This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Service and Repair Manual
Serial Number Range
SX™-150 from SX15015H-101 to

SX15016H-499
This manual includes:
Repair procedures
from SX150H-500 Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance

procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1268496

Rev A4
December 2018
Service and Repair Manual December 2018
Introduction
Intr oducti on Intr oducti on
Important Technical Publications

Read, understand and obey the safety rules and Genie has endeavored to deliver the highest
operating instructions in the appropriate Operator's degree of accuracy possible. However, continuous
Manual on your machine before attempting any improvement of our products is a Genie policy.
procedure. Therefore, product specifications are subject to
change without notice.
This manual provides troubleshooting and repair
procedures for qualified service professionals. Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
Basic mechanical, hydraulic and electrical skills are communications will be carefully considered for
required to perform most procedures. However, future printings of this and all other manuals.
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that Contact Us:
maintenance and repair be performed at an
authorized Genie dealer service center. Internet: www.genielift.com
E-mail: [email protected]
Compliance Find a Manual for this Model

Go to http://www.genielift.com
Machine Classification
Use the links to locate Service Manuals,
Group B/Type 3 as defined by ISO 16368
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
Copyright © 2015 by Terex Corporation

1268496 Rev A3, October 2018
First Edition, First Printing
Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries.
ii SX-150 Part No. 1268496

December 2018 Service and Repair Manual
Introduction
Revision History
Revision Date Section Procedure / Page / Description
A 9/2015 Initial Release
A1 9/2016 Introduction Serial Number Legend
A2 6/2017 Repair 8-3 Platform Level and Rotation Manifold
8-4 Jib Boom Manifold
8-5 Function Enable Manifold
Fault Codes Fault Code Source
A3 10/2018 Repair 8-3A Platform Level and Rotation Manifold
8-4A Jib Boom Manifold
Schematics Electrical Schematics
A4 12/2018 Specifications Rotate hub torque value
Reference Examples:
Section – Repair Procedure, 4-2 Electronic Version
Click on any content or procedure in the Table of Contents to view
Section – Fault Codes, All charts the update.
Section – Schematics, Legends and schematics
Part No. 1268496 SX-150 iii

Introduction
Serial Number Legend

To August 31, 2016
1 Model 1 Sequence number

2 Model year 2 Serial label (located under cover)
3 Facility code 3 Serial number (stamped on chassis)
From September 1, 2016
1 Model 1 Serial label (located under cover)

2 Facility code 2 Serial number (stamped on chassis)
3 Sequence number
iv SX-150 Part No. 1268496

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.
Do Not Perform Maintenance

Unless:
R You are trained and qualified to perform
maintenance on this machine.
R You read, understand and obey:
· manufacturer's instructions and safety rules
· employer's safety rules and worksite
regulations
· applicable governmental regulations
R You have the appropriate tools, lifting
equipment and a suitable workshop.
Part No. 1268496 SX-150 v

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. machine should be your top priority.
Read each procedure thoroughly. This Be sure to keep sparks, flames and lighted
manual and the decals on the machine, tobacco away from flammable and
use signal words to identify the following: combustible materials like battery gases
and engine fuels. Always have an
Safety alert symbol—used to alert approved fire extinguisher within easy
personnel to potential personal reach.
injury hazards. Obey all safety
messages that follow this symbol Be sure that all tools and working areas
to avoid possible injury or death. are properly maintained and ready for
use. Keep work surfaces clean and free of
Indicates a imminently hazardous debris that could get into machine
situation which, if not avoided, will components and cause damage.
result in death or serious injury.
Be sure any forklift, overhead crane or
Indicates a potentially hazardous other lifting or supporting device is fully
situation which, if not avoided, capable of supporting and stabilizing the
could result in death or serious weight to be lifted. Use only chains or
injury. straps that are in good condition and of
ample capacity.
Indicates a potentially hazardous
situation which, if not avoided, Be sure that fasteners intended for one
may cause minor or moderate time use (i.e., cotter pins and self-locking
injury. nuts) are not reused. These components
may fail if they are used a second time.
situation which, if not avoided, Be sure to properly dispose of old oil or
may result in property damage. other fluids. Use an approved container.
Please be environmentally safe.
Be sure to wear protective eye wear and
other protective clothing if the situation Be sure that your workshop or work area
warrants it. is properly ventilated and well lit.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel-toed shoes.
vi SX-150 Part No. 1268496

December 2018
Table of Contents
Introduction Introduction........................................................................................................... ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend .......................................................................................... iv
Section 1 Safety Rules .......................................................................................................... v

General Safety Rules ............................................................................................. v
Section 2 Specifications ....................................................................................................... 1

Machine Specifications ........................................................................................... 1
Performance Specifications .................................................................................... 2
Hydraulic Oil Specifications .................................................................................... 3
Hydraulic Component Specifications...................................................................... 5
Manifold Component Specifications ....................................................................... 6
Deutz TD2011L04i Engine Specifications .............................................................. 7
Deutz TD 2.9 Engine Specifications ....................................................................... 8
Perkins 1104D-44T Engine Specifications ............................................................. 9
Perkins 854F-34T Engine Specifications ............................................................. 11
Machine Torque Specifications ............................................................................ 12
Hydraulic Hose and Fitting Torque Specifications ............................................... 13
Torque Procedure ................................................................................................ 14
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 ............. 25
How to Adjust the Function Speeds ................................................................ 27
How to Adjust the Function Ramp Rate Setting.............................................. 28
Part No. 1268496 SX-150 vii

December 2018
Table of Contents
Platform Components ........................................................................................29

2-1 Platform ..........................................................................................................29
2-2 Platform Leveling Cylinder .............................................................................30
2-3 Platform Rotator .............................................................................................31
How to Bleed the Platform Rotator ..................................................................32
2-4 Platform Level Sensor ....................................................................................33
2-5 Platform Overload System (if equipped) ........................................................34
2-6 Platform Overload Recovery Message ..........................................................36
Jib Boom Components ......................................................................................38

3-1 Jib Boom.........................................................................................................39
3-2 Jib Boom Lift Cylinder ....................................................................................40
3-3 How to Remove the Jib Boom Bellcrank ........................................................41
3-4 Jib Boom Bellcrank Angle Sensor ..................................................................42
Boom Components ............................................................................................45

4-1 Primary Boom Cable Track ............................................................................46
4-2 Primary Boom .................................................................................................48
How to Remove the Primary Boom .................................................................49
How to Disassemble the Primary Boom ..........................................................51
4-3 Primary Boom Lift Cylinder.............................................................................55
4-4 Extension Cylinder .........................................................................................57
4-5 Boom Extend and Retract Cables ..................................................................60
How to Replace the Boom Extend/Retract Cables .........................................65
4-6 Primary Boom Angle Sensor ..........................................................................68
4-7 Boom Length Sensor ......................................................................................71
Engines ................................................................................................................74
5-1 RPM Adjustment ............................................................................................74
5-2 Flex Plate........................................................................................................74
How to Install the Flex Plate ............................................................................75
viii SX-150 Part No. 1268496

December 2018
Table of Contents
Ground Controls ................................................................................................. 76

6-1 Bypass/Recovery Key Switch ........................................................................ 76
How to Use the Recovery Mode ..................................................................... 77
6-2 Circuit Boards ................................................................................................. 78
6-3 Membrane Decal ............................................................................................ 80
6-4 Full Machine Calibration................................................................................. 81
Display Module ................................................................................................... 83
Hydraulic Pumps ................................................................................................ 90

7-1 Function Pump ............................................................................................... 90
How to Prime the Function Pump ................................................................... 91
How to Adjust the Function Pump Standby Pressure ..................................... 91
How to Adjust the Function Pump Pressure Compensator ............................ 93
7-2 Drive Pump..................................................................................................... 94
How to Prime the Drive Pump ......................................................................... 96
Manifolds ............................................................................................................. 98
8-1 Function Manifold ........................................................................................... 98
8-2 Valve Adjustments - Function Manifold ........................................................ 104
8-3 Platform Level and Rotation Manifold to SN SX150H-518 ......................... 106
8-3A Platform Level and Rotation Manifold from SN SX150H-619................... 107
8-4 Jib Boom Manifold to SN SX150H-518 ........................................................ 108
8-4A Jib Boom Manifold from SN SX150H-519 ................................................. 109
8-5 Function Enable Manifold............................................................................. 110
8-6 Steer and Axle Manifold ............................................................................... 112
8-7 Valve Adjustments - Steer and Axle Manifold .............................................. 116
8-8 Traction Manifold Components .................................................................... 117
8-9 Valve Adjustments - Traction Manifold ........................................................ 121
8-10 Generator Manifold Component ................................................................. 122
8-11 Valve Coils ................................................................................................. 123
Turntable Rotation Components .................................................................... 125

9-1 Turntable Rotation Assembly ....................................................................... 125
How to Adjust the Turntable Rotation Gear Backlash .................................. 126
9-2 Turntable Level Sensor ................................................................................ 127
Part No. 1268496 SX-150 ix

December 2018
Table of Contents
Axle Components .............................................................................................130

10-1 Steer Sensors .............................................................................................130
How to Calibrate a Replacement Steer Sensor ............................................132
How to Calibrate All Steer Sensors ...............................................................133
10-2 Steer Cylinders ...........................................................................................135
10-3 Axle Extension Cylinders............................................................................136
10-4 Axle Angle Sensors ....................................................................................137
Generators.........................................................................................................139
11-1 Welder Generator .......................................................................................139
Section 4 Fault Codes .......................................................................................................140

Introduction .........................................................................................................140
Control System Fault Codes ...........................................................................141

Fault Matrix .........................................................................................................160
Fault Code Source ..............................................................................................161
Deutz TD 2.9 L4 Engine Fault Codes .................................................................164
Perkins 854F-34T Engine Fault Code ................................................................179
Section 5 Schematics ........................................................................................................188

Introduction .........................................................................................................188
Wire Circuit Legend ............................................................................................189
Wire Color Legend ..............................................................................................193
Limit Switches and Angle Sensors .....................................................................198
Circuit Connector Legend ...................................................................................202
Connector Pin Legend ........................................................................................205
Engine Relay and Fuse Panel Legend-
Deutz TD2011 and Perkins 1104D Models ................................................219
Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models ............................220
Engine Relay and Fuse Panel Legend- Perkins 854F Models ...........................221
Telematics Connector Pin Legend .....................................................................222
Electrical Symbols Legend .................................................................................223
Hydraulic Symbols Legend .................................................................................224
x SX-150 Part No. 1268496

December 2018
Table of Contents
Electrical Schematics – Control Circuits ....................................................... 225

Control Circuits - Horn ........................................................................................ 226
Control Circuits - Power ..................................................................................... 227
Control Circuits - Can Bus .................................................................................. 230
Control Circuits - Deutz TD2011L04i Engine ..................................................... 231
Control Circuits - Deutz 2.9 Engine .................................................................... 234
Control Circuits - Perkins 1104D-44T Engine .................................................... 235
Control Circuits - Perkins 854 Engine ................................................................ 238
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 ........................ 251
Control Circuits - Platform Level and Jib Bellcrank Level .................................. 254
Control Circuits - Platform Load Sense .............................................................. 255
Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights ............ 258
Control Circuits - Recovery PLD ........................................................................ 259
Control Circuits - Telematics .............................................................................. 262
Generator Receptacle Wiring- ANSI/CSA .......................................................... 263
Generator Receptacle Wiring- CE ...................................................................... 266
Perkins 1104D-44T Engine Electrical Schematic ............................................... 267
Perkins 854F-34T Engine Electrical Schematic ................................................. 270
Perkins 854F-34T Engine Harness .................................................................... 271
Deutz TD2.9 Engine Electrical Schematic ......................................................... 274
Deutz TD2.9 Engine Harness............................................................................. 275
Hydraulic SchematicsH ................................................................................... 277

Hydraulic Schematic to SX150H-518 ................................................................. 278
Hydraulic Schematic from SX150H-519 ............................................................. 279
Electrical Schematic to SN SX150H-518 ........................................................... 281
Electrical Schematic from SN SX150H-519 ....................................................... 282
Part No. 1268496 SX-150 xi

Specifications
Section 2 Specific ati ons
Machine Specifications
Tires and wheels
Tire size 445D50/710, FF
Tire ply rating 18
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
Wheel width 15 in
38.1 cm
Wheel lugs 10 @ 3/4 - 16
Lug nut torque, dry 320 ft-lbs
434 Nm
Fluid capacities
Fuel tank 50 gal
189 liters
Hydraulic tank 110 gal
416 liters
Hydraulic system (including tank) 175 gal
663 liters
Drive hubs 67 fl oz
1981 cc
Turntable rotation drive hub 43 fl oz
1262 cc
Drive hub oil type: SAE 90 multipurpose hypoid
gear oil API service classification GL5
For operational specifications, refer to the

Operator's Manual.
Continuous improvement of our products is a
Genie policy. Product specifications are
subject to change without notice or obligation.
Part No. 1268496 SX-150 1

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
36ft / 8.9 sec Primary boom extend/retract 30 - 33 sec /
11 m / 8.9 sec 0 - 100 in / 254 cm
Raised or extended 0.4 mph Primary boom up/down (stowed) 80 - 88 sec / 82°
0.64 km/h Primary boom up/down 100 - 110 sec / 82°
36 ft / 62-68 sec (stringpot = 76 in / 193 cm)
11 m / 62-68 sec
Primary boom up/down 45 - 50 sec / 20°
Boom above 125 ft / 38.1 m 0.1 mph (stringpot = 158 in / 401 cm)
0.16 km/h
18 ft / 124 - 132 sec Primary boom up/down 71 - 80 sec / 20°
5.5 m / 124 - 132 sec (stringpot = 238 in / 605 cm)
Braking distance, maximum Primary boom up/down 26 - 31 sec / 5°

(stringpot = 370 in / 940 cm)
High range on paved surface 6 ft / 2 m
Turntable rotate, drive enable to 38 - 42 sec
Gradeability Refer to Operator's Manual drive enable (80°) fully stowed
drive enable (80°)
stringpot = 36 in / 91.4 cm
drive enable (80°)
stringpot = 76 in / 193 cm
(above 75 ft / 22.8 m)
drive enable (80°)
stringpot = 258 in / 655 cm (above
125 ft / 38.1 m)
For operational specifications, refer to the
Operator's Manual.
2 SX-150 Part No. 1268496

Specifications
Hydraulic Oil Specifications Do not top off with incompatible

hydraulic fluids. Hydraulic fluids
Hydraulic Fluid Specifications may be incompatible due to the
Genie specifications require hydraulic oils which are differences in base additive
designed to give maximum protection to hydraulic chemistry. When incompatible
systems, have the ability to perform over a wide fluids are mixed, insoluble
temperature range, and the viscosity index should materials may form and deposit
exceed 140. They should provide excellent antiwear, in the hydraulic system,
oxidation prevention, corrosion inhibition, seal plugging hydraulic lines, filters,
conditioning, and foam and aeration suppression control valves and may result in
properties.
component damage.
Cleanliness level, ISO 15/13
minimum Note: Do not operate the machine when the
Water content, 250 ppm ambient air temperature is consistently above
maximum 120°F / 49°C.
Recommended Hydraulic Fluid
Hydraulic oil type Chevron Rando HD Premium Hydraulic Fluid Temperature
Viscosity grade 32 Range
Viscosity index 200
Optional Hydraulic Fluids
Mineral based Shell Tellus S2 V 32
Shell Tellus S2 V 46
Shell Tellus S4 VX 32 Shell
Shell Donax TG (Dexron III)
Chevron 5606A
Biodegradable Petro Canada Environ MV 46
Fire resistant UCON Hydrolube HP-5046
Note: Genie specifications require additional
equipment and special installation instructions for Ambient air temperature
the approved optional fluids. Consult Genie Product
Support before use. 1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
Optional fluids may not have the 3 UCON Hydrolube HP-5046D
same hydraulic lifespan and 4 Chevron Rando HD premium oil MV
may result in component
damage.
Note: Extended machine operation can cause the

hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.
Part No. 1268496 SX-150 3

Specifications
Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

MV Fluid Properties Fluid Properties
ISO Grade 32 ISO Grade 15
Viscosity index 200 Viscosity index 300
Kinematic Viscosity Kinematic Viscosity
cSt @ 200°F / 100°C 7.5 cSt @ 200°F / 100°C 5.5
cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C 15.0
cSt @ -40°F / -40°C 510
Brookfield Viscosity
cP @ -4°F / -20°C 1040 Flash point 180°F / 82°C
cP @ -22°F / -30°C 3310 Pour point -81°F / -63°C
Flash point 375°F / 190°C Maximum continuous operating 124°F / 51°C
Pour point -58°F / -50°C temperature
Maximum continuous operating 171°F / 77°C Note: Use of Chevron 5606A hydraulic fluid, or
temperature equivalent, is required when ambient temperatures
Note: A hydraulic oil heating system is are consistently below 0°F / -17°C unless an oil
recommended when the ambient temperature is heating system is used.
consistently below 0°F / -18°C.
Continued use of Chevron
Note: Do not operate the machine when the 5606A hydraulic fluid, or
ambient temperature is below -20°F / -29°C with equivalent, when ambient
Rando HD Premium MV. temperatures are consistently
above 32°F / 0°C may result in
component damage
4 SX-150 Part No. 1268496

Specifications
Petro-Canada Environ MV 46 Hydraulic Component

Fluid Properties Specifications
ISO Grade 46 Drive Pump
Viscosity index 154 Type: bi-directional variable displacement piston pump
Kinematic Viscosity Displacement per revolution 2.8 cu in
cSt @ 200°F / 100°C 8.0 46 cc
cSt @ 104°F / 40°C 44.4
Flow rate @ 2450 rpm 30 gpm
Flash point 482°F / 250°C 114 L/min
Pour point -49°F / -45°C Drive pressure, maximum 3625 psi
Maximum continuous operating 180°F / 82°C 250 bar
temperature Charge Pump
Type gerotor
Shell Tellus S4 VX Fluid Displacement per revolution 0.85 cu in
13.9 cc
Properties Flow rate @ 2450 rpm 9 gpm
ISO Grade 32 34 L/min
Viscosity index 300 Charge pressure @ 2450 rpm 315 psi

Neutral position 21.7 bar
Kinematic Viscosity
cSt @ 200°F / 100°C 9 Function pump - Middle Pump
cSt @ 104°F / 40°C 33.8 Type: variable displacement piston pump
Brookfield Viscosity Displacement per revolution 0 to 1.8 cu in
cSt @ -4°F / -20°C 481 0 to 30 cc
cSt @ -13°F / -25°C 702.4
cSt @ -40°F / -40°C 2624 Flow rate @ 2450 rpm 0 to 20 gpm
0 to 76.4 L/min
Flash point >100
Pressure, maximum 2700 psi
Pour point -76°F / -60°C 183 bar
Maximum continuous operating 103°F / 75°C Pressure compensator 2700 psi
temperature 183 bar
Standby pressure 350 psi
24 bar
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade 46
Viscosity index 192
Kinematic Viscosity
cSt @ 149°F / 65°C 22
cSt @ 104°F / 40°C 46
cSt @ 0°F / -18°C 1300
Flash point None
Pour point -81°F / -63°C
Maximum continuous operating 189°F / 87°C
temperature
Part No. 1268496 SX-150 5

Specifications
Function pump - End Pump Brakes

Type variable Brake relief pressure 160 psi
displacement 11 bar
piston pump Drive Motors
Displacement per revolution 0 to 1.8 cu in
Displacement per revolution 1.19 cu in
0 to 30 cc
high speed: 19.5 cc
Flow rate @ 2450 rpm 0 to 20 gpm
Displacement per revolution 2.7 cu in
0 to 76.4 L/min
low speed 45 cc
Pressure, maximum 2900 psi
Hydraulic Filters
200 bar
High pressure filter: Beta 5 ≥1000
Pressure compensator 2900 psi
200 bar High pressure filter bypass pressure 102 psi
7 bar
Standby pressure 350 psi
24 bar Medium pressure filter Beta 3 ≥200
Auxiliary Pump Medium pressure filter bypass 51 psi
pressure 3.5 bar
Type fixed displacement
gear pump Hydraulic tank return filter 10 micron with
25 psi / 1.7 bar
Displacement per revolution 0.15 cu in bypass
2.47 cc
Drive motor case drain return filter Beta 10 ≥2
Function manifold
System relief valve pressure, 3200 psi Manifold Component
maximum 221 bar Specifications
Primary boom extend relief pressure 2500 psi
(measured at PTEST port) 172 bar Plug torque
Platform Manifold SAE No. 2 36 in-lbs / 4 Nm
Platform rotate and platform level 0.2 gpm SAE No. 4 10 ft-lbs / 13 Nm
flow regulator 0.76 L/min SAE No. 6 14 ft-lbs / 19 Nm
Steer/Axle Manifold SAE No. 8 38 ft-lbs / 51 Nm
Axle extend relief pressure 2400 psi SAE No. 10 41 ft-lbs / 55 Nm
165 bar
SAE No. 12 56 ft-lbs / 76 Nm
Traction Manifold
Hot oil relief pressure 250 psi
17.2 bar
6 SX-150 Part No. 1268496

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 4 135°C
Bore and Stroke 3.78 x 4.92 inches Oil Pressure switch
96 x 125 mm
Horsepower net intermittent @ 74 hp 11 - 24 Nm
2400 rpm 55 kW
Pressure switch point 22 psi
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle 1300 rpm Injection pump pressure, maximum 15,000 psi
High idle 2450 rpm 1034 bar
Compression ratio 17.5:1 Injector opening pressure 3046 psi

210 bar
Compression pressure pressure (psi or bar) of the
Fuel requirement
lowest cylinder must be at least 75% of the highest
cylinder For fuel requirements, refer to the engine Operator
Manual for your engine.
Governor centrifugal
mechanical Starter motor
Valve Clearance, cold Current draw, normal load 140 - 200A
Intake 0.012 in Cranking speed 250 - 350 rpm
0.3 mm Battery – Auxiliary power units
Exhaust 0.020 in Type 6V DC
0.5 mm
Quantity 2
Lubrication system
Battery capacity, maximum 285 AH
Oil pressure, hot (@ 2000 rpm) 40 to 60 psi
2.8 to 4.1 bar Reserve capacity @ 25A rate 745 minutes
Oil capacity (including filter) 12.8 quarts Battery – Engine starting and control system
12.1 liters Type 12V DC, Group 31
Oil viscosity requirements Quantity 1
-22°F to 86°F / -30°C to 30°C 5W-30 Battery capacity, maximum 1000A
(synthetic) Reserve capacity @ 25A rate 200 Minutes
-4°F to 104°F / -20°C to 40°C 10W-40 Alternator output 80A @ 14V DC
Above 5°F / -15°C 15W-40 Fan belt deflection 3/8 to 1/2 inch
Unit ships with 15W-40. Extreme operating 9 to 12 mm
temperatures may require the use of alternative
engine oils. For oil requirements, refer to the Engine
Operator Manual for your engine.
Part No. 1268496 SX-150 7

Specifications
Deutz TD 2.9 Engine Oil temperature switch

Displacement 177 cu. in 11 - 24 Nm
2.9 liters
Number of cylinders 4 135°C
Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch
92 x 110 mm
Horsepower net intermittent @ 74.2 hp 11 - 24 Nm
2600 rpm 55 kW
Induction system turbocharged 1.5 bar
Firing order 1-3-4-2 Fuel injection system Motorpal
Low idle, standby 1000 rpm Injection pump pressure, maximum 15,000 psi
Low idle, function enable 1500 rpm 1034 bar
High idle 2500 rpm Injector opening pressure 3046 psi

210 bar
Compression ratio 17.4:1
Fuel requirement
Compression pressure pressure (psi or bar) of the
For fuel requirements, refer to the engine Operator
cylinder
Starter motor
Governor electronic
Current draw, normal load 140 - 200A
Lubrication system
Cranking speed 250 - 350 rpm
2.8 to 4.1 bar Battery – Engine starting and control system
Oil capacity (including filter) 9.4 quarts Type 12V DC, Group 31
8.9 liters Quantity 1
Oil viscosity requirements Battery capacity, maximum 1000A
-22°F to 86°F / -30°C to 30°C 5W-30 Reserve capacity @ 25A rate 200 Minutes
(synthetic)
Alternator output 95A @ 14V DC
-4°F to 104°F / -20°C to 40°C 10W-40
Fan belt deflection 3/8 to 1/2 inch
Above 5°F / -15°C 15W-40 9 to 12 mm
Unit ships with 15W-40.
Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Manual for your engine.
8 SX-150 Part No. 1268496

Specifications
Perkins 1104D-44T Oil Pressure switch

Displacement 268.5 cu. in 11 - 24 Nm
4.4 liters
Number of cylinders 4 0.55 bar
Bore and Stroke 4.13 x 5 inches Oil Sensor Settings
105 x 127 mm
0 psi 10 ohms
Horsepower net intermittent @
2200 rpm 68 hp / 50.7 kW 50 psi 120 ohms
74 hp / 55.2 kW Fuel injection system
Induction system turbocharged Transfer pump pressure 10-12 psi /
Firing order 1-3-4-2 0.69-0.83 bar
Injection pressure (4264+116 psi) /
Low idle 1300 rpm
(294+8 bar)
High idle 2450 rpm
Fuel requirement
Compression ratio 18.2:1
Compression pressure pressure (psi or bar) of the Manual for your engine.
lowest cylinder must be at least 75% of the highest Starter motor
cylinder
Current draw, normal load 115A
Governor centrifugal
mechanical Cranking speed 200 - 250 rpm
Valve Clearance, cold Battery – Auxiliary power units
Intake 0.008 in Type 6V DC
0.2 mm Quantity 2
Exhaust 0.018 in Battery capacity, maximum 285 AH
0.45 mm
Reserve capacity @ 25A rate 745 minutes
Lubrication system
Battery – Engine starting and control system
Type 12V DC, Group 31
2.8 to 4.1 bar
Quantity 1
Oil capacity (including filter) 10.4 quarts
9.8 liters Battery capacity, maximum 1000A
Oil viscosity requirements Reserve capacity @ 25A rate 200 Minutes
-22°F to 86°F / -30°C to 30°C 5W-20

-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Unit ships with 15W-40. Extreme operating
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator
Part No. 1268496 SX-150 9

Specifications
Perkins 1104D-44T cont.

Engine coolant
Capacity 9.5 quarts
(engine only) 9 liters
Coolant temperature switch
11 - 24 Nm
110°C
Temperature Sensor Settings
215°F 37 ohms
102°C
170°F 78 ohms
82°C
Fan belt deflection 3/8 to 1/2 inch
9 to 12 mm
10 SX-150 Part No. 1268496

Specifications
Perkins 854F-34T Oil Pressure switch

Installation torque 18.4 ft-lbs
Displacement 207 cu. in 25 Nm
3.4 liters
Number of cylinders 4 0.82 bar
Bore and Stroke 3.89 x 4.33 inches Oil Sensor Settings
99 x 110 mm
0 psi 10 ohms
Horsepower net intermittent @
2500 rpm 50 psi 120 ohms
74 hp / 55.2 kW
Fuel injection system
Induction system turbocharged Transfer pump pressure 10-12 psi /
Firing order 1-3-4-2 0.69-0.83 bar
Standby speed 1000 rpm Injection pressure 23000 psi /
(1600 bar)
Low idle 1500 rpm
Fuel requirement
High idle 2450 rpm
Compression ratio 17.0:1 Manual for your engine.
Compression pressure pressure (psi or bar) of the Glow plugs
cylinder Initial load (0-10 sec) 80A
Continuous load (>10 sec) 40A
Governor Electronic
Starter motor
Lubrication system
Current draw, normal load 68A
2.8 to 4.1 bar Cranking speed 130 - 200 rpm
Minimum oil pressure 12 psi Battery – Auxiliary power units

0.82 bar Type 6V DC
Oil capacity (including filter) 7.7 quarts Quantity 2
7.3 liters
Battery capacity, maximum 285 AH
Oil viscosity requirements Reserve capacity @ 25A rate 745 minutes
-22°F to 86°F / -30°C to 30°C 5W-20 Battery – Engine starting and control system
-4°F to 104°F / -20°C to 40°C 10W-40 Type 12V DC, Group 31
Above 5°F / -15°C 15W-40 Quantity 1
Unit ships with 15W-40. Extreme operating Battery capacity, maximum 1000A
temperatures may require the use of alternative engine
oils. For oil requirements, refer to the Engine Operator Reserve capacity @ 25A rate 200 Minutes
Part No. 1268496 SX-150 11

Specifications
Perkins 854F-34T cont. Machine Torque Specifications

Engine coolant
Platform Rotator
Capacity 16.5 quarts
(50/50 extended life) 15.6 liters 1-8 center bolt, GR 5, dry 615 ft-lbs
834 Nm
Coolant temperature switch
3/8-16 bolts, GR 8, dry 35 ft-lbs*
Installation torque 18.4 ft-lbs *use blue thread locking compound 47.5 Nm*
25 Nm
Jib Boom Rotator
Maximum continuous temperature 226°F
108°C Rotate bearing mounting bolts 200 ft-lbs
271 Nm
Temperature Sensor Settings
Turntable rotate assembly
215°F 37 ohms
102°C Rotate bearing mounting bolts, lubricated 455ft-lbs
(30w motor oil) 617 Nm
170°F 78 ohms
82°C Rotate drive hub mounting bolts, dry 70 ft-lbs
95 Nm
Backlash plate mounting bolts, lubricated 320 ft-lbs
Fan belt deflection 3/8 to 1/2 inch 434 Nm
9 to 12 mm
Drive motors and hubs
Drive hub mounting bolts, lubricated 205 ft-lbs
288 Nm
Drive motor mounting bolts, dry 165 ft-lbs
224 Nm
Engine vibration isolators
Compressed height >0.375 in
Compressed height <0.625 in

12 SX-150 Part No. 1268496

Specifications
Hydraulic Hose and Fitting

Torque Specifications SAE O-ring Boss Port
Your machine is equipped with Parker Seal-Lok™ (tube fitting - installed into Aluminum)
(all types)
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends be SAE Dash Size Torque
torqued to specification when they are removed and -4 14 ft-lbs / 19 Nm
installed or when new hoses or fittings are installed. -6 23 ft-lbs / 31.2 Nm
-8 36 ft-lbs / 54.2 Nm
Seal-Lok™ Fittings -10 62 ft-lbs / 84 Nm
(hose end - ORFS) -12 84 ft-lbs / 114 Nm
SAE Dash Size Torque -16 125 ft-lbs / 169.5 Nm
-4 10 ft-lbs / 13.6 Nm -20 151 ft-lbs / 204.7 Nm
-6 30 ft-lbs / 40.7 Nm -24 184 ft-lbs / 249.5 Nm
-8 40 ft-lbs / 54.2 Nm
-10 60 ft-lbs / 81.3 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Adjustable Fitting Non-adjustable fitting

JIC 37° Fittings 1 jam nut
(swivel nut or hose connection)
SAE Dash Size Thread Size Flats
-4 7/16-20 2 SAE O-ring Boss Port
-6 9/16-18 1¼ (tube fitting - installed into Steel)
-8 3/4-16 1 SAE Dash Size Torque
-10 7/8-14 1 -4 ORFS / 37° (Adj) 15 ft-lbs / 20.3 Nm
-12 1 1/16-12 1 ORFS (Non-adj) 26 ft-lbs / 35.3 Nm
37° (Non-adj) 22 ft-lbs / 30 Nm
-16 1 5/16-12 1
-6 ORFS (Adj / Non-adj) 35 ft-lbs / 47.5 Nm
-20 1 5/8-12 1 37° (Adj / Non-adj) 29 ft-lbs / 39.3 Nm
-24 1 7/8-12 1 -8 ORFS (Adj / Non-adj) 60 ft-lbs / 81.3 Nm
37° (Adj / Non-adj) 52 ft-lbs / 70.5 Nm
-10 ORFS (Adj / Non-adj) 100 ft-lbs / 135.6 Nm
37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm
-12 (All types) 135 ft-lbs / 183 Nm
-16 (All types) 200 ft-lbs / 271.2 Nm
-20 (All types) 250 ft-lbs / 339 Nm
-24 (All types) 305 ft-lbs / 413.5 Nm
Part No. 1268496 SX-150 13

Specifications
Torque Procedure
JIC 37° fittings
Seal-Lok™ fittings 1 Align the tube flare (hex nut) against the nose
of the fitting body (body hex fitting) and tighten
1 Replace the O-ring. The O-ring must be
the hex nut to the body hex fitting to hand tight,
replaced anytime the seal has been broken.
approximately 30 in-lbs / 3.4 Nm.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger 2 Using a permanent ink marker, make a
tight. reference mark on one the flats of the hex nut
and continue the mark onto the body of the hex
Note: The O-ring in Parker Seal Lok™ fittings and
fitting. Refer to Illustration 1.
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the
O-ring field service kit (Genie part number 49612).
2 Lubricate the O-ring before installation.
3 Be sure the O-ring face seal is seated and
retained properly.
4 Position the tube and nut squarely on the face
seal end of the fitting, and tighten the nut finger
tight.
Illustration 1
5 Tighten the nut or fitting to the appropriate
torque. Refer to the appropriate torque chart in 1 hex nut
this section. 2 reference mark
6 Operate all machine functions and inspect the 3 body hex fitting
hose, fittings and related components to
confirm there are no leaks.
14 SX-150 Part No. 1268496

Specifications
3 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.
Note: The marks indicate the correct tightening
positions have been determined. Use the second
mark on the body hex fitting to properly tighten the
joint after it has been loosened.
Illustration 2
1 body hex fitting
2 reference mark
3 second mark
4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.
5 Operate all machine functions and inspect the
hose, fittings and related components to
confirm there are no leaks.
Part No. 1268496 SX-150 15

This page intentionally left blank.
16 SX-150 Part No. 1268496

Repair Procedures
Section 3 Repair Pr oc edures
Machine Configuration:
R 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
R Repair procedures shall be completed by a · The red Emergency Stop button in the off
person trained and qualified on the repair of this position at both the ground and platform
machine. controls
R Immediately tag and remove from service a · Wheels chocked
damaged or malfunctioning machine.
· All external AC power supply disconnected
R Repair any machine damage or malfunction from the machine
before operating the machine.
· Boom in the stowed position
· Turntable secured with the turntable rotation
Before Repairs Start: lock
R Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual on your machine.
R Be sure that all necessary tools and parts are
available and ready for use.
R Use only Genie approved replacement parts.
R Read each procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
Part No. 1268496 SX-150 17

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. Then to re-assemble,
perform the disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous

situation which, if not avoided, will

situation which, if not avoided,
could result in death or serious
injury.

may cause minor or moderate
injury.

may result in property damage.
Indicates that a specific result is expected after

performing a series of steps.
Indicates that an incorrect result has occurred
after performing a series of steps.
18 SX-150 Part No. 1268496

Platform Controls
1-1
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.
Refer to Repair Procedure, How to Calibrate a
Joystick.
How to Remove the Circuit Board

