Terex Genie SX -180 Service And Repair Manual

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Service and Repair Manual

-180

™

Serial Number Range

from SX18014-101 to

SX18016-599

from SX180H-600

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. 1268497

Rev A4

December 2018

Table of Contents

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Summary of Contents for Terex Genie SX -180

Page 1 Service and Repair Manual Serial Number Range -180 ™ This manual includes: Repair procedures from SX18014-101 to SX18016-599 Fault Codes from SX180H-600 Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268497 Rev A4 December 2018...
Page 2: Find A Manual For This Model
Unrestricted with proper operation, inspection and scheduled maintenance. Copyright © 2015 by Terex Corporation 1268497 Rev A3, October 2018 First Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. SX-180 Part No. 1268497...
Page 3 December 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 9/2016 Introduction Serial Number Legend 6/2017 Repair 8-3 Platform Level and Rotation Manifold 8-4 Jib Boom Manifold 8-5 Function Enable Manifold Fault Codes Fault Code Source 10/2018...
Page 4: Serial Number Legend
Service and Repair Manual December 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Sequence number 2 Model year 2 Serial number (stamped on chassis) 3 Facility code 3 Serial label (located under cover) From September 1, 2016 1 Model 1 Serial number (stamped on chassis) 2 Facility code...
Page 5: Safety Rules
December 2018 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 2018 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 2018 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 2018 Table of Contents Platform Components ..................29 2-1 Platform ......................29 2-2 Platform Leveling Cylinder ................30 2-3 Platform Rotator ..................... 31 How to Bleed the Platform Rotator ..............32 2-4 Platform Level Sensor ..................33 2-5 Platform Overload System (if equipped) ............34 2-6 Platform Overload Recovery Message ............
Page 9 December 2018 Table of Contents Display Module ....................88 Hydraulic Pumps ....................95 7-1 Function Pump ....................95 How to Prime the Function Pump ..............96 How to Adjust the Function Pump Standby Pressure ........96 How to Adjust the Function Pump Pressure Compensator ......98 7-2 Drive Pump.....................
Page 10 December 2018 Table of Contents Generators......................144 11-1 Welder Generator ..................144 Section 4 Fault Codes ....................... 145 Introduction ......................145 Control System Fault Codes ................146 Fault Matrix ......................165 Fault Code Source ....................166 Deutz TD 2.9 L4 Engine Fault Codes ..............169 Perkins 854F-34T Engine Fault Code ..............
Page 11 December 2018 Table of Contents Control Circuits - Turntable Rotate ..............252 Control Circuits - Boom Up/Down ..............253 Control Circuits - Boom Extend/Retract ............. 256 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate ......257 Control Circuits - Platform Level and Jib Bellcrank Level ........260 Control Circuits - Platform Load Sense ..............
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 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 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 Viscosity index ISO Grade Kinematic Viscosity Viscosity index cSt @ 200°F / 100°C Kinematic Viscosity cSt @ 104°F / 40°C 44.4 cSt @ 149°F / 65°C Flash point...
Page 18: Hydraulic Component Specifications
Service and Repair Manual December 2018 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 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 Displacement 220.9 cu. in 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.78 x 4.92 inches 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 Displacement 177 cu. in 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C Bore and Stroke 3.6 x 4.3 inches 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 Displacement 268.5 cu. in 11 - 24 Nm 4.4 liters Pressure switch point 8 psi Number of cylinders 0.55 bar Bore and Stroke 4.13 x 5 inches 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 Displacement 207 cu. in 25 Nm 3.4 liters Pressure switch point 12 psi Number of cylinders 0.82 bar Bore and Stroke 3.89 x 4.33 inches 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 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 2018 Specifications Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port (tube fitting - installed into Aluminum) Your machine is equipped with Parker Seal-Lok™ (all types) ORFS or 37° JIC fittings and hose ends. Genie SAE Dash Size Torque specifications require that fittings and hose ends be...
Page 27: Torque Procedure
December 2018 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Seal-Lok™ fittings Align the tube flare (hex nut) against the nose of the fitting body (body hex fitting) and tighten Replace the O-ring. The O-ring must be the hex nut to the body hex fitting to hand tight, replaced anytime the seal has been broken.
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 Repair Pr oc edures Machine Configuration: 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 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 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 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 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 33: Joysticks
December 2018 Service and Repair Manual Platform Controls Press the minus button twice, then press the enter button twice. Joysticks Use the scroll button to scroll through the menu until DELETE DRIVE JOYSTICK How to Calibrate a Joystick DEFAULTS is displayed. Press the plus button to select YES, then The joystick controllers on this machine utilize press the enter button.
