To dismantle the wheel hub on a Terex SX-105 XC:

1. Remove the tire and wheel hub assembly.
2. Place the hub on a flat surface.
3. Gently pry the bearing seal out of the hub.
4. Remove the rear bearing.

When reassembling, install the dust cap, then the tire and wheel hub, and torque the wheel lug nuts to specification.

This answer is automatically generated

Surendra singh

May 30, 2025

How to open front hub

1 comments:

Mr. Anderson

May 30, 2025

To open the front hub on a Terex SX-105 XC (Models with TraX):

1. Locate the hub disconnect pin in the center of the drive hub.
2. Manually depress the pin and rotate the drive hub until one of the two plugs is at the lowest point.
3. Select the drive hub to be serviced. Loosen and remove as many sprocket retaining fasteners as possible from the hub adapter.
4. Drive the machine slightly in either direction to access the remaining fasteners. Do not remove the retaining fasteners.
5. Chock the tracks at the opposite end to prevent rolling.
6. Center a 20,000 lbs (10,000 kg) capacity lifting jack under the drive chassis between the tracks.
7. Lift the machine until the tracks are off the ground and place jack stands under the chassis.
8. Remove the plugs and drain the oil into a suitable container.

This answer is automatically generated

Summary of Contents for Terex Genie SX-105 XC

Page 1 Service and Repair Manual Serial Number Range SX™-105 XC™ This manual includes: from SX105D-174 Repair procedures SX™-125 XC™ from SX125D-101 Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1271700GT Rev E May 2020...
Page 2: Find A Manual For This Model
Copyright © 2017 by Terex Corporation 1271700GT Rev E, May 2020 First Edition, Fifth Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 3 May 2020 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 2/2017 Initial Release 5/2017 Repair 1-2 Joysticks 2-5 Platform Overload System 2-6 platform Overload Recovery Message 4-6 Primary Boom Angle Sensor 4-7 Boom Length Seneor 6-1 Bypass / Recovery key switch 10-4 Axle Angle Sensors Display Module –...
Page 4: Serial Number Legend
Service and Repair Manual May 2020 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 5: Safety Rules
May 2020 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...
Page 6 Service and Repair Manual May 2020 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
May 2020 Service and Repair Manual Safety Rules Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
Page 8 Service and Repair Manual May 2020 Safety Rules Section 3 Repair Procedures ..................... 17 Introduction ......................17 Platform Controls ....................19 1-1 Platform Circuit Board ..................19 How to Remove the LED Circuit Board ............20 1-2 Joysticks ......................20 How to Reset a Proportional Valve Coil Default ..........
Page 9 May 2020 Service and Repair Manual Safety Rules Boom Components .................... 43 4-1 Cable Track ....................44 4-2 Primary Boom ....................47 4-3 Primary Boom Lift Cylinder ................59 4-4 Extension Cylinder ..................61 4-5 Boom Extend and Retract Cables ..............64 How to Replace the Boom Extend/Retract Cables .........
Page 10 Service and Repair Manual May 2020 Safety Rules Manifolds ......................98 8-1 Function Manifold ..................98 8-2 Valve Adjustments - Function Manifold ............104 8-3 Platform Level and Rotation Manifold ............105 8-4 Platform Rotate Counterbalance Valve Manifold Components……………..106 8-5 Function Enable Manifold ................107 8-6 Steer and Axle Manifold ................
Page 11 May 2020 Service and Repair Manual Safety Rules Section 4 Fault Codes ....................... 136 Introduction ......................136 Control System Fault Codes ................137 Fault Matrix ......................155 Fault Code Source ..................... 156 Fault Code Display – Deutz Models……………………………………………...159 Deutz TD 2.9 L4 Engine Fault Codes .............. 160 Deutz TCD 2.2 L3 Engine Fault Codes ............
Page 12 Service and Repair Manual May 2020 Safety Rules Control Circuits - Deutz 2.9 Engine/Deutz TCD 2.2 L3........245 Control Circuits - Perkins 1104D-44T Engine ............ 245 Control Circuits - Perkins 854 Engine ..............249 Control Circuits - Axle Extend/Retract ............... 250 Control Circuits - Steering ..................
Page 13: Specifications
May 2020 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications, SX-125 Machine Specifications, SX-105 XC model XC model Tires and wheels Tires and wheels Tire size 445D50/710 Tire size 385/65 D22.5 Tire ply rating Tire ply rating Tire weight, new foam-filled 850 lbs Tire weight, new foam-filled...
Page 14: Performance Specifications
Service and Repair Manual May 2020 Specifications Performance Specifications，SX- Performance Specifications，SX- 105 XC model 125 XC model Drive speed, maximum Drive speed, maximum Stowed position, high speed 3 mph Stowed position, high speed 3 mph 4.8 km/h 4.8 km/h 36ft / 8.0–8.4 sec 36ft / 8.0–8.4 sec 11 m / 8.0–8.4 sec 11 m / 8.0–8.4 sec...
Page 15 May 2020 Service and Repair Manual Specifications Turntable rotate, drive 54.5 - 60 sec Do not top off with incompatible enable to drive enable hydraulic fluids. Hydraulic fluids (40°) may be incompatible due to the > 80 ft differences in base additive chemistry.
Page 16 Service and Repair Manual May 2020 Specifications Chevron 5606A Hydraulic Oil Chevron Rando HD Premium Oil Fluid Properties MV 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 15.0 cSt @ 104°F / 40°C...
Page 17 May 2020 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 May 2020 Specifications Hydraulic Component Auxiliary Pump Specifications Type fixed displacement gear pump Displacement per revolution 0.15 cu in Drive Pump 2.47 cc Type: bi-directional variable displacement piston pump Function manifold Displacement per revolution 2.8 cu in System relief valve pressure, 3200 psi 46 cc...
Page 19: Manifold Component Specifications
May 2020 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 May 2020 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
May 2020 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 Service and Repair Manual May 2020 Specifications Deutz TCD 2.2 L3 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2.2 liters Temperature switch point 257°F Number of cylinders 125°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...
Page 23 May 2020 Service and Repair Manual 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 24 Service and Repair Manual May 2020 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 25 May 2020 Service and Repair Manual 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 26: Machine Torque Specifications
Service and Repair Manual May 2020 Specifications Machine Torque Specifications Perkins 854F-34T cont. Engine coolant Platform Rotator Capacity 16.5 quarts 1-8 center bolt, GR 5, dry) 615 ft-lbs (50/50 extended life) 15.6 liters 834 Nm Coolant temperature switch 1/2-13 bolts, GR 8 80 ft-lbs* Installation torque 18.4 ft-lbs...
Page 27: Hydraulic Hose And Fitting Torque Specifications
May 2020 Service and Repair Manual 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 specifications require that fittings and hose ends 14 ft-lbs / 19 Nm be torqued to specification when they are removed...
Page 28: Torque Procedure
Service and Repair Manual May 2020 Specifications Torque Procedure Seal-Lok™ fittings Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger tight.
Page 29: Repair Procedures
May 2020 Service and Repair Manual Platform Controls 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 May 2020 Platform Controls 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 Circuit Board
May 2020 Service and Repair Manual Platform Controls Attach a grounded wrist strap to the ground screw inside the control box. Platform Circuit Board Electrocution/burn hazard. Electrocution/burn hazard. Contact with electrically charged Contact with electrically charged circuits could result in death or circuits could result in death or serious injury.
Page 32: How To Remove The Led Circuit Board
Service and Repair Manual May 2020 Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Board Joysticks Push in the red Emergency Stop button to the off position at both the ground and platform How to Calibrate a Joystick controls.
