Page 1 Service and Repair Manual Serial Number Range -150 ™ from SX15015H-101 This manual includes: to SX15016H-499 Repair procedures Fault Codes from SX150H-500 Electrical and to SX150H-611 Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.
Page 2: Introduction
Copyright © 2015 by Terex Corporation 1268496GT Rev B, December 2019 First Edition, Second 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 December 2019 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, 8-4, 8-5 Fault Codes Fault Code Source 10/2018 Repair 8-3A, 8-4A Schematics Electrical schematics 12/2018 Specifications...
Page 4: Serial Number Legend
Service and Repair Manual December 2019 Introduction Serial Number Legend To August 31, 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number (stamped on chassis) 6 Serial label (located under cover) From September 1, 2016 1 Model 2 Facility code 3 Sequence number...
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 ....................17 Introduction ......................17 Platform Controls ....................19 1-1 Platform Circuit Board ..................19 How to Remove the LED Circuit Board ............20 1-2 Joysticks ......................21 How to Reset a Proportional Valve Coil Default ..........24 How to Set the Function Thresholds and Default Functions Speeds....
Page 9 December 2019 Table of Contents Boom Components .................... 43 4-1 Primary Boom Cable Track ................44 4-2 Primary Boom....................46 How to Remove the Primary Boom ..............47 How to Disassemble the Primary Boom ............49 4-3 Primary Boom Lift Cylinder ................52 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 8-3 Platform Level and Rotation Manifold Components, to SX150H-518 ..100 8-3A Platform Level and Rotation Manifold Components, from SX150H-519 ... 101 8-4 Jib Boom Manifold Components, to SX150H-518 ........
Page 11 December 2019 Table of Contents Section 4 Fault Codes ....................... 139 Introduction ......................139 Control System Fault Codes ................140 Fault Matrix ......................159 Fault Code Source ..................... 160 Deutz TD 2.9 L4 Engine Fault Codes ..............163 Perkins 854F-34T Engine Fault Code ..............178 Section 5 Schematics ......................
Page 12 December 2019 Table of Contents Electrical Schematics – Control Circuits ............223 Control Circuits - Horn ..................224 Control Circuits - Power ..................225 Control Circuits - Can Bus .................. 228 Control Circuits - Deutz TD2011L04i Engine ............. 229 Control Circuits - Deutz TD 2.9 L4Engine ............232 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: Repair Procedures
December 2019 Service and Repair Manual Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
Page 30 Service and Repair Manual December 2019 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 2019 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 2019 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 2019 Service and Repair Manual 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 34 Service and Repair Manual December 2019 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 2019 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 2019 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 37: How To Set The Function Thresholds And Default Functions Speeds
December 2019 Service and Repair Manual 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 38 Service and Repair Manual December 2019 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 2019 Service and Repair Manual 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 40 Service and Repair Manual December 2019 Platform Controls Press the previous button until the function to be adjusted is displayed. Press the plus button to increase the ramp rate or press the minus button to decrease the ramp rate. Press the enter button to save the setting in memory.
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. How to Remove the Platform Contact with electrically charged circuits could result in death or Separate the foot switch quick disconnect serious injury.
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 Insert the key into the bypass/recovery key switch and turn it to the bypass position. Platform Level Sensor Note: The platform level calibration value will not be saved correctly unless the key switch is in the The platform level sensor is mounted to the side of bypass position and the calibration toggle switch is the platform rotator.
Page 46: Platform Overload System (If Equipped)
Service and Repair Manual December 2019 Platform Components Determine the limit switch trigger point: Platform Overload System (if Gently move the platform up and down by equipped) hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle.
Page 47: Platform Overload Recovery Message
December 2019 Service and Repair Manual Platform Components Confirm the setting: Platform Overload Recovery Start the engine from the platform controls. Message Lift the test weight off the platform floor using a suitable lifting device. If the ground controls LCD screen displays Place the test weight back onto the center of OVERLOAD RECOVERY, the emergency lowering the platform floor using a suitable lifting...
