Terex SX135XCH-101 Service And Repair Manual
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Terex SX135XCH-101 Service And Repair Manual

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Service and Repair Manual
SX
-135 XC
™
Serial Number Range
™
SX135XCH-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. 1263383GT
Rev C5
December 2018

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  • Page 1 Service and Repair Manual Serial Number Range -135 XC ™ ™ SX135XCH-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. 1263383GT Rev C5...

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1263383GT Rev C, June 2017 First Edition, Third Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "SX" and "XC" are trademarks of Terex South Dakota, Inc.

  • Page 3: Revision History

    December 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 10/2016 Initial Release 1/2017 Cover Changed part number from 1263382GT to 1263383GT Repair How to Adjust Load Cell Pre-load Update Function Manifold, Steer Manifold 1/2017 Specifications Platform rotator torque...
  • Page 4 Service and Repair Manual December 2018 Introduction Revision History Revision Date Section Procedure / Page / Description 8/2018 Fault Codes Added LSB1RS/LSJ1RO Cross-check, Jib Bellcrank Loop Valve, Platform Level Loop Valve, Axle Retract Enable Valve, Fuel Level Sensor Rotate drive hub torque value 12/2018 Specifications 10-1 Cal.

  • Page 5: Serial Number Legend

    December 2018 Service and Repair Manual Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) Part No. 1263383GT SX™-135 XC™...

  • Page 6: Safety Rules

    Service and Repair Manual December 2018 Safety Rules Section 1 Safety R ules 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 7 December 2018 Service and Repair Manual 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 8: Table Of Contents

    December 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History ..................... iii Serial Number Legend .................... v Section 1 Safety Rules ......................vi General Safety Rules .................... vi Section 2 Specifications .......................
  • Page 9 December 2018 Table of Contents Section 3 Repair Procedures ..................... 17 Introduction ......................17 Platform Controls ....................19 1-1 Platform Circuit Board ..................19 How to Remove the LED Circuit Board ............20 1-2 Joysticks ......................20 How to Reset a Proportional Valve Coil Default ..........23 How to Set the Function Thresholds and Default Functions Speeds .....
  • Page 10 December 2018 Table of Contents Boom Components .................... 49 4-1 Primary Boom Cable Track ................50 4-2 Primary Boom ....................53 How to Remove the Primary boom ..............54 How to Disassemble the Primary Boom ............56 4-3 Primary Boom Lift Cylinder ................59 4-4 Extension Cylinder ..................
  • Page 11 December 2018 Table of Contents Manifolds ......................94 8-1 Function Manifold Components ..............94 8-2 Valve Adjustments - Function Manifold ............98 8-3 Jib Manifold Components ................100 8-4 Platform and Rotator Manifold Components ..........102 8-5 Steer and Axle Manifold Components ............104 8-6 Function Enable Manifold ................
  • Page 12 December 2018 Table of Contents Section 5 Schematics ......................180 Introduction ......................180 Wire Circuit Legend .................... 181 Wire Color Legend ....................185 Limit Switches and Angle Sensors ..............189 Circuit Connector Legend ................... 193 Connector Pin Legend ..................196 VEC Module - Deutz TD2011L04i and Perkins 1104D-44T Models ....

  • Page 13: Specifications

    December 2018 Service and Repair Manual Specifications Section 2 Specific ati ons 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...

  • Page 14: Performance Specifications

    Service and Repair Manual December 2018 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 15: Hydraulic Oil Specifications

    December 2018 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 16 Service and Repair Manual December 2018 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 17 December 2018 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 18: Hydraulic Component Specifications

    Service and Repair Manual December 2018 Specifications Hydraulic Component Auxiliary Pump Specifications Type fixed displacement gear pump Drive Pump Displacement per revolution 0.15 cu in 2.47 cc Type: bi-directional variable displacement piston pump Function manifold Displacement per revolution 2.8 cu in 46 cc System relief valve pressure, 3200 psi...

  • Page 19: Manifold Component Specifications

    December 2018 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 20: Deutz Td2011L04I Engine Specifications

    Service and Repair Manual December 2018 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 21: Deutz Td 2.9 Engine Specifications

    December 2018 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 22: Perkins 1104D-44T Engine Specifications

    Service and Repair Manual December 2018 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 23 December 2018 Service and Repair Manual Specifications Perkins 1104D-44T cont. Engine coolant Capacity 9.5 quarts (engine only) 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 37 ohms 102°C...