Page 33 May 2020 Service and Repair Manual Platform Controls Drive functions: Steer functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key switch to platform controls.
Page 34 Service and Repair Manual May 2020 Platform Controls Primary boom extend/retract functions: Primary boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key...
Page 35 May 2020 Service and Repair Manual Platform Controls Jib boom up/down functions: Turntable rotate functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key switch to platform controls.
Page 36: How To Reset A Proportional Valve Coil Default
Service and Repair Manual May 2020 Platform Controls How to R es et a Proportional Valve Coil D efault How to Set the F unction T hresholds and D efault Func tions Speeds How to Reset a Proportional How to Set the Function Valve Coil Default Thresholds and Default Functions Speeds...
Page 37 May 2020 Service and Repair Manual Platform Controls Function speeds: Slowly move the joystick off center in the opposite direction just until the machine Note: Be sure the machine is in the stowed function starts to move, then move the position and the boom is rotated between the joystick very slowly towards the neutral or circle end tires.
Page 38: How To Adjust The Function Speeds
Service and Repair Manual May 2020 Platform Controls How to Adj ust the Functi on Speeds How to Adjust the Function Once the function speeds have been set, press and hold the engine start button until Speeds the engine shuts off. Do not press the red Emergency Stop button.
Page 39: How To Adjust The Function Ramp Rate Setting
May 2020 Service and Repair Manual Platform Controls How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function Ramp Press the previous button until the function to be adjusted is displayed. Rate Setting Press the plus button to increase the ramp The ramp rate setting of a joystick controls the rate or press the minus button to decrease...
Page 40: Platform Components
Service and Repair Manual December 2019 Platform Components Remove the weld cable from the platform (if equipped). Platform Electrocution/burn hazard. Contact with electrically charged How to Remove the Platform circuits could result in death or serious injury. Remove all rings, Separate the foot switch quick disconnect watches and other jewelry.
Page 41: Platform
May 2020 Service and Repair Manual Platform Components Secure the platform leveling cylinder to the jib boom for support. Platform Leveling Cylinder Tag, disconnect and plug the hydraulic hoses from the platform leveling cylinder at the The platform leveling cylinder keeps the platform bulkhead fittings located inside the boom tube level through the entire range of boom motion.
Page 42 Service and Repair Manual December 2019 Platform Components Use a soft metal drift to remove the rod-end How to Bleed the Platform pivot pin. Leveling Cylinder Crushing hazard. The jib boom Note: Do not start the engine. Use auxiliary power will fall when the platform for all machine functions in this procedure.
Page 43: Platform Rotator
May 2020 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 Service and Repair Manual December 2019 Platform Components Remove the pin retaining fasteners from the Remove the power to platform cover plate jib boom and jib boom leveling arms to from the electrical outlet box. Do not platform rotator pivot pins. Do not remove the disconnect the wiring.
Page 45: How To Bleed The Platform Rotator
May 2020 Service and Repair Manual Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Rotator Platform Level Sensor Note: Do not start the engine. Use auxiliary power The platform level sensor is mounted to the side of for all machine functions in this procedure.
Page 46 Service and Repair Manual December 2019 Platform Components Locate the calibration toggle switch at the top Press the enter or previous button on the of the ground control box. Activate calibration LCD screen until EXIT is displayed. mode by moving the toggle switch in the left Press the plus button or minus button to direction.
Page 47: Platform Overload System (If Equipped)
May 2020 Service and Repair Manual Platform Components Remove the key from the main key switch. Insert the key into the bypass/recovery key Platform Overload System switch and turn it to the bypass position. Proper calibration of the platform overload system Note: The platform overload calibration values will is essential to safe machine operation.
Page 48 Service and Repair Manual December 2019 Platform Components Press the enter or previous button on the Add an additional test weight equal to 5% of LCD screen until LOAD CELL FULL LOAD the rated capacity onto the calibration weight LBS or LOAD CELL FULL LOAD KGS is to overload the platform.
Page 49 May 2020 Service and Repair Manual Platform Components How to Perform a Zero Load Cell How to Replace the Load Cell Calibration Sensor Perform this procedure when the required weight Note: The preload adjustment should only be for full load calibration is not available. This performed after the load cell sensor has been procedure will re-calibrate the zero load point replaced..
Page 50: Platform Overload Recovery Message
Service and Repair Manual December 2019 Platform Components Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message Press the enter or previous button on the LCD screen until CLEAR OVERLOAD If the ground controls LCD screen displays RECOVERY is displayed.
Page 51 Error! No text of specified style in document. Error! No text of specified style in document. Repair Procedures 1 platform rotator 4 platform leveling cylinder 2 jib arm 5 bell crank 3 jib cylinder 6 jib compression arm Error! No text of specified style in document.Error! No text of specified style in document.
Page 52: Jib Boom Components
Service and Repair Manual December 2019 Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
Page 53: Jib Boom Components
May 2020 Service and Repair Manual Jib Boom Components Remove the pin retaining fasteners from the Remove the pin retaining fastener from the jib boom lift cylinder rod-end pivot pin. Do not platform leveling cylinder rod-end pivot pin. remove the pin. Use a soft metal drift to remove the platform Slide both of the jib boom leveling arms off of leveling cylinder rod-end pivot pin.
Page 54 Service and Repair Manual December 2019 Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom Lift Cylinder the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom Lift hydraulic oil can penetrate and Cylinder burn skin.
Page 55 Error! No text of specified style in document. Error! No text of specified style in document. Repair Procedures 1 boom tube #3 4 boom tube #0 2 boom tube #2 5 primary lift cylinder 3 boom tube #1 6 secondary extension cylinder Error! No text of specified style in document.Error! No text of specified style in document.
Page 56: Boom Components
Service and Repair Manual May 2020 Boom Components Tag and disconnect the black electrical connector from the bottom of the control box. Cable Track Remove the platform-end boom cable tube mounting fasteners at the engine side of the The cable track and boom cable guides the cables machine.
Page 57 May 2020 Service and Repair Manual Boom Components Remove the cable track roller guide mounting If not removing the boom from the machine, fasteners from the ground controls side of the proceed to step 19. machine at the platform end. Tag, disconnect and plug the primary Remove the roller guide from the cable track extension cylinder hydraulic hoses on the side...
Page 58 Service and Repair Manual May 2020 Boom Components If not removing the boom from the machine, Attach a lifting strap from an overhead crane to each end of the cable track assembly. proceed to step 25. Carefully lift the assembly. Carefully lift the Pull the hydraulic hoses from the boom cable assembly from the boom and set it on a tube located under the cable track at the...
Page 59 May 2020 Service and Repair Manual Boom Components How to Repair the Boom Cable Track Boom Component damage hazard. The boom cable track can be How to Shim the Boom damaged if it is twisted. Measure each upper, side and lower wear pad.
Page 60 Service and Repair Manual May 2020 Boom Components Pivot end upper wear pads How to Remove the Boom Loosen the wear pad mounting fasteners. Bodily injury hazard. This Add shims by hand until snug. procedure requires specific repair skills, lifting equipment and a Note: Do not use force when adding the shims.