Page 48 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 49: 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. 1268496GT ™ -150...
Page 50: 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 51: 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 52: 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 53: 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 54 Service and Repair Manual December 2019 Jib Boom Components Temporarily install a control box door retaining 14 Press and hold the engine start button for fastener between the door and the box to approximately 5 seconds to shut off the engine prevent the control box door from moving the and to save the calibration settings.
Page 55: 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. 1268496GT ™ -150...
Page 56: 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 57 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 58: 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 59: 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 60 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 61: How To Disassemble The Primary Boom
December 2019 Service and Repair Manual Boom Components How to Dis ass embl e the Primary Boom How to Disassemble the Primary Remove the jib boom bellcrank. Refer to Repair Procedure, How to Remove the Jib Boom Boom Bellcrank. Bodily injury hazard. This Remove the boom primary extension cylinder.
Page 62 Service and Repair Manual December 2019 Boom Components Remove the #3 and #4 boom tubes: 19 Attach the #3 boom tube to a forklift, and lift the tube enough to relieve the pressure from 12 At the platform end, remove the #4 boom the lower wear pads, begin sliding the tube retract bolt and secure the retract cables to the from the boom assembly.
Page 63 December 2019 Service and Repair Manual Boom Components 30 Begin pulling the #2 boom tube from the #1 Remove the #2 boom tube: boom tube. 23 At the pivot end of the machine, remove the Note: Make sure the tube remains parallel to the #1 shims from the wear pads between the #1 and boom tube while removing.
Page 64: Primary Boom Lift Cylinder
Service and Repair Manual December 2019 Boom Components Attach an overhead 10 ton / 9071 kg crane to the platform end of the boom for support. Do Primary Boom Lift Cylinder not lift the boom. The primary boom lift cylinder raises and lowers Note: Place the lifting strap between the cable track the primary boom.
Page 65 December 2019 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 Bodily injury hazard.
Page 66: Extension Cylinder
Service and Repair Manual December 2019 Boom Components Tag and disconnect the limit switch harnesses. Remove the fasteners to the limit Extension Cylinder switch harness mounting bracket and remove the bracket. The primary boom extension cylinder is located inside the boom assembly and incorporates cables Tag and disconnect limit switch 3RO (6).
Page 67 December 2019 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.
Page 68: Boom Extend And Retract Cables
Service and Repair Manual December 2019 Boom Components 14 Remove the locking plates securing the extend cylinder to boom #1 (1). (Illustration 1) Boom Extend and Retract Cables 15 Remove the cable guards (2) covering the How to Adjust the Boom sheaves attached to the extend cylinder.
Page 69 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 70 Service and Repair Manual December 2019 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 71 December 2019 Service and Repair Manual Boom Components 20 Loosen the retract cable retract bolt (6). 28 Measure the gap between boom tubes #3 and (Illustration 1) #4 using measuring points (7) and (8). (Illustration 1) 21 Tighten the three extend cable adjustment bolts (4) (Illustration 2) until the gap between Result: The measurement is between 1 in / 2.6 cm and 1.5 in / 3.8 cm more than dimension...
Page 72 Service and Repair Manual December 2019 Boom Components 35 Torque the #4 retract bolt to 70 ft-lbs / 95 Nm. 45 Fully retract the boom and lower the boom to the horizontal position. 36 Start the engine and fully raise and extend the boom approximately 15 ft / 4.6 m.
Page 73: How To Replace The Boom Extend/Retract Cables
December 2019 Service and Repair Manual Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom Extend/Retract Cables Note: The cable sheaves must be inspected when replacing the cables. Remove the primary boom extension cylinder. Refer to Repair Procedure, How to Remove the Primary Boom Extension Cylinder.
Page 74 Service and Repair Manual December 2019 Boom Components Remove the fasteners securing the idler pulley 10 Remove the center mounting bolt securing the holding the upper extend cables and remove sheave to the cover plate (3). the pulley (3). (Illustration 1) 11 Remove the remaining fasteners securing the Remove the upper side wear pads (4) from the cover plate to the #3 boom tube.
