Page 1 Service and Repair Manual Serial Number Range SX-135 XC This manual includes: from SX135H-101 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...
Page 2: Introduction
Manuals, Parts Manuals and Operator's Manuals. Copyright © 2016 by Terex Corporation 1263382 Rev A, October 2016 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. SX-135 XC Part No. 1263382...
Page 3 October 2016 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 10/2016 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...
Page 4: Serial Number Legend
Service and Repair Manual October 2016 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) SX-135 XC Part No. 1263382...
Page 5: Safety Rules
October 2016 Service and Repair Manual Safety Rules Section 1 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 6 Service and Repair Manual October 2016 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 7: Table Of Contents
October 2016 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ...................
Page 8 October 2016 Table of Contents 2-2 Platform Leveling Cylinder ................31 2-3 Platform Rotator ..................... 32 How to Bleed the Platform Rotator ..............33 2-4 Platform Level Sensor ..................34 2-5 Platform Overload System ................35 2-6 Platform Overload Recovery Message ............38 Jib Boom Components ..................
Page 9 October 2016 Table of Contents Display Module ....................83 Hydraulic Pumps ....................90 7-1 Function Pump ....................90 How to Prime the Function Pump ..............91 How to Adjust the Function Pump Standby Pressure ........91 How to Adjust the Function Pump Pressure Compensator ......93 7-2 Drive Pump .....................
Page 10 October 2016 Table of Contents Section 4 Fault Codes ....................... 139 Introduction ......................139 Control System Fault Codes ................140 Fault Matrix ......................159 Fault Code Source ....................160 Deutz TD 2.9 L4 Engine Fault Codes .............. 163 Perkins 854F-34T Engine Fault Code ............. 178 Section 5 Schematics ......................
Page 11: Specifications
October 2016 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications Tires and wheels Tire size 445D50/710, FF Tire ply rating Tire weight, new foam-filled 850 lbs (minimum) 386 kg Overall tire diameter 45.47 in 115.5 cm Wheel diameter 28 in 71.1 cm Wheel width...
Page 12: Performance Specifications
Service and Repair Manual October 2016 Specifications Performance Specifications Boom function speeds, maximum from platform controls Drive speed, maximum Jib boom up/down - retracted 60 - 65 sec Stowed position, high speed 2.7 mph Jib boom up/down - extended 120 - 130 sec 3.7 km/h Jib boom extend/retract 50 - 60 sec...
Page 13: Hydraulic Oil Specifications
October 2016 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
Page 14 Service and Repair Manual October 2016 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
Page 15 October 2016 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...
Page 16: Hydraulic Component Specifications
Service and Repair Manual October 2016 Specifications Hydraulic Component Platform rotate and platform level 0.2 gpm flow regulator 0.76 L/min Specifications Steer/Axle Manifold Axle extend relief pressure 2400 psi Drive Pump 165 bar Type: bi-directional variable displacement piston pump Traction Manifold Displacement per revolution 2.8 cu in Hot oil relief pressure...
Page 17: Manifold Component Specifications
October 2016 Service and Repair Manual Specifications Manifold Component Brakes Specifications Brake relief pressure 160 psi 11 bar Plug torque Drive Motors SAE No. 2 36 in-lbs / 4 Nm Displacement per revolution 1.19 cu in high speed: 19.5 cc SAE No.
Page 18: Deutz Td2011L04I Engine Specifications
Service and Repair Manual October 2016 Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 220.9 cu. in Displacement 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C 3.78 x 4.92 inches Bore and Stroke Oil Pressure switch 96 x 125 mm...
Page 19: Deutz Td 2.9 Engine Specifications
October 2016 Service and Repair Manual Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 177 cu. in Displacement 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
Page 20: Perkins 1104D-44T Engine Specifications
Service and Repair Manual October 2016 Specifications Perkins 1104D-44T Oil Pressure switch Installation torque 8 - 18 ft-lbs 268.5 cu. in Displacement 11 - 24 Nm 4.4 liters Pressure switch point 8 psi Number of cylinders 0.55 bar 4.13 x 5 inches Bore and Stroke Oil Sensor Settings 105 x 127 mm...
Page 21 October 2016 Service and Repair Manual Specifications Perkins 1104D-44T cont. Engine coolant Capacity 9.5 quarts (engine only) 9 liters Coolant temperature switch 8 - 18 ft-lbs Installation torque 11 - 24 Nm Temperature switch point 230°F 110°C Temperature Sensor Settings 215°F 37 ohms 102°C...
Page 22: Perkins 854F-34T Engine Specifications
Service and Repair Manual October 2016 Specifications Perkins 854F-34T Oil Pressure switch Installation torque 18.4 ft-lbs 207 cu. in Displacement 25 Nm 3.4 liters Pressure switch point 12 psi Number of cylinders 0.82 bar 3.89 x 4.33 inches Bore and Stroke Oil Sensor Settings 99 x 110 mm 0 psi...
Page 23: Machine Torque Specifications
October 2016 Service and Repair Manual Specifications Machine Torque Specifications Perkins 854F-34T cont. Engine coolant Platform Rotator Capacity 16.5 quarts 1-8 center bolt, GR 5, dry 615 ft-lbs (50/50 extended life) 15.6 liters 834 Nm Coolant temperature switch 1/2-13 bolts, GR 8, dry 90 ft-lbs* 18.4 ft-lbs Installation torque...
Page 24: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual October 2016 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends...
Page 25: Torque Procedure
October 2016 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand replaced anytime the seal has been broken.
Page 26 Service and Repair Manual October 2016 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 27 October 2016 Service and Repair Manual This page intentionally left blank. Part No. 1263382 SX-135 XC...
Page 28: Repair Procedures
Service and Repair Manual October 2016 Repair Procedures Machine Configuration: Section 3 Repair Procedures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
Page 29: About This Section
October 2016 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
Page 30: Platform Controls
Service and Repair Manual October 2016 Platform Controls Platform Circuit Board Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: When the platform circuit board is replaced, the joystick controllers will need to be calibrated.
Page 31: How To Remove The Led Circuit Board
October 2016 Service and Repair Manual Platform Controls How to Remove the LED Circuit Board How to Remove the LED Circuit Attach a grounded wrist strap to the ground screw inside the control box. Board Electrocution/burn hazard. Push in the red Emergency Stop button to the Contact with electrically charged off position at both the ground and platform circuits could result in death or...
Page 32: Joysticks
Service and Repair Manual October 2016 Platform Controls Press the minus button twice, then press the enter button twice. Joysticks Use the scroll button to scroll through the menu until DELETE DRIVE JOYSTICK How to Calibrate a Joystick DEFAULTS is displayed. Press the plus button to select YES, then The joystick controllers on this machine utilize press the enter button.
Page 33 October 2016 Service and Repair Manual Platform Controls Steer functions: Primary boom extend/retract functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key switch to platform controls.
Page 34 Service and Repair Manual October 2016 Platform Controls Primary boom up/down functions: Jib boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key...
