Page 1 ™ from SX18014-101 This manual includes: to SX18016-599 Repair procedures Fault Codes from SX180H-600 Electrical and to SX180H-744 Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268497GT Rev B December 2019...
Page 2: Introduction
Copyright © 2015 by Terex Corporation 1268497GT Rev B, December 2019 First Edition, Second Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "SX" is a trademark of Terex South Dakota, Inc.
Page 3: Revision History
December 2019 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 9/2016 Introduction Serial Number Legend 6/2017 Repair 8-3, 8-4, 8-5 Fault Codes Fault Code Source 10/2018 Repair 8-3A, 8-4A Schematics Hydraulic Schematics 12/2018 Specifications...
Page 4: Serial Number Legend
Service and Repair Manual December 2019 Introduction Serial Number Legend To August 31, 2016 1 Model 1 Sequence number 2 Model year 2 Serial number (stamped on chassis) 3 Facility code 3 Serial label (located under cover) From September 1, 2016 1 Model 1 Serial number (stamped on chassis) 2 Facility code...
Page 5: Safety Rules
December 2019 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 6: Personal Safety
Service and Repair Manual December 2019 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.
Page 7: Table Of Contents
December 2019 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
Page 8 December 2019 Table of Contents Section 3 Repair Procedures ....................17 Introduction ......................17 Platform Controls ....................19 1-1 Platform Circuit Board ..................19 How to Remove the LED Circuit Board ............20 1-2 Joysticks ......................21 How to Reset a Proportional Valve Coil Default ..........24 How to Set the Function Thresholds and Default Functions Speeds....
Page 9 December 2019 Table of Contents Boom Components .................... 42 4-1 Cable Track ....................43 4-2 Primary Boom....................45 4-3 Primary Boom Lift Cylinder ................52 4-4 Extension Cylinder ..................54 4-5 Boom Extend and Retract Cables ..............58 How to Replace the Boom Extend/Retract Cables ......... 62 4-6 Boom Internal Cable Track ................
Page 10 December 2019 Table of Contents Manifolds ......................94 8-1 Function Manifold ................... 94 8-2 Valve Adjustments - Function Manifold ............100 8-3 Platform Level and Rotation Manifold (to SX180H-612) ......102 8-3A Platform Level and Rotation Manifold (from SX180H-613) ....... 103 8-4 Jib Boom Manifold (to SX180H-612) ............
Page 11 December 2019 Table of Contents Section 4 Fault Codes ....................... 141 Introduction ......................141 Control System Fault Codes ................142 Fault Matrix ......................161 Fault Code Source ..................... 162 Deutz TD 2.9 L4 Engine Fault Codes ..............165 Perkins 854F-34T Engine Fault Code ..............180 Section 5 Schematics ......................
Page 12 December 2019 Table of Contents Control Circuits - Axle Extend/Retract ..............239 Control Circuits - Steering .................. 242 Control Circuits - Propel ..................243 Control Circuits - Turntable Rotate ..............246 Control Circuits - Boom Up/Down............... 247 Control Circuits - Boom Extend/Retract ............. 250 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate ......
Page 13: Specifications
December 2019 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Tires and wheels Tire size 445D50/710, FF Tire ply rating Tire weight, new foam-filled 850 lbs (minimum) 386 kg Overall tire diameter 45.47 in 115.5 cm Wheel diameter 28 in 71.1 cm...
Page 14: Performance Specifications
Service and Repair Manual December 2019 Specifications Performance Specifications Boom function speeds, maximum from platform controls Drive speed, maximum Jib boom up/down 58 - 62 sec Stowed position, high speed 2.3 mph Jib boom rotate CW/CCW 60° 28 - 32 sec 3.7 km/h Primary boom extend/retract 30 - 33 sec /...
Page 15: Hydraulic Oil Specifications
December 2019 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
Page 16 Service and Repair Manual December 2019 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...
Page 17 December 2019 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...
Page 18: Hydraulic Component Specifications
Service and Repair Manual December 2019 Specifications Hydraulic Component Function Pump - End Pump Specifications Type variable displacement piston pump Drive Pump Displacement per revolution 0 to 1.8 cu in Type: bi-directional variable displacement piston pump 0 to 30 cc Displacement per revolution 2.8 cu in Flow rate @ 2450 rpm...
Page 19: Manifold Component Specifications
December 2019 Service and Repair Manual Specifications Manifold Component Brakes Specifications Brake relief pressure 160 psi 11 bar Plug torque Drive Motors SAE No. 2 36 in-lbs / 4 Nm Displacement per revolution 1.19 cu in high speed: 19,5 cc SAE No.
Page 20: Deutz Td2011L04I Engine Specifications
Service and Repair Manual December 2019 Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 220.9 cu. in Displacement 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C 3.78 x 4.92 inches Bore and Stroke Oil Pressure switch 96 x 125 mm...
Page 21: Deutz Td 2.9 Engine Specifications
December 2019 Service and Repair Manual Specifications Deutz TD 2.9 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs 177 cu. in Displacement 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
Page 22: Perkins 1104D-44T Engine Specifications
Service and Repair Manual December 2019 Specifications Perkins 1104D-44T Oil Pressure switch Installation torque 8 - 18 ft-lbs 268.5 cu. in Displacement 11 - 24 Nm 4.4 liters Pressure switch point 8 psi Number of cylinders 0.55 bar 4.13 x 5 inches Bore and Stroke Oil Sensor Settings 105 x 127 mm...
Page 23 December 2019 Service and Repair Manual Specifications Perkins 1104D-44T cont. Engine coolant Capacity 9.5 quarts (engine only) 9 liters Coolant temperature switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Temperature switch point 230°F 110°C Temperature Sensor Settings 215°F 37 ohms 102°C...
Page 24: Perkins 854F-34T Engine Specifications
Service and Repair Manual December 2019 Specifications Perkins 854F-34T Oil Pressure switch Installation torque 18.4 ft-lbs 207 cu. in Displacement 25 Nm 3.4 liters Pressure switch point 12 psi Number of cylinders 0.82 bar 3.89 x 4.33 inches Bore and Stroke Oil Sensor Settings 99 x 110 mm 0 psi...
Page 25: Machine Torque Specifications
December 2019 Service and Repair Manual Specifications Machine Torque Specifications Perkins 854F-34T cont. Engine coolant Platform Rotator Capacity 16.5 quarts 1-8 center bolt, GR 5, dry 615 ft-lbs (50/50 extended life) 15.6 liters 834 Nm Coolant temperature switch 3/8-16 bolts, GR 8, dry 35 ft-lbs* Installation torque 18.4 ft-lbs...
Page 26: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual December 2019 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...
Page 27: Torque Procedure
December 2019 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
Page 28 Service and Repair Manual December 2019 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 29: Observe And Obey
December 2019 Service and Repair Manual Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
Page 30: About This Section
Service and Repair Manual December 2019 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.
Page 31: Platform Controls
December 2019 Service and Repair Manual Platform Controls Platform Circuit Board Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: When the platform circuit board is replaced, the joystick controllers will need to be calibrated.
Page 32: How To Remove The Led Circuit Board
Service and Repair Manual December 2019 Platform Controls How to R emove the LED Circui t Board How to Remove the LED Circuit Attach a grounded wrist strap to the ground screw inside the control box. Board Electrocution/burn hazard. Push in the red Emergency Stop button to the Contact with electrically charged off position at both the ground and platform circuits could result in death or...
Page 33: Joysticks
December 2019 Service and Repair Manual Platform Controls Drive functions: Joysticks Turn the key switch to the off position. Press and hold the enter button on the ground How to Calibrate a Joystick control panel while turning the key switch to platform controls.
Page 34 Service and Repair Manual December 2019 Platform Controls Steer functions: Primary boom extend/retract functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to platform controls.
Page 35 December 2019 Service and Repair Manual Platform Controls Primary boom up/down functions: Jib boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground Press and hold the enter button on the ground control panel while turning the key switch to control panel while turning the key switch to...
Page 36: How To Reset A Proportional Valve Coil Default
Service and Repair Manual December 2019 Platform Controls How to R es et a Proportional Valve Coil D efault How to Reset a Proportional Turntable rotate functions: Valve Coil Default Turn the key switch to the off position. Note: Use the following chart to identify the Press and hold the enter button on the ground description of each LCD screen control button used control panel while turning the key switch to...