Page 34 Service and Repair Manual December 2018 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 35 December 2018 Service and Repair Manual 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 36: How To Reset A Proportional Valve Coil Default
Service and Repair Manual December 2018 Platform Controls How to R es et a Proportional Val ve Coil D efault How to Reset a Proportional Valve Turntable rotate functions: 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 37: How To Set The Function Thresholds And Default Functions Speeds
December 2018 Service and Repair Manual Platform Controls How to Set the F unc tion 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 Functions function starts to move, then move the joystick Speeds...
Page 38 Service and Repair Manual December 2018 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 39: How To Adjust The Function Speeds
December 2018 Service and Repair Manual Platform Controls How to Adj ust the Functi on Speeds Press the enter button to save the setting in memory. How to Adjust the Function Press the enter or previous button on the Speeds LCD screen until EXIT is displayed.
Page 40: How To Adjust The Function Ramp Rate Setting
Service and Repair Manual December 2018 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 41: Platform Components
December 2018 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 2018 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 2018 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 2018 Platform Components How to Bleed the Pl atfor m R otator Support the jib boom leveling arms with a suitable lifting device. How to Bleed the Platform Rotator Use a soft metal drift to remove both pins and Note: Do not start the engine.
Page 45: Platform Level Sensor
December 2018 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 (If Equipped)
Service and Repair Manual December 2018 Platform Components 11 Press the enter or previous button on the LCD screen until EXIT is displayed. Platform Overload System (if 12 Press the plus button or minus button to equipped) select YES and then press the enter button. Proper calibration of the platform overload system 13 Remove the fastener that was temporarily is essential to safe machine operation.
Page 47 December 2018 Service and Repair Manual Platform Components Determine the limit switch trigger point: Confirm the setting: Gently move the platform up and down by Start the engine from the platform controls. hand, so it bounces approximately 1 to Lift the test weight off the platform floor using a 2 inches / 2.5 to 5 cm.
Page 48: Platform Overload Recovery Message
Service and Repair Manual December 2018 Platform Components Test all machine functions from the platform controls. Platform Overload Recovery Result: All platform control functions should Message (software V2.0 and later) not operate. If the ground controls LCD screen displays 10 Turn the key switch to ground controls. OVERLOAD RECOVERY, the emergency lowering 11 Test all machine functions from the ground system has been used while the platform was...
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 5 bellcrank 2 jib boom 6 jib boom lift cylinder 3 jib rotator 7 platform leveling cylinder 4 bellcrank leveling cylinder SX-180 Part No. 1268497...
Page 51: Jib Boom
December 2018 Service and Repair Manual 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 boom lift cylinder barrel-end pivot pin. How to Remove the Jib Boom 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 52: Jib Boom Lift 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 soft Jib Boom Lift Cylinder 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 to Cylinder...
Page 53: How To Remove The Jib Boom Bellcrank
December 2018 Service and Repair Manual 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 54: Jib Boom Bellcrank Angle Sensor
Service and Repair Manual December 2018 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 55 December 2018 Service and Repair Manual Jib Boom Components Locate the calibration toggle switch at the top 11 Press the plus button to select YES, then of the ground control box. Activate calibration press the enter button to accept. mode by moving the toggle switch in the left 12 Adjust the jib bellcrank until it is level to gravity.
Page 56 Service and Repair Manual December 2018 Jib Boom Components 16 Press the plus button to select YES, then press the enter button to accept. 17 Turn the key back to the run position and remove the key from the bypass/recovery key switch.
Page 57: Boom Components
December 2018 Service and Repair Manual Boom Components 1 boom tube #1 5 primary lift cylinder 2 boom tube #2 6 boom tube #0 3 boom tube #3 7 secondary extension cylinder 4 boom tube #4 Part No. 1268497 SX-180...
Page 58: 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 59 December 2018 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 2018 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 61 December 2018 Service and Repair Manual Boom Components 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. This procedure requires specific repair Note: Do not use force when adding the shims.
Page 62 Service and Repair Manual December 2018 Boom Components Attach a lifting strap from an overhead crane to 10 Tag, disconnect and plug the secondary boom the rod end of the primary boom lift cylinder. extension cylinder hydraulic hoses. Cap the fittings on the cylinder.
Page 63 December 2018 Service and Repair Manual Boom Components How to Disassemble the Primary 17 Disconnect the electrical connector from the primary boom angle sensor. Boom Note: The primary boom angle sensor is located on Bodily injury hazard. This the pivot pin on the tank side of the boom. procedure requires specific repair skills, lifting equipment and a 18 Remove the primary boom angle sensor...
