve Adjustments Function Manifold 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold 3 Start the engine from the...

Page 104: ...lectronic displacement controller EDC located on the pump The only adjustment that can be made to the pump is the neutral or null adjustment Any internal service to the pump should be performed at an authorized Sauer Danfoss service center Contact Genie Product Support to locate your local authorized service center How to Remove the Drive Pump Component damage hazard The work area and surfaces whe...

Page 105: ...ard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Support the pumps with a suitable lifting device and remove the two drive pump mounting fasteners 5 Carefully pull the drive pump out until the pump coupler separates from the flex plate 6 Remove the drive pump from t...

Page 106: ...Disconnect the engine wiring harness from the fuel shutoff solenoid at the injector pump Deutz models Hold the manual fuel shutoff valve clockwise to the closed position 3 Have another person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches approximately 250 psi 17 bar 4 Perkins models Connect the en...

Page 107: ...October 2016 Service and Repair Manual Hydraulic Pumps Part No 1263382 SX 135 XC 97 This page intentionally left blank ...

Page 108: ...nal valve W Primary boom extend retract 19 21 ft lbs 25 7 28 5 Nm 6 Solenoid operated 3 position 4 way directional valve X Primary boom lift cylinder up down 33 37 ft lbs 45 50 Nm 7 Proportional solenoid operated 2 position 2 way directional valve normally closed L Primary lift cylinder up down high speed control 33 37 ft lbs 45 50 Nm 8 Proportional solenoid operated 2 position 2 way directional v...

Page 109: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 99 ...

Page 110: ...tem Function Torque 13 Check valve 5 psi 0 34 bar C Prevents hydraulic pressure from flowing back into auxiliary pump 1 19 21 ft lbs 25 7 28 5 Nm 14 Relief valve 3200 psi 221 bar E System relief 24 26 ft lbs 32 6 35 4 Nm 15 Orifice 0 025 in 0 635 mm Y 16 Relief valve 1970 psi 135 8 bar H Primary and secondary retract pressure limit 46 54 ft lbs 62 6 73 4 Nm ...

Page 111: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 101 ...

Page 112: ...emove the cap 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve higher than specified 6 Repeat step 3 to confirm relief valve pressure 7 Remove the pressure gauge How to Adjust the Primary Boom Extend Relief Valve Note Perform this procedure with the ax...

Page 113: ...and relief valve Setting the valve to the combined pressure will insure the relief valve is set to the correct pressure 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Tip over hazard Do not adjust the relief valve high...

Page 114: ...19 21 ft lbs 25 8 28 6 Nm 4 Solenoid valve 3 position 4 way EJ Bellcrank level up down 19 21 ft lbs 25 8 28 6 Nm 5 Solenoid valve 2 position 2 way normally open EK Bellcrank up down level loop valve 19 21 ft lbs 25 8 28 6 Nm 6 Relief valve 1100 psi 75 8 bar EC Jib extend relief 19 21 ft lbs 25 8 28 6 Nm 7 Pressure compensator valve 150 psi 10 3 bar EI Bellcrank up down compensator 19 21 ft lbs 25 ...

Page 115: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 105 ...

Page 116: ...8 28 6 Nm 2 Proportional solenoid valve 3 position 4 way DD Platform up down circuit 19 21 ft lbs 25 8 28 6 Nm 3 Solenoid valve 2 position 2 way normally open DC Platform level loop lock valve 25 30 ft lbs 33 9 40 7 Nm 4 Flow control valve 0 2 gpm 0 76 L min DE Regulates flow in up down circuit 19 21 ft lbs 25 8 28 6 Nm 5 Flow control valve 0 2 gpm 0 76 L min DA Regulates flow in left right circui...

Page 117: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 107 ...

Page 118: ...nt steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 6 Flow control valve 2 1 gpm 8 L min BL Right rear steer cylinder extend circuit 20 25 ft lbs 27 34 Nm 7 Solenoid valve 3 position 4 way BQ Steer left right right rear steer cylinder 20 25 ft lbs 27 34 Nm 8 Check valve BY Prevents right rear steer cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 9 Check valve BX Prev...

Page 119: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 109 ...

Page 120: ...cylinder from moving when not steering 20 25 ft lbs 27 34 Nm 19 Flow control valve 1 5 gpm 5 7 L min BM Right rear steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 20 Flow control valve 1 5 gpm 5 7 L min BG Left front steer cylinder retract circuit 20 25 ft lbs 27 34 Nm 21 Flow control valve 2 1 gpm 8 L min BF Left front steer cylinder extend circuit 20 25 ft lbs 27 34 Nm 22 Flow control valve...

Page 121: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 111 ...

Page 122: ...e Manifold The jib boom manifold is mounted inside the primary extension boom at the platform end Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 2 way A Enables function pumps to provide hydraulic pressure for all boom and steer axle functions 20 25 ft lbs 27 34 Nm ...

Page 123: ...2 Locate the axle relief valve on the steer and axle manifold Hold the relief valve with a wrench and remove the cap 3 Start the engine from the platform controls and press down the foot switch Press and hold the axle extend button at the platform controls Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 4 Turn the engine off 5 Adjust th...

Page 124: ...5 ft lbs 27 1 33 9 Nm 5 Shuttle Valve 3 position 3 way AO Charge pressure circuit that directs hot oil out of low pressure side of drive pumpp 50 55 ft lbs 67 8 74 6 Nm 6 Relief valve 250 psi 17 23 bar AN Charge pressure circuit 20 25 ft lbs 27 1 33 9 Nm 7 Orifice Plug 0 030 inch 0 762 mm AV Brake and two speed circuit 20 25 ft lbs 27 1 33 9 Nm 8 Check valve AU Anti cavitation 20 25 ft lbs 27 1 33...

Page 125: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 115 ...

Page 126: ...der combiner valve AP 30 35 ft lbs 40 7 47 5 Nm 14 Orifice 2 gpm 7 6 L min AL Equalizes pressure on both sides of divider combiner valve AM 30 35 ft lbs 40 7 47 5 Nm 15 Check valve AJ Anti cavitation 20 25 ft lbs 27 1 33 9 Nm 16 Flow divider combiner valve AM Controls flow to circle end drive motors in forward and reverse 90 100 ft lbs 122 135 6 Nm 17 Flow divider combiner valve AP Controls flow t...

Page 127: ...October 2016 Service and Repair Manual Manifolds Part No 1263382 SX 135 XC 117 ...

