Page 1 Service and Repair Manual Serial Number Range -150 ™ from SX150H-612 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. 1300669GT Rev A December 2019...
Page 2: Introduction
Copyright © 2015 by Terex Corporation 1300669GT Rev A, December 2019 Second Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "SX" is a trademark of Terex South Dakota, Inc.
Page 3: Revision History
December 2019 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 12/2019 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 December 2019 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) ™ -150 Part No. 1300669GT...
Page 5: Safety Rules
December 2019 Service and Repair Manual 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 6 Service and Repair Manual December 2019 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
December 2019 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
Page 8 December 2019 Table of Contents Section 3 Repair Procedures ....................18 Introduction ......................18 Platform Controls ....................20 1-1 Platform Circuit Board ..................20 How to Remove the LED Circuit Board ............21 1-2 Joysticks ......................22 How to Reset a Proportional Valve Coil Default ..........25 How to Set the Function Thresholds and Default Functions Speeds....
Page 9 December 2019 Table of Contents Boom Components .................... 45 4-1 Primary Boom Cable Track ................46 4-2 Primary Boom....................48 How to Remove the Primary Boom ..............49 How to Disassemble the Primary Boom ............51 4-3 Primary Boom Lift Cylinder ................53 4-4 Extension Cylinder ..................
Page 10 December 2019 Table of Contents Manifolds ......................92 8-1 Function Manifold Components..............92 8-2 Valve Adjustments - Function Manifold ............98 8-3A Platform Level and Rotation Manifold Components ........100 8-4 Jib Boom Manifold Components ..............101 8-5 Function Enable Manifold ................102 8-6 Steer and Axle Manifold Components ............
Page 11 December 2019 Table of Contents Section 4 Fault Codes ....................... 132 Introduction ......................132 Control System Fault Codes ................133 Fault Matrix ......................152 Fault Code Source ..................... 153 Deutz TD 2.9 L4 Engine Fault Codes ..............156 Perkins 854F-34T Engine Fault Code ..............171 Section 5 Schematics ......................
Page 12 December 2019 Table of Contents Electrical Schematics – Control Circuits ............217 Control Circuits - Horn ..................218 Control Circuits - Power ..................219 Control Circuits - Can Bus .................. 222 Control Circuits - Deutz TD2011L04i Engine ............. 223 Control Circuits - Deutz TD 2.9 L4Engine ............226 Control Circuits - Perkins 1104D-44T Engine ............
Page 13: Specifications
December 2019 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 2019 Specifications Performance Specifications Boom function speeds, maximum from platform controls Drive speed, maximum Jib boom up/down 58 - 62 sec Stowed position, high speed 2.3 mph Jib boom rotate CW/CCW 60° 28 - 32 sec 3.7 km/h Primary boom extend/retract 30 - 33 sec /...
Page 15: Hydraulic Oil Specifications
December 2019 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 2019 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 2019 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 2019 Specifications Hydraulic Component Function Pump - End Pump Specifications Type variable displacement piston pump Drive Pump Displacement per revolution 0 to 1.8 cu in Type: bi-directional variable displacement piston pump 0 to 30 cc Displacement per revolution 2.8 cu in Flow rate @ 2450 rpm...
Page 19: Manifold Component Specifications
December 2019 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 2019 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 2019 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 2019 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 2019 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 2019 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 2019 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 3/8-16 bolts, GR 8, dry 35 ft-lbs* Installation torque 18.4 ft-lbs...
Page 26: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual December 2019 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 2019 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 2019 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 December 2019 Service and Repair Manual This page intentionally left blank. Part No. 1300669GT ™ -150...
Page 30: Repair Procedures
Service and Repair Manual December 2019 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 31 December 2019 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 32: Platform Controls
Service and Repair Manual December 2019 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 33: How To Remove The Led Circuit Board
December 2019 Service and Repair Manual Platform Controls How to R emove the LED Circui t 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 34: Joysticks
Service and Repair Manual December 2019 Platform Controls Drive functions: Joysticks Turn the key switch to the off position. Press and hold the enter button on the ground How to Calibrate a Joystick control panel while turning the key switch to platform controls.
Page 35 December 2019 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 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 platform controls.