1 Push in the red Emergency Stop button to the
off position at both the ground and platform
controls.
2 Locate the cables that connect to the bottom of
the control box. Number each cable and its
location at the control box.
3 Disconnect the cables from the bottom of the
platform control box.
4 Remove the control cable receptacle retaining
fasteners from the bottom of the platform
control box.
5 Remove the platform control box lid retaining
fasteners. Open the control box lid.
6 Locate the circuit board mounted to the inside
of the platform control box.
Part No. 1268496 SX-150 19

Platform Controls
How to R emove the LED Circui t Board
7 Attach a grounded wrist strap to the ground How to Remove the LED Circuit
screw inside the control box.
Board
Electrocution/burn hazard. 1 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 controls.
watches and other jewelry. 2 Remove the platform control box lid retaining
fasteners. Open the control box lid.
Component damage hazard. 3 Locate the circuit board mounted to the inside
Electrostatic discharge (ESD) of the platform control box.
can damage printed circuit board
components. Maintain firm Electrocution/burn hazard.
contact with a metal part of the Contact with electrically charged
machine that is grounded at all circuits could result in death or
times when handling printed serious injury. Remove all rings,
circuit boards OR use a watches and other jewelry.
grounded wrist strap.
Component damage hazard.
8 Tag and carefully disconnect the wire Electrostatic discharge (ESD)
connectors from the circuit board. can damage printed circuit board
9 Tag and disconnect the ribbon cable from the components. Maintain firm
LED circuit board. contact with a metal part of the
machine that is grounded at all
10 Remove the circuit board mounting fasteners. times when handling printed
11 Carefully remove the circuit board from the circuit boards OR use a
control box. grounded wrist strap.
4 Tag and carefully disconnect the ribbon cables

from the membrane circuit board.
5 Remove the circuit board mounting fasteners.
6 Carefully remove the LED circuit board from
the platform control box lid. Do not lose the
plastic spacers.
Note: When installing the LED circuit board, be sure
the plastic spacers are installed between the circuit
board and the control box lid.
20 SX-150 Part No. 1268496

Platform Controls
1-2 3 Press the minus button twice, then press the

enter button twice.
Joysticks
4 Use the scroll button to scroll through the
menu until DELETE DRIVE JOYSTICK
How to Calibrate a Joystick DEFAULTS is displayed.
The joystick controllers on this machine utilize 5 Press the plus button to select YES, then
digital Hall Effect technology for proportional control. press the enter button.
If a joystick controller is disconnected or replaced, it 6 Do not start the engine.
must be calibrated before that particular machine
function will operate. 7 Locate the drive/steer joystick.
Note: The joystick must be calibrated before the 8 Move the drive/steer joystick full stroke in the
threshold, max-out or ramping can be set. forward direction and hold for 5 seconds, then
return to the center or neutral position.
Note: After each joystick is calibrated, check the
9 Move the drive/steer joystick full stroke in the
display at the ground control box. There should be
reverse direction and hold for 5 seconds, then
no calibration faults shown on the display. If
calibration faults exist, repeat procedure for that
joystick controlled function. Result: The alarm at the ground controls
should sound for a successful calibration.
Note: If Joystick Not Calibrated is displayed at the
ground control box, proceed to step 7 for that
joystick controlled function procedure.
Note: Perform this procedure with the engine off.
Note: Use the following chart to identify the
description of each LCD screen control button used
in this procedure.
Plus Minus Previous Enter

Drive functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground
control panel while turning the key switch to
platform controls. Hold the enter button for
approximately 5 seconds.
Part No. 1268496 SX-150 21

Platform Controls
Steer functions: Primary boom extend/retract functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 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. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until DELETE STEER JOYSTICK menu until DELETE PRIMARY BOOM
DEFAULTS is displayed. EXTEND/RETRACT JOYSTICK DEFAULTS
is displayed.
5 Press the plus button to select YES, then
press the enter button. 5 Press the plus button to select YES, then
press the enter button.
6 Do not start the engine.
7 Locate the drive/steer joystick.
7 Locate the thumb rocker switch on top of the
8 Move the drive/steer joystick or thumb rocker
primary boom/turntable rotate joystick.
switch (if equipped) full stroke in the left
direction and hold for 5 seconds, then return to 8 Move the primary boom extend/retract thumb
the center or neutral position. rocker switch full stroke in the extend direction
and hold for 5 seconds, then return to
9 Move the drive/steer joystick or thumb rocker
thecenter or neutral position.
switch (if equipped) full stroke in the right
direction and hold for 5 seconds, then return to 9 Move the primary boom extend/retract thumb
the center or neutral position. rocker switch full stroke in the retract direction
and hold for 5 seconds, then return to the
Result: The alarm at the ground controls
center or neutral position.
22 SX-150 Part No. 1268496

Platform Controls
Primary boom up/down functions: Jib boom up/down functions:

1 Turn the key switch to the off position. 1 Turn the key switch to the off position.
2 Press and hold the enter button on the ground 2 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. Hold the enter button for platform controls. Hold the enter button for
approximately 5 seconds. approximately 5 seconds.
3 Press the minus button twice, then press the 3 Press the minus button twice, then press the
enter button twice. enter button twice.
4 Use the scroll button to scroll through the 4 Use the scroll button to scroll through the
menu until DELETE PRIMARY BOOM menu until RESET JIB BOOM UP/DOWN
UP/DOWN JOYSTICK DEFAULTS is JOYSTICK DEFAULTS is displayed.
displayed.
5 Press the plus button to select YES, then press the enter button.
7 Locate the jib boom joystick.
7 Locate the primary boom/turntable rotate
8 Move the jib boom joystick full stroke in the up
joystick.
direction and hold for 5 seconds, then return to
8 Move the boom/turntable rotate joystick full the center or neutral position.
stroke in the up direction and hold for
9 Move the jib boom joystick full stroke in the
5 seconds, then return to the center or neutral
down direction and hold for 5 seconds, then
position.
9 Move the boom/turntable rotate joystick full
stroke in the down direction and hold for
5 seconds, then return to the center or neutral
position.
Part No. 1268496 SX-150 23

Platform Controls
How to R es et a Proportional Val ve Coil D efault
Turntable rotate functions: How to Reset a Proportional Valve

1 Turn the key switch to the off position. Coil Default
2 Press and hold the enter button on the ground Note: Use the following chart to identify the
control panel while turning the key switch to description of each LCD screen control button used
platform controls. Hold the enter button for in this procedure.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through the
menu until DELETE TURNTABLE ROTATE Plus Minus Previous Enter
JOYSTICK DEFAULTS is displayed.
Note: This procedure only needs to be performed if
5 Press the plus button to select YES, then a proportional valve has been replaced.
Note: After the valve coil defaults have been set,
6 Do not start the engine. each machine function threshold and default
7 Locate the primary boom/turntable rotate function speed must be set. Refer to Repair
joystick. Procedure, How to Set the Function Thresholds
and Default Function Speeds.
8 Move the boom/turntable joystick full stroke in
the left direction and hold for 5 seconds, then 1 Turn the key switch to the off position.
return to the center or neutral position. 2 Press and hold the enter button on the ground
9 Move the boom/turntable joystick full stroke in control panel while turning the key switch to
the right direction and hold for 5 seconds, then platform controls. Hold the enter button for
return to the center or neutral position. approximately 5 seconds.
Result: The alarm at the ground controls 3 Press the minus button twice, then press the
should sound for a successful calibration. enter button twice.
4 Use the previous button to scroll through the
menu until the function valve that needs to be
reset is displayed. Press the plus button to
select yes, then press the enter button to save
the setting.
5 Press the enter or previous button on the
LCD screen until EXIT is displayed.
6 Press the plus button or minus button to
select YES and then press the enter button.
24 SX-150 Part No. 1268496

Platform Controls
How to Set the F unc tion T hresholds and D efault Func tions Speeds
How to Set the Function 6 Slowly move the joystick off center in the
opposite direction just until the machine
Thresholds and Default Functions function starts to move, then move the joystick
Speeds very slowly towards the neutral or center
position just before the machine function
Note: Before the threshold and default function
stops. Do not let go of the joystick.
speeds can be set, the boom function proportional
valve coil defaults must be set first. Refer to Repair 7 While holding the joystick in position, press the
Procedure, How to Reset a Proportional Valve Coil engine start button at the platform controls to
Default. set the joystick controller threshold.
Note: If a boom function proportional valve coil has 8 Repeat steps for each joystick controlled
not been replaced and just want to reset the machine function:
function speed to original factory settings, proceed
· turntable rotate left/right.
to Function speeds procedure.
· primary boom extend/retract.
1 Start the engine from the platform controls.
· drive forward/reverse.
2 Press down the foot switch.
9 Once the threshold has been set, press and
Note: Be sure the engine rpm is set to foot switch hold the engine start button until the engine
activated high idle. shuts off. Do not press the red Emergency
Function threshold: Stop button.
Note: Approximately 3 seconds after the engine
3 Select a joystick controlled function that needs
shuts off, the alarm at the ground controls will
to have the threshold set.
sound to indicate the settings are being saved in
4 Slowly move the joystick off center in either memory.
direction just until the machine function starts
to move, then move the joystick very slowly 10 At the ground controls, turn the key switch to
towards the neutral or center position just the off position, wait a moment and then turn
before the machine function stops. Do not let the key switch to platform controls.
go of the joystick. 11 Check the display at the ground controls to be
5 While holding the joystick in position, press the sure there are no calibration faults.
engine start button at the platform controls to Note: There should be no calibration faults shown
set the joystick controller threshold. on the display. If calibration faults exist, repeat this
procedure.
Part No. 1268496 SX-150 25

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.
tires.
Note: Approximately 3 seconds after the engine
Note: Perform this procedure with the machine on a shuts off, the alarm at the ground controls will
firm, level surface that is free of obstructions. sound to indicate the settings are being saved in
memory.
13 Select the function that needs the function 16 At the ground controls, turn the key switch to
speeds set. the off position, wait a moment and then turn
the key switch to platform controls.
14 Primary boom extend/retract functions:
Move the joystick full stroke in the extend 17 Check the display at the ground controls to be
direction. When the alarm sounds, move the sure there are no calibration faults.
joystick in the opposite direction full stroke until Note: There should be no calibration faults shown
the alarm sounds again. Return the joystick to on the display. If calibration faults exist, repeat this
center. procedure.
Turntable rotate functions: Move the joystick
full stroke in either the left or right direction.
When the drive enable indicator light turns on,
move the joystick in the opposite direction full
stroke until the alarm sounds. Return the
joystick to center.
Extend the boom approximately 4 ft / 1.2 m,
then again move the joystick full stroke in the
opposite direction until the alarm sounds.
Return the joystick to center.
Raise and extend the boom approximately
85 ft / 26 m, then again move the joystick full
stroke in the opposite direction until the alarm
sounds. Return the joystick to center.
26 SX-150 Part No. 1268496

Platform Controls
How to Adj ust the Functi on Speeds
How to Adjust the Function 6 Press the enter button to save the setting in
memory.
Speeds
Note: Perform this procedure with the boom in the
stowed position.
Note: Use the following chart to identify the select YES and then press the enter button.
in this procedure. 9 Continue to perform this procedure until the
machine function speed meets specification.
Refer to Specifications, Performance
Specifications.

1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Press the plus button twice, then press the
minus button twice.
4 Press the previous button until the function to
be adjusted is displayed.
5 Press the plus button to increase the speed or
press the minus button to decrease the speed.
Part No. 1268496 SX-150 27

Platform Controls
How to Adj ust the Functi on R amp R ate Setti ng
How to Adjust the Function Ramp 4 Press the previous button until the function to
be adjusted is displayed.
Rate Setting
5 Press the plus button to increase the ramp
The ramp rate setting of a joystick controls the time
rate or press the minus button to decrease the
at which it takes for the joystick to reach maximum
ramp rate.
output, when moved out of the neutral position. The
ramp rate settings of a joystick can be changed to 6 Press the enter button to save the setting in
compensate for hydraulic pump wear to maintain memory.
peak performance from the machine.
Note: Perform this procedure with the boom in the LCD screen until EXIT is displayed.
stowed position. 8 Press the plus button or minus button to
Note: Use the following chart to identify the select YES and then press the enter button.
in this procedure.

1 Pull out the red Emergency Stop button to the
on position at both the ground and platform
controls.
3 Press the plus button twice, then press the
previous button twice.
28 SX-150 Part No. 1268496

Platform Components
2-1 9 Remove the weld cable from the platform (if

equipped).
Platform
How to Remove the Platform circuits could result in death or
1 Separate the foot switch quick disconnect serious injury. Remove all rings,
plug. watches and other jewelry.
2 Support the platform with an appropriate lifting 10 Support the platform mounting weldment, but
device. do not apply any lifting pressure.
3 Locate the cables that connect to the bottom of 11 Remove the eight mounting bolts from the
the control box. Number each cable and its platform mounting weldment.
location at the platform control box.
12 Remove the center bolt and slide the platform
4 Disconnect the cables from the bottom of the mounting weldment off of the platform rotator.
platform control box.
Crushing hazard. The platform
5 Remove the platform control box mounting mounting weldment may
fasteners. Remove the platform control box become unbalanced and fall if it
and set it aside. is not properly supported.
6 Remove the air line to platform bracket
retaining fasteners (if equipped).
7 Remove the power to platform cover plate from
the electrical outlet box. Do not disconnect the
wiring.
8 Remove the power to platform electrical outlet

box from the platform and lay it to the side.
Part No. 1268496 SX-150 29

Platform Components
2-2 4 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 5 Support the rod end of the platform level
level through the entire range of boom motion. The cylinder.
platform is maintained level to the turntable. To
accomplish this, the ECM at the ground controls 6 Remove the pin retaining fasteners from the
compares the difference in readings between the platform leveling cylinder rod-end pivot pin.
platform angle sensor and the turntable level Use a soft metal drift to remove the barrel-end
sensor, which then sends a signal to the platform pivot pin.
controls to open or close the appropriate platform 7 Carefully pull the platform leveling cylinder out
level proportional valve on the platform manifold to of the boom to access the hydraulic hoses.
maintain a level platform. The platform leveling
cylinder is equipped with counterbalance valves to 8 Tag, disconnect and plug the hydraulic hoses
prevent movement in the event of a hydraulic line from the platform leveling cylinder. Cap the
failure. fittings on the cylinder.
Bodily injury hazard. Spraying
How to Remove the Platform hydraulic oil can penetrate and
burn skin. Loosen hydraulic
Leveling Cylinder connections very slowly to allow
Note: When removing a hose assembly or fitting, the oil pressure to dissipate
the O-ring (if equipped) on the fitting and/or hose gradually. Do not allow oil to
end must be replaced. All connections must be squirt or spray.
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque 9 Remove the platform leveling cylinder from the
Specifications. machine.
1 Raise the jib boom slightly and place blocks Crushing hazard. The platform
under the platform. leveling cylinder may fall if not
properly supported when
2 Lower the jib boom until the platform is resting removed from the machine.
on the blocks just enough to support the
platform.
Note: Do not rest the entire weight of the boom on
the blocks.
3 Secure the platform leveling cylinder to the jib
boom for support.
30 SX-150 Part No. 1268496

Platform Components
2-3 3 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. sensitive instrument. It can be
damaged internally if is dropped
How to Remove the Platform or sustains any physical shock,
even if the damage is not visible.
Rotator
4 Tag, disconnect and plug the hydraulic hoses
Component damage hazard. from the platform rotator manifold. Cap the
Mark the platform mounting fittings on the manifold.
weldment and the rotator flange
before removing the platform Bodily injury hazard. Spraying
mounting weldment. The hydraulic oil can penetrate and
platform mounting weldment burn skin. Loosen hydraulic
must be replaced in the exact connections very slowly to allow
same position on the rotator the oil pressure to dissipate
flange as it was before removal. gradually. Do not allow oil to
If a new rotator is installed or the squirt or spray.
rotator is disassembled, proper
alignment can be achieved by 5 Tag, disconnect and plug the hydraulic hoses
rotating the rotator all the way to from the platform manifold. Cap the fittings on
the left and then installing the the manifold.
platform mounting weldment all
the way in the left position. Bodily injury hazard. Spraying
hydraulic oil can penetrate and
Note: When removing a hose assembly or fitting, burn skin. Loosen hydraulic
the O-ring (if equipped) on the fitting and/or hose connections very slowly to allow
end must be replaced. All connections must be the oil pressure to dissipate
torqued to specification during installation. Refer to gradually. Do not allow oil to
Specifications, Hydraulic Hose and Fitting Torque squirt or spray.
Specifications.
6 Remove the pin retaining fasteners from the jib
1 Remove the platform. Refer to Repair boom and jib boom leveling arms to platform
Procedure, How to Remove the Platform. rotator pivot pins. Do not remove the pins.
2 Tag and disconnect the electrical connector
from the platform angle sensor.
Part No. 1268496 SX-150 31

Platform Components
How to Bleed the Pl atfor m R otator
7 Support the jib boom leveling arms with a How to Bleed the Platform Rotator
suitable lifting device.
Note: Do not start the engine. Use auxiliary power
8 Use a soft metal drift to remove both pins and for all machine functions in this procedure.
remove the platform rotator from the machine.
1 Rotate the platform full right, then full left until
Crushing hazard. The jib boom air is completely out of the rotator. Bleeding the
leveling arms may fall if they are valve is not necessary.
not properly supported when the
jib boom leveling arm pivot pin is
removed.
Component damage hazard. The

platform angle sensor is a very
sensitive instrument. It can be
damaged internally if is dropped
or sustains any physical shock,
even if the damage is not visible.
32 SX-150 Part No. 1268496

Platform Components
2-4 4 Locate the calibration toggle switch at the top

of the ground control box. Activate calibration
Platform Level Sensor mode by moving the toggle switch in the left
The platform level sensor is mounted to the side of direction.
the platform rotator. The platform level sensor is 5 Temporarily install a control box door retaining
monitored by the control system to maintain a level fastener between the door and the box to
platform through boom range of motion. If a prevent the control box door from moving the
platform level sensor is replaced, it must be toggle switch while calibrating the machine.
calibrated prior to machine operation.
6 Insert the key into the bypass/recovery key
switch and turn it to the bypass position.
How to Calibrate the Platform Note: The platform level calibration value will not be
Level Sensor saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
Note: Perform this procedure with the machine on a
activated.
firm, level surface.
stowed position.
ground controls. Hold the enter button for
Note: Use the following chart to identify the approximately 5 seconds.
description of each LCD screen control button used 8 Enter sensor calibration mode by pressing the
in this procedure. buttons at the ground controls in the following
sequence: (plus)(enter)(enter)(plus).
LCD screen until SET PLATFORM LEVEL
SENSOR TO GRAVITY is displayed.
Plus Minus Previous Enter 10 Press the plus button to select YES, then
1 Secure a digital level to one of the side railings press the enter button to accept.
of the platform. Note: The platform level sensor is calibrated at the
2 Start the machine and level the platform to factory for the correct millivolt/degree and will not
gravity. Turn the machine off. need to be adjusted.
3 Open the ground control box.
Part No. 1268496 SX-150 33

Platform Components
11 Press the enter or previous button on the 2-5

Platform Overload System (if
12 Press the plus button or minus button to equipped)
13 Remove the fastener that was temporarily Proper calibration of the platform overload system
installed. Close the control box door and install is essential to safe machine operation. Continued
the door retaining fasteners. use of an improperly calibrated platform overload
system could result in the system failing to sense an
Note: When the control box door is closed, the overloaded platform. The stability of the machine is
calibration toggle switch is automatically activated compromised and it could tip over.
to exit out of calibration mode.
How to Calibrate the Platform

Overload System (if equipped)
firm, level surface.
1 Level the platform.
2 Determine the maximum platform capacity.
Refer to the machine serial plate.
3 Using a suitable lifting device, place an
appropriate test weight equal to that of the
maximum platform capacity at the center of the
platform floor.
34 SX-150 Part No. 1268496

Platform Components
Determine the limit switch trigger point: Confirm the setting:

4 Gently move the platform up and down by 5 Start the engine from the platform controls.
hand, so it bounces approximately 1 to
6 Lift the test weight off the platform floor using a
2 inches / 2.5 to 5 cm. Allow the platform to
settle.
7 Place the test weight back onto the center of
Result: The overload indicator light and the
the platform floor using a suitable lifting device.
alarm is on. Slowly tighten the load spring
adjustment nut by turning it clockwise just until Result: The alarm should be off. The platform
the overload indicator light and alarm turns off. overload indicator light should be off at the
platform controls and there should be no error
Note: The platform will need to be moved up and
message on the LCD display at the ground
down and allowed to settle in between adjustments.
controls.
Note: There may be a 2 second delay before the Note: There may be an 2 second delay before the
overload indicator lights flash and the alarm overload indicator lights and alarm turn off.
sounds.
8 Add an additional 15 lbs / 6.8 kg test weight to
Result: The overload indicator light and the original test weight to overload the
alarm is off. Slowly loosen the load spring platform.
adjustment nut by turning it counterclockwise
just until the overload indicator light and alarm Result: The alarm should be sounding. The
turn on. platform overload indicator light should be
flashing at the platform controls and platform
Note: There may be a 2 second delay before the overload should be displayed on the LCD
overload indicator lights flash and the alarm screen at the ground controls.
sounds.
Note: There may be a 2 second delay before the
Note: The platform will need to be moved up and overload indicator lights flash and the alarm
down and allowed to settle in between adjustments. sounds.
Part No. 1268496 SX-150 35

Platform Components
9 Test all machine functions from the platform 2-6

controls.
Platform Overload Recovery
Result: All platform control functions should Message
not operate.
10 Turn the key switch to ground controls. If the ground controls LCD screen displays
OVERLOAD RECOVERY, the emergency lowering
11 Test all machine functions from the ground system has been used while the platform was
controls. overloaded.
Result: All ground control functions should not
operate. How to Clear the Platform
Overload Recovery Message
Note: This message shall be cleared by a person
trained and qualified on the troubleshooting and
repair of this machine.
in this procedure.

ground controls. Hold the enter button for
36 SX-150 Part No. 1268496

Platform Components
3 Press the buttons on the ground controls in the

following sequence:
(plus)(minus)(minus)(plus).
LCD screen until CLEAR OVERLOAD
RECOVERY is displayed.
5 Press the plus button or the minus button to
select YES. Then press the buttons in the
following sequence:
(plus)(plus)(plus)(minus). and press the
enter button to accept.
Note: The passcode buttons
(plus)(plus)(plus)(minus) must be entered in the
proper sequence before the enter button is
pressed.
Part No. 1268496 SX-150 37

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
38 SX-150 Part No. 1268496

Jib Boom Components
3-1 5 Support the barrel end of the cylinder with a

Jib Boom
6 Remove the pin retaining fastener from the jib
boom lift cylinder barrel-end pivot pin.
How to Remove the Jib Boom
7 Use a soft metal drift to remove the pin and let
Note: Perform this procedure with the boom in the the cylinder hang down.
stowed position.
8 Attach a lifting strap from an overhead crane to
Note: When removing a hose assembly or fitting, the jib boom.
the O-ring (if equipped) on the fitting and/or hose
9 Remove the pin retaining fastener from the jib
end must be replaced. All connections must be
boom pivot pin.
Specifications, Hydraulic Hose and Fitting Torque 10 Use a soft metal drift to remove the pin and
Specifications. remove the jib boom from the jib rotator.
1 Remove the platform. Refer to Repair Crushing hazard. The jib boom
Procedure, How to Remove the Platform. may become unbalanced and fall
when it is removed from the
2 Remove the platform mounting weldment and
machine if it is not properly
the platform rotator. Refer to Repair
supported by the overhead
Procedure, How to Remove the Platform
crane.
Rotator.
3 Support the jib boom with a suitable lifting 11 Remove the pin retaining fasteners from the jib
device. boom lift cylinder rod-end pivot pin. Do not
remove the pin.
4 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on 12 Attach a lifting strap from an overhead crane to
the cylinder. the lug on the rod end of the jib boom lift
cylinder.
hydraulic oil can penetrate and 13 Use a soft metal drift to remove the jib boom lift
burn skin. Loosen hydraulic cylinder rod-end pivot pin. Remove the jib
connections very slowly to allow boom lift cylinder from the jib boom bellcrank.
the oil pressure to dissipate
Crushing hazard. The jib boom
gradually. Do not allow oil to lift cylinder may become
squirt or spray. unbalanced and fall when it is
removed from the machine if it is
not properly supported by the
overhead crane.
Part No. 1268496 SX-150 39

Jib Boom Components
3-2 4 Remove the pin retaining fasteners from the jib

boom lift cylinder rod-end pivot pin. Use a soft
Jib Boom Lift Cylinder metal drift to remove the pin and let the
cylinder hang down.
How to Remove the Jib Boom Lift 5 Attach a lifting strap from an overhead crane to
Cylinder the barrel end of jib boom lift cylinder.
Note: Perform this procedure with the boom in the 6 Remove the pin retaining fasteners from the jib
stowed position. boom lift cylinder barrel-end pivot pin. Use a
soft metal drift to remove the pin.
Note: When removing a hose assembly or fitting,
7 Remove the jib boom lift cylinder from the
machine.
torqued to specification during installation. Refer to Crushing hazard. The jib boom
Specifications, Hydraulic Hose and Fitting Torque lift cylinder may become
Specifications. unbalanced and fall when it is
removed from the machine if it is
1 Raise the jib boom slightly and place blocks
not properly supported by the
under the platform mounting weldment. Lower
overhead crane.
the jib boom until the platform is resting on the
blocks just enough to support the platform.
Note: Do not rest the entire weight of the boom on
the blocks.
2 Tag, disconnect and plug the jib boom lift
cylinder hydraulic hoses. Cap the fittings on
the cylinder.
connections very slowly to allow
gradually. Do not allow oil to
squirt or spray.
3 Support the rod end of the jib boom lift cylinder

with a suitable lifting device.
40 SX-150 Part No. 1268496

Jib Boom Components
3-3 7 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
Note: Perform this procedure with the boom in the damaged if it is not properly
stowed position. supported when the rod-end
pivot pin is removed.
the O-ring (if equipped) on the fitting and/or hose 8 Remove the pin retaining fastener from the jib
end must be replaced. All connections must be boom bellcrank pivot pin.
Specifications, Hydraulic Hose and Fitting Torque 9 Use a soft metal drift to remove the jib boom
Specifications. bellcrank pivot pin. Remove the jib boom
bellcrank from the machine.
1 Remove the platform. Refer to Repair
Procedure, How to Remove the Platform. Crushing hazard. The jib boom
bellcrank may become
2 Remove the platform mounting weldment and unbalanced and fall if it is not
the platform rotator. Refer to Repair properly supported when it is
Procedure, How to Remove the Platform removed from the machine.
Rotator.
3 Remove the jib boom. Refer to Repair
Procedure, How to Remove the Jib Boom.
the jib boom bellcrank.
5 Support the rod end of the bellcrank leveling
cylinder with a suitable lifting device. Protect
the cylinder rod from damage.
6 Remove the pin retaining fastener from the
bellcrank leveling cylinder rod-end pivot pin.
Part No. 1268496 SX-150 41

Jib Boom Components
3-4 Note: Use the following chart to identify the

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. If a jib boom
bellcrank angle sensor is replaced, it must be
calibrated prior to machine operation. The jib boom Plus Minus Previous Enter
bellcrank angle sensor is mounted to the bellcrank 1 Place a digital level with a magnetic base, on
pivot pin on the engine side of the machine. the underside of the jib bellcrank as shown in
Illustration 1.
How to Calibrate the Jib Boom
Bellcrank Angle Sensor
Note: If the primary boom angle sensor has been
removed or replaced, it must to be calibrated before
the jib boom bellcrank angle sensor. Refer to
Repair Procedure, How to Calibrate the Primary
Boom Angle Sensor.
firm, level surface and in the stowed position with
the axles extended.
Note: A digital level will be required to perform this
procedure.
Illustration 1
Note: A kit is available through Genie Product
Support (Genie part number 58351). This kit 1 digital level
includes a digital level with a magnetic base and
cable harnesses. 2 Raise the jib boom to a slightly less than
horizontal position.
3 Push in the ground controls red Emergency
Stop button to the off position. Do not turn the
key switch to the off position.
42 SX-150 Part No. 1268496

Jib Boom Components
5 Locate the calibration toggle switch at the top 11 Press the plus button to select YES, then
of the ground control box. Activate calibration press the enter button to accept.
mode by moving the toggle switch in the left
12 Adjust the jib bellcrank until it is level to gravity.
direction.
Note: While in the jib bellcrank level sensor
6 Temporarily install a control box door retaining
calibration mode, the platform level up and platform
fastener between the door and the box to
level down buttons on the TCON will activate the jib
prevent the control box door from moving the
bellcrank level up and level down valves.
toggle switch while calibrating the machine.
7 Remove the key from the main key switch. 13 At the JIB BELLCRANK LEVEL TO GRAVITY?
Insert the key into the bypass/recovery key screen, Press the plus button to select YES,
switch and turn it to the bypass position. then press the enter button to accept.
Note: The angle sensor calibration values will not Note: If the engine is started to adjust the jib
be saved correctly unless the key switch is in the bellcrank, press and hold the engine start button for
bypass position and the calibration toggle switch is five seconds.
activated. Note: If the system exits out of calibration mode
8 Press and hold the enter button on the ground when the engine is started, repeat step 9 and
control panel while pulling out the ground continue to step 12.
controls red Emergency Stop button to the on 14 Press and hold the engine start button for
position. Hold the enter button for approximately 5 seconds to shut off the engine
approximately 5 seconds and then release it. and to save the calibration settings.
9 Enter sensor calibration mode by pressing the Note: Do not turn the engine off with the key switch
buttons at the ground controls in the following or red Emergency Stop button or all calibration
sequence: (plus)(enter)(enter)(plus). points or values will not be saved.
LCD screen until DELETE JIB LEVEL ANGLE
SENSOR CALIBRATION is displayed.
Part No. 1268496 SX-150 43

Jib Boom Components

press the enter button to accept.
17 Turn the key back to the run position and
remove the key from the bypass/recovery key
switch. Insert the key into the main key switch
and turn it to ground controls.
18 Wait approximately 20 seconds and turn the
machine off by pressing the red Emergency
Stop button in.
19 Remove the fastener that was temporarily
installed. Close the control box door and install
the door retaining fasteners.
Note: When the control box door is closed, the
calibration toggle switch is automatically activated
20 Use the key to turn the bypass / recovery key
switch to the run position.
Note: Be sure that the bypass/recovery key switch
is in the run position before attempting to operate
the machine.
21 Pull out the red Emergency Stop button. Start
the engine and lower the boom to the stowed
position. Be sure there are no calibration faults
shown on the display.
22 Remove the digital level from jib bellcrank.
44 SX-150 Part No. 1268496

Boom Components
1 boom tube #1 4 boom tube #4

2 boom tube #2 5 primary lift cylinder
3 boom tube #3
Part No. 1268496 SX-150 45

Boom Components
4-1 4 Pull the electrical cables out of the lower cable

track that lead to the primary boom.
Primary Boom Cable Track
The primary boom cable track guides the cables Cables can be damaged if they
and hoses running up the boom. It can be repaired are kinked or pinched.
link by link without removing the cables and hoses
that run through it. Removing the entire primary 5 Tag and disconnect the electrical connectors
boom cable track is only necessary when from the jib boom manifold located at the
performing major repairs that involve removing the platform end of the primary boom.
primary boom.
6 Tag, disconnect and plug the two hydraulic
hoses from the side of the jib boom manifold
How to Remove the Primary that lead to the primary boom cable track. Cap
Boom Cable Track the fittings on the manifold.
Note: When removing a hose assembly or fitting, Bodily injury hazard. Spraying
the O-ring (if equipped) on the fitting and/or hose hydraulic oil can penetrate and
end must be replaced. All connections must be burn skin. Loosen hydraulic
torqued to specification during installation. Refer to connections very slowly to allow
Specifications, Hydraulic Hose and Fitting Torque the oil pressure to dissipate
Specifications. gradually. Do not allow oil to
squirt or spray.
firm, level surface. 7 Tag and disconnect the electrical connector
from the limit switches on the sides of the
Note: Perform this procedure with the boom in the primary boom. Do not remove the limit
stowed position. switches.
1 Tag and disconnect the electrical connectors 8 Remove the retaining fasteners from the cable
from the boom #1 cable track. track guide at the platform end of the boom.
2 Disconnect the AC electrical wire and option Remove the cable track guide from the
wires and hoses. machine.
3 Tag and disconnect the ground box 9 Disconnect the platform box harness, the AC
harnesses. electrical cable and option wires and hoses
from the platform.
10 Pull the wires and hoses from the jib boom.
46 SX-150 Part No. 1268496

Boom Components
11 Secure the upper and lower tracks together. How to Repair the Primary Boom
Crushing hazard. If the upper Cable Track
and lower cable tracks are not
properly secured together, the
The boom cable track can be
cable track could become
damaged if it is twisted.
unbalanced and fall when
removed from the machine. Note: A cable track repair kit is available through
the Genie Service Parts Department.
12 Attach a lifting strap to each end of the cable
track from an overhead crane for support. Do 1 Visually inspect the cable track and determine
not apply any lifting pressure. which 4-link section needs to be replaced.
13 Remove the mounting fasteners that attach the 2 Support the cable track assembly above the
cable track to the primary boom. section to be replaced.
14 Carefully remove the cable track from the 3 Carefully remove the snap rings and pins from
machine and lay it on a structure capable of each end of the damaged section of cable
supporting it. track.
Crushing hazard. The primary 4 Remove the retaining fasteners from the upper
boom cable track could become black rollers from the 4-link section of cable
unbalanced and fall when track to be replaced. Remove the rollers.
removed from the primary boom 5 Lift up the hoses and cables and carefully
if not properly supported by the remove the damaged 4-link section of cable
overhead crane. track.
Component damage hazard. Component damage hazard.