Page 128: ...om the ground controls 5 Press and hold the function enable high rpm select button rabbit symbol position Note the reading on the pressure gauge 6 Turn the engine off 7 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 8 Hold the hot oil relief valve and remove the cap 9 Start the engine from the ground controls 10 Press and hold the ...

Page 129: ...diverter valve 19 21 ft lbs 25 7 28 5 Nm 2 Solenoid Valve FB Pilot valve to diverter valve 33 37 ft lbs 45 50 Nm 3 Relief valve 3200 psi 221 bar FC Generator relief valve 24 26 ft lbs 32 6 35 4 Nm 4 Solenoid Valve FD Charge pressure circuit 33 37 ft lbs 45 50 Nm 5 Check valve FE Prevents oil to generator 7 8 ft lbs 9 5 10 8 Nm 6 Needle valve FF Charge pressure circuit 45 50 ft lbs 61 68 Nm 7 Count...

Page 130: ...Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is se...

Page 131: ...n the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ωresistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connec...

Page 132: ...raulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Attach a lifting strap from an overhead crane or other suitable lifting device to the lifting eye on the turntable rotation assembly 5 Remove the drive hub mounting bolts and remove the turntable rotation assembly from the machine 6 ...

Page 133: ...oosen the lock nut on the adjustment bolt 5 Turn the adjustment bolt clockwise until it contacts the backlash pivot plate 1 backlash pivot plate 2 adjustment bolt with lock nut 3 backlash pivot plate mounting bolts 6 Turn the adjustment bolt 1 2 to 3 4 turn counterclockwise Tighten the lock nut on the adjustment bolt 7 Pull the backlash pivot plate away from the turntable until it contacts the adj...

Page 134: ...us Enter 1 Push in the ground controls red Emergency Stop button to the off position 2 Open the ground control box 3 Locate the calibration toggle switch at the top of the ground control box Activate calibration mode by moving the toggle switch in the left direction 4 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving ...

Page 135: ... X Axis 2 X Axis 3 Platform end 11 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button Note If the measured angle already matches the angle shown on the display at the ground controls press the plus button or minus button to change the angle and then change back to the measured value The system must detect a change in...

Page 136: ...button on the LCD screen until EXIT is displayed 15 Press the plus button to select YES then press the enter button to accept 16 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in 17 Remove the fastener that was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the cali...

Page 137: ...There is a steer sensor mounted to the top of each steer yoke upper pivot pin How to Replace a Steer Sensor Note When the steer sensor is replaced both the sensor and magnet must be replaced as a set Note Perform this procedure with the axles fully retracted and the boom in the stowed position 1 Align the remaining wheels on the machine so they are visually parallel to the chassis as close as poss...

Page 138: ...ged into the sensor 6 Rotate the sensor housing in a clockwise direction until the sensor cable is pointing away from the machine Refer to Illustration 2 7 Install the steer sensor cover retaining fasteners Do not tighten the cover retaining fasteners 8 Connect the steer sensor assembly cable to the main harness 9 Calibrate the steer sensor Refer to Repair Procedure How to Calibrate a Replacement ...

Page 139: ...d into the pivot pin and that the fasteners are securely tightened How to Calibrate All Steer Sensors How to Calibrate All Steer Sensors Note This procedure will only need to be performed if the ground controls circuit board TCON has been replaced Note Perform this procedure with the axles retracted and the tires straightened Note Use the following chart to identify the description of each LCD scr...

Page 140: ...sensor cover fasteners Note If available WebGPI can also be used for this procedure 7 Remove the key from the main key switch Insert the key into the bypass recovery key switch and turn it to the bypass position Note The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated 8 Push in the red Emerge...

Page 141: ...screen until DELETE _____ STEER SENSORS CALIBRATION is displayed Example DELETE BLUE END BLUE SIDE STEER SENSORS CALIBRATION FL 17 Press the plus button to select YES then press the enter button to accept 18 Press the enter or previous button on the LCD screen until EXIT is displayed 19 Press the plus button to select YES then press the enter button to accept 20 Push in the red Emergency Stop butt...

Page 142: ...ng cylinder from the machine Crushing hazard The steer cylinder may become unbalanced and fall if not properly supported by the lifting device when removed from the machine 10 3 Axle Extension Cylinders How to Remove an Axle Extension Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to spec...

Page 143: ...nced and fall if not properly supported by the lifting device 10 4 Axle Angle Sensors The axle angle sensors measure the axle angle and communicates that information to the ground controls ECM There are two axle angle sensors They are located on opposite axle pivot pins at each end of the chassis How to Calibrate the Axle Angle Sensors Note Use the following chart to identify the description of ea...

Page 144: ... the following sequence plus enter enter plus 8 Press the enter or previous button on the LCD screen until DELETE AXLE ANGLE SENSORS CALIBRATION is displayed 9 Press the plus button to select YES then press the enter button to accept 10 At the AXLE ANGLES FULLY RETRACTED screen press the plus button to select YES then press the enter button to accept 11 When the AXLE ANGLES FULLY EXTENDED screen i...

Page 145: ...nsors measure the axle angle and communicates that information to the ground controls ECM There are two axle angle sensors They are located on opposite axle pivot pins at each end of the chassis How to Calibrate the Axle Angle Sensors Note Use the following chart to identify the description of each LCD screen control button used in this procedure Plus Minus Previous Enter Note If an axle angle sen...

Page 146: ... the following sequence plus enter enter plus 8 Press the enter or previous button on the LCD screen until DELETE AXLE ANGLE SENSORS CALIBRATION is displayed 9 Press the plus button to select YES then press the enter button to accept 10 At the AXLE ANGLES FULLY RETRACTED screen press the plus button to select YES then press the enter button to accept 11 When the AXLE ANGLES FULLY EXTENDED screen i...

Page 147: ...t was temporarily installed Close the control box door and install the door retaining fasteners Note When the control box door is closed the calibration toggle switch is automatically activated to exit out of calibration mode 18 Use the key to turn the bypass recovery key switch to the run position Note Be sure that the bypass recovery key switch is in the run position before attempting to operate...

Page 148: ...e adjustment screw clockwise until it stops 1 Needle valve 3 Turn the adjusting screw counterclockwise two turns 4 Start the engine from the platform controls 5 Turn on the generator from the platform controls and let the generator run for at least three minutes 6 Insert the leads from a multimeter set to register frequency HZ and turn the needle valve until the frequency is 2 Hz above the normal ...

Page 149: ...ed All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary...