  • Page 24: Perkins 854F-34T Engine Specifications

    Service and Repair Manual December 2018 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 25: Machine Torque Specifications

    December 2018 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 500 ft-lbs (50/50 extended life) 15.6 liters 678 Nm Coolant temperature switch 1/2-13 bolts, GR 8, threadlock 90 ft-lbs Installation torque 18.4 ft-lbs...

  • Page 26: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual December 2018 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...

  • Page 27: Torque Procedure

    December 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
  • Page 28 Service and Repair Manual December 2018 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 29: Repair Procedures

    December 2018 Service and Repair Manual Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures  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 30: About This Section

    Service and Repair Manual December 2018 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 31: Platform Controls

    December 2018 Service and Repair Manual Platform Controls Attach a grounded wrist strap to the ground screw inside the control box. Platform Circuit Board Electrocution/burn hazard. Contact with electrically charged Electrocution/burn hazard. circuits could result in death or Contact with electrically charged serious injury.

  • Page 32: How To Remove The Led Circuit Board

    Service and Repair Manual December 2018 Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Board Joysticks Push in the red Emergency Stop button to the How to Calibrate a Joystick off position at both the ground and platform controls.
  • Page 33 December 2018 Service and Repair Manual Platform Controls Use the scroll button to scroll through the Move the drive/steer joystick or thumb rocker menu until DELETE DRIVE JOYSTICK switch (if equipped) full stroke in the right DEFAULTS is displayed. direction and hold for 5 seconds, then return to the center or neutral position.
  • Page 34 Service and Repair Manual December 2018 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 ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...

  • Page 35: How To Reset A Proportional Valve Coil Default

    December 2018 Service and Repair Manual Platform Controls How to R es et a Proportional Valve Coil D efault 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 ground description of each LCD screen control button used control panel while turning the key switch to...

  • Page 36: How To Set The Function Thresholds And Default Functions Speeds

    Service and Repair Manual December 2018 Platform Controls How to Set the F unction T hresholds and D efault Func tions 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...
  • Page 37 December 2018 Service and Repair Manual Platform Controls Function speeds: 15 Once the function speeds have been set, press and hold the engine start button until the Note: Be sure the machine is in the stowed position engine shuts off. Do not press the red and the boom is rotated between the circle end Emergency Stop button.

  • Page 38: How To Adjust The Function Speeds

    Service and Repair Manual December 2018 Platform Controls How to Adj ust the Functi on 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

    December 2018 Service and Repair Manual Platform Controls How to Adj ust the Functi on R amp R ate Setti ng 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 the...

  • Page 40: Platform Components

    Service and Repair Manual December 2018 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

    December 2018 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 December 2018 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

    December 2018 Service and Repair Manual Platform Components How to Bleed the Pl atform R otator 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 December 2018 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

    December 2018 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 December 2018 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: How To Perform A Zero Load Cell Calibration

    December 2018 Service and Repair Manual Platform Components Confirm the setting: How to Per form a Z ero Load C ell C alibr ation How to Perform a Zero Load Cell Calibration 26 Lift the calibration weight off the platform floor using a suitable lifting device.

  • Page 48: How To Replace The Platform Overload Load Cell

    Service and Repair Manual December 2018 Platform Components How to R eplac e the Platform Ov erload Load C ell How to Replace the Load Cell Sensor Platform Overload Recovery Message Note: The preload adjustment should only be performed after the load cell sensor has been If the ground controls LCD screen displays replaced.
  • Page 49 December 2018 Service and Repair Manual Platform Components Press the buttons on the ground controls in the following sequence: (plus)(minus)(minus)(plus). Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed. Press the plus button or the minus button to select YES.

  • Page 50: Jib Boom Components

    Service and Repair Manual December 2018 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 51: Jib Boom

    December 2018 Service and Repair Manual Jib Boom Components 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 52 Service and Repair Manual December 2018 Jib Boom Components 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.

  • Page 53: Jib Boom Lift Cylinder

    December 2018 Service and Repair Manual Jib Boom Components 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.