Page 64 Service and Repair Manual December 2018 Boom Components 14 Remove the red locking brackets from the Remove the jib boom bellcrank. Refer to #4 extend cable pivot assembly. Repair Procedure, How to Remove the Jib Boom Bellcrank. 15 Remove the nuts on the #4 extend cables and remove the #4 pivot assembly.
Page 65 December 2018 Service and Repair Manual Boom Components Remove the #2 boom tube: 19 Attach the #3 boom tube to a forklift, and lift the tube enough to relieve the pressure from the 23 At the pivot end of the machine, remove the lower wear pads.
Page 66 Service and Repair Manual December 2018 Boom Components 28 Remove the fasteners securing the lower wear 32 Remove the final two side wear pads from the pads and remove the wear pads and aluminum platform end of the machine. block between the #1 and #2 boom tubes. Note: Pay careful attention to the location and 29 Back the wire cables from the opening below amount of shims used with each wear pad.
Page 67 December 2018 Service and Repair Manual Boom Components 38 Remove an upper side wear pad and the lower 43 Remove the lower wear pads between the side wear pad from the opposite side of the #0 and #1 boom tubes. boom between the #0 and #1 boom tubes.
Page 68: Primary Boom Lift Cylinder
Service and Repair Manual December 2018 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 the Note: Place the lifting strap between the cable track primary boom.
Page 69 December 2018 Service and Repair Manual 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 overhead Bodily injury hazard.
Page 70: Extension Cylinder
Service and Repair Manual December 2018 Boom Components Tag and disconnect the limit switch harnesses. Remove the fasteners to the limit switch Extension Cylinders harness mounting bracket and remove the bracket. The primary boom extension cylinder is located inside the boom assembly and incorporates cables Tag and disconnect limit switch 3RO (6).
Page 71 December 2018 Service and Repair Manual Boom Components Lay the inner cable track and hoses down and 10 At the platform end of the machine, loosen the out of the way. retract cable equalizer bolts at the #1 and #2 boom tubes. 11 Remove the retaining fasteners from the red cable adjustment locking brackets.
Page 72 Service and Repair Manual December 2018 Boom Components 14 Remove the locking plates securing the extend 21 Support and slide the primary boom extension cylinder to boom #1 (1). (Illustration 1) cylinder out of the boom assembly while guiding the cables out of the boom and place it 15 Remove the cable guards (2) covering the on a structure capable of supporting it.
Page 73 December 2018 Service and Repair Manual Boom Components How to Remove the Secondary Loosen but do not remove the extension cylinder support bracket and wear pad. Boom Extension Cylinder Bodily injury hazard. Do not Bodily injury hazard. This operate the machine unless the procedure requires specific repair secondary extend cylinder skills, lifting equipment and a...
Page 74: Boom Extend And Retract Cables
Service and Repair Manual December 2018 Boom Components Protect the boom lift cylinder rod from damage. Boom Extend and Retract Cables Use a soft metal drift to remove both pivot pins. Remove the secondary boom extension cylinder from the machine while guiding the How to Adjust the Boom barrel end of the cylinder out of the boom.
Page 75 December 2018 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 76 Service and Repair Manual December 2018 Boom Components 11 Loosen the jam nut on the cable tension retract bracket. Do not remove the nuts. 12 Tighten the retract bolt using a torque wrench until boom tube #3 begins to move. Note: If the torque wrench reaches 105 ft-lbs / 142 Nm and boom tube #3 hasn't moved, loosen the extend cable adjustment bolts 5 turns and continue...
Page 77 December 2018 Service and Repair Manual Boom Components 19 Re-measure the gap between boom tubes 25 Fully retract the boom and lower the boom to #1 and #2 from points (11) and (12) the horizontal position. (dimension “A”) and boom tubes #2 and 26 Stop the engine.
Page 78 Service and Repair Manual December 2018 Boom Components 29 Loosen the two extend cable adjustment bolts 39 Re-measure the gap between boom tubes (1) five turns. (Illustration 2) #1 and #2 from points (11) and (12) (dimension “A”) and boom tubes #3 and 30 At the platform end of the boom, locate the #4 from points (7) and (8).
Page 79: How To Replace The Boom Extend/Retract Cables
December 2018 Service and Repair Manual 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 80 Service and Repair Manual December 2018 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 81 December 2018 Service and Repair Manual 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 82: Boom Internal Cable Track
Service and Repair Manual December 2018 Boom Components 32 Remove the equalizing bracket from the #4 boom retract cables. Boom Internal Cable Track 33 Attach electrician's tape to the #4 retract cable at the pivot end of the machine. How to Remove the Boom Internal 34 Attach a suitable device to pull the #3 and Cable Track #4 boom tubes approximately 2 feet / 0.6 m.
Page 83 December 2018 Service and Repair Manual Boom Components At the weldment securing the rod end of the lift Tag, disconnect and plug the hydraulic hoses cylinder to the boom, locate the two fasteners from the primary boom extension cylinder. Cap securing the internal cable track assembly to the fittings on the cylinder.
Page 84 Service and Repair Manual December 2018 Boom Components 11 At the pivot end, note the position of the 13 Support the assembly as it is removed from the locating U notch on the cable tube. Pull the boom. cable track and cable tube from the boom Note: Reverse the procedure to install the assembly.
Page 85: 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 86 Service and Repair Manual December 2018 Boom Components Press and hold the enter button on the ground 13 Start the engine from the ground controls. control panel while pulling out the ground 14 Press and hold a function enable/speed select controls red Emergency Stop button to the on button and the primary boom up button until position.