Page 150: ...d neutral Alarm sounds Check for damaged wiring to the joystick Check the connections to ensure the connector terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Value Too High Value Too Low Value at 0 V Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Joystick Just calibrated Initiate one second beep of audib...

Page 151: ...oom Up Extend Down TT Rotate and Propel Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO Propel allowed once boom is fully stowed Display message on LCD Alarm sounds Power up controller with problem corrected Value Too High Value Too Low Value at 0 V Not calibrated Primary Up only active from TCON activate alarm Calibrate Sensor Just calibrated Initiate one second ...

Page 152: ...t allowed and Boom Down allowed if fully retracted as sensed by LSB3RS Alarm sounds Display message on LCD BOOM LENGTH SENSORS CROSS CHECK FAULT Power up controller with problem corrected RSB1AO boom angle Active Cross check Fault Check Disable Boom Up Extend Down TT Rotate and Propel powers in SCON Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO Alarm sounds Disp...

Page 153: ... problem corrected LTB1LO LSB3RO 3 ft Cross check Fault Check Disable Boom Up Extend Down TT Rotate and Propel powers in SCON Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RS Alarm sounds Display message on LCD LTB1LO LSB4RO CROSS CHECK FAULT Power up controller with problem corrected LSB2RO 151ft LSB4EO 150 ft Cross check Fault Check Disable Boom Up Extend Down TT...

Page 154: ...sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Primary Boom Retract Valve Primary Boom Up Valve Primary Boom Down Valve Primary Lock Out Valve 1 Primary Lock Out Valve 2 Engine Speed Range Check underspeed Display message on LCD Engine is running below 50 RPM Check fuel system Oil Pressure Range Check low oil pressure Display mes...

Page 155: ...e wiring or SCON PCON Tether Power P3 Fault Check Display message on LCD TETHER POWER P3 FAULT Power up controller with problem corrected Valve Power P6R1 Fault Check Display message on LCD VALVE POWER P6R1 FAULT Power up controller with problem corrected Engine Power P6R2 Fault Check Display message on LCD ENGINE POWER P3 FAULT Power up controller with problem corrected Enable Input P7 Fault Chec...

Page 156: ...ck Display message on LCD TEST POINT P18 FAULT Power up controller with problem corrected Platform Level Valve P22 Fault Check Display message on LCD PLAT LEVEL VALVE P22 FAULT Power up controller with problem corrected Primary Up Down Valve Power P22R Fault Check Display message on LCD PRI UP DN VLV PWR P22R FAULT Power up controller with problem corrected Propel Power P38 Fault Check Display mes...

Page 157: ... Self clearing transient Turntable Rotate Buttons on TCON Fault Check both buttons pressed Turntable rotate disabled Display message on LCD Check ribbon and connector from membrane switch If necessary replace membrane switch Turntable Rotate Speed Not calibrated Display message on LCD and allow operation at default speed Perform auto calibrate procedure Turntable Rotate Flow Valve Not calibrated N...

Page 158: ...e Too High Replace SCON Value Too Low Value at 0 V Out of Tolerance Just calibrated Initiate one second beep of audible warning device Self clearing transient Safety Turntable Level Sensor X Direction Value at 5 0 V Flash unit out of level icon and LED and activate alarm Check that SCON is grounded Value Too High Replace SCON Value Too Low Value at 0 V Out of Tolerance Just calibrated Initiate one...

Page 159: ...irection is zero Display message on LCD Calibrate Thresholds Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Primary Boom Extend Retract Flow Valve Not calibrated Normal function except th...

Page 160: ... 0 V Not calibrated Primary up only active from TCON activate alarm Calibrate Sensor Just calibrated Initiate one second beep of audible warning device Self clearing transient Safety Primary Boom Angle Sensor Value at 5 0 V Disable Boom Up Extend Down TT Rotate and Propel Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO Propel allow once boom is fully stowed Displa...

Page 161: ...rm Rotate Clockwise Valve Fault Check Fault Check Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Platform Rotate Counterclockwise Valve Jib Up Down Flow Valve s Not calibrated Normal function except threshold for one or the other direction is zero Display message on LCD Perform calibration procedure Just calibrated Initiate one second b...

Page 162: ...zero Display message on LCD Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for opens in the wiring or a bad ground Replace coil if necessary Value Too Low Platform Level Up Platform Level Down Flow Valve Not calibrated Normal function ex...

Page 163: ...ctor terminals have not backed out Substitute a known good joystick If necessary replace and recalibrate joystick Value Too High Value Too Low Value at 0 V Not calibrated Joystick Speed and Direction frozen at zero and neutral Just calibrated Initiate one second beep of audible warning device Self clearing transient Jib Rotate Joystick Value at 5 0 V Limited Speed and Direction frozen at zero and ...

Page 164: ...ated Primary up only active from TCON activate alarm Perform calibration procedure Just calibrated Initiate one second beep of audible warning device Self clearing transient Rear Axle Angle Sensor Value at 5 0 V Primary up and Extend disabled axle extend and retract LED flash Check for an open ground circuit going to the sensor Value Too High Primary up and Extend disabled axle extend and retract ...

Page 165: ...calibrated Initiate one second beep of audible warning device Self clearing transient Propel Valves Forward Reverse Not calibrated Joystick Speed and Direction frozen at zero and neutral Calibrate Thresholds Propel EDC Forward Reverse Just calibrated Initiate one second beep of audible warning device Self clearing transient Value Too High Limited Speed and Direction frozen at zero and neutral Alar...

Page 166: ...d circuit going to the sensor Value Too High Limited Speed and Direction frozen at zero and neutral Alarm sounds Sensor is out of range Check sensor and actuating pin for proper installation Repair or replace sensor and recalibrate Value Too Low Value at 0 V Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for 5 0 VDC at the sensor Check for damaged wiring going to the sen...

Page 167: ...ON board Repair or replace as necessary Steer Valves LF RF LR RR Fault Check Limited Speed and Direction frozen at zero and neutral Alarm sounds Check for defective or damaged wiring Check for an open or shorted valve coil Repair or replace as necessary Jib Bellcrank Sensor Value at 5 0 V Primary up and extend disabled Alarm sounds Power up controller with problem corrected Value Too High Value To...

Page 168: ...back inside Operational Envelope PBMLS Safety Envelope Position Check Disable Boom Up Down Extend TT Rotate Propel and Ignition Fuel Boom Retract allowed All functions allowed once boom is lowered back into envelope Alarm Sounds Display message on LCD PRIMARY BOOM PBMLS SAFETY ENVELOPE Return Boom back inside Operational Envelope Boom Envelope Safety Position Check Disable Boom Down Extend and Ign...