  • Page 54: Jib Boom Level Cylinder

    Service and Repair Manual December 2018 Jib Boom Components 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 55: Jib Boom Extension Cylinder

    December 2018 Service and Repair Manual Jib Boom Components Remove the external snap rings from the jib boom level cylinder barrel-end pivot pin. Use a Jib Boom Extension Cylinder 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 56 Service and Repair Manual December 2018 Jib Boom Components 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.

  • Page 57: How To Remove The Jib Boom Bellcrank

    December 2018 Service and Repair Manual Jib Boom Components 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 58: Jib Boom Bellcrank Angle Sensor

    Service and Repair Manual December 2018 Jib Boom Components 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 59 December 2018 Service and Repair Manual Jib Boom Components Note: Use the following chart to identify the Locate the calibration toggle switch at the top description of each LCD screen control button used of the ground control box. Activate calibration in this procedure.
  • Page 60 Service and Repair Manual December 2018 Jib Boom Components 13 Fully raise the jib boom using the jib up button 17 Press and hold the engine start button for until it stops. approximately 5 seconds to shut off the engine and to save the calibration settings. 14 Place a digital level with a magnetic base, on the vertical surface of the jib bellcrank Result: An audible alarm sounds for 1 second.

  • Page 61: Boom Components

    December 2018 Service and Repair Manual 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 62: Primary Boom Cable Track

    Service and Repair Manual December 2018 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 63 December 2018 Service and Repair Manual 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 primary Remove the cable track guide from the boom cable track.
  • Page 64 Service and Repair Manual December 2018 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 65: Primary Boom

    December 2018 Service and Repair Manual 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 66: How To Remove The Primary Boom

    Service and Repair Manual December 2018 Boom Components How to R emove the Primary boom How to Remove the Primary Pivot end upper wear pads Boom 10 Loosen the wear pad mounting fasteners. 11 Add shims by hand until snug. Bodily injury hazard.
  • Page 67 December 2018 Service and Repair Manual Boom Components Remove the jib boom. Refer to Repair Tag, disconnect and plug the primary boom Procedure, How to Remove the Jib Boom. extension cylinder hydraulic hoses. Cap the fittings on the cylinder. Note: When the jib boom is installed, the jib boom angle sensor will need to be calibrated.

  • Page 68: How To Disassemble The Primary Boom

    Service and Repair Manual December 2018 Boom Components How to Dis ass embl e 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 69 December 2018 Service and Repair Manual 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 70 Service and Repair Manual December 2018 Boom Components 23 Remove the fasteners securing the lower wear 27 Remove the final two side wear pads from the 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 71: Primary Boom Lift Cylinder

    December 2018 Service and Repair Manual 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 track the primary boom.
  • Page 72 Service and Repair Manual December 2018 Boom Components Tag, disconnect and plug the boom lift cylinder 14 Remove the pin retaining fastener from the hydraulic hoses. barrel-end pivot pin. Do not remove the pin. 15 Support the boom lift cylinder with an Bodily injury hazard.

  • Page 73: Extension Cylinder

    December 2018 Service and Repair Manual Boom Components Remove the retaining fasteners from the boom end cover at the pivot end of the boom. Extension Cylinder Remove the cover from the machine. The primary boom extension cylinder is located Tag and disconnect the limit switch inside the boom assembly and incorporates cables harnesses.
  • Page 74 Service and Repair Manual December 2018 Boom Components 10 Loosen the #3 extend cable adjustment bolts 10 turns (about 1 in / 2.54 cm). Note: Do not over loosen the extend cables. 11 Remove the locking plates securing the extend cylinder to boom #1 (1). (Illustration 1) 12 Remove the locking plates securing the extend cylinder to boom #2 (2).

  • Page 75: Boom Extend And Retract Cables

    December 2018 Service and Repair Manual Boom Components Boom 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.
  • Page 76 Service and Repair Manual December 2018 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 77 December 2018 Service and Repair Manual Boom Components 16 Start the engine and fully raise and extend the 25 Fully retract the boom and lower the boom to boom approximately 15 ft / 4.6 m. the horizontal position. 17 Fully retract the boom and lower the boom to 26 Stop the engine.

  • Page 78: How To Replace The Boom Extend/Retract Cables

    Service and Repair Manual December 2018 Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom Remove the retract cable retaining bolts and attach an electrician's tape or rope to the Extend/Retract Cables cable.