Page 36 Service and Repair Manual December 2019 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 37: How To Reset A Proportional Valve Coil Default
December 2019 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 38: How To Set The Function Thresholds And Default Functions Speeds
Service and Repair Manual December 2019 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 39 December 2019 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 40: How To Adjust The Function Speeds
Service and Repair Manual December 2019 Platform Controls How to Adj ust the Functi on Speeds How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function How to Adjust the Function Ramp Speeds Rate Setting Note: Perform this procedure with the boom in the...
Page 41: Platform Components
December 2019 Service and Repair Manual 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 42: Platform Leveling Cylinder
Service and Repair Manual December 2019 Platform Components Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to Platform Leveling Cylinder remove the barrel-end pivot pin. The platform leveling cylinder keeps the platform Support the rod end of the platform level level through the entire range of boom motion.
Page 43: Platform Rotator
December 2019 Service and Repair Manual 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 44: How To Bleed The Platform Rotator
Service and Repair Manual December 2019 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 45: Platform Level Sensor
December 2019 Service and Repair Manual 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 46: Platform Overload System
Service and Repair Manual December 2019 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 47 December 2019 Service and Repair Manual Platform Components Remove the key from the main key switch. 17 Press the enter or previous button on the Insert the key into the bypass/recovery key LCD screen until LOAD CELL FULL LOAD switch and turn it to the bypass position. LBS or LOAD CELL FULL LOAD KGS is displayed.
Page 48: How To Perform A Zero Load Cell Calibration
Service and Repair Manual December 2019 Platform Components How to Per form a Z ero Load C ell C alibr ation How to Perform a Zero Load Cell 29 Add an additional test weight equal to 5% of the rated capacity onto the calibration weight Calibration to overload the platform.
Page 49: How To Replace The Platform Overload Load Cell
December 2019 Service and Repair Manual 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 50 Service and Repair Manual December 2019 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 51: Jib Boom Components
December 2019 Service and Repair Manual Jib Boom Components 1 platform rotator 5 bellcrank 2 jib boom 6 jib boom lift cylinder 3 jib rotator 7 platform leveling cylinder 4 bellcrank leveling cylinder Part No. 1300669GT ™ -150...
Page 52: Jib Boom
Service and Repair Manual December 2019 Jib Boom Components Support the barrel end of the cylinder with a suitable lifting device. Jib Boom Remove the pin retaining fastener from the jib How to Remove the Jib Boom boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin and let Note: Perform this procedure with the boom in the the cylinder hang down.
Page 53: Jib Boom Lift Cylinder
December 2019 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Lift Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Lift Attach a lifting strap from an overhead crane Cylinder...
Page 54: How To Remove The Jib Boom Bellcrank
Service and Repair Manual December 2019 Jib Boom Components Use a soft metal drift to remove the bellcrank leveling cylinder rod-end pivot pin. How to Remove the Jib Boom Bellcrank Crushing hazard. The bellcrank leveling cylinder may be damaged if it is not properly Note: Perform this procedure with the boom in the supported when the rod-end stowed position.
Page 55: Jib Boom Bellcrank Angle Sensor
December 2019 Service and Repair Manual Jib Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Jib Boom Bellcrank Angle Sensor in this procedure. The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion.
Page 56 Service and Repair Manual December 2019 Jib Boom Components Remove the key from the main key switch. 15 Press the enter or previous button on the Insert the key into the bypass/recovery key LCD screen until EXIT is displayed. switch and turn it to the bypass position. 16 Press the plus button to select YES, then Note: The angle sensor calibration values will not press the enter button to accept.
Page 57: Boom Components
December 2019 Service and Repair Manual Boom Components 1 boom tube #1 4 boom tube #4 2 boom tube #2 5 primary lift cylinder 3 boom tube #3 Part No. 1300669GT ™ -150...
Page 58: Primary Boom Cable Track
Service and Repair Manual December 2019 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 59 December 2019 Service and Repair Manual Boom Components How to Repair the Primary Boom 11 Secure the upper and lower tracks together. Cable Track Crushing hazard. If the upper and lower cable tracks are not Component damage hazard. properly secured together, the The boom cable track can be cable track could become damaged if it is twisted.
Page 60: Primary Boom
Service and Repair Manual December 2019 Boom Components Remove the upper rollers from the replacement section of cable track. Primary Boom Lift up the hoses and cables and carefully How to Shim the Boom insert the new 4-link section of cable track. Component damage hazard.