Page 75 December 2019 Service and Repair Manual Boom Components #3 Boom retract cables: 32 Remove the equalizing bracket from the #4 boom retract cables. 21 Remove the fastener and the retract cable 33 Attach electrician's tape to the #4 retract cable guide between boom tubes #2 and #3.
Page 76: Primary Boom Angle 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 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 77 December 2019 Service and Repair Manual Boom Components 17 At the PRIMARY BOOM ANGLE TO 10 Press the plus button to select YES, then press the enter button to accept. GRAVITY 32 DEG screen, press the plus or minus button to adjust the display to the exact 11 Place the digital level on top of the primary value shown on the digital level, then press the boom near the pivot and note the angle...
Page 78 Service and Repair Manual December 2019 Boom Components 22 Press and hold a function enable/speed select 28 Wait approximately 20 seconds and turn the button and the primary boom button until the machine off by pressing the red Emergency boom is fully raised. Stop button in.
Page 79: Boom Length Sensor
December 2019 Service and Repair Manual Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Boom Length Sensor in this procedure. How to Calibrate the Primary Boom Length Sensor Note: Perform this procedure with the machine on a firm, level surface with the axles extended.
Page 80 Service and Repair Manual December 2019 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 engine control panel while pulling out the ground and to save the calibration settings.
Page 81: Engines
December 2019 Service and Repair Manual Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel Service or Maintenance Manual for your machine, and has a splined center to drive the pump.
Page 82: How To Install The Flex Plate
Service and Repair Manual December 2019 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 83: Ground Controls
December 2019 Service and Repair Manual Ground Controls How to Use the Bypass Mode Bypass/Recovery Key Switch Tip-over hazard. Operating the machine outside of the operating The turntable control box (TCON) is the envelope while in Bypass mode communication and operations center for the will result in death or serious machine.
Page 84: How To Use The Recovery Mode
Service and Repair Manual December 2019 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 85: Circuit Boards
December 2019 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 86 Service and Repair Manual December 2019 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 87: Membrane Decal
December 2019 Service and Repair Manual Ground Controls Carefully remove the membrane decal from the control box lid while guiding the ribbon Membrane Decal cables out of the control box lid. Remove any decal adhesive from the control The membrane decal is a special decal that box lid with a mild solvent.
Page 88: Full Machine Calibration
Service and Repair Manual December 2019 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 89: Display Module
December 2019 Service and Repair Manual Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 90 Service and Repair Manual December 2019 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 91 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Forward extended drive speed % 120% (max) 100% (default) Drive Functions and hold the enter button and 50% (min) turn key switch to on position.
Page 92 Service and Repair Manual December 2019 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 and Speeds turn key switch to on position. Release the enter button and Primary boom up speed <80ft press...
Page 93 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and hold Primary boom up/down Lift Functions the enter button and turn key ramp acceleration % Ramps switch to on position. Primary boom up/down Release the enter button and press ramp deceleration %...
Page 94 Service and Repair Manual December 2019 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 95 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press AC Generator (NONE/7.5KW/12.5KW) Options and hold the enter button and turn key switch to on position. Release the enter button and press (minus)(minus)(plus)(plus).
Page 96: Hydraulic Pumps
Service and Repair Manual December 2019 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 97: How To Prime The Function Pump
December 2019 Service and Repair Manual Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose...
Page 98 Service and Repair Manual December 2019 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 99: How To Adjust The Function Pump Pressure Compensator
December 2019 Service and Repair Manual Hydraulic Pumps How to Adj ust the Functi on Pum p Press ure Com pens ator How to Adjust the Function Pump Pressure reads more than 350 psi / 25 bar Pressure Compensator Loosen the set screw for the standby pressure adjustment screw on the rear function pump.