Page 169: ...h crosscheck OFF OFF OFF OFF OFF Primary 2 Cylinder crosscheck OFF OFF OFF Boom Envelope Safety Interlock OFF OFF OFF Axle Safety Not Stowed OFF OFF Axles crosscheck Angle sensor vs safety switch es OFF OFF OFF OFF Axle not fully extended and TT Rotate stowed and in drive disable zone OFF OFF Turntable Tilt Angle crosscheck SCON internal sensors 3 in a delta configuration OFF OFF OFF OFF OFF Loss ...

Page 170: ...n 3 SCON Controller Area Network 4 Primary Boom Angle Zone 5 Primary Boom Length Switches Cross Check 8 PCON Controller Area Network 9 Engine 18 DCON Controller Area Network 20 Boom Extend Retract Joystick 21 Boom Up Down Joystick 26 Boom Extend Retract Buttons 27 Boom Up Down Buttons 28 Boom Angle Sensors Cross Check SCON 29 LSB2RS LSB4ES Cross Check SCON 30 Propel Joystick 35 Propel Valve 40 Tur...

Page 171: ... Buttons 113 Jib Rotate Buttons 117 Propel Power P38 118 Turntable Rotate Power P39 121 Valve Power P6R1 122 Engine Power P6R2 123 Enable Input Power P7 Fault Source ID Description 124 Enable Output Power P7R 125 Primary Down Power P9A 126 IGN Fuel Power P9B 127 Primary Extend Power P10 128 Primary Up Power P11 129 Axle Retract Power P12 132 Platform Level Power P22 133 Primary Up Down Valve Power...

Page 172: ...Platform Rotate Toggle Switch 175 Platform Level Flow Valve 176 Platform Rotate Valve 180 Boom Length Sensor 195 Safety Platform Overload SCON 220 RSB1AO Active Cross Check 221 LTB1LO Active Cross Check 222 Axle Extend Retract Toggle Switch 235 RSB1AO LSB1DO Cross Check 236 LTB1LO LSB3RO Cross Check 237 LTB1LO LSB4EO Cross Check 238 Pressure Comp Enable 1 Valve 239 Pressure Comp Enable 2 Generator...

Page 173: ...EGR Valve signal range check low 51 5 1223 Actuator EGR Valve open load 51 6 1014 Actuator error EGR Valve signal range check high SPN FMI KWP Description 51 6 1022 Actuator error EGR Valve signal range check high 51 6 1224 Actuator EGR Valve over current 51 6 1230 Actuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible 51 11 1231 Actuator error E...

Page 174: ...shold exceeded 105 3 994 Sensor error charged air temperature signal range check high 105 4 995 Sensor error charged air temperature signal range check low SPN FMI KWP Description 108 3 412 Sensor error ambient air press signal range check high 108 4 413 Sensor error ambient air press signal range check low 110 0 98 High coolant temperature warning threshold exceeded 110 0 99 High coolant temperat...

Page 175: ...9 Sensor ambient air temperature plausibility error 172 2 983 Intake air sensor plausibility error 172 3 981 Sensor error intake air signal range check high 172 4 982 Sensor error intake air sensor signal range check low SPN FMI KWP Description 174 0 481 High low fuel temperature warning threshold exceeded 174 0 482 High Low fuel temperature shut off threshold exceeded 175 0 740 Physical range che...

Page 176: ...ignal range check high 411 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Fr...

Page 177: ...ector 4 in firing order 654 5 571 Injector 4 in firing order interruption of electric connection 676 11 543 Cold start aid relay error 676 11 544 Cold start aid relay open load SPN FMI KWP Description 677 3 956 Starter relay high side short circuit to battery 677 3 960 Starter relay low side short circuit to battery 677 4 957 Starter relay high side short circuit to ground 677 4 961 Starter relay ...

Page 178: ...ust gas temperature upstream turbine warning threshold exceeded 1180 1 1194 Physical range check low for exhaust gas temperature upstream turbine 1180 1 1461 Turbocharger Wastegate CAN feedback shut off threshold exceeded SPN FMI KWP Description 1180 1 1463 Exhaust gas temperature upstream turbine shut off threshold exceeded 1180 3 1067 Sensor error exhaust gas temperature upstream turbine signal ...

Page 179: ... AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 SPN FMI KWP Description 2798 4 1338 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 1 2798 4 1339 Injector diagnostics short circuit to ground monitoring Test in Cyl Bank 0 2798 4 1340 Injector diagnostics short circuit to ground...

Page 180: ...exhaust gas temperature downstream DOC signal range check low 523006 3 34 Controller mode switch short circuit to battery 523006 4 35 Controller mode switch short circuit to ground 523008 1 648 Manipulation control was triggered SPN FMI KWP Description 523008 2 649 Timeout error in Manipulation control 523009 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Press...

Page 181: ...or of CAN Receive Frame TSC1AR Retarder 523612 12 387 Internal software error ECU injection cut off 523612 12 612 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 613 Internal ECU monitoring detection reported error 523612 12 614 Internal ECU monitoring detection reported error 523612 12 615 Internal ECU monitoring detection reported error 523612 12 616 Internal E...

Page 182: ...xceeded RailMeUn3 523613 2 864 Setpoint of metering unit in overrun mode not plausible 523615 3 594 Metering unit Fuel System short circuit to battery highside SPN FMI KWP Description 523615 3 596 Metering unit Fuel System short circuit to battery low side 523615 4 595 Metering unit Fuel System short circuit to ground high side 523615 4 597 Metering Unit Fuel System short circuit to ground low sid...

Page 183: ... 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value programming IMA injector 2 in firing order SPN FMI KWP Description 523897 13 561 check of missing injector adjustment value programming IMA injector 3 in firing order 523898 13 562 check of missing injector adjustment value programming IMA injector 4 i...

Page 184: ...nce Control integrator injector 4 in firing order maximum value exceeded 523932 1 118 Fuel Balance Control integrator injector 4 in firing order minimum value exceeded 523935 12 168 Timeout Error of CAN Transmit Frame EEC3VOL1 Engine send messages SPN FMI KWP Description 523936 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zerofuel calibration injector 1 in...