Page 35: How To Reset A Proportional Valve Coil Default
October 2016 Service and Repair Manual Platform Controls How to Reset a Proportional Valve Coil Default How to Reset a Proportional Turntable rotate functions: Valve Coil Default Turn the key switch to the off position. Note: Use the following chart to identify the Press and hold the enter button on the description of each LCD screen control button ground control panel while turning the key...
Page 36: How To Set The Function Thresholds And Default Functions Speeds
Service and Repair Manual October 2016 Platform Controls How to Set the Function Thresholds and Default Functions Speeds How to Set the Function Slowly move the joystick off center in the opposite direction just until the machine Thresholds and Default function starts to move, then move the joystick Functions Speeds very slowly towards the neutral or center...
Page 37 October 2016 Service and Repair Manual Platform Controls Function speeds: 15 Once the function speeds have been set, press and hold the engine start button until Note: Be sure the machine is in the stowed the engine shuts off. Do not press the red position and the boom is rotated between the circle Emergency Stop button.
Page 38: How To Adjust The Function Speeds
Service and Repair Manual October 2016 Platform Controls How to Adjust the Function Speeds How to Adjust the Function Press the enter button to save the setting in memory. Speeds Press the enter or previous button on the Note: Perform this procedure with the boom in the LCD screen until EXIT is displayed.
Page 39: How To Adjust The Function Ramp Rate Setting
October 2016 Service and Repair Manual Platform Controls How to Adjust the Function Ramp Rate Setting How to Adjust the Function Ramp Press the previous button until the function to be adjusted is displayed. Rate Setting Press the plus button to increase the ramp The ramp rate setting of a joystick controls the time rate or press the minus button to decrease at which it takes for the joystick to reach maximum...
Page 40: Platform Components
Service and Repair Manual October 2016 Platform Components Remove the weld cable from the platform (if equipped). Platform Electrocution/burn hazard. Contact with electrically charged How to Remove the Platform circuits could result in death or serious injury. Remove all rings, Separate the foot switch quick disconnect watches and other jewelry.
Page 41: Platform Leveling Cylinder
October 2016 Service and Repair Manual Platform Components Place a block under the platform leveling cylinder for support. Platform Leveling Cylinder Remove the external snap rings from the The platform leveling cylinder keeps the platform barrel-end pivot pin. Use a soft metal drift to level through the entire range of boom motion.
Page 42: Platform Rotator
Service and Repair Manual October 2016 Platform Components Remove the platform angle sensor retaining fasteners. Remove the platform angle sensor Platform Rotator from the platform rotator. The platform rotator is a hydraulically activated Component damage hazard. The helical gear assembly used to rotate the platform platform angle sensor is a very 160 degrees.
Page 43: How To Bleed The Platform Rotator
October 2016 Service and Repair Manual Platform Components How to Bleed the Platform Rotator How to Bleed the Platform Support the jib boom leveling arms with a suitable lifting device. Rotator Use a soft metal drift to remove both pins and Note: Do not start the engine.
Page 44: Platform Level Sensor
Service and Repair Manual October 2016 Platform Components Locate the calibration toggle switch at the top of the ground control box. Activate calibration Platform Level Sensor mode by moving the toggle switch in the left direction. The platform level sensor is mounted to the side of the platform rotator.
Page 45: Platform Overload System
October 2016 Service and Repair Manual Platform Components 11 Press the enter or previous button on the LCD screen until EXIT is displayed. Platform Overload System 12 Press the plus button or minus button to Proper calibration of the platform overload system select YES and then press the enter button.
Page 46 Service and Repair Manual October 2016 Platform Components 15 Press the plus button to select YES, then Turn the key switch to ground controls. press the enter button to accept. Open the ground control box. 16 Add weight to the platform corresponding to Locate the calibration toggle switch at the top the rated capacity of the machine, determined of the ground control box.
Page 47 October 2016 Service and Repair Manual Platform Components Confirm the setting: 30 Test all machine functions from the ground controls. 26 Lift the calibration weight off the platform floor using a suitable lifting device. Result: All ground control functions should not operate.
Page 48: Platform Overload Recovery Message
Service and Repair Manual October 2016 Platform Components Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message Press the enter or previous button on the LCD screen until CLEAR OVERLOAD If the ground controls LCD screen displays RECOVERY is displayed.
Page 49: Jib Boom Components
October 2016 Service and Repair Manual Jib Boom Components 1 platform rotator 9 jib lift cylinder 2 boom #5 10 platform leveling cylinder 3 boom #4 11 platform vertical link 4 bellcrank 12 platform lower link 5 jib angle sensor 13 jib rest pad 6 bellcrank leveling cylinder 14 platform level sensor...
Page 50: Jib Boom
Service and Repair Manual October 2016 Repair Procedures Tag, disconnect and plug the two hydraulic hoses from the jib boom manifold that lead to Jib Boom the platform manifold. Cap the fittings on the manifold. How to Remove the Jib Boom Bodily injury hazard.
Page 51 October 2016 Service and Repair Manual Repair Procedures Place blocks between the upper and lower 13 Remove the jib boom angle sensor mounting cable tracks and secure the upper and lower bracket fasteners from the side of the primary tracks together. extension boom.
Page 52: Jib Boom Lift Cylinder
Service and Repair Manual October 2016 Repair Procedures 19 Secure the jib boom lift cylinder to the jib boom with a strap or other suitable device. Jib Boom Lift Cylinder 20 Raise the jib boom to a horizontal position using the overhead crane. How to Remove the Jib Boom Lift 21 Attach a second lifting strap from the Cylinder...
Page 53: Jib Boom Level Cylinder
October 2016 Service and Repair Manual Repair Procedures Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Level Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Attach a lifting strap from an overhead crane Level Cylinder...
Page 54: Jib Boom Extension Cylinder
Service and Repair Manual October 2016 Repair Procedures Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use Jib Boom Extension Cylinder a soft metal drift to remove the pin. Tag, disconnect and plug the jib boom level How to Remove the Jib Boom cylinder hydraulic hoses from the jib boom Extension Cylinder...
Page 55 October 2016 Service and Repair Manual Repair Procedures Extend the jib boom until the jib boom 10 Pull the electrical cables out of the lower cable extension cylinder rod-end pivot pin is track that lead to the primary boom. accessible. 11 Attach a lifting strap from a second overhead Tag, disconnect and plug the two hydraulic crane to the pivot end of the jib boom for...
Page 56: How To Remove The Jib Boom Bellcrank
Service and Repair Manual October 2016 Repair Procedures 17 Attach a lifting strap from an overhead crane to the barrel end of the jib boom extension How to Remove the Jib Boom cylinder. Bellcrank 18 Remove the pin retaining fasteners from the jib boom extension cylinder barrel-end pivot Note: Perform this procedure with the boom in the pin.
Page 57: Jib Boom Bellcrank Angle Sensor
October 2016 Service and Repair Manual Repair Procedures Use a soft metal drift to remove the bellcrank lower link pivot pin. Jib Boom Bellcrank Angle Sensor Crushing hazard. The bellcrank The jib boom bellcrank angle sensor is monitored leveling cylinder may be by the control system to keep the jib boom damaged if it is not properly bellcrank vertical and to help maintain a level...