The boom cable track can be Cables and hoses can be
damaged if it is twisted. damaged if they are kinked or
pinched.
Cables and hoses can be
damaged if they are kinked or
pinched.
Part No. 1268496 SX-150 47

Boom Components
6 Remove the upper rollers from the 4-2

replacement section of cable track.
Primary Boom
7 Lift up the hoses and cables and carefully
insert the new 4-link section of cable track.
How to Shim the Boom
Cables and hoses can be 1 Measure each upper, side and lower wear pad.
damaged if they are kinked or Note: If a wear pad is not less than specification,
pinched. perform the following procedure.
8 Connect the ends of the replacement cable Platform end wear pads
track section to the existing cable track using
the pins and snap rings. 2 Extend the boom until the wear pads are
accessible at the platform end of the machine.
9 Install the rollers onto the new section of cable
track. 3 Loosen the wear pad mounting fasteners.
10 Operate the primary boom extend/retract 4 Add shims by hand until snug.
function through a full cycle to ensure smooth Note: Do not use force when adding the shims.
operation of the new section of cable track.
5 Tighten the mounting fasteners.
6 Remove the boom end cover retaining
fasteners at the pivot end of the boom.
Remove the boom end cover from the
machine..
Pivot end side wear pads
7 Loosen the wear pad mounting fasteners.
8 Add shims by hand until snug.
Note: Do not use force when adding the shims.
9 Tighten the mounting fasteners.
48 SX-150 Part No. 1268496

Boom Components
How to R emove the Pri mar y Boom
Pivot end upper wear pads How to Remove the Primary

10 Loosen the wear pad mounting fasteners. Boom
11 Add shims by hand until snug. Bodily injury hazard. This
Note: Do not use force when adding the shims. procedure requires specific repair
skills, lifting equipment and a
12 Remove one shim from each upper wear pad suitable workshop. Attempting
only. this procedure without these skills
and tools could result in death or
Note:The wear pad clearance should be 0.060 in / serious injury and significant
1.52 mm. component damage. Dealer
13 Tighten the mounting fasteners. service is strongly recommended.
14 Replace the covers. Note: When removing a hose assembly or fitting,

15 Extend and retract the boom through an entire
cycle. Check for tight spots that may cause
binding of the boom.
Specifications, Hydraulic Hose and Fitting Torque
Primary boom wear pad Minimum Specifications.
specifications
Platform end stowed position.
Bottom and side wear pads 0.63 in
16 mm Note: Most repair procedures to the boom
assembly components can be performed with the
Top wear pads 0.35 in
(#1 to #2; #2 to #3) 9 mm boom attached.
Top wear pads 0.47 in Note: The boom assembly may be removed with
(#3 to #4) 12 mm the cable track attached.
Pivot end
1 Attach an overhead 10 ton / 9071 kg crane to
Top wear pads 0.63 in the platform end of the boom for support. Do
16 mm not lift the boom.
Side wear pads 0.47 in
12 mm 2 Place a block under the rod end of the primary
boom lift cylinder.
Grease Specification
Lube a Boom grease
Genie part number 110147
Part No. 1268496 SX-150 49

Boom Components
3 Attach a lifting strap from an overhead crane to 12 Remove the jib boom. Refer to Repair
the rod end of the primary boom lift cylinder. Procedure, How to Remove the Jib Boom.
4 Remove the pin retaining fastener from the Note: When the jib boom is installed, the jib boom
boom lift cylinder rod-end pivot pin. Use a soft angle sensor will need to be calibrated. Refer to
metal drift to remove the pin. Protect the Repair Procedure, How to Calibrate the Jib Boom
cylinder rod from damage. Bellcrank Angle Sensor.
Crushing hazard. The boom lift 13 Remove the primary boom cable track. Refer
cylinder may fall when the to Repair Procedure, How to Remove the
rod-end pivot pin is removed if Cable Track.
the boom lift cylinder is not 14 Remove the end cover from the pivot end of
properly supported by the the primary boom.
overhead crane.
15 Remove the limit switch mounting fasteners
from the limit switch on the ground controls
Crushing hazard. The boom
side of the primary boom. Do not disconnect
may fall when the rod-end pivot
the wiring. Remove the limit switch.
pin is removed if the boom is not
properly supported by the
overhead crane.
5 Place support blocks under the boom lift

cylinder.
boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Protect the
cylinder rod from damage.
7 Using the Auxiliary Power Unit, retract the
boom lift cylinder until the rod end will clear the
boom weldment.
8 Carefully lower the rod end of the boom lift
cylinder down onto the support blocks.
9 Tag, disconnect and plug the boom lift cylinder
hydraulic hoses.
10 Remove the platform. Refer to Repair
Procedure, How to Remove the Platform.
11 Remove the platform mounting weldment and
the platform rotator. Refer to Repair
Rotator.
50 SX-150 Part No. 1268496

Boom Components
How to Dis ass embl e the Primar y Boom
16 Disconnect the electrical connector from the

primary boom angle sensor.
How to Disassemble the Primary
Note: The primary boom angle sensor is located on Boom
the pivot pin on the tank side of the boom.
Bodily injury hazard. This
17 Remove the primary boom angle sensor procedure requires specific repair
bracket mounting fasteners and remove the skills, lifting equipment and a
primary boom angle sensor from the primary suitable workshop. Attempting
boom. Do not remove the angle sensor from this procedure without these skills
the bracket. and tools could result in death or
Note: When the primary boom is installed, the serious injury and significant
primary boom angle sensor will need to be component damage. Dealer
calibrated. Refer to Repair Procedure, How to service is strongly recommended.
Calibrate the Primary Boom Angle Sensor.
18 Attach a 10 ton / 9071 kg overhead crane to the O-ring (if equipped) on the fitting and/or hose
the pivot end of the primary boom. Do not end must be replaced. All connections must be
apply any lifting pressure. torqued to specification during installation. Refer to
19 Remove the pin retaining fasteners from the
Specifications.
primary boom pivot pins.
20 Use a soft metal drift to remove the primary 1 Level the boom.
boom pivot pins. 2 Remove the platform. Refer to Repair
21 Carefully remove the primary boom from the Procedure, How to Remove the Platform.
machine and place it on a structure capable of 3 Remove the platform mounting weldment and
supporting it. the platform rotator. Refer to Repair
Crushing hazard. The primary
Rotator.
boom could become unbalanced
and fall when removed from the 4 Remove the jib boom. Refer to Repair
machine if not properly attached Procedure, How to Remove the Jib Boom.
to the overhead crane.
5 Remove the jib boom lift cylinder. Refer to
Repair Procedure, How to Remove the Jib
Boom Lift Cylinder.
Part No. 1268496 SX-150 51

Boom Components
6 Remove the jib boom bellcrank. Refer to 14 Remove the red locking brackets from the
Repair Procedure, How to Remove the Jib #4 extend cable pivot assembly.
Boom Bellcrank. 15 Remove the nuts on the #4 extend cables and
7 Remove the boom primary extension cylinder. remove the #4 pivot assembly.
Refer to Repair Procedure, How to Remove 16 At the pivot end of the machine, remove the
the Boom Primary Extension Cylinder. shims from the wear pads between the #2 and
8 The boom tubes can be disassembled without #3 boom tubes.
removing the cable track assembly. If you Note: Pay careful attention to the location and
choose to remove the cable track assembly, amount of shims used with each wear pad.
Refer to Repair Procedure, How to Remove
the Cable Track. 17 Using a strap, secure the #2 tube to the
#1 tube.
9 Remove the brackets supporting the cable
track assembly from the #3 and #4 boom 18 At the platform end, remove the shims from the
tubes lower channel and upper side wear pads
between the #2 and #3 boom tubes.
10 Place blocks between the cable tracks and
cable tubes for support. Note: Pay careful attention to the location and
amount of shims used with each wear pad.
11 Strap together the boom cable tubes, blocks of
wood, and the cable track.
Cables, hoses, boom cable tube
and cable track can be
damaged if they are kinked or
pinched.
Remove the #3 and #4 boom tubes:

12 At the platform end, remove the #4 boom
retract bolt and secure the retract cables to the
#4 boom tube.
13 Tag and disconnect the harness to limit switch
3RS and 4EOS. Remove the bracket and limit
switch from the #2 boom tube.
Tip-over hazard. Failure to
install the correct proximity
and/or limit switches in the
correct location will result in the
machine tipping over, resulting
in death or serious injury.
52 SX-150 Part No. 1268496

Boom Components
19 Attach the #3 boom tube to a forklift, and lift the Remove the #2 boom tube:
tube enough to relieve the pressure from the
lower wear pads, begin sliding the tube from 23 At the pivot end of the machine, remove the
the boom assembly. shims from the wear pads between the #1 and
#2 boom tubes.
Note: Make sure the tube remains parallel to the
#2 boom tube while removing. Note: Pay careful attention to the location and
20 When approximately 10 feet of the #3 boom
tube remains in the #2 boom tube, attach a 24 At the platform end, remove the top wear pads
strap from a suitable overhead lifting device between the #1 and #2 boom tubes.
and slightly lift the tube. Note: Pay careful attention to the location and
Crushing hazard. The #3 and
#4 boom tubes may become 25 At the platform end, remove the shims from the
unbalanced and fall when they upper side wear pad and lower side wear pads
are removed from the # 2 boom from the opposite side of the boom between
tube if it is not properly the #1 and #2 boom tubes.
supported and attached to the
overhead crane. Note: Pay careful attention to the location and
Note: During removal, the overhead crane strap will
26 Remove the bolts supporting the cable track
need to be adjusted for proper balancing.
assembly from the #2 boom tube.
21 Remove the fasteners securing the lower wear Note: You may have to lift the cable track assembly
pads between the #2 and #3 boom tubes. to clear the tab on the #2 boom tube when it is
Note: This will allow the retract cables to come out removed.
with the boom tubes.
27 Attach the #2 boom tube to a forklift, and lift the
22 Support and slide the #4 boom and #3 boom tube enough to relieve the pressure from the
tubes from the boom assembly. lower wear pads.
Note: Remove the retract wire cables with the boom
tube.
Part No. 1268496 SX-150 53

Boom Components
28 Remove the fasteners securing the lower wear 32 Remove the final two side wear pads from the
pads and remove the wear pads and aluminum platform end of the machine.
block between the #1 and #2 boom tubes.
Note: Pay careful attention to the location and
29 Back the wire cables from the opening below amount of shims used with each wear pad.
the #1 boom tube into the tube and then push
them out the end of the #1 boom tube. 33 Support and slide the #2 boom tube from the
boom assembly.
Note: This will allow the retract cables to come out
with the boom tubes. Remove the retract wire
cables with the #2 boom tube
30 Begin pulling the #2 boom tube from the
#1 boom tube.
Note: Make sure the tube remains parallel to the
#1 boom tube while removing.
31 When approximately 10 feet of the #2 boom
tube remains in the #1 boom tube, attach a
strap from a suitable overhead lifting device
and slightly lift the tube.
Crushing hazard. The number
2 boom tube may become
unbalanced and fall when it is
removed from the number
1 boom tube if it is not properly
supported and attached to the
overhead crane.
Note: During removal, the overhead crane strap will

need to be adjusted for proper balancing.
54 SX-150 Part No. 1268496

Boom Components
4-3 3 Attach an overhead 10 ton / 9071 kg crane to

the platform end of the boom for support. Do
Primary Boom Lift Cylinder not lift the boom.
The primary boom lift cylinder raises and lowers the Note: Place the lifting strap between the cable track
primary boom. The primary boom lift cylinder is assembly and the boom.
equipped with a counterbalance valve to prevent
movement in the event of a hydraulic line failure. 4 Remove the boom storage area cover
retaining fasteners. Remove the cover from
the machine.
How to Remove the Boom Lift
Cylinder boom lift cylinder rod-end pivot pin. Use a soft
metal drift to remove the pin. Protect the
Bodily injury hazard. This
cylinder rod from damage.
procedure requires specific repair
skills, lifting equipment and a Crushing hazard. The boom lift
suitable workshop. Attempting cylinder may fall when the
this procedure without these skills rod-end pivot pin is removed if
and tools could result in death or the boom lift cylinder is not
serious injury and significant properly supported by the
component damage. Dealer overhead crane.
service is strongly recommended.
Note: When removing a hose assembly or fitting, Crushing hazard. The boom
the O-ring (if equipped) on the fitting and/or hose may fall when the rod-end pivot
end must be replaced. All connections must be pin is removed if the boom is not
torqued to specification during installation. Refer to properly supported by the
Specifications, Hydraulic Hose and Fitting Torque overhead crane.
Specifications.
6 Place support blocks under the boom lift
1 Raise the boom until there is approximately cylinder.
4 feet / 1.2 m between the turntable and boom 7 Using the Auxiliary Power Unit, retract the
rest pad. boom lift cylinder until the rod end will clear the
2 Attach a lifting strap from an overhead crane or boom weldment.
other suitable lifting device to the rod end of 8 Carefully lower the rod end of the boom lift
the the boom lift cylinder. cylinder down onto the support blocks.
Part No. 1268496 SX-150 55

Boom Components
9 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.
Bodily injury hazard. Spraying 15 Support the boom lift cylinder with an overhead
hydraulic oil can penetrate and crane.
burn skin. Loosen hydraulic 16 Use a slide hammer to remove the boom lift
connections very slowly to allow cylinder barrel-end pivot pin through the
the oil pressure to dissipate access hole in the engine side turntable riser.
squirt or spray. 17 With the boom lift cylinder being supported by
the overhead crane, pull the boom lift cylinder
10 Carefully raise the boom with the overhead toward the platform until it is out.
crane until the barrel end of the boom lift
cylinder is accessible. Crushing hazard. The boom lift
cylinder may become
11 Remove the engine pivot plate retaining unbalanced and fall if it is not
fastener. Swing the engine pivot plate out properly supported when it is
away from the machine. removed from the machine.
Component damage hazard. Be

careful not to damage the
proximity and/or limit switches
when removing the boom lift
cylinder.

1 engine pivot plate anchor hole The cables and hydraulic hoses
2 engine pivot plate retaining fastener can be damaged if the boom lift
cylinder is pulled across them.
12 Locate the engine pivot plate anchor hole at
the pivot end of the engine pivot plate.
13 Install the bolt that was just removed into the
anchor hole to secure the engine pivot plate
from moving.
Crushing hazard. Failure to install
the bolt into the engine pivot plate
to secure it from moving could
56 SX-150 Part No. 1268496

Boom Components
4-4 3 Tag and disconnect the limit switch harnesses.

Remove the fasteners to the limit switch
Extension Cylinder harness mounting bracket and remove the
The primary boom extension cylinder is located bracket.
inside the boom assembly and incorporates cables 4 Tag and disconnect limit switch 3RO (6).
and pulleys that are responsible for extending the Remove the mounting bracket with the limit
boom tubes. The extension cylinder is equipped switch attached. (Illustration 1)
with counterbalance valves to prevent movement in
the event of a hydraulic line failure. 5 Disconnect and remove the string
potentiometer from boom tube #1. Remove the
clevis from boom tube #2.
How to Remove the Primary 6 Tag and disconnect the harness from cable
Boom Extension Cylinder tension limit switch 6S (4). Remove the bracket
and limit switch. Remove cable tension limit
Bodily injury hazard. This switch 5S (5) from the mounting bracket.
procedure requires specific repair (Illustration 1)
skills, lifting equipment and a
suitable workshop. Attempting Note: The mounting bracket must remain attached
this procedure without these skills to the extend cylinder.
and tools could result in death or
serious injury and significant
from the primary boom extension cylinder. Cap
component damage. Dealer
the fittings on the cylinder.
service is strongly recommended.
Note: When removing a hose assembly or fitting, hydraulic oil can penetrate and
the O-ring (if equipped) on the fitting and/or hose burn skin. Loosen hydraulic
end must be replaced. All connections must be connections very slowly to allow
torqued to specification during installation. Refer to the oil pressure to dissipate
Specifications, Hydraulic Hose and Fitting Torque gradually. Do not allow oil to
Specifications. squirt or spray.
1 Raise the boom to a horizontal position and
fully retract the primary extension cylinder. 8 Remove the fasteners from the inner cable
track mounting bracket at the primary boom
2 Remove the retaining fasteners from the boom extension cylinder.
end cover at the pivot end of the boom.
Remove the cover from the machine.
Part No. 1268496 SX-150 57

Boom Components
9 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. Remove
the red locking brackets.
Bodily injury hazard. Failure to
install the red cable adjustment
locking bracket would allow the
cable mounting bolts to loosen
and fall out which could result in
death or serious injury.
12 Loosen the #4 extend cable adjustment bolts.

13 Loosen the #3 extend cable adjustment bolts
10 turns (about 1 in / 2.54 cm).
Note: Do not over loosen the extend cables.
Note: When reassembling the extend cable
assembly, tighten the three extend cable
adjustment bolts so the cable mounting blocks (1)
line up with the weldment edge (2) as shown in
Illustration 2.
llustration 1
Illustration 2
1 #4 extend cable nut
2 6S limit switch 1 extend cable block
3 #3 extend cable adjusting bolt 2 weldment alignment edge
4 5S limit switch actuator bracket
5 #2 extend cylinder mounting plate
6 3RO limit switch
7 #1 extend cylinder mounting plate
58 SX-150 Part No. 1268496

Boom Components
14 Remove the locking plates securing the extend 21 Support and slide the primary boom extension
cylinder to boom #1 (1). (Illustration 1) cylinder out of the boom assembly while
guiding the cables out of the boom and place it
15 Remove the cable guards (2) covering the
on a structure capable of supporting it.
sheaves attached to the extend cylinder.
(Illustration 1) Crushing hazard. The primary
16 Remove the locking plates (7) securing the boom extension cylinder may
extend cylinder sheaves to boom #2. become unbalanced and fall
(Illustration 1) when it is removed from the
boom if it is not properly
17 Remove the locking plates (3) securing the supported and attached to the
retract cables to boom #3. (Illustration 1) overhead crane.
18 Remove the fasteners securing the three
#3 boom extend adjustment bolt mounting Component damage hazard.
block. Cables can be damaged if they
are kinked, pinched or snagged
19 Attach a suitable lifting device to the extend during removal.
cylinder arms that will allow the cylinder to be
lifted to clear the mounting plates on the Note: During removal, the overhead crane strap will
#1 boom and pulled from the boom assembly. need to be adjusted for proper balancing.
support the cylinder as it is removed from the
boom assembly.
Part No. 1268496 SX-150 59

Boom Components
4-5
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. The boom extend and
retract functions should operate smoothly and be
free of hesitation, jerking and unusual noise.
1 Start the engine from the ground controls.
2 Raise and extend the boom approximately
15 feet / 4.6 m.
3 Fully retract the boom and lower to the
horizontal position.
4 Stop the engine.
5 Measure the distance between boom tubes
#1 and #2, measuring from the points
identified as (11) and (12). (Illustration 1) This
is dimension "A".
Note: The distance should be approximately 1 in /
2.6 cm. The actual measurement will be a function
of the primary extend/retract cylinder. Illustration 1
1 Boom tube #1
2 Boom tube #2
3 Boom tube #3
4 Boom tube #4
5 Boom #4 retract bolt
6 Boom #3 retract bolt
7 Boom #4 measuring edge
8 Boom #3 measuring surface
10 Boom #2 measuring surface
60 SX-150 Part No. 1268496

Boom Components
6 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". The gap is in tolerance.
Proceed to step 28.
Result: The measurement is more than 1.5 in /
3.8 cm greater than dimension "A". Proceed to
step 7.
Result: The measurement is less than 1 in /
step 20.
7 Remove the boom end cover from the pivot
end of the machine.
8 Locate the red locking brackets (2) covering
the cable adjustment bolts at the pivot end of
the boom (Illustration 2).
9 Loosen each of the three extend cable
adjustment bolts (4) five turns. (Illustration 2)
Illustration 2
1 #4 extend cable adjustment nuts
2 locking brackets
3 cable tension limit switch 6S
4 #3 extend cable adjustment bolts
5 cable tension limit switch 5S
6 limit switch actuator bracket
10 At the platform end of the boom, locate the

retract cable bolt under the # 1 boom tube (6).
(Illustration 1)
Part No. 1268496 SX-150 61

Boom Components
11 Loosen the jam nut on the cable tension retract 19 Re-measure the gap between boom tubes
bracket. Do not remove the nuts. #1 and #2 from points (11) and (12)
(dimension “A”) and boom tubes #2 and
12 Tighten the retract bolt using a torque wrench
#3 from points (9) and (10). (Illustration 1)
until boom tube #3 begins to move.
Note: If the torque wrench reaches 105 ft-lbs / 142
Nm and boom tube #3 hasn't moved, loosen the
extend cable adjustment bolts 5 turns and continue
Proceed to step 28.
tightening the boom tube #1 retract bolt.
13 Tighten the retract bolt until the gap between 3.8 cm greater than dimension "A". Repeat the
boom tubes #2 and #3 is 1 to 1.5 in / 2.5 to procedure beginning with step 9.
3.8 cm greater than dimension "A".
14 Torque the three extend cable adjustment 2.6 cm greater than dimension "A". Proceed to
bolts to 35 ft-lbs / 47.5 Nm. Make small step 20.
adjustments to the three bolts to insure the
cable break limit switch whisker is centered in 20 Loosen the retract cable retract bolt (6).
the limit switch actuator bracket (6). (Illustration 1)
(Illustration 2) 21 Tighten the three extend cable adjustment
15 Torque the #1 retract bolt to 105 ft-lbs / 142 bolts (4) (Illustration 2) until the gap between
Nm. boom tubes #2 and #3 is between 1 in / 2.6 cm
and 1.5 in / 3.8 cm plus dimension “A”.
16 Start the engine and fully raise and extend the
boom approximately 15 ft / 4.6 m. 22 Torque the retract cable retract bolt to
105 ft-lbs / 142 Nm.
17 Fully retract the boom and lower the boom to
the horizontal position. 23 Torque the three extend cable adjustment
bolts (4) to 35 ft-lbs / 47.5 Nm. Make small
18 Stop the engine. adjustments to the three bolts to insure the
cable tension limit switch arm (6) is centered in
the limit switch actuator bracket. (Illustration 1)
boom approximately 15 ft / 4.6 m.
62 SX-150 Part No. 1268496

Boom Components
25 Fully retract the boom and lower the boom to 29 Loosen the two extend cable adjustment bolts
the horizontal position. (1) five turns. (Illustration 2)
26 Stop the engine. 30 At the platform end of the boom, locate the
#4 retract cable retract bolt attached to the
27 Re-measure the gap between boom tubes
#2 boom tube (5). (Illustration 1)
#1 and #2 from points (11) and (12)
(dimension “A”) and boom tubes #2 and 31 Loosen the jam nut on the cable tension retract
#3 from points (9) and (10). (Illustration 1) bracket. Do not remove the nuts.
Result: The measurement is between 1 in / 32 Tighten the retract bolt using a torque wrench
2.6 cm and 1.5 in / 3.8 cm more than until boom tube #4 begins to move.
Note: If the torque wrench reaches 70 ft-lbs / 95 Nm
Proceed to step 28.
and boom tube #4 has not moved, loosen the
Result: The measurement is more than 1.5 in / #4 extend cable adjustment nuts 5 turns and
3.8 cm greater than dimension "A". Repeat the continue tightening the boom tube #4 retract bolt.
procedure beginning with step 9.
33 Tighten the retract bolt until the gap between
Result: The measurement is less than 1 in / boom tubes #3 and #4 is 1.5 in / 3.8 cm
2.6 cm greater than dimension "A". Repeat the greater than dimension "A".
34 Torque the two extend cable adjustment nuts
28 Measure the gap between boom tubes #3 and (1) to 35 ft-lbs / 47.5 Nm. Make small
#4 using measuring points (7) and (8). adjustments to the two nuts to insure the cable
(Illustration 1) tension limit switch arm (3) is centered in the
Result: The measurement is between 1 in / limit switch actuator bracket. (Illustration 2)
2.6 cm and 1.5 in / 3.8 cm more than 35 Torque the #4 retract bolt to 70 ft-lbs / 95 Nm.
Proceed to step 48. 36 Start the engine and fully raise and extend the
boom approximately 15 ft / 4.6 m.
3.8 cm greater than dimension "A". Proceed to 37 Fully retract the boom and lower the boom to
step 29. the horizontal position.
Result: The measurement is less than 1 in / 38 Stop the engine.

step 40.
Part No. 1268496 SX-150 63

Boom Components
39 Re-measure the gap between boom tubes 45 Fully retract the boom and lower the boom to
#1 and #2 from points (11) and (12) the horizontal position.
46 Stop the engine.
47 Re-measure the gap between boom tubes
#1 and #2 from points (11) and (12)
Proceed to step 48.
3.8 cm greater than dimension "A". Repeat the
Proceed to step 48.
step 40.
40 Loosen the retract cable retract bolt (5).
(Illustration 1)
41 Tighten the two extend cable adjustment nuts procedure beginning with step 40.
(1) (Illustration 2) until the gap between boom
48 Install the red locking brackets (2) over the
tubes #3 and #4 is between 1” and 1.5” plus
cable adjustment bolts. A flat edge of each bolt
dimension “A”.
head must be on top for the locking bracket to
42 Torque the retract cable retract bolt to 70 ft-lbs secure the bolts (Illustration 2).
/ 95 Nm.
Bodily injury hazard. Failure to
43 Torque the two extend cable adjustment nuts install the red cable adjustment
(1) to 35 ft-lbs / 47.5 Nm. Make small locking bracket would allow the
adjustments to the bolts to insure the cable cable mounting bolts to loosen
break limit switch arm (4) is centered in the and fall out which could result in
limit switch bracket. (Illustration 1) death or serious injury.
boom approximately 15 ft / 4.6 m. 49 Lower the boom to the stowed position.
64 SX-150 Part No. 1268496

Boom Components
How to R eplac e the Boom Extend/R etr act Cables
How to Replace the Boom

Extend/Retract Cables
Note: The cable sheaves must be inspected when
replacing the cables.
1 Remove the primary boom extension cylinder.
Refer to Repair Procedure, How to Remove
the Primary Boom Extension Cylinder.
#3 Boom extend cables:
2 The #3 boom extend cables remain attached
to the extension cylinder during removal.
#4 Boom extend cables:
3 Remove the cable tension limit switch
mounting bracket.
4 Remove the nut (1) securing the extend cable
to pivoting adjustment assembly (2).
(Illustration 1)
Illustration 1
1 #4 extend cable nut
2 #4 cable pivot assembly
3 idler pully
4 side wear pad
5 #3 retract cable
6 cable retainer
7 #4 extend cable
8 #4 retract cable
5 Remove the cable pivot assembly (2).
Part No. 1268496 SX-150 65

Boom Components
6 Remove the fasteners securing the idler pulley 10 Remove the center mounting bolt securing the
holding the upper extend cables and remove sheave to the cover plate (3).
the pulley (3). (Illustration 1)
11 Remove the remaining fasteners securing the
7 Remove the upper side wear pads (4) from the cover plate to the #3 boom tube. Do not
#4 boom tube. (Illustration 1) remove the fasteners labeled (2) at this time.
(Illustration 2)
8 Remove the anti-rotation bolts from the extend
cable. Attach electrician's tape to the threaded 12 Remove the side wear pad (4).
end of the extend cable.
13 Loosen the fasteners (2) securing the sheave
9 At the platform end, loosen but do not remove mounting plate to the boom tube.
the fasteners labeled (1). (Illustration 2)
14 Remove the sheave from the bearing.
15 At the platform end, pull on the cable that was
above the sheave and then feed the cable that
was below the sheave toward the pivot end.
16 Remove the cable retainer (6) securing the
ends of #4 extend cable and #4 retract cable.
(Illustration 1)
17 Attach electrician's tape to the lower end of the
#4 extend cable.
18 At the platform end, pull the upper end of the
cable from the boom tube and then the lower
end.
19 Perform the procedure on the other extend
cable.
20 Reverse the procedure to install the new
extend cable beginning with the lower end of
the cable.
Illustration 2
1 wear pad fastener
2 sheave mounting fastener
3 sheave retaining bolt
4 side wear pad
66 SX-150 Part No. 1268496

Boom Components
#3 Boom retract cables: 32 Remove the equalizing bracket from the

#4 boom retract cables.
21 Remove the fastener and the retract cable
guide between boom tubes #2 and #3. 33 Attach electrician's tape to the #4 retract cable
at the pivot end of the machine.
22 Remove the retract bolt from the #3 boom
retract cables at the platform end of the 34 Attach a suitable device to pull the #3 and
#1 boom. #4 boom tubes approximately 2 feet / 0.6 m.
Using an suitable overhead lifting device,
23 Remove the equalizing bracket from the attach a strap to the #3 and #4 boom tubes
#3 boom retract cables. and slightly lift the tubes.
24 At the platform end, attach electrician's tape to Note: This will relieve the pressure on the aluminum
the cable. spacers that guide the retract cables.
25 At the pivot end of the boom, remove the guide
35 Remove the aluminum spacers.
bracket between the #1 and #2 boom tubes.
26 At the pivot end, pull the retract cable out of the 36 At the platform end, pull the retract cable out of
boom tubes. the boom tube.
37 Repeat the procedure for the other retract
27 Repeat the procedure for the other retract
cable.
cable.
retract cable.
retract cable.
#4 Boom retract cables: 39 Adjust the boom extend/retract cables. Refer
to Repair Procedure, How to Adjust the Boom
29 Remove the #4 retaining sheave weldment Extend and Retract Cables.
from the #3 boom.
30 Remove the #4 retract cable sheave pin and
sheave.
31 Remove the retract bolt from the #4 boom
retract cables at the platform end of the
#2 boom.
Part No. 1268496 SX-150 67

Boom Components
4-6 Note: Use the following chart to identify the

Primary Boom Angle Sensor in this procedure.
The primary boom angle sensor is used to limit the
angle of the primary boom relative to the angle of
the turntable and gravity.
How to Calibrate the Primary Plus Minus Previous Enter

Boom Angle Sensor 1 Push in the ground controls red Emergency
Stop button to the off position.
Note: If the angle sensor is replaced, both the
sensor and magnet must be replaced as a set. 2 Turn the key switch to ground controls.
Note: Perform this procedure with the machine on a 3 Open the ground control box.
firm, level surface and in the stowed position with 4 Locate the calibration toggle switch at the top
the axles extended. of the ground control box. Activate calibration
Note: The turntable level sensor must be calibrated mode by moving the toggle switch in the left
prior to calibrating the primary boom. direction.
Note: RSB1AO and RSB1AS are calibrated at the
same time.
prevent the control box door from moving the
Note: Primary boom angle must be calibrated toggle switch while calibrating the machine.
before calibrating boom length. 6 Remove the key from the main key switch.
Note: If the calibration flags between SCON and Insert the key into the bypass/recovery key
TCON do not agree after calibration, a crosscheck switch and turn it to the bypass position.
fault is generated and recorded and the affected Note: The angle sensor calibration values will not
boom function is inhibited. be saved correctly unless the key switch is in the
bypass position and the calibration toggle switch is
activated.
procedure.
Note: A kit is available through Genie Product
Support (Genie part number 58351). This kit
cable harnesses.
68 SX-150 Part No. 1268496

Boom Components
7 Press and hold the enter button on the ground 13 Start the engine from the ground controls.
control panel while pulling out the ground
14 Press and hold a function enable/speed select
controls red Emergency Stop button to the on
button and the primary boom up button until
position. Hold the enter button for
the digital level displays 15 degrees.
approximately 5 seconds and then release it.
15 At the PRIMARY BOOM ANGLE TO GRAVITY
8 Enter sensor calibration mode by pressing the
15 DEG screen, press the plus or minus
buttons at the ground controls in the following
button to adjust the display to the exact value
shown on the digital level, then press the enter
9 Press the enter or previous button on the button.
LCD screen until DELETE PRIMARY BOOM
Note: If the measured angle already matches the
ANGLE SENSOR is displayed.
angle shown on the display at the ground controls,
10 Press the plus button to select YES, then press the plus button or minus button to change
press the enter button to accept. the angle and then change back to the measured
value. The system must detect a change in
11 Place the digital level on top of the primary
displayed value to record the calibrated value.
boom near the pivot and note the angle
displayed on the digital level. 16 Press and hold a function enable/speed select
12 Press the enter button until PRIMARY BOOM button and the primary boom up button until
ANGLE TO GRAVITY -2.6 DEG is displayed, the digital level displays 32 degrees.
press the plus or minus button to adjust the 17 At the PRIMARY BOOM ANGLE TO GRAVITY
display to the exact value shown on the digital 32 DEG screen, press the plus or minus
level, then press the enter button. button to adjust the display to the exact value
Note: If the measured angle already matches the shown on the digital level, then press the enter
angle shown on the display at the ground controls, button.
press the plus button or minus button to change Note: If the measured angle already matches the
the angle and then change back to the measured angle shown on the display at the ground controls,
value. The system must detect a change in press the plus button or minus button to change
displayed value to record the calibrated value. the angle and then change back to the measured
Note: If the system exits out of calibration mode
when the engine is started, repeat step 8 and
continue to step 13.
Part No. 1268496 SX-150 69

Boom Components
18 Press and hold a function enable/speed select 22 Press and hold a function enable/speed select
button and the primary boom up button until button and the primary boom button until the
the digital level displays 49 degrees. boom is fully raised.
19 At the PRIMARY BOOM ANGLE TO GRAVITY 23 At the PRIMARY BOOM ANGLE TO GRAVITY
49 DEG screen, press the plus or minus 82 DEG screen, press the plus or minus
button to adjust the display to the exact value button to adjust the display to the exact value
shown on the digital level, then press the enter shown on the digital level, then press the enter
button. button.
Note: If the measured angle already matches the Note: If the measured angle already matches the
angle shown on the display at the ground controls, angle shown on the display at the ground controls,
press the plus button or minus button to change press the plus button or minus button to change
the angle and then change back to the measured the angle and then change back to the measured
value. The system must detect a change in value. The system must detect a change in
displayed value to record the calibrated value. displayed value to record the calibrated value.
20 Press and hold a function enable/speed select 24 Press and hold the engine start button for
button and the primary boom up button until approximately 5 seconds to shut off the engine
the digital level displays 66 degrees. and to save the calibration settings.
21 At the PRIMARY BOOM ANGLE TO GRAVITY Note: Do not turn the engine off with the key switch
66 DEG screen, press the plus or minus or red Emergency Stop button or all calibration
button to adjust the display to the exact value points or values will not be saved.
shown on the digital level, then press the enter
button. 25 Press the enter or previous button on the
Note: If the measured angle already matches the
angle shown on the display at the ground controls, 26 Press the plus button to select YES, then
press the plus button or minus button to change press the enter button to accept.
the angle and then change back to the measured 27 Turn the key back to the run position and
value. The system must detect a change in remove the key from the bypass/recovery key
displayed value to record the calibrated value. switch. Insert the key into the main key switch
and turn it to ground controls.
70 SX-150 Part No. 1268496

Boom Components
28 Wait approximately 20 seconds and turn the 4-7

Stop button in.
Boom Length Sensor
installed. Close the control box door and install How to Calibrate the Primary
the door retaining fasteners. Boom Length Sensor
Note: When the control box door is closed, the Note: Perform this procedure with the machine on a
calibration toggle switch is automatically activated firm, level surface with the axles extended.
Note: The turntable level sensor must be calibrated
30 Pull out the red Emergency Stop button. Start prior to calibrating the primary boom.
the engine and lower the boom to the stowed
position. Be sure there are no calibration faults Note: LTB1LO and LTB1LS are calibrated at the
shown on the display. same time.
Note: Primary boom angle must be calibrated
before calibrating boom length.
Note: Platform leveling is set to default parameters
to avoid platform out of level faults during
calibration.
Note: If the calibration flags between SCON and
TCON do not agree after calibration, a crosscheck
fault is generated and recorded and the affected
boom function is inhibited.
Part No. 1268496 SX-150 71