Page 87 December 2018 Service and Repair Manual Boom Components 18 Press and hold a function enable/speed select 22 Press and hold a function enable/speed select button and the primary boom up button until button and the primary boom button until the the digital level displays 49 degrees.
Page 88: Boom Length Sensor
Service and Repair Manual December 2018 Boom Components 28 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Boom Length Sensor Stop button in. 29 Remove the fastener that was temporarily How to Calibrate the Primary installed.
Page 89 December 2018 Service and Repair Manual Boom Components 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 pulling out the ground in this procedure.
Page 90 Service and Repair Manual December 2018 Boom Components 18 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Result: An audible alarm sounds for 1 second. Calibration has been stored. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved.
Page 91: 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 and Service or Maintenance Manual for your machine, has a splined center to drive the pump.
Page 92: 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 93: 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 injury machine.
Page 94 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 platform control buttons to level the platform.
Page 95: 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 96 Service and Repair Manual December 2018 Ground Controls How to Remove the ALC-1000 Component damage hazard. Electrostatic discharge (ESD) Circuit Board can damage printed circuit board components. Maintain firm Push in the red Emergency Stop button to the contact with a metal part of the off position at both the ground and platform machine that is grounded at all controls.
Page 97: Membrane Decal
December 2018 Service and Repair Manual Ground Controls Tag and carefully disconnect the wire connectors from the circuit board. Membrane Decal Carefully disconnect the LCD circuit board The membrane decal is a special decal that ribbon cable from the ECM circuit board. consists of a decal with an electronic membrane on Carefully disconnect the two ribbon cables the backside.
Page 98: Full Machine Calibration
Service and Repair Manual December 2018 Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Full Machine Calibration board. Full machine calibration must be completed in the Electrocution/burn hazard. proper sequence when the ALC-1000 circuit board Contact with electrically charged (TCON) in the ground control box has been circuits could result in death or...
Page 99 December 2018 Service and Repair Manual Ground Controls Full machine calibration must be completed in the following sequence: · Select engine configuration. Refer to Repair Section Display Module. Unit of Measure and Language. · Joysticks. Refer to Repair Procedure, How to Calibrate a Joystick.
Page 100: Display Module
Service and Repair Manual December 2018 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 101 December 2018 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 102 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection Drive Functions With key switch , press Forward extended drive speed % 120% (max) 100% (default) and hold the enter button and 50% (min) turn key switch to on position.
Page 103 December 2018 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 104 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and hold Primary boom up/down Ramps the enter button and turn key switch ramp acceleration % to on position. Primary boom up/down Release the enter button and press ramp deceleration %...
Page 105 December 2018 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press Set unit X-axis to gravity and hold the enter button Set unit Y-axis to gravity and turn key switch to on Set platform level to gravity (YES/NO) position.
Page 106 Service and Repair Manual December 2018 Display Module Screen or Menu Procedure Description Range or Selection Options With key switch , press AC Generator (NONE/7.5KW/12.5KW) and hold the enter button and turn key switch to on position. Release the enter button and press (minus)(minus)(plus)(plus).
Page 107: Hydraulic Pumps
December 2018 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 The function pump is a pressure compensated, hydraulic oil can penetrate and variable displacement piston pump.
Page 108: How To Prime The Function Pump
Service and Repair Manual December 2018 Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pump 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 109 December 2018 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 110: How To Adjust The Function Pump Pressure Compensator
Service and Repair Manual December 2018 Hydraulic Pumps How to Adj ust the Functi on Pump Press ure Compens 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 111: Drive Pump
December 2018 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 112 Service and Repair Manual December 2018 Hydraulic Pumps Locate the two hydraulic tank valves at the Carefully pull the drive pump out until the pump hydraulic tank. Close the valves. coupler separates from the flex plate. Remove the drive pump from the machine. Component damage hazard.
Page 113: How To Prime The Drive Pump
December 2018 Service and Repair Manual Hydraulic Pumps How to Prime the Dri ve Pump How to Prime the Drive Pump Component damage hazard. Be sure to open the two hydraulic tank valves before performing this procedure. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A"...
Page 114: Manifolds
Service and Repair Manual December 2018 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 Solenoid operated 2 position 2 way 33-37 ft-lbs / Primary boom cylinder retract directional valve...