Page 185: ...3998 4 1327 Injector cylinder bank 2 slave short circuit 523999 12 1328 Injector powerstage output Slave defect 524014 1 1254 Air pressure glow plug flush line below limit SPN FMI KWP Description 524016 2 1259 Amount of air is not plausible to pump speed 524016 2 1260 Calculated amount of air is not plausible to HFM reading 524016 11 1258 HFM sensor electrical fault 524021 11 1263 Burner fuel line...

Page 186: ...omRxDPFBrnAirPmp 524104 9 1676 Timeout error of CAN Receive Frame ComRxDPFCtl 524105 9 1668 Timeout error of CAN Transmit Frame ComEGRMsFlw 524106 9 1677 Timeout error of CAN Receive Frame ComRxEGRMsFlw1 524107 9 1678 Timeout error of CAN Receive Frame ComRxEGRMsFlw2 SPN FMI KWP Description 524108 9 1669 Timeout error of CAN Transmit Frame ComEGRTVActr 524109 9 1679 Timeout error of CAN Receive Fr...

Page 187: ... KWP Description 524120 9 1682 Timeout error of CAN Receive Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN Receive Frame ComRxTrbChActr 524122 9 1684 Timeout error of CAN Receive Frame ComRxUQSens 524123 9 1685 Timeout error of CAN Receive Frame ComSCRHtCtl 524124 9 1686 Timeout error of CAN Receive Frame ComTxAT1IMG 524125 9 1687 Timeout error of CAN Receive Frame ComTxTrbChActr ...

Page 188: ...t 97 15 Water In Fuel Indicator High least severe Fuel Contains Water 100 2 Engine Oil Pressure Erratic Intermittent or Incorrect Switch Circuits Test 100 17 Engine Oil Pressure Low least severe 1 Oil Pressure Is Low 102 3 Engine Intake Manifold 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 102 4 Engine Intake Manifold 1 Pressure Voltage Below Normal Engine Pres...

Page 189: ...re Problem 157 2 Engine Injector Metering Rail 1 Pressure Erratic Intermittent or Incorrect Fuel Rail Pressure Problem 157 3 Engine Injector Metering Rail 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 157 4 Engine Injector Metering Rail 1 Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Test 157 10 Engine Injector Metering Rail 1 Pressu...

Page 190: ...tic Intermittent or Incorrect Idle Validation Switch Circuit Test 593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is about to occur This code does not represent a fault If equipped the warning lamp will come on 594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has occurred This code does not represent a ...

Page 191: ...54 5 Engine Injector Cylinder 04 Current Below Normal Injector Solenoid Circuit Test 654 6 Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Circuit Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifted Low Injector Data Incorrect Test 676 5 Engine GloW Plug Relay Current Below Normal Glow Plug Starti...

Page 192: ...ld Air Pressure Is Low 1188 5 Engine Turbocharger Wastegate Actuator 1 Position Current Below Normal Solenoid Valve Test 1188 6 Engine Turbocharger Wastegate Actuator 1 Position Current Above Normal Solenoid Valve Test 1209 3 Engine Exhaust Gas Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 1209 4 Engine Exhaust Gas Pressure Voltage Below Normal Engine Pressure Sen...

Page 193: ...ECU Instance Special Instruction Electrical Power Supply Test 2880 2 Engine Operator Primary Intermediate Speed Select Erratic Intermittent or Incorrect Throttle Switch Circuit Test 2880 3 Engine Operator Primary Intermediate Speed Select Voltage Above Normal Throttle Switch Circuit Test 2880 4 Engine Operator Primary Intermediate Speed Select Voltage Below Normal Throttle Switch Circuit Test 2970...

Page 194: ...51 3 Particulate Trap Differential Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 3251 4 Particulate Trap Differential Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit Test 3251 7 Particulate Trap Differential Pressure Not Responding Properly Diesel Particulate Filter Has Differential Pressure Problem 3251 10 Particulate Trap Differential ...

Page 195: ...g 1 Not Responding Properly Glow Plug Starting Aid Test 5325 7 Engine Glow Plug 2 Not Responding Properly Glow Plug Starting Aid Test 5326 7 Engine Glow Plug 3 Not Responding Properly Glow Plug Starting Aid Test 5327 7 Engine Glow Plug 4 Not Responding Properly Glow Plug Starting Aid Test 5419 5 Engine Throttle Actuator 1 Current Below Normal Motorized Valve Test 5419 6 Engine Throttle Actuator 1 ...

Page 196: ...Service and Repair Manual October 2016 186 SX 135 XC Part No 1263382 This page intentionally left blank ...

Page 197: ...safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watch...

Page 198: ...or control 74 is the number of the circuit for the primary 1 lock out valve PL stands for Primary Lockout S 62 BST This is the circuit that communicates to the onboard computers of the machine that the boom is fully stowed S stands for safety 62 is the number of the circuit for boom stowed and BST stands for Boom Stowed P 48 LP P stands for power 48 is the circuit number for work lamps and LP stan...

Page 199: ... Left DER Drive Enable Right DTH Data High DTL Data Low EDC Electrical Displacement Control ENL Envelope Lockout ENV Envelope Light ERL Extend Retract Lockout ESL Engine Status Lamp Suffix Definition ESP Engine Speed Select FAP Axle Front Position FB Flashing Beacon FE Function Enable FL Fuel Select gas LP FLR Filter Restricted FLT Filter Switch FP Fuel Pump FS Float Switch FSL Fuel Solenoid FTS F...

Page 200: ... Control PEL Primary Ext Ret Lockout PER Primary Boom Extend Retract Flow Control PES Primary Boom Up Down Signal PL Primary Lockout PLD Platform Level Down Suffix Definition PLF Platform Level Flow Control PLL Propel Lockout PLS Primary Boom Extend Retract Signal PLU Platform Level Up PRC Platform Rotate Control PRF Platform Rotate Flow Control PRL Platform Rotate Left CCW PRR Platform Rotate Rig...

Page 201: ...SCW Steering Valve CW SEN Sensor SER Sec Boom Extend Retract Flow Control SHD CAN Shield SLD Secondary Boom Lockout Valve riser down SLE Secondary Boom Lockout Valve extend SP Spare SS Speed Sensor STC Steer Control Signal Suffix Definition STR Starter SUD Sec Boom Up Down Flow Control TAX Tilt Alarm X axis TAY Tilt Alarm Y axis TCN Ground Control TCN Ground Control Panel TET Tether TRF Turntable ...