Page 37: How To Set The Function Thresholds And Default Functions Speeds
December 2019 Service and Repair Manual Platform Controls How to Set the F unction T hresholds and D efault Func tions Speeds How to Set the Function Slowly move the joystick off center in the opposite direction just until the machine Thresholds and Default function starts to move, then move the joystick Functions Speeds...
Page 38 Service and Repair Manual December 2019 Platform Controls Function speeds: 15 Once the function speeds have been set, press and hold the engine start button until the Note: Be sure the machine is in the stowed position engine shuts off. Do not press the red and the boom is rotated between the circle end Emergency Stop button.
Page 39: How To Adjust The Function Speeds
December 2019 Service and Repair Manual Platform Controls How to Adj ust the Functi on Speeds How to Adj ust the Functi on R amp R ate Setti ng How to Adjust the Function How to Adjust the Function Ramp Speeds Rate Setting Note: Perform this procedure with the boom in the...
Page 40: Platform Components
Service and Repair Manual December 2019 Platform Components Remove the weld cable from the platform (if equipped). Platform Electrocution/burn hazard. How to Remove the Platform Contact with electrically charged circuits could result in death or Separate the foot switch quick disconnect serious injury.
Page 41: Platform Leveling Cylinder
December 2019 Service and Repair Manual Platform Components Remove the pin retaining fasteners from the barrel-end pivot pin. Use a soft metal drift to Platform Leveling Cylinder remove the barrel-end pivot pin. The platform leveling cylinder keeps the platform Support the rod end of the platform level level through the entire range of boom motion.
Page 42: Platform Rotator
Service and Repair Manual December 2019 Platform Components Remove the platform angle sensor retaining fasteners. Remove the platform angle sensor Platform Rotator from the platform rotator. The platform rotator is a hydraulically activated Component damage hazard. The helical gear assembly used to rotate the platform platform angle sensor is a very 160 degrees.
Page 43: How To Bleed The Platform Rotator
December 2019 Service and Repair Manual Platform Components How to Bleed the Pl atform R otator How to Bleed the Platform Support the jib boom leveling arms with a suitable lifting device. Rotator Use a soft metal drift to remove both pins and Note: Do not start the engine.
Page 44: Platform Level Sensor
Service and Repair Manual December 2019 Platform Components Insert the key into the bypass/recovery key switch and turn it to the bypass position. Platform Level Sensor Note: The platform level calibration value will not be saved correctly unless the key switch is in the The platform level sensor is mounted to the side of bypass position and the calibration toggle switch is the platform rotator.
Page 45: Platform Overload System (If Equipped)
December 2019 Service and Repair Manual Platform Components Determine the limit switch trigger point: Platform Overload System (if Gently move the platform up and down by equipped) hand, so it bounces approximately 1 to 2 inches / 2.5 to 5 cm. Allow the platform to settle.
Page 46: Platform Overload Recovery Message
Service and Repair Manual December 2019 Platform Components Confirm the setting: Platform Overload Recovery Start the engine from the platform controls. Message (software V2.0 and later) Lift the test weight off the platform floor using a suitable lifting device. If the ground controls LCD screen displays Place the test weight back onto the center of OVERLOAD RECOVERY, the emergency lowering the platform floor using a suitable lifting...
Page 47 December 2019 Service and Repair Manual Platform Components Press the buttons on the ground controls in the following sequence: (plus)(minus)(minus)(plus). Press the enter or previous button on the LCD screen until CLEAR OVERLOAD RECOVERY is displayed. Press the plus button or the minus button to select YES.
Page 48: Jib Boom Components
Service and Repair Manual December 2019 Jib Boom Components 1 platform rotator 5 bellcrank 2 jib boom 6 jib boom lift cylinder 3 jib rotator 7 platform leveling cylinder 4 bellcrank leveling cylinder ™ -180 Part No. 1268497GT...
Page 49: Jib Boom
December 2019 Service and Repair Manual Jib Boom Components Support the barrel end of the cylinder with a suitable lifting device. Jib Boom Remove the pin retaining fastener from the jib How to Remove the Jib Boom boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the pin and let Note: Perform this procedure with the boom in the the cylinder hang down.
Page 50: Jib Boom Lift Cylinder
Service and Repair Manual December 2019 Jib Boom Components Remove the pin retaining fasteners from the jib boom lift cylinder rod-end pivot pin. Use a Jib Boom Lift Cylinder soft metal drift to remove the pin and let the cylinder hang down. How to Remove the Jib Boom Lift Attach a lifting strap from an overhead crane Cylinder...
Page 51: How To Remove The Jib Boom Bellcrank
December 2019 Service and Repair Manual Jib Boom Components Use a soft metal drift to remove the bellcrank leveling cylinder rod-end pivot pin. How to Remove the Jib Boom Bellcrank Crushing hazard. The bellcrank leveling cylinder may be damaged if it is not properly Note: Perform this procedure with the boom in the supported when the rod-end stowed position.
Page 52: Jib Boom Bellcrank Angle Sensor
Service and Repair Manual December 2019 Jib Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Jib Boom Bellcrank Angle Sensor in this procedure. The jib boom bellcrank angle sensor is monitored by the control system to keep the jib boom bellcrank vertical and to help maintain a level platform through boom range of motion.
Page 53 December 2019 Service and Repair Manual Jib Boom Components Remove the key from the main key switch. 14 Press and hold the engine start button for Insert the key into the bypass/recovery key approximately 5 seconds to shut off the switch and turn it to the bypass position.
Page 54: Boom Components
Service and Repair Manual December 2019 Boom Components 1 boom tube #1 5 primary lift cylinder 2 boom tube #2 6 boom tube #0 3 boom tube #3 7 secondary extension cylinder 4 boom tube #4 ™ -180 Part No. 1268497GT...
Page 55: Primary Boom Cable Track
December 2019 Service and Repair Manual Boom Components Pull the electrical cables out of the lower cable track that lead to the primary boom. Primary Boom Cable Track Component damage hazard. The primary boom cable track guides the cables Cables can be damaged if they and hoses running up the boom.
Page 56: How To Repair The Primary Boom Cable Track
Service and Repair Manual December 2019 Boom Components How to Repair the Primary Boom 11 Secure the upper and lower tracks together. Cable Track Crushing hazard. If the upper and lower cable tracks are not Component damage hazard. properly secured together, the The boom cable track can be cable track could become damaged if it is twisted.
Page 57: Primary Boom
December 2019 Service and Repair Manual Boom Components Pivot end upper wear pads Primary Boom 10 Loosen the wear pad mounting fasteners. 11 Add shims by hand until snug. How to Shim the Boom Note: Do not use force when adding the shims. Measure each upper, side and lower wear 12 Remove one shim from each upper wear pad pad.
Page 58 Service and Repair Manual December 2019 Boom Components How to Remove the Primary Attach a lifting strap from an overhead crane to the rod end of the primary boom lift cylinder. Boom Remove the pin retaining fastener from the Bodily injury hazard. This boom lift cylinder rod-end pivot pin.
Page 59 December 2019 Service and Repair Manual Boom Components 10 Tag, disconnect and plug the secondary boom 17 Disconnect the electrical connector from the extension cylinder hydraulic hoses. Cap the primary boom angle sensor. fittings on the cylinder. Note: The primary boom angle sensor is located on the pivot pin on the tank side of the boom.
Page 60 Service and Repair Manual December 2019 Boom Components How to Disassemble the Primary Remove the jib boom bellcrank. Refer to Repair Procedure, How to Remove the Jib Boom Boom Bellcrank. Bodily injury hazard. This Remove the boom primary extension cylinder. procedure requires specific repair Refer to Repair Procedure, How to Remove skills, lifting equipment and a...
Page 61 December 2019 Service and Repair Manual Boom Components Remove the #3 and #4 boom tubes: 19 Attach the #3 boom tube to a forklift, and lift the tube enough to relieve the pressure from 12 At the platform end, remove the #4 boom the lower wear pads.
Page 62 Service and Repair Manual December 2019 Boom Components Remove the #2 boom tube: 28 Remove the fasteners securing the lower wear pads and remove the wear pads and 23 At the pivot end of the machine, remove the aluminum block between the #1 and #2 boom shims from the wear pads between the #1 and tubes.
Page 63 December 2019 Service and Repair Manual Boom Components Remove the #1 boom tube: 41 Remove limit switches 2RO and 2RS and bracket from boom tube #0. 34 Strap and secure the secondary boom extension cylinder to the #0 boom tube. Tip-over hazard.