Page 100: Drive Pump
Service and Repair Manual December 2019 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 101 December 2019 Service and Repair Manual Hydraulic Pumps Locate the two hydraulic tank valves at the Carefully pull the drive pump out until the hydraulic tank. Close the valves. pump coupler separates from the flex plate. Remove the drive pump from the machine. Component damage hazard.
Page 102: How To Prime The Drive Pump
Service and Repair Manual December 2019 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"...
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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...
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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: Platform Level And Rotation Manifold Components, To Sx150H-518
Service and Repair Manual December 2019 Manifolds Platform Level and Rotation Manifold Components, to SX150H-518 The platform manifold is mounted under the jib boom. Index Schematic Description Function Torque Item Proportional Directional Control valve, 3 25-30 ft-lbs Jib level up/down position 5 way 34-41 Nm Jib boom up/down circuit, regulates...
Page 113: 8-3A Platform Level And Rotation Manifold Components, From Sx150H-519
December 2019 Service and Repair Manual Manifolds 8-3A Platform Level and Rotation Manifold Components, from SX150H-519 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...
Page 114: Jib Boom Manifold Components, To Sx150H-518
Service and Repair Manual December 2019 Manifolds Jib Boom Manifold Components, to SX150H-518 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 26-28 Nm Jib boom rotate circuit, regulates...
Page 115: 8-4A Jib Boom Manifold Components, From Sx150H-519
December 2019 Service and Repair Manual Manifolds 8-4A Jib Boom Manifold Components, from SX150H-519 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 2 19-21 ft-lbs Jib level up/down 26-28 Nm...
Page 116: 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 118: Steer And Axle Manifold Components, To Sx150H-507
Service and Repair Manual December 2019 Steer and Axle Manifold Components, to SX150H-507 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...
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Page 120 Service and Repair Manual December 2019 Steer and Axle Manifold Components, continued (to SX150H-507) Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 165 30-35 ft-lbs Axle extend/retract circuit 41-47 Nm Prevents left rear steer cylinder 20-25 ft-lbs Check valve from moving when not steering...
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Page 122: 8-6A Steer And Axle Manifold Components, From Sx150H-508
Service and Repair Manual December 2019 8-6A Steer and Axle Manifold Components, from SX150H-508 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 124 Service and Repair Manual December 2019 Steer and Axle Manifold, continued (from SX150H-508) 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 / 165 30-35 ft-lbs Axle extend/retract circuit 41-47 Nm Prevents left rear steer cylinder...
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Page 126: 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.
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Page 128: Traction Manifold Components
Service and Repair Manual December 2019 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 130 Service and Repair Manual December 2019 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 132: Valve Adjustments - Traction Manifold
Service and Repair Manual December 2019 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 133: Generator Manifold Component
December 2019 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 Solenoid Valve, 2 position 2 way valve 33-37 ft-lbs /...
Page 134: Valve Coils
Service and Repair Manual December 2019 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 135 December 2019 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 136: Turntable Rotation Components
Service and Repair Manual December 2019 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 137: How To Adjust The Turntable Rotation Gear Backlash
December 2019 Service and Repair Manual Turntable Rotation Components Turn the adjustment bolt 1/2 to 3/4 turn How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable counterclockwise. Tighten the lock nut on the Rotation Gear Backlash adjustment bolt.
Page 138: Turntable Level Sensor
Service and Repair Manual December 2019 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 139 December 2019 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 140 Service and Repair Manual December 2019 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 141: Axle Components
December 2019 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be replaced, install the new activator pin per The steer sensors measure steer angle and Illustration 1.
Page 142 Service and Repair Manual December 2019 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 143: How To Calibrate A Replacement Steer Sensor
December 2019 Service and Repair Manual Axle Components How to C alibr ate a R epl acem ent 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 144: How To Calibrate All Steer Sensors
Service and Repair Manual December 2019 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 Left front (square-end, blue side) and right performed if the ground controls circuit board...