Page 115 December 2018 Service and Repair Manual Manifolds Part No. 1268497 SX-180...
Page 116 Service and Repair Manual December 2018 Manifolds Function Manifold Components, continued Schematic Index No. Description Function Torque Item Prevents hydraulic pressure from 19-21 ft-lbs / Check valve, 5 psi / 0.34 bar flowing back into auxiliary pump #1 25.7-28.5 Nm 24-26 ft-lbs / Relief valve, 3200 psi / 221 bar System relief...
Page 117 December 2018 Service and Repair Manual Manifolds Part No. 1268497 SX-180...
Page 118 Service and Repair Manual December 2018 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 62.6-73.4 Nm Pilot operated 3 position, 4 way, Boom lift cylinder up/down 46-54 ft-lbs / directional valve...
Page 119 December 2018 Service and Repair Manual Manifolds Part No. 1268497 SX-180...
Page 120: Valve Adjustments - Function Manifold
Service and Repair Manual December 2018 Manifolds How to Adjust the Primary Boom Valve Adjustments - Function Manifold Extend Relief Valve Note: Perform this procedure with the axles How to Adjust the Function extended. Manifold Relief Valve Locate limit switch LSB4EO/S on the cable track side of boom #2.
Page 121 December 2018 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 122: Platform Level And Rotation Manifold To Sn Sx180H-612
Service and Repair Manual December 2018 Manifolds Platform Level and Rotation Manifold Components to SX180H-612 The platform manifold is mounted under the jib boom. Index Schematic Description Function Torque Item Proportional Directional Control valve, 25-30 ft-lbs / Jib level up/down 3 position 5 way 33.9-40.7 Nm Jib boom up/down circuit, regulates...
Page 123: 8-3A Platform Level And Rotation Manifold From Sn Sx180H-613
December 2018 Service and Repair Manual Manifolds 8-3A Platform Level and Rotation Manifold Components from SX180H-613 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 25.8-28.6 Nm 19-21 ft-lbs /...
Page 124: Jib Boom Manifold To Sn Sx180H-612
Service and Repair Manual December 2018 Manifolds Jib Boom Manifold Components to SX180H-612 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 / Check valve, 25 psi / 1.7 bar Holds oil in jib boom manifold 25.8-28.6 Nm Jib boom rotate circuit, regulates...
Page 125: 8-4A Jib Boom Manifold From Sn Sx180H-613
December 2018 Service and Repair Manual Manifolds 8-4A Jib Boom Manifold Components from SX180H-613 The jib boom manifold is mounted on the primary extension boom at the platform end. Schematic Index No. Description Function Torque Item Proportional solenoid valve,2 position 19-21 ft-lbs / Jib level up/down 2 way...
Page 126: Function Enable Manifold
Service and Repair Manual December 2018 Manifolds Function Enable Manifold 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 128: Steer And Axle Manifold
Service and Repair Manual December 2018 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 retract 20-25 ft-lbs / Flow control valve, 1.5 gpm / 5.7 L/min circuit...
Page 129 December 2018 Service and Repair Manual Part No. 1268497 SX-180...
Page 130 Service and Repair Manual December 2018 Steer and Axle Manifold, continued Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 30-35 ft-lbs / Axle extend/retract circuit 165 bar 41-47 Nm Prevents left rear steer cylinder 20-25 ft-lbs / Check valve from moving when not steering 27-34 Nm...
Page 131 December 2018 Service and Repair Manual Part No. 1268497 SX-180...
Page 132: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual December 2018 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.
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Page 134: 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 135 December 2018 Service and Repair Manual Manifolds Part No. 1268497 SX-180...
Page 136 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 137 December 2018 Service and Repair Manual Manifolds Part No. 1268497 SX-180...
Page 138: 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 139: 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 140: Valve Coils
Service and Repair Manual December 2018 Manifolds Valve Coil Resistance 8-11 Specification Valve Coils Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As How to Test a Coil 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 141 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 142: 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 143: How To Adjust The Turntable Rotation Gear Backlash
December 2018 Service and Repair Manual Turntable Rotation Components How to Adj ust the Tur ntabl e R otati on Gear Bac klas h Turn the adjustment bolt 1/2 to 3/4 turn counterclockwise. Tighten the lock nut on the How to Adjust the Turntable adjustment bolt.
Page 144: 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. Locate the calibration toggle switch at the top How to Calibrate the Turntable of the ground control box.
Page 145 December 2018 Service and Repair Manual Turntable Rotation Components Enter sensor calibration mode by pressing the 10 Place the digital level along the X axis of the buttons at the ground controls in the following turntable. sequence: (plus)(enter)(enter)(plus). 1 -X Axis 2 +X Axis 3 Platform end 1 Run...
Page 146 Service and Repair Manual December 2018 Turntable Rotation Components 13 Press the plus button or minus button to 18 Use the key to turn the bypass / recovery key adjust the display to the exact value shown on switch to the run position. the digital level and press the enter button.
Page 147: 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 The steer sensors measure steer angle and replaced, install the new activator pin per Illustration communicates that information to the ground controls ECM.
Page 148 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 149: How To Calibrate A Replacement Steer Sensor
December 2018 Service and Repair Manual Axle Components How to C alibr ate a Repl acement Steer Sens or How to Calibrate a Replacement 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable Steer Sensor angled away from the tire.