Page 64: Primary Boom Lift Cylinder
Service and Repair Manual December 2019 Boom Components Attach an overhead 10 ton / 9071 kg crane to the platform end of the boom for support. Do Primary Boom Lift Cylinder not lift the boom. The primary boom lift cylinder raises and lowers Note: Place the lifting strap between the cable track the primary boom.
Page 65 December 2019 Service and Repair Manual Boom Components Tag, disconnect and plug the boom lift cylinder 14 Remove the pin retaining fastener from the hydraulic hoses. barrel-end pivot pin. Do not remove the pin. 15 Support the boom lift cylinder with an Bodily injury hazard.
Page 66: Extension Cylinders
Service and Repair Manual December 2019 Boom Components Tag and disconnect the limit switch harnesses. Remove the fasteners to the limit Extension Cylinders switch harness mounting bracket and remove the bracket. The primary boom extension cylinder is located inside the boom assembly and incorporates cables Tag and disconnect limit switch 3RO (6).
Page 67 December 2019 Service and Repair Manual Boom Components Lay the inner cable track and hoses down and 10 At the platform end of the machine, loosen the out of the way. retract cable equalizer bolts at the #1 and #2 boom tubes. 11 Remove the retaining fasteners from the red cable adjustment locking brackets.
Page 68 Service and Repair Manual December 2019 Boom Components How to Remove the Secondary 14 Remove the locking plates securing the extend cylinder to boom #1 (1). (Illustration 1) Boom Extension Cylinder 15 Remove the cable guards (2) covering the Bodily injury hazard. This sheaves attached to the extend cylinder.
Page 69 December 2019 Service and Repair Manual Boom Components Loosen but do not remove the extension Protect the boom lift cylinder rod from cylinder support bracket and wear pad. damage. Use a soft metal drift to remove both pivot Bodily injury hazard. Do not pins.
Page 70: Boom Extend And Retract Cables
Service and Repair Manual December 2019 Boom Components Boom Extend and Retract Cables How to Adjust the Boom Extend/Retract Cables Properly adjusted extend/retract cables are essential to safe machine operation. Failure to maintain proper adjustment of the cables could result in unsafe operating conditions and may cause component damage.
Page 71 December 2019 Service and Repair Manual Boom Components Measure the distance between boom tubes #2 and #3 using points (9) and (10). (Illustration 1) The gap should be 1 in / 2.6 cm to 1.5 in / 3.8 cm greater than dimension "A". Result: The measurement is between 1 in / 2.6 cm and 1.5 in / 3.8 cm more than dimension "A".
Page 72 Service and Repair Manual December 2019 Boom Components 13 Tighten the retract bolt until the gap between 23 Torque the three extend cable adjustment boom tubes #2 and #3 is 1 to 1.5 in / 2.5 to bolts (4) to 35 ft-lbs / 47.5 Nm. Make small 3.8 cm greater than dimension "A".
Page 73 December 2019 Service and Repair Manual Boom Components 29 Loosen the two extend cable adjustment bolts 39 Re-measure the gap between boom tubes (1) five turns. (Illustration 2) #1 and #2 from points (11) and (12) (dimension “A”) and boom tubes #3 and 30 At the platform end of the boom, locate the #4 from points (7) and (8).
Page 74: How To Replace The Boom Extend/Retract Cables
Service and Repair Manual December 2019 Boom Components How to R eplac e the Boom Extend/R etr act Cables How to Replace the Boom 45 Fully retract the boom and lower the boom to the horizontal position. Extend/Retract Cables 46 Stop the engine. Note: The cable sheaves must be inspected when 47 Re-measure the gap between boom tubes replacing the cables.
Page 75 December 2019 Service and Repair Manual Boom Components Remove the fasteners securing the idler pulley holding the upper extend cables and remove the pulley (3). (Illustration 1) Remove the upper side wear pads (4) from the #4 boom tube. (Illustration 1) Remove the anti-rotation bolts from the extend cable.
Page 76 Service and Repair Manual December 2019 Boom Components #3 Boom retract cables: 10 Remove the center mounting bolt securing the sheave to the cover plate (3). 21 Remove the fastener and the retract cable 11 Remove the remaining fasteners securing the guide between boom tubes #2 and #3.
Page 77: Boom Internal Cable Track
December 2019 Service and Repair Manual Boom Components 32 Remove the equalizing bracket from the #4 boom retract cables. Boom Internal Cable Track 33 Attach electrician's tape to the #4 retract cable How to Remove the Boom at the pivot end of the machine. Internal Cable Track 34 Attach a suitable device to pull the #3 and #4 boom tubes approximately 2 feet / 0.6 m.
Page 78 Service and Repair Manual December 2019 Boom Components Tag, disconnect and plug the hydraulic hoses 11 At the pivot end, note the position of the from at the fittings just below the primary locating U notch on the cable tube. Pull the boom.
Page 79: Primary Boom Angle Sensor
December 2019 Service and Repair Manual Boom Components 13 Support the assembly as it is removed from the boom. Primary Boom Angle Sensor Note: Reverse the procedure to install the The primary boom angle sensor is used to limit the assembly.
Page 80 Service and Repair Manual December 2019 Boom Components 10 Press the plus button to select YES, then Note: Use the following chart to identify the press the enter button to accept. description of each LCD screen control button used in this procedure. 11 Place the digital level on top of the primary boom near the pivot and note the angle displayed on the digital level.
Page 81 December 2019 Service and Repair Manual Boom Components 17 At the PRIMARY BOOM ANGLE TO 22 Press and hold a function enable/speed select GRAVITY 32 DEG screen, press the plus or button and the primary boom button until the minus button to adjust the display to the exact boom is fully raised.
Page 82: Boom Length Sensor
Service and Repair Manual December 2019 Boom Components Note: Use the following chart to identify the description of each LCD screen control button used Boom Length Sensor in this procedure. How to Calibrate the Primary Boom Length Sensor Note: Perform this procedure with the machine on a firm, level surface with the axles extended.
Page 83 December 2019 Service and Repair Manual Boom Components 18 Press and hold the engine start button for Press and hold the enter button on the ground approximately 5 seconds to shut off the control panel while pulling out the ground engine and to save the calibration settings.
Page 84: Engines
Service and Repair Manual December 2019 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the engine Refer to Maintenance Procedure in the appropriate and the pump. It is bolted to the engine flywheel Service or Maintenance Manual for your machine, and has a splined center to drive the pump.
Page 85: How To Install The Flex Plate
December 2019 Service and Repair Manual Engines How to Ins tall the Fl ex Plate Perkins engines: Torque the pump plate How to Install the Flex Plate mounting bolts in sequence to 23 ft-lbs / 31 Install the flex plate onto the engine flywheel Nm.
Page 86: Ground Controls
Service and Repair Manual December 2019 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 87: How To Use The Recovery Mode
December 2019 Service and Repair Manual 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 88: Circuit Boards
Service and Repair Manual December 2019 Ground Controls Turn and hold the bypass/recovery key switch to the recovery position. The switch must be Circuit Boards held in the recovery position. The ground control box contains a replaceable Result: The auxiliary power unit will turn on membrane decal with touch sensitive buttons for and the boom will begin the following recovery various machine functions.
Page 89 December 2019 Service and Repair Manual Ground Controls How to Remove the LCD Display How to Remove the ALC-1000 Screen Circuit Board Circuit Board Push in the red Emergency Stop button to the Push in the red Emergency Stop button to the off position at both the ground and platform off position at both the ground and platform controls.
Page 90: Membrane Decal
Service and Repair Manual December 2019 Ground Controls Remove any decal adhesive from the control box lid with a mild solvent. Membrane Decal Note: Do not allow any solvent to come in contact with the LCD display screen. The membrane decal is a special decal that consists of a decal with an electronic membrane on Install the new membrane decal while guiding the backside.
Page 91: Full Machine Calibration
December 2019 Service and Repair Manual Ground Controls Note: Start this procedure with the booms in the fully stowed position and the axle retracted. Full Machine Calibration Full machine calibration must be completed in the following sequence: Full machine calibration must be completed in the proper sequence when the ALC-1000 circuit board •...
Page 92: Display Module
Service and Repair Manual December 2019 Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 93 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa (metric) 0-31000 kPa Primary angle degrees -2°...