Page 58 Service and Repair Manual October 2016 Repair Procedures Note: Use the following chart to identify the Locate the calibration toggle switch at the top description of each LCD screen control button of the ground control box. Activate calibration used in this procedure. mode by moving the toggle switch in the left direction.
Page 59 October 2016 Service and Repair Manual Repair Procedures 11 Press the plus button to select YES, then 19 Press the plus button to select YES, then press the enter button to accept. press the enter button to accept. 12 Start the engine and use the platform level up 20 Turn the key back to the run position and button to fully extend the jib level cylinder.
Page 60: Boom Components
Service and Repair Manual October 2016 Boom Components 1 boom tube #1 4 boom lift cylinder 2 boom tube #2 5 bellcrank level cylinder 3 boom tube #3 6 bellcrank vertical link 7 bellcrank lower link 8 boom angle sensor 9 lower cable track 10 cable track 11 jib manifold...
Page 61: Primary Boom Cable Track
October 2016 Service and Repair Manual Boom Components Pull the electrical cables out of the lower cable track that lead to the primary boom. Primary Boom Cable Track Component damage hazard. The primary boom cable track guides the cables Cables can be damaged if they and hoses running up the boom.
Page 62 Service and Repair Manual October 2016 Boom Components 10 Remove the retaining fasteners from the cable 15 Locate the two hydraulic hoses inside the end track guide at the platform end of the boom. of the secondary boom that lead to the Remove the cable track guide from the primary boom cable track.
Page 63 October 2016 Service and Repair Manual Boom Components How to Repair the Primary Boom 20 Remove the mounting fasteners that attach the lower cable track to the primary boom lift Cable Track cylinder. Component damage hazard. 21 Remove the mounting fasteners that attach The boom cable track can be the cable track to the primary boom.
Page 64: Primary Boom
Service and Repair Manual October 2016 Boom Components Remove the upper rollers from the replacement section of cable track. Primary Boom Lift up the hoses and cables and carefully insert the new 4-link section of cable track. How to Shim the Boom Component damage hazard.
Page 65: Primary Boom
October 2016 Service and Repair Manual Boom Components Pivot end upper wear pads Primary Boom 10 Loosen the wear pad mounting fasteners. 11 Add shims by hand until snug. How to Remove the Primary Note: Do not use force when adding the shims. Boom 12 Remove one shim from each upper wear pad only.
Page 66 Service and Repair Manual October 2016 Boom Components Note: Most repair procedures to the boom Tag, disconnect and plug the primary boom assembly components can be performed with the extension cylinder hydraulic hoses. Cap the boom attached. fittings on the cylinder. Note: The boom assembly may be removed with Bodily injury hazard.
Page 67: How To Disassemble The Primary Boom
October 2016 Service and Repair Manual Boom Components How to Disassemble the Primary Boom How to Disassemble the Primary Remove the jib boom bellcrank. Refer to Repair Procedure, How to Remove the Jib Boom Boom Bellcrank. Bodily injury hazard. This Remove the boom primary extension cylinder.
Page 68 Service and Repair Manual October 2016 Boom Components Remove the #2 boom tube: 15 Attach the #3 boom tube to a forklift, and lift the tube enough to relieve the pressure from 18 Tag and disconnect the harness to limit switch the lower wear pads, begin sliding the tube 3RS and 4EOS.
Page 69 October 2016 Service and Repair Manual Boom Components 23 Remove the fasteners securing the lower 27 Remove the final two side wear pads from the wear pads and remove the wear pads and platform end of the machine. aluminum block between the #1 and #2 boom Note: Pay careful attention to the location and tubes.
Page 70: Primary Boom Lift Cylinder
Service and Repair Manual October 2016 Boom Components Attach an overhead 10 ton / 9071 kg crane to the platform end of the boom for support. Do Primary Boom Lift Cylinder not lift the boom. The primary boom lift cylinder raises and lowers Note: Place the lifting strap between the cable the primary boom.
Page 71 October 2016 Service and Repair Manual Boom Components Tag, disconnect and plug the boom lift 14 Remove the pin retaining fastener from the cylinder hydraulic hoses. barrel-end pivot pin. Do not remove the pin. 15 Support the boom lift cylinder with an Bodily injury hazard.
Page 72: Extension Cylinder
Service and Repair Manual October 2016 Boom Components Tag and disconnect the limit switch harnesses. Remove the fasteners to the limit Extension Cylinder switch harness mounting bracket and remove the bracket. The primary boom extension cylinder is located inside the boom assembly and incorporates cables Disconnect and remove the string and pulleys that are responsible for extending the potentiometer from boom tube #1.
Page 73 October 2016 Service and Repair Manual Boom Components Loosen the #3 extend cable adjustment bolts 10 turns (about 1 in / 2.54 cm). Note: Do not over loosen the extend cables. Remove the locking plates securing the extend cylinder to boom #1 (1). (Illustration 1) Remove the locking plates securing the extend cylinder to boom #2 (2).
Page 74: Boom Extend And Retract Cables
Service and Repair Manual October 2016 Boom Components Support and slide the primary boom extension cylinder out of the boom assembly while Boom Extend and Retract Cables guiding the cables out of the boom and place it on a structure capable of supporting it. How to Adjust the Boom Crushing hazard.
Page 75 October 2016 Service and Repair Manual Boom Components Measure the distance between boom tubes #2 and #3 using points (10) and (11). (Illustration 1) The 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".
Page 76 Service and Repair Manual October 2016 Boom Components 15 Torque the #1 retract bolt to 70 ft-lbs / 94.9 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.
Page 77: How To Replace The Boom Extend/Retract Cables
October 2016 Service and Repair Manual Boom Components How to Replace the Boom Extend/Retract Cables How to Replace the Boom 25 Fully retract the boom and lower the boom to the horizontal position. Extend/Retract Cables 26 Stop the engine. Note: The cable sheaves must be inspected when 27 Re-measure the gap between boom tubes replacing the cables.
Page 78 Service and Repair Manual October 2016 Boom Components At the pivot end remove the string potentiometer. Remove the fasteners securing the red extend cable locking bracket. Illustration 2 1 red extend cable locking bracket 2 retract cable retaining plate 3 retract cable Remove the fasteners securing the retract cable retaining plate, and lay the retract cable on the bottom of the boom.
Page 79: Primary Boom Angle Sensor
October 2016 Service and Repair Manual Boom Components Note: Use the following chart to identify the description of each LCD screen control button Primary Boom Angle Sensor used in this procedure. The primary boom angle sensor is used to limit the angle of the primary boom relative to the angle of the turntable and gravity.
Page 80 Service and Repair Manual October 2016 Boom Components 13 Press and hold a function enable/speed select Press and hold the enter button on the button and the primary boom button until the ground control panel while pulling out the boom stops at the end of the lift cylinder ground controls red Emergency Stop button to stroke.
Page 81: Boom Length Sensor
October 2016 Service and Repair Manual Boom Components 19 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Boom Length Sensor Stop button in. 20 Remove the fastener that was temporarily How to Calibrate the Primary installed.