Page 61: How To Remove The Primary Boom
December 2019 Service and Repair Manual 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 62 Service and Repair Manual December 2019 Boom Components Remove the pin retaining fastener from the 13 Remove the primary boom cable track. Refer boom lift cylinder rod-end pivot pin. Use a soft to Repair Procedure, How to Remove the metal drift to remove the pin. Protect the Cable Track.
Page 63: How To Disassemble The Primary Boom
December 2019 Service and Repair Manual Boom Components Remove the brackets supporting the cable How to Dis ass embl e the Primary Boom How to Disassemble the Primary track assembly from the #3 and #4 boom Boom tubes 10 Place blocks between the cable tracks and Bodily injury hazard.
Page 64 Service and Repair Manual December 2019 Boom Components 18 At the platform end, remove the shims from Remove the #2 boom tube: the lower channel and upper side wear pads 23 At the pivot end of the machine, remove the between the #2 and #3 boom tubes.
Page 65: Primary Boom Lift Cylinder
December 2019 Service and Repair Manual Boom Components 28 Remove the fasteners securing the lower wear pads and remove the wear pads and Primary Boom Lift Cylinder aluminum block between the #1 and #2 boom tubes. The primary boom lift cylinder raises and lowers the primary boom.
Page 66 Service and Repair Manual December 2019 Boom Components Attach an overhead 10 ton / 9071 kg crane to Tag, disconnect and plug the boom lift cylinder the platform end of the boom for support. Do hydraulic hoses. not lift the boom. Bodily injury hazard.
Page 67: Extension Cylinder
December 2019 Service and Repair Manual Boom Components 14 Remove the pin retaining fastener from the barrel-end pivot pin. Do not remove the pin. Extension Cylinder 15 Support the boom lift cylinder with an The primary boom extension cylinder is located overhead crane.
Page 68 Service and Repair Manual December 2019 Boom Components Lay the inner cable track and hoses down and Tag and disconnect the limit switch out of the way. harnesses. Remove the fasteners to the limit switch harness mounting bracket and remove the bracket.
Page 69 December 2019 Service and Repair Manual Boom Components 17 Remove the locking plates (3) securing the 10 At the platform end of the machine, loosen the retract cables to boom #3. (Illustration 1) retract cable equalizer bolts at the #1 and #2 boom tubes.
Page 70: Boom Extend And Retract Cables
Service and Repair Manual December 2019 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 71 December 2019 Service and Repair Manual Boom Components Measure the distance between boom tubes #2 and #3 using points (9) and (10). (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 72 Service and Repair Manual December 2019 Boom Components 20 Loosen the retract cable retract bolt (6). 11 Loosen the jam nut on the cable tension (Illustration 1) retract bracket. Do not remove the nuts. 21 Tighten the three extend cable adjustment 12 Tighten the retract bolt using a torque wrench bolts (4) (Illustration 2) until the gap between until boom tube #3 begins to move.
Page 73 December 2019 Service and Repair Manual Boom Components 28 Measure the gap between boom tubes #3 and 37 Fully retract the boom and lower the boom to #4 using measuring points (7) and (8). the horizontal position. (Illustration 1) 38 Stop the engine. Result: The measurement is between 1 in / 39 Re-measure the gap between boom tubes 2.6 cm and 1.5 in / 3.8 cm more than...
Page 74: How To Replace The Boom Extend/Retract Cables
Service and Repair Manual December 2019 Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom 45 Fully retract the boom and lower the boom to the horizontal position. Extend/Retract Cables 46 Stop the engine. Note: The cable sheaves must be inspected when 47 Re-measure the gap between boom tubes replacing the cables.
Page 75 December 2019 Service and Repair Manual Boom Components Remove the fasteners securing the idler pulley holding the upper extend cables and remove the pulley (3). (Illustration 1) Remove the upper side wear pads (4) from the #4 boom tube. (Illustration 1) Remove the anti-rotation bolts from the extend cable.
Page 76 Service and Repair Manual December 2019 Boom Components #3 Boom retract cables: 10 Remove the center mounting bolt securing the sheave to the cover plate (3). 21 Remove the fastener and the retract cable 11 Remove the remaining fasteners securing the guide between boom tubes #2 and #3.