Page 94 Service and Repair Manual December 2019 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Forward extended drive speed % 120% (max) 100% (default) Drive Functions and hold the enter button 50% (min) and turn key switch to on Forward not stowed drive 120% (max) 100% (default) position.
Page 95 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Primary boom up speed stowed Boom Function and hold the enter button Speeds and turn key switch to on position.
Page 96 Service and Repair Manual December 2019 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Primary boom up/down ramp Lift Functions hold the enter button and turn key acceleration % Ramps switch to on position. Primary boom up/down ramp Release the enter button and deceleration %...
Page 97 December 2019 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Set unit X-axis to gravity Sensor Calibration and hold the enter button Set unit Y-axis to gravity and turn key switch to on position.
Page 98 Service and Repair Manual December 2019 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press AC Generator (NONE/7.5KW/12.5KW) Options and hold the enter button and turn key switch to on position. Release the enter button and press (minus)(minus)(plus)(plus).
Page 99: Hydraulic Pumps
December 2019 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and The function pump is a pressure compensated, burn skin.
Page 100: How To Prime The Function Pump
Service and Repair Manual December 2019 Hydraulic Pumps How to Prime the F uncti on Pump How to Adj ust the Functi on Pum p Standby Pr ess ure How to Prime the Function Pump How to Adjust the Function Pump Standby Pressure Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose...
Page 101 December 2019 Service and Repair Manual Hydraulic Pumps Pressure reads 350 psi / 25 bar Pressure reads less than 350 psi / 25 bar One or both of the function pumps may be at Loosen the set screw for the standby pressure the correct pressure.
Page 102: How To Adjust The Function Pump Pressure Compensator
Service and Repair Manual December 2019 Hydraulic Pumps How to Adj ust the Functi on Pum p Press ure Com pens ator How to Adjust the Function Pump Pressure reads more than 350 psi / 25 bar Pressure Compensator Loosen the set screw for the standby pressure adjustment screw on the rear function pump.
Page 103: How To Remove The Drive Pump
December 2019 Service and Repair Manual Hydraulic Pumps Loosen the set screw for the pressure compensator adjustment screw. Drive Pump The drive pump is a bi-directional variable displacement piston pump. The pump output is controlled by the electronic displacement controller (EDC), located on the pump.
Page 104 Service and Repair Manual December 2019 Hydraulic Pumps Locate the two hydraulic tank valves at the Carefully pull the drive pump out until the hydraulic tank. Close the valves. pump coupler separates from the flex plate. Remove the drive pump from the machine. Component damage hazard.
Page 105: How To Prime The Drive Pump
December 2019 Service and Repair Manual Hydraulic Pumps How to Prime the Driv e Pum p How to Prime the Drive Pump Component damage hazard. Be sure to open the two hydraulic tank valves before performing this procedure. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to either the "A"...
Page 106: Manifolds
Service and Repair Manual December 2019 Manifolds Function Manifold Components – View 1 The function manifold is mounted next to the hydraulic tank on the ground control side of the machine. Index Schematic Description Function Torque Item Solenoid operated 2 position 2 way 33-37 ft-lbs / Primary boom cylinder retract directional valve...
Page 107 December 2019 Service and Repair Manual Manifolds Part No. 1268497GT ™ -180...
Page 108 Service and Repair Manual December 2019 Manifolds Function Manifold Components, continued Schematic Index No. Description Function Torque Item Prevents hydraulic pressure from 19-21 ft-lbs / Check valve, 5 psi / 0.34 bar flowing back into auxiliary pump #1 25.7-28.5 Nm 24-26 ft-lbs / Relief valve, 3200 psi / 221 bar System relief...
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Page 110: Function Manifold Components - View
Service and Repair Manual December 2019 Manifolds Function Manifold Components – View 2 Schematic Index No. Description Function Torque Item Pilot operated 3 position, 4 way, Boom cylinder extend / retract 46-54 ft-lbs / directional valve circuit 62.6-73.4 Nm Pilot operated 3 position, 4 way, Boom lift cylinder up/down 46-54 ft-lbs / directional valve...
Page 111 December 2019 Service and Repair Manual Manifolds Part No. 1268497GT ™ -180...
Page 112: Valve Adjustments - Function Manifold
Service and Repair Manual December 2019 Manifolds How to Adjust the Primary Boom Valve Adjustments - Extend Relief Valve Function Manifold Note: Perform this procedure with the axles extended. How to Adjust the Function Locate limit switch LSB4EO/S on the cable Manifold Relief Valve track side of boom #2.
Page 113 December 2019 Service and Repair Manual Manifolds Simultaneously push and hold the function enable/high speed button and the primary boom extend button with the primary boom fully extended. Observe the pressure reading on the pressure gauge. Refer to Specifications, Hydraulic Component Specifications.
Page 114: Platform Level And Rotation Manifold (To Sx180H-612)
Service and Repair Manual December 2019 Manifolds Platform Level and Rotation Manifold Components to SX180H-612 The platform manifold is mounted under the jib boom. Index Schematic Description Function Torque Item Proportional Directional Control valve, 25-30 ft-lbs / Jib level up/down 3 position 5 way 33.9-40.7 Nm Jib boom up/down circuit, regulates...
Page 115: 8-3A Platform Level And Rotation Manifold (From Sx180H-613)
December 2019 Service and Repair Manual Manifolds 8-3A Platform Level and Rotation Manifold Components from SX180H-613 The platform manifold is mounted under the jib boom. Index Schematic Description Function Torque Item 19-21 ft-lbs / Proportional solenoid valve, 3 position 4 way Jib level up/down 25.8-28.6 Nm 19-21 ft-lbs /...
Page 116: Jib Boom Manifold (To Sx180H-612)
Service and Repair Manual December 2019 Manifolds Jib Boom Manifold Components to SX180H-612 The jib boom manifold is mounted on the primary extension boom at the platform end. Schematic Index No. Description Function Torque Item 19-21 ft-lbs / Check valve, 25 psi / 1.7 bar Holds oil in jib boom manifold 25.8-28.6 Nm Jib boom rotate circuit, regulates...
Page 117: 8-4A Jib Boom Manifold (From Sx180H-613)
December 2019 Service and Repair Manual Manifolds 8-4A Jib Boom Manifold Components from SX180H-613 The jib boom manifold is mounted on the primary extension boom at the platform end. Schematic Index No. Description Function Torque Item Proportional solenoid valve, 2 position 19-21 ft-lbs / Jib level up/down 2 way...
Page 118: Function Enable Manifold
Service and Repair Manual December 2019 Manifolds Function Enable Manifold Components The function enable manifold is located on the engine side below the hydraulic pumps. Index No. Description Schematic Item Function Torque Enables function pumps to provide 20-25 ft-lbs Solenoid valve, 2 position 2 way hydraulic pressure for all boom and 27-34 Nm steer/axle functions...
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Page 120: Steer And Axle Manifold Components, To Sx180H-604
Service and Repair Manual December 2019 Steer and Axle Manifold Components, to SX180H-604 The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine. Index Schematic Description Function Torque Item Right front steer cylinder retract 20-25 ft-lbs Flow control valve, 1.5 gpm / 5,7 L/min circuit...
Page 121 December 2019 Service and Repair Manual Part No. 1268497GT ™ -180...
Page 122 Service and Repair Manual December 2019 Steer and Axle Manifold Components, continued (to SX180H-604) Schematic Index No. Description Function Torque Item Pressure reducing valve, 2400 psi / 30-35 ft-lbs Axle extend/retract circuit 165 bar 41-47 Nm Prevents left rear steer cylinder 20-25 ft-lbs Check valve from moving when not steering...
Page 123 December 2019 Service and Repair Manual Part No. 1268497GT ™ -180...
Page 124: 8-6A Steer And Axle Manifold Components, From Sx180H-605
Service and Repair Manual December 2019 8-6A Steer and Axle Manifold Components, from SX180H-605 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 125 December 2019 Service and Repair Manual Part No. 1268497GT ™ -180...
Page 126 Service and Repair Manual December 2019 Steer and Axle Manifold Components, continued (from SX180H-605) Schematic Index No. Description Function Torque Item 33-37 ft-lbs Solenoid valve, 2 position 2 way Axle retract 45-50 Nm Pressure reducing valve, 2400 psi / 30-35 ft-lbs Axle extend/retract circuit 165 bar 41-47 Nm...