Page 145 December 2019 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 146: Steer Cylinders
Service and Repair Manual December 2019 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 147: Axle Angle Sensors
December 2019 Service and Repair Manual Axle Components 10-4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Angle Sensors cylinder. The axle angle sensors measure the axle angle Note: Connect the pressure hose from the power and communicates that information to the ground unit to the "R"...
Page 148 Service and Repair Manual December 2019 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 149 December 2019 Service and Repair Manual Axle Components 16 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in. 17 Remove the fastener that was temporarily installed. Close the control box door and install the door retaining fasteners.
Page 150: Generators
Service and Repair Manual December 2019 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 Frequency Insert the leads from a multimeter set to register frequency (HZ) and turn the needle...
Page 151: Fault Codes
December 2019 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.
Page 152: Control System Fault Codes
Service and Repair Manual December 2019 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 153 December 2019 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 154 Service and Repair Manual December 2019 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 155 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem corrected. Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 156 Service and Repair Manual December 2019 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 157 December 2019 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 158 Service and Repair Manual December 2019 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 159 December 2019 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 160 Service and Repair Manual December 2019 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 161 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 162 Service and Repair Manual December 2019 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 163 December 2019 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 164 Service and Repair Manual December 2019 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 165 December 2019 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 166 Service and Repair Manual December 2019 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 167 December 2019 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 168 Service and Repair Manual December 2019 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 169 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit Sensor zero and neutral, Alarm sounds. going to the sensor Value Too High Limited Speed and Direction frozen at...
Page 170 Service and Repair Manual December 2019 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 171: Fault Matrix
December 2019 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 172: Fault Code Source
Service and Repair Manual December 2019 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 173 December 2019 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 174 Service and Repair Manual December 2019 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 175: Deutz Td 2.9 L4 Engine Fault Codes
December 2019 Service and Repair Manual 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 176 Service and Repair Manual December 2019 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 177 December 2019 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 178 Service and Repair Manual December 2019 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 179 December 2019 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 180 Service and Repair Manual December 2019 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 181 December 2019 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 182 Service and Repair Manual December 2019 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 183 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring detection reported error 523470 Maximum rail pressure in limp...
Page 184 Service and Repair Manual December 2019 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 185 December 2019 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 186 Service and Repair Manual December 2019 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 187 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not plausible to HFM reading...
Page 188 Service and Repair Manual December 2019 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 189 December 2019 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 190: Perkins 854F-34T Engine Fault Code
Service and Repair Manual December 2019 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 191 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test Engine Coolant Temperature :Voltage Above...
Page 192 Service and Repair Manual December 2019 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 193 December 2019 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 194 Service and Repair Manual December 2019 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 195 December 2019 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 196 Service and Repair Manual December 2019 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 197 December 2019 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 199: Schematics
December 2019 Service and Repair Manual 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 200: Wire Circuit Legend
Service and Repair Manual December 2019 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 201 December 2019 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 202 Service and Repair Manual December 2019 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 203 December 2019 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 204: Wire Color Legend
Service and Repair Manual December 2019 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 205 December 2019 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 206 Service and Repair Manual December 2019 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 207 December 2019 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 208 Service and Repair Manual December 2019 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 209: Limit Switches And Angle Sensors
December 2019 Service and Repair Manual Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Stringpot Rear...
Page 210 Service and Repair Manual December 2019 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 211 December 2019 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 212 Service and Repair Manual December 2019 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 213: Circuit Connector Legend
December 2019 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 214 Service and Repair Manual December 2019 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 215 December 2019 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 216: Connector Pin Legend
Service and Repair Manual December 2019 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 217 December 2019 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 218 Service and Repair Manual December 2019 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 219 December 2019 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 220 Service and Repair Manual December 2019 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 221 December 2019 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 222 Service and Repair Manual December 2019 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 223 December 2019 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 224 Service and Repair Manual December 2019 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 225 December 2019 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 226 Service and Repair Manual December 2019 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...