Page 82 Service and Repair Manual October 2016 Boom Components Note: Use the following chart to identify the Press and hold the enter button on the description of each LCD screen control button ground control panel while pulling out the used in this procedure. ground controls red Emergency Stop button to the on position.
Page 83 October 2016 Service and Repair Manual Boom Components 18 Press 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.
Page 84: Engines
Service and Repair Manual October 2016 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Refer to Maintenance Procedure in the appropriate engine and the pump. It is bolted to the engine Service or Maintenance Manual for your machine, flywheel and has a splined center to drive the Check and Adjust the Engine RPM.
Page 85: How To Install The Flex Plate
October 2016 Service and Repair Manual Engines Perkins engines: Torque the pump plate How to Install the Flex Plate How to Install the Flex Plate mounting bolts in sequence to 23 ft-lbs / 31 Nm. Then torque the pump plate mounting Install the flex plate onto the engine flywheel bolts in sequence to 47 ft-lbs / 63 Nm.
Page 86: Ground Controls
Service and Repair Manual October 2016 Ground Controls How to Use the Bypass Mode Bypass/Recovery Key Switch Tip-over hazard. Operating the machine outside of the operating The turntable control box (TCON) is the envelope while in Bypass mode communication and operations center for the will result in death or serious machine.
Page 87 October 2016 Service and Repair Manual Ground Controls How to Use the Recovery Mode Turn the bypass/recovery key switch to the bypass position. Recovery is only to be used as a last attempt to Using auxiliary power, operate the ground lower the platform when the operator in the control buttons to level the platform.
Page 88: Circuit Boards
Service and Repair Manual October 2016 Ground Controls Turn and hold the bypass/recovery key switch to the recovery position. The switch must be Circuit Boards held in the recovery position. The ground control box contains a replaceable Result: The auxiliary power unit will turn on membrane decal with touch sensitive buttons for and the boom will begin the following recovery various machine functions.
Page 89 October 2016 Service and Repair Manual Ground Controls How to Remove the ALC-1000 Component damage hazard. Electrostatic discharge (ESD) Circuit Board can damage printed circuit board components. Maintain firm Push in the red Emergency Stop button to the contact with a metal part of the off position at both the ground and platform machine that is grounded at all controls.
Page 90: Membrane Decal
Service and Repair Manual October 2016 Ground Controls Tag and carefully disconnect the wire connectors from the circuit board. Membrane Decal Carefully disconnect the LCD circuit board The membrane decal is a special decal that ribbon cable from the ECM circuit board. consists of a decal with an electronic membrane Carefully disconnect the two ribbon cables on the backside.
Page 91: Full Machine Calibration
October 2016 Service and Repair Manual Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Full Machine Calibration board. Full machine calibration must be completed in the Electrocution/burn hazard. proper sequence when the ALC-1000 circuit board Contact with electrically charged (TCON) in the ground control box has been circuits could result in death or...
Page 92 Service and Repair Manual October 2016 Ground Controls • Joysticks. Refer to Repair Procedure, How to Calibrate a Joystick. • Turntable level sensor. Refer to Repair Procedure, How to Calibrate the Turntable Level Sensor. • Platform level sensor. Refer to Repair Procedure, How to Calibrate the Platform Level Sensor.
Page 93: Display Module
October 2016 Service and Repair Manual Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 94 Service and Repair Manual October 2016 Display Module Screen or Menu Procedure Description Range or Selection With key switch on, press the Hydraulic pressure PSI 0-4500 PSI Machine Status (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa (metric) 0-31000 kPa Primary angle degrees -2°...
Page 95 October 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Forward extended drive speed % 120% (max) 100% (default) Drive Functions and hold the enter button 50% (min) and turn key switch to on Forward not stowed drive 120% (max) 100% (default) position.
Page 96 Service and Repair Manual October 2016 Display Module Screen or Menu Procedure Description Range or Selection Boom Function With key switch , press Primary boom up speed stowed and hold the enter button Speeds and turn key switch to on position.
Page 97 October 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Primary boom up/down Lift Functions hold the enter button and turn key ramp acceleration % Ramps switch to on position. Primary boom up/down Release the enter button and ramp deceleration %...
Page 98 Service and Repair Manual October 2016 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Set unit X-axis to gravity Sensor Calibration and hold the enter button Set unit Y-axis to gravity and turn key switch to on position.
Page 99 October 2016 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press AC Generator (NONE/7.5KW/12.5KW) Options and hold the enter button and turn key switch to on position. Release the enter button and press (minus)(minus)(plus)(plus).
Page 100: Hydraulic Pumps
Service and Repair Manual October 2016 Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying The function pump is a pressure compensated, hydraulic oil can penetrate and variable displacement piston pump.
Page 101: How To Prime The Function Pump
October 2016 Service and Repair Manual Hydraulic Pumps How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Connect a 0 to 5000 psi / 0 to 350 bar end must be replaced.
Page 102 Service and Repair Manual October 2016 Hydraulic Pumps Pressure reads 350 psi / 25 bar Pressure reads less than 350 psi / 25 bar One or both of the function pumps may be at Loosen the set screw for the standby pressure the correct pressure.
Page 103: How To Adjust The Function Pump Pressure Compensator
October 2016 Service and Repair Manual Hydraulic Pumps How to Adjust the Function Pump Pressure Compensator How to Adjust the Function Pump Pressure reads more than 350 psi / 25 bar Pressure Compensator Loosen the set screw for the standby pressure adjustment screw on the rear function pump.
Page 104: Drive Pump
Service and Repair Manual October 2016 Hydraulic Pumps Loosen the set screw for the pressure compensator adjustment screw. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Page 105 October 2016 Service and Repair Manual Hydraulic Pumps Locate the two hydraulic tank valves at the Carefully pull the drive pump out until the hydraulic tank. Close the valves. pump coupler separates from the flex plate. Remove the drive pump from the machine. Component damage hazard.
Page 106: How To Prime The Drive Pump
Service and Repair Manual October 2016 Hydraulic Pumps How to Prime the Drive Pump How to Prime the Drive Pump Component damage hazard. Be sure to open the two hydraulic tank valves before performing this procedure. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A"...
Page 107 October 2016 Service and Repair Manual Hydraulic Pumps This page intentionally left blank Part No. 1263382 SX-135 XC...
Page 108: Manifolds
Service and Repair Manual October 2016 Manifolds Function Manifold Components The function manifold is mounted next to the hydraulic tank on the ground control side of the machine. Index Schematic Description Function Torque Item Orifice, 0.025 in / 0.635 mm Orifice, 0.025 in / 0.635 mm Primary boom extend/retract circuit, regulates pressure drop...
Page 109 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 110 Service and Repair Manual October 2016 Manifolds Function Manifold Components, View 1 continued Schematic Index No. Description Function Torque Item Prevents hydraulic pressure from 19-21 ft-lbs / Check valve, 5 psi / 0.34 bar flowing back into auxiliary pump #1 25.7-28.5 Nm 24-26 ft-lbs / Relief valve, 3200 psi / 221 bar...