Page 150: How To Calibrate All Steer Sensors
Service and Repair Manual December 2018 Axle Components How to C alibr ate All Steer Sensors How to Calibrate All Steer Using a voltmeter set to DC voltage, probe the back of the electrical connector at pins B and Sensors Note: This procedure will only need to be performed Left front (square-end, blue side) and right if the ground controls circuit board (TCON) has...
Page 151 December 2018 Service and Repair Manual Axle Components Delete all Steer Sensor Calibrations Press and hold the enter button on the ground control panel while pulling out the ground 11 Press the enter or previous button on the controls red Emergency Stop button to the on LCD screen until DELETE ALL STEER position.
Page 152: Steer Cylinders
Service and Repair Manual December 2018 Axle Components 10-2 20 Push in the red Emergency Stop button to the off position. Steer Cylinders 21 Remove the fastener that was temporarily installed. Close the control box door and install How to Remove a Steer Cylinder the door retaining fasteners.
Page 153: Axle Extension Cylinders
December 2018 Service and Repair Manual Axle Components 10-3 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Extension Cylinders cylinder. Note: Connect the pressure hose from the power How to Remove an Axle unit to the "R"...
Page 154: Axle Angle Sensors
Service and Repair Manual December 2018 Axle Components 10-4 Temporarily install a control box door retaining fastener between the door and the box to Axle Angle Sensors prevent the control box door from moving the toggle switch while calibrating the machine. The axle angle sensors measure the axle angle and communicates that information to the ground Remove the key from the main key switch.
Page 155 December 2018 Service and Repair Manual Axle Components Enter sensor calibration mode by pressing the 16 Wait approximately 20 seconds and turn the buttons at the ground controls in the following machine off by pressing the red Emergency sequence: (plus)(enter)(enter)(plus). Stop button in.
Page 156: 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 157: Fault Codes
December 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use.
Page 158: 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 159 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 160 Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type Effects Recovery Actions Fault Check RSB1AO/RSB1AS Disable Boom Up, Extend, Down, TT Power up controller with problem Cross-check Rotate, and Propel powers in SCON. corrected. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RS.
Page 161 December 2018 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Fault Check RSB1AO/LSB1DO (10°) Disable Boom Up, Extend, Down, TT Power up controller with problem Cross-check Rotate, and Propel powers in SCON. corrected. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 162 Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type Effects Recovery Actions Fault Check LSB2RS (151ft)/LSB4ES Disable Boom Up, Extend, Down, TT Power up controller with problem (150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
Page 163 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 164 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 165 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 166 Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type Effects Recovery Actions Fault Check Turntable Rotate Clockwise 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 167 December 2018 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Check that SCON is grounded Safety Turntable Level Primary up and extend disabled, Alarm Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 168 Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Operational Primary Boom Disable Boom Up, Extend, Down, TT Power up controller with problem Angle Sensor Rotate, and Propel. Boom Retract corrected.
Page 169 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 170 Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type Effects Recovery Actions Not calibrated Perform calibration procedure Jib Level (Bellcrank) Normal function except threshold for Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD.
Page 171 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 172 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 173 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 174 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 175 December 2018 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Value at 5.0 V Right Rear Steer Angle 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 176 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 and Ignition/Fuel. Boom Down and Envelope Retract allowed. All functions allowed once boom is lowered back into envelope.
Page 177: 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 178: 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 179 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 180 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 181: 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 182 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 183 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 184 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 185 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 186 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 187 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 188 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 189 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 523470 Maximum rail pressure in limp detection reported error...
Page 190 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 191 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 192 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 193 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 523960...