Page 127 December 2019 Service and Repair Manual Part No. 1268497GT ™ -180...
Page 128: Valve Adjustments - Steer And Axle Manifold
Service and Repair Manual December 2019 Manifolds Turn the engine off. Valve Adjustments - Steer and Adjust the internal hex socket. Turn it clockwise to increase the pressure or Axle Manifold counterclockwise to decrease the pressure. Install the relief valve cap. How to Adjust the Axle Relief Component damage hazard.
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Page 130: Traction Manifold Components
Service and Repair Manual December 2019 Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the circle end of the machine Index Schematic Description Function Torque Item 30-35 ft-lbs Check valve Anti-cavitation 40,7-47,5 Nm 26-30 ft-lbs Solenoid Valve, 2 position 3 way Two-speed drive motor shift 35,3-40,7 Nm...
Page 131 December 2019 Service and Repair Manual Manifolds Part No. 1268497GT ™ -180...
Page 132 Service and Repair Manual December 2019 Manifolds Traction Manifold Components, continued Index Schematic Description Function Torque Item Equalizes pressure on both sides of 30-35 ft-lbs Orifice, 3 gpm / 11,4 L/min divider/combiner valve AP 40,7-47,5 Nm Equalizes pressure on both sides of 30-35 ft-lbs Orifice, 3 gpm / 11,4 L/min divider/combiner valve AM...
Page 133 December 2019 Service and Repair Manual Manifolds Part No. 1268497GT ™ -180...
Page 134: Valve Adjustments - Traction Manifold
Service and Repair Manual December 2019 Manifolds Hold the hot oil relief valve and remove the cap. Valve Adjustments - Traction Start the engine from the ground controls. Manifold 10 Press and hold the function enable/high rpm How to Adjust the Hot Oil Relief select button (rabbit symbol) position.
Page 135: Generator Manifold Component
December 2019 Service and Repair Manual Manifolds 8-10 Generator Manifold Components The oil diverter manifold is mounted near the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item 19-21 ft-lbs Check valve Controls flow to diverter valve 26-28 Nm Solenoid valve, 2 position 2 way valve 33-37 ft-lbs...
Page 136: Valve Coils
Service and Repair Manual December 2019 Manifolds Valve Coil Resistance 8-11 Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
Page 137 December 2019 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 138: Turntable Rotation Components
Service and Repair Manual December 2019 Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from the machine. Turntable Rotation Assembly Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 139: How To Adjust The Turntable Rotation Gear Backlash
December 2019 Service and Repair Manual Turntable Rotation Components Turn the adjustment bolt 1/2 to 3/4 turn How to Adj ust the Tur ntabl e R otati on Gear Backlash How to Adjust the Turntable counterclockwise. Tighten the lock nut on the Rotation Gear Backlash adjustment bolt.
Page 140: Turntable Level Sensor
Service and Repair Manual December 2019 Turntable Rotation Components Push in the ground controls red Emergency Stop button to the off position. Turntable Level Sensor Open the ground control box. How to Calibrate the Turntable Locate the calibration toggle switch at the top Level Sensor of the ground control box.
Page 141 December 2019 Service and Repair Manual Turntable Rotation Components Enter sensor calibration mode by pressing the 10 Place the digital level along the X axis of the buttons at the ground controls in the following turntable. sequence: (plus)(enter)(enter)(plus). 1 -X Axis 2 +X Axis 3 Platform end 1 Run...
Page 142 Service and Repair Manual December 2019 Turntable Rotation Components 13 Press the plus button or minus button to adjust the display to the exact value shown on the digital level and press the enter button. Note: If the measured angle already matches the angle shown on the display at the ground controls, press the plus button or minus button to change the angle and then change back to the measured...
Page 143: Axle Components
December 2019 Service and Repair Manual Axle Components 10-1 Remove the steer sensor cover retaining fasteners. Remove the steer sensor assembly. Steer Sensors Note: If the sensor activator pin needs to be replaced, install the new activator pin per The steer sensors measure steer angle and Illustration 1.
Page 144 Service and Repair Manual December 2019 Axle Components Position the new steer sensor assembly over 10 Position the new steer sensor assembly over the sensor activator pin with the sensor cable the sensor activator pin with the sensor cable angled towards the tire. Refer to Illustration 2. angled away from the tire.
Page 145: How To Calibrate A Replacement Steer Sensor
December 2019 Service and Repair Manual Axle Components How to C alibr ate a R epl acem ent Steer Sens or How to C alibr ate All Steer Sensors How to Calibrate a Replacement How to Calibrate All Steer Steer Sensor Sensors Note: If a steer angle sensor has been removed or Note: This procedure will only need to be...
Page 146 Service and Repair Manual December 2019 Axle Components Left front (square-end, blue side) and right Press and hold the enter button on the ground rear (circle-end, yellow side) angle control panel while pulling out the ground controls red Emergency Stop button to the on sensors: Rotate the sensor cover clockwise position.
Page 147 December 2019 Service and Repair Manual Axle Components Delete a Single Steer Sensor Calibration Delete all Steer Sensor Calibrations 15 To calibrate a single steer sensor, delete the 11 Press the enter or previous button on the specific steer sensor calibration LCD screen until DELETE ALL STEER SENSORS CALIBRATION is displayed.
Page 148: Steer Cylinders
Service and Repair Manual December 2019 Axle Components 10-2 10-3 Steer Cylinders Axle Extension Cylinders How to Remove a Steer Cylinder How to Remove an Axle Extension Cylinder Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Note: When removing a hose assembly or fitting, end must be replaced.
Page 149: Axle Angle Sensors
December 2019 Service and Repair Manual Axle Components 10-4 Connect the hydraulic hoses from a portable hydraulic power unit to the axle extension Axle Angle Sensors cylinder. The axle angle sensors measure the axle angle Note: Connect the pressure hose from the power and communicates that information to the ground unit to the "R"...
Page 150 Service and Repair Manual December 2019 Axle Components Temporarily install a control box door retaining Enter sensor calibration mode by pressing the fastener between the door and the box to buttons at the ground controls in the following prevent the control box door from moving the sequence: (plus)(enter)(enter)(plus).
Page 151 December 2019 Service and Repair Manual Axle Components 16 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in. 17 Remove the fastener that was temporarily installed. Close the control box door and install the door retaining fasteners.
Page 152: Generators
Service and Repair Manual December 2019 Generators Start the engine from the platform controls. 11-1 Turn on the generator from the platform Welder Generator controls and let the generator run for at least three minutes. How to Set the Welder Generator Insert the leads from a multimeter set to Frequency register frequency (HZ) and turn the needle...
Page 153: Observe And Obey
December 2019 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.
Page 154: Control System Fault Codes
Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Ext/Ret Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 155 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Boom Up/Down Fault Check (both Primary Boom Up/Down disabled, Check ribbon and connector from buttons on TCON buttons pressed) display message on LCD membrane switch.
Page 156 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/RSB1AS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem corrected. Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RS.
Page 157 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem corrected. Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 158 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions LSB2RS (151ft)/LSB4ES Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem corrected. (150 ft) Cross-check Rotate, and Propel powers in SCON. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 159 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Axle Extend/Retract Fault Check Axle extend/retract disabled. Display Check for defective or damaged wiring Switches message on LCD or switches. Power up controller with problem corrected.
Page 160 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Extend Power P10 Fault Check Display message on LCD PRI Power up controller with problem EXTEND POWER P10 FAULT corrected. Primary Up Power P11 Fault Check Display message on LCD PRI UP Power up controller with problem...
Page 161 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 162 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Turntable Rotate Clockwise Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring. Valve zero and neutral, Alarm sounds. Check for an open or shorted valve coil.
Page 163 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Safety Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded Sensor Y Direction sounds Value Too High Replace SCON Value Too Low Value at 0 V...
Page 164 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem corrected. Angle Sensor Rotate, and Propel. Boom Retract allowed and Boom Down allowed if fully retracted as sensed by LSB3RO.
Page 165 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Platform Level Sensor Y Value at 5.0 V Primary up and extend disabled, Alarm Power up controller with problem Direction sounds corrected. Value Too High Value Too Low Value at 0 V Just calibrated...
Page 166 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Jib Level (Bellcrank) Not Calibrated Normal function except threshold for Perform calibration procedure Up/Down Flow Valve(s) one or the other direction is zero. Display message on LCD.