Page 227 December 2019 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 228 Service and Repair Manual December 2019 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 229 December 2019 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 230: Engine Relay And Fuse Panel Legend - Deutz Td2011L04I And Perkins
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 231: 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 232: 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 233: 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 234: 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, 3 Cylinder, double acting Differential sensing valve or motor)
Page 235: Electrical Schematics - Control Circuits
December 2019 Service and Repair Manual Control Circuits - Horn...
Page 236: Control Circuits - Horn
Service and Repair Manual December 2019 Control Circuits - Horn ™ -150 Part No. 1268496GT...
Page 237: Control Circuits - Power
December 2019 Service and Repair Manual Control Circuits - Power Part No. 1268496GT ™ -150...
Page 238 Service and Repair Manual December 2019 Control Circuits - Power...
Page 239 December 2019 Service and Repair Manual Control Circuits - Can Bus...
Page 240: Control Circuits - Can Bus
Service and Repair Manual December 2019 Control Circuits - Can Bus ™ -150 Part No. 1268496GT...
Page 241: Control Circuits - Deutz Td2011L04I Engine
December 2019 Service and Repair Manual Control Circuits - Deutz TD2011L04i Engine Part No. 1268496GT ™ -150...
Page 242 Service and Repair Manual December 2019 Control Circuits - Deutz TD2011L04i Engine...
Page 243 December 2019 Service and Repair Manual Control Circuits - Deutz TD 2.9 L4Engine...
Page 244: Control Circuits - Deutz Td 2.9 L4Engine
Service and Repair Manual December 2019 Control Circuits - Deutz TD 2.9 L4 Engine ™ -150 Part No. 1268496GT...
Page 245: Control Circuits - Perkins 1104D-44T Engine
December 2019 Service and Repair Manual Control Circuits - Perkins 1104D-44T Engine Part No. 1268496GT ™ -150...
Page 246 Service and Repair Manual December 2019 Control Circuits - Perkins 1104D-44T Engine...
Page 247 December 2019 Service and Repair Manual Control Circuits - Perkins 854F-34T Engine...
Page 248: Control Circuits - Perkins 854F-34T Engine
Service and Repair Manual December 2019 Control Circuits - Perkins 854F-34T Engine ™ -150 Part No. 1268496GT...
Page 249: Control Circuits - Axle Extend/Retract
December 2019 Service and Repair Manual Control Circuits - Axle Extend/Retract Part No. 1268496GT ™ -150...
Page 250 Service and Repair Manual December 2019 Control Circuits - Axle Extend/Retract...
Page 251 December 2019 Service and Repair Manual Control Circuits - Steering...
Page 252: Control Circuits - Steering
Service and Repair Manual December 2019 Control Circuits - Steering ™ -150 Part No. 1268496GT...
Page 253: Control Circuits - Propel
December 2019 Service and Repair Manual Control Circuits - Propel Part No. 1268496GT ™ -150...
Page 254 Service and Repair Manual December 2019 Control Circuits - Propel...
Page 255 December 2019 Service and Repair Manual Control Circuits - Turntable Rotate...
Page 256: Control Circuits - Turntable Rotate
Service and Repair Manual December 2019 Control Circuits - Turntable Rotate ™ -150 Part No. 1268496GT...
Page 257: Control Circuits - Boom Up/Down
December 2019 Service and Repair Manual Control Circuits - Boom Up/Down Part No. 1268496GT ™ -150...
Page 258 Service and Repair Manual December 2019 Control Circuits - Boom Up/Down...
Page 259 December 2019 Service and Repair Manual Control Circuits - Boom Extend/Retract...
Page 260: Control Circuits - Boom Extend/Retract
Service and Repair Manual December 2019 Control Circuits - Boom Extend/Retract ™ -150 Part No. 1268496GT...
Page 261: Control Circuits - Jib Up/Down, Jib Rotate And Platform Rotate
December 2019 Service and Repair Manual Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate Part No. 1268496GT ™ -150...
Page 262 Service and Repair Manual December 2019 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate...
Page 263 December 2019 Service and Repair Manual Control Circuits - Platform Level and Jib Bellcrank Level...