Page 111 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 112: Valve Adjustments - Function Manifold
Service and Repair Manual October 2016 Manifolds How to Adjust the Primary Boom Valve Adjustments - Extend Relief Valve Function Manifold Note: Perform this procedure with the axles extended. How to Adjust the Function Locate limit switch LSB4EO on the bottom of boom #1.
Page 113 October 2016 Service and Repair Manual Manifolds Simultaneously push and hold the function enable and the primary boom extend button with the primary boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications. Note: The pressure at the ptest port on the function manifold is a combination of pressures produced by the differential valve and relief valve.
Page 114: Platform Level And Rotation Manifold
Service and Repair Manual October 2016 Manifolds Jib Manifold Components The jib manifold is mounted on the side of the # 3 Boom. Index Schematic Description Function Torque Item 19-21 ft-lbs / Proportional solenoid valve, 3 position 4 way Jib boom up/down 25.8-28.6 Nm 19-21 ft-lbs / Proportional solenoid valve, 3 position 4 way...
Page 115 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 116: Platform Manifold
Service and Repair Manual October 2016 Manifolds Platform and Rotator Manifold Components The platform manifold is mounted on the platform and the rotator manifold is mounted on the rotator. Schematic Index No. Description Function Torque Item Proportional solenoid valve, 3 position 19-21 ft-lbs / Platform left/right circuit 4 way...
Page 117 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 118: Steer And Axle Manifold
Service and Repair Manual October 2016 Manifolds Steer and Axle Manifold The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Right front steer cylinder retract 20-25 ft-lbs / Flow control valve, 1.5 gpm / 5.7 L/min circuit...
Page 119 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 120 Service and Repair Manual October 2016 Manifolds Steer and Axle Manifold, continued Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 30-35 ft-lbs / Axle extend/retract circuit 165 bar 41-47 Nm Prevents left rear steer cylinder 20-25 ft-lbs / Check valve from moving when not steering...
Page 121 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 122: Function Enable Manifold
Service and Repair Manual October 2016 Manifolds Function Enable Manifold The jib boom manifold is mounted inside the primary extension boom at the platform end. Index No. Description Schematic Item Function Torque Enables function pumps to provide 20-25 ft-lbs / Solenoid valve, 2 position 2 way hydraulic pressure for all boom and 27-34 Nm...
Page 123: Valve Adjustments - Steer And Axle Manifold
October 2016 Service and Repair Manual Manifolds Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it clockwise to increase the pressure or Axle Manifold counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
Page 124: Traction Manifold Components
Service and Repair Manual October 2016 Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic Description Function Torque Item 30-35 ft-lbs / Check valve Anti-cavitation 40.7-47.5 Nm 26-30 ft-lbs / Solenoid Valve, 2 position 3 way Two-speed drive motor shift...
Page 125 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 126 Service and Repair Manual October 2016 Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic Description Function Torque Item Equalizes pressure on both sides of 30-35 ft-lbs / Orifice, 2 gpm / 7.6 L/min divider/combiner valve AP 40.7-47.5 Nm...
Page 127 October 2016 Service and Repair Manual Manifolds Part No. 1263382 SX-135 XC...
Page 128: Valve Adjustments - Traction Manifold
Service and Repair Manual October 2016 Manifolds Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Start the engine from the ground controls. Manifold 10 Press and hold the function enable/high rpm select button (rabbit symbol) position. How to Adjust the Hot Oil 11 Adjust the internal hex socket until the Relief Valve...
Page 129: Generator Manifold Component
October 2016 Service and Repair Manual Manifolds 8-10 Generator Manifold Components The oil diverter manifold is mounted near the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item 19-21 ft-lbs / Check valve Controls flow to diverter valve 25.7-28.5 Nm 33-37 ft-lbs / Solenoid Valve...
Page 130: Valve Coils
Service and Repair Manual October 2016 Manifolds Valve Coil Resistance 8-11 Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
Page 131 October 2016 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 132: Turntable Rotation Components
Service and Repair Manual October 2016 Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 133: How To Adjust The Turntable Rotation Gear Backlash
October 2016 Service and Repair Manual Turntable Rotation Components Turn the adjustment bolt 1/2 to 3/4 turn How to Adjust the Turntable Rotation Gear Backlash How to Adjust the Turntable counterclockwise. Tighten the lock nut on the Rotation Gear Backlash adjustment bolt.
Page 134: Turntable Level Sensor
Service and Repair Manual October 2016 Turntable Rotation Components Push in the ground controls red Emergency Stop button to the off position. Turntable Level Sensor Open the ground control box. How to Calibrate the Turntable Locate the calibration toggle switch at the top of the ground control box.
Page 135 October 2016 Service and Repair Manual Turntable Rotation Components Enter sensor calibration mode by pressing the 10 Place the digital level along the X axis of the buttons at the ground controls in the following turntable. sequence: (plus)(enter)(enter)(plus). 1 -X Axis 2 +X Axis 3 Platform end 11 Press the plus button or minus button to...
Page 136 Service and Repair Manual October 2016 Turntable Rotation Components 18 Use the key to turn the bypass / recovery key 13 Press the plus button or minus button to switch to the run position. adjust the display to the exact value shown on the digital level and press the enter button.
Page 137: Axle Components
October 2016 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor Steer Sensors assembly. Note: If the sensor activator pin needs to be The steer sensors measure steer angle and replaced, install the new activator pin per communicates that information to the ground controls ECM.
Page 138 Service and Repair Manual October 2016 Axle Components Left front (square-end, blue side) and right rear Rotate the sensor housing in a clockwise (circle-end, yellow side) angle sensors: direction until the sensor cable is pointing away from the machine. Refer to Illustration 2. Install the steer sensor cover retaining fasteners.
Page 139: How To Calibrate All Steer Sensors
October 2016 Service and Repair Manual Axle Components How to Calibrate All Steer Sensors How to Calibrate All Steer 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable Sensors angled away from the tire. Refer to Illustration Note: This procedure will only need to be performed if the ground controls circuit board 11 Align the sensor with the pin and install the...
Page 140 Service and Repair Manual October 2016 Axle Components Using a voltmeter set to DC voltage, probe the Press and hold the enter button on the back of the electrical connector at pins B and ground control panel while pulling out the ground controls red Emergency Stop button to the on position.
Page 141 October 2016 Service and Repair Manual Axle Components Delete all Steer Sensor Calibrations 20 Push in the red Emergency Stop button to the off position. 11 Press the enter or previous button on the 21 Remove the fastener that was temporarily LCD screen until DELETE ALL STEER installed.
Page 142: Steer Cylinders
Service and Repair Manual October 2016 Axle Components 10-2 10-3 Steer Cylinders Axle Extension Cylinders How to Remove a Steer Cylinder 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 Note: When removing a hose assembly or fitting, end must be replaced.
Page 143: Axle Angle Sensors
October 2016 Service and Repair Manual Axle Components 10-4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Angle Sensors cylinder. The axle angle sensors measure the axle angle Note: Connect the pressure hose from the power and communicates that information to the ground unit to the "R"...