Boom Components
Note: Use the following chart to identify the 8 Press and hold the enter button on the ground
description of each LCD screen control button used control panel while pulling out the ground
in this procedure. controls red Emergency Stop button to the on
9 Enter sensor calibration mode by pressing the
buttons at the ground controls in the following
1 With the boom in the stowed position, start the
LCD screen until DELETE PRIMARY BOOM
engine and fully raise the boom to its maximum
LENGTH CALIBRATION is displayed.
angle.
2 Push in the ground controls red Emergency
12 Start the engine and attempt to retract the
3 Turn the key switch to ground controls.
boom to insure it is fully retracted.
5 Locate the calibration toggle switch at the top LCD screen until BOOM FULLY
of the ground control box. Activate calibration RETRACTED? is displayed.
direction.
15 Fully extend the boom.
prevent the control box door from moving the 16 Press the enter or previous button on the
toggle switch while calibrating the machine. LCD screen until BOOM FULLY EXTENDED?
is displayed.
7 Remove the key from the main key switch.
Insert the key into the bypass/recovery key 17 Press the plus button to select YES, then
switch and turn it to the bypass position. press the enter button to accept.
Note: The length sensor calibration values will not
be saved correctly unless the key switch is in the
bypass / recovery position.
72 SX-150 Part No. 1268496

Boom Components
18 Press and hold the engine start button for

approximately 5 seconds to shut off the engine
and to save the calibration settings.
Result: An audible alarm sounds for 1 second.
Calibration has been stored.
Note: Do not turn the engine off with the key switch
or red Emergency Stop button or all calibration
points or values will not be saved.
21 Turn the bypass/recovery key switch to the run
position.
22 Remove the key from the bypass/recovery key
switch and insert the key into the main key
switch.
24 Start the engine and retract the boom to the
stowed position.Verify there are no primary
boom length sensor calibration faults shown
on the display.
Part No. 1268496 SX-150 73

Engines
5-1 5-2
RPM Adjustment Flex Plate
Refer to Maintenance Procedure in the appropriate The flex plate acts as a coupler between the engine
Service or Maintenance Manual for your machine, and the pump. It is bolted to the engine flywheel and
Check and Adjust the Engine RPM. has a splined center to drive the pump.
How to Remove the Flex Plate

1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located on the
drive pump.
2 Support the drive pump with an appropriate
lifting device. Then remove all of the pump
mounting plate to engine bell housing bolts.
3 Carefully pull the pump away from the engine
and secure it from moving.
4 Remove the flex plate mounting fasteners,
then remove the flex plate from the engine
flywheel.
74 SX-150 Part No. 1268496

Engines
How to Ins tall the Fl ex Plate
How to Install the Flex Plate 3 Perkins engines: Torque the pump plate
mounting bolts in sequence to 23 ft-lbs / 31
1 Install the flex plate onto the engine flywheel Nm. Then torque the pump plate mounting
with the rubber vibration isolators towards the bolts in sequence to 47 ft-lbs / 63 Nm.
pump.
2 Use blue thread locking compound and torque
the flex plate mounting bolts in sequence to
28 ft-lbs / 38 Nm. Then torque the flex plate
Nm.
3 Apply a high viscosity coupling grease (Genie
part number 128025) to the splines of the
pump shaft and flex plate.
4 Install the pump plate and pump assembly
onto the engine.
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
Perkins 1104D pump plate

Perkins 854F pump plate
Deutz and Perkins models
How to Install the Pump Plate

1 Using a suitable lifting device, install the pump
plate and pump assembly onto the engine.
2 Deutz engines: Torque the pump plate
Nm. Then torque the pump plate mounting Deutz TD2011L04i pump plate
bolts in sequence to 47 ft-lbs / 63 Nm.
Deutz TD2.9 pump plate
Part No. 1268496 SX-150 75

Ground Controls
6-1 How to Use the Bypass Mode

Bypass/Recovery Key Switch Tip-over hazard. Operating the
machine outside of the operating
The turntable control box (TCON) is the envelope while in Bypass mode
communication and operations center for the will result in death or serious injury
machine. The turntable control box contains two if proper operating procedures
key switches. The main key switch towards the top and safety precautions are not
of the control box is for selection of ground or followed. Do not use this mode if
platform controls. The key switch at the bottom of you are not trained and familiar
the control box is the Bypass/Recovery key switch. with the operating envelope of the
Bypass and Recovery modes are only intended for machine.
certain circumstances and are not part of normal
machine operation. If either the Bypass or the Note: Before using the Bypass mode, make sure
Recovery function is required, this indicates there you understand the fault code or issue affecting the
may be faults with the machine. Contact trained operation of the machine to be sure the use of
personnel immediately. bypass is required.
Bypass is used for a platform out-of-level condition The Bypass mode will allow the platform to be
and calibrating certain machine parameters. manually leveled when an out-of-level condition
exists. In the event that the platform angle is greater
Recovery is only to be used as a last attempt to
than 10° from level, the boom angle and platform
lower the platform when the operator in the platform
level functions are disabled. Use of the Bypass
is unable to do so, system failure or in emergency mode will allow the platform to be manually
situations. adjusted to within the normal operating envelope,
±4.5°. Only auxiliary power can be used to correct
an out of level platform fault.
1 Turn the engine off.
2 Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.
Note: The main key switch must remain in the
ground control position.
1 Run
2 Bypass / Recovery
3 Recovery
76 SX-150 Part No. 1268496

Ground Controls
How to Us e the R ec overy Mode
3 Turn the bypass/recovery key switch to the How to Use the Recovery Mode
bypass position.
Recovery is only to be used as a last attempt to
4 Using auxiliary power, operate the ground lower the platform when the operator in the platform
control buttons to level the platform. is unable to do so, system failure or in emergency
Note: Only the auxiliary power unit can be used to situations.
correct an out of level platform fault.
Bodily injury hazard. When using
5 Turn the bypass/recovery key switch to the run recovery mode, the platform may
position. not fully lower to the ground when
the recovery mode is completed.
6 Remove the key from the bypass/recovery key Failure to use only suitable
switch and insert the key into the main key equipment and/or practices to
switch. allow the operator to safely exit
Note: If the Bypass function has been used, there the platform could result in death
may be faults with the machine. Check the LCD or serious injury.
screen on the ground control box for machine faults,
then contact trained service personnel. Bodily injury hazard. Platform
leveling is not active when using
recovery mode. The platform
could reach high out-of-level
conditions when using this mode.
The operator will need to secure
themself to the platform to
prevent falling injury.
The recovery sequence will automatically retract

the primary boom and then lower the primary boom
using the auxiliary power unit to allow the operator
at the platform controls to exit the platform.
1 Turn the main key switch to ground controls.
Remove the key from the main key switch and
insert the key into the bypass/recovery key
switch.
Part No. 1268496 SX-150 77

Ground Controls
2 Turn and hold the bypass/recovery key switch 6-2

to the recovery position. The switch must be
held in the recovery position.
Circuit Boards
Result: The auxiliary power unit will turn on The ground control box contains a replaceable
and the boom will begin the following recovery membrane decal with touch sensitive buttons for
sequence. various machine functions. The ground control box
also contains two printed circuit boards:
· The primary boom will retract.
The LCD (Liquid Crystal Display) circuit board
· The primary boom will lower. is mounted to the inside of the control box lid which
Note: The key switch must be held in the recovery controls the LCD display screen.
position until the recovery sequence is complete or
The ECM circuit board is the main circuit board for
until the operator in the platform can safely exit the
platform. the machine. All operating parameters and
configuration of options for the machine are stored
Note: If any boom safety limit switches are faulty, in the ECM memory.
the boom will only retract and not lower and the
operator will need to be recovered from that point. Note: When the ECM circuit board is replaced, the
joysticks will need to be calibrated. Refer to Repair
Note: If the Recovery function has been used, this Procedure, How to Calibrate a Joystick.
will indicate there are faults with the machine. Tag
and remove the machine from service until the fault Note: When the ECM circuit board is replaced, all
has been corrected by trained personnel. the boom, platform and axle angle sensors will
need to be calibrated and in a specific order.
Contact Genie Product Support.
How to Remove the LCD Display

Screen Circuit Board
off position at both the ground and platform
controls.
2 Remove the ground control box lid fasteners.
78 SX-150 Part No. 1268496

Ground Controls
Component damage hazard. How to Remove the ALC-1000

Electrostatic discharge (ESD)
can damage printed circuit board Circuit Board
components. Maintain firm 1 Push in the red Emergency Stop button to the
contact with a metal part of the off position at both the ground and platform
machine that is grounded at all controls.
times when handling printed
circuit boards OR use a 2 Remove the ground control box lid fasteners.
grounded wrist strap. 3 Open the ground control box.
4 Carefully disconnect the LCD circuit board 4 Tag and disconnect the harnesses from the
ribbon cable from the ECM circuit board. ground control box.
5 Remove the LCD display circuit board 5 Remove the control cable receptacle retaining
retaining fasteners. fasteners from the side of the control box.
6 Carefully remove the LCD display circuit board 6 Attach a grounded wrist strap to the ground
from the ground control box lid. screw inside the control box.

can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
circuit boards OR use a
grounded wrist strap.
Part No. 1268496 SX-150 79

Ground Controls
7 Tag and carefully disconnect the wire 6-3

connectors from the circuit board.
Membrane Decal
8 Carefully disconnect the LCD circuit board
ribbon cable from the ECM circuit board. The membrane decal is a special decal that
consists of a decal with an electronic membrane on
9 Carefully disconnect the two ribbon cables the backside. The membrane contains touch
from the membrane decal at the ECM circuit sensitive areas that, when pushed, activate the
board. machine functions. The membrane contains touch
10 Remove the circuit board mounting fasteners. sensitive areas that activate the machine functions.
11 Carefully remove the circuit board from the
control box. How to Replace the Membrane
Decal
1 Turn the key switch to the off position and push
in the red Emergency Stop button to the off
position at both the ground and platform
controls.
2 Remove the ground control box lid fasteners.
80 SX-150 Part No. 1268496

Ground Controls
4 Carefully disconnect the two ribbon cables 6-4

from the membrane decal at the ECM circuit
board.
Full Machine Calibration
Electrocution/burn hazard. Full machine calibration must be completed in the
Contact with electrically charged proper sequence when the ALC-1000 circuit board
circuits could result in death or (TCON) in the ground control box has been
serious injury. Remove all rings, replaced or the turntable level sensor (SCON) has
watches and other jewelry. been replaced.
Component damage hazard. How to Fully Calibrate the

can damage printed circuit board Machine
components. Maintain firm Calibration procedures shall only be completed by
contact with a metal part of the qualified technicians that have Genie factory
machine that is grounded at all service training.
circuit boards OR use a Tip-over hazard. Failure to
grounded wrist strap. calibrate the machine in the
proper sequence could cause the
5 Carefully remove the membrane decal from machine to tip over resulting in
the control box lid while guiding the ribbon death or serious injury.
cables out of the control box lid.
6 Remove any decal adhesive from the control
procedure.
box lid with a mild solvent.
Note: Do not allow any solvent to come in contact Note: A kit is available through Genie Product
with the LCD display screen. Support (Genie part number 58351). This kit
7 Install the new membrane decal while guiding cable harnesses.
the ribbon cables through the control box lid.
8 Connect the ribbon cables to the ECM circuit description of each LCD screen control button used
board. in this procedure.
9 Close the control box lid and install the
retaining fasteners.

Note: Start this procedure with the booms in the
fully stowed position and the axle retracted.
Part No. 1268496 SX-150 81

Ground Controls
Full machine calibration must be completed in the
following sequence:
· Select engine configuration. Refer to Repair

Section Display Module. Unit of Measure
and Language.
· Joysticks. Refer to Repair Procedure, How
to Calibrate a Joystick.
· Turntable level sensor. Refer to Repair
Procedure, How to Calibrate the Turntable
Level Sensor.
· Platform level sensor. Refer to Repair
Procedure, How to Calibrate the Platform
Level Sensor.
· Axle angle sensors. Refer to Repair
Procedure, How to Calibrate the Axle Angle
Sensors.
· Steer sensors. Refer to Repair Procedure,
How to Calibrate All Steer Sensors.
· Primary boom angle sensor. Refer to Repair
Procedure, How to Calibrate the Primary
Boom Angle Sensor.
· Primary boom length sensor. Refer to
Repair Procedure, How to Calibrate the
Primary Boom Length Sensor.
· Jib boom bellcrank angle sensor. Refer to
Repair Procedure, How to Calibrate the Jib
Boom Bellcrank Sensor.
· Select option configuration. Refer to Repair
Section, Display Module, Options.
82 SX-150 Part No. 1268496

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. Calibration and parameter settings must be completed by a person

trained and qualified on the repair of this machine. Failure to properly calibrate or set
parameters could cause the machine to tip over resulting in death or serious injury.
Note: The key switch must be in the off position before entering the programming mode.
Note: Use the following chart to identify the description of each LCD screen control button used in this
procedure.

Activation of the enter or previous buttons scrolls through the screens. To change parameter values or
select a setting, use the plus button (to increase or scroll forward) and the minus button (to decrease or
scroll backwards). Then press the enter button to save the new value to memory. An audible beep will
indicate a save to memory. Use the enter and previous buttons to scroll to the EXIT menu. Use the plus
button to change to YES and use the enter button to exit.
Screen or Menu Procedure Description Range or Selection

Operator Default Hourmeter (on power up)
Engine speed
Engine oil pressure PSI (English)
Engine oil pressure kPa (metric)
Engine temperature °F (Engiish) engine temp will not display

until temp is >100°F
Engine temperature °C (metric) engine temp will not display
until temp is >38°C
Primary boom angle to gravity
Turntable level sensor X° direction
Turntable level sensor Y° direction
Platform level sensor degree
Battery volts
Part No. 1268496 SX-150 83

Display Module

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° to +83°
Length sensor extension inches 0in to 682in
Length sensor extension 0cm to 1732cm

centimeters
Axles fully extended YES/NO
Jib bellcrank angle -10° to +10°
DPF regeneration mode Auto/Force/Inhibit

Unit of Measure With key switch OFF, press and hold the Metric/English (measurement English, German,
and Language enter button and turn key switch to on units) French, Spanish,
position. Portuguese, Italian,
Release the enter button and press Dutch, and Swedish.
(plus)(minus)(minus)(plus) Deutz 2.9L Turbo
(D2.9T)
Set engine Deutz TD2011L04i
(DL04i)
Perkins 1104D-44T
(P1104)
Perkins 854F (P854T)
Overload With key switch OFF, press and hold the Clear Overload Recovery A passcode is required
Recovery enter button and turn key switch to on to clear message
(software V2.0 position.
and later) Release the enter buton and press
(plus)(minus)(minus)(plus)
Default Reset With key switch OFF, press and hold the Delete drive functions
enter button and turn key switch to on
position.
Release the enter button and press
(minus)(minus)(previous)(previous) Delete boom function speeds
Delete lift function ramps
Delete all (Contact Genie

Product Support before using
this option)
84 SX-150 Part No. 1268496

Display Module

Drive Functions With key switch OFF, press Forward extended drive speed % 120% (max) 100% (default)
and hold the enter button and 50% (min)
turn key switch to on position.
Forward not stowed drive 120% (max) 100% (default)
Release the enter button and speed % 50% (min)
press
(plus)(plus)(enter)(enter). Forward low drive speed % 120% (max) 100% (default)
50% (min)
Forward high drive speed % 120% (max) 100% (default)
50% (min)
Reverse extended drive speed % 120% (max) 100% (default)
50% (min)
Reverse not stowed drive 120% (max) 100% (default)
speed % 50% (min)
Reverse low drive speed % 120% (max) 100% (default)
50% (min)
Reverse high drive speed % 120% (max) 100% (default)
50% (min)
Drive acceleration % 125% (max) 100% (default)
25% (min)
Drive deceleration % 125% (max) 100% (default)
25% (min)
Speed limit on steer angle 100% (max) 50% (default)
0%
Part No. 1268496 SX-150 85

Display Module

Boom Function With key switch OFF, press Primary boom up speed stowed
Speeds and hold the enter button
and turn key switch to on
position. Primary boom up speed <80ft
Release the enter button and
press Primary boom up speed >80ft
(plus)(plus)(minus)(minus)
Primary boom up speed <120ft
Primary boom down speed stowed
Primary boom down speed <80ft
Primary boom down speed >80ft 120% max, 50% min,
Primary boom down speed >120ft 100% (default)
Primary boom down speed >150ft
Primary boom down speed >170ft
Primary boom extend speed
Primary boom retract speed
Jib up speed
Jib down speed
Jib rotate CW speed
Jib rotate CCW speed
Turntable rotate speed retracted
Turntable rotate speed not

retracted
Turntable rotate speed > 75'
Turntable rotate speed > 125'
86 SX-150 Part No. 1268496

Display Module

Lift Functions With key switch OFF, press and hold Primary boom up/down
Ramps the enter button and turn key switch ramp acceleration %
to on position.
Primary boom up/down
Release the enter button and press ramp deceleration %
(plus)(plus)(previous)(previous).
Primary boom extend/retract
ramp acceleration %
Primary boom extend/retract 150% max and 50% min
ramp deceleration % 100% (default),
Turntable rotate ramp 5% increment
acceleration %
Turntable rotate ramp
deceleration %
Jib up/down ramp
acceleration %
Jib up/down ramp
deceleration %
Jib rotate ramp
acceleration %
Jib rotate ramp
deceleration %
Valve Calibration With key switch OFF, press and hold Delete drive valve calibration
the enter button and turn key
Delete boom extend/retract
switch to on position.
valve calibration
Release the enter button and press
(minus)(minus)(enter)(enter). Delete turntable rotate valve
calibration
Allow turntable rotate speed YES/NO
calibration
Delete drive joystick
calibration
Delete boom up/down
joystick calibration
Delete boom extend/retract
Delete turntable rotate
Delete steer joystick
calibration
Delete jib up/down joystick
calibration
Delete jib rotate joystick
calibration
Part No. 1268496 SX-150 87

Display Module

Sensor Calibration With key switch OFF, press Set unit X-axis to gravity
and hold the enter button Set unit Y-axis to gravity
and turn key switch to on
position. Set platform level to gravity (YES/NO)
Release the enter button Platform level sensor millivolts/degree
and press
(plus)(enter)(enter)(plus). Delete axles angle sensors calibration?
(YES/NO)
Axle angle fully retracted (YES/NO)
Axle angle fully extended (YES/NO)
Delete all steer sensors calibrations?
(YES/NO)
Delete blue end blue side steer sensor
(LF) calibration? (YES/NO)
Delete yellow end blue side steer
sensor (LR) calibration? (YES/NO)
Delete blue end yellow side steer
sensor (RF) calibration? (YES/NO)
Delete yellow end yellow side steer Use +/- buttons to adjust
sensor (RR) calibration? (YES/NO)
Delete primary boom angle sensor
calibration? (YES/NO)
primary boom angle to gravity -2.6°
primary boom angle to gravity 15°
Delete boom length sensor calibration?
(YES/NO)
Boom fully retracted (YES/NO)
Boom fully extended (YES/NO)
Delete jib level angle sensor
calibration? (YES/NO)
Set jib level to gravity (YES/NO)
88 SX-150 Part No. 1268496

Display Module

Options With key switch OFF, press AC Generator (NONE/7.5KW/12.5KW)
and hold the enter button and
turn key switch to on position.
Release the enter button and
press
(minus)(minus)(plus)(plus).
Allow platform functions with AC (NO/YES)
generator ON?
Alarm options No (NO AL)/Motion (MO AL)/
Travel (TR AL)/ Descent (DE
AL)/ Travel and Descent (TD
AL)
Lift/Drive No (NO CO)/ Drive cut out
while not stowed (DCONS)/
Lifting or driving (LORDR)
Proximity Kill Switch? (NONE/PROX)
Platform Overload sensing? (NONE/PLFTS)
Flashing Beacon? (NO/YES)
Disable Steer Mode Change

while Driving? (NO/YES)
Rocker Switch steering? (NO/YES)
Foot Switch Lockout 30.0 max and 0.0 min, 10.0

(0-30 minutes) (default) Holding +/- button
will cause display to scroll
through options or increment
number settings
automatically at 0.2 min
increase/decrease
Platform Always Level to Gravity? (NO/YES)
Axle Motion Only While Driving? (NO/YES)
Chassis Tilt Options (CODRV/COALL)
Boom Length Limit (NONE/150FT/135FT/120FT)

(SX180)
(NONE/135FT/120FT/100FT)
(SX150)
Part No. 1268496 SX-150 89

Hydraulic Pumps
7-1 2 Tag, disconnect and plug the function pump

hydraulic hoses. Cap the fittings on the pump.
Function Pump
The function pump is a pressure compensated, hydraulic oil can penetrate and
variable displacement piston pump. Any internal burn skin. Loosen hydraulic
service to the pump should be performed at an connections very slowly to allow
authorized Sauer-Danfoss service center. Contact the oil pressure to dissipate
Genie Product Support to locate your local gradually. Do not allow oil to
authorized service center. squirt or spray.
3 Support the pump with a suitable lifting device.

How to Remove the Function
Pump 4 Remove the two pump mounting fasteners.
Carefully remove the pump.
the O-ring (if equipped) on the fitting and/or hose Component damage hazard. Be
end must be replaced. All connections must be sure to open the two hydraulic
torqued to specification during installation. Refer to tank valves and prime the pump
Specifications, Hydraulic Hose and Fitting Torque after installing the pump.
Specifications.
1 Locate the two hydraulic tank valves at the
hydraulic tank. Close the valves.
The engine must not be started
with the hydraulic tank shut-off
valves in the closed position or
component damage will occur. If
open closed
the tank valves are closed,
remove the key from the key
switch and tag the machine to
inform personnel of the
condition.
90 SX-150 Part No. 1268496

Hydraulic Pumps
How to Prime the F uncti on Pump How to Adj ust the Functi on Pump Standby Pr ess ure
How to Prime the Function Pump How to Adjust the Function Pump
Note: When removing a hose assembly or fitting, Standby Pressure
the O-ring (if equipped) on the fitting and/or hose 1 Connect a 0 to 5000 psi / 0 to 350 bar
end must be replaced. All connections must be pressure gauge to the test port on the function
torqued to specification during installation. Refer to manifold
Specifications. 2 Start the engine from the ground controls and
allow the engine to run at low idle.
1 Remove the case drain hydraulic hose from
the top of the function pump. 3 Observe the pressure reading on the pressure
gauge.
Note: The case drain hose is the smaller of the two
hoses on top of the function pump and closest to Result: The pressure gauge shows 350 psi /
the drive pump. 25 bar. One or both of the functions pumps are
correctly set. Proceed to step 4.
2 Locate and open the hydraulic tank shut-off
valve at the hydraulic tank that supplies Result: If the gauge shows a reading lower
hydraulic oil to the function pump. Do not open than 350 psi / 25 bar, both the function pumps
the valve for the drive pump. need to be adjusted higher Proceed to step 6.
3 When hydraulic fluid begins to come out of the Result: If the gauge shows a reading higher
case drain port of the function pump, install the than 350 psi / 25 bar, one or both of the
function pump case drain hose. function pumps need to be adjusted lower.
Proceed to step 8.
4 Clean up any oil that may have spilled.
Properly discard the used oil. Note: The reading will show the higher pressure of
the two function pumps.
6 Check for hydraulic leaks.
Part No. 1268496 SX-150 91

Hydraulic Pumps
Pressure reads 350 psi / 25 bar Pressure reads less than 350 psi / 25 bar
4 One or both of the function pumps may be at 6 Loosen the set screw for the standby pressure
the correct pressure. Loosen the set screw for adjustment screw on the rear function pump.
the standby pressure adjustment on the rear Turn the adjustment screw clockwise (higher
function pump and turn the adjustment screw pressure) until the pressure reads 350 psi /
clockwise (higher pressure). If the pressure 25 bar. Tighten the set screw.
increases above 350 psi / 25 bar, turn the
7 Loosen the set screw for the standby pressure
screw counterclockwise (lower pressure) until
adjustment screw on the mid function pump.
the gauge shows 350 psi / 25 bar. Tighten the
Turn the adjustment screw clockwise (higher
set screw.
pressure) until the pressure reads greater than
5 Loosen the set screw for the standby pressure 350 psi / 25 bar, then turn the adjustment
adjustment on the middle function pump and screw counterclockwise (lower pressure) until
turn the adjustment screw clockwise until the the pressure reads 350 psi / 25 bar. Tighten
pressure reads higher than 350 psi / 25 bar. the set screw. Proceed to step 11.
Once the gauge reads higher than 350 psi /
25 bar, turn the adjustment screw
counterclockwise until the gauge reads 350 psi
/ 25 bar. Tighten the set screw. Proceed to
step 11.
1 standby pressure set screw

2 standby pressure adjustment screw
92 SX-150 Part No. 1268496

Hydraulic Pumps
How to Adj ust the Functi on Pump Press ure Compens ator
Pressure reads more than 350 psi / 25 bar How to Adjust the Function Pump
8 Loosen the set screw for the standby pressure Pressure Compensator
adjustment screw on the rear function pump.
Note: Two people will be required to perform this
Turn the adjustment screw counterclockwise
procedure.
(lower pressure) and note if the pressure
drops. If so turn the adjust screw 1 Confirm the system relief pressure is set to
counterclockwise (higher pressure) until the specification. Refer to Repair Procedure,
pressure reads 350 psi / 25 bar. If the pressure Valve Adjustments - Function Manifold.
does not drop, turn the screw slightly
counterclockwise to lower the pressure and 2 Connect a 0 to 5000 psi / 0 to 350 bar
proceed to step 7. pressure gauge to the test port on the function
manifold
9 Loosen the set screw for the standby pressure
adjustment screw on the mid function pump. 3 Start the engine from the ground controls and
Turn the adjustment screw counterclockwise change the rpm to high idle.
until the pressure reads 350 psi / 25 bar. 4 Push and hold the high speed function enable
Tighten the set screw. Proceed to step 8. button (rabbit symbol). Do not activate any
10 Turn the adjustment screw on the rear function boom functions.
pump clockwise until the pressure reads 5 Locate the function enable solenoids below the
greater than 350 psi / 25 bar, then turn the function pumps on the engine tray. Disconnect
screw counterclockwise until the gauge reads the wire connector from the inside solenoid
350 psi / 25 bar. Tighten the adjustment screw. and observe the pressure reading on the
11 Turn the engine off and remove the pressure pressure gauge.
gauge. Result: The gauge should show 2900 psi /
200 bar on the end pump.
Result: If the gauge does not show 2900 psi /
200 bar, proceed to step 7 to adjust the
function pump pressure compensator.
6 Reconnect the wire connector to the inside
solenoid and disconnect the wire connector
from the outer solenoid.
Result: The gauge should show 2700 psi /
186 bar on the middle pump.
Result: If the gauge does not show 2700 psi /
186 bar, proceed to step 7 to adjust the
function pump pressure compensator.
Part No. 1268496 SX-150 93

Hydraulic Pumps
7 Loosen the set screw for the pressure 7-2
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. The only adjustment
that can be made to the pump is the neutral or null
adjustment. Any internal service to the pump should
be performed at an authorized Sauer-Danfoss
service center. Contact Genie Product Support to
locate your local authorized service center.
How to Remove the Drive Pump

1 pressure compensator set screw Component damage hazard. The
2 pressure compensator adjustment screw work area and surfaces where
this procedure will be performed
8 Adjust the pressure compensator pressure. must be clean and free of debris
Turn the adjustment screw clockwise to that could get into the hydraulic
increase the pressure or counterclockwise to system and cause severe
decrease the pressure. Tighten the set screw. component damage. Dealer
service is recommended.
Component damage hazard. Do
not adjust the pressure Note: When removing a hose assembly or fitting,
compensator higher than the O-ring (if equipped) on the fitting and/or hose
specified. end must be replaced. All connections must be
9 Verify that the wire connectors to both Specifications, Hydraulic Hose and Fitting Torque
solenoids are securely connected. Specifications.
10 Turn the engine off and remove the pressure
1 Disconnect the wiring plug at the electronic
gauge.
displacement controller (EDC), located on the
drive pump.
94 SX-150 Part No. 1268496

Hydraulic Pumps
2 Locate the two hydraulic tank valves at the 5 Carefully pull the drive pump out until the pump
hydraulic tank. Close the valves. coupler separates from the flex plate.
6 Remove the drive pump from the machine.
The pump(s) may become
unbalanced and fall if not
properly supported.

The engine must not be started
open closed
with the hydraulic tank shut-off
Component damage hazard. valves in the closed position or
The engine must not be started component damage will occur. If
with the hydraulic tank shut-off the tank valves are closed,
valves in the closed position or remove the key from the key
component damage will occur. If switch and tag the machine to
the tank valves are closed, inform personnel of the
remove the key from the key condition.
switch and tag the machine to
inform personnel of the
condition.

from the drive and function pumps. Cap the
fittings on the pumps.
squirt or spray.
4 Support the pumps with a suitable lifting device

and remove the two drive pump mounting
fasteners.
Part No. 1268496 SX-150 95

Hydraulic Pumps
How to Prime the Dri ve Pump
How to Prime the Drive Pump

Component damage hazard. Be
sure to open the two hydraulic
tank valves before performing
this procedure.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure

gauge to either the "A" or "B" test port on the
drive pump.
2 Perkins models: Disconnect the engine
wiring harness from the fuel shutoff solenoid at
the injector pump.
Deutz models: Hold the manual fuel shutoff
valve clockwise to the closed position.
3 Have another person crank the engine with the
starter motor for 15 seconds, wait 15 seconds,
then crank the engine an additional
15 seconds or until the pressure reaches
approximately 250 psi / 17 bar.
4 Perkins models: Connect the engine wiring
harness to the fuel solenoid.
Deutz models: Release the manual fuel
shutoff valve.
6 Check for hydraulic leaks.
96 SX-150 Part No. 1268496

Part No. 1268496 SX-150 97

Manifolds
8-1
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
No. Item
1 Orifice, 0.025 in / 0.635 mm
2 Orifice, 0.025 in / 0.635 mm
Primary boom extend/retract
circuit, regulates pressure drop 33-37 ft-lbs /
3 Differential sensing valve, 150 psi / 10.3 bar I
across secondary boom 45-50 Nm
extend/retract proportional valve
Proportional solenoid operated 2 position Primary boom extend/retract, 33-37 ft-lbs /
4 J
2 way directional valve normally closed proportional speed control 45-50 Nm
Solenoid operated 3 position 4 way 19-21 ft-lbs /
5 W Primary boom extend/retract
directional valve 25.7-28.5 Nm
6 X Primary boom lift/ cylinder up/down
directional valve 45-50 Nm
Proportional solenoid operated 2 position Primary lift cylinder up/down high 33-37 ft-lbs /
7 L
2 way directional valve normally closed speed control 45-50 Nm
Proportional solenoid operated 2 position Primary lift cylinder up/down low 19-21 ft-lbs /
8 K
2 way directional valve normally closed speed control 25.7-28.5 Nm
Prevents the draining of hydraulic
19-21 ft-lbs /
9 Check valve, 5 psi / 0.34 bar V oil from the jib manifold and
25.7-28.5 Nm
platform manifold
19-21 ft-lbs /
10 Check valve, 5 psi / 0.34 bar A Pressure Circuit #2
25.7-28.5 Nm
19-21 ft-lbs /
11 Check valve, 5 psi / 0.34 bar B Pressure Circuit #1
25.7-28.5 Nm
Prevents hydraulic pressure from 19-21 ft-lbs /
12 Check valve, 5 psi / 0.34 bar D
flowing back into auxiliary pump #2 25.7-28.5 Nm
98 SX-150 Part No. 1268496

Manifolds
Part No. 1268496 SX-150 99

Manifolds
Function Manifold Components, View 1 continued

Schematic
Index No. Description Function Torque
Item
Prevents hydraulic pressure from 19-21 ft-lbs /
13 Check valve, 5 psi / 0.34 bar C
flowing back into auxiliary pump #1 25.7-28.5 Nm
24-26 ft-lbs /
14 Relief valve, 3200 psi / 221 bar E System relief
32.6-35.4 Nm
15 Orifice, 0.025 in / 0.635 mm Y
Primary and secondary retract 46-54 ft-lbs /
16 Relief valve, 2500 psi / 172.4 bar H
pressure limit 62.6-73.4 Nm
100 SX-150 Part No. 1268496

Manifolds
Part No. 1268496 SX-150 101

Manifolds
Function Manifold Components – View 2

Schematic
Item
Pilot operated 3 position, 4 way, Boom cylinder extend / retract 46-54 ft-lbs /
17 R
directional valve circuit 62.6-73.4 Nm
Pilot operated 3 position, 4 way, Boom lift cylinder up/down 46-54 ft-lbs /
18 P
directional valve circuit 62.6-73.4 Nm
Turntable rotate circuit,
Differential sensing valve, 150 psi / regulates pressure drop across 19-21 ft-lbs /
19 F
10.3 bar turntable rotate proportional 25.7-28.5 Nm
valve
19-21 ft-lbs /
20 Solenoid operated proportional valve M Turntable rotate, speed control
25.7-28.5 Nm
21 N Turntable rotate circuit
directional valve 32.6-35.4 Nm
Holds hydraulic oil in boom 33-37 ft-lbs /
22 Check valve, 100 psi / 6.9 bar Q
extend circuit 45-50 Nm
102 SX-150 Part No. 1268496

Manifolds
Part No. 1268496 SX-150 103

Manifolds
8-2
Valve Adjustments - How to Adjust the Primary Boom
Function Manifold Extend Relief Valve
Note: Perform this procedure with the axles
How to Adjust the Function extended.
Manifold Relief Valve 1 Locate limit switch LSB4EO on the cable track
side of boom #2.
stowed position. 2 Disconnect the wire connector from the limit
switch and connect a jumper wire to pin 1 and
Note: Refer to Function Manifold Component list to pin 2 of the deutsch connector on the upper
locate the system relief valve. limit switch cable.
1 Connect a 0 to 5000 psi / 0 to 350 bar Note: The correct wire connector will be a 4 pin
pressure gauge to the test port on the function connector with a red and blue marker on the cable.
manifold
3 Start the engine and fully extend the primary
2 Start the engine and raise the boom slightly boom. Turn the engine off.
and completely lower the jib boom. Turn off the
engine. 4 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the ptest port on the
3 Push and hold the auxiliary button and the jib function manifold.
down button and observe the pressure reading
on the pressure gauge. Refer to 5 Start the engine from the ground controls and
Specifications, Hydraulic Component press and release the rpm select button until
Specifications. the engine changes to high idle.
4 Use a wrench to hold the relief valve and

remove the cap.
5 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
6 Repeat step 3 to confirm relief valve pressure.

7 Remove the pressure gauge.
104 SX-150 Part No. 1268496

Manifolds
6 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.
Note: The pressure at the ptest port on the function
manifold is a combination of pressures produced by
the differential valve and relief valve. Setting the
valve to the combined pressure will insure the relief
valve is set to the correct pressure.
7 Turn the engine off. Use a wrench to hold the
relief valve and remove the cap.
8 Adjust the internal hex socket. Turn it
clockwise to increase the pressure or
Tip-over hazard. Do not adjust
the relief valve higher than
specified.
9 Repeat step 6 to confirm relief valve pressure.