Page 202: ... Propel drive valves P39 Turntable rotate flow control valve Color Circuit Primary Function RD 1 Primary boom up driver RD BK 2 Primary boom down driver RD WH 3 Primary boom up down flow control proportional valve driver WH 4 Turntable rotate left valve driver WH BK 5 Turntable rotate right valve driver WH RD 6 Turntable rotate flow control proportional valve driver BK 7 Primary boom extend BK WH ...

Page 203: ...4 Power to safety interlock switches engine Color Circuit Primary Function GR BK 55 Axle oscillation RD 56 Foot switch TCON estop power RD WH 57 Boom down safety interlock RD BK 58 Safety interlock to engine GR WH 59 Chain break circuit GR WH 60 Axle extend GR 61 Axle retract OR 62 Boom stowed safety OR RD 63 Power to boom envelope safety switch OR BK 64 Power for operational switches BL WH 65 Low...

Page 204: ... Steer Signal RD 112 Steer Signal to Solenoid Valve OR RD 113 Multi function Valve BK RD 114 Load Moment Overweight RD BK 115 Load Moment Underweight OR 116 Hydraulic Oil Cooler Color Circuit Primary Function RD 117 Flashing Beacon OR 118 Lift Speed Reduction BL 119 Hydraulic Pressure Sensor Output OR 120 Oil Cooler Fan GR 121 Axle Oscillate Left GR BK 122 Axle Oscillate Right RD BK 123 Primary Bo...

Page 205: ...ignal WH BK 161 Secondary Boom Joystick Signal OR 162 Joystick 5V DC power BL WH 163 Primary Extend Retract Signal RD WH 164 Primary Up Down Signal WH RD 165 TT Rotate Signal Color Circuit Primary Function OR 166 Boom Length Signal Safety OR BK 167 Boom Length Signal Operational BL RD 168 Primary Boom Hydraulic Valve Lockout GR 169 Envelope Active LED WH RD 170 Load Sense Relay Source WH BK 171 Lo...

Page 206: ...it WH RD 191 Multi Function Pressure Relief WH BK 192 Jib Rotate Left WH RD 193 Jib Rotate Right WH RD 194 Speed Select Input OR RD 195 Electric Brake Source YL 196 2 5V Sensor Power WH 197 Hour Meter RD 198 12V Sensor Power WH RD 199 Thermal Switch BL 226 Telematics Remote Disable GR 227 Engine Control CAN 2 0 J1939 Low YL 228 Engine Control CAN 2 0 J1939 High BR N A Ground or Return ...

Page 207: ...through its range of operational functions The rotation or angle sensors utilize Hall Effect technology and must be calibrated when replaced Included in this group are envelope limit switches which sense the extended length and angle of the booms and rotational position of the turntable An example is the drive enable limit switch which disables the drive function anytime the boom is rotated past t...

Page 208: ...Proximity Switch LSJ1RS Out of stowed safety Normally closed contacts open when jib boom is retracted 5 Jib Boom down Operational Proximity Switch LSJ1DO Normally open contacts close when jib boom is in stowed position 6 Jib Bellcrank Sensor Bellcrank Level Sensor 7 Platform Overload Load Cell LCP1LS 8 Primary Boom Angle Sensor RSB1AO S 9 Cable Tension Safety Limit Switch LSB5S Primary extend powe...

Page 209: ...sed switch contacts open when turntable is rotated in the right direction 2 Turntable 1 Safety Limit Switch LST1S Prevents the turntable from rotating past either rear tire when the axles are retracted Normally closed switch contacts open when turntable is rotated past either rear tire with the axles retracted 3 Turntable 2 Operational Limit Switch LST2O Activates the drive enable zone when the tu...

Page 210: ...nformation for adjusting steering neutral setting during axle extension 4 Rear Axle 1 Angle Operational Rotary Sensor RSRA1SO Provides rear axle positioning information for adjusting steering neutral setting during axle extension 5 Left Front 1 Steer Operational Rotary Sensor RSLF1SO Provides wheel position information during steering Master wheel in all steer modes except rear steer 6 Right Front...

Page 211: ...J34 2 pin Deutsch DTP connector swivel upper J35 6 pin Deutsch DT connector swivel upper J36 3 pin Deutsch SAE DT connector swivel upper Number Description J37 2 pin Deutsch DTP connector swivel lower J38 6 pin Deutsch DTP connector swivel lower J55 6 pin Deutsch DT connector for platform tilt sensor S6 J57 4 pin Deutsch DTP connector for throttle solenoid J58 2 pin Deutsch DT pri boom up dwn F C ...

Page 212: ...eutsch DT drive enable right LST1O J125 4 pin Deutsch DT drive enable left LST2O J126 4 pin Deutsch DT drive enable safety LST1S J127 6 pin Deutsch DTM pri boom up dwn TT rot joystick JC7 Number Description J135 2 pin Deutsch DT jib bellcrank up valve Y85 J136 2 pin Deutsch DT jib bellcrank down valve Y86 J137 4 pin Deutsch DT front axle safety switch LSFA1ES J138 4 pin Deutsch DT rear axle safety...

Page 213: ...ve Y89 J203 2 pin Deutsch DT jib rotate CCW valve Y90 J205 4 pin Deutsch DT jib rotated CW LSJ2RO J206 2 pin Deutsch DT jib rotated CCW LSJ3RO J207 4 pin Deutsch DT 3 5ft extend safety LSB3RS J208 12 pin Deutsch DT lower limit to zero tube cable J209 4 pin Deutsch DT 151ft retract safety LSB2RS Number Description J210 2 pin Deutsch DT 10 deg angle oper LSB1DO J211 4 pin Deutsch DT 3ft extend oper ...

Page 214: ... OL Low Current On Off Solenoid Output 0 1 x 3 Amps PM Prop Medium Current Proportional Solenoid Output 0 5 x 3 Amps LED LED Output LED Output Driver RLY Relay Output Relay Output Driver 0 1 x 0 3 Amps EDC EDC Output Linear Current Control propel AI Analog Input 0 to 5 Vdc DI Digital Input 0 or Vbat Voltage FAC Frequency AC Input 0 to 1 kHZ 0 to 13 8 Vptop RDF Ground Ref signal power GND to extern...

Page 215: ...2V when PCON POWER OUT PWR ENBL are active and the foot switch is closed P11 07 CONT P _22 P 56PRV RD WH Relay control signal or power signal o f PCON normally controlled by the platform tilt safety switch output but may be over ridden in bypass recovery mode P11 08 RLY SPARE RLY OUT Power relay coil P11 09 RLY FLASHING BEACON RLY C117FB RD Flashing beacon relay P11 10 COM CAN SHIELD Termination f...