Page 167 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Platform Rotate Switches Fault Check (both Primary Boom Up/Down disabled. Power up controller with problem buttons pressed) Display message on LCD corrected. Platform Level Switches Fault Check (both Primary Boom Ext/Ret disabled.
Page 168 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Front Axle Angle Sensor Value at 5.0 V Primary up and Extend disabled, axle Check for an open ground circuit extend and retract LED flash going to the sensor Value Too High Primary up and Extend disabled, axle...
Page 169 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Propel Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 170 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions Left Front Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit Sensor zero and neutral, Alarm sounds. going to the sensor Value Too High Limited Speed and Direction frozen at...
Page 171 December 2019 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Right Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit Sensor zero and neutral, Alarm sounds. going to the sensor Value Too High Limited Speed and Direction frozen at...
Page 172 Service and Repair Manual December 2019 Control System Fault Codes Error Source Error Type Effects Recovery Actions PBMAS Safety Envelope Position Check Disable Boom Up, TT Rotate, Propel Return Boom back inside Operational Envelope and Ignition/Fuel. Boom Down and Retract allowed. All functions allowed once boom is lowered back into envelope.
Page 173: Fault Matrix
December 2019 Service and Repair Manual Control System Fault Codes P_38 - Propel P_39 - Turntable P_10 - Primary P_11 - Primary P_9A - Primary P_9B - (P13-17 TCON) Rotate (P13-19 Boom Extend Up (P12-09 Down (P12-06 Ignition/Fuel TCON) (P12-08 TCON) TCON) TCON) (P12-07 TCON)
Page 174: Fault Code Source
Service and Repair Manual December 2019 Control System Fault Codes Fault Source and Type will display as: Fault Source Description Source Type SCON Controller Area Network “ ID XXX_xx FAULT “ Primary Boom Angle Zone Where XXX is the one to three digit Fault Source Primary Boom Length Switches Cross-Check and xx is the two digit Fault Type.
Page 175 December 2019 Service and Repair Manual Control System Fault Codes Fault Source Fault Source Description Description Turntable Level Sensor X-Direction Enable Output Power P7R Turntable Level Snesor Y-Direction Primary Down Power P9A Boom Length Sensors Cross-Check (SCON) IGN/Fuel Power P9B Boom Safety Envelope (SCON) Primary Extend Power P10 Turntable Controller - Platform Controller...
Page 176 Service and Repair Manual December 2019 Control System Fault Codes Fault Source Description Brake Valve Motor Shift Valve Chassis Tilt Sensors Cross-Check (SCON) Jib Bellcrank Level Sensor Jib Bellcrank Level Flow Valve AUX Relay Platform Level Toggle Switch Platform Rotate Toggle Switch Platform Level Flow Valve Platform Rotate Valve Boom Length Sensor...
Page 177: Deutz Td 2.9 L4 Engine Fault Codes
December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1022 Actuator error EGR-Valve; signal KWP = Keyword Protocol range check high SPN FMI Description 1224 Actuator EGR-Valve; over 1019 EGR-Valve, short circuit to current...
Page 178 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Sensor error ambient air press.; KWP = Keyword Protocol signal range check high SPN FMI Description Sensor error ambient air press.; signal range check low High oil pressure;...
Page 179 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier High low fuel temperature; KWP = Keyword Protocol warning threshold exceeded SPN FMI Description High Low fuel temperature; shut off threshold exceeded 1180 Physical range check high for...
Page 180 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008 Sensor error EGR cooler...
Page 181 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier Starter relay high side; short KWP = Keyword Protocol circuit to battery SPN FMI Description Starter relay low side; short circuit to battery Injector 1 (in firing order);...
Page 182 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature KWP = Keyword Protocol upstream turbine; shut off threshold exceeded SPN FMI Description 1180 3 1067...
Page 183 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error KWP = Keyword Protocol of short circuit to ground measurement cyl. Bank 1 SPN FMI Description 2798 4...
Page 184 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523008 Timeout error in Manipulation KWP = Keyword Protocol control FMI KWP Description 523009 Pressure Relief Valve (PRV) reached maximun allowed 4766 1029 Physical range check high for...
Page 185 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 Internal ECU monitoring detection reported error 523470 Maximum rail pressure in limp...
Page 186 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523615 Metering unit (Fuel-System); KWP = Keyword Protocol short circuit to battery low side FMI KWP Description 523615 Metering unit (Fuel-System);...
Page 187 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523897 check of missing injector KWP = Keyword Protocol adjustment value programming (IMA) injector 3 (in firing order) FMI KWP Description 523898 check of missing injector...
Page 188 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523936 Timeout Error of KWP = Keyword Protocol CAN-Transmit-Frame FMI KWP Description EEC3VOL2; Engine send messages 523922 1262 Burner Shut Off Valve;...
Page 189 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524016 1259 Amount of air is not plausible to KWP = Keyword Protocol pump speed FMI KWP Description 524016 1260 Calculated amount of air is not plausible to HFM reading...
Page 190 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524108 9 1669 Timeout error of KWP = Keyword Protocol CAN-Transmit-Frame KWP Description ComEGRTVActr 524109 9 1679 Timeout error of 524035 12 1341 Injector diagnostics;...
Page 191 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier KWP = Keyword Protocol KWP Description 524120 9 1682 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag 524121 9 1683 Timeout error of CAN-Receive-Frame ComRxTrbChActr 524122 9...
Page 192: Perkins 854F-34T Engine Fault Code
Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test Position :Voltage Above Normal Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test Position :Voltage Be- low Normal Accelerator Pedal Position 2 :Voltage Above...
Page 193 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test Engine Coolant Temperature :Voltage Above...
Page 194 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit- Above Normal Test Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -...
Page 195 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test Engine Injector Cylinder #02 :Data Drifted Low...
Page 196 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test Valve :Erratic, Intermittent, or Incorrect 1076 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test...
Page 197 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test Control:Current Below Normal 2791 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test Control :Current Above Normal 2791...
Page 198 Service and Repair Manual December 2019 Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test Temperature : High- least severe (1) 3219 After treatment #1 Intake Gas Sensor at Oxygen Level- Test...
Page 199 December 2019 Service and Repair Manual Control System Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Refer to Engine Manual 3702 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test Inhibited Status : Current Above Normal 4765 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -...
Page 200 Service and Repair Manual December 2019 This page intentionally left blank. ™ -180 Part No. 1268497GT...
Page 201: Before Troubleshooting
December 2019 Service and Repair Manual Schematics Section 5 About This Section Schem atics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.
Page 202: Wire Circuit Legend
Service and Repair Manual December 2019 Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
Page 203 December 2019 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 204 Service and Repair Manual December 2019 Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 205 December 2019 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 206: Wire Color Legend
Service and Repair Manual December 2019 Wire Color Legend Power Circuits Wire Coloring All cylinder extension colors are solid and all Primary up valve retract functions are striped black. When using Ignition/Fuel black wire, the stripe shall be white. Primary boom extend valve All rotations that are LEFT or CW are solid, Primary boom up valve RIGHT or CCW are striped and black.
Page 207 December 2019 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function WH/RD Power to temp sender Primary boom up driver Auxiliary Power RD/BK Primary boom down driver RD/BK Platform level alarm RD/WH Primary boom up/down flow control proportional valve driver RD/WH...
Page 208 Service and Repair Manual December 2019 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 209 December 2019 Service and Repair Manual 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 210 Service and Repair Manual December 2019 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 211: Limit Switches And Angle Sensors
December 2019 Service and Repair Manual Limit Switches and Angle Sensors Types of Limit Switches Numbering Legend There are two types of limit switches, found in Limit Front Circuit Load Operational various locations throughout the machine: Switch Axle Number moment mechanical-type operational/safety switches and Stringpot Rear...
Page 212 Service and Repair Manual December 2019 Limit Switches and Angle Sensors Switches and Sensors - Primary Boom Index Description Schematic Item Function Controlled Switch Type and Operation Boom #0 - 151ft (boom fully LSB2RO Activates P1 lockout valve Normally open switch retracted) Operational Limit Switch during retract.
Page 213 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 214 Service and Repair Manual December 2019 Limit Switches and Angle Sensors Switches and Sensors - Drive Chassis Index Description Schematic Item Function Controlled Switch Type and Operation Front Axle #1Extended Safety Limit LSFA1ES Disables boom functions when Normally open Switch. axles are retracted.