10 Connect the limit switch connector that was
disconnected in step 2.
11 Remove the pressure gauge.
12 Start the engine and fully retract the primary
boom. Turn the engine off.
Part No. 1268496 SX-150 105

Manifolds
8-3
Platform Level and Rotation Manifold Components
to SX150H-518
The platform manifold is mounted under the jib boom.
Index Schematic
No. Item
Proportional Directional Control valve, 25-30 ft-lbs /
1 DC Jib level up/down 33.9-40.7 Nm
3 position 5 way
Jib boom up/down circuit, regulates
Pressure compensator valve, 150 psi / 19-21 ft-lbs /
2 DD pressure drop across jib boom 25.8-28.6 Nm
10.3 bar
up/down proportional. valve
19-21 ft-lbs /
3 Proportional solenoid valve, 3 position 4 way DE Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
4 Solenoid valve, 3 position 4 way DF Platform rotate left/right 25.8-28.6 Nm
19-21 ft-lbs /
5 Flow control valve, 0.2 gpm / 0.76 L/min DG Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
6 Flow control valve, 0.2 gpm / 0.76 L/min DH Platform rotate left/right circuit 25.8-28.6 Nm
106 SX-150 Part No. 1268496

Manifolds
8-3A
Platform Level and Rotation Manifold Components
from SX150H-519
The platform manifold is mounted under the jib boom.
Index Schematic
No. Item
19-21 ft-lbs /
1 Proportional solenoid valve, 3 position 4 way DG Jib level up/down 25.8-28.6 Nm
19-21 ft-lbs /
2 Solenoid valve, 3 position 4 way DB Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
3 Solenoid valve, 3 position 4 way DF Jib level up/down 25.8-28.6 Nm
19-21 ft-lbs /
4 Proportional solenoid valve DD Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
5 Solenoid valve, 2 position 2 way DH Platform level up/down 25.8-28.6 Nm
19-21 ft-lbs /
6 Flow control valve, 0.2 gpm / 0.76 L/min DA Platform rotate left/right circuit 25.8-28.6 Nm
19-21 ft-lbs /
7 Flow control valve, 0.2 gpm / 0.76 L/min DC Platform rotate left/right circuit 25.8-28.6 Nm
Part No. 1268496 SX-150 107

Manifolds
8-4
Jib Boom Manifold Components
to SX150H-518
The jib boom manifold is mounted on the primary extension boom at the platform end.
Schematic
Item
19-21 ft-lbs /
1 Check valve, 25 psi / 1.7 bar EE Holds oil in jib boom manifold
25.8-28.6 Nm
Jib boom rotate circuit, regulates
Pressure sensing valve, 150 psi / 19-21 ft-lbs /
2 EC pressure drop across jib boom rotate
10.3 bar 25.8-28.6 Nm
proportional. valve
Proportional solenoid valve, 3 position 25-30 ft-lbs /
3 ED Jib bellcrank level
4 way 33.9-40.7 Nm
4 EB Jib rotate left/right
3 position 5 way 25.8-28.6 Nm
108 SX-150 Part No. 1268496

Manifolds
8-4A
Jib Boom Manifold Components
from SX150H-519
The jib boom manifold is mounted on the primary extension boom at the platform end.
Schematic
Item
Proportional solenoid valve,2 position 19-21 ft-lbs /
1 EF Jib level up/down
2 way 25.8-28.6 Nm
19-21 ft-lbs /
2 Solenoid Valve EH Jib rotate left/right
25.8-28.6 Nm
Jib boom rotate circuit, regulates
Pressure sensing valve, 150 psi / 19-21 ft-lbs /
3 EC pressure drop across jib boom rotate
10.3 bar 25.8-28.6 Nm
proportional. valve
19-21 ft-lbs /
4 Check valve, 25 psi / 1.7 bar EE Holds oil in jib boom manifold
25.8-28.6 Nm
5 EB Jib rotate left/right
3 position 5 way 25.8-28.6 Nm
19-21 ft-lbs /
6 Solenoid Valve EG Jib rotate left/right
25.8-28.6 Nm
Proportional solenoid valve, 3 position 25-30 ft-lbs /
7 ED Jib bellcrank level
4 way 33.9-40.7 Nm
Part No. 1268496 SX-150 109

Manifolds
8-5
Function Enable Manifold
The function enable manifold is located on the engine side below the hydraulic pumps.
Index No. Description Schematic Item Function Torque

Enables function pumps to provide
20-25 ft-lbs /
1 Solenoid valve, 2 position 2 way A hydraulic pressure for all boom and
27-34 Nm
steer/axle functions
110 SX-150 Part No. 1268496

Part No. 1268496 SX-150 111

8-6
Steer and Axle Manifold Components
The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index Schematic
No. Item
Right front steer cylinder retract 20-25 ft-lbs /
1 Flow control valve, 1.5 gpm / 5.7 L/min BI
circuit 27-34 Nm
Prevents right front steer cylinder 20-25 ft-lbs /
2 Check valve BC
from moving when not steering 27-34 NM
Prevents left front steer cylinder from 20-25 ft-lbs /
3 Check valve BB
moving when not steering 27-34 Nm
Prevents right front steer cylinder 20-25 ft-lbs /
4 Check valve BW
from moving when not steering 27-34 Nm
Prevents left front steer cylinder from 20-25 ft-lbs /
5 Check valve BV
Right rear steer cylinder extend 20-25 ft-lbs /
6 Flow control valve, 2.1 gpm / 8 L/min BL
circuit 27-34 Nm
Steer left/right, right rear steer 20-25 ft-lbs /
7 Solenoid valve, 3 position 4 way BQ
cylinder 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs /
8 Check valve BY
Prevents left rear steer cylinder from 20-25 ft-lbs /
9 Check valve BX
Steer left/right, left rear steer 20-25 ft-lbs /
10 Solenoid valve, 3 position 4 way BP
cylinder 27-34 Nm
20-25 ft-lbs /
11 Flow control valve, 2.1 gpm / 8 L/min BJ Left rear steer cylinder extend circuit
27-34 Nm
50-55 ft-lbs /
12 Flow control valve, 9 gpm / 34 L/min BS Axle extend/retract circuit
68-75 Nm
50-55 ft-lbs /
13 Solenoid Valve, 2 position 3 way BU Axle retract
68-75 Nm
50-55 ft-lbs /
14 Solenoid Valve, 2 position 3 way BT Axle extend
68-75 Nm
112 SX-150 Part No. 1268496

Part No. 1268496 SX-150 113

Steer and Axle Manifold, continued

Schematic
Item
Pressure reducing valve, 2400 psi / 30-35 ft-lbs /
15 BR Axle extend/retract circuit
165 bar 41-47 Nm
Prevents left rear steer cylinder 20-25 ft-lbs /
16 Check valve BD
Left rear steer cylinder retract 20-25 ft-lbs /
17 Flow control valve, 1.5 gpm / 5.7 L/min BK
circuit 27-34 Nm
Prevents right rear steer cylinder 20-25 ft-lbs /
18 Check valve BE
Right rear steer cylinder retract 20-25 ft-lbs /
19 Flow control valve, 1.5 gpm / 5.7 L/min BM
circuit 27-34 Nm
Left front steer cylinder retract 20-25 ft-lbs /
20 Flow control valve, 1.5 gpm / 5.7 L/min BG
circuit 27-34 Nm
Left front steer cylinder extend 20-25 ft-lbs /
21 Flow control valve, 2.1 gpm / 8 L/min BF
circuit 27-34 Nm
Right front steer cylinder extend 20-25 ft-lbs /
22 Flow control valve, 2.1 gpm / 8 L/min BH
circuit 27-34 Nm
Steer left/right, left front steer 20-25 ft-lbs /
23 Solenoid valve, 3 position 4 way BN
cylinder 27-34 Nm
Steer left/right, right front steer 20-25 ft-lbs /
24 Solenoid valve, 3 position 4 way B0
cylinder 27-34 Nm
25 Pilot operated piston A
114 SX-150 Part No. 1268496

Part No. 1268496 SX-150 115

Manifolds
8-7 4 Turn the engine off.

Valve Adjustments - Steer and 5 Adjust the internal hex socket. Turn it
Axle Manifold clockwise to increase the pressure or
How to Adjust the Axle Relief Component damage hazard. Do
Valve not adjust the relief valve
pressures higher than
specifications.
the axles extended.
6 Repeat steps 3 through 5 to confirm relief
Note: Refer to Steer and Axle Manifold list to locate valve pressure.
the axle relief valve. 7 Remove the pressure gauge.
Note: Two people will be required to perform this
procedure.
1 Connect a 0 to 5000 psi / 0 to 350 bar
pressure gauge to the test port on the steer
and axle manifold.
2 Locate the axle relief valve on the steer and
axle manifold. Hold the relief valve with a
wrench and remove the cap.
3 Start the engine from the platform controls and
press down the foot switch. Press and hold the
axle extend button at the platform controls.
Observe the pressure reading on the pressure
gauge. Refer to Specifications, Hydraulic
Component Specifications.
116 SX-150 Part No. 1268496

Manifolds
8-8
Traction Manifold Components
The traction manifold is mounted inside the drive chassis at the circle end of the machine
Index Schematic
No. Item
30-35 ft-lbs /
1 Check valve AZ Anti-cavitation
40.7-47.5 Nm
26-30 ft-lbs /
2 Solenoid Valve, 2 position 3 way AX Two-speed drive motor shift
35.3-40.7 Nm
26-30 ft-lbs /
3 Solenoid Valve, 2 position 3 way AY Brake release
35.3-40.7 Nm
Keeps brakes released if temporary loss of 20-25 ft-lbs /
4 Check valve AW
charge pressure 27.1-33.9 Nm
Charge pressure circuit that directs hot oil 50-55 ft-lbs /
5 Shuttle Valve, 3 position 3 way AO
out of low pressure side of drive pumpp 67.8-74.6 Nm
20-25 ft-lbs /
6 Relief valve, 250 psi / 17.23 bar AN Charge pressure circuit
27.1-33.9 Nm
20-25 ft-lbs /
7 Orifice Plug, 0.030 inch / 0.762 mm AV Brake and two-speed circuit
27.1-33.9 Nm
20-25 ft-lbs /
8 Check valve AU Anti-cavitation
27.1-33.9 Nm
30-35 ft-lbs /
9 Check valve BA Anti-cavitation
40.7-47.5 Nm
Controls flow to square end drive motors in 90-100 ft-lbs /
10 Flow divider/combiner valve AR
forward and reverse 122-135.6 Nm
20-25 ft-lbs /
11 Check valve AK Anti-cavitation
27.1-33.9 Nm
Equalizes pressure on both sides of 30-35 ft-lbs /
12 Orifice, 2 gpm / 7.6 L/min AS
divider/combiner valve 40.7-47.5 Nm
Part No. 1268496 SX-150 117

Manifolds
118 SX-150 Part No. 1268496

Manifolds
Traction Manifold Components

Index Schematic
No. Item
13 Orifice, 2 gpm / 7.6 L/min AQ
divider/combiner valve AP 40.7-47.5 Nm
14 Orifice, 2 gpm / 7.6 L/min AL
divider/combiner valve AM 40.7-47.5 Nm
20-25 ft-lbs /
15 Check valve AJ Anti-cavitation
27.1-33.9 Nm
Controls flow to circle end drive motors in 90-100 ft-lbs /
16 Flow divider/combiner valve AM
forward and reverse 122-135.6 Nm
Controls flow to divider/combiner valves AM 90-100 ft-lbs /
17 Flow divider/combiner valve AP
and AR 122-135.6 Nm
20-25 ft-lbs /
18 Check valve AT Anti-cavitation
27.1-33.9 Nm
Part No. 1268496 SX-150 119

Manifolds
120 SX-150 Part No. 1268496

Manifolds
8-9 8 Hold the hot oil relief valve and remove the
cap.
Valve Adjustments - Traction
Manifold 9 Start the engine from the ground controls.
10 Press and hold the function enable/high rpm
select button (rabbit symbol) position.
How to Adjust the Hot Oil Relief
11 Adjust the internal hex socket until the
Valve pressure reading on the gauge is 40 psi /
Note: The hydraulic oil temperature must be 100°F 2.8 bar less than the pressure reading on the
to 150°F / 38°C to 65.5°C before performing this pump. Turn it clockwise to increase the
procedure. pressure or counterclockwise to decrease the
pressure. Install the relief valve cap.
1 Connect a 0 to 600 psi / 0 to 50 bar pressure
gauge to either the "A" or "B" test port on the 12 Turn the engine off.
drive pump. 13 Remove the pressure gauge.
2 Locate the hot oil relief valve on the traction
manifold. Hold the relief valve and remove the
cap.
3 Turn the internal hex socket clockwise fully
until it stops. Install the cap.
5 Press and hold the function enable/high rpm
select button (rabbit symbol) position. Note the
reading on the pressure gauge.
6 Turn the engine off.
7 Remove the pressure gauge from the drive
pump. Connect the gauge to the test port
located on the traction manifold.
Part No. 1268496 SX-150 121

Manifolds
8-10
Generator Manifold Components
The oil diverter manifold is mounted near the hydraulic generator located in the engine compartment.
Index Schematic
No. Item
19-21 ft-lbs /
1 Check valve FD Controls flow to diverter valve
25.7-28.5 Nm
33-37 ft-lbs /
2 Solenoid Valve FC Pilot valve to diverter valve
45-50 Nm
24-26 ft-lbs /
3 Relief valve, 3200 psi / 221 bar FF Generator relief valve
32.6-35.4 Nm
33-37 ft-lbs /
4 Solenoid Valve FA Charge pressure circuit
45-50 Nm
7-8 ft-lbs /
5 Check valve FG Prevents oil to generator
9.5-10.8 Nm
45-50 ft-lbs /
6 Needle valve FB Charge pressure circuit
61-68 Nm
Counterbalance valve 4.5:1 2000 psi / Adds backpressure to generator 45-50 ft-lbs /
7 FE
138 bar circuit 61-68 Nm
122 SX-150 Part No. 1268496

Manifolds
8-11 Valve Coil Resistance

Valve Coils Specification
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 increase or decrease by 4% for each 18°F / 10°C
valve. Critical to normal operation is continuity that your air temperature increases or decreases
within the coil that provides this force field. from 68°F / 20°C.
Since coil resistance is sensitive to temperature, Valve Coil Resistance Specification
resistance values outside specification can produce
Function Manifold
erratic operation. When coil resistance decreases
below specification, amperage increases. As schematic item L 4.5Ω@12v
resistance rises above specification, voltage schematic item K 5.4Ω@12v
increases.
schematic item J, N, T, U 7.1Ω@12v
While valves may operate when coil resistance is schematic item W, X 6.2Ω@12v
outside specification, maintaining coils within schematic Item M 8.8Ω@12v
specification will help ensure proper valve function
over a wide range of operating temperatures. Steer Manifold
schematic item BT, BU 5.6Ω@12v
Electrocution/burn hazard. schematic item BF, BH, BJ, BL 7.2@12v
circuits could result in death or Traction Manifold
serious injury. Remove all rings, schematic item AX, AY 7.2Ω@12v
watches and other jewelry. Jib Manifold
1 Tag and disconnect the wiring from the coil to schematic item EB, ED 6.2Ω@10v
be tested. Platform Manifold
2 Test the coil resistance. schematic item DB, DD, DG 6.2Ω@10v

Function Enable Manifold
Result: The resistance should be within
specification, plus or minus 30%. schematic item A 7.2Ω@12v
Generator Manifold
Result: If the resistance is not within
specification, plus or minus 30%, replace the schematic item FB, FD 7.1Ω@12v
coil.
Part No. 1268496 SX-150 123

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.
1 Test the coil for resistance. Refer to Repair 1 multimeter

Procedure, How to Test a Coil. 2 9v DC battery
3 10Ω resistor
2 Connect a 10W resistor to the negative
4 coil
terminal of a known good 9V DC battery.
Connect the other end of the resistor to a Note: Dotted lines in illustration indicate a reversed
terminal on the coil. connection as specified in step 6.
Resistor 10Ω 3 Set a multimeter to read DC current.
Genie part number 27287
Note: The multimeter, when set to read DC current,
Note: The battery should read 9V DC or more when should be capable of reading up to 800 mA.
measured across the terminals.
4 Connect the negative lead to the other terminal
on the coil.
5 Momentarily connect the positive lead from the
multimeter to the positive terminal on the 9V
DC battery. Note and record the current
reading.
6 At the battery or coil terminals, reverse the
connections. Note and record the current
reading.
Result: Both current readings are greater than
0 mA and are different by a minimum of 20%.
The coil is good.
Result: If one or both of the current readings
are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.
124 SX-150 Part No. 1268496

Turntable Rotation Components
9-1 5 Remove the drive hub mounting bolts and

remove the turntable rotation assembly from
Turntable Rotation Assembly the machine.
6 Repeat steps 3 through 5 for the other
How to Remove a Turntable turntable rotation assembly.
Rotation Assembly Tip-over hazard. If the turntable
Note: When removing a hose assembly or fitting, rotation lock pin is not properly
the O-ring (if equipped) on the fitting and/or hose installed, machine stability is
end must be replaced. All connections must be compromised and the machine
torqued to specification during installation. Refer to could tip over when the drive hub
Specifications, Hydraulic Hose and Fitting Torque is removed from the machine,
Specifications. which could result in death or
serious injury.
Note: Perform this procedure with the primary boom
between the circle-end tires and with the machine Crushing hazard. The drive hub
on a firm, level surface. could become unbalanced and
1 Secure the turntable from rotating with the fall if not properly supported by an
turntable rotation lock pin. overhead crane or lifting device
when removed from the machine.
2 Remove the ground controls side fixed
turntable cover. Note: When installing a turntable rotation assembly,
the rotation gear backlash must be adjusted. Refer
3 Tag, disconnect the hydraulic hoses from the to Repair Procedure, Adjust the Turntable Rotation
turntable rotation motor. Cap the fittings on the Gear Backlash.
motor.
squirt or spray.
4 Attach a lifting strap from an overhead crane or

other suitable lifting device to the lifting eye on
the turntable rotation assembly.
Part No. 1268496 SX-150 125


How to Adj ust the Tur ntabl e R otati on Gear Bac klas h
7 Turn the adjustment bolt 1/2 to 3/4 turn

counterclockwise. Tighten the lock nut on the
How to Adjust the Turntable adjustment bolt.
Rotation Gear Backlash 8 Pull the backlash pivot plate away from the
1 Secure the turntable from rotating with the turntable until it contacts the adjustment bolt.
turntable rotation lock pin. Then lubricate the mounting fasteners on the
backlash pivot plate and torque to
2 Remove the fixed turntable cover at the ground specification. Refer to Specifications, Machine
controls side of the machine. Torque Specifications.
3 Loosen the backlash pivot plate mounting 9 Rotate the turntable through an entire rotation.
bolts. Check for tight spots that could cause binding.
4 Push the backlash pivot plate towards the Readjust if necessary.
turntable as far as possible (this will push the
rotation pinion gears into the turntable bearing
ring gear).
5 Loosen the lock nut on the adjustment bolt.
6 Turn the adjustment bolt clockwise until it
contacts the backlash pivot plate.
1 backlash pivot plate

2 adjustment bolt with lock nut
3 backlash pivot plate mounting bolts
126 SX-150 Part No. 1268496

9-2 1 Push in the ground controls red Emergency

Turntable Level Sensor
How to Calibrate the Turntable 3 Locate the calibration toggle switch at the top
of the ground control box. Activate calibration
Level Sensor mode by moving the toggle switch in the left
Note: If the Safety Controller (SCON) has been direction.
replaced, the entire machine needs to be calibrated 4 Temporarily install a control box door retaining
in a specific order. Refer to Repair Procedure, How fastener between the door and the box to
to Fully Calibrate the Machine. prevent the control box door from moving the
Note: Perform this procedure with the boom fully
retracted and in the stowed position and with the 5 Turn the key switch to ground controls.
machine on a firm, level surface.
6 Remove the key from the main key switch.
Note: A digital level will be required to perform this Insert the key into the bypass/recovery key
procedure. switch and turn it to the bypass position.
Note: A kit is available through Genie Product Note: The angle sensor calibration values will not
Support (Genie part number 58351). This kit be saved correctly unless the key switch is in the
includes a digital level with a magnetic base and bypass position and the calibration toggle switch is
cable harnesses. activated.
Note: Use the following chart to identify the 7 Press and hold the enter button on the ground
description of each LCD screen control button used control panel while pulling out the ground
in this procedure. controls red Emergency Stop button to the on
Part No. 1268496 SX-150 127

8 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.
1 -X Axis
2 +X Axis
3 Platform end
1 Run
2 Bypass / Recovery 11 Press the plus button or minus button to
3 Recovery adjust the display to the exact value shown on
the digital level and press the enter button.
LCD screen until SET UNIT X AXIS LEVEL TO Note: If the measured angle already matches the
GRAVITY is displayed. 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
LCD screen,until SET UNIT Y AXIS LEVEL TO
GRAVITY is displayed.Place the digital level
along the Y axis of the turntable.
1 + Y Axis
2 - Y Axis
128 SX-150 Part No. 1268496

13 Press the plus button or minus button to 18 Use the key to turn the bypass / recovery key
adjust the display to the exact value shown on switch to the run position.
the digital level and press the enter button.
Note: Be sure that the bypass/recovery key switch
Note: If the measured angle already matches the is in the run position before attempting to operate
angle shown on the display at the ground controls, the machine.
press the plus button or minus button to change
the angle and then change back to the measured 19 Start the engine. Be sure there are no
value. The system must detect a change in calibration faults shown on the display.
16 Wait approximately 20 seconds and turn the
Stop button in.
Part No. 1268496 SX-150 129

Axle Components
10-1 3 Remove the steer sensor cover retaining

fasteners. Remove the steer sensor assembly.
Steer Sensors
Note: If the sensor activator pin needs to be
The steer sensors measure steer angle and replaced, install the new activator pin per Illustration
communicates that information to the ground 1.
controls ECM. The steer sensor on the ground
controls side of the machine at the square-end acts
as the lead sensor when in front wheel steer mode.
In rear wheel steer mode, the steer sensor on the
ground controls side of the machine at the
circle-end acts as the lead sensor. The other three
sensors follow the position, or steer angle, of the
lead sensor. There is a steer sensor mounted to the
top of each steer yoke upper pivot pin.
How to Replace a Steer Sensor

Note: When the steer sensor is replaced, both the
sensor and magnet must be replaced as a set.
Note: Perform this procedure with the axles fully Illustration 1
retracted and the boom in the stowed position. (square end, yellow side and circle end, blue side shown)
1 Align the remaining wheels on the machine so

they are visually parallel to the chassis as
close as possible.
2 Disconnect the steer sensor assembly cable
from the main harness to be replaced.
130 SX-150 Part No. 1268496

Axle Components
Left front (square-end, blue side) and right rear 6 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.
7 Install the steer sensor cover retaining
fasteners. Do not tighten the cover retaining
fasteners.
8 Connect the steer sensor assembly cable to
the main harness.
9 Calibrate the steer sensor. Refer to Repair
Procedure, How to Calibrate a Replacement
Steer Sensor.
Note: Be sure the yoke pivot pin retaining plate is
fully engaged into the pivot pin and that the
fasteners are securely tightened.
Right front (square-end, yellow side) and left
rear (circle-end, blue side) angle sensors:
Illustration 2
1 installed position
2 starting position
3 sensor cover
4 rotation arrow
4 Position the new steer sensor assembly over

the sensor activator pin with the sensor cable
angled towards the tire. Refer to Illustration 2.
5 Align the sensor with the pin and install the
sensor on to the pin.
Note: Be sure the sensor activator pin is engaged
into the sensor.
Illustration 3
1 starting position
2 installed position
3 sensor cover
4 rotation arrow
Part No. 1268496 SX-150 131

Axle Components
How to C alibr ate a Repl acement Steer Sens or
10 Position the new steer sensor assembly over How to Calibrate a Replacement
the sensor activator pin with the sensor cable
angled away from the tire. Refer to Illustration
Steer Sensor
3. Note: If a steer angle sensor has been removed or
replaced, the steer angle sensors will need to be
11 Align the sensor with the pin and install the
calibrated.
sensor on to the pin.
Note: Be sure the sensor activator pin is engaged Note: Perform this procedure with the axles
into the sensor. retracted and the tires straightened.
12 Rotate the sensor housing in a clockwise Note: Two people will be required to perform this
direction until the sensor cable is pointing procedure.
away from the machine. Refer to Illustration 2. Note: Be sure the yoke pivot pin retaining plate is
13 Install the steer sensor cover retaining fully engaged into the pivot pin and that the
fasteners. Do not tighten the cover retaining fasteners are securely tightened.
fasteners.
14 Connect the steer sensor assembly cable to
the main harness. 2 Select the proper steer mode. If a front
(square-end) steer angle sensor has been
15 Calibrate the steer sensor. Refer to Repair replaced, select rear steer mode. If a rear
Procedure, How to Calibrate a Replacement (circle-end) steer angle sensor has been
Steer Sensor. replaced, select front steer mode.
Note: Be sure the yoke pivot pin retaining plate is 3 Have another person press down the foot
fully engaged into the pivot pin and that the switch.
fasteners are securely tightened.
4 At the new steer angle sensor, loosen the steer
angle sensor cover retaining fasteners. Do not
remove the fasteners or the sensor cover.
5 Rotate the sensor cover clockwise or
counterclockwise until the tire is straight in
relation with the other tires. Tighten the sensor
cover fasteners.
Note: If available, WebGPI can also be used for this
procedure.
off position.
132 SX-150 Part No. 1268496

Axle Components
How to C alibr ate All Steer Sensors
How to Calibrate All Steer 5 Using a voltmeter set to DC voltage, probe the
back of the electrical connector at pins B and
Sensors C.
Note: This procedure will only need to be performed
6 Left front (square-end, blue side) and right
if the ground controls circuit board (TCON) has
rear (circle-end, yellow side) angle
been replaced.
sensors: Rotate the sensor cover clockwise or
Note: Perform this procedure with the axles counterclockwise until the voltage reading is
retracted and the tires straightened. between 1.4 to 1.6V DC. Tighten the sensor
cover fasteners.
description of each LCD screen control button used Right front (square-end, yellow side) and
in this procedure. left rear (circle-end, blue side) angle
sensors: Rotate the sensor cover clockwise or
counterclockwise until the voltage reading is
between 3.4 to 3.6V DC. Tighten the sensor
cover fasteners.
Note: If available, WebGPI can also be used for this
Plus Minus Previous Enter procedure.
1 Locate the calibration toggle switch at the top 7 Remove the key from the main key switch.
of the ground control box. Activate calibration Insert the key into the bypass/recovery key
mode by moving the toggle switch in the left switch and turn it to the bypass position.
direction.
Note: The angle sensor calibration values will not
2 Temporarily install a control box door retaining be saved correctly unless the key switch is in the
fastener between the door and the box to bypass position and the calibration toggle switch is
prevent the control box door from moving the activated.
3 Turn the key switch to ground controls and pull off position.
out the ground controls red Emergency Stop
button to the on position.
4 Loosen the steer angle sensor cover retaining
fasteners. Do not remove the fasteners or the
sensor cover.
Part No. 1268496 SX-150 133

Axle Components
9 Press and hold the enter button on the ground Delete all Steer Sensor Calibrations
control panel while pulling out the ground
controls red Emergency Stop button to the on 11 Press the enter or previous button on the
position. Hold the enter button for LCD screen until DELETE ALL STEER
approximately 5 seconds and then release it. SENSORS CALIBRATION is displayed. Press
the plus button to select YES, then press the
enter button to accept.
14 Proceed to step 21.
Delete a Single Steer Sensor Calibration
15 To calibrate a single steer sensor, delete the
specific steer sensor calibration
LCD screen until DELETE _____ STEER
SENSORS CALIBRATION is displayed.
Example: DELETE BLUE END BLUE SIDE
1 Run
STEER SENSORS CALIBRATION (FL).
2 Bypass / Recovery 17 Press the plus button to select YES, then
3 Recovery press the enter button to accept.
10 Enter sensor calibration mode by pressing the 18 Press the enter or previous button on the
buttons at the ground controls in the following LCD screen until EXIT is displayed.
sequence: (plus)(enter)(enter)(plus). 19 Press the plus button to select YES, then
134 SX-150 Part No. 1268496

Axle Components
20 Push in the red Emergency Stop button to the 10-2

off position.
Steer Cylinders
the door retaining fasteners. How to Remove a Steer Cylinder
Note: When the control box door is closed, the Note: When removing a hose assembly or fitting,
calibration toggle switch is automatically activated the O-ring (if equipped) on the fitting and/or hose
to exit out of calibration mode. end must be replaced. All connections must be
22 Use the key to turn the bypass / recovery key Specifications, Hydraulic Hose and Fitting Torque
switch to the run position. Specifications.
Note: Be sure that the bypass/recovery key switch Note: Perform this procedure with the axles
is in the run position before attempting to operate extended.
the machine.
from the steer cylinder. Cap the fittings on the
cylinder.
squirt or spray.
2 Support the steer cylinder with a suitable lifting

device. Protect the cylinder rod from damage.
3 Remove the pin retaining fasteners from both
steer cylinder pivot pins.
4 Use a soft metal drift to remove the pin.
5 Remove the steering cylinder from the
machine.
Crushing hazard. The steer
cylinder may become unbalanced
and fall if not properly supported
by the lifting device when
removed from the machine.
Part No. 1268496 SX-150 135

Axle Components
10-3 4 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" port of the cylinder and the return
Extension Cylinder hose from the power unit to the "E" port on the
cylinder.
the O-ring (if equipped) on the fitting and/or hose 5 Support the axle extension cylinder with a
end must be replaced. All connections must be suitable lifting device. Protect the cylinder rod
torqued to specification during installation. Refer to from damage.
Specifications, Hydraulic Hose and Fitting Torque 6 Remove the pin retaining fasteners from both
Specifications. axle extension cylinder pivot pins.
Note: Perform this procedure with the machine on a 7 Use a soft metal drift to remove the pin.
the axles extended. 8 Using the portable hydraulic power unit, retract
the axle extension cylinder until the ends of the
Note: This procedure will require the use of a cylinder clear the axles.
portable hydraulic power unit.
9 Remove the axle extension cylinder from the
1 Tag, disconnect and plug the hydraulic hoses machine.
from the axle extension cylinder. Cap the
fittings on the cylinder. Crushing hazard. The axle
extension cylinder may become
Bodily injury hazard. Spraying unbalanced and fall if not properly
hydraulic oil can penetrate and supported by the lifting device.
squirt or spray.
2 Remove the axle extension limit switch cover

fasteners. Remove the cover.
3 Remove the limit switch mounting fasteners
and remove the limit switch. Do not disconnect
the wiring.
136 SX-150 Part No. 1268496

Axle Components
10-4 4 Temporarily install a control box door retaining

Axle Angle Sensors prevent the control box door from moving the
The axle angle sensors measure the axle angle and toggle switch while calibrating the machine.
communicates that information to the ground 5 Remove the key from the main key switch.
controls ECM. There are two axle angle sensors. Insert the key into the bypass/recovery key
They are located on opposite axle pivot pins at each switch and turn it to the bypass position.
end of the chassis.
How to Calibrate the Axle Angle

Sensors
in this procedure.

Note: If an axle angle sensor has been removed or
replaced, the axle angle sensors will need to be
calibrated. 1 Run
2 Bypass / Recovery
Note: Perform this procedure with the axles fully 3 Recovery
retracted and the boom in the stowed position.
Note: The angle sensor calibration values will not
Note: Two people will be required to perform this be saved correctly unless the key switch is in the
procedure. bypass position and the calibration toggle switch is
1 Push in the ground controls red Emergency activated.
Stop button to the off position. 6 Press and hold the enter button on the ground
2 Turn the key switch to ground controls. control panel while pulling out the ground
controls red Emergency Stop button to the on
3 Locate the calibration toggle switch at the top position. Hold the enter button for
of the ground control box. Activate calibration approximately 5 seconds and then release it.
direction.
Part No. 1268496 SX-150 137

Axle Components
7 Enter sensor calibration mode by pressing the 16 Wait approximately 20 seconds and turn the
buttons at the ground controls in the following machine off by pressing the red Emergency
sequence: (plus)(enter)(enter)(plus). Stop button in.
8 Press the enter or previous button on the 17 Remove the fastener that was temporarily
LCD screen until DELETE AXLE ANGLE installed. Close the control box door and install
SENSORS CALIBRATION is displayed. the door retaining fasteners.
9 Press the plus button to select YES, then Note: When the control box door is closed, the
press the enter button to accept. calibration toggle switch is automatically activated
10 At the AXLE ANGLES FULLY RETRACTED
screen, press the plus button to select YES, 18 Use the key to turn the bypass / recovery key
then press the enter button to accept. switch to the run position.
11 When the AXLE ANGLES FULLY EXTENDED Note: Be sure that the bypass/recovery key switch
screen is displayed, turn the main key switch to is in the run position before attempting to operate
platform controls, start the engine and fully the machine.
extend the axles.
Note: If the system exits out of calibration mode
when the engine is started, repeat step 10.
15 Press and hold the engine start button for
approximately 5 seconds to shut off the engine
and to save the calibration settings.
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. 1 Run
2 Bypass / Recovery
3 Recovery
138 SX-150 Part No. 1268496

Generators
11-1 4 Start the engine from the platform controls.