  • Page 79: Primary Boom Angle Sensor

    December 2018 Service and Repair Manual Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Primary Boom Angle Sensor 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 December 2018 Boom Components 15 Press and hold the engine start button for Press the enter or previous button on the approximately 5 seconds to shut off the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR is displayed. engine and to save the calibration settings.

  • Page 81: Boom Length Sensor

    December 2018 Service and Repair Manual Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Boom Length Sensor in this procedure. How to Calibrate the Primary Boom Length Sensor Note: Perform this procedure with the machine on Plus Minus Previous...
  • Page 82 Service and Repair Manual December 2018 Boom Components 18 Press and hold the engine start button for Press and hold the enter button on the ground approximately 5 seconds to shut off the control panel while pulling out the ground engine and to save the calibration settings.

  • Page 83: Engines

    December 2018 Service and Repair Manual Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel Service or Maintenance Manual for your machine, and has a splined center to drive the pump.

  • Page 84: How To Install The Flex Plate

    Service and Repair Manual December 2018 Engines How to Ins tall the Fl ex Plate Perkins engines: Torque the pump plate How to Install the Flex Plate mounting bolts in sequence to 23 ft-lbs / 31 Install the flex plate onto the engine flywheel Nm.

  • Page 85: Ground Controls

    December 2018 Service and Repair Manual 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 86 Service and Repair Manual December 2018 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 87: Circuit Boards

    December 2018 Service and Repair Manual 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 88 Service and Repair Manual December 2018 Ground Controls How to Remove the LCD Display How to Remove the ALC-1000 Screen Circuit Board Circuit Board Push in the red Emergency Stop button to the Push in the red Emergency Stop button to the off position at both the ground and platform off position at both the ground and platform controls.

  • Page 89: Membrane Decal

    December 2018 Service and Repair Manual Ground Controls Remove any decal adhesive from the control box lid with a mild solvent. Membrane Decal Note: Do not allow any solvent to come in contact with the LCD display screen. The membrane decal is a special decal that consists of a decal with an electronic membrane on Install the new membrane decal while guiding the backside.

  • Page 90: Full Machine Calibration

    Service and Repair Manual December 2018 Ground Controls Note: Start this procedure with the booms in the fully stowed position and the axle retracted. Full Machine Calibration Full machine calibration must be completed in the following sequence: Full machine calibration must be completed in the proper sequence when the ALC-1000 circuit board •...

  • Page 91: Display Module

    December 2018 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 92 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (English) (plus)(minus) buttons at the same time. Hydraulic pressure kPa (metric) 0-31000 kPa Primary angle degrees -2°...
  • Page 93 December 2018 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 94 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection Boom Function With key switch , press Primary boom up speed stowed Speeds and hold the enter button and turn key switch to on Primary boom up speed <80ft position.
  • Page 95 December 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Primary boom up/down ramp Lift Functions hold the enter button and turn key acceleration % Ramps switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
  • Page 96 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Delete TT tilt sensor calibration Sensor Calibration and hold the enter button Set unit X-axis to gravity and turn key switch to on Set unit Y-axis to gravity position.
  • Page 97 December 2018 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 98: Hydraulic Pumps

    Service and Repair Manual December 2018 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 99: How To Prime The Function Pump

    December 2018 Service and Repair Manual Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure 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...
  • Page 100 Service and Repair Manual December 2018 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 101: How To Adjust The Function Pump Pressure Compensator

    December 2018 Service and Repair Manual Hydraulic Pumps How to Adj ust the Functi on Pum p Press ure Com pens ator 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 102: Drive Pump

    Service and Repair Manual December 2018 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 103 December 2018 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 104: How To Prime The Drive Pump

    Service and Repair Manual December 2018 Hydraulic Pumps How to Prime the Driv e Pum p 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 105 December 2018 Service and Repair Manual This page intentionally left blank. Part No. 1263383GT SX™-135 XC™...

  • Page 106: Manifolds

    Service and Repair Manual December 2018 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 115-125 ft-lbs / Solenoid valve, 3 position 4 way CC Primary boom extend/retract 156-170 Nm Primary boom extend relief...
  • Page 107 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...
  • Page 108 Service and Repair Manual December 2018 Manifolds Function Manifold Components Schematic Index No. Description Function Torque Item Proportional solenoid valve, 3 way Primary lift cylinder up/down low 20 ft-lbs / speed control 27.1 Nm 75-85 ft-lbs / Solenoid valve, 3 position 4 way Primary boom up/down 102-115 Nm Primary lift cylinder up/down high...
  • Page 109 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...