Page 77: Primary Boom Angle Sensor
December 2019 Service and Repair Manual Boom Components 32 Remove the equalizing bracket from the #4 boom retract cables. Primary Boom Angle Sensor 33 Attach electrician's tape to the #4 retract cable The primary boom angle sensor is used to limit the at the pivot end of the machine.
Page 78 Service and Repair Manual December 2019 Boom Components 10 Press the plus button to select YES, then Note: Use the following chart to identify the press the enter button to accept. description of each LCD screen control button used in this procedure. 11 Place the digital level on top of the primary boom near the pivot and note the angle displayed on the digital level.
Page 79 December 2019 Service and Repair Manual Boom Components 17 At the PRIMARY BOOM ANGLE TO 22 Press and hold a function enable/speed select GRAVITY 32 DEG screen, press the plus or button and the primary boom button until the minus button to adjust the display to the exact boom is fully raised.
Page 80: Boom Length Sensor
Service and Repair Manual December 2019 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 a firm, level surface with the axles extended.
Page 81 December 2019 Service and Repair Manual 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 82: Engines
Service and Repair Manual December 2019 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 83: How To Install The Flex Plate
December 2019 Service and Repair Manual 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 84: Ground Controls
Service and Repair Manual December 2019 Ground Controls How to Use the Bypass Mode Tip-over hazard. Operating the Bypass/Recovery Key Switch machine outside of the operating envelope while in Bypass mode The turntable control box (TCON) is the will result in death or serious communication and operations center for the injury if proper operating machine.
Page 85: How To Use The Recovery Mode
December 2019 Service and Repair Manual Ground Controls How to Us e the R ec ov ery Mode 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 86: Circuit Boards
Service and Repair Manual December 2019 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 87 December 2019 Service and Repair Manual 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 88: Membrane Decal
Service and Repair Manual December 2019 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 89: Full Machine Calibration
December 2019 Service and Repair Manual 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 90: Display Module
Service and Repair Manual December 2019 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 91 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa (metric) 0-31000 kPa Primary angle degrees -2°...
Page 92 Service and Repair Manual December 2019 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 93 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Primary boom up speed stowed Boom Function and hold the enter button Speeds and turn key switch to on position.
Page 94 Service and Repair Manual December 2019 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 95 December 2019 Service and Repair Manual 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 96 Service and Repair Manual December 2019 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 97: Hydraulic Pumps
December 2019 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and The function pump is a pressure compensated, burn skin.
Page 98: How To Prime The Function Pump
Service and Repair Manual December 2019 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 99 December 2019 Service and Repair Manual 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 100: How To Adjust The Function Pump Pressure Compensator
Service and Repair Manual December 2019 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 101: Drive Pump
December 2019 Service and Repair Manual 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 102 Service and Repair Manual December 2019 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 103: How To Prime The Drive Pump
December 2019 Service and Repair Manual 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 104: Manifolds
Service and Repair Manual December 2019 Manifolds Function Manifold Components – View 1 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 105 December 2019 Service and Repair Manual Manifolds Part No. 1300669GT ™ -150...
Page 106 Service and Repair Manual December 2019 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 26-28 Nm 24-26 ft-lbs Relief valve, 3200 psi / 221 bar System relief...
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Page 108 Service and Repair Manual December 2019 Manifolds Function Manifold Components – View 2 Schematic Index No. Description Function Torque Item Pilot operated 3 position, 4 way, Boom cylinder extend / retract 46-54 ft-lbs directional valve circuit 63-73 Nm Pilot operated 3 position, 4 way, Boom lift cylinder up/down 46-54 ft-lbs directional valve...
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Page 110: Valve Adjustments - Function Manifold
Service and Repair Manual December 2019 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 cable track Manifold Relief Valve side of boom #2.
Page 111 December 2019 Service and Repair Manual Manifolds Simultaneously push and hold the function enable/high speed button 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.
Page 112: 8-3A Platform Level And Rotation Manifold Components
Service and Repair Manual December 2019 Manifolds Platform Level and Rotation Manifold Components The platform manifold is mounted under the jib boom. Index Schematic Description Function Torque Item 19-21 ft-lbs Proportional solenoid valve, 3 position 4 way Jib level up/down 26-29 Nm 19-21 ft-lbs Solenoid valve, 3 position 4 way...