Page 61 May 2020 Service and Repair Manual Boom Components Disconnect the electrical connector from the Lower the boom with the overhead crane to a primary boom angle sensor. horizontal position. Raise the boom approximately 4 feet / 1.2m. Remove the boom end cover retaining fasteners from the pivot end of the boom.
Page 62 Service and Repair Manual May 2020 Boom Components Remove the rue ring from the devis from the How to Disassemble the Boom, boom pivot pin. Remove the devis pin. SX-125 XC Models Remove the anti rotation clamp retaining Note: Complete disassembly of the boom is only fastener from the boom pivot pin.
Page 63 May 2020 Service and Repair Manual Boom Components Remove the cable clamp from the cable break Remove the pulley pivot pin retaining fasteners from the number 2 boom tube at the limit switch wiring. pivot end of the boom. Remove the pulley pivot pins, cable guards and pulleys.
Page 64: Primary Boom
Service and Repair Manual May 2020 Boom Components Remove the red cable adjustment locking Attach a lifting strap from an overhead crane bracket retaining fasteners. Remove the red to the lifting eye on the primary boom locking bracket from the machine. extension cylinder.
Page 65 May 2020 Service and Repair Manual Boom Components Remove the retaining fasteners from the limit Attach a lifting strap from an overhead crane switch cover on the side of the number 0 to the number 3 boom tube at the platform boom tube at the platform end of the boom.
Page 66 Service and Repair Manual May 2020 Boom Components Support and slide the number 2 boom tube Support the secondary boom extend cylinder out of the number 1 boom tube. When the with an overhead crane or other suitable lifting number 2 boom tube is approximately halfway device.
Page 67 May 2020 Service and Repair Manual Boom Components Remove and label the top and side wear pads How to Disassemble the Boom, from the number 0 boom tube at the platform SX-105 Models end of the boom. Do not remove the bottom wear pads.
Page 68 Service and Repair Manual May 2020 Boom Components Remove the cotter pin and clevis pin from both cables. Note: When installing a clevis pin, always replace the cotter pin with a new one. Remove the lower external snap ring and washer from the cable break limit switch actuator pivot pin.
Page 69 May 2020 Service and Repair Manual Boom Components Remove the retaining fasteners from the limit switch cover on top of the number 2 boom tube at the platform end of the machine. Carefully remove the cover with proximity and limit switches from the top of the number 2 boom tube at the platform end of the boom.
Page 70 Service and Repair Manual May 2020 Boom Components the boom. Do not remove the bottom wear of the boom. Do not remove the bottom wear pads. pads. Note: Pay careful attention to the location and Note: Pay careful attention to the location and amount of shims used with each wear pad.
Page 71 May 2020 Service and Repair Manual Boom Components Place support blocks under the boom lift cylinder. Boom Lift Cylinder Remove the pin retaining fastener from the boom lift cylinder rod-end pivot pin. Use a soft How to Remove the Boom Lift metal drift to remove the pin.
Page 72 Service and Repair Manual May 2020 Boom Components Remove the engine pivot plate retaining With the boom lift cylinder being supported by fastener. Swing the engine pivot plate out the overhead crane, pull the boom lift cylinder away from the machine. toward the platform until it is out.
Page 73 May 2020 Service and Repair Manual Boom Components Remove the access covers. Extension Cylinders Secure the number 2 and number 3 boom tubes together with a strap or chain to prevent The primary boom extension cylinder is located them from moving. inside the boom assembly and incorporates cables Unhook length transducer from the cable and pulleys that are responsible for extending the...
Page 74 Service and Repair Manual May 2020 Boom Components Tag, disconnect and plug the hydraulic hoses Push the cable break actuator and cables from the primary boom extension cylinder. towards the platform end of the boom Cap the fittings on the cylinder. approximately 18 inches / 46 cm.
Page 75: Extension Cylinder
May 2020 Service and Repair Manual Boom Components How to Remove the Secondary Remove the two cable adjustment bolts. Boom Extension Cylinder, SX- Remove the cable-end block mounting plate 125 XC Models fasteners. Remove the cable-end block mounting plate. Bodily injury hazard. This Remove the trunnion pin retaining fasteners.
Page 76: Boom Extend And Retract Cables
Service and Repair Manual May 2020 Boom Components Tag, disconnect and plug the secondary boom extension cylinder hydraulic hoses. Cap Boom Extend / Retract Cables the fittings on the cylinder. Bodily injury hazard. Spraying How to Adjust the Boom hydraulic oil can penetrate and burn skin.
Page 77 May 2020 Service and Repair Manual Boom Components Locate the red locking bracket (c) covering At the pivot end of the boom (Illustration 1), the cable adjustment bolts at the pivot end of turn the cable adjustment bolts (b) clockwise the boom (Illustration 1).
Page 78 Service and Repair Manual May 2020 Boom Components At the platform end of the boom, tighten the Install the red locking bracket over the cable hex jam nut (h) on the cable tension equalizer adjustment bolts. A flat edge of each bolt bracket located underneath the number 1 head (b) must be on top for the locking boom tube (Illustration 3).
Page 79: How To Replace The Boom Extend/Retract Cables
May 2020 Service and Repair Manual Boom Components How to Replace the Boom Boom retract cables: Extend/ Retract Cables Remove the fastener from the boom retract cable at the platform end of the #1 boom. Note: The cable pulley must also be replaced when replacing the cables.
Page 80: Primary Boom Angle Sensor
Service and Repair Manual May 2020 Boom Components Secure the number 2 and number 3 booms together at the platform end with a chain or Primary Boom Angle Sensor strap to prevent them from moving. The primary boom angle sensor is used to limit the Install the boom extension cylinder assembly angle of the primary boom relative to the angle of into the boom.
Page 81 May 2020 Service and Repair Manual Boom Components Note: Use the following chart to identify the Press and hold the enter button on the description of each LCD screen control button ground control panel while pulling out the used in this procedure. ground controls red Emergency Stop button to the on position.
Page 82 Service and Repair Manual May 2020 Boom Components Start the engine from the ground controls. Press and hold a function enable/speed select button and the primary boom up button until Press and hold a function enable/speed select the digital level displays 40 degrees. button and the primary boom up button until the digital level displays 6 degrees.
Page 83: Boom Length Sensor
May 2020 Service and Repair Manual Boom Components At the PRIMARY BOOM ANGLE TO GRAVITY 74 DEG screen, press the plus or Boom Length Sensor minus button to adjust the display to the exact value shown on the digital level, then press the enter button.
Page 84 Service and Repair Manual May 2020 Boom Components Note: Use the following chart to identify the Press and hold the enter button on the description of each LCD screen control button ground control panel while pulling out the used in this procedure. ground controls red Emergency Stop button to the on position.
Page 85 May 2020 Service and Repair Manual Boom Components 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 86: Engines
Service and Repair Manual May 2020 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Refer to Maintenance Procedure in the appropriate engine and the pump. It is bolted to the engine Service or Maintenance Manual for your machine, flywheel and has a splined center to drive the Check and Adjust the Engine RPM.
Page 87 May 2020 Service and Repair Manual Engines How to Ins tall the Fl ex Plate Nm. Then torque the pump plate mounting How to Install a Flex Plate bolts in sequence to 47 ft-lbs / 63 Nm. Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump.
Page 88: Diesel Particle Filter Regeneration - Deutz Tcd 2.2 L3 Engine