Page 144 Service and Repair Manual October 2016 Axle Components Temporarily install a control box door retaining Enter sensor calibration mode by pressing the fastener between the door and the box to buttons at the ground controls in the following prevent the control box door from moving the sequence: (plus)(enter)(enter)(plus).
Page 145: Axle Angle Sensors
October 2016 Service and Repair Manual Axle Components 10-4 16 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Axle Angle Sensors Stop button in. The axle angle sensors measure the axle angle 17 Remove the fastener that was temporarily and communicates that information to the ground installed.
Page 146 Service and Repair Manual October 2016 Axle Components Temporarily install a control box door retaining Enter sensor calibration mode by pressing the fastener between the door and the box to buttons at the ground controls in the following prevent the control box door from moving the sequence: (plus)(enter)(enter)(plus).
Page 147 October 2016 Service and Repair Manual Axle Components 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.
Page 148: Generators
Service and Repair Manual October 2016 Generators 11-1 Start the engine from the platform controls. Welder Generator Turn on the generator from the platform controls and let the generator run for at least three minutes. How to Set the Welder Generator Insert the leads from a multimeter set to Frequency register frequency (HZ) and turn the needle...
Page 149: Fault Codes
October 2016 Service and Repair Manual Fault Codes Before Troubleshooting: Section 4 Fault Codes  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.
Page 150: Control System Fault Codes
Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
Page 151 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from buttons on TCON buttons pressed) display message on LCD membrane switch.
Page 152 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/RSB1AS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem Cross-check Rotate, and Propel powers in SCON. corrected. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RS.
Page 153 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem Cross-check Rotate, and Propel powers in SCON. corrected. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 154 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions LSB2RS (151ft)/LSB4ES Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem (150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
Page 155 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Axle Extend/Retract Fault Check Axle extend/retract disabled. Display Check for defective or damaged wiring Switches message on LCD or switches. Power up controller with problem corrected.
Page 156 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Extend Power P10 Fault Check Display message on LCD PRI Power up controller with problem EXTEND POWER P10 FAULT corrected. Primary Up Power P11 Fault Check Display message on LCD PRI UP Power up controller with problem...
Page 157 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
Page 158 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged Valve zero and neutral, Alarm sounds wiring. Check for an open or shorted valve coil.
Page 159 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 160 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem Angle Sensor Rotate, and Propel. Boom Retract corrected.
Page 161 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Platform Level Sensor Y Value at 5.0 V Primary up and extend disabled, Alarm Power up controller with problem Direction sounds corrected. Value Too High Value Too Low Value at 0 V Just calibrated...
Page 162 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Jib Level (Bellcrank) Not calibrated Normal function except threshold for Perform calibration procedure Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD Just calibrated Initiate one second beep of audible...
Page 163 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Platform Rotate Switches Fault Check (both Primary Boom Up/Down disabled. Power up controller with problem buttons pressed) Display message on LCD corrected. Platform Level Switches Fault Check (both Primary Boom Ext/Ret disabled.
Page 164 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Front Axle Angle Sensor Value at 5.0 V Primary up and Extend disabled, axle Check for an open ground circuit extend and retract LED flash going to the sensor Value Too High Primary up and Extend disabled, axle...
Page 165 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Propel Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds joystick.
Page 166 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit Sensor zero and neutral, Alarm sounds going to the sensor Value Too High Limited Speed and Direction frozen at...
Page 167 October 2016 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit Sensor zero and neutral, Alarm sounds going to the sensor Value Too High Limited Speed and Direction frozen at...
Page 168 Service and Repair Manual October 2016 Control System Fault Codes Error Source Error Type Effects Recovery Actions PBMAS Safety Envelope Position Check Disable Boom Up, TT Rotate, Propel Return Boom back inside Operational and Ignition/Fuel. Boom Down and Envelope Retract allowed. All functions allowed once boom is lowered back into envelope.
Page 169: Fault Matrix
October 2016 Service and Repair Manual Control System Fault Codes P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary P_9A - Primary P_9B - (P13-17 TCON) Rotate (P13-19 Boom Extend Up (P12-09 Down (P12-06 Ignition/Fuel TCON) (P12-08 TCON) TCON) TCON) (P12-07 TCON)
Page 170: Fault Code Source
Service and Repair Manual October 2016 Control System Fault Codes Fault Source and Type will display as: Fault Source Description Source Type SCON Controller Area Network “ ID XXX_xx FAULT “ Primary Boom Angle Zone Where XXX is the one to three digit Fault Source and xx is the two digit Fault Type.
Page 171 October 2016 Service and Repair Manual Control System Fault Codes Fault Source Fault Source Description Description Turntable Level Sensor X-Direction Enable Output Power P7R Turntable Level Snesor Y-Direction Primary Down Power P9A Boom Length Sensors Cross-Check (SCON) IGN/Fuel Power P9B Boom Safety Envelope (SCON) Primary Extend Power P10 Turntable Controller - Platform Controller...
Page 172 Service and Repair Manual October 2016 Control System Fault Codes Fault Source Description Brake Valve Motor Shift Valve Chassis Tilt Sensors Cross-Check (SCON) Jib Bellcrank Level Sensor Jib Bellcrank Level Flow Valve AUX Relay Platform Level Toggle Switch Platform Rotate Toggle Switch Platform Level Flow Valve Platform Rotate Valve Boom Length Sensor...
Page 173: Deutz Td 2.9 L4 Engine Fault Codes
October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN FMI Description SPN = Suspect Parameter Number 1022 Actuator error EGR-Valve; signal FMI = Failure Mode Identifier range check high KWP = Keyword Protocol 1224 Actuator EGR-Valve; over SPN FMI Description current...
Page 174 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; KWP = Keyword Protocol signal range check high SPN FMI Description Sensor error ambient air press.;...
Page 175 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI Description High Low fuel temperature;...
Page 176 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description Sensor error EGR cooler...
Page 177 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI Description Starter relay low side;...
Page 178 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off threshold exceeded SPN FMI Description...
Page 179 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout KWP = Keyword Protocol error of short circuit to ground measurement cyl.
Page 180 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 Pressure Relief Valve (PRV) reached maximun allowed 4766...
Page 181 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring Maximum rail pressure in limp...
Page 182 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 Metering unit (Fuel-System);...
Page 183 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 check of missing injector KWP = Keyword Protocol adjustment value programming (IMA) injector 3 (in firing order) FMI KWP Description check of missing injector 523898...
Page 184 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description EEC3VOL2; Engine send messages 1262 Burner Shut Off Valve;...
Page 185 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not...
Page 186 Service and Repair Manual October 2016 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame KWP Description ComEGRTVActr 1341 Injector diagnostics; time out 1679 Timeout error of 524035 12 524109 9...
Page 187 October 2016 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol KWP Description 1682 Timeout error of 524120 9 CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9...
Page 188: Perkins 854F-34T Engine Fault Code
Service and Repair Manual October 2016 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test Position :Voltage Above Normal Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test Position :Voltage Be- low Normal Accelerator Pedal Position 2 :Voltage Above...
Page 189 October 2016 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test...
Page 190 Service and Repair Manual October 2016 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit- Above Normal Test Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -...