Page 194 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 524035 12 1341 Injector diagnostics; time out 524109 9 1679 Timeout error of error in the SPI communication...
Page 195 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 196: 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 197 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 Engine Temperature Sensor Open or Short Circuit -...
Page 198 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 199 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 200 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 201 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 202 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 203 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 -...
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Page 205: Schematics
December 2018 Service and Repair Manual Schematics Section 5 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.
Page 206: Wire Circuit Legend
Service and Repair Manual December 2018 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the circuit prefix, circuit number and circuit suffix. Control The circuit prefix indicates the type of circuit. Data The circuit number describes the function of the circuit.
Page 207 December 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 208 Service and Repair Manual December 2018 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 209 December 2018 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 210: Wire Color Legend
Service and Repair Manual December 2018 Wire Color Legend Wire Coloring Jib, Jib Level, Platform Level Propel (drive) valves All cylinder extension colors are solid and all Turntable rotate flow control valve retract functions are striped black. When using Color Circuit # Primary Function black wire, the stripe shall be white.
Page 211 December 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function WH/RD Power to temp sender GR/BK Axle oscillation Auxiliary Power Foot switch/TCON estop power RD/BK Platform level alarm RD/WH Boom down safety interlock RD/WH Drive Motor shift (speed) RD/BK...
Page 212 Service and Repair Manual December 2018 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 213 December 2018 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary Boom Angle Signal Boom Length Signal Safety Safety OR/BK Boom Length Signal Operational Secondary Boom Angle Signal BL/RD Primary Boom Hydraulic Valve Safety Lockout BL/RD...
Page 214 Service and Repair Manual December 2018 Wire Color Legend Color Circuit # Primary Function Safety cross check Data Receive BK/WH Data Transmit WH/RD Multi-Function Pressure Relief WH/BK Jib Rotate Left WH/RD Jib Rotate Right WH/RD Speed Select Input OR/RD Electric Brake Source 2.5V Sensor Power Hour Meter +12V Sensor Power...
Page 215: 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 Rear Stringpot...
Page 216 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 Boom #0 - 151ft (boom fully LSB2RO Activates P1 lockout valve Normally open switch retracted) Operational Limit Switch during retract.
Page 217 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 218 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 219: 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 220 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 221 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 222: 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 223 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 224 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 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236: Engine Relay And Fuse Panel Legend- Deutz Td2011 & Perkins 1104D
Service and Repair Manual December 2018 Engine Relay and Fuse Panel Legend- Deutz TD2011 and Perkins 1104D Models 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...
Page 237: Engine Relay And Fuse Panel Legend- Deutz Td2.9 Models
December 2018 Service and Repair Manual Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models Deutz TD2.9 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 238: Engine Relay And Fuse Panel Legend- Perkins 854F Models
Service and Repair Manual December 2018 Engine Relay and Fuse Panel Legend- Perkins 854F Models 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 239: 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 240: 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 241: 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 242 Service and Repair Manual December 2018 This page intentionally left blank. SX-180 Part No. 1268497...
Page 243: Electrical Schematics - Control Circuits
December 2018 Service and Repair Manual Control Circuits - Horn...
Page 244: Control Circuits - Horn
Service and Repair Manual December 2018 Control Circuits - Horn SX-180 Part No. 1268497...
Page 245: Control Circuits - Power
December 2018 Service and Repair Manual Control Circuits - Power Part No. 1268497 SX-180...
Page 246 Service and Repair Manual December 2018 Control Circuits - Power...
Page 247 December 2018 Service and Repair Manual Control Circuits - Can Bus...
Page 248: Control Circuits - Can Bus
Service and Repair Manual December 2018 Control Circuits - Can Bus SX-180 Part No. 1268497...
Page 249: Control Circuits - Deutz Td2011L04I Engine
December 2018 Service and Repair Manual Control Circuits - Deutz TD2011L04i Engine Part No. 1268497 SX-180...
Page 250 Service and Repair Manual December 2018 Control Circuits - Deutz TD2011L04i Engine...
Page 251 December 2018 Service and Repair Manual Control Circuits - Deutz 2.9 Engine...
Page 252: Control Circuits - Deutz 2.9 Engine
Service and Repair Manual December 2018 Control Circuits - Deutz 2.9 Engine SX-180 Part No. 1268497...
Page 253: Control Circuits - Perkins 1104D-44T Engine
December 2018 Service and Repair Manual Control Circuits - Perkins 1104D-44T Engine Part No. 1268497 SX-180...
Page 254 Service and Repair Manual December 2018 Control Circuits - Perkins 1104D-44T Engine...