  • Page 110: Valve Adjustments - Function Manifold

    Service and Repair Manual December 2018 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 111 December 2018 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 112: Jib Manifold Components

    Service and Repair Manual December 2018 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 113 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...

  • Page 114: Platform And Rotator Manifold Components

    Service and Repair Manual December 2018 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 115 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...

  • Page 116: Steer And Axle Manifold Components

    Service and Repair Manual December 2018 Manifolds Steer and Axle Manifold Components 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 extend 20-25 ft-lbs / Flow control valve, 2.1 gpm / 8 L/min circuit...
  • Page 117 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...
  • Page 118 Service and Repair Manual December 2018 Manifolds Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 33-37 ft-lbs / Axle extend/retract circuit 165.5 bar 45-50 Nm Prevents left rear steer cylinder 20-25 ft-lbs / Check valve, 65 psi / 4.5 bar from moving when not steering 27-34 Nm Prevents right rear steer cylinder...
  • Page 119 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...

  • Page 120: Function Enable Manifold

    Service and Repair Manual December 2018 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 121: Valve Adjustments - Steer And Axle Manifold

    December 2018 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 122: Traction Manifold Components

    Service and Repair Manual December 2018 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 123 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...
  • Page 124 Service and Repair Manual December 2018 Manifolds Traction Manifold Components 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 Equalizes pressure on both sides of 30-35 ft-lbs / Orifice, 2 gpm / 7.6 L/min divider/combiner valve AM...
  • Page 125 December 2018 Service and Repair Manual Manifolds Part No. 1263383GT SX™-135 XC™...

  • Page 126: Valve Adjustments - Traction Manifold

    Service and Repair Manual December 2018 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 Relief 11 Adjust the internal hex socket until the Valve...

  • Page 127: Generator Manifold Component

    December 2018 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 128: Valve Coils

    Service and Repair Manual December 2018 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 129 December 2018 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 130: Turntable Rotation Components

    Service and Repair Manual December 2018 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 131: How To Adjust The Turntable Rotation Gear Backlash

    December 2018 Service and Repair Manual Turntable Rotation Components Turn the adjustment bolt 1/2 to 3/4 turn How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable counterclockwise. Tighten the lock nut on the Rotation Gear Backlash adjustment bolt.

  • Page 132: Turntable Level Sensor

    Service and Repair Manual December 2018 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 133 December 2018 Service and Repair Manual Turntable Rotation Components 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. Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus).
  • Page 134 Service and Repair Manual December 2018 Turntable Rotation Components 13 Press the plus button or minus button to 16 Press the plus button or minus button to adjust the display to the exact value shown on adjust the display to the exact value shown on the digital level and press the enter button.

  • Page 135: Axle Components

    December 2018 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be replaced, install the new activator pin per The steer sensors measure steer angle and Illustration 1.
  • Page 136 Service and Repair Manual December 2018 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 137: How To Calibrate All Steer Sensors

    December 2018 Service and Repair Manual Axle Components How to C alibr ate 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 138 Service and Repair Manual December 2018 Axle Components Using a voltmeter set to DC voltage, probe the Press and hold the enter button on the ground back of the electrical connector at pins B and control panel while pulling out the ground controls red Emergency Stop button to the on position.
  • Page 139 December 2018 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 140: Steer Cylinders

    Service and Repair Manual December 2018 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 141: Axle Angle Sensors

    December 2018 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 142 Service and Repair Manual December 2018 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 143 December 2018 Service and Repair Manual Axle Components 12 Press the plus button to select YES, then press the enter button to accept. 13 Press the enter or previous button on the LCD screen until EXIT is displayed. 14 Press the plus button to select YES, then press the enter button to accept.