Page 113: Jib Boom Manifold Components
December 2019 Service and Repair Manual Manifolds Jib Boom Manifold Components The jib boom manifold is mounted on the primary extension boom at the platform end. Schematic Index No. Description Function Torque Item 19-21 ft-lbs Solenoid valve, 2 position 2 way Jib level up/down 26-28 Nm Counterbalance valve, 3:1 3300 psi /...
Page 114: Function Enable Manifold
Service and Repair Manual December 2019 Manifolds Function Enable Manifold Components The function enable manifold is located on the engine side below the hydraulic pumps. 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 steer/axle functions...
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Page 116: Steer And Axle Manifold Components
Service and Repair Manual December 2019 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...
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Page 118 Service and Repair Manual December 2019 Steer and Axle Manifold Components, continued Schematic Index No. Description Function Torque Item 33-37 ft-lbs Solenoid valve, 2 position 2 way Axle retract 45-50 Nm Pressure reducing valve, 2400 psi / 30-35 ft-lbs Axle extend/retract circuit 165 bar 41-47 Nm Prevents left rear steer cylinder...
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Page 120: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual December 2019 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 121: Traction Manifold Components
December 2019 Service and Repair Manual 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 35,3-40,7 Nm...
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Page 123 December 2019 Service and Repair Manual Manifolds Traction Manifold Components, continued Index Schematic Description Function Torque Item Equalizes pressure on both sides of 30-35 ft-lbs Orifice, 3 gpm / 11,4 L/min divider/combiner valve AP 40,7-47,5 Nm Equalizes pressure on both sides of 30-35 ft-lbs Orifice, 3 gpm / 11,4 L/min divider/combiner valve AM...
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Page 125: Valve Adjustments - Traction Manifold
December 2019 Service and Repair Manual 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 How to Adjust the Hot Oil Relief select button (rabbit symbol) position.
Page 126: Generator Manifold Component
Service and Repair Manual December 2019 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 26-28 Nm Solenoid valve, 2 position 2 way valve 33-37 ft-lbs...
Page 127: Valve Coils
December 2019 Service and Repair Manual 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 128 Service and Repair Manual December 2019 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 129: Turntable Rotation Components
December 2019 Service and Repair Manual Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from the machine. Turntable Rotation Assembly Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 130: How To Adjust The Turntable Rotation Gear Backlash
Service and Repair Manual December 2019 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 131: Turntable Level Sensor
December 2019 Service and Repair Manual 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 Level Sensor of the ground control box.
Page 132 Service and Repair Manual December 2019 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 1 Run...
Page 133 December 2019 Service and Repair Manual Turntable Rotation Components 13 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured...
Page 134: Axle Components
Service and Repair Manual December 2019 Axle Components Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. 10-1 Steer Sensors Note: If the sensor activator pin needs to be replaced, install the new activator pin per Illustration 1. The steer sensors measure steer angle and communicates that information to the ground controls ECM.
Page 135 December 2019 Service and Repair Manual Axle Components Position the new steer sensor assembly over 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable the sensor activator pin with the sensor cable angled towards the tire. Refer to Illustration 2. angled away from the tire.
Page 136: How To Calibrate A Replacement Steer Sensor
Service and Repair Manual December 2019 Axle Components How to C alibr ate a R epl acem ent Steer Sens or How to C alibr ate All Steer Sensors How to Calibrate a Replacement How to Calibrate All Steer Steer Sensor Sensors Note: If a steer angle sensor has been removed or Note: This procedure will only need to be...