Service and Repair Manual May 2020 Engines 5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3 Engine The combustion of diesel fuel results in soot, which is separated in the diesel particle filter (DPF). This must be regenerated as the contamination with soot increases.
Page 89: Ground Controls
May 2020 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 90 Service and Repair Manual May 2020 Ground Controls How to Use the Recovery Mode Turn the bypass/recovery key switch to the bypass position. Recovery is only to be used as a last attempt to Using auxiliary power, operate the ground lower the platform when the operator in the control buttons to level the platform.
Page 91: Circuit Boards
May 2020 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 92 Service and Repair Manual May 2020 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 93: Membrane Decal
May 2020 Service and Repair Manual Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane Contact with electrically charged on the backside.
Page 94: Full Machine Calibration
Service and Repair Manual May 2020 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 95: Display Module
May 2020 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 96 Service and Repair Manual May 2020 Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the (plus)(minus) buttons at the same time. Primary angle degrees -2° to +83° Length sensor extension 0in to 682in inches Length sensor extension 0cm to 1732cm...
Page 97 May 2020 Service and Repair Manual 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 50% (min) and turn key switch to on Forward not stowed drive 120% (max) 100% (default) position.
Page 98 Service and Repair Manual May 2020 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 99 May 2020 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and Primary boom up/down Ramps hold the enter button and turn key ramp acceleration % switch to on position. Primary boom up/down Release the enter button and ramp deceleration %...
Page 100 Service and Repair Manual May 2020 Display Module Screen or Menu Procedure Description Range or Selection Valve Calibration With key switch , press and Delete drive valve calibration hold the enter button and turn Delete boom extend/retract key switch to on position. valve calibration Release the enter button and Delete turntable rotate valve...
Page 101 May 2020 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Sensor Calibration With key switch , press Delete TT level sensor cal and hold the enter button Set unit X-axis to gravity and turn key switch to on Set unit Y-axis to gravity position.
Page 102 Service and Repair Manual May 2020 Display Module Screen or Menu Procedure Description Range or Selection Options With key switch , press AC Generator (NONE/3KW/7.5KW/12.5KW) and hold the enter button and turn key switch to on position. Engine start Aid Time 0-30 sec Release the enter button and press...
Page 103: Hydraulic Pumps
May 2020 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 104: How To Prime The Function Pump
Service and Repair Manual May 2020 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 105 May 2020 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 the correct pressure.
Page 106: How To Adjust The Function Pump Pressure Compensator
Service and Repair Manual May 2020 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 Note: Two people will be required to perform this function pump.
Page 107: Drive Pump
May 2020 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 108 Service and Repair Manual May 2020 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 109: How To Prime The Drive Pump
May 2020 Service and Repair Manual Hydraulic Pumps How to Prime the Driv e Pum p How to Prime the Drive Pump Component damage hazard. Be sure to open the two hydraulic tank valves before performing this procedure. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A"...
Page 110: Manifolds
Service and Repair Manual May 2020 Manifolds Function Manifold Components, SX-125 XC – 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 Prevents the draining of hydraulic 18-20 ft-lbs / Check valve, 10 psi / 0.7 bar oil from the platform manifold...
Page 111 May 2020 Service and Repair Manual Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 112 Service and Repair Manual May 2020 Manifolds Function Manifold Components, SX-125 XC – View 2 Schematic Index No. Description Function Torque Item Block flow from function pump 46-50 ft-lbs / 62- Check valve, 5 psi / 0.35 bar and auxiliary pump #1 to 67 Nm auxiliary pump #2 Block flow from auxiliary pump...
Page 113 May 2020 Service and Repair Manual Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 114 Service and Repair Manual May 2020 Manifolds Function Manifold Components, SX-105 XC Schematic Index No. Description Function Torque Item Prevents the draining of 18-20 ft-lbs / 25- Check valve, 10 psi / 0.7 bar hydraulic oil from the platform 27 Nm manifold Primary lift, 28-30 ft-lbs / 38-...
Page 115 May 2020 Service and Repair Manual Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 116: Valve Adjustments - Function Manifold
Service and Repair Manual May 2020 Manifolds How to Adjust the Boom Extend Valve Adjustments - Function Relief Valve Manifold Note: Perform this procedure with the boom in the stowed position. How to Adjust the Function Locate limit switch LSB4EO/S on the cable track side of boom #2.
Page 117 May 2020 Service and Repair Manual Manifolds Platform Manifold Components The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Orifice, 0.03in / 0.76mm Jib boom control, Proportional solenoid operated 3 position 5 18-20 ft-lbs / 24-27 Nm way directional valve up/down...
Page 118: Platform Rotate Counterbalance Valve Manifold Components
Service and Repair Manual May 2020 Manifolds Platform Rotate Counterbalance Valve Manifold Components Schematic Index No. Description Function Torque Item 37-44 ft-lbs / Counterbalance valve Platform rotate left 50-60 Nm 37-44 ft-lbs / Counterbalance valve Platform rotate right 50-60 Nm SX™-105 XC™...
Page 119: Function Enable Manifold
May 2020 Service and Repair Manual Manifolds Function Enable Manifold The function enable manifold is mounted on the charge filter mount forming beside the function pump. Index No. Description Schematic Item Function Torque Enables function pumps to provide 20-25 ft-lbs / 27- Solenoid valve, 2 position, 2 way hydraulic pressure for all boom 34 Nm...
Page 120: Steer And Axle Manifold
Service and Repair Manual December 2019 Manifolds Steer and Axle Manifold The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Right front steer cylinder extend 20-25 ft-lbs / Flow control valve, 2.1 gpm / 8 L/min circuit...
Page 121 May 2020 Service and Repair Manual Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 122 Service and Repair Manual December 2019 Manifolds Steer and Axle Manifold, continued Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 30-35 ft-lbs / 41- Axle extend/retract circuit 165 bar 47 Nm Prevents left rear steer cylinder 20-25 ft-lbs / 27- Check valve from moving when not steering...
Page 123 May 2020 Service and Repair Manual Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 124: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual May 2020 Manifolds Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it clockwise to increase the pressure or Axle Manifold counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
Page 125: Traction Manifold Components
May 2020 Service and Repair Manual Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic Description Function Torque Item 30-35 ft-lbs / Check valve Anti-cavitation 40.7-47.5 Nm 26-30 ft-lbs / Solenoid Valve, 2 position 3 way Two-speed drive motor shift...
Page 126 Service and Repair Manual December 2019 Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 127 May 2020 Service and Repair Manual Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic Description Function Torque Item Equalizes pressure on both sides of 30-35 ft-lbs / 40.7- Orifice, 2 gpm / 7.6 L/min divider/combiner valve AP 47.5 Nm...
Page 128 Service and Repair Manual December 2019 Manifolds SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 129 May 2020 Service and Repair Manual Manifolds Generator Manifold Components The generator manifold is mounted near the hydraulic generator located above the function manifold. Index Schematic Description Function Torque Item 19-21 ft-lbs / Check valve Controls flow to diverter valve 25.7-28.5 Nm 33-37 ft-lbs / Solenoid valve...