  • Page 144: Generators

    Service and Repair Manual December 2018 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 145: Fault Codes

    December 2018 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t 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 146: Control System Fault Codes

    Service and Repair Manual December 2018 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 147 December 2018 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 148 Service and Repair Manual December 2018 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 corrected. Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RS.
  • Page 149 December 2018 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 corrected. Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
  • Page 150 Service and Repair Manual December 2018 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 corrected. (150 ft) Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
  • Page 151 December 2018 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 152 Service and Repair Manual December 2018 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 153 December 2018 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 154 Service and Repair Manual December 2018 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 wiring. Valve zero and neutral, Alarm sounds. Check for an open or shorted valve coil.
  • Page 155 December 2018 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 156 Service and Repair Manual December 2018 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 corrected. Angle Sensor Rotate, and Propel. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
  • Page 157 December 2018 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 158 Service and Repair Manual December 2018 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.
  • Page 159 December 2018 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 160 Service and Repair Manual December 2018 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 161 December 2018 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 162 Service and Repair Manual December 2018 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 163 December 2018 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 164 Service and Repair Manual December 2018 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 Envelope and Ignition/Fuel. Boom Down and Retract allowed. All functions allowed once boom is lowered back into envelope.

  • Page 165: Fault Matrix

    December 2018 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 166: Fault Code Source

    Service and Repair Manual December 2018 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 167 December 2018 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 168 Service and Repair Manual December 2018 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 169: Deutz Td 2.9 L4 Engine Fault Codes

    December 2018 Service and Repair Manual Control System 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 1019...
  • Page 170 Service and Repair Manual December 2018 Control System 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.; signal range check low High oil pressure;...
  • Page 171 December 2018 Service and Repair Manual Control System 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; shut off threshold exceeded 1180 Physical range check high for...
  • Page 172 Service and Repair Manual December 2018 Control System 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 1008 Sensor error EGR cooler...
  • Page 173 December 2018 Service and Repair Manual Control System 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; short circuit to battery Injector 1 (in firing order);...
  • Page 174 Service and Repair Manual December 2018 Control System 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 1180 3 1067...
  • Page 175 December 2018 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error KWP = Keyword Protocol of short circuit to ground measurement cyl. Bank 1 SPN FMI Description 2798 4...
  • Page 176 Service and Repair Manual December 2018 Control System 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 1029 Physical range check high for...
  • Page 177 December 2018 Service and Repair Manual Control System 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 detection reported error 523470 Maximum rail pressure in limp...
  • Page 178 Service and Repair Manual December 2018 Control System 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 179 December 2018 Service and Repair Manual Control System 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 523898 check of missing injector...
  • Page 180 Service and Repair Manual December 2018 Control System 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 523922 1262 Burner Shut Off Valve;...
  • Page 181 December 2018 Service and Repair Manual Control System 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 plausible to HFM reading...
  • Page 182 Service and Repair Manual December 2018 Control System 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 524109 9 1679 Timeout error of 524035 12 1341 Injector diagnostics;...
  • Page 183 December 2018 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol KWP Description 524120 9 1682 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9...

  • Page 184: Perkins 854F-34T Engine Fault Code

    Service and Repair Manual December 2018 Control System Fault Codes 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 185 December 2018 Service and Repair Manual Control System Fault Codes 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 Engine Coolant Temperature :Voltage Above...
  • Page 186 Service and Repair Manual December 2018 Control System Fault Codes 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 187 December 2018 Service and Repair Manual Control System Fault Codes 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 188 Service and Repair Manual December 2018 Control System Fault Codes 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 189 December 2018 Service and Repair Manual Control System Fault Codes 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 2791...
  • Page 190 Service and Repair Manual December 2018 Control System Fault Codes 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 191 December 2018 Service and Repair Manual Control System Fault Codes 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 192: Schematics

    Service and Repair Manual December 2018 Schematics Section 5 About This Section Schem atics 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.

  • Page 193: Wire Circuit Legend

    December 2018 Service and Repair Manual Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
  • Page 194 Service and Repair Manual December 2018 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 195 December 2018 Service and Repair Manual 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 196 Service and Repair Manual December 2018 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 197: Wire Color Legend

    December 2018 Service and Repair Manual Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary up valve retract functions are striped black. When using Ignition/Fuel black wire, the stripe shall be white. Primary boom extend valve All rotations that are LEFT or CW are solid, Primary boom up valve RIGHT or CCW are striped and black.
  • Page 198 Service and Repair Manual December 2018 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 199 December 2018 Service and Repair Manual 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 200 Service and Repair Manual December 2018 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Lift Power Relay Jib Bellcrank Up Flow Control 48 Volt Alternator field (or Battery) BL/BK Jib Bellcrank Down Flow Control 24 Volt Battery BL/WH Jib Bellcrank Sensor Envelope or Load Sense...