Page 216: ...h 1 drive enable right P12 16 DI LSB1DO C68PBD BL Input primary boom lowered 10 deg operational P12 17 DI 12V SIG TO PLD C64LS OR BK Tied high 12V for proper operation of PLD P12 18 DI LSB2RO C69PBE BK Input primary boom section 1 retracted 151ft retracted operational P12 19 DI LSB3RO C70PBE BL WH Input primary boom fully retracted for PLD 3ft retracted operational P12 20 DI LSB4EO C71PBE BL BK In...

Page 217: ...EDC EDC FWD C30EDC WH Electrical displacement control forward P13 11 EDC EDC REV C31EDC WH BK Electrical displacement control reverse P13 12 AI OIL_PRESSURE C25PSR WH BK Input from oil pressure sender P13 13 AI OIL WATER_TEMP C26TSR WH RD Input from oil water temperature sender P13 14 REF TT_TILT_SNSR_GND Ground for turntable tilt sensor P13 15 SNSR TT_TILT_SNSR_PWR SNSR_5V Supply voltage for turn...

Page 218: ... to drive light relay P14 14 REF VALVE_RETURN_5 Valve ground return P14 15 DI HYD_FILTER1 DI Grounding switch input from hydraulic filter 1 P14 16 DI HYD_FILTER2 DI Grounding switch input from hydraulic filter 2 P14 17 DI BOOM REVERSE LOAD DI Grounding switch input from boom reverse proximity switch P14 18 DI BOOM OVERLOAD DI Grounding switch input from boom overload switch P14 19 OH SPARE OM ON O...

Page 219: ... J17 6 CONT OUTPUT PWR ENABLE C47OUT WH BK Function enable J17 7 PWR P_6R1 P53LS BK WH Safety circuit power J17 8 PWR P_7R S56PRV RD BK Safety circuit power J17 9 CONT SERV OR OPER REC SRV REC WH Service recovery mode signal J17 10 PWR P_22 P56PRV RD Safety circuit power platform level bypass J17 11 CONT OPER REC P_15 OR BK Power to PLD while in recovery mode J17 12 CONT P_7 P_7 PLAT GR WH Power f...

Page 220: ...for platform level up down jib up down and jib bellcrank up down in TCON mode P21 08 NOT USED P21 09 NOT USED P21 10 COM CAN SHIELD Termination for CAN cable shield P21 11 NOT USED P21 12 NOT USED P21 13 BOOT Boot P21 14 NOT USED P21 15 CONT OUT PWR ENBL C47OUT WH BK 12V when platform E Stop is pulled out P21 16 CONT HRN RLY CNTRL C46HRN WH Output from horn membrane switch on PCON P21 17 COM CAN L...

Page 221: ...ootswitch prox sensor and limit switches P22 17 CONT FOOT SW RTN C56FTS RD Power from footswitch P_7 circuit P22 18 DI JIB ROTATED CCW C215JRO WH RD Jib rotated CCW operational signal from LSJ3RO P22 19 REF PL TILT SNSR GND P85RET BR Ground for platform tilt sensor operational P22 20 AI PL TILT SNSR C84TAY GR BK Analog signal input for platform tilt sensor operational P22 21 SNSR PL TILT SNSR PWR ...

Page 222: ... joystick JC3 J29 7 AI STEER DUAL AXIS C159STC BL WH Dual axis steer signal from propel joystick JC3 J29 8 AI PROPEL C160JPL WH RD Propel signal from propel joystick JC3 J29 9 AI SPARE AI J29 10 AI PRIMARY EXT RET C163PES BL WH Boom extend retract signal from boom joystick JC2 J29 11 AI PRIMARY UP DOWN C164PLS RD WH Boom up down signal from boom joystick JC7 J29 12 AI TT ROTATE C165TRS WH RD Turnt...

Page 223: ...ch TS9 J169 7 DI PLAT LVL UP PLAT LVL UP OR Platform level up signal TS9 J169 8 DI PLAT LVL DOWN PLAT LVL DN OR BK Platform level down signal TS9 J169 9 REF GND GND2 BR Joystick case ground JC8 J169 10 PWR OUT PWR ENBL ESTOP RET BK Return from PCON E Stop P2 output power enable circuit J169 11 BOOT J169 12 REF GND GND12 BR PCON alarm ground J169 13 REF GND GND1 BR Joystick case ground JC3 J169 14 ...

Page 224: ...witch input J1 7 DI DRIVE ENABLE DRV ENBL BL WH Drive Enable toggle switch input J1 8 NOT USED J1 9 DI AXLE RETRACT AXLE RET GR Axle Retract toggle switch input J1 10 REF GND1 GND1 BR Ground for toggle switch inputs J1 11 DI ENGINE SPEED SELECT ENG SPEED BK RD Engine Speed toggle switch input J1 12 DI AXLE EXTEND AXLE EXT GR WH Axle Extend toggle switch input J1 13 DI DRIVE SPEED SELECT DRV SPEED ...

Page 225: ...sed P31 09 DI AXLE NOT RET RTN Not used active low P31 10 COM CAN SHIELD Not used P31 11 COM RS232 RXD Not used P31 12 COM RS232 TXD Not used P31 13 BOOT BOOT P31 14 NOT USED P31 15 DI AXLE NOT EXT RTN Not used active high P31 16 NOT USED P31 17 COM CAN LOW D81CAN GR CAN bus connection P31 18 COM CAN HIGH D82CAN YL CAN bus connection P31 19 COM RS232GND Not used P31 20 AI FRONT AXLE POSITION SENSO...

Page 226: ... sensor P32 11 AI LR STEER SNSR C111LRS OR Analog signal input for left rear steer sensor P32 12 AI RF STEER SNSR C111RFS OR Analog signal input for right front steer sensor P32 13 AI LF STEER SNSR C111LFS OR Analog signal input for left front steer sensor P32 14 REF VALVE_RETURN_2 VLVRET2 BR Valve ground return P32 15 OM BRAKE V32BRK WH RD ON OFF valve drive brake P32 16 OM LR STEER RIGHT V36LRS ...