Page 130: Valve Adjustments - Traction Manifold
Service and Repair Manual May 2020 Manifolds 8-10 Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Start the engine from the platform controls. Manifold Drive the machine at low speed with the joystick small angle. How to Adjust the Hot Oil Note the reading on the pressure gauge.
Page 131: Valve Coils
May 2020 Service and Repair Manual 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 132: How To Test A Coil Diode
Service and Repair Manual May 2020 Manifolds How to T est a Coil Di ode 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.
Page 133: Turntable Rotation Components
May 2020 Service and Repair Manual Turntable Rotation Components Remove the drive hub mounting bolts and Turntable Rotation Assembly remove the turntable rotation assembly from the machine. How to Remove a Turntable Repeat steps 3 through 5 for the other Rotation Assembly turntable rotation assembly.
Page 134 Service and Repair Manual May 2020 Turntable Rotation Components Pull the backlash pivot plate away from the How to Adjust the Turntable turntable until it contacts the adjustment bolt. Rotation Gear Backlash Then lubricate the mounting fasteners on the backlash pivot plate and torque to Secure the turntable from rotating with the specification.
Page 135: Turntable Level Sensor
May 2020 Service and Repair Manual Turntable Rotation Components Push in the ground controls red Emergency Stop button to the off position. Turntable Level Sensor Open the ground control box. Locate the calibration toggle switch at the top How to Calibrate the Turntable of the ground control box.
Page 136 Service and Repair Manual May 2020 Turntable Rotation Components Enter sensor calibration mode by pressing the 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 Run 2 Bypass 3 Recovery Press the enter or previous button on the LCD screen until SET UNIT X AXIS LEVEL...
Page 137 May 2020 Service and Repair Manual Turntable Rotation Components Note: If the measured angle already matches the Press the plus button or minus button to angle shown on the display at the ground controls, adjust the display to the exact value shown on press the plus button or minus button to change the digital level and press the enter button.
Page 138: Axle Components
Service and Repair Manual May 2020 Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor Steer Sensors assembly. The steer sensors measure steer angle and Note: If the sensor activator pin needs to be communicates that information to the ground replaced, install the new activator pin per controls ECM.
Page 139 December 2019 Service and Repair Manual 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 140: How To Calibrate A Replacement Steer Sensor
Service and Repair Manual May 2020 Axle Components How to C alibr ate a R epl acem ent Steer Sensor How to Calibrate a Replacement Position the new steer sensor assembly over the sensor activator pin with the sensor cable Steer Sensor angled away from the tire.
Page 141: How To Calibrate All Steer Sensors
December 2019 Service and Repair Manual 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 Sensors and C. Note: This procedure will only need to be Left front (square-end, blue side) and right performed if the ground controls circuit board...
Page 142 Service and Repair Manual May 2020 Axle Components Delete all Steer Sensor Calibrations Press and hold the enter button on the ground control panel while pulling out the Press the enter or previous button on the ground controls red Emergency Stop button to LCD screen until DELETE ALL STEER the on position.
Page 143: Steer Cylinders
December 2019 Service and Repair Manual Axle Components 10-2 Push in the red Emergency Stop button to the off position. Steer Cylinders Remove the fastener that was temporarily installed. Close the control box door and How to Remove a Steer Cylinder install the door retaining fasteners.
Page 144: Axle Extension Cylinders
Service and Repair Manual May 2020 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 145: Axle Angle Sensors
December 2019 Service and Repair Manual Axle Components 10-4 Temporarily install a control box door retaining fastener between the door and the Axle Angle Sensors box to prevent the control box door from moving the toggle switch while calibrating the The axle angle sensors measure the axle angle machine.
Page 146 Service and Repair Manual May 2020 Axle Components Press the enter or previous button on the Enter sensor calibration mode by pressing the LCD screen until EXIT is displayed. buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). Press the plus button to select YES, then press the enter button to accept.
Page 147: Repair Procedures
May 2020 Service and Repair Manual Repair Procedures 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 148 Service and Repair Manual May 2020 Generators 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 149: Control System Fault Codes
May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the joystick. Check the connections to zero and neutral, Alarm sounds Value Too High ensure the connector terminals have...
Page 150 Service and Repair Manual May 2020 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 151 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/RSB1AS Cross- Fault Check Disable Boom Up, Extend, Down, TT Rotate, Power up controller with check and Propel powers in SCON. Boom Retract problem corrected.
Page 152 Service and Repair Manual May 2020 Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Rotate, Power up controller with Cross-check and Propel powers in SCON. Boom Retract problem corrected.
Page 153 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions LSB2RS (101ft)/LSB4ES Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem (100 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
Page 154 Service and Repair Manual May 2020 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 155 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Extend Power P10 Fault Check Display message on LCD PRI Power up controller with problem EXTEND POWER P10 FAULT corrected. Primary Up Power P11 Fault Check Display message on LCD PRI UP Power up controller with problem...
Page 156 Service and Repair Manual May 2020 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 157 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged Valve zero and neutral, Alarm sounds wiring. Check for an open or shorted valve coil.
Page 158 Service and Repair Manual May 2020 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 159 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem Angle Sensor Rotate, and Propel. Boom Retract corrected.
Page 160 Service and Repair Manual May 2020 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 161 May 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Platform Level Up / Platform Not calibrated Normal function except threshold for Perform calibration procedure Level Down Flow Valve one or the other direction is zero. Display message on LCD Initiate one second beep of audible Just calibrated...
Page 162 Service and Repair Manual May 2020 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 163 May 2020 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 164 Service and Repair Manual May 2020 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 Limited Speed and Direction frozen at Sensor is out of range.
Page 165 May 2020 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 166 Service and Repair Manual May 2020 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 167 May 2020 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 168 Service and Repair Manual May 2020 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 169 May 2020 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 170 Service and Repair Manual May 2020 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 171: Fault Code Display - Deutz Models
May 2020 Service and Repair Manual Fault Code Display – Deutz Models How to Retrieve Active Engine Fault Codes - Deutz TCD 2.2 L3 and TD 2.9 L4 Models The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle...
Page 172: Deutz Td 2.9 L4 Engine Fault Codes
Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine 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;...