Page 264: Control Circuits - Platform Level And Jib Bellcrank Level
Service and Repair Manual December 2019 Control Circuits - Platform Level and Jib Bellcrank Level ™ -150 Part No. 1268496GT...
Page 265: Control Circuits - Platform Load Sense
December 2019 Service and Repair Manual Control Circuits - Platform Load Sense Part No. 1268496GT ™ -150...
Page 266 Service and Repair Manual December 2019 Control Circuits - Platform Load Sense...
Page 267 December 2019 Service and Repair Manual Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights...
Page 268: Control Circuits - Flashing Beacons, Oil Cooler And Drive/Work Lights
Service and Repair Manual December 2019 Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights ™ -150 Part No. 1268496GT...
Page 269: Control Circuits - Recovery Pld
December 2019 Service and Repair Manual Control Circuits - Recovery PLD Part No. 1268496GT ™ -150...
Page 270 Service and Repair Manual December 2019 Control Circuits - Recovery PLD...
Page 271 December 2019 Service and Repair Manual Control Circuits - Telematics...
Page 272: Control Circuits - Telematics
Service and Repair Manual December 2019 Control Circuits - Telematics ™ -150 Part No. 1268496GT...
Page 273: Generator Receptacle Wiring- Ansi/Csa
December 2019 Service and Repair Manual Generator Receptacle Wiring- ANSI/CSA Part No. 1268496GT ™ -150...
Page 274 Service and Repair Manual December 2019 Generator Receptacle Wiring - ANSI/CSA...
Page 275 December 2019 Service and Repair Manual Generator Receptacle Wiring - CE...
Page 276: Generator Receptacle Wiring- Ce
Service and Repair Manual December 2019 Generator Receptacle Wiring - CE ™ -150 Part No. 1268496GT...
Page 277: Perkins 1104D-44T Engine Electrical Schematic
December 2019 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic Part No. 1268496GT ™ -150...
Page 278 Service and Repair Manual December 2019 Perkins 1104D-44T Engine Electrical Schematic...
Page 279 December 2019 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...
Page 280: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual December 2019 Perkins 854F-34T Engine Electrical Schematic ™ -150 Part No. 1268496GT...
Page 281: Perkins 854F-34T Engine Harness
December 2019 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1268496GT ™ -150...
Page 282 Service and Repair Manual December 2019 Perkins 854F-34T Engine Harness...
Page 283 December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Electrical Schematic...
Page 284: Deutz Td 2.9 L4 Engine Electrical Schematic
Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Electrical Schematic ™ -150 Part No. 1268496GT...
Page 285: Deutz Td 2.9 L4 Engine Harness
December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Harness Part No. 1268496GT ™ -150...
Page 286 Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Harness...
Page 287: Hydraulic Schematics
December 2019 Service and Repair Manual Hydraulic Schematic (to SX150H-507)
Page 288: Hydraulic Schematic (To Sx150H-507)
Service and Repair Manual December 2019 Hydraulic Schematic (to SX150H-507) ™ -150 Part No. 1268496GT...
Page 289: Hydraulic Schematic (From Sx150H-508 To Sx150H-518)
December 2019 Service and Repair Manual Hydraulic Schematic (from SX150H-508 to SX150H-518) Part No. 1268496GT ™ -150...
Page 290 Service and Repair Manual December 2019 Hydraulic Schematic (from SX150H-508 to SX150H-518)
Page 291: Hydraulic Schematic (From Sx150H-519)
December 2019 Service and Repair Manual Hydraulic Schematic (from SX150H-519) Part No. 1268496GT ™ -150...
Page 292 Service and Repair Manual December 2019 Hydraulic Schematic (from SX150H-519)
Page 293: Electrical Schematic (To Sx150H-518)
TCON MEMBRANE PANEL (MS2) SX-150 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 ES0554D PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE DRIVE AXLE ENGINE...
Page 294: Electrical Schematic (From Sx150H-519)
TCON MEMBRANE PANEL (MS2) SX-150 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...

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