Page 215: Circuit Connector Legend
December 2019 Service and Repair Manual Circuit Connector Legend Number Description Number Description Molex connector on toggle/LED pcb 2 pin Deutsch DTP connector (swivel-lower) Ribbon connector from TCON to membrane 6 pin Deutsch DTP connector (swivel-lower) 6 pin Deutsch DT connector for platform tilt Ribbon connector from TCON to membrane sensor (S6) 4 pin Deutsch DTP connector for throttle...
Page 216 Service and Repair Manual December 2019 Circuit Connector Legend Number Description Number Description 2 pin Deutsch DT two speed motor stroke J135 2 pin Deutsch DT jib bellcrank up valve (Y85) valve (Y27) J136 2 pin Deutsch DT jib bellcrank down valve 2 pin Deutsch DT RR steer right valve (Y55) (Y86) 2 pin Deutsch DT RR steer left valve (Y56)
Page 217 December 2019 Service and Repair Manual Circuit Connector Legend Number Description Number Description J160 6 pin Deutsch DT front axle sensor (RSFA10) J210 2 pin Deutsch DT 10 deg angle oper (LSB1DO) J161 6 pin Deutsch DT rear axle sensor (RSRA10) J211 4 pin Deutsch DT 3ft extend oper (LSB3RO) J162...
Page 218: Connector Pin Legend
Service and Repair Manual December 2019 Connector Pin Legend Pin location - 4 pin Pin location - 23 pin Pin location - 35 pin connector connector connector Pin location - 12 pin connector Abbreviation High Current On/Off Solenoid Output (3 < x < 6 Amps) Medium Current On/Off Solenoid Output (0.5 <...
Page 219 December 2019 Service and Repair Manual Connector Pin Legend J11 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P11-01 P CON G ND GNDPCON-BR PCON ground P11-02 P CON P OWE R P 52PCON-WH Power output to PCON. Unregulate d 12V auto motive power.
Page 220 Service and Repair Manual December 2019 Connector Pin Legend J12 Black 35 Pin Connector Pin No. Type Signal Name Circuit No. Signal Description P12-01 SCON ECU GND SCONGND-BR Ground for SCON ECU P12-02 DCON ECU PWR P21DCON-WH 12V power for ECU power P12-03 P_6R1 P53LS-WH/BK...
Page 221 December 2019 Service and Repair Manual Connector Pin Legend J13 White 23 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description P13-01 VALVE_RETURN_1 Valve ground return (return for throttle RPM solenoid) P13-02 THROTTLE C35RPM-BK/RD Provides power to throttle actuator relay P13-03 FUEL/IGNITION C21IGN-WH...
Page 222 Service and Repair Manual December 2019 Connector Pin Legend J14 White 35 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description P14-01 VALVE_RETURN_4 VLVRET4-BR Valve ground return P14-02 PRI BM U/D FC VLV #2 V03PUD2-GR/WH Proportional PWM valve drive (primary boom up/down valve #2 -GROSS-) P14-03 PRI BM E/R FC VLV...
Page 223 December 2019 Service and Repair Manual Connector Pin Legend J17 - 16 Pin Connector Pin NO. Type Signal Name Circuit NO. Signal Description J17-1 PWR TO TCON ESTOP BL/BK Power to TCON E-Stop (P1) J17-2 NOT USED J17-3 SERV/CAL MODE Service/calibration mode signal J17-4 CONT...
Page 224 Service and Repair Manual December 2019 Connector Pin Legend J21 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P21-01 PCON GND GNDPCON-BR PCON ground P21-02 PCON PWR P52PCON-WH Power for PCON P21-03 NOT USED P21-04 CONT S56PRV-RD 12V when footswitch is pressed...
Page 225 December 2019 Service and Repair Manual Connector Pin Legend J22 White 35 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P22-01 VALVE_RETURN_1 VLVRET1-BR Valve ground return P22-02 SPARE OM ON/OFF valve drive P22-03 PLAT ROT CCW V18PRR-GR/BK ON/OFF valve drive (platform rotate CCW - right) P22-04 PLAT ROT CW...
Page 226 Service and Repair Manual December 2019 Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J29-1 JOYSTICK_GND_2 JSGND2-BR Joystick signal ground (JC8) J29-2 JOYSTICK_GND_3 JSGND3-BR Joystick signal ground (JC2) J29-3 SNSR JOYSTICK_PWR_2 P162JPW2-OR Joystick power (JC8) J29-4 SNSR JOYSTICK_PWR_3 P162JPW3-OR...
Page 227 December 2019 Service and Repair Manual Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J169-1 JIB ROTATE C213JRS-RD/BK Jib rotate CW/CCW signal from jib joystick (JC8) J169-2 GND4-BR Joystick case ground (JC7) J169-3 JIB UP/DOWN C156JUD-GR/WH Jib up/down signal from jib joystick (JC8)
Page 228 Service and Repair Manual December 2019 Connector Pin Legend Circuit Board Connector Pin NO. Type* Signal Name Circuit NO. Signal Description J1-1 PWR-HORN HORN PWR-RD Power for Service Horn button J1-2 RET-HORN HORN RET-GR Return for Service Horn button J1-3 GENERATOR ON/OFF GEN ON/OFF-GR/WH Generator toggle switch input J1-4...
Page 229 December 2019 Service and Repair Manual Connector Pin Legend J31 Black 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P31-01 DCON ECU GND GNDDCON-BR DCON ground P31-02 DCON ECU PWR P21DCON-WH Power for DCON P31-03 P_6R1 P53LS-WH/BK Power for motor speed and brake valves P31-04...
Page 230 Service and Repair Manual December 2019 Connector Pin Legend J32 White 23 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P32-01 VALVE_RETURN_1 VLVRET1-BR Valve ground return P32-02 AXLE RETRACT V61AXRT-GR ON/OFF valve drive (axle retract) P32-03 AXLE EXTEND V60AXEX-GR/WH ON/OFF valve drive (axle extend) P32-04...
Page 231 December 2019 Service and Repair Manual Connector Pin Legend J121 Gray 12 Pin Connector Pin NO. Type* Signal Name Circuit NO. Signal Description P121-01 LOAD SENSE S132LDS-BL/WH Digital input from load sense switch P121-02 LSB3RS+LSB2RS S42BRT-OR/RD Digital input from LSB3RS+LSB2RS limit (FULLY RETRACTED) switches P121-03...
Page 232: Engine Relay And Fuse Panel Legend - Deutz Td2011L04I And Perkins
Service and Repair Manual December 2019 Engine Relay and Fuse Panel Legend - Deutz TD2011L04i and Perkins 1104D-44T Models Number Component Description CR77A PCE#1 CR28 Engine / Fuel Relay CR17 Hydraulic Oil Cooler Fan Relay CR77B PCE#2 CR41 Flashing Beacon Relay Horn Relay Fuse, 20A, RPM Solenoid Fuse, 30A, Eng / Start / Alt...
Page 233: Engine Relay And Fuse Panel Legend - Deutz Td 2.9 L4 Models
December 2019 Service and Repair Manual Engine Relay and Fuse Panel Legend - Deutz TD 2.9 L4 Models Number Component Description CR39 Engine Shutdown CR77A PCE #1 Engine Alt. Relay CR17 Hydraulic Oil Cooler / Fan Relay CR28 Fuel Pump CR77B PCE #2 CR41...
Page 234: Engine Relay And Fuse Panel Legend - Perkins 854F-34T Models
Service and Repair Manual December 2019 Engine Relay and Fuse Panel Legend - Perkins 854F-34T Models Number Component Description CR77A PCE#1 Engine Alt CR17 Hydraulic Oil Cooler Fan Relay CR77B PCE#2 Fuse, 30A, ECU Power Fuse, 20A, Key Switch Power CR41 Flashing Beacon Relay Horn Relay...
Page 235: Electrical Symbols Legend
December 2019 Service and Repair Manual Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch Circuit connection Limit Switch Power relay Coil with suppression Fuel or RPM solenoid Connection - no Circuits crossing no Quick disconnect Circuit breaker with...
Page 236: Hydraulic Symbols Legend
Service and Repair Manual December 2019 Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve or motor) 3 way...
Page 237: Electrical Schematics - Control Circuits
December 2019 Service and Repair Manual Control Circuits - Horn...
Page 238: Control Circuits - Horn
Service and Repair Manual December 2019 Control Circuits - Horn ™ -180 Part No. 1268497GT...