Page 173 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; KWP = Keyword Protocol signal range check high SPN FMI Description Sensor error ambient air press.;...
Page 174 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI Description High Low fuel temperature;...
Page 175 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
Page 176 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI Description Starter relay low side;...
Page 177 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off threshold exceeded SPN FMI Description...
Page 178 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout KWP = Keyword Protocol error of short circuit to ground measurement cyl.
Page 179 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 Pressure Relief Valve (PRV) reached maximun allowed 4766...
Page 180 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring 523470...
Page 181 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 Metering unit (Fuel-System);...
Page 182 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 check of missing injector KWP = Keyword Protocol adjustment value programming (IMA) injector 3 (in firing order) FMI KWP Description 523898 check of missing injector...
Page 183 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 Timeout Error of CAN-Transmit- KWP = Keyword Protocol Frame EEC3VOL2; Engine send FMI KWP Description messages 523922 1262 Burner Shut Off Valve;...
Page 184 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not...
Page 185 May 2020 Service and Repair Manual Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout error of CAN-Transmit- KWP = Keyword Protocol Frame ComEGRTVActr KWP Description 524109 9 1679 Timeout error of CAN-Receive- 524035 12...
Page 186 Service and Repair Manual May 2020 Deutz TD 2.9 L4 Engine Fault Codes 524122 9 1684 Timeout error of CAN-Receive- SPN = Suspect Parameter Number Frame ComRxUQSens FMI = Failure Mode Identifier KWP = Keyword Protocol 524123 9 1685 Timeout error of CAN-Receive- Frame ComSCRHtCtl KWP Description 524124 9...
Page 187: Deutz Tcd 2.2 L3 Engine Fault Codes
May 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC SPN Description 1077 411 Engine exhaust gas DTC = Diagnostic Trouble Code recirculation. Signal value above FMI = Failure Mode Identifier maximum limit. SPN = Suspect Parameter Number 1078 411 Engine exhaust gas DTC SPN FMI...
Page 188 Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Fault Codes DTC SPN Description DTC = Diagnostic Trouble Code 1134 3251 3 DPF voltage above normal or FMI = Failure Mode Identifier shorted to high. SPN = Suspect Parameter Number 1135 3251 4 DPF voltage below normal or DTC SPN FMI...
Page 189 May 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC SPN Description DTC = Diagnostic Trouble Code 1209 157 Engine fuel injector metering rail FMI = Failure Mode Identifier pressure voltage below normal SPN = Suspect Parameter Number or shorted to low.
Page 190 Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1308 677 Engine starter motor relay SPN = Suspect Parameter Number current below normal or shorted DTC SPN FMI Description to low.
Page 191 May 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1392 51 Engine throttle valve 1, position SPN = Suspect Parameter Number 1 voltage below normal or DTC SPN FMI Description shorted to low.
Page 192 Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 3349 Timeout error of CAN receive SPN = Suspect Parameter Number frame TSC1TR; control signal. DTC SPN Description 1485...
Page 193 May 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier Ambient air temperature sensor SPN = Suspect Parameter Number voltage below normal or shorted DTC SPN Description to low.
Page 194 Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 5363 Engine cylinder 6 fuel injiection SPN = Suspect Parameter Number quantity current below normal or DTC SPN Description open circuit.
Page 195 May 2020 Service and Repair Manual Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 4257 Engine fuel 1 injector, group 3 SPN = Suspect Parameter Number missing injector adjustment DTC SPN Description value programming injector 3.
Page 196 Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Fault Codes DTC = Diagnostic Trouble Code Description FMI = Failure Mode Identifier Actual engine percent torque. SPN = Suspect Parameter Number DFC to report the fault in DTC SPN Description energizing time companrison.
Page 197: Perkins 854F-34T Engine Fault Code
May 2020 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test Position :Voltage Above Normal Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test Position :Voltage Be- low Normal Accelerator Pedal Position 2 :Voltage Above...
Page 198 Service and Repair Manual May 2020 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test...
Page 199 May 2020 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit- Above Normal Test Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -...
Page 200 Service and Repair Manual May 2020 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Current Above Injector Solenoid Circuit - Test Normal Engine Injector Cylinder #02 :Data Drifted High...
Page 201 May 2020 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test Valve :Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test...
Page 202 Service and Repair Manual May 2020 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhaust Gas Recirculation (EGR) Motorized Valve- Test Valve Control:Current Below Normal 2791 Engine Exhaust Gas Recirculation (EGR) Motorized Valve - Test Valve Control :Current Above Normal...
Page 203 May 2020 Service and Repair Manual Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test Temperature : High- least severe (1) 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test...
Page 204 Service and Repair Manual May 2020 Perkins 854F-34T Engine Fault Code SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test Inhibited Status : Current Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -...
Page 205 December 2019 Service and Repair Manual Fault Codes This page intentionally left blank. Part No. 1271700GT SX-125 XC...
Page 206: Schematics
Service and Repair Manual May 2020 Introduction Section 5 Schem atics 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.
Page 207: Wire Circuit Legend
May 2020 Service and Repair Manual Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
Page 208 Service and Repair Manual May 2020 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 209 May 2020 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 210 Service and Repair Manual May 2020 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 211: Wire Color Legend
December 2019 Service and Repair Manual Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary up valve retract functions are striped black. When Ignition/Fuel using 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 212 Service and Repair Manual May 2020 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Primary boom up driver WH/RD Power to temp sender RD/BK Primary boom down driver Auxiliary Power RD/WH Primary boom up/down flow RD/BK Platform level alarm control proportional valve driver...
Page 213 December 2019 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function GR/BK Axle oscillation Hydraulic Filter restricted Foot switch/TCON estop power Platform Level Safety Power RD/WH Boom down safety interlock RD/BK Platform Level Safety Output RD/BK Safety interlock to engine Platform Level Safety Ground...
Page 214 Service and Repair Manual May 2020 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Flashing Beacon Primary Boom Angle Signal Safety Lift Speed Reduction Secondary Boom Angle Signal Hydraulic Pressure Sensor Safety Output BL/RD Drive Enable Left Oil Cooler Fan BL/WH Drive Enable Right...
Page 215 December 2019 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Boom Length Signal Safety Safety cross check OR/BK Boom Length Signal Operational Data Receive BL/RD Primary Boom Hydraulic Valve BK/WH Data Transmit Lockout WH/RD Multi-Function Pressure Relief...
Page 216: Limit Switches And Angle Sensors
Service and Repair Manual December 2019 Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Stringpot Rear...
Page 217 December 2019 Service and Repair Manual Limit Switches and Angle Sensors Switches and Sensors - Primary Boom, SX-125 XC Index Description Schematic Item Function Controlled Switch Type and Operation Boom #0 - 101ft (boom fully LSB2RO Activates P1 lockout valve Normally open switch retracted) Operational Limit Switch during retract.