Page 191 October 2016 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test Engine Injector Cylinder #02 :Data Drifted Low...
Page 192 Service and Repair Manual October 2016 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test Valve :Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test...
Page 193 October 2016 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test Control:Current Below Normal 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test Control :Current Above Normal...
Page 194 Service and Repair Manual October 2016 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test Temperature : High- least severe (1) 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test...
Page 195 October 2016 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test Inhibited Status : Current Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -...
Page 196 Service and Repair Manual October 2016 This page intentionally left blank. SX-135 XC Part No. 1263382...
Page 197: Schematics
October 2016 Service and Repair Manual Schematics About This Section Section 5 Schematics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, ...
Page 198: Wire Circuit Legend
Service and Repair Manual October 2016 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. Control The circuit prefix indicates the type of circuit. Data The circuit number describes the function of the circuit.
Page 199 October 2016 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 200 Service and Repair Manual October 2016 Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 201 October 2016 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 202: Wire Color Legend
Service and Repair Manual October 2016 Wire Color Legend Wire Coloring Jib, Jib Level, Platform Level Propel (drive) valves All cylinder extension colors are solid and all Turntable rotate flow control valve retract functions are striped black. When Color Circuit # Primary Function using black wire, the stripe shall be white.
Page 203 October 2016 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function WH/RD Power to temp sender GR/BK Axle oscillation Auxiliary Power Foot switch/TCON estop power RD/BK Platform level alarm RD/WH Boom down safety interlock RD/WH Drive Motor shift (speed) RD/BK...
Page 204 Service and Repair Manual October 2016 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Hydraulic Filter restricted Flashing Beacon Platform Level Safety Power Lift Speed Reduction RD/BK Platform Level Safety Output Hydraulic Pressure Sensor Output Platform Level Safety Ground Oil Cooler Fan RD/BK...
Page 205 October 2016 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary Boom Angle Signal Boom Length Signal Safety Safety OR/BK Boom Length Signal Operational Secondary Boom Angle Signal BL/RD Primary Boom Hydraulic Valve Safety Lockout BL/RD...
Page 206 Service and Repair Manual October 2016 Wire Color Legend Color Circuit # Primary Function Safety cross check Data Receive BK/WH Data Transmit WH/RD Multi-Function Pressure Relief WH/BK Jib Rotate Left WH/RD Jib Rotate Right WH/RD Speed Select Input OR/RD Electric Brake Source 2.5V Sensor Power Hour Meter +12V Sensor Power...
Page 207: Limit Switches And Angle Sensors
October 2016 Service and Repair Manual Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Stringpot Rear...
Page 208 Service and Repair Manual October 2016 Limit Switches and Angle Sensors Switches and Sensors - Primary Boom Index Description Schematic Item Function Controlled Switch Type and Operation Primary Boom Extended Operational LSB4EO Primary boom fully extended Normally closed; Limit Switch contacts open whenboom sections #2 and #3 fully extended...
Page 209 October 2016 Service and Repair Manual Limit Switches and Angle Sensors Switches and Sensors - Turntable Index Description Schematic Item Function Controlled Switch Type and Operation Turntable #1 Operational Limit LST1O Activates the drive enable Normally closed Switch zone when the turntable is switch;contacts open rotated in the right direction.
Page 210 Service and Repair Manual October 2016 Limit Switches and Angle Sensors Switches and Sensors - Drive Chassis Index Description Schematic Item Function Controlled Switch Type and Operation Front Axle #1Extended Safety Limit LSFA1ES Disables boom functions when Normally open Switch. axles are retracted.
Page 211: Circuit Connector Legend
October 2016 Service and Repair Manual Circuit Connector Legend Number Description Number Description Molex connector on toggle/LED pcb 2 pin Deutsch DTP connector (swivel-lower) Ribbon connector from TCON to membrane 6 pin Deutsch DTP connector (swivel-lower) 6 pin Deutsch DT connector for platform tilt Ribbon connector from TCON to membrane sensor (S6) 4 pin Deutsch DTP connector for throttle...
Page 212 Service and Repair Manual October 2016 Circuit Connector Legend Number Description Number Description 2 pin Deutsch DT two speed motor stroke J135 2 pin Deutsch DT jib bellcrank up valve (Y85) valve (Y27) J136 2 pin Deutsch DT jib bellcrank down valve 2 pin Deutsch DT RR steer right valve (Y55) (Y86) 2 pin Deutsch DT RR steer left valve (Y56)
Page 213 October 2016 Service and Repair Manual Circuit Connector Legend Number Description Number Description J160 6 pin Deutsch DT front axle sensor (RSFA10) J210 2 pin Deutsch DT 10 deg angle oper (LSB1DO) J161 6 pin Deutsch DT rear axle sensor (RSRA10) J211 4 pin Deutsch DT 3ft extend oper (LSB3RO) J162...
Page 214: Connector Pin Legend
Service and Repair Manual October 2016 Connector Pin Legend Pin location - 4 pin Pin location - 23 pin Pin location - 35 pin connector connector connector Pin location - 12 pin connector Abbreviation High Current On/Off Solenoid Output (3 < x < 6 Amps) Medium Current On/Off Solenoid Output (0.5 <...
Page 215 October 2016 Service and Repair Manual Connector Pin Legend J11 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P11-01 P CON G ND GNDPCON-BR PCON ground P11-02 P CON P OWE R P 52PCON-WH Power output to PCON. Unregulate d 12V auto motive power.
Page 216 Service and Repair Manual October 2016 Connector Pin Legend J12 Black 35 Pin Connector Pin No. Type Signal Name Circuit No. Signal Description P12-01 SCON ECU GND SCONGND-BR Ground for SCON ECU P12-02 DCON ECU PWR P21DCON-WH 12V power for ECU power P12-03 P_6R1 P53LS-WH/BK...
Page 217 October 2016 Service and Repair Manual Connector Pin Legend J13 White 23 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description P13-01 VALVE_RETURN_1 Valve ground return (return for throttle RPM solenoid) P13-02 THROTTLE C35RPM-BK/RD Provides power to throttle actuator relay P13-03 FUEL/IGNITION C21IGN-WH...
Page 218 Service and Repair Manual October 2016 Connector Pin Legend J14 White 35 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description P14-01 VALVE_RETURN_4 VLVRET4-BR Valve ground return P14-02 PRI BM U/D FC VLV #2 V03PUD2-GR/WH Proportional PWM valve drive (primary boom up/down valve #2 -GROSS-) P14-03 PRI BM E/R FC VLV...
Page 219 October 2016 Service and Repair Manual Connector Pin Legend J17 - 16 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description J17-1 PWR TO TCON ESTOP BL/BK Power to TCON E-Stop (P1) J17-2 NOT USED J17-3 SERV/CAL MODE Service/calibration mode signal J17-4 CONT...
Page 220 Service and Repair Manual October 2016 Connector Pin Legend J21 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P21-01 PCON GND GNDPCON-BR PCON ground P21-02 PCON PWR P52PCON-WH Power for PCON P21-03 NOT USED P21-04 CONT S56PRV-RD 12V when footswitch is pressed...