Welder Generator 5 Turn on the generator from the platform
controls and let the generator run for at least
three minutes.
How to Set the Welder Generator
6 Insert the leads from a multimeter set to
Frequency register frequency (HZ) and turn the needle
Note: Perform this procedure with the machine on a valve until the frequency is 2 Hz above the
firm, level surface. normal frequency.
Note: The normal frequency will be either 50 Hz or
60 Hz, depending on the country.
stowed position.
7 While holding the adjusting screw, tighten the
1 Plug a 1000 watt load into the generator outlet
retaining nut on the needle valve.
like a portable work light or heater.
8 Turn off the generator and then turn off the
2 Loosen the retaining nut on the needle valve
engine.
and screw the adjustment screw clockwise
until it stops.
1 Needle valve
3 Turn the adjusting screw counterclockwise two

turns.
Part No. 1268496 SX-150 139

Fault Codes
Section 4 Faul t Codes
Before Troubleshooting:
R Read, understand and obey the safety rules
R Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey: R Read each appropriate fault code thoroughly.
Attempting short cuts may produce hazardous
R Troubleshooting and repair procedures shall be
conditions.
completed by a person trained and qualified on
the repair of this machine R Be aware of the following hazards and follow
generally accepted safe workshop practices.
R Immediately tag and remove from service a
damaged or malfunctioning machine. Electrocution/burn hazard.
R Repair any machine damage or malfunction Contact with electrically charged
before operating the machine. circuits could result in death or
R Unless otherwise specified, perform each watches and other jewelry.
procedure with the machine in the following
configuration: Note: Two persons will be required to safely
perform some troubleshooting procedures.
· Machine parked on a firm, level surface
· Key switch in the off position with the key
removed
· The red Emergency Stop button in the off
position at both the ground and platform
controls
· Wheels chocked
· All external AC power supply disconnected
from the machine
· Boom in the stowed position
· Turntable secured with the turntable rotation
lock
· Welder disconnected from the machine (if
equipped with the weld cable to platform
option)
140 SX-150 Part No. 1268496

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. Check the connections to
Value Too High
ensure the connector terminals have
Value Too Low not backed out. Substitute a known
good joystick. If necessary replace and
Value at 0 V recalibrate joystick.
Not calibrated Joystick Speed and Direction frozen at Calibrate Joystick.
zero and neutral.
Just calibrated Initiate one second beep of audible Self-clearing (transient)
warning device
Primary Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
zero and neutral.
warning device
Steer Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
zero and neutral.
warning device
Part No. 1268496 SX-150 141


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. If necessary replace
membrane switch.
Primary Boom Ext/Ret Fault Check (both Primary Boom Ext/Retract disabled, Check ribbon and connector from
buttons on TCON buttons pressed) display message on LCD membrane switch. If necessary replace
membrane switch.
Primary Extend/Retract Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
Speed operation at default speed
Operational Primary Boom Value at 5.0 V Disable Boom Up, Extend Down, TT Power up controller with problem
Length Sensor Rotate, and Propel. Boom Retract corrected.
allowed and Boom Down allowed if fully
Value Too High
retracted as sensed by LSB3RO.
Value Too Low Propel allowed once boom is fully
stowed. Display message on LCD.
Value at 0 V Alarm sounds
Not calibrated Primary Up only active from TCON Calibrate Sensor
activate alarm
warning device
Safety Primary Boom Length Value at 5.0 V Disable Boom Up, Extend Down, TT Power up controller with problem
Sensor Rotate, and Propel. Boom Retract corrected.
Value Too High
Value Too Low Propel allowed once boom is fully
stowed. Display message on LCD.
Value at 0 V Alarm sounds
Not calibrated Primary up only active from TCON, Calibrate Sensor
activate alarm
warning device
142 SX-150 Part No. 1268496


RSB1AO/RSB1AS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, and Propel powers in SCON. corrected.
Boom Retract allowed and Boom Down
allowed if fully retracted as sensed by
LSB3RS. Alarm sounds. Propel
allowed once boom is fully stowed.
Display message on LCD: BOOM
ANGLE SENSORS CROSS CHECK
FAULT.
LTB1LO/LTB1LS Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
LSB3RS. Alarm sounds. Display
message on LCD: BOOM LENGTH
SENSORS CROSS CHECK FAULT.
RSB1AO (boom angle) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Active Cross-check Rotate, and Propel powers in SCON. corrected.
LSB3RO. Alarm sounds. Display
message on LCD: RSB1AO ACTIVE
CROSS CHECK FAULT.
LTB1LO (boom length) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Active Cross-check Rotate, and Propel powers in SCON. corrected.
message on LCD: LTB1AO ACTIVE
CROSS CHECK FAULT.
Part No. 1268496 SX-150 143


RSB1AO/LSB1DO (10°) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
message on LCD: LTB1AO ACTIVE
CROSS CHECK FAULT.
LTB1LO/LSB3RO (3 ft) Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
LSB3RS. Alarm sounds. Display
message on LCD: LTB1LO/LSB4RO
CROSS CHECK FAULT.
LSB2RO (151ft)/LSB4EO Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
(150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
message on LCD: LSB2RO/LSB4EO
CROSS CHECK FAULT.
144 SX-150 Part No. 1268496


LSB2RS (151ft)/LSB4ES Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
(150 ft) Cross-check Rotate, and Propel powers in SCON. corrected.
message on LCD: LSB2RS/LSB4ES
CROSS CHECK FAULT.
Primary Boom Extend Valve Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
zero and neutral, Alarm sounds. Check for an open or shorted valve coil.
Repair or replace as necessary.
Primary Boom Retract Valve
Primary Boom Up Valve
Primary Boom Down Valve
Primary Lock-Out Valve #1
Primary Lock-Out Valve #2
Engine Speed Range Check Display message on LCD Engine is running below 50 RPM.
(underspeed) Check fuel system.
Oil Pressure Range Check (low Display message on LCD Oil pressure is low. Check sender and
oil pressure) oil level.
Water/Oil Temperature Range Check Display message on LCD Engine is overheating. Check sender,
(high temp) water or oil level or radiator/heat
exchanger.
Oil Pressure Sender Fault Check Display message on LCD Check wiring to senders for opens or
shorts. Repair or replace senders.
Water/Oil Temp Sender
Part No. 1268496 SX-150 145


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.
Axle Valves Fault Check Limited Speed and Direction frozen at Check for defective or damaged wiring.
zero and neutral, Alarm sounds. Check for an open or shorted valve coil.
DCON CAN Bus Fault Check Display message on LCD Disable Check CAN bus wiring from TCON to
propel DCON through rotator. Repair or
replace wiring or DCON.
CAN Bus Fault Check Display message on LCD Check CAN bus wiring from TCON to
SCON/PCON. Repair or replace wiring
or SCON/PCON.
Tether Power P3 Fault Check Display message on LCD TETHER Power up controller with problem
POWER P3 FAULT corrected.
Valve Power P6R1 Fault Check Display message on LCD VALVE Power up controller with problem
POWER P6R1 FAULT corrected.
Engine Power P6R2 Fault Check Display message on LCD ENGINE Power up controller with problem
Enable Input P7 Fault Check Display message on LCD ENABLE Power up controller with problem
INPUT P7 FAULT corrected.
Enable Output P7R Fault Check Display message on LCD ENABLE Power up controller with problem
OUTPUT P7R FAULT corrected.
DCON Valve Power P7R Fault Check Display message on LCD DCON Power up controller with problem
VALVE POWER P7R FAULT corrected.
Primary Down Power P9A Fault Check Display message on LCD PRI DOWN Power up controller with problem
POWER P9A FAULT corrected.
Ignition/Fuel Power P9B Fault Check Display message on LCD IGN/FUEL Power up controller with problem
POWER P9B FAULT corrected.
146 SX-150 Part No. 1268496


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
Axle Retract Power P12 Fault Check Display message on LCD AXLE Power up controller with problem
RETRACT POWER P12 FAULT corrected.
Test Point P14 (not currently Fault Check Display message on LCD TEST POINT Power up controller with problem
used) P14 FAULT corrected.
Test Point P18 (not currently Fault Check Display message on LCD TEST POINT Power up controller with problem
used) P18 FAULT corrected.
Platform Level Valve P22 Fault Check Display message on LCD PLAT LEVEL Power up controller with problem
VALVE P22 FAULT corrected.
Primary Up/Down Valve Fault Check Display message on LCD PRI UP/DN Power up controller with problem
Power P22R VLV PWR P22R FAULT corrected.
Propel Power P38 Fault Check Display message on LCD PROPEL Power up controller with problem
PWR P38 FAULT corrected.
Turntable Rotate Power P39 Fault Check Display message on LCD Power up controller with problem
TURNTABLE ROTATE P39 FAULT corrected.
Secondary Up/Ext Power Fault Check Display message on LCD SEC UP/EXT Power up controller with problem
P30 (not currently used) POWER P30 FAULT corrected.
Platform Overload Fault Check Display message on LCD Power up controller with problem
(if active) corrected.
Platform Overload Switches
Inconsistent
Part No. 1268496 SX-150 147


Turntable Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
not backed out. Substitute a known
Value Too Low good joystick. If necessary replace and
recalibrate joystick.
Value at 0 V
zero and neutral.
warning device
Turntable Rotate Buttons on Fault Check (both Turntable rotate disabled Display Check ribbon and connector from
TCON buttons pressed) message on LCD membrane switch. If necessary replace
membrane switch.
Turntable Rotate Speed Not calibrated Display message on LCD and allow Perform auto calibrate procedure.
operation at default speed
Turntable Rotate Flow Valve Not calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
Display message on LCD.
warning device
Value Too High Limited Speed and Direction frozen at Check for opens in the wiring or a bad
zero and neutral, Alarm sounds. ground. Replace coil if necessary
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary
148 SX-150 Part No. 1268496


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.
Turntable Rotate
Counterclockwise Valve
Operational Turntable Level Value at 5.0 V Flash unit out of level icon and LED and Check that SCON is grounded
Sensor X Direction activate alarm
Value Too High Replace SCON
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Safety Turntable Level Value at 5.0 V Flash unit out of level icon and LED and Check that SCON is grounded
Sensor X Direction activate alarm
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Operational Turntable Level Value at 5.0 V Primary up and extend disabled, Alarm Check that SCON is grounded
Sensor Y Direction sounds
Value Too Low
Value at 0 V
Out of Tolerance
warning device
Part No. 1268496 SX-150 149


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 Low
Value at 0 V
Out of Tolerance
warning device
Primary Boom Up/Down Not calibrated Normal function except threshold for Calibrate Thresholds.
Flow Valve(s) (#1 and #2) one or the other direction is zero.
warning device
Value Too Low
Primary Boom Not calibrated Normal function except threshold for Calibrate Thresholds.
Extend/Retract Flow Valve one or the other direction is zero.
warning device
Value Too Low
150 SX-150 Part No. 1268496


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.
Propel allow once boom is fully stowed.
Display message on LCD. Alarm
sounds.
Value Too High
Value Too Low
Value at 0 V
activate alarm
warning device
Safety Primary Boom Angle Value at 5.0 V Disable Boom Up, Extend, Down, TT Power up controller with problem
Sensor Rotate, and Propel. Boom Retract corrected.
Propel allow once boom is fully stowed.
Display message on LCD. Alarm
sounds.
Value Too High
Value Too Low
Value at 0 V
activate alarm
warning device
Part No. 1268496 SX-150 151


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
warning device
Platform Rotate Clockwise Fault Check Fault Check Check for defective or damaged wiring.
Valve Check for an open or shorted valve coil.
Platform Rotate
Counterclockwise Valve
Jib Up/Down Flow Valve(s) Not calibrated Normal function except threshold for Perform calibration procedure
one or the other direction is zero.
warning device
Value Too Low
152 SX-150 Part No. 1268496


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.
warning device
Value Too Low
Jib Rotate CW/CCW Flow Not calibrated Normal function except threshold for Perform calibration procedure
Valve(s) one or the other direction is zero.
warning device
Value Too Low
Platform Level Up / Platform Not calibrated Normal function except threshold for one Perform calibration procedure
Level Down Flow Valve or the other direction is zero. Display
message on LCD.
warning device
Value Too Low Limited Speed and Direction frozen at Check for shorts to ground in the
zero and neutral, Alarm sounds. wiring. Replace coil if necessary
Part No. 1268496 SX-150 153


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. Display Power up controller with problem
buttons pressed) message on LCD corrected.
Jib Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value Too Low good joystick. If necessary replace
and recalibrate joystick.
Value at 0 V
Not calibrated Joystick Speed and Direction frozen at
zero and neutral.
warning device
Jib Rotate Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value at 0 V
zero and neutral.
warning device
154 SX-150 Part No. 1268496


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 Sensor is out of range. Check sensor
extend and retract LED flash and actuating pin for proper
installation. Repair or replace sensor
Value Too Low
and recalibrate.
Value at 0 V Primary up and Extend disabled, axle Check for 5.0 VDC at the sensor.
extend and retract LED flash Check for damaged wiring going to
the sensor. Check that the % .0 VDC
LED is lit on the TCON board. Repair
or replace as necessary
Not calibrated Primary up only active from TCON, Perform calibration procedure
activate alarm
warning device
Rear 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 Sensor is out of range. Check sensor
extend and retract LED flash and actuating pin for proper
Value Too Low
and recalibrate.
Value at 0 V Primary up and Extend disabled, axle Check for 5.0 VDC at the sensor.
extend and retract LED flash Check for damaged wiring going to
Not calibrated Primary up only active from TCON, Perform calibration procedure
activate alarm
warning device
Part No. 1268496 SX-150 155


Propel Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the
Value Too High
Value at 0 V
Not calibrated Joystick Speed and Direction frozen at Calibrate Thresholds.
zero and neutral.
warning device
Propel Valves Not calibrated Joystick Speed and Direction frozen at Calibrate Thresholds.
Forward/Reverse zero and neutral.
Propel EDC Just calibrated Initiate one second beep of audible Self-clearing (transient)
Forward/Reverse warning device
Value Too Low Check for shorts to ground in the
wiring. Replace coil if necessary
Motor Valve Speed Fault Check Limited Speed and Direction frozen at Check for defective or damaged
zero and neutral, Alarm sounds. wiring. Check for an open or shorted
valve coil. Repair or replace as
Brake Valve
necessary.
156 SX-150 Part No. 1268496


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 Sensor is out of range. Check sensor
zero and neutral, Alarm sounds. and actuating pin for proper
and recalibrate.
Value Too Low
Value at 0 V Limited Speed and Direction frozen at Check for 5.0 VDC at the sensor.
zero and neutral, Alarm sounds. Check for damaged wiring going to
Right Front Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
and recalibrate.
Value Too Low
Left Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
and recalibrate.
Value Too Low
Part No. 1268496 SX-150 157


Right Rear Steer Angle Value at 5.0 V Limited Speed and Direction frozen at Check for an open ground circuit
and recalibrate.
Value Too Low
Steer Valves - LF, RF, LR, Fault Check Limited Speed and Direction frozen at Check for defective or damaged
RR zero and neutral, Alarm sounds. wiring. Check for an open or shorted
valve coil. Repair or replace as
necessary.
Jib Bellcrank Sensor Value at 5.0 V Primary up and extend disabled, Alarm Power up controller with problem
sounds corrected.
Value Too High
Value Too Low
Value at 0 V
SCON Tilt Sensor Calibration check Display X direction and Y direction not Re-power after entering tilt x axis and
calibrated y axis matrix information
Footswitch Timeout Calibration check Display message on LCD Recycle power
LSJ2RS/LSJ3RO Fault Check Disable Boom Up, Extend, Down, TT Power up controller with problem
Cross-check Rotate, Jib Rotate CCW, Up, Down, corrected.
Platform Up, Down, Rotate and Propel.
Boom Retract and Jib Rotate CW
allowed. Alarm sounds. Display
message on LCD: LSJ2RS/LSJ3RO
CROSS-CHECK FAULT
Jib Bellcrank Loop Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
zero and neutral, Alarm sounds. corrected.
Platform Level Loop Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
Axle Retract Enable Valve Fault Check Limited Speed and Direction frozen at Power up controller with problem
Fuel Level Sensor Value at 5.0 V Display message on LCD Power up controller with problem
corrected.
Value Too High
Value Too Low
158 SX-150 Part No. 1268496


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. Alarm Sounds. Display
message on LCD PRIMARY BOOM
PBMAS SAFETY ENVELOPE
PBMLS Safety Envelope Position Check Disable Boom Up, Down, Extend, TT Return Boom back inside Operational
Rotate, Propel and Ignition/Fuel. Boom Envelope
Retract allowed. All functions allowed
once boom is lowered back into
envelope. Alarm Sounds. Display
message on LCD PRIMARY BOOM
PBMLS SAFETY ENVELOPE
Boom Envelope Safety Position Check Disable Boom Down, Extend, and Return Boom back inside Operational
Ignition/Fuel. Boom Retract and Up Envelope
allowed. All functions allowed once
boom is lowered back into envelope.
Alarm Sounds. Display message on
LCD PRIMARY BOOM SAFETY
ENVELOPE
Part No. 1268496 SX-150 159

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)
P_22 - Jib Jib Lvl P_22R - Primary P_12 - Axle
Pwr Up/Down FC Retract (P121-08
SCON)
P_38 P_39 P_10 P_11 P_9A P_9B P_22 P_22R P_12
Turntable tilt Y axis (+5°, secondary OFF OFF OFF

boom not stowed)
Primary Boom Angle (crosscheck) OFF OFF OFF OFF OFF*
Primary Boom Length (crosscheck) OFF OFF OFF OFF OFF*
Primary 2 Cylinder (crosscheck) OFF OFF OFF*
Boom Envelope Safety Interlock OFF OFF OFF
Axle Safety Not Stowed OFF OFF
Axles crosscheck Angle sensor vs. OFF OFF OFF OFF
safety switch(es)
Axle (not fully extended) and TT OFF OFF
Rotate (stowed and in drive disable
zone)
Turntable Tilt Angle (crosscheck OFF OFF OFF OFF OFF
SCON internal sensors 3 in a delta
configuration)
Loss of CAN OFF OFF OFF OFF OFF* OFF
Platform Overload (SCON pin #1) OFF
Platform Out of Level (>10°) OFF
Jib Bellcrank Out of Level (>10°) OFF
Boom Safety (max angle) OFF OFF OFF OFF
Boom Safety (max length) OFF OFF OFF OFF OFF OFF
Axle Retract Safety OFF
Cable Tension (#1 or #2) OFF
* P-9A and P-10 energized if boom is fully retracted as indicated by LSB3RS
160 SX-150 Part No. 1268496

Fault Source and Type will display as: Fault Source
Source Type ID Description
“ ID XXX_xx FAULT “ 3 SCON Controller Area Network
Where XXX is the one to three digit Fault Source 4 Primary Boom Angle Zone
and xx is the two digit Fault Type. 5 Primary Boom Length Switches Cross-Check
8 PCON Controller Area Network
TCON - Turntable Controller
9 Engine
PCON - Platform Controller 18 DCON Controller Area Network
SCON - Safety Controller 20 Boom Extend/Retract Joystick
DCON - Drive Controller 21 Boom Up/Down Joystick

26 Boom Extend/Retract Buttons
Fault Type 27 Boom Up/Down Buttons
ID Description 28 Boom Angle Sensors Cross-Check (SCON)
11 Value at 5V 29 LSB2RS/LSB4ES Cross-Check (SCON)
12 Value too High 30 Propel Joystick
13 No Response 35 Propel Valve
15 Value too Low 40 Turntable Rotate Joystick
16 Value at 0V 43 Footswitch Timeout
17 Not Calibrated 44 Jib Up/Down Joystick
21 Fault 48 PBMAS Safety Envelope (SCON)
26 Timeout 49 Jib Up/Down Buttons
31 Invalid Setup 50 Jib Up/Down Flow Valve
32 Min Cal Too Low 52 Steer Joystick
33 Min Cal Too High 53 Left Front Steer Sensor
54 Right Front Steer Sensor
55 Left Rear Steer Sensor
56 Right Rear Steer Sensor
59 Rocker Steer Joystick
61 PBMLS Safety Envelope (SCON)
63 Front Axle Sensor
64 Rear Axle Sensor
Part No. 1268496 SX-150 161

Fault Source Fault Source

ID Description ID Description
65 Turntable Level Sensor X-Direction 124 Enable Output Power P7R
66 Turntable Level Snesor Y-Direction 125 Primary Down Power P9A
67 Boom Length Sensors Cross-Check (SCON) 126 IGN/Fuel Power P9B
68 Boom Safety Envelope (SCON) 127 Primary Extend Power P10
70 Turntable Controller - Platform Controller 128 Primary Up Power P11
Software Version
129 Axle Retract Power P12
73 Engine Pressure Sensor
132 Platform Level Power P22
74 Engine Temperature Sensor
133 Primary Up/Down Valve Power P22R
75 LSB2RO/LSB4EO Cross-Check 134 DCON Valve Power P7R
80 TCON/SCON Calibration Inconsistent 142 Turntable Rotate CW Valve
81 Boom Up/Down Flow Valve (Fine)
143 Turntable Rotate CCW Valve
82 Boom Extend/Retract Flow Valve
144 Axle Safety Not Stowed (SCON)
83 Boom Extend/Retract Speed 145 Boom Up Valve
85 Boom Up/Down Speed 146 Boom Down Valve
86 Boom Angle Sensor
147 Platform Overload Switches Inconsistent
90 Jib Rotate Flow Valve (SCON)
91 Turntable Rotate Buttons 148 Boom Extend Valve
92 Turntable Rotate Flow Valve 149 Boom Retract Valve
93 Turntable Rotate Speed 150 Overload Recovery
94 Boom Length Sensor 152 Boom Up/Down Flow Valve (Gross)
95 Jib Rotate Joystick 153 Primary Lockout P1 Valve
98 Platform Level Sensor 154 Primary Lockout P2 Valve
99 Platform Level Buttons 157 Axles Fully Extended Cross-Check (SCON)
110 Platform Rotate Buttons 158 Drive Disable Zone and Axles Not Fully
Extended (SCON)
113 Jib Rotate Buttons
160 Left Front Steer Valve
117 Propel Power P38
118 Turntable Rotate Power P39 161 Right Front Steer Valve
121 Valve Power P6R1 162 Left Rear Steer Valve

163 Right Rear Steer Valve
122 Engine Power P6R2
164 Axle Valve
123 Enable Input Power P7
165 Boom Not Retracted and Chassis Tilted (SCON)
162 SX-150 Part No. 1268496

Fault Source
ID Description
166 Brake Valve
167 Motor Shift Valve
168 Chassis Tilt Sensors Cross-Check (SCON)
170 Jib Bellcrank Level Sensor
171 Jib Bellcrank Level Flow Valve
172 AUX Relay
173 Platform Level Toggle Switch
174 Platform Rotate Toggle Switch
175 Platform Level Flow Valve
176 Platform Rotate Valve
180 Boom Length Sensor
195 Safety Platform Overload (SCON)
220 RSB1AO Active Cross-Check
221 LTB1LO Active Cross-Check
222 Axle Extend/Retract Toggle Switch
235 RSB1AO/LSB1DO Cross-Check
236 LTB1LO/LSB3RO Cross-Check
237 LTB1LO/LSB4EO Cross-Check
238 Pressure Comp Enable #1 Valve
239 Pressure Comp Enable #2/Generator Valve
245 Check Machine Software Type at TCON
246 Check Machine Software Type at SCON
247 TCON/SCON Software Inconsistent
Part No. 1268496 SX-150 163

SPN FMI KWP Description

SPN = Suspect Parameter Number
FMI = Failure Mode Identifier
51 6 1022 Actuator error EGR-Valve; signal
range check high
KWP = Keyword Protocol
51 6 1224 Actuator EGR-Valve; over
current
51 3 1019 EGR-Valve, short circuit to
51 6 1230 Actuator error EGR-Valve;
battery
Overload by short-circuit
51 3 1024 Position sensor error of actuator
51 7 1016 Actuator position for EGR-Valve
EGR-Valve; signal range check
not plausible
high
51 11 1231 Actuator error EGR-Valve; Power
51 3 1226 EGR-Valve; short circuit to
stage over temp due to high
battery (A02)
current
51 12 1018 Actuator EGR-Valve; powerstage
battery (A67)
over temperature
51 12 1021 Mechanical actuator defect
ground
EGR-Valve
51 4 1025 Position sensor error actuator
51 12 1225 Actuator EGR-Valve; over
EGR-Valve; signal range check
temperature
low
94 1 474 Low fuel pressure; warning
threshold exceeded
ground (A02)
94 1 475 Low fuel pressure; shut off
threshold exceeded
ground (A67)
94 3 472 Sensor error low fuel pressure;
1 4 1232 Actuator error EGR-Valve;
signal range check high
Voltage below threshold
94 4 473 Sensor error low fuel pressure;
signal range check low
range check low
97 3 464 Sensor error water in fuel; signal
51 5 1017 Actuator EGR-Valve; open load
range check high
97 4 465 Sensor error water in fuel; signal
range check low
range check low
51 5 1223 Actuator EGR-Valve; open load
97 12 1157 Water in fuel level prefilter;
51 6 1014 Actuator error EGR-Valve; signal maximum value exceeded
range check high
164 SX-150 Part No. 1268496

SPN = Suspect Parameter Number SPN FMI KWP Description

FMI = Failure Mode Identifier 108 3 412 Sensor error ambient air press.;
KWP = Keyword Protocol signal range check high
SPN FMI KWP Description 108 4 413 Sensor error ambient air press.;
100 0 734 High oil pressure; warning signal range check low
threshold exceeded 110 0 98 High coolant temperature;
100 0 735 High oil pressure; shut off warning threshold exceeded
threshold exceeded 110 0 99 High coolant temperature; shut
100 1 736 Low oil pressure; warning off threshold exceeded
threshold exceeded 110 3 96 Sensor error coolant temp.;
100 1 737 Low oil pressure; shut off signal range check high
threshold exceeded 110 4 97 Sensor error coolant temp.;
100 3 732 Sensor error oil pressure; signal signal range check low
range check high 111 1 101 Coolant level too low
100 4 733 Sensor error oil pressure sensor; 132 11 1 Air flow sensor load correction
signal range check low factor exceeding the maximum
102 2 88 Charged air pressure above drift limit; plausibility error
warning threshold 132 11 2 Air flow sensor load correction
102 2 89 Charged air pressure above shut factor exceeding drift limit;
off threshold plausibility error
102 4 777 Sensor error charged air press.; 132 11 3 Air flow sensor low idle correction
signal range check low factor exceeding the maximum
drift limit
105 0 996 High charged air cooler
temperature; warning threshold 132 11 4 Air flow sensor load correction
exceeded factor exceeding the maximum
drift limit
105 0 997 High charged air cooler
temperature; shut off threshold 157 3 877 Sesnor error rail pressure; signal
exceeded range check high
105 3 994 Sensor error charged air 157 4 878 Sensor error rail pressure; signal
temperature; signal range check range check low
high
105 4 995 Sensor error charged air
temperature; signal range check
low
Part No. 1268496 SX-150 165


FMI = Failure Mode Identifier 174 0 481 High low fuel temperature;
KWP = Keyword Protocol warning threshold exceeded
SPN FMI KWP Description 174 0 482 High Low fuel temperature; shut
168 0 1180 Physical range check high for off threshold exceeded
battery voltage 175 0 740 Physical range check high for oil
168 1 1181 Physical range check low for temperature
battery voltage 175 0 745 High oil temperature; warning
168 2 47 High battery voltage; warning threshold exceeded
threshold exceeded 175 0 746 High oil temperature; shut off
168 2 48 Low battery voltage; warning threshold exceeded
threshold exceeded 175 1 741 Physical range check low for oil
168 3 45 Sensor error battery voltage; temperature
signal range check high 175 2 738 Sensor oil temperature;
168 4 46 Sensor error battery voltage; plausibility error
signal range check low 175 2 739 Sensor oil temperature;
171 3 417 Sensor error environment plausibility error oil temperature
temperature; signal range check too high
high 175 3 743 Sensor error oil temperature;
171 4 418 Sensor error environment signal range check high
temperature; signal range check 175 4 744 Sensor error oil temperature;
low signal range check low
172 0 1182 Physical range check high for 190 0 389 Engine speed above warning
intake air temperature threshold (FOC-Level 1)
172 1 1183 Physical range check low for 190 2 421 Offset angle between crank- and
intake air temperature camshaft sensor is too large
172 2 9 Sensor ambient air temperature; 190 8 419 Sensor camshaft speed;
plausibility error disturbed signal
172 2 983 Intake air sensor; plausibility
error
172 3 981 Sensor error intake air; signal
range check high
172 4 982 Sensor error intake air sensor;
166 SX-150 Part No. 1268496


FMI = Failure Mode Identifier 412 3 1007 Sensor error EGR cooler
KWP = Keyword Protocol downstream temperature; signal
SPN FMI KWP Description range check high
190 8 422 Sensor crankshaft speed; 412 4 1008 Sensor error EGR cooler
disturbed signal downstream temperature; signal
range check low
190 11 390 Engine speed above warning
threshold (FOC-Level 2) 520 9 306 Timeout Error of
CAN-Receive-Frame TSC1TR;
190 12 420 Sensor camshaft speed; no Setpoint
signal
597 2 49 Break lever mainswitch and
190 12 423 Sensor crankshaft speed; no break lever redundancy switch
signal status not plausible
190 14 391 Engine speed above warning 624 3 971 SVS lamp; short circuit to batt.
threshold (Overrun Mode)
624 4 972 SVS lamp; short circuit to grd.
190 14 1222 Camshaft- and Crankshaft speed
sensor signal not available on 624 5 969 SVS lamp; open load
CAN 624 12 970 SVS lamp; powerstage over
411 0 791 Physical range check high for temperature
differential pressure Venturiunit 630 12 376 Access error EEPROM memory
(EGR) (delete)
411 1 792 Physical range check low for 630 12 377 Access error EEPROM memory
differential pressure Venturiunit (read)
(EGR)
630 12 378 Access error EEPROM memory
411 3 795 Sensor error differential pressure (write)
Venturiunit (EGR); signal range
639 14 84 CAN-Bus 0 "BusOff-Status"
check high
651 3 580 Injector 1 (in firing order); short
411 4 381 Physical range check low for
circuit
EGR differential pressure
651 4 586 High side to low side short circuit
411 4 796 Sensor error differential pressure
in the injector 1 (in firing order)
Venturiunit (EGR); signal range
check low
Part No. 1268496 SX-150 167


FMI = Failure Mode Identifier 677 3 956 Starter relay high side; short
KWP = Keyword Protocol circuit to battery
SPN FMI KWP Description 677 3 960 Starter relay low side; short circuit
651 5 568 Injector 1 (in firing order); to battery
interruption of electric connection 677 4 957 Starter relay high side; short
652 3 581 Injector 2 (in firing order); short circuit to ground
circuit 677 4 961 Starter relay low side; short circuit
652 4 587 High side to low side short circuit to ground
in the injector 2 (in firing order) 677 5 958 Starter relay; no load error
652 5 569 Injector 2 (in firing order); 677 12 959 Starter relay; powerstage over
interruption of electric connection temperature
653 3 582 Injector 3 (in firing order); short 703 3 426 Engine running lamp; short circuit
circuit to battery
653 4 588 High side to low side short circuit 703 4 427 Engine running lamp; short circuit
in the injector 3 (in firing order) to ground
653 5 570 Injector 3 (in firing order); 703 5 424 Engine running lamp; open load
interruption of electric connection
703 12 425 Engine running lamp;
654 3 583 Injector 4 (in firing order); short powerstage over temperature
circuit
729 5 545 Cold start aid relay open load
654 4 589 High side to low side short circuit
729 12 547 Cold start aid relay; over
in the injector 4 (in firing order)
temperature error
654 5 571 Injector 4 (in firing order);
898 9 305 Timeout Error of
interruption of electric connection
CAN-Receive-Frame TSC1TE;
676 11 543 Cold start aid relay error. Setpoint
676 11 544 Cold start aid relay open load 1079 13 946 Sensor supply voltage monitor
1 error (ECU)
1080 13 947 Sensor supply voltage monitor
2 error (ECU)
168 SX-150 Part No. 1268496


FMI = Failure Mode Identifier 1180 1 1463 Exhaust gas temperature
KWP = Keyword Protocol upstream turbine; shut off
SPN FMI KWP Description threshold exceeded
1109 2 121 Engine shut off demand ignored 1180 3 1067 Sensor error exhaust gas
temperature upstream turbine;
1136 0 1398 Physikal range check high for signal range check high
ECU temperature
1180 11 1066 Sensor exhaust gas temperature
1136 1 1399 Physikal range check low for upstream turbine; plausibility
ECU temperature error
1136 3 1400 Sensor error ECU temperature; 1188 2 1414 Wastegate; status message from
signal range check high ECU missing
1136 4 1401 Sensor error ECU temperature; 1188 7 1415 Wastegate actuator; blocked
1188 11 1411 Wastegate actuator; internal
1176 3 849 Sensor error pressure sensor error
upstream turbine; signal range
check high 1188 11 1412 Wastegate actuator; EOL
calibration not performed
1176 4 850 Sensor error pressure sensor correctly
downstream turbine; signal range
check high 1188 11 1416 Wastegate actuator; over
temperature (> 145øC)
1180 0 1193 Physical range check high for
exhaust gas temperature 1188 11 1417 Wastegate actuator; over
upstream turbine temperature (> 135øC)
1180 0 1460 Turbocharger Wastegate CAN 1188 11 1418 Wastegate actuator; operating
feedback; warning threshold voltage error
exceeded 1188 13 1413 Wastegate actuator calibration
1180 0 1462 Exhaust gas temperature deviation too large, recalibration
upstream turbine; warning required
threshold exceeded 1231 14 85 CAN-Bus 1 "BusOff-Status"
1180 1 1194 Physical range check low for 1235 14 86 CAN-Bus 2 "BusOff-Status"
exhaust gas temperature
upstream turbine
1180 1 1461 Turbocharger Wastegate CAN
feedback; shut off threshold
exceeded
Part No. 1268496 SX-150 169


FMI = Failure Mode Identifier 2798 4 1338 Injector diagnostics; timeout error
KWP = Keyword Protocol of short circuit to ground
SPN FMI KWP Description measurement cyl. Bank 1
1237 2 747 Override switch; plausibility error 2798 4 1339 Injector diagnostics; short circuit
to ground monitoring Test in Cyl.
1322 12 610 Too many recognized misfires in Bank 0
more than one cylinder
2798 4 1340 Injector diagnostics; short circuit
1323 12 604 Too many recognized misfires in to ground monitoring Test in Cyl.
cylinder 1 (in firing order) Bank 1
1324 12 605 Too many recognized misfires in 3224 2 127 DLC Error of
cylinder 2 (in firing order) CAN-Receive-Frame AT1IG1
1325 12 606 Too many recognized misfires in NOX Sensor (SCR-system
cylinder 3 (in firing order) upstream cat; DPF-system
downstream cat); length of frame
1326 12 607 Too many recognized misfires in incorrect
cylinder 4 (in firing order)
2659 0 1524 Physical range check high for CAN-Receive-Frame AT1IG1;
EGR exhaust gas mass flow NOX sensor upstream
2659 1 1525 Physical range check low for 3248 4 1047 Sensor error particle filter
EGR exhaust gas mass flow downstream temperature; signal
2659 2 1523 Exhaust gas recirculation AGS range check low
sensor; plausibility error 3699 2 1616 DPF differential pressure sensor
2659 2 1527 AGS sensor temperature exhaust and a further sensor or actuator
gas mass flow; plausibility error CRT system defective
2659 12 1526 Exhaust gas recirculation; AGS 3699 2 1617 Temperature sensor us. and ds.
sensor has "burn off" not DOC simultaneously defect
performed 3699 14 1615 Maximum stand-still-duration
2797 4 1337 Injector diagnostics; timeout error reached; oil exchange required
of short circuit to ground 4765 0 1039 Physical range check high for
measurement cyl. Bank 0 exhaust gas temperature
upstream (DOC)
4765 1 1042 Physical range check low for
exhaust gas temperature
upstream (DOC)
170 SX-150 Part No. 1268496


FMI = Failure Mode Identifier 523008 2 649 Timeout error in Manipulation
KWP = Keyword Protocol control
SPN FMI KWP Description 523009 9 825 Pressure Relief Valve (PRV)
4766 0 1029 Physical range check high for reached maximun allowed
exhaust gas temperature opening count
downstream (DOC) 523009 10 833 Pressure relief valve (PRV)
4766 1 1032 Physical range check low for reached maximun allowed open
exhaust gas temperature time
downstream (DOC) 523212 9 171 Timeout Error of
4768 2 1036 Sensor exhaust gas temperature CAN-Receive-Frame
upstream (DOC); plausibility ComEngPrt; Engine Protection
error 523216 9 198 Timeout Error of
4768 3 1044 Sensor error exhaust gas CAN-Receive-Frame
temperature upstream (DOC); PrHtEnCmd; pre-heat command,
signal range check high engine command
4768 4 1045 Sensor error exhaust gas 523240 9 179 Timeout CAN-message
temperature upstream (DOC) FunModCtl; Function Mode
signal range check low Control
4769 2 1026 Sensor exhaust gas temperature 523350 4 565 Injector cylinder-bank 1; short
downstream (DOC); plausibility circuit
error 523352 4 566 Injector cylinder-bank 2; short
4769 3 1034 Sensor error exhaust gas circuit
temperature downstream (DOC); 523354 12 567 Injector powerstage output defect
signal range check high
523470 2 826 Pressure Relief Valve (PRV)
4769 4 1035 Sensor error exhaust gas forced to open; performed by
temperature downstream (DOC); pressure increase
523470 2 827 Pressure Relief Valve (PRV)
523006 3 34 Controller mode switch; short forced to open; performed by
circuit to battery pressure shock
523006 4 35 Controller mode switch; short
circuit to ground
523008 1 648 Manipulation control was
triggered
Part No. 1268496 SX-150 171