Page 218 Service and Repair Manual December 2019 Limit Switches and Angle Sensors Switches and Sensors - Primary Boom, SX-105 XC Index Description Schematic Item Function Controlled Switch Type and Operation Boom #2 - 100 ft (boom #2, #3 LSB4EO fully extended) Operational Limit Switch Boom #2 - 3.
Page 219 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 220 Service and Repair Manual May 2020 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 221: Circuit Connector Legend
May 2020 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 222 Service and Repair Manual May 2020 Circuit Connector Legend Number Description Number Description 2 pin Deutsch DT two speed motor stroke J128 6 pin Deutsch DTM jib up/down/plat rot valve (Y27) joystick (Jcb) 2 pin Deutsch DT RR steer right valve (Y55) J137 4 pin Deutsch DT front axle safety switch (LSFA1ES)
Page 223 May 2020 Service and Repair Manual Circuit Connector Legend Number Description Number Description J160 6 pin Deutsch DT front axle sensor (RSFA10) J210 4 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 224: Connector Pin Legend
Service and Repair Manual May 2020 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 225 May 2020 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 Power output to PCON. Unregulate d 12V auto motive P11-02 P CON P OWE R P 52PCON-WH...
Page 226 Service and Repair Manual May 2020 Connector Pin Legend J12 Black 35 Pin Connector, SX-125 XC 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 227 May 2020 Service and Repair Manual Connector Pin Legend J12 Black 35 Pin Connector, SX-105 XC 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 228 Service and Repair Manual May 2020 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 229 May 2020 Service and Repair Manual Connector Pin Legend J14 White 35 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description P14-01 VALVE_RETURN_4 VLVRET4-BR Valve ground return Proportional PWM valve drive (primary boom up/down P14-02 PRI BM U/D FC VLV #2 V03PUD2-GR/WH valve #2 -GROSS-) P14-03...
Page 230 Service and Repair Manual May 2020 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 231 May 2020 Service and Repair Manual Connector Pin Legend J21 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P21-01 PCON GND GNDPCON-BR PCON ground P21-02 PCON PWR P52PCON-WH Power for PCON P21-03 NOT USED P21-04 CONT S56PRV-RD 12V when footswitch is pressed...
Page 232 Service and Repair Manual May 2020 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 JIB EXTEND NO connection P22-03 PLAT ROT CCW V18PRR-GR/BK ON/OFF valve drive (platform rotate CCW - right) P22-04 PLAT ROT CW V17PRL-GR...
Page 233 May 2020 Service and Repair Manual Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J29-1 JOYSTICK_GND_2 JSGND2-BR Joystick signal ground (JC8) J29-2 JOYSTICK_GND_3 JSGND3-BR Joystick signal ground (JC2) J29-3 SNSR JOYSTICK_PWR_2 P162JPW2-OR Joystick power (JC8) J29-4 SNSR JOYSTICK_PWR_3 P162JPW3-OR...
Page 234 Service and Repair Manual May 2020 Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J169-1 PLAT ROTATE C16PRL-OR/RD Platform rotate CW/CCW signal from jib joystick (JC6) J169-2 GND4-BR Joystick case ground (JC7) J169-3 JIB UP/DOWN C156JUD-GR/WH Jib up/down signal from jib joystick (JC6)
Page 235 May 2020 Service and Repair Manual Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J1-1 PWR-HORN HORN PWR-RD Power for Service Horn button J1-2 RET-HORN HORN RET-GR Return for Service Horn button J1-3 GENERATOR ON/OFF GEN ON/OFF-GR/WH Generator toggle switch input J1-4...
Page 236 Service and Repair Manual May 2020 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 237 May 2020 Service and Repair Manual Connector Pin Legend J32 White 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P32-01 VALVE_RETURN_1 VLVRET1-BR Valve ground return P32-02 AXLE RETRACT V61AXRT-GR ON/OFF valve drive (axle retract) P32-03 AXLE EXTEND V60AXEX-GR/WH ON/OFF valve drive (axle extend) P32-04...
Page 238 Service and Repair Manual May 2020 Connector Pin Legend J121 Gray 12 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P121-01 LOAD SENSE 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 239 May 2020 Service and Repair Manual Connector Pin Legend Pin NO. Type* Signal Name Circuit NO. Signal Description P122-01 ECU PWR P21DCON-WH Power for SCON/DCON ECU P122-02 LTB1LS (BOOM C166PRS-OR Analog signal input for boom length (safety) LENGTH) P122-03 RSB1AS (BOOM C141PBS-RD Analog signal input for boom angle (safety) ANGLE)
Page 240: Engine Relay And Fuse Panel Legend-Deutz Td2011 And Perkins 1104D Models
Service and Repair Manual May 2020 Engine Relay and Fuse Panel Legend- Deutz TD2011 and Perkins 1104D Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler...
Page 241 December 2019 Service and Repair Manual Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models Number Component Description CR15B Glow Plugs CR15A Glow Plugs CR28 Fuel Power CR39 Deutz Aux. Shoutdown Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler...
Page 242: Engine Relay And Fuse Panel Legend- Perkins 854F Models
Service and Repair Manual December 2019 Engine Relay and Fuse Panel Legend- Perkins 854F Models Number Component Description CR81B ECU Power CR81A ECU Power Starter SPARE Horn CR77 Function Enable Ignition CR41 Flashing Beacons CR49 Work / Drive Lights CR17 Hydraulic Oil Cooler F27A Fuse, 30A, ECU Power...
Page 243: Telematics Connector Pin Legend
May 2020 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 Battery Positive –...
Page 244: Electrical Symbols Legend
Service and Repair Manual May 2020 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 245: Hydraulic Symbols Legend
May 2020 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...
Page 246: Control Circuits - Horn
Service and Repair Manual May 2020 Control Circuits - Horn...
Page 247 May 2020 Service and Repair Manual Control Circuits - Horn SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 248: Control Circuits - Power
Service and Repair Manual May 2020 Control Circuits - Power SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 249 May 2020 Service and Repair Manual Control Circuits - Power...
Page 250: Control Circuits - Can Bus
Service and Repair Manual May 2020 Control Circuits - Can Bus, SX-125 XC...
Page 251 May 2020 Service and Repair Manual Control Circuits - Can Bus, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 252 Service and Repair Manual May 2020 Control Circuits - Can Bus, SX-105 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 253 May 2020 Service and Repair Manual Control Circuits - Can Bus, SX-105 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 254: Control Circuits - Deutz Td2011L04I Engine
Service and Repair Manual May 2020 Control Circuits - Deutz TD2011L04i Engine...
Page 255 May 2020 Service and Repair Manual Control Circuits - Deutz TD2011L04i Engine...
Page 256: Control Circuits - Deutz 2.9 Engine/Deutz Tcd 2.2 L3
Service and Repair Manual May 2020 Control Circuits - Deutz 2.9 Engine/ Deutz TCD 2.2 L3 Engine...
Page 257 May 2020 Service and Repair Manual Control Circuits - Deutz 2.9 Engine/ Deutz TCD 2.2 L3 Engine SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 258: Control Circuits - Perkins 1104D-44T Engine
Service and Repair Manual May 2020 Control Circuits - Perkins 1104D-44T Engine SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 259 May 2020 Service and Repair Manual Control Circuits - Perkins 1104D-44T Engine...
Page 260: Control Circuits - Perkins 854 Engine
Service and Repair Manual May 2020 Control Circuits - Perkins 854 Engine...
Page 261 May 2020 Service and Repair Manual Control Circuits - Perkins 854 Engine SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 262: Control Circuits - Axle Extend/Retract
Service and Repair Manual May 2020 Control Circuits - Axle Extend/Retract SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 263 May 2020 Service and Repair Manual Control Circuits - Axle Extend/Retract...
Page 264: Control Circuits - Steering
Service and Repair Manual May 2020 Control Circuits - Steering...
Page 265 May 2020 Service and Repair Manual Control Circuits - Steering SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 266: Control Circuits - Propel