Page 137 December 2019 Service and Repair Manual 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 138 Service and Repair Manual December 2019 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 139: Steer Cylinders
December 2019 Service and Repair Manual 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 140: Axle Angle Sensors
Service and Repair Manual December 2019 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 141 December 2019 Service and Repair Manual 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 142 Service and Repair Manual December 2019 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 143: Generators
December 2019 Service and Repair Manual Generators Start the engine from the platform controls. 11-1 Turn on the generator from the platform Welder Generator 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 144: Fault Codes
Service and Repair Manual December 2019 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 145: Control System Fault Codes
December 2019 Service and Repair Manual 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 146 Service and Repair Manual December 2019 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 147 December 2019 Service and Repair Manual 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 148 Service and Repair Manual December 2019 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 149 December 2019 Service and Repair Manual 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 150 Service and Repair Manual December 2019 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 151 December 2019 Service and Repair Manual 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 152 Service and Repair Manual December 2019 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 153 December 2019 Service and Repair Manual 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 154 Service and Repair Manual December 2019 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 155 December 2019 Service and Repair Manual 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 156 Service and Repair Manual December 2019 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 157 December 2019 Service and Repair Manual 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 158 Service and Repair Manual December 2019 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 159 December 2019 Service and Repair Manual 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 160 Service and Repair Manual December 2019 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 161 December 2019 Service and Repair Manual 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 162 Service and Repair Manual December 2019 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 163 December 2019 Service and Repair Manual 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 164: Fault Matrix
Service and Repair Manual December 2019 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 165: Fault Code Source
December 2019 Service and Repair Manual 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 Primary Boom Length Switches Cross-Check and xx is the two digit Fault Type.
Page 166 Service and Repair Manual December 2019 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 167 December 2019 Service and Repair Manual 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 168: Deutz Td 2.9 L4 Engine Fault Codes
Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1022 Actuator error EGR-Valve; signal KWP = Keyword Protocol range check high SPN FMI Description 1224 Actuator EGR-Valve; over 1019 EGR-Valve, short circuit to current...
Page 169 December 2019 Service and Repair Manual 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 170 Service and Repair Manual December 2019 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 171 December 2019 Service and Repair Manual 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 172 Service and Repair Manual December 2019 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 173 December 2019 Service and Repair Manual 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 174 Service and Repair Manual December 2019 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 175 December 2019 Service and Repair Manual 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 176 Service and Repair Manual December 2019 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 177 December 2019 Service and Repair Manual 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 178 Service and Repair Manual December 2019 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 179 December 2019 Service and Repair Manual 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 180 Service and Repair Manual December 2019 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 181 December 2019 Service and Repair Manual 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 182 Service and Repair Manual December 2019 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 183: Perkins 854F-34T Engine Fault Code
December 2019 Service and Repair Manual 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 184 Service and Repair Manual December 2019 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 185 December 2019 Service and Repair Manual 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 186 Service and Repair Manual December 2019 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 187 December 2019 Service and Repair Manual 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 188 Service and Repair Manual December 2019 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 189 December 2019 Service and Repair Manual 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 190 Service and Repair Manual December 2019 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 -...
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Page 192: Schematics
Service and Repair Manual December 2019 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 2019 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 2019 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 2019 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 2019 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 2019 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 2019 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function WH/RD Power to temp sender Primary boom up driver Auxiliary Power RD/BK Primary boom down driver RD/BK Platform level alarm RD/WH Primary boom up/down flow control proportional valve driver RD/WH...
Page 199 December 2019 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function GR/BK Axle oscillation Hydraulic Filter restricted Foot switch/TCON estop power Platform Level Safety Power RD/WH Boom down safety interlock RD/BK Platform Level Safety Output RD/BK Safety interlock to engine Platform Level Safety Ground...
Page 200 Service and Repair Manual December 2019 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Flashing Beacon Primary Boom Angle Signal Safety Lift Speed Reduction Secondary Boom Angle Signal Hydraulic Pressure Sensor Safety Output BL/RD Drive Enable Left Oil Cooler Fan BL/WH Drive Enable Right...
Page 201 December 2019 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Boom Length Signal Safety Safety cross check OR/BK Boom Length Signal Operational Data Receive BL/RD Primary Boom Hydraulic Valve BK/WH Data Transmit Lockout WH/RD Multi-Function Pressure Relief...
Page 202: Limit Switches And Angle Sensors
Service and Repair Manual December 2019 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 203 December 2019 Service and Repair Manual Limit Switches and Angle Sensors Switches and Sensors - Primary Boom Index Description Schematic Item Function Controlled Switch Type and Operation Jib Rotated CCW Safety Limit Switch LSJ2RS Normally closed switch;contacts open when jib boom is in stowed position.