523612 12 613 Internal ECU monitoring
detection reported error
523470 7 876 Maximum rail pressure in limp detection reported error
home mode exceeded (PRV) 523612 12 615 Internal ECU monitoring
523470 11 831 The PRV can not be opened at detection reported error
this operating point with a 523612 12 616 Internal ECU monitoring
pressure shock detection reported error
523470 11 832 Rail pressure out of tolerance 523612 12 617 Internal ECU monitoring
range detection reported error
523470 12 828 Open Pressure Relief Valve 523612 12 618 Internal ECU monitoring
(PRV); shut off condition detection reported error
523470 12 829 Open Pressure Relief Valve 523612 12 619 Internal ECU monitoring
(PRV); warning condition detection reported error
523470 14 830 Pressure Relief Valve (PRV) is 523612 12 620 Internal ECU monitoring
open detection reported error
523550 12 980 T50 start switch active for too 523612 12 621 Internal ECU monitoring
long detection reported error
523601 13 948 Sensor supply voltage monitor 523612 12 623 Internal ECU monitoring
3 error (ECU) detection reported error
523603 9 126 Timeout Error of 523612 12 624 Internal ECU monitoring
CAN-Receive-Frame AMB; detection reported error
Ambient Temperature Sensor
523605 9 300 Timeout Error of detection reported error
CAN-Receive-Frame TSC1AE;
Traction Control 523612 12 627 Internal ECU monitoring
CAN-Receive-Frame TSC1AR; 523612 12 628 Internal ECU monitoring
Retarder detection reported error
523612 12 387 Internal software error ECU;
injection cut off
172 SX-150 Part No. 1268496


523615 3 596 Metering unit (Fuel-System);
short circuit to battery low side
523612 12 637 Internal ECU monitoring short circuit to ground high side
detection reported error 523615 4 597 Metering Unit (Fuel-System);
523612 12 1170 Internal software error ECU short circuit to ground low side
523612 14 973 Softwarereset CPU SWReset_0 523615 5 592 Metering unit (Fuel-System);
open load
523612 14 974 Softwarereset CPU SWReset_1
523612 14 975 Softwarereset CPU SWReset_2
powerstage over temperature
523613 0 856 Maximum positive deviation of
523619 2 488 Physical range check high for
rail pressure exceeded
(RailMeUn0) exhaust gas temperature
upstrem (SCR-CAT)
523613 0 857 Maximum positive deviation of
523698 11 122 Shut off request from supervisory
rail pressure in metering unit
monitoring function
exceeded (RailMeUn1)
523613 0 858 Railsystem leakage detected
(RailMeUn10) CAN-Transmit-Frame AmbCon;
Weather environments
523613 0 859 Maximum negative deviation of
523718 3 1488 SCR mainrelay; short circuit to
rail pressure in metering unit
battery (only CV56B)
exceeded (RailMeUn2)
523613 0 860 Negative deviation of rail 523718 4 1489 SCR mainrelay; short circuit to
ground (only CV56B)
pressure second stage
(RailMeUn22) 523718 5 1486 SCR mainrelay; open load (only
CV56B)
523613 0 862 Maximum rail pressure exceeded
(RailMeUn4) 523718 12 1487 SCR mainrelay; powerstage over
temperature (only CV56B)
523613 1 861 Minimum rail pressure exceeded
(RailMeUn3) 523766 9 281 Timeout Error of
CAN-Receive-Frame Active
523613 2 864 Setpoint of metering unit in
TSC1AE
overrun mode not plausible
short circuit to battery highside CAN-Receive-Frame Passive
TSC1AE
Part No. 1268496 SX-150 173


FMI = Failure Mode Identifier 523897 13 561 check of missing injector
KWP = Keyword Protocol adjustment value programming
SPN FMI KWP Description (IMA) injector 3 (in firing order)
523768 9 283 Timeout Error of 523898 13 562 check of missing injector

CAN-Receive-Frame Active adjustment value programming
TSC1AR (IMA) injector 4 (in firing order)
523769 9 284 Timeout Error of 523910 6 1261 Air Pump; over current
CAN-Receive-Frame Passive 523913 3 74 Sensor error glow plug control
TSC1AR diagnostic line voltage; signal
523770 9 285 Timeout Error of range check high
CAN-Receive-Frame Passive 523913 4 75 Sensor error glow plug control
TSC1DE diagnostic line voltage; signal
523776 9 291 Timeout Error of range check low
CAN-Receive-Frame TSC1TE - 523914 3 78 Glow plug control; short circuit to
active battery
523777 9 292 Passive Timeout Error of 523914 4 79 Glow plug control; short circuit to
CAN-Receive-Frame TSC1TE; ground
Setpoint
523914 5 76 Glow plug control; open load
523778 9 293 Active Timeout Errorof
523914 5 1216 Glow plug control release line;
CAN-Receive-Frame TSC1TR
short circuit error
523779 9 294 Passive Timeout Error of
523914 11 1217 Glow plug control; internal error
CAN-Receive-Frame TSC1TR
523914 12 77 Glow plug control; powerstage
over temperature
CAN-Transmit-Frame TrbCH;
Status Wastegate 523919 2 1378 Sensor air pump airpressure;
plausibility error
CAN-Receive-Frame UAA10; 523920 2 1379 Sensor exhaust gas back
AGS sensor service message pressure burner; plausibility error
CAN-Receive-Frame UAA11;
AGS sensor data
523895 13 559 Check of missing injector
adjustment value programming
(IMA) injector 1 (in firing order)
523896 13 560 check of missing injector
adjustment value programming
(IMA) injector 2 (in firing order)
174 SX-150 Part No. 1268496


CAN-Transmit-Frame
SPN FMI KWP Description EEC3VOL2; Engine send
messages
523922 7 1262 Burner Shut Off Valve; blocked
closed 523946 0 1158 Zerofuel calibration injector 1 (in
firing order); maximum value
523922 7 1264 Burner Shut Off Valve; blocked
exceeded
closed
523946 1 1164 Zerofuel calibration injector 1 (in
523929 0 109 Fuel Balance Control integrator
firing order); minimum value
injector 1 (in firing order);
exceeded
maximum value exceeded
exceeded
minimum value exceeded
exceeded
523930 1 116 Fuel Balance Control integrator 523948 0 1160 Zerofuel calibration injector 3 (in
exceeded
exceeded
exceeded
exceeded
523932 1 118 Fuel Balance Control integrator 523960 0 1011 Physical range check high for
EGR cooler downstream temp.
CAN-Transmit-Frame
EEC3VOL1; Engine send
messages
Part No. 1268496 SX-150 175


524016 2 1259 Amount of air is not plausible to
pump speed
524016 2 1260 Calculated amount of air is not
523960 0 1458 High exhaust gas temperature plausible to HFM reading
EGR cooler downstream; 524016 11 1258 HFM sensor; electrical fault
warning threshold exceeded
524021 11 1263 Burner fuel line pipe leak behind
523960 1 1012 Physical range check low for Shut Off Valve
EGR cooler downstream temp.
524024 11 1302 Deviation of the exhaust gas
523960 1 1459 High exhaust gas temperature
temp. setpoint to actual value
EGR cooler downstream; shut off downstream (DOC) too high
threshold exceeded
524028 2 1431 CAN message PROEGRActr;
523980 14 1187 Bad quality of reduction agent plausibility error
detected
523981 11 918 Urea-tank without heating
CAN-Receive-Frame
function (heating phase)
ComEGRActr - exhaust gas
523982 0 360 Powerstage diagnosis disabled; recirculation positioner
high battery voltage
524030 7 1440 EGR actuator; internal error
523982 1 361 Powerstage diagnosis disabled; 524031 13 1441 EGR actuator; calibration error
low battery voltage
524032 2 1442 EGR actuator; status message
523988 3 1245 Charging lamp; short circuit to EGRCust is missing
battery
524033 7 1443 EGR actuator; due to overload in
523988 4 1246 Charging lamp; short circuit to Save Mode
ground
524034 3 1438 Disc separator; short circuit to
523988 5 1243 Charging lamp; open load battery
523988 12 1244 Charging lamp; over temp. 524034 4 1439 Disc separator; short circuit to
523998 4 1327 Injector cylinder bank 2 slave; ground
short circuit 524034 5 1436 Disc Separator; open load
523999 12 1328 Injector powerstage output Slave 524034 12 1437 Disc Separator; powerstage over
defect temperature
524014 1 1254 Air pressure glow plug flush line;
below limit
176 SX-150 Part No. 1268496


524108 9 1669 Timeout error of
CAN-Transmit-Frame
SPN FMI KWP Description ComEGRTVActr
524035 12 1341 Injector diagnostics; time out 524109 9 1679 Timeout error of
error in the SPI communication CAN-Receive-Frame
ComRxEGRTVActr
524057 2 1505 Electric fuel pump; fuel pressure
build up error 524110 9 1670 Timeout error of
CAN-Transmit-Frame
ComETVActr
CAN-Transmit-Frame
DPFBrnAirPmpCtl 524111 9 1680 Timeout error of
524098 9 1664 Timeout error of CAN-Receive-Frame
ComRxETVActr
CAN-Transmit-Frame
ComDPFBrnPT 524112 9 1671 Timeout ComITVActr
524099 9 1665 Timeout error of 524113 9 1681 Timeout error of
CAN-Transmit-Frame CAN-Receive-Frame
ComDPFC1 ComRxITVActr
CAN-Transmit-Frame CAN-Transmit-Frame A1DOC
ComDPFHisDat 524115 9 1660 Timeout error of
524101 9 1667 Timeout error of CAN-Transmit-Frame AT1S
CAN-Transmit-Frame 524116 9 1661 Timeout error of
ComDPFTstMon CAN-Transmit-Frame SCR2
CAN-Receive-Frame CAN-Transmit-Frame SCR3
ComRxDPFBrnAirPmpCtl
CAN-Receive-Frame
CAN-Receive-Frame ComRxCM1
ComRxDPFBrnAirPmp
CAN-Receive-Frame
CAN-Receive-Frame ComRxCustSCR3
ComRxDPFCtl
CAN-Transmit-Frame
ComEGRMsFlw
CAN-Receive-Frame
ComRxEGRMsFlw1
CAN-Receive-Frame
ComRxEGRMsFlw2
Part No. 1268496 SX-150 177


CAN-Receive-Frame
ComRxSCRHtDiag
CAN-Receive-Frame
ComRxTrbChActr
CAN-Receive-Frame
ComRxUQSens
CAN-Receive-Frame
ComSCRHtCtl
CAN-Receive-Frame
ComTxAT1IMG
CAN-Receive-Frame
ComTxTrbChActr
178 SX-150 Part No. 1268496


SPN FMI Description Refer to Engine Manual
27 3 Engine Exhaust Gas Recirculation Valve Valve Position Sensor- Test
Position :Voltage Above Normal
27 4 Engine Exhaust Gas Recirculation Valve Valve Position Sensor - Test
Position :Voltage Be- low Normal
29 3 Accelerator Pedal Position 2 :Voltage Above Analog Throttle Position Sensor Circuit - Test
Normal
29 4 Accelerator Pedal Position 2 :Voltage Below Analog Throttle Position Sensor Circuit - Test
Normal
51 3 Engine Throttle Valve 1Position :Voltage Above Valve Position Sensor - Test
Normal
51 4 Engine Throttle Valve 1 Position :Voltage Below Valve Position Sensor - Test
Normal
91 3 Accelerator Pedal Position 1 :Voltage Above Analog Throttle Position Sensor Circuit - Test
Normal
91 4 Accelerator Pedal Position 1: Voltage Below Analog Throttle Position Sensor Circuit - Test
Normal
97 15 Water In Fuel Indicator :High - least severe Fuel Contains Water
100 2 Engine Oil Pressure :Erratic,Intermittent,or Switch Circuits - Test
Incorrect
100 17 Engine Oil Pressure :Low - least severe (1) Oil Pressure Is Low
102 3 Engine Intake Manifold #1 Pressure:Voltage Engine Pressure Sensor Open or Short Circuit - Test
Above Normal
102 4 Engine Intake Manifold #1 Pressure :Voltage Engine Pressure Sensor Open or Short Circuit - Test
Below Normal
102 20 Engine Intake Manifold #1Pressure :Data Engine Pressure Sensor Open or Short Circuit - Test
Drifted High
102 21 Engine Intake Manifold #1Pressure :Data Engine Pressure Sensor Open or Short Circuit - Test
Drifted Low
105 3 Engine Intake Manifold #1 Engine Temperature Sensor Open or Short Circuit -
Temperature :Voltage Above Normal Test
105 4 Engine Intake Manifold #1 Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Below Normal Test
107 2 Engine Air Filter 1Differential Pressure : Switch Circuits - Test
Erratic,Intermittent,or Incorrect
107 15 Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted
least severe (1)
107 16 Engine Air Filter 1Differential Pressure :High - Inlet Air Is Restricted
moderate severity(2)
Part No. 1268496 SX-150 179


108 3 Barometric Pressure :Voltage Above Normal Engine Pressure Sensor Open or Short Circuit - Test
108 4 Barometric Pressure :Voltage Below Normal Engine Pressure Sensor Open or Short Circuit - Test
110 3 Engine Coolant Temperature :Voltage Above Engine Temperature Sensor Open or Short Circuit -
Normal Test
110 4 Engine Coolant Temperature :Voltage Below Engine Temperature Sensor Open or Short Circuit -
Normal Test
110 15 Engine Coolant Temperature :High - least severe Coolant Temperature Is High
(1)
110 16 Engine Coolant Temperature:High - moderate Coolant Temperature Is High
severity (2)
152 2 Number Of ECU Resets :Erratic,Intermittent,or ECM Memory - Test
Incorrect
157 0 Engine Injector Metering Rail#1Pressure : High - Fuel Rail Pressure Problem
most severe (3)
157 2 Engine Injector Metering Rail #1 Pressure : Fuel Rail Pressure Problem
Erratic, Intermittent, or Incorrect
157 3 Engine Injector Metering Rail#1 Pressure : Engine Pressure Sensor Open or Short Circuit - Test
Voltage Above Normal
157 4 Engine Injector Metering Rail #1 Engine Pressure Sensor Open or Short Circuit - Test
Pressure :Voltage Below Normal
157 10 Engine Injector Metering Rail#1 Pressure : Engine Pressure Sensor Open or Short Circuit - Test
Abnormal Rate of Change
157 16 Engine Injector Metering Rail#1 Pressure : High - Fuel Rail Pressure Problem
moderate severity (2)
157 17 Engine Injector Metering Rail#1Pressure :Low - Fuel Rail Pressure Problem
least severe (1)
157 18 Engine Injector Metering Rail#1Pressure :Low - Fuel Rail Pressure Problem
168 3 Battery Potential/ Power Input 1 :Voltage Above Ignition Keyswitch Circuit and Battery Supply Circuit
Normal - Test
166 2 Engine Rated Power :Erratic, Intermittent or ECM Memory- Test
Incorrect
166 14 Engine Rated Power :Special Instruction ECM Memory - Test
168 4 Battery Potential/ Power Input 1 :Voltage Below Ignition Keyswitch Circuit and Battery Supply Circuit
Normal - Test
180 SX-150 Part No. 1268496


172 3 Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit-
Above Normal Test
172 4 Engine Air Inlet Temperature Sensor :Voltage Engine Temperature Sensor Open or Short Circuit -
Below Normal Test
173 3 Engine Exhaust Gas Temperature : Voltage Engine Temperature Sensor Open or Short Circuit -
Above Normal Test
173 4 Engine Exhaust Gas Temperature :Voltage Engine Temperature Sensor Open or Short Circuit-
Below Normal Test
174 3 Engine Fuel Temperature1 :Voltage Above Engine Temperature Sensor Open or Short Circuit -
Normal Test
174 4 Engine Fuel Temperature 1 :Voltage Below Engine Temperature Sensor Open or Short Circuit -
Normal Test
190 8 Engine Speed :Abnormal Frequency,Pulse Engine Speed/Timing Sensor Circuit - Test
Width,or Period
190 15 Engine Speed :High - least severe (1) Engine Over speeds
558 2 Accelerator Pedal1Low Idle Switch :Erratic, Idle Validation Switch Circuit- Test
Intermittent, or Incorrect
593 31 Engine Idle Shutdown has Shutdown Engine This code indicates that an engine idle shutdown is
about to occur. This code does not represent a fault. If
equipped, the warning lamp will come on.
594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shut down has
occurred.This code does not represent a fault. If
equipped,the warning lamp will flash and the
shutdown lamp will come on.
623 6 Red Stop Lamp :Current Above Normal Indicator Lamp Circuit- Test
624 6 Amber Warning Lamp :Current Above Normal Indicator Lamp Circuit - Test
630 2 Calibration Memory :Erratic, Intermittent, or Injector Data Incorrect- Test
Incorrect
637 11 Engine Timing Sensor :Other Failure Mode Engine Speed/Timing Sensor Circuit- Test
639 9 J1939 Network #1 :Abnormal Update Rate CAN Data Link Circuit - Test
639 14 J1939 Network #1:Special Instruction CAN Data Link Circuit - Test
651 5 Engine Injector Cylinder #01 : Current Below Injector Solenoid Circuit - Test
Normal
651 6 Engine Injector Cylinder #01 : Current Above Injector Solenoid Circuit- Test
Normal
651 20 Engine Injector Cylinder#01 :Data Drifted High Injector Data Incorrect- Test
651 21 Engine Injector Cylinder#01 :Data Drifted Low Injector Data Incorrect - Test
Part No. 1268496 SX-150 181


652 5 Engine Injector Cylinder #02 :Current Below Normal Injector Solenoid Circuit - Test
652 6 Engine Injector Cylinder #02 :Current Above Normal Injector Solenoid Circuit - Test
652 20 Engine Injector Cylinder #02 :Data Drifted High Injector Data Incorrect- Test
652 21 Engine Injector Cylinder #02 :Data Drifted Low Injector Data Incorrect- Test
653 21 Engine Injector Cylinder #03 :Data Drifted Low Injector Data Incorrect - Test
654 21 Engine Injector Cylinder #04 :Data Drifted Low Injector Data Incorrect - Test
676 5 Engine GloW Plug Relay : Current Below Normal Glow Plug Starting Aid - Test
676 6 Engine Glow Plug Relay :Current Above Normal Glow Plug Starting Aid - Test
676 19 Engine Glow Plug Relay :Data Error Glow Plug Starting Aid- Test
677 3 Engine Starter Motor Relay :Voltage Above Normal Start Relay Circuit - Test
677 5 Engine Starter Motor Relay :Current Below Normal Start Relay Circuit - Test
677 6 Engine Starter Motor Relay :Current Above Normal Start Relay Cricuit - Test
723 8 Engine Speed Sensor #2 :Abnormal Engine Speed/liming Sensor Circuit - Test
Frequency,Pulse Width, or Period
976 2 PTO Governor State : Erratic,Intermittent, or PTO Switch Circuit - Test
Incorrect
1041 2 Start Signal Indicator :Erratic,Intermittent,or Start Relay Circuit- Test
Incorrect
182 SX-150 Part No. 1268496


1076 2 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test
Valve :Erratic, Intermittent, or Incorrect
1076 5 Engine Fuel Injection Pump Fuel Control Solenoid Valve - Test
Valve :Current Below Normal
1076 6 Engine Fuel Injection Pump Fuel Control Solenoid Valve- Test
Valve :Current Above Normal
1081 5 Engine Wait to Start Lamp :Current Below Indicator Lamp Circuit - Test
Normal
1081 6 Engine Wait to Start Lamp :Current Above Indicator Lamp Circuit- Test
Normal
1127 16 Engine Turbocharger 1 Boost Pressure : High - Intake Manifold Air Pressure Is High
1127 18 Engine Turbocharger 1 Boost Pressure :Low - Intake Manifold Air Pressure Is Low
1188 5 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve - Test
Position :Current Below Normal
1188 6 Engine Turbocharger Wastegate Actuator 1 Solenoid Valve - Test
Position :Current Above Normal
1209 3 Engine Exhaust Gas Pressure :Voltage Above Engine Pressure Sensor Open or Short Circuit - Test
Normal
1209 4 Engine Exhaust Gas Pressure :Voltage Below Engine Pressure Sensor Open or Short Circuit- Test
Normal
1221 2 Continuously Monitored Systems ECM Memory- Test
Support/Status ;Erratic,Intermittent,or Incorrect
1221 14 Continuously Monitored Systems Another diagnostic code has requested engine speed
Support/Status : Special Instruction limitation. The warning lamp will flash.The engine
speed is limited to 1200rpm. Troubleshoot all other
diagnostic codes.No troubleshooting is required for
this diagnostic code.
1239 0 Engine Fuel Leakage 1 :High- most severe (3) Fuel Rail Pressure Problem
1485 7 ECM Main Relay :Not Responding Properly Electrical Power Supply- Test
1485 14 ECM Main Relay :Special Instruction Electrical Power Supply- Test
Part No. 1268496 SX-150 183


2791 5 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test
Control:Current Below Normal
2791 6 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve - Test
Control :Current Above Normal
2791 7 Engine Exhaust Gas Recirculation (EGR) Valve Motorized Valve- Test
Control :Not Responding Properly
2797 6 Engine Injector Group 1 :Current Above Normal Injector Solenoid Circuit- Test
2797 7 Engine Injector Group 1 :Not Responding Injector Solenoid Circuit - Test
Property
2798 6 Engine Injector Group 2 :Current Above Normal Injector Solenoid Circuit- Test
2840 12 ECU Instance :Failure ECM Memory- Test
2840 14 ECU Instance :Special Instruction Electrical Power Supply- Test
2880 2 Engine Operator Primary Intermediate Speed Throttle Switch Circuit - Test
Select :Erratic, Intermittent,or Incorrect
Select :Voltage Above Normal
Select : Voltage Below Normal
2970 2 Accelerator Pedal 2 Low Idle Switch :Erratic, Idle Validation Switch Circuit- Test
Intermittent, or Incorrect
3217 3 After treatment #1 Intake 02 :Voltage Above Oxygen Level- Test
Normal
3217 4 After treatment #1 Intake 02 :Voltage Below Oxygen Level - Test
Normal
3217 5 After treatment #1 Intake 02 :Current Below Oxygen Level- Test
Normal
3217 6 After treatment #1 Intake 02 :Current Above Oxygen Level- Test
Normal
3217 12 After treatment #1 Intake 02 :Failure Oxygen Level- Test
3217 13 After treatment #1 Intake 02 : Out of Calibration Oxygen Level- Test
3217 15 After treatment #1 Intake 02 : High - least Oxygen Level- Test
severe (1)
184 SX-150 Part No. 1268496


3219 15 After treatment #1 Intake Gas Sensor at Oxygen Level- Test
Temperature : High- least severe (1)
3219 17 After treatment #1 Intake Gas Sensor at Oxygen Level- Test
Temperature : Low - least severe (1)
3222 3 After treatment #1 Intake Gas Sensor Heater : Oxygen Level- Test
Voltage Above Normal
3222 4 After treatment #1 Intake Gas Sensor Oxygen Level- Test
Heater :Voltage Below Normal
3222 5 After treatment #1 Intake Gas Sensor Oxygen Level- Test
Heater :Current Below Normal
3242 3 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Above Normal Test
3242 4 Particulate Trap Intake Gas Engine Temperature Sensor Open or Short Circuit-
Temperature :Voltage Below Normal Test
3251 0 Particulate Trap Differential Pressure : High- Diesel Particulate Filter Collects Excessive Soot
most severe (3)
3251 3 Particulate Trap Differential Pressure:Voltage Engine Pressure Sensor Open or Short Circuit - Test
Above Normal
3251 4 Particulate Trap Differential Pressure :Voltage Engine Pressure Sensor Open or Short Circuit- Test
Below Normal
3251 7 Particulate Trap Differential Pressure :Not Diesel Particulate Filter Has Differential Pressure
Responding Properly Problem
3251 10 Particulate Trap Differential Pressure :Abnormal Diesel Particulate Filter Has Differential Pressure
Rate of Change Problem
3251 16 Particulate Trap Differential Diesel Particulate Filter Collects Excessive Soot
Pressure :High-moderate severity (2)
3251 17 Particulate Trap Differential Pressure : Low - Diesel Particulate Filter Has Differential Pressure
least severe (1) Problem
3509 2 Sensor Supply Voltage 1: Erratic,Intermittent,or 5 Volt Sensor Supply Circuit- Test
Incorrect
3510 2 Sensor Supply Voltage 2 : Erratic,Intermittent, 5 Volt Sensor Supply Circuit- Test
or Incorrect
3511 2 Sensor Supply Voltage 3 : Erratic,Intermittent,or 5 Volt Sensor Supply Circuit - Test
Incorrect
3697 6 Particulate Trap Lamp Command :Current Indicator Lamp Circuit- Test
Above Normal
3698 6 Exhaust System High Temperature Lamp Indicator Lamp Circuit- Test
Command :Current Below Normal
Part No. 1268496 SX-150 185


3702 6 Diesel Particulate Filter Active Regeneration Indicator Lamp Circuit- Test
Inhibited Status : Current Above Normal
4765 3 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit -
Intake Gas Temperature :Voltage Above Test
Normal
4765 4 After treatment #1 Diesel Oxidation Catalyst Engine Temperature Sensor Open or Short Circuit-
Intake Gas Temperature :Voltage Below Normal Test
5055 17 Engine Oil Viscosity : Low - least severe (1) Oil Contains Fuel
5055 18 Engine Oil Viscosity : Low - moderate severity Oil Contains Fuel
(2)
5099 6 Engine Oil Pressure Low Lamp Data : Current Indicator Lamp Circuit- Test
Above Normal
5319 31 After treatment Diesel Particulate Filter Diesel Particulate Filter Active Regeneration Was
Incomplete Regeneration Interrupted
5324 7 Engine Glow Plug 1: Not Responding Properly Glow Plug Starting Aid - Test
5325 7 Engine Glow Plug 2 :Not Responding Properly Glow Plug Starting Aid - Test
5419 5 Engine Throttle Actuator #1 :Current Below Motorized Valve- Test
Normal
5419 6 Engine Throttle Actuator #1 :Current Above Motorized Valve - Test
Normal
5419 7 Engine Throttle Actuator #1 :Not Responding Motorized Valve- Test
Properly
5571 2 High Pressure Common Rail Fuel Pressure Fuel Rail Pressure Problem
Relief Valve :Erratic, Intermittent, or Incorrect
Relief Valve :Not Responding Properly
Relief Valve : Abnormal Rate of Change
Relief Valve : Special Instruction
Relief Valve :High - moderate severity (2)
5826 16 Emission Control System Operator Inducement Refer to "Operator Inducement Codes".
Severity :High - moderate severity (2)
186 SX-150 Part No. 1268496

Part No. 1268496 SX-150 187

Schematics
Section 5 Schematics
About This Section

There are two groups of schematics in this section.
Electrical Schematics
Observe and Obey: circuits could result in death or
R Troubleshooting and repair procedures shall be watches and other jewelry.
completed by a person trained and qualified on
the repair of this machine
Hydraulic Schematics
R Immediately tag and remove from service a
damaged or malfunctioning machine. Bodily injury hazard. Spraying
R Repair any machine damage or malfunction burn skin. Loosen hydraulic
before operating the machine.
Before Troubleshooting: the oil pressure to dissipate
R Read, understand and obey the safety rules squirt or spray.
R Be sure that all necessary tools and test
equipment are available and ready for use.
188 SX-150 Part No. 1268496

Wire Circuit Legend
Circuit numbering
1 Circuit numbers consist of three parts: the Circuit prefix
circuit prefix, circuit number and circuit suffix.
C Control
The circuit prefix indicates the type of circuit.
The circuit number describes the function of D Data
the circuit. The circuit suffix provides an E Engine
abbreviation for the number or may be used to G Gauges
further define the function of this portion of the
N Neutral
circuit. It also may be used to indicate the final
end of the circuit, i.e., LS or limit sw. P Power
R Relay Output
2 The circuit number may be used more than
once in a circuit. S Safety
V Valve
For Example:
C 74 PL – This is the circuit for the lockout valve #1.
C stands for control, 74 is the number of the circuit
for the primary #1 lock out valve. PL stands for
Primary Lockout.
S 62 BST – This is the circuit that communicates to
the onboard computers of the machine that the
boom is fully stowed. S stands for safety, 62 is the
number of the circuit for boom stowed and BST
stands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuit
number for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is the
wire that feeds the relay coil for the work lamp. All
other numbers remain the same.
V61AXR – V stands for valve power. Number
61 stands for axle retracted circuit; AXR stands for
Axle retracted.
R46HRN – R stands for Relay output, supplying
power to the horn (HRN). Number 46 is the circuit
number for the horn.
Part No. 1268496 SX-150 189

Wire Circuit Legend
Suffix Definition Suffix Definition

ABV Auxiliary Boom Valve ESP Engine Speed Select
AF Alternator Field FAP Axle Front Position
AFV Auxiliary Forward Valve FB Flashing Beacon
AH Auxiliary Hydraulic Pump FE Function Enable
ANG Angle FL Fuel Select (gas/LP)
APV Auxiliary Platform Valve FLR Filter Restricted
ARV Auxiliary Reverse Valve FLT Filter Switch
ASV Auxiliary Steer/Drive Valve FP Fuel Pump
AXE Axle Extend Valve FS Float Switch
AXO Axle Oscillate FSL Fuel Solenoid
AXR Axle Retract Valve FTS Foot switch Signal
BAT Battery FWD Forward
BEX Boom Extended GEN AC Generator
BRK Brake GND Ground
BST Boom Stowed HG Hydraulic Generator
BV Bypass Valves HRN Horn
CAL Calibrate HS High RPM
CAN CAN Signal IGN Ignition
CAT CATS Module JBD Jib Bellcrank Down
CNK Chain Break JBE Jib Extend
DCN Drive Chassis Controller JBR Jib Retract
DE Drive Enable JBS Jib Sensor
DEL Drive Enable Left JBU Jib Bellcrank Up
DER Drive Enable Right JD Jib Down
DTH Data High JER Jib Extend/Retract Control
DTL Data Low JFC Jib Up/Down Flow Control
EDC Electrical Displacement Control JPL Propel Signal
ENL Envelope Lockout JPW Joystick 5V DC Power
ENV Envelope Light JRL Jib Rotate Left (CCW)
ERL Extend/Retract Lockout JRR Jib Rotate Right (CW)
ESL Engine Status Lamp
190 SX-150 Part No. 1268496

Wire Circuit Legend

JSV Jib Select Valve PLF Platform Level Flow Control
JU Jib Up PLL Propel Lockout
JUD Jib Up/Down Control PLS Primary Boom Extend/Retract Signal
LDS Load Sensor PLU Platform Level Up
LF Left Front PRC Platform Rotate Control
LFS Left Front Steer Sensor PRF Platform Rotate Flow Control
LO Lockout PRL Platform Rotate Left (CCW)
LOF Low fuel PRR Platform Rotate Right (CW)
LPS Lamps PRV Proportional Valve
LR Left Rear PS Pressure Switches
LRS Left Rear Steer Sensor PSE Program Setup Enable
LS Limit Switch PSL Power to Length Sensor
LS Low RPM PSR Pressure Sender
LSR Lift Speed Reduction PTA Platform Tilt Alarm
MFV Multi Function Valve PTS Platform Tilt Sensor
MS Motor Shift (Speed) PUD Primary Boom Up/Down Flow Control
PBD Primary Boom Down PWR Power
PBE Primary Boom Extend PXS Proximity Sensor
PBL Primary Boom Extend/Retract Lockout RAP Axle Rear Position
Valve RCV Recovery
PBR Primary Boom Retract REC Receptacle
PBS Primary Boom Angle Sensor RET Return
PBU Primary Boom Up REV Reverse
PCE Pressure Comp Enable RF Right Front
PCN Platform Control RFS Right Front Steer Sensor
PEL Primary Ext/Ret Lockout RL Retract Lockout
PER Primary Boom Extend/Retract Flow Control RPM RPM
PES Primary Boom Up/Down Signal RR Right Rear
PL Primary Lockout
PLD Platform Level Down
Part No. 1268496 SX-150 191

Wire Circuit Legend

RRS Right Rear Steer Sensor STR Starter
RS Rotary Sensor SUD Sec Boom Up/Down Flow Control
SA Start Aid (Glow Plug or choke) TAX Tilt Alarm X axis
SB Secondary Boom TAY Tilt Alarm Y axis
SBD Sec Boom Down TCN Ground Control
SBE Sec Boom Extend TCN Ground Control Panel
SBL Sec Boom Elevated TET Tether
SBR Sec Boom Retract TRF Turntable Rotate Flow Control
SBS Sec Boom Angle Sensor TRR Turntable Rotate Right (CW)
SBU Sec Boom Up TS Temp Switches
SCC Steering Valve (CCW) TSR Temp Sender
SCW Steering Valve (CW) TSW Test Switch
SEN Sensor TTA Turntable Tilt Alarm
SER Sec Boom Extend/Retract Flow Control TTS Turntable Tilt Sensor
SHD CAN Shield
SLD Secondary Boom Lockout Valve (riser down)
SLE Secondary Boom Lockout Valve (extend)
SP Spare
SS Speed Sensor
STC Steer Control Signal
192 SX-150 Part No. 1268496