Page 221 October 2016 Service and Repair Manual Connector Pin Legend J22 White 35 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P22-01 VALVE_RETURN_1 VLVRET1-BR Valve ground return P22-02 SPARE OM ON/OFF valve drive P22-03 PLAT ROT CCW V18PRR-GR/BK ON/OFF valve drive (platform rotate CCW - right) P22-04 PLAT ROT CW...
Page 222 Service and Repair Manual October 2016 Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J29-1 JOYSTICK_GND_2 JSGND2-BR Joystick signal ground (JC8) J29-2 JOYSTICK_GND_3 JSGND3-BR Joystick signal ground (JC2) J29-3 SNSR JOYSTICK_PWR_2 P162JPW2-OR Joystick power (JC8) J29-4 SNSR JOYSTICK_PWR_3 P162JPW3-OR...
Page 223 October 2016 Service and Repair Manual Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J169-1 JIB ROTATE C213JRS-RD/BK Jib rotate CW/CCW signal from jib joystick (JC8) J169-2 GND4-BR Joystick case ground (JC7) J169-3 JIB UP/DOWN C156JUD-GR/WH Jib up/down signal from jib joystick (JC8)
Page 224 Service and Repair Manual October 2016 Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J1-1 PWR-HORN HORN PWR-RD Power for Service Horn button J1-2 RET-HORN HORN RET-GR Return for Service Horn button J1-3 GENERATOR ON/OFF GEN ON/OFF-GR/WH Generator toggle switch input J1-4...
Page 225 October 2016 Service and Repair Manual Connector Pin Legend J31 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P31-01 DCON ECU GND GNDDCON-BR DCON ground P31-02 DCON ECU PWR P21DCON-WH Power for DCON P31-03 P_6R1 P53LS-WH/BK Power for motor speed and brake valves P31-04...
Page 226 Service and Repair Manual October 2016 Connector Pin Legend J32 White 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P32-01 VALVE_RETURN_1 VLVRET1-BR Valve ground return P32-02 AXLE RETRACT V61AXRT-GR ON/OFF valve drive (axle retract) P32-03 AXLE EXTEND V60AXEX-GR/WH ON/OFF valve drive (axle extend) P32-04...
Page 227 October 2016 Service and Repair Manual Connector Pin Legend J121 Gray 12 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P121-01 LOAD SENSE S132LDS-BL/WH Digital input from load sense switch P121-02 LSB3RS+LSB2RS S42BRT-OR/RD Digital input from LSB3RS+LSB2RS limit (FULLY RETRACTED) switches P121-03...
Page 228: Vec Module- Deutz Td2011L04I And Perkins 1104D-44T Models
Service and Repair Manual October 2016 VEC Module- Deutz TD2011L04i and Perkins 1104D-44T Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F22A...
Page 229: Vec Module- Deutz Td2.9 Models
October 2016 Service and Repair Manual VEC Module- Deutz TD2.9 Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power CR39 Deutz Aux. Shutdown Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F22A...
Page 230: Vec Module- Perkins 854F Models
Service and Repair Manual October 2016 VEC Module- Perkins 854F Models Number Component Description CR81B ECU Power CR81A ECU Power Starter SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F27A Fuse 30A, ECU Power F27C Fuse, 2A, ECU Signal...
Page 231: Telematics Connector Pin Legend
October 2016 Service and Repair Manual Telematics Connector Pin Legend Genie installed Telematics connector is wired with an Active High digital input. Connector Pin Numbering Note: A Deutsch plug p/n DT06-08SA mates with the Genie Telematics connector Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case System Power 12 VDC...
Page 232: Electrical Symbols Legend
Service and Repair Manual October 2016 Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no Circuits crossing no Quick disconnect Circuit breaker with...
Page 233 October 2016 Service and Repair Manual Electrical Symbols Legend Part No. 1263382 SX-135 XC...
Page 234: Hydraulic Symbols Legend
Service and Repair Manual October 2016 Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...
Page 235: Generator Receptacle Wiring- Ansi/Csa
October 2016 Service and Repair Manual Generator Receptacle Wiring- ANSI/CSA Part No. 1263382 SX-135 XC...
Page 236: Generator Receptacle Wiring- Ce
Service and Repair Manual October 2016 Generator Receptacle Wiring- CE SX-135 XC Part No. 1263382...
Page 237: Generator Receptacle Wiring- Aux
October 2016 Service and Repair Manual Generator Receptacle Wiring- AUX Part No. 1263382 SX-135 XC...
Page 238 Service and Repair Manual October 2016 Perkins 1104D-44T Engine Electrical Schematic...
Page 239: Perkins 1104D-44T Engine Electrical Schematic
October 2016 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic Part No. 1263382 SX-135 XC...
Page 240: Perkins 1104D-44T Engine Electrical Schematic
Service and Repair Manual October 2016 Perkins 1104D-44T Engine Electrical Schematic SX-135 XC Part No. 1263382...
Page 241 October 2016 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...
Page 242 Service and Repair Manual October 2016 Perkins 854F-34T Engine Electrical Schematic...
Page 243: Perkins 854F-34T Engine Electrical Schematic
October 2016 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic Part No. 1263382 SX-135 XC...
Page 244: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual October 2016 Perkins 854F-34T Engine Electrical Schematic SX-135 XC Part No. 1263382...
Page 245 October 2016 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...
Page 246 Service and Repair Manual October 2016 Perkins 854F-34T Engine Harness...
Page 247: Perkins 854F-34T Engine Harness
October 2016 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1263382 SX-135 XC...
Page 248 Service and Repair Manual October 2016 SX-135 XC Part No. 1263382...
Page 249 October 2016 Service and Repair Manual Deutz 2.9TF Engine Harness Part No. 1263382 SX-135 XC...
Page 250 Service and Repair Manual October 2016 Deutz 2.9TF Engine Harness...
Page 251 October 2016 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic...
Page 252: Deutz Td2.9 Engine Electrical Schematic
Service and Repair Manual October 2016 Deutz 2.9TF Engine Electrical Schematic SX-135 XC Part No. 1263382...
Page 253: Deutz Td2.9 Engine Electrical Schematic
October 2016 Service and Repair Manual Deutz 2.9TF Engine Electrical Schematic Part No. 1263382 SX-135 XC...
Page 254 Service and Repair Manual October 2016 Deutz 2.9TF Engine Electrical Schematic...
Page 255: Hydraulic Schematic
October 2016 Service and Repair Manual Hydraulic Schematic Part No. 1263382 SX-135 XC...
Page 256 Service and Repair Manual October 2016 Hydraulic Schematic...
Page 257: Electrical Schematic
TCON MEMBRANE PANEL (MS2) LOCKOUT VALVE #1 SIGNAL CAN GATEWAY PRI BOOM LENGTH 3' STATUS & TCON LCD KEY SWITCH PRI BOOM LENGTH 151' STATUS PRI BOOM DOWN STATUS SERV BYPASS WH/BK GROUND SEC BOOM EXT/RET FC RECOVERY SIGNAL SEC BOOM EXT/RET FC RECOVERY SIGNAL PLATFORM PCON SERVICE...

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