Page 204 Service and Repair Manual December 2019 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 205 December 2019 Service and Repair Manual 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 206: Circuit Connector Legend
Service and Repair Manual December 2019 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 207 December 2019 Service and Repair Manual 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 208 Service and Repair Manual December 2019 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 209: Connector Pin Legend
December 2019 Service and Repair Manual 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 210 Service and Repair Manual December 2019 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 211 December 2019 Service and Repair Manual 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 212 Service and Repair Manual December 2019 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 213 December 2019 Service and Repair Manual 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 214 Service and Repair Manual December 2019 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 215 December 2019 Service and Repair Manual 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 216 Service and Repair Manual December 2019 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 217 December 2019 Service and Repair Manual 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 218 Service and Repair Manual December 2019 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 219 December 2019 Service and Repair Manual 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 220 Service and Repair Manual December 2019 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 221 December 2019 Service and Repair Manual 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 222 Service and Repair Manual December 2019 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 223 December 2019 Service and Repair Manual Connector Pin Legend J122 Black 12 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P122-01 ECU PWR P21DCON-WH Power for SCON/DCON ECU P122-02 LTB1LS (BOOM C166PRS-OR Analog signal input for boom length (safety) LENGTH) P122-03 RSB1AS (BOOM...
Page 224: Engine Relay And Fuse Panel Legend - Deutz Td2011L04I And Perkins 1104D-44T Models
Service and Repair Manual December 2019 Engine Relay and Fuse Panel Legend - Deutz TD2011L04i and Perkins 1104D-44T Models Number Component Description CR77A PCE#1 CR28 Engine / Fuel Relay CR17 Hydraulic Oil Cooler Fan Relay CR77B PCE#2 CR41 Flashing Beacon Relay Horn Relay Fuse, 20A, RPM Solenoid Fuse, 30A, Eng / Start / Alt...
Page 225: Engine Relay And Fuse Panel Legend - Deutz Td 2.9 L4 Models
December 2019 Service and Repair Manual Engine Relay and Fuse Panel Legend - Deutz TD 2.9 L4 Models Number Component Description CR39 Engine Shutdown CR77A PCE #1 Engine Alt. Relay CR17 Hydraulic Oil Cooler / Fan Relay CR28 Fuel Pump CR77B PCE #2 CR41...
Page 226: Engine Relay And Fuse Panel Legend - Perkins 854F-34T Models
Service and Repair Manual December 2019 Engine Relay and Fuse Panel Legend - Perkins 854F-34T Models Number Component Description CR77A PCE#1 Engine Alt CR17 Hydraulic Oil Cooler Fan Relay CR77B PCE#2 Fuse, 30A, ECU Power Fuse, 20A, Key Switch Power CR41 Flashing Beacon Relay Horn Relay...
Page 227: Electrical Symbols Legend
December 2019 Service and Repair Manual 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 228: Hydraulic Symbols Legend
Service and Repair Manual December 2019 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 229 December 2019 Service and Repair Manual Control Circuits - Horn...
Page 230 Service and Repair Manual December 2019 Control Circuits - Horn ™ -150 Part No. 1300669GT...
Page 231 December 2019 Service and Repair Manual Control Circuits - Power Part No. 1300669GT ™ -150...
Page 232 Service and Repair Manual December 2019 Control Circuits - Power...
Page 233 December 2019 Service and Repair Manual Control Circuits - Can Bus...
Page 234 Service and Repair Manual December 2019 Control Circuits - Can Bus ™ -150 Part No. 1300669GT...
Page 235 December 2019 Service and Repair Manual Control Circuits - Deutz TD2011L04i Engine Part No. 1300669GT ™ -150...
Page 236 Service and Repair Manual December 2019 Control Circuits - Deutz TD2011L04i Engine...
Page 237 December 2019 Service and Repair Manual Control Circuits - Deutz TD 2.9 L4Engine...
Page 238 Service and Repair Manual December 2019 Control Circuits - Deutz TD 2.9 L4 Engine ™ -150 Part No. 1300669GT...
Page 239 December 2019 Service and Repair Manual Control Circuits - Perkins 1104D-44T Engine Part No. 1300669GT ™ -150...
Page 240 Service and Repair Manual December 2019 Control Circuits - Perkins 1104D-44T Engine...
Page 241 December 2019 Service and Repair Manual Control Circuits - Perkins 854F-34T Engine...
Page 242 Service and Repair Manual December 2019 Control Circuits - Perkins 854F-34T Engine ™ -150 Part No. 1300669GT...