Service and Repair Manual May 2020 Control Circuits - Propel SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 267 May 2020 Service and Repair Manual Control Circuits - Propel...
Page 268: Control Circuits - Turntable Rotate
Service and Repair Manual May 2020 Control Circuits - Turntable Rotate...
Page 269 May 2020 Service and Repair Manual Control Circuits - Turntable Rotate SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 270: Control Circuits - Boom Up/Down
Service and Repair Manual May 2020 Control Circuits - Boom Up/Down, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 271 May 2020 Service and Repair Manual Control Circuits - Boom Up/Down, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 272 Service and Repair Manual May 2020 Control Circuits - Boom Up/Down, SX-105 XC...
Page 273 May 2020 Service and Repair Manual Control Circuits - Boom Up/Down, SX-105 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 274: Control Circuits - Boom Extend/Retract
Service and Repair Manual May 2020 Control Circuits - Boom Extend/Retract, SX-125 XC...
Page 275 May 2020 Error! No text of specified style in document. Control Circuits - Boom Extend/Retract, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 276 Service and Repair Manual May 2020 Control Circuits - Boom Extend/Retract, SX-105 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 277 May 2020 Error! No text of specified style in document. Control Circuits - Boom Extend/Retract, SX-105 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 278 Error! No text of specified style in document. May 2017 Control Circuits - Jib Up/Down and Platform Rotate SX-125 XC Part No. 1271700...
Page 279 May 2020 Service and Repair Manual Control Circuits - Jib Up/Down and Platform Rotate...
Page 280 Service and Repair Manual May 2020 Control Circuits - Platform Level...
Page 281 May 2020 Service and Repair Manual Control Circuits - Platform Level SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 282: Control Circuits - Platform Load Sense
Service and Repair Manual May 2020 Control Circuits - Platform Load Sense SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 283 May 2020 Service and Repair Manual Control Circuits - Platform Load Sense...
Page 284 Service and Repair Manual May 2020 Control Circuits - Flashing Beacons, Oil Cooler and Drive Lamps...
Page 285 May 2020 Service and Repair Manual Control Circuits - Flashing Beacons, Oil Cooler and Drive Lamps SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 286: Control Circuits - Recovery Pld
Service and Repair Manual May 2020 Control Circuits - Recovery PLD, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 287 May 2020 Service and Repair Manual Control Circuits - Recovery PLD, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 288 Service and Repair Manual May 2020 Control Circuits - Recovery PLD, SX-105 XC...
Page 289 May 2020 Service and Repair Manual Control Circuits - Recovery PLD, SX-105 XC...
Page 290: Control Circuits - Telematics
Service and Repair Manual May 2020 Control Circuits - Telematics...
Page 291 July 2017 Service and Repair Manual Control Circuits - Telematics Part No. 1271700 SX-125 XC...
Page 292: Generator Receptacle Wiring- Ansi/Csa
Service and Repair Manual July 2017 Generator Receptacle Wiring- ANSI/CSA SX-125 XC Part No. 1271700...
Page 293 July 2017 Service and Repair Manual Generator Receptacle Wiring- ANSI/CSA...
Page 294: Generator Receptacle Wiring-Aus
Service and Repair Manual May 2020 Generator Receptacle Wiring-AUS...
Page 295 July 2017 Service and Repair Manual Generator Receptacle Wiring-AUS...
Page 296: Generator Receptacle Wiring- Ce
Error! No text of specified style in document. December 2015 Generator Receptacle Wiring - CE SX-105 • SX-125 Part No. 1271700...
Page 297 May 2020 Service and Repair Manual Generator Receptacle Wiring - CE SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 298 Service and Repair Manual May 2020 Perkins 1104D-44T Engine Electrical Schematic J1 6 BL ACK 4 PIN J1 3 W HIT E 2 3 PIN POW ER HARN ENGINE HARN S 1 3 7 P L L -RD/W H S 1 3 9 T RF -W H/RD ACTIVE HIGH TELEMATICS OPTION SHOWN...
Page 299: Perkins 1104D-44T Engine Electrical Schematic
May 2020 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic...
Page 300: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual May 2020 Perkins 854F-34T Engine Electrical Schematic...
Page 301 May 2020 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic J13 WH I TE 23 PI N EN G I N E H AR N VLVR ET3- BR V45H G - G R / WH S137PLL- R D / WH S139TR F- WH / R D C B 9 ENGINE CAN BUS...
Page 302 Service and Repair Manual May 2020 Perkins 854F-34T Engine Harness DE TA IL "C": P E RK INS 854F-E 34T TIE RIV E NGINE J233B - ENGINE INT ERFACE (10PIN) J233B-A IN J1H I A16-R D J233B-B IN J1LO A32-BK J233B-C IN J2LO A31-BK J233B-D...
Page 303: Perkins 854F-34T Engine Harness
May 2020 Service and Repair Manual Perkins 854F-34T Engine Harness SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 304: Deutz Td2011L04I Engine Electrical Schematic
Service and Repair Manual May 2020 Deutz TD2011L04i Engine Electrical Schematic J1 6 B L A CK 4 P IN J1 3 W HIT E 2 3 P IN GROUND B OX HA RN E NGINE HA RN DEUTZ 2011 ENGINE SHOWN S 1 3 7 P L L -R D /W H S 1 3 9 T R F -W H /R D ACTIVE HIGH...
Page 305 May 2020 Service and Repair Manual Deutz TD2011L04i Engine Electrical Schematic SX™-105 XC™ • SX™-125 XC™ Part No. 1271700GT...
Page 306: Deutz Td2.9 Engine Electrical Schematic
Service and Repair Manual May 2020 Deutz TD2.9 Engine Electrical Schematic...
Page 307 May 2020 Service and Repair Manual Deutz TD2.9 Engine Electrical Schematic J13 WH I TE 23 P I N E N G I N E H A R N V LV R E T3- B R V 45H G - G R / WH S 137P LL- R D / WH S 139TR F- WH / R D C B 9...
Page 308 Service and Repair Manual May 2020 Deutz TD2.9 Engine Harness DETAIL "B" - DUETZ 2.9L TURBO TIER IV ENGINE X17-3 START ER RELAY SIGNAL X17-2 STARRT ER RELAY GND J231-D2.1 (60PIN) J232-D2.2 (92PIN) X17-61 D2.2-1 ECU PWR INJECTOR 3 P20PWR-RD D2.1-2 INJ3 A02-BK INJECTOR 3 (A02)
Page 309: Deutz Td2.9 Engine Harness
May 2020 Service and Repair Manual Deutz TD2.9 Engine Harness SX™-105 XC™ • SX™-125 XC™ Part No. 1271700...
Page 310: Deutz Tcd2.2 L3 Engine Electrical Schematic
Service and Repair Manual May 2020 Deutz TCD 2.2 L3 Engine Electrical Schematic TCON J16 BLACK 4 PIN J13 WHITE 23 PIN POWER HARN ENGINE HARN VLVRET 3-BR V45HG-GR/ WH S137PLL-RD/WH S139TRF-WH/ RD J224 GREY 12 PIN TELEMA TICS E NGI NE CA N B US TO CA N GATE WAY (S HE E T 6) C21IGN-WH...
Page 311 May 2020 Service and Repair Manual Deutz TCD2.2 L3 Engine Harness ENGINE INTERFACE CONN - SEE ES*** FOR ENGINE SIDE HARNESS DETAIL "E" - DEUTZ 2.2 STAGE 5 ENGINE C16 DIAG C134 KSP GR /BK GND BR D227 CAN - GR D227CA N1- GR D228CA N1+ Y L D104 CAN - GR...
Page 312: Electrical Schematic - Contact Alarm
Service and Repair Manual May 2020 Electrical Schematic - Contact Alarm SX-105 XC • SX-125 XC Part No. 1271700GT...
Page 313 May 2020 Service and Repair Manual Electrical Schematic - Contact Alarm SX™-105 XC™ • SX™-125 XC™ Part No. 1271700...
Page 314: Hydraulic Schematic, Sx-125 Xc
Service and Repair Manual May 2020 Hydraulic Schematic, SX-125 XC SX-105 XC • SX-125 XC Part No. 1271700GT...
Page 315 May 2020 Service and Repair Manual Hydraulic Schematic, SX-125 XC SX™-105 XC™ • SX™-125 XC™ Part No. 1271700...
Page 316: Hydraulic Schematic, Sx-105 Xc
Service and Repair Manual October 2019 Hydraulic Schematic, SX-105 XC SX-105 XC • SX-125 XC Part No. 1271700GT...
Page 317 May 2020 Service and Repair Manual Hydraulic Schematic, SX-105 XC...
Page 318 Service and Repair Manual May 2020 -125 XC - Deutz CAN GATEWAY LO C KO U T VAL VE #1 SIG N AL LO C KO U T VAL VE #1 SIG N AL TCO N MEMBRANE PANEL (MS2) PC ON &...

This manual is also suitable for:

Genie sx-125 xc

Terex Genie SX-105 XC Service And Repair Manual

Safety Rules

Specifications

Repair Procedures

Platform Controls

Platform Components

Jib Boom Components

Boom Components

Engines

Ground Controls

Display Module

Hydraulic Pumps

Manifolds

Turntable Rotation Components

Axle Components

Repair Procedures

Control System Fault Codes

Fault Code Display - Deutz Models

Deutz TD 2.9 L4 Engine Fault Codes

Deutz TCD 2.2 L3 Engine Fault Codes

Perkins 854F-34T Engine Fault Code

Schematics

Electrical Schematics - Control Circuits

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