Page 227: ...1 OM P_39 S139TRF WH RD Safety circuit for turntable rotate power P121 12 REF GND SCONGND BR Ground for SCON ECU J122 Black 12 Pin Connector Pin NO Type Signal Name Circuit NO Signal Description P122 01 PWR ECU PWR P21DCON WH Power for SCON DCON ECU P122 02 AI LTB1LS BOOM LENGTH C166PRS OR Analog signal input for boom length safety P122 03 AI RSB1AS BOOM ANGLE C141PBS RD Analog signal input for bo...

Page 228: ... CR15A Glow Plugs 3 CR28 Fuel Power 4 SPARE 5 CR5 Horn 6 CR77 Function Enable 7 CR2 Ignition 8 CR41 Flashing Beacons 9 CR49 Work Drive Lights 10 CR17 Hydraulic Oil Cooler 11 F22A Fuse 30A Glow Plugs 12 F22C Fuse 2A GP Signal 13 F22B Fuse 30A Glow Plugs 14 F23 Fuse 30A Fuel Ignition 15 F46 Fuse 10A Horn 16 F7 Fuse 30A Accessory 17 D1 Alternator Diode 18 F20 Fuse 20A Hi Lo RPM ...

Page 229: ...8 Fuel Power 4 CR39 Deutz Aux Shutdown 5 CR5 Horn 6 CR77 Function Enable 7 CR2 Ignition 8 CR41 Flashing Beacons 9 CR49 Work Drive Lights 10 CR17 Hydraulic Oil Cooler 11 F22A Fuse 30A Glow Plugs 12 F22C Fuse 2A GP Signal 13 F22B Fuse 30A Glow Plugs 14 F23 Fuse 30A Fuel Ignition 15 F46 Fuse 10A Horn 16 F7 Fuse 30A Accessory 17 D1 Alternator Diode 18 F20 Fuse 20A ECU Power ...

Page 230: ...ower 3 CR1 Starter 4 SPARE 5 CR5 Horn 6 CR77 Function Enable 7 CR2 Ignition 8 CR41 Flashing Beacons 9 CR49 Work Drive Lights 10 CR17 Hydraulic Oil Cooler 11 F27A Fuse 30A ECU Power 12 F27C Fuse 2A ECU Signal 13 F27B Fuse 30A ECU Power 14 F23 Fuse 30A Start Ignition 15 F46 Fuse 10A Horn 16 F7 Fuse 30A Accessory 17 D1 Alternator Diode 18 F27D Fuse 20A Engine KSP ...

Page 231: ... Monitor Engine Hours 4 Digital Output 2 12 VDC Key Switch Activation 12V key switch on 0V key switch off Monitor machine utilization 5 Digital Output 3 12 VDC Foot switch 12V active 0V inactive Monitor machine utilization 6 Digital Input 1 12 VDC Remote Disable Engine Start Remotely Prevent Engine Start 7 Databus H CAN HIGH Genie Databus J1939 Engine Messages Receive Proprietary Genie Telematics ...

Page 232: ...nection no terminal Battery separator Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Main Key switch Service Bypass Key switch Steer sensor Auxiliary Pump Tilt sensor Relay Power relay Emergency Stop button Hydraulic oil cooling fan Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally open Oil pressure switch normally ...

Page 233: ...October 2016 Service and Repair Manual Electrical Symbols Legend Part No 1263382 SX 135 XC 223 ...

Page 234: ...uttle valve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator Solenoid operated proportional valve Pressure reducing valve Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid opera...

Page 235: ...October 2016 Service and Repair Manual Generator Receptacle Wiring ANSI CSA Part No 1263382 SX 135 XC 225 ...

Page 236: ...Service and Repair Manual October 2016 Generator Receptacle Wiring CE 226 SX 135 XC Part No 1263382 ...

Page 237: ...October 2016 Service and Repair Manual Generator Receptacle Wiring AUX Part No 1263382 SX 135 XC 227 ...

Page 238: ...Service and Repair Manual October 2016 228 Perkins 1104D 44T Engine Electrical Schematic ...

Page 239: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 229 Perkins 1104D 44T Engine Electrical Schematic ...

Page 240: ...Service and Repair Manual October 2016 230 SX 135 XC Part No 1263382 Perkins 1104D 44T Engine Electrical Schematic ...

Page 241: ...October 2016 Service and Repair Manual 231 Perkins 1104D 44T Engine Electrical Schematic ...

Page 242: ...Service and Repair Manual October 2016 232 Perkins 854F 34T Engine Electrical Schematic ...

Page 243: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 233 Perkins 854F 34T Engine Electrical Schematic ...

Page 244: ...Service and Repair Manual October 2016 234 SX 135 XC Part No 1263382 Perkins 854F 34T Engine Electrical Schematic ...

Page 245: ...October 2016 Service and Repair Manual 235 Perkins 854F 34T Engine Electrical Schematic ...

Page 246: ...Service and Repair Manual October 2016 236 Perkins 854F 34T Engine Harness ...

Page 247: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 237 Perkins 854F 34T Engine Harness ...

Page 248: ...Service and Repair Manual October 2016 238 SX 135 XC Part No 1263382 ...

Page 249: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 239 Deutz 2 9TF Engine Harness ...

Page 250: ...Service and Repair Manual October 2016 240 Deutz 2 9TF Engine Harness ...

Page 251: ...October 2016 Service and Repair Manual 241 Deutz TD2 9 Engine Electrical Schematic ...

Page 252: ...Service and Repair Manual October 2016 242 SX 135 XC Part No 1263382 Deutz 2 9TF Engine Electrical Schematic ...

Page 253: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 243 Deutz 2 9TF Engine Electrical Schematic ...

Page 254: ...Service and Repair Manual October 2016 244 Deutz 2 9TF Engine Electrical Schematic ...

Page 255: ...October 2016 Service and Repair Manual Part No 1263382 SX 135 XC 245 Hydraulic Schematic ...

Page 256: ...Service and Repair Manual October 2016 246 Hydraulic Schematic ...

Page 257: ...L BL WH ENG START BK HORN RET GR HORN PWR RD 10C RIBBON CABLE NC NC 21 22 RED 12 11 C154JRO BK WH C154JRO BK WH C62PBS OR 7 4 6 J20 PUR NC 22 21 13 14 NO RSLF1SO LF STEER SNSR S14 J110 RSRF1SO RF STEER SNSR S13 J109 LOWER LS HARNESS BOOM CABLE J142 1 J142 2 5 S42BRT OR P57PBD RD WH P63LS OR RD GR OR WH RD P20BAT OR GND OR WH P23PCON BK J155A 1 J155A 2 GND OR WH P20BAT OR J155C 1 TO LIGHT OPTION RE...

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