Page 239: Control Circuits - Power
December 2019 Service and Repair Manual Control Circuits - Power Part No. 1268497GT ™ -180...
Page 240 Service and Repair Manual December 2019 Control Circuits - Power...
Page 241 December 2019 Service and Repair Manual Control Circuits - Can Bus...
Page 242: Control Circuits - Can Bus
Service and Repair Manual December 2019 Control Circuits - Can Bus ™ -180 Part No. 1268497GT...
Page 243: Control Circuits - Deutz Td2011L04I Engine
December 2019 Service and Repair Manual Control Circuits - Deutz TD2011L04i Engine Part No. 1268497GT ™ -180...
Page 244 Service and Repair Manual December 2019 Control Circuits - Deutz TD2011L04i Engine...
Page 245 December 2019 Service and Repair Manual Control Circuits - Deutz TD 2.9 L4Engine...
Page 246: Control Circuits - Deutz Td 2.9 L4Engine
Service and Repair Manual December 2019 Control Circuits - Deutz TD 2.9 L4 Engine ™ -180 Part No. 1268497GT...
Page 247: Control Circuits - Perkins 1104D-44T Engine
December 2019 Service and Repair Manual Control Circuits - Perkins 1104D-44T Engine Part No. 1268497GT ™ -180...
Page 248 Service and Repair Manual December 2019 Control Circuits - Perkins 1104D-44T Engine...
Page 249 December 2019 Service and Repair Manual Control Circuits - Perkins 854F-34T Engine...
Page 250: Control Circuits - Perkins 854F-34T Engine
Service and Repair Manual December 2019 Control Circuits - Perkins 854F-34T Engine ™ -180 Part No. 1268497GT...
Page 251: Control Circuits - Axle Extend/Retract
December 2019 Service and Repair Manual Control Circuits - Axle Extend/Retract Part No. 1268497GT ™ -180...
Page 252 Service and Repair Manual December 2019 Control Circuits - Axle Extend/Retract...
Page 253 December 2019 Service and Repair Manual Control Circuits - Steering...
Page 254: Control Circuits - Steering
Service and Repair Manual December 2019 Control Circuits - Steering ™ -180 Part No. 1268497GT...
Page 255: Control Circuits - Propel
December 2019 Service and Repair Manual Control Circuits - Propel Part No. 1268497GT ™ -180...
Page 256 Service and Repair Manual December 2019 Control Circuits - Propel...
Page 257 December 2019 Service and Repair Manual Control Circuits - Turntable Rotate...
Page 258: Control Circuits - Turntable Rotate
Service and Repair Manual December 2019 Control Circuits - Turntable Rotate ™ -180 Part No. 1268497GT...
Page 259: Control Circuits - Boom Up/Down
December 2019 Service and Repair Manual Control Circuits - Boom Up/Down Part No. 1268497GT ™ -180...
Page 260 Service and Repair Manual December 2019 Control Circuits - Boom Up/Down...
Page 261 December 2019 Service and Repair Manual Control Circuits - Boom Extend/Retract...
Page 262: Control Circuits - Boom Extend/Retract
Service and Repair Manual December 2019 Control Circuits - Boom Extend/Retract ™ -180 Part No. 1268497GT...
Page 263: Control Circuits - Jib Up/Down, Jib Rotate And Platform Rotate
December 2019 Service and Repair Manual Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate Part No. 1268497GT ™ -180...
Page 264 Service and Repair Manual December 2019 Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate...
Page 265 December 2019 Service and Repair Manual Control Circuits - Platform Level and Jib Bellcrank Level...
Page 266: Control Circuits - Platform Level And Jib Bellcrank Level
Service and Repair Manual December 2019 Control Circuits - Platform Level and Jib Bellcrank Level ™ -180 Part No. 1268497GT...
Page 267: Control Circuits - Platform Load Sense
December 2019 Service and Repair Manual Control Circuits - Platform Load Sense Part No. 1268497GT ™ -180...
Page 268 Service and Repair Manual December 2019 Control Circuits - Platform Load Sense...
Page 269 December 2019 Service and Repair Manual Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights...
Page 270: Control Circuits - Flashing Beacons, Oil Cooler And Drive/Work Lights
Service and Repair Manual December 2019 Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights ™ -180 Part No. 1268497GT...
Page 271: Control Circuits - Recovery Pld
December 2019 Service and Repair Manual Control Circuits - Recovery PLD Part No. 1268497GT ™ -180...
Page 272 Service and Repair Manual December 2019 Control Circuits - Recovery PLD...
Page 273 December 2019 Service and Repair Manual Control Circuits - Telematics...
Page 274: Control Circuits - Telematics
Service and Repair Manual December 2019 Control Circuits - Telematics ™ -180 Part No. 1268497GT...
Page 275: Generator Receptacle Wiring- Ansi/Csa
December 2019 Service and Repair Manual Generator Receptacle Wiring- ANSI/CSA Part No. 1268497GT ™ -180...
Page 276 Service and Repair Manual December 2019 Generator Receptacle Wiring - ANSI/CSA...
Page 277 December 2019 Service and Repair Manual Generator Receptacle Wiring - CE...
Page 278: Generator Receptacle Wiring- Ce
Service and Repair Manual December 2019 Generator Receptacle Wiring - CE ™ -180 Part No. 1268497GT...
Page 279: Perkins 1104D-44T Engine Electrical Schematic
December 2019 Service and Repair Manual Perkins 1104D-44T Engine Electrical Schematic Part No. 1268497GT ™ -180...
Page 280 Service and Repair Manual December 2019 Perkins 1104D-44T Engine Electrical Schematic...
Page 281 December 2019 Service and Repair Manual Perkins 854F-34T Engine Electrical Schematic...
Page 282: Perkins 854F-34T Engine Electrical Schematic
Service and Repair Manual December 2019 Perkins 854F-34T Engine Electrical Schematic ™ -180 Part No. 1268497GT...
Page 283: Perkins 854F-34T Engine Harness
December 2019 Service and Repair Manual Perkins 854F-34T Engine Harness Part No. 1268497GT ™ -180...
Page 284 Service and Repair Manual December 2019 Perkins 854F-34T Engine Harness...
Page 285 December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Electrical Schematic...
Page 286: Deutz Td 2.9 L4 Engine Electrical Schematic
Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Electrical Schematic ™ -180 Part No. 1268497GT...
Page 287: Deutz Td 2.9 L4 Engine Harness
December 2019 Service and Repair Manual Deutz TD 2.9 L4 Engine Harness Part No. 1268497GT ™ -180...
Page 288 Service and Repair Manual December 2019 Deutz TD 2.9 L4 Engine Harness...
Page 289: Hydraulic Schematics
December 2019 Service and Repair Manual Hydraulic Schematic, to SX180H-604...
Page 290: Hydraulic Schematic, To Sx180H-604
Service and Repair Manual December 2019 Hydraulic Schematic, to SX180H-604 ™ -180 Part No. 1268497GT...
Page 291: Hydraulic Schematic, From Sx180H-605 To Sx180H-612
December 2019 Service and Repair Manual Hydraulic Schematic, from SX180H-605 to SX180H-612 Part No. 1268497GT ™ -180...
Page 292 Service and Repair Manual December 2019 Hydraulic Schematic, from SX180H-605 to SX180H-612...
Page 293: Hydraulic Schematic, From Sx180H-613
December 2019 Service and Repair Manual Hydraulic Schematic, from SX180H-613 Part No. 1268497GT ™ -180...
Page 294 Service and Repair Manual December 2019 Hydraulic Schematic, from SX180H-613...
Page 295: Electrical Schematic, To Sx180H-318
TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 from SX180H-101 to SX180H-318 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE...
Page 296: Electrical Schematic, From Sx180H-319 To Sx180H-612
TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 from SX180H-319 to SX180H-612 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE...
Page 297: Electrical Schematic, From Sx180H-613
TCON MEMBRANE PANEL (MS2) SX-180 ELECTRICAL SCHEMATIC with Deutz TD2011L04i Engine PRIMARY BOOM UP/DOWN SERVICE PCON HORN AND TURNTABLE PRIMARY BOOM JIB UP/DOWN AND TS17 TS15 TS23 TS22 from SX180H-613 PCON PLATFORM PLATFORM E-STOP ROTATE DRIVE & STEERING AUXILIARY START ENGINE DRIVE AXLE...

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Terex SX180H-744 Service And Repair Manual

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