  • Page 201: Limit Switches And Angle Sensors

    December 2018 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 202 Service and Repair Manual December 2018 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 203 December 2018 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 204 Service and Repair Manual December 2018 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 205: Circuit Connector Legend

    December 2018 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 206 Service and Repair Manual December 2018 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 207 December 2018 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 208: Connector Pin Legend

    Service and Repair Manual December 2018 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 209 December 2018 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 210 Service and Repair Manual December 2018 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 211 December 2018 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 212 Service and Repair Manual December 2018 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 213 December 2018 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 214 Service and Repair Manual December 2018 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 215 December 2018 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 216 Service and Repair Manual December 2018 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 217 December 2018 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 218 Service and Repair Manual December 2018 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 219 December 2018 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 220 Service and Repair Manual December 2018 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 221 December 2018 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 222: Vec Module - Deutz Td2011L04I And Perkins 1104D-44T Models

    Service and Repair Manual December 2018 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 223: Vec Module - Deutz Td2.9 Models

    December 2018 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 224: Vec Module - Perkins 854F Models

    Service and Repair Manual December 2018 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...

  • Page 225: Telematics Connector Pin Legend

    December 2018 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 226: Electrical Symbols Legend

    Service and Repair Manual December 2018 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 227: Hydraulic Symbols Legend

    December 2018 Service and Repair Manual 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 228: Generator Receptacle Wiring - Ansi/Csa

    Service and Repair Manual December 2018 Generator Receptacle Wiring - ANSI/CSA SX™-135 XC™ Part No. 1263383GT...

  • Page 229: Generator Receptacle Wiring - Ce

    December 2018 Service and Repair Manual Generator Receptacle Wiring - CE Part No. 1263383GT SX™-135 XC™...

  • Page 230: Generator Receptacle Wiring - Aus

    Service and Repair Manual December 2018 Generator Receptacle Wiring - AUS SX™-135 XC™ Part No. 1263383GT...
  • Page 231 December 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...

  • Page 232: Perkins 1104D-44T Engine Electrical Schematic

    Service and Repair Manual December 2018 Perkins 1104D-44T Engine Electrical Schematic SX™-135 XC™ Part No. 1263383GT...

  • Page 233: Perkins 1104D-44T Engine Electrical Schematic

    December 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic Part No. 1263383GT SX™-135 XC™...
  • Page 234 Service and Repair Manual December 2018 Perkins 1104D-44T Engine Electrical Schematic...
  • Page 235 December 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...

  • Page 236: Perkins 854F-34T Engine Electrical Schematic

    Service and Repair Manual December 2018 Perkins 854F-34T Engine Electrical Schematic SX™-135 XC™ Part No. 1263383GT...

  • Page 237: Perkins 854F-34T Engine Electrical Schematic

    December 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic Part No. 1263383GT SX™-135 XC™...
  • Page 238 Service and Repair Manual December 2018 Perkins 854F-34T Engine Electrical Schematic...
  • Page 239 December 2018 Service and Repair Manual Perkins 854F-34T Engine Harness...

  • Page 240: Perkins 854F-34T Engine Harness

    Service and Repair Manual December 2018 Perkins 854F-34T Engine Harness SX™-135 XC™ Part No. 1263383GT...

  • Page 241: Deutz 2.9Tf Engine Harness

    December 2018 Service and Repair Manual Deutz 2.9TF Engine Harness Part No. 1263383GT SX™-135 XC™...
  • Page 242 Service and Repair Manual December 2018 Deutz 2.9TF Engine Harness...
  • Page 243 December 2018 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic...

  • Page 244: Deutz Td2.9 Engine Electrical Schematic

    Service and Repair Manual December 2018 Deutz TD2.9 Engine Electrical Schematic SX™-135 XC™ Part No. 1263383GT...

  • Page 245: Deutz Td2.9 Engine Electrical Schematic

    December 2018 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic Part No. 1263383GT SX™-135 XC™...
  • Page 246 Service and Repair Manual December 2018 Deutz TD2.9 Engine Electrical Schematic...

  • Page 247: Hydraulic Schematic

    December 2018 Service and Repair Manual Hydraulic Schematic Part No. 1263383GT SX™-135 XC™...
  • Page 248 Service and Repair Manual December 2018 Hydraulic Schematic...

  • Page 249: 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...

This manual is also suitable for:

Genie sx-135xc

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