Page 255 December 2018 Service and Repair Manual Control Circuits - Perkins 854 Engine...
Page 256: Control Circuits - Perkins 854 Engine
Service and Repair Manual December 2018 Control Circuits - Perkins 854 Engine SX-180 Part No. 1268497...
Page 257: Control Circuits - Axle Extend/Retract
December 2018 Service and Repair Manual Control Circuits - Axle Extend/Retract Part No. 1268497 SX-180...
Page 258 Service and Repair Manual December 2018 Control Circuits - Axle Extend/Retract...
Page 259 December 2018 Service and Repair Manual Control Circuits - Steering...
Page 260: Control Circuits - Steering
Service and Repair Manual December 2018 Control Circuits - Steering SX-180 Part No. 1268497...
Page 261: Control Circuits - Propel
December 2018 Service and Repair Manual Control Circuits - Propel Part No. 1268497 SX-180...
Page 262 Service and Repair Manual December 2018 Control Circuits - Propel...
Page 263 December 2018 Service and Repair Manual Control Circuits - Turntable Rotate...
Page 264: Control Circuits - Turntable Rotate
Service and Repair Manual December 2018 Control Circuits - Turntable Rotate SX-180 Part No. 1268497...
Page 265: Control Circuits - Boom Up/Down
December 2018 Service and Repair Manual Control Circuits - Boom Up/Down Part No. 1268497 SX-180...
Page 266 Service and Repair Manual December 2018 Control Circuits - Boom Up/Down...
Page 267 December 2018 Service and Repair Manual Control Circuits - Boom Extend/Retract...
Page 268: Control Circuits - Boom Extend/Retract
Service and Repair Manual December 2018 Control Circuits - Boom Extend/Retract SX-180 Part No. 1268497...
Page 269: Control Circuits - Jib Up/Down, Jib Rotate And Platform Rotate
December 2018 Service and Repair Manual Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate Part No. 1268497 SX-180...
Page 270 Service and Repair Manual December 2018 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate...
Page 271 December 2018 Service and Repair Manual Control Circuits - Platform Level and Jib Bellcrank Level...
Page 272: Control Circuits - Platform Level And Jib Bellcrank Level
Service and Repair Manual December 2018 Control Circuits - Platform Level and Jib Bellcrank Level SX-180 Part No. 1268497...
Page 273: Control Circuits - Platform Load Sense
December 2018 Service and Repair Manual Control Circuits - Platform Load Sense Part No. 1268497 SX-180...
Page 274 Service and Repair Manual December 2018 Control Circuits - Platform Load Sense...
Page 275 December 2018 Service and Repair Manual Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights...
Page 276: Control Circuits - Flashing Beacons, Oil Cooler And Drive/Work Lights
Service and Repair Manual December 2018 Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights SX-180 Part No. 1268497...
Page 277: Control Circuits - Recovery Pld
December 2018 Service and Repair Manual Control Circuits - Recovery PLD Part No. 1268497 SX-180...
Page 278 Service and Repair Manual December 2018 Control Circuits - Recovery PLD...
Page 279 December 2018 Service and Repair Manual Control Circuits - Telematics...
Page 280: Control Circuits - Telematics
Service and Repair Manual December 2018 Control Circuits - Telematics SX-180 Part No. 1268497...
Page 281: Generator Receptacle Wiring- Ansi/Csa
December 2018 Service and Repair Manual Generator Receptacle Wiring- ANSI/CSA Part No. 1268497 SX-180...
Page 282 Service and Repair Manual December 2018 Generator Receptacle Wiring- ANSI/CSA...
Page 283 December 2018 Service and Repair Manual Generator Receptacle Wiring - CE...
Page 284: Generator Receptacle Wiring- Ce
Service and Repair Manual December 2018 Generator Receptacle Wiring - CE SX-180 Part No. 1268497...
Page 285: Perkins 1104D-44T Engine Electrical Schematic
December 2018 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic Part No. 1268497 SX-180...
Page 286 Service and Repair Manual December 2018 Perkins 1104D-44T Engine Electrical Schematic...
Page 287 December 2018 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...
Page 288: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual December 2018 Perkins 854F-34T Engine Electrical Schematic SX-180 Part No. 1268497...
Page 289: Perkins 854F-34T Engine Harness
December 2018 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1268497 SX-180...
Page 290 Service and Repair Manual December 2018 Perkins 854F-34T Engine Harness...
Page 291 December 2018 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic...
Page 292: Deutz Td2.9 Engine Electrical Schematic
Service and Repair Manual December 2018 Deutz TD2.9 Engine Electrical Schematic SX-180 Part No. 1268497...
Page 293: Deutz Td2.9 Engine Harness
December 2018 Service and Repair Manual Deutz TD2.9 Engine Harness Part No. 1268497 SX-180...
Page 294 Service and Repair Manual December 2018 Deutz TD2.9 Engine Harness...
Page 295 December 2018 Service and Repair Manual Hydraulic Schematic to SX180H-612...
Page 296: Hydraulic Schematic To Sn Sx180H-612
Service and Repair Manual December 2018 Hydraulic Schematic to SX180H-612 SX-180 Part No. 1268497...
Page 297: Hydraulic Schematic From Sx180H-613
December 2018 Service and Repair Manual Hydraulic Schematic from SX180H-613 Part No. 1268497 SX-180...
Page 298 Service and Repair Manual December 2018 Hydraulic Schematic from SX180H-613...
Page 299: Electrical Schematic To Sx180H-612
TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE DRIVE AXLE ENGINE DRIVE...
Page 300: Electrical Schematic From Sx180H-613
TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN From SN SX180H-101 to SX180H-612 AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE...
Page 301 TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 from SX180H-613 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE DRIVE AXLE...

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Terex Genie SX -180 Service And Repair Manual

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