Page 243 December 2019 Service and Repair Manual Control Circuits - Axle Extend/Retract Part No. 1300669GT ™ -150...
Page 244 Service and Repair Manual December 2019 Control Circuits - Axle Extend/Retract...
Page 245 December 2019 Service and Repair Manual Control Circuits - Steering...
Page 246 Service and Repair Manual December 2019 Control Circuits - Steering ™ -150 Part No. 1300669GT...
Page 247 December 2019 Service and Repair Manual Control Circuits - Propel Part No. 1300669GT ™ -150...
Page 248 Service and Repair Manual December 2019 Control Circuits - Propel...
Page 249 December 2019 Service and Repair Manual Control Circuits - Turntable Rotate...
Page 250 Service and Repair Manual December 2019 Control Circuits - Turntable Rotate ™ -150 Part No. 1300669GT...
Page 251 December 2019 Service and Repair Manual Control Circuits - Boom Up/Down Part No. 1300669GT ™ -150...
Page 252 Service and Repair Manual December 2019 Control Circuits - Boom Up/Down...
Page 253 December 2019 Service and Repair Manual Control Circuits - Boom Extend/Retract...
Page 254 Service and Repair Manual December 2019 Control Circuits - Boom Extend/Retract ™ -150 Part No. 1300669GT...
Page 255 December 2019 Service and Repair Manual Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate Part No. 1300669GT ™ -150...
Page 256 Service and Repair Manual December 2019 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate...
Page 257 December 2019 Service and Repair Manual Control Circuits - Platform Level and Jib Bellcrank Level...
Page 258 Service and Repair Manual December 2019 Control Circuits - Platform Level and Jib Bellcrank Level ™ -150 Part No. 1300669GT...
Page 259 December 2019 Service and Repair Manual Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights Part No. 1300669GT ™ -150...
Page 260 Service and Repair Manual December 2019 Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights...
Page 261 December 2019 Service and Repair Manual Control Circuits - Recovery PLD...
Page 262 Service and Repair Manual December 2019 Control Circuits - Recovery PLD ™ -150 Part No. 1300669GT...
Page 263 December 2019 Service and Repair Manual Control Circuits - Telematics Part No. 1300669GT ™ -150...
Page 264 Service and Repair Manual December 2019 Control Circuits - Telematics...
Page 265 December 2019 Service and Repair Manual Generator Receptacle Wiring - ANSI / CSA...
Page 266 Service and Repair Manual December 2019 Generator Receptacle Wiring - ANSI/CSA ™ -150 Part No. 1300669GT...
Page 267 December 2019 Service and Repair Manual Generator Receptacle Wiring - CE Part No. 1300669GT ™ -150...
Page 268 Service and Repair Manual December 2019 Generator Receptacle Wiring - CE...
Page 269 December 2019 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...
Page 270 Service and Repair Manual December 2019 Perkins 1104D-44T Engine Electrical Schematic ™ -150 Part No. 1300669GT...
Page 271 December 2019 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic Part No. 1300669GT ™ -150...
Page 272 Service and Repair Manual December 2019 Perkins 854F-34T Engine Electrical Schematic...
Page 273 December 2019 Service and Repair Manual Perkins 854F-34T Engine Harness...
Page 274 Service and Repair Manual December 2019 Perkins 854F-34T Engine Harness ™ -150 Part No. 1300669GT...
Page 275 December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Electrical Schematic Part No. 1300669GT ™ -150...
Page 276 Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Electrical Schematic...
Page 277 December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Harness...
Page 278 Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Harness ™ -150 Part No. 1300669GT...
Page 279 December 2019 Service and Repair Manual Hydraulic Schematic...
Page 280 Service and Repair Manual December 2019 Hydraulic Schematic...
Page 281 TCON MEMBRANE PANEL (MS2) CAN GATEWAY KEY SWITCH LOCKOUT VALVE #1 SIGNAL LOCKOUT VALVE #1 SIGNAL SERVICE & TCON LCD BYPASS GROUND PRI BOOM LENGTH 3' STATUS PRI BOOM LENGTH 3' STATUS HORN (BN5) PLATFORM PLATFORM PCON GENERATOR AUXILIARY START ENGINE DRIVE AXLE...

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