Wire Color Legend
Wire Coloring P22 Jib, Jib Level, Platform Level

P38 Propel (drive) valves
1 All cylinder extension colors are solid and all
P39 Turntable rotate flow control valve
retract functions are striped black. When using
black wire, the stripe shall be white. Color Circuit # Primary Function
RD 1 Primary boom up driver
2 All rotations that are LEFT or CW are solid,
RIGHT or CCW are striped and black. When RD/BK 2 Primary boom down driver
the wire is black, the stripe is white. RD/WH 3 Primary boom up/down flow
control proportional valve driver
3 All proportional valve wiring is striped.
WH 4 Turntable rotate left valve driver
WH/BK 5 Turntable rotate right valve driver
Wire Color Legend WH/RD 6 Turntable rotate flow control
BL Blue proportional valve driver
BL/BK Blue/Black BK 7 Primary boom extend
BL/RD Blue/Red BK/WH 8 Primary boom retract
BL/WH Blue/White BK/RD 9 Primary boom Extend/Retract

proportional valve driver
BK Black
BL 10 Secondary boom up valve driver
BK/RD Black/Red
BL/BK 11 Secondary boom down valve
BK/WH Black/White driver
BK/YL Black/Yellow BL/WH 12 Secondary boom up/down flow
BR Brown control proportional valve driver
GR Green BL/RD 13 Drive enable
GR/BK Green/Black OR 14 Platform level up valve
GR/WH Green/White OR/BK 15 Platform level down valve
RD Red OR/RD 16 Platform up/down flow control
proportional valve driver
RD/BK Red/Black
GR 17 Platform rotate left valve driver
RD/WH Red/White
GR/BK 18 Platform rotate right valve driver
OR Orange
GR/WH 19 Jib select valve driver circuit
OR/BK Orange/Black
RD 20 12V DC battery supply
OR/RD Orange/Red
WH 21 12V DC ignition supply
WH White
BK 22 Key switch power to platform
WH/BK White/Black
WH 23 Power to platform
WH/RD White/Red
RD 24 Power to warning senders
YL Yellow
WH/BK 25 Power to oil pressure sender
Power Circuits
P9A Primary up valve
P9B Ignition/Fuel
P10 Primary boom extend valve
P11 Primary boom up valve
P12 Axle Retract
Part No. 1268496 SX-150 193

Wire Color Legend
Color Circuit # Primary Function Color Circuit # Primary Function

WH/RD 26 Power to temp sender GR/BK 55 Axle oscillation
RD 27 Auxiliary Power RD 56 Foot switch/TCON estop power
RD/BK 28 Platform level alarm RD/WH 57 Boom down safety interlock
RD/WH 29 Drive Motor shift (speed) RD/BK 58 Safety interlock to engine
WH 30 Forward/EDC-A GR/WH 59 Chain break circuit
WH/BK 31 Reverse/EDC-B GR/WH 60 Axle extend
WH/RD 32 Brake GR 61 Axle retract
BK 33 Start OR 62 Boom stowed (safety)
BK/WH 34 Start Aid (glow plug or choke) OR/RD 63 Power to boom envelope safety
BK/RD 35 High Engine speed select switch
BL 36 Steer clockwise OR/BK 64 Power for operational switches
BL/BK 37 Steer counterclockwise BL/WH 65 Low fuel indication
BL/WH 38 Gasoline BL 66 Drive Enable
BL/RD 39 LPG BL 67 Secondary boom not stowed
OR 40 Limit switch signal stowed RD 68 Primary Boom lowered

(operational)
OR/BK 41 RPM signal
BL 69 Primary boom #1 extended
OR/RD 42 Boom retracted signal
BL/WH 70 Primary boom #2 retracted
GR 43 Jib Up
BL/BK 71 Primary boom #2 extended
GR/BK 44 Jib Down
BL/WH 72 Secondary boom extended
GR/WH 45 AC Generator
BL/RD 73 Secondary boom retracted
WH 46 Horn
RD 74 Primary #1 Lockout
WH/BK 47 Output Power Enable
RD/WH 75 Primary #2 Lockout
WH/RD 48 Work Lamp
BL 76 Primary boom #3 extended
WH/BK 49 Motion Lamp
WH 77 Lower Angle #1 operational
BL 50 Auxiliary Boom
WH/BK 78 Upper Angle #2 operational
BL/WH 51 Auxiliary Steer
BK 79 Power from TCON ESTOP
BL/RD 52 Auxiliary Platform
N/A 80 Can 2.0/J1939 Shield
WH/BK 53 Boom envelope safety valve cutoff
GR 81 Can 2.0/J1939 Low
BK/WH 54 Power to safety interlock switches
(engine) YL 82 Can 2.0/J1939 High
GR/WH 83 Tilt signal X axis
GR/BK 84 Tilt signal Y axis
GR 85 Tilt sensor power
194 SX-150 Part No. 1268496

Wire Color Legend

OR 86 Hydraulic Filter restricted RD 117 Flashing Beacon
RD 87 Platform Level Safety Power OR 118 Lift Speed Reduction
RD/BK 88 Platform Level Safety Output BL 119 Hydraulic Pressure Sensor Output
BR 89 Platform Level Safety Ground OR 120 Oil Cooler Fan
RD/BK 90 Proximity Kill GR 121 Axle Oscillate Left
RD/WH 91 Gate Interlock GR/BK 122 Axle Oscillate Right
WH/BK 92 Motor Speed (LO/HI) RD/BK 123 Primary Boom Angle Signal
WH/RD 93 Motor Bypass Operational
WH 94 Load Sensor RD/WH 124 Secondary Boom Angle Signal

Operational
OR 95 Tether ESTOP return
WH/RD 125 Secondary Boom Lockout (Extend
RD 96 Tether Power Enable)
BK 97 Tether ESTOP Power WH/BK 126 Secondary Boom Lockout (Riser
WH 98 J1708 + (high) Down Enable)
BK 99 J1708- (low) GR 127 ECU Test Switch
WH/RD 100 Outrigger lowered OR/RD 128 Low Engine Speed
WH/BK 101 Outrigger raised RD/BK 129 Descent Alarm
OR 102 Pothole protector up WH/RD 130 Travel Alarm
OR/RD 103 Pothole protector down BL 131 Motion Alarm
BK/WH 104 Proprietary Data buss - (I.e. ITT GR 132 Platform Load Input
or AP) GR/WH 133 Platform Load Alarm
BK/RD 105 Proprietary Data buss + (I.e. ITT GR/BK 134 Key Switch power
or AP)
BL/WH 135 Fuel Pump
GR 106 Spare
RD 136 Power to Safety Module
RD 107 Alternator Field
RD/WH 137 Drive Power (P_38)
BL/WH 108 Engine Status
RD/BK 138 Primary Boom Up/Secondary
GR/WH 109 Sensor Power Boom Down-Extend (P_11/30)
BK 110 Sensor Return WH/RD 139 Turntable Rotate Flow Control
OR 111 Steer Signal Safety (P_39)
RD 112 Steer Signal to Solenoid Valve OR/RD 140 Boom Envelope Safety
OR/RD 113 Multi-function Valve
BK/RD 114 Load Moment Overweight
RD/BK 115 Load Moment Underweight
OR 116 Hydraulic Oil Cooler
Part No. 1268496 SX-150 195

Wire Color Legend

RD 141 Primary Boom Angle Signal OR 166 Boom Length Signal Safety
Safety OR/BK 167 Boom Length Signal Operational
OR 142 Secondary Boom Angle Signal BL/RD 168 Primary Boom Hydraulic Valve
Safety Lockout
BL/RD 143 Drive Enable Left GR 169 Envelope Active LED
BL/WH 144 Drive Enable Right WH/RD 170 Load Sense Relay Source
RD/WH 145 Calibrate WH/BK 171 Load Sense Relay Sink
BL 146 Jib Bellcrank Up Flow Control BL 172 UP/DN Flow Control Ground
BL/BK 147 Jib Bellcrank Down Flow Control BK 173 Ext/Ret Flow Control Ground
BL/WH 148 Jib Bellcrank Sensor WH 174 Key Switch Power, Ground
GR/WH 149 Jib Up/Down Flow Control Position
GR/BK 150 Hydraulic Generator Bypass WH/BK 175 Load Sensor Signal Operational
GR 151 Hydraulic EDC Output GR/WH 176 Secondary Extend/Retract FC
BK 152 Injector Retard BL/RD 177 Extend/Retract Lockout
BK 153 Jib Extend BK 178 Control Module Status Light
BK/WH 154 Jib Retract GR 179 Drive Power Relay
OR/RD 155 Pressure Comp. Enable BK 180 Lift Power Relay
GR/WH 156 Jib Up/Down OR 181 48 Volt Alternator field (or Battery)
BK/RD 157 Jib Extend/Retract RD 182 24 Volt Battery
BL/RD 158 Steer Signal Rocker BL 183 Envelope or Load Sense
BL/WH 159 Steer Joystick Signal Recovery
WH/RD 160 Propel Joystick Signal WH 184 Program setup Enable
WH/BK 161 Secondary Boom Joystick Signal WH 185 Encode A
OR 162 Joystick 5V DC power BL 186 Encode B
BL/WH 163 Primary Extend/Retract Signal BL 187 Bootstrap or Program Enable
RD/WH 164 Primary Up/Down Signal

WH/RD 165 TT Rotate Signal
196 SX-150 Part No. 1268496

Wire Color Legend
Color Circuit # Primary Function

GR 188 Safety cross check
BK 189 Data Receive
BK/WH 190 Data Transmit
WH/RD 191 Multi-Function Pressure Relief
WH/BK 192 Jib Rotate Left
WH/RD 193 Jib Rotate Right
WH/RD 194 Speed Select Input
OR/RD 195 Electric Brake Source
YL 196 2.5V Sensor Power
WH 197 Hour Meter
RD 198 +12V Sensor Power
WH/RD 199 Thermal Switch
BL 226 Telematics Remote Disable
GR 227 Engine Control
CAN 2.0 / J1939 Low
YL 228 Engine Control
CAN 2.0 / J1939 High
BR N/A Ground or Return
Part No. 1268496 SX-150 197

Limit Switches and Angle Sensors
Types of Limit Switches Numbering Legend

LS FA 1 L O
There are two types of limit switches, found in LS Limit FA Front Circuit L Load O Operational
various locations throughout the machine: Switch Axle Number moment
mechanical-type operational/safety switches and LT Stringpot RA Rear
Axle
A Angle S Safety
rotation or angle sensors. As in aircraft, which RS Rotary LF Left Front D Down

Sensor
features redundant safety systems, each
LR Left Rear E Extend
mechanical operational switch is backed up with a
RF Right R Retract
separate, independently functioning safety switch. Front
RR Right
The mechanical-type operational or safety Rear
J Jib Boom
switches are used to sense a positive displacement
or movement of the limit switch actuator, or arm, as P Boom
the machine moves through its range of operational T Turntable
functions. The rotation or angle sensors utilize Hall

Effect technology and must be calibrated when
replaced. Included in this group are envelope limit
switches which sense the extended length and
angle of the booms and rotational position of the
turntable.
An example is the drive enable limit switch, which
disables the drive function anytime the boom is
rotated past the rear tires, indicated by the 'circle'
end of the drive chassis.In some cases, the engine
will be stopped if safety parameters are exceeded.
198 SX-150 Part No. 1268496

Switches and Sensors - Primary Boom

Index Description Schematic Item Function Controlled Switch Type and
Operation
1 Jib Rotated CCW Safety Limit Switch LSJ2RS Normally closed
switch;contacts open
when jib boom is in
stowed position.
2 Jib Rotated CCW Operational Limit LSJ3RO
Switch
3 Boom #2 - 150 ft (boom #2, #3, LSB4EO
#4 fully extended) Operational Limit
Switch
4 Boom #2 - 2. ft (boom fully retracted) LSB3RS Out of stowed safety
Safety Limit Switch
5 Boom Angle Operational/Safety RSB1AO/S
Rotary Sensor
6 Boom Angle - 10° Operational Limit LSB1DO
Switch
7 Cable Tension #1 Safety Limit Switch LSB5S
8 Cable Tension #2 Safety Limit Switch LSB6S
9 Boom Length Operational/Safety LTB1LO/S
Stringpot
10 Boom #0 - 2 ft (boom fully retracted) LSB3RO Out of stowed. Normally open
Operational Limit Switch switch;contacts close
when primary boom is
fully retracted.
Part No. 1268496 SX-150 199

Switches and Sensors - Turntable

Operation
1 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. when turntable is
rotated in the right
direction.
2 Turntable #1 Safety Limit Switch LST1S Prevents the turntable from Normally closed
rotating past either rear tire switch;contacts open
when the axles are when turntable is
retracted. rotated past either
rear tire with the axles
retracted.
3 Turntable #2 Operational Limit LST2O Activates the drive enable Normally closed
Switch zone when the turntable is switch;contacts open
rotated in the left direction. when turntable is
rotated in the left
direction.
counterweight end platform end
200 SX-150 Part No. 1268496

Switches and Sensors - Drive Chassis

Operation
1 Front Axle #1Extended Safety Limit LSFA1ES Disables boom functions when Normally open
Switch. axles are retracted. switch;contacts close
when axle is fully
extended.
2 Rear Axle #1Extended Safety Limit LSRA1ES Disables boom functions when Normally open
Switch axles are retracted. switch;contacts close
when axle is fully
extended
3 Front Axle #1 Angle Operational Rotary RSFA1SO Provides front axle positioning
Sensor information for adjusting
steering neutral setting during
axle extension.
4 Rear Axle #1 Angle Operational Rotary RSRA1SO Provides rear axle positioning
Sensor information for adjusting
steering neutral setting during
axle extension.
5 Left Front #1 Steer Operational Rotary RSLF1SO Provides wheel position
Sensor information during steering.
Master wheel in all steer modes
except rear steer.
6 Right Front #1 Steer Operational Rotary RSRF1SO Provides wheel position
7 Left Rear #1 Steer Operational Rotary RSLR1SO Provides wheel position
Master wheel when in rear steer
mode.
8 Right Rear #1 Steer Operational Rotary RSRR1SO Provides wheel position
Blue side
Blue end Yellow end

Front Rear
Square end Circle end
Platform end
Yellow side
Part No. 1268496 SX-150 201

Circuit Connector Legend

Number Description Number Description
J1 Molex connector on toggle/LED pcb J37 2 pin Deutsch DTP connector (swivel-lower)
J9 Ribbon connector from TCON to membrane J38 6 pin Deutsch DTP connector (swivel-lower)
#1 J55 6 pin Deutsch DT connector for platform tilt
J10 Ribbon connector from TCON to membrane sensor (S6)
#2 J57 4 pin Deutsch DTP connector for throttle
J11 Black 23 pin AMP connector on TCON solenoid
J12 Black 35 pin AMP connector on TCON J58 2 pin Deutsch DT pri boom up/dwn F.C. valve
J13 White 23 pin AMP connector on TCON #1 (Y45)
J14 White 35 pin AMP connector on TCON J58A 2 pin Deutsch DT pri boom up/dwn F.C. valve
#2 (Y45A)
J15 Black 4 pin DTP connector on PCON
J59 2 pin Deutsch DT primary boom up valve
J17 16 pin Molex mini fit circuit board to key (Y22)
switch
J60 2 pin Deutsch DT primary boom down valve
J20 8 pin Deutsch DT lower/upper LS harness (Y21)
J20B 2 pin Deutsch DT cable tension #2 harness J61 2 pin Deutsch DT pri boom extend/retract
J21 Black 23 pin AMP connector on PCON F.C. valve (Y76)
J22 White 35 pin AMP connector on PCON J62 2 pin Deutsch DT pri boom extend valve
(Y79)
J24 10 pin connector PCON PCB to toggle/LED
driver PCB J63 2 pin Deutsch DT pri boom retract valve (Y80)
J25 6 pin Deutsch DTM conn on drive/steer J69 2 pin Deutsch DT TT rotate CW/CCW F.C.
joystick (JC3) valve (Y77)
J26 6 pin Deutsch DTM conn on extend/retract J70 2 pin Deutsch DT turntable rotate CW valve
joystick (JC2) (Y52)
J29 16 pin Molex conn on PCON PCB J71 2 pin Deutsch DT turntable rotate CCW valve
(Y53)
J31 Black 23 pin AMP connector on DCON
J76 2 pin Deutsch DT platform rotate CW valve
J32 White 23 pin AMP connector on DCON
(Y70)
J33 3 pin Deutsch SAE DT connector
J77 2 pin Deutsch DT platform rotate CCW valve
(swivel-upper)
(Y71)
J34 2 pin Deutsch DTP connector (swivel-upper)
J78 2 pin Deutsch DT jib up valve (Y72)
J35 6 pin Deutsch DT connector (swivel-upper)
J79 2 pin Deutsch DT jib down valve (Y73)
J36 3 pin Deutsch SAE DT connector
J80 2 pin Deutsch DT platform level up valve
(swivel-upper)
(Y20)
J81 2 pin Deutsch DT platform level down valve
(Y19)
J82 4 pin Deutsch DT proximity kill (LSP1PROX)
J84 2 pin Deutsch DT footswitch (FS1)
202 SX-150 Part No. 1268496


J87 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
J91 2 pin Deutsch DT RR steer right valve (Y55) (Y86)
J92 2 pin Deutsch DT RR steer left valve (Y56) J137 4 pin Deutsch DT front axle safety switch
J93 2 pin Deutsch DT LR steer right valve (Y57) (LSFA1ES)
J94 2 pin Deutsch DT LR steer left valve (Y58) J138 4 pin Deutsch DT rear axle safety switch
(LSRA1ES)
J95 2 pin Deutsch DT RF steer right valve (Y59)
J142 2 pin Deutsch DT boom cable to lower LS
J96 2 pin Deutsch DT RF steer left valve (Y60) harness
J97 2 pin Deutsch DT LF steer right valve (Y61) J144 10 pin AMP connector to Deutz engine
J98 2 pin Deutsch DT LF steer left valve (Y62) J146 2 pin Deutsch DT lower LS to function
J99 2 pin Deutsch DT axle extend valve (Y99) harness
J100 2 pin Deutsch DT axle retract valve (Y100) J147A 1 way Deutsch DTHD upper to lower boom
cable
J106 2 pin Deutsch DT brake release valve (Y2)
J147B 3/8 in stud term TCON to lower boom cable
J107 3 pin Deutsch DT RR steer sensor
(P52PCON)
(RSRR1SO)
J148A 1 way Deutsch DTHD upper to lower boom
J108 3 pin Deutsch DT LR steer sensor
cable
(RSLR1SO)
J148B 3/8 in stud term TCON to lower boom cable
J109 3 pin Deutsch DT RF steer sensor
(GNDPCON)
(RSRF1SO)
J149 2 pin Deutsch DTP upper to lower boom cable
J110 3 pin Deutsch DT LF steer sensor
(RSLF1SO) J150 4 pin Deutsch DT upper to lower boom cable
J114 6 pin Deutsch DT pri boom angle sensor J151 3 pin Deutsch SAE DT upper to lower boom
(RSB1AO/S) cable
J120 4 pin Packard weatherpack EDC connection J152A 3 pin Deutsch SAE tee harness
J121 12 pin Deutsch DTM gray SCON module #1 J152B 3 pin Deutsch SAE tee harness
J122 12 pin Deutsch DTM green SCON module #2 J153 4 pin Deutsch DT engine to function harness
J124 2 pin Deutsch DT drive enable right (LST1O) J155A 2 way Deutsch DTP plat to upper boom cable
J125 4 pin Deutsch DT drive enable left (LST2O) J155B 2 way Deutsch DTP upper to lower boom
cable
J126 4 pin Deutsch DT drive enable safety
(LST1S) J155C 2 way Deutsch DTP lower boom cable to
swing
J127 6 pin Deutsch DTM pri boom up/dwn/TT rot
joystick (JC7) J157 2 pin Deutsch DT plat harness to upper boom
cable
Part No. 1268496 SX-150 203


J160 6 pin Deutsch DT front axle sensor (RSFA10) J210 2 pin Deutsch DT 10 deg angle oper
J161 6 pin Deutsch DT rear axle sensor (RSRA10) (LSB1DO)
J162 6 pin Deutsch DT jib bellcrank tilt sensor J211 4 pin Deutsch DT 3ft extend oper (LSB3RO)
(S21) J213 4 pin Deutsch DT 150ft extend oper/safety
J166 2 pin Deutsch DT function enable valve #1 (LSB4EO/S)
(Y74) J215 2 pin Deutsch DT lower LS to engine harness
J166A 2 pin Deutsch DT function enable valve #2 J216 2 pin Deutsch DT hyd generator valve (Y91)
(Y74A) J217 2 pin Deutsch DT hyd generator bypass valve
J169 20 pin Molex conn on PCON PCB (Y92)
J171 2 pin Deutsch DT hydraulic oil cooler sensor J218 6 pin Deutsch DTM jib up/dwn/jib rot joystick
J172 2 pin Deutsch DT hydraulic oil cooler fan (JC8)
J173 2 pin Deutsch DT boom cable to engine J219 2 pin Deutsch DT primary lockout valve #1
harness (Y87)
J192A 4 pin Deutsch DT cable break safety #1 J220 2 pin Deutsch DT primary lockout valve #2
(LSB5S) (Y88)
J192B 2 pin Deutsch DT cable break safety #2 J222A 4 pin Deutsch DT zero tube limit to cable
(LSB6S) tension cable #1
J199 6 pin Deutsch DT pri boom length sensor J222B 2 pin Deutsch DTP upper limit to cable
(LTB1LO/S) tension cable #2
J202 2 pin Deutsch DT jib rotate CW valve (Y89)

J203 2 pin Deutsch DT jib rotate CCW valve (Y90)
J205 4 pin Deutsch DT jib rotated CW (LSJ2RO)
J206 2 pin Deutsch DT jib rotated CCW (LSJ3RO)
J207 4 pin Deutsch DT 3.5ft extend safety
(LSB3RS)
J208 12 pin Deutsch DT lower limit to zero tube
cable
J209 4 pin Deutsch DT 151ft retract safety
(LSB2RS)
204 SX-150 Part No. 1268496

Connector Pin Legend
Pin location - 4 pin Pin location - 23 pin Pin location - 35 pin connector
connector connector
Pin location - 12 pin

connector
Abbreviation
OH High Current On/Off Solenoid Output (3 < x < 6 Amps)
OM Medium Current On/Off Solenoid Output (0.5 < x < 3 Amps)
OL Low Current On/Off Solenoid Output (0.1 < x < 3 Amps)
PM Prop. Medium Current Proportional Solenoid Output (0.5 < x < 3 Amps)
LED LED Output LED Output Driver
RLY Relay Output Relay Output Driver (0.1 < x < 0.3 Amps)
EDC EDC Output Linear Current Control (propel)
AI Analog Input (0 to +5 Vdc)
DI Digital Input (0 or 'Vbat' Voltage)
FAC Frequency AC Input (0 to 1 kHZ / 0 to 13.8 Vptop)
RDF Ground Ref signal power / GND to external sensors, input power(s) and ground
PWR 12V Power (x > 6 Amps)
CONT 12V Power (x < 1 Amp)
SNSR Sensor Power 5.0 Vdc Supply for sensors
Part No. 1268496 SX-150 205


J11 Black 23 Pin Connector
Pin NO. Type* Signal Name Circuit NO. Signal Description
P11-01 REF P CON G ND GNDPCON-BR PCON ground
P11-02 PWR P CON P OWE R P 52PCON-WH Power output to PCON. Unregulate d 12V auto motive
power.
P11-03 RLY HORN RELAY COIL C46HRN-WH Power to service horn relay
P11-04 CONT OUT PWR ENBL C47OUT-WH/BK Bi -directional relay control signal. Normally low,
switched to 12V PWR-PCON ESTOP is high and the
emergency stop switch is closed.
P11-05 PWR PWR-PCON ESTOP P 23PCO N-BK Output signal to PCON. Provides 12V power to the
emergency stop switch.
P11-06 CONT P _7 S 56PRV -RD Bi -directional relay control signal. Normally low,
switched to 12V when PCON POWER & OUT PWR
ENBL are active and the foot-switch is closed.
P11-07 CONT P _22 P 56PRV -RD/WH Relay control signal or power signal o f PCON, normally
controlled by the platform tilt safety switch output, but
may be over-ridden in bypass / recovery mode.
P11-08 RLY SPARE RLY OUT Power relay coil
P11-09 RLY FLASHING BEACON RLY C117FB-RD Flashing beacon relay
P11-10 COM CAN SHIELD Termination for CA N cable shield
P11-11 CONT S ERV /CAL MODE C145CAL-RD/WH 12V calibration mode signal for SCON
P11-12 NOT USED No connection
P11-13 !BOOT !BOOT
P11-14 FAC CAL FREQ 1 Calibration frequency 1
P11-16 FAC CAL FREQ 2 Calibration frequency 2
P11-17 COM CAN LO W D81CAN(-)-G R CAN bus connection
P11-18 COM CAN HIGH D82CAN(+ )-YL CAN bus connection
P11-21 REF DIAG GND Ground
P11-22 PWR DIAG PWR (12V ) 12V power for TCON, DCON, and SCON
206 SX-150 Part No. 1268496


Pin No. Type Signal Name Circuit No. Signal Description
P12-01 REF SCON ECU GND SCONGND-BR Ground for SCON ECU
P12-02 PWR DCON ECU PWR P21DCON-WH 12V power for ECU power
P12-03 PWR P_6R1 P53LS-WH/BK Safety circuit power (to DCON, SCON)
P12-04 PWR P_6R2 P54ENG-BK/WH Safety circuit power (to SCON)
P12-05 PWR P_7R S56PRV-RD Safety circuit power (to DCON, SCON)
P12-06 PWR P_9A P57PBD-RD/WH Safety circuit for boom down (power)
P12-07 PWR P_9B P58LS-RD/BK Safety circuit for fuel/ignition (power)
P12-08 PWR P_10 S59CNBK-GR/WH Safety circuit for boom extend - cable break (power)
P12-09 PWR P_11 S140ENL-OR/RD Safety circuit for boom up (power)
P12-10 PWR P_12 C61AXRT-GR Safety circuit for axle retract (signal)
P12-11 DI P_14 Monitoring circuit
P12-12 DI P_18 Monitoring circuit
P12-13 PWR OPER SW PWR C64LS-OR/BK Power for Operational Limit Switches
P12-14 DI LOW FUEL - FST1S C65LOFL-BL/WH Low fuel float switch
P12-15 DI DRV ENBL R - LST1O C144DER-BL/WH Turntable stowed switch 1 (drive enable right)
P12-16 DI LSB1DO C68PBD-BL Input - primary boom lowered (10 deg operational)
P12-17 DI 12V SIG TO PLD C64LS-OR/BK Tied high (12V) for proper operation of PLD
P12-18 PWR OPER SW PWR C64LS-OR/BK Power for Operational Limit Switches
P12-19 DI LSB3RO C70PBE-BL/WH Input - primary boom fully retracted for PLD (3ft retracted
operational)
P12-20 DI LSB4EO C71PBE-BL/BK Input - primary boom sections 2-4 extended (150ft extended
operational)
P12-21 DI LSB2RS S69PBE-BK/WH Input - primary boom section #1 retracted (151ft retracted
safety)
P12-22 DI SPARE DI Spare
P12-23 OM P1 SEQ SX-180 only
P12-24 OM P2 SEQ SX-180 only
P12-25 REF SNSR GND SNSR GND-BR Ground to angle sensor
P12-26 SNSR SNSR PWR (5V) P109ANG-GR/WH Power to angle sensor (5.0VDC)
P12-27 AI AUX HYD PRESSURE IN Signal from auxiliary hydraulic pressure sensor
P12-28 DI DRV ENBL L - LST2O C143DEL-BL/RD Turntable stowed switched 2 (drive enable left)
P12-31 DI BOOM STOWED Override for boom transport
P12-32 AI RSB1AO (BOOM ANGLE)C123PBS-RD/BK Primary angle sensor input to TCON
P12-33 AI LTB1LO (BOOM C167PRS-OR/BK Primary length sensor input to TCON
LENGTH)
P12-34 PWR P_30 Safety power feed to P_30
P12-35 REF VALVE RETURN VLVRET-BR Valve return
Part No. 1268496 SX-150 207


J13 White 23 Pin Connector
Pin NO. Type Signal Name Circuit NO. Signal Description
P13-01 REF VALVE_RETURN_1 Valve ground return (return for throttle RPM
solenoid)
P13-02 RLY THROTTLE C35RPM-BK/RD Provides power to throttle actuator relay
P13-03 RLY FUEL/IGNITION C21IGN-WH Provides power to engine shutdown actuator relay
coil
P13-04 RLY START AID RLY C34SA-BK/WH Provides power to choke/glow plug relay
P13-05 PM FWD PWM Forward proportional PWM valve drive
P13-06 PM REV PWM Reverse proportional PWM valve drive
P13-07 RLY SERVICE HORN C46HRN-WH Output to service horn
P13-08 OM KEYSWITCH PWR ON/OFF valve drive to LP selector on throttle body
P13-09 RLY STARTER RELAY C33STR-BK Tier IV engines only
P13-10 EDC EDC FWD C30EDC(+)-WH Electrical displacement control (forward)
P13-11 EDC EDC REV C31EDC(-)-WH/BK Electrical displacement control (reverse)
P13-12 AI OIL_PRESSURE C25PSR-WH/BK Input from oil pressure sender
P13-13 AI OIL/WATER_TEMP C26TSR-WH/RD Input from oil/water temperature sender
P13-14 REF TT_TILT_SNSR_GND Ground for turntable tilt sensor
P13-15 SNSR TT_TILT_SNSR_PWR Supply voltage for turntable tilt sensor
(SNSR_5V)
P13-16 REF VALVE_RETURN_2 Valve ground return (return for glow plugs)
P13-17 PWR P_38 PWR TO PROPEL S137PLL-RD/WH Safety power feed to propel drivers from SCON
P13-18 FAC ALTERNATOR RPM C41RPM-OR/BK Input from alternator indicating engine RPM
P13-19 PWR P_39 PWR TO TTROT S139TRF-WH/RD Safety power feed to turntable rotate flow control
FC valve
P13-20 AI TT_TILT_X_AXIS Analog input from tilt sensor (spare)
P13-21 AI TT_TILT_Y_AXIS Analog input from tilt sensor (spare)
P13-22 OM AC GENERATOR V45HG-GR/WH Output to ON/ OFF generator valve
P13-23 REF VALVE_RETURN_3 Valve ground return
208 SX-150 Part No. 1268496


P14-01 REF VALVE_RETURN_4 VLVRET4-BR Valve ground return
P14-02 PM PRI BM U/D FC VLV #2 V03PUD2-GR/WH Proportional PWM valve drive (primary boom up/down
valve #2 -GROSS-)
P14-03 PM PRI BM E/R FC VLV V09PER-BK/RD Proportional PWM valve drive (primary boom
extend/retract)
P14-04 PM TT ROT FC VLV V06TRF-WH/RD Proportional PWM valve drive (turntable rotate)
P14-05 PM PRI BM U/D FC VLV #1 V03PUD1-RD/WH Proportional PWM valve drive (primary boom up/down
valve #1 -FINE-)
P14-06 PM SPARE PM Proportional PWM valve drive
P14-07 OM PRI_UP_VLV V01PBU-RD ON/OFF valve drive (primary boom up)
P14-08 OM PRI_DOWN_VLV V02PBD-RD/BK ON/OFF valve drive (primary boom down)
P14-09 OM PRI_EXTEND_VLV V07PBE-BK ON/OFF valve drive (primary boom extend)
P14-10 OM PRI_RETRACT_VLV V08PBR-BK/WH ON/OFF valve drive (primary boom retract)
P14-12 OM SPARE OM ON/OFF valve drive
P14-13 RLY DRIVE LIGHT RELAY C49LP-WH/BK Feeds power to drive light relay
P14-14 REF VALVE_RETURN_5 Valve ground return
P14-15 DI HYD_FILTER1 DI Grounding switch input from hydraulic filter #1
P14-16 DI HYD_FILTER2 DI Grounding switch input from hydraulic filter #2
P14-17 DI BOOM REVERSE LOAD DI Grounding switch input from boom reverse proximity
switch
P14-18 DI BOOM OVERLOAD DI Grounding switch input from boom overload switch
P14-19 OH SPARE OM ON/OFF valve drive
P14-20 OH SPARE OM ON/OFF valve drive
P14-23 OM MULTI_FUNCT_VLV ON/OFF valve drive
P14-25 OM ROTATE_CW_VLV V04TRL-WH ON/OFF valve drive (rotate clockwise)
P14-26 OM ROTATE_CCW_VLV V05TRR-WH/BK ON/OFF valve drive (rotate counter-clockwise)
P14-32 OM AUX_RELAY C27AUX-RD Relay coil feed
P14-33 OM PRESS COMP ENBL VLV #2 V155PCE2-OR/BL ON/OFF valve drive (Activate Pressure Comp Valve on
pump)
P14-34 OM PRESS COMP ENBL VLV #1 V155PCE1-OR/RD ON/OFF valve drive (Activate Pressure Comp Valve on
pump)
P14-35 OM AC GENERATOR BYPASS V150BV-GR/BK Output to ON/OFF Generator Bypass
VALVE
Part No. 1268496 SX-150 209


J17 - 16 Pin Connector
J17-1 PWR PWR TO TCON ESTOP BL/BK Power to TCON E-Stop (P1)
J17-2 NOT USED
J17-3 PWR SERV/CAL MODE WH Service/calibration mode signal
J17-4 CONT ECU POWER C47OUT-WH/BK Power to TCON ECU
J17-5 PWR PCON MODE P23PCON-BK Output signal to PCON. Provides 12V power to the
emergency stop switch.
J17-6 CONT OUTPUT PWR ENABLE C47OUT-WH/BK Function enable
J17-7 PWR P_6R1 P53LS-BK/WH Safety circuit power
J17-8 PWR P_7R S56PRV-RD/BK Safety circuit power
J17-9 CONT SERV. OR OPER. REC. SRV REC-WH Service/recovery mode signal
J17-10 PWR P_22 P56PRV-RD Safety circuit power (platform level bypass)
J17-11 CONT OPER. REC. P_15-OR/BK Power to PLD while in recovery mode
J17-12 CONT P_7 P_7 PLAT-GR/WH Power for function enable while in recovery mode
J17-13 PWR P_11 S140ENL-OR/RD Power for boom up in service mode
J17-14 CONT TCON MODE RD/WH TCON mode power
J17-15 CONT ALARM PWR ALM PWR-BL TCON alarm signal
J17-16 REF ALARM GND ALM GND-BR TCON alarm ground
210 SX-150 Part No. 1268496


P21-01 REF PCON GND GNDPCON-BR PCON ground
P21-02 PWR PCON PWR P52PCON-WH Power for PCON
P21-03 NOT USED
P21-04 CONT P_7 S56PRV-RD 12V when footswitch is pressed
P21-05 NOT USED
P21-06 NOT USED
P21-07 PWR P_22 P56PRV-RD/WH Power for platform level up/down, jib up/down,
and jib bellcrank up/down in TCON mode
P21-08 NOT USED
P21-09 NOT USED
P21-10 COM CAN SHIELD Termination for CAN cable shield
P21-11 NOT USED
P21-12 NOT USED
P21-13 !BOOT !Boot
P21-14 NOT USED
P21-15 CONT OUT PWR ENBL C47OUT-WH/BK 12V when platform E-Stop is pulled out
P21-16 CONT HRN RLY CNTRL C46HRN-WH Output from horn membrane switch on PCON
P21-17 COM CAN LOW D81CAN(-)-GR CAN bus connection
P21-18 COM CAN HIGH D82CAN(+)-YL CAN bus connection
P21-19 NOT USED
P21-20 NOT USED
P21-21 NOT USED
P21-22 NOT USED
P21-23 PWR PWR-PCON P23PCON-BK Power to PCON E-Stop
ESTOP
Part No. 1268496 SX-150 211


P22-03 OM PLAT ROT CCW V18PRR-GR/BK ON/OFF valve drive (platform rotate CCW - right)
P22-04 OM PLAT ROT CW V17PRL-GR ON/OFF valve drive (platform rotate CW - left)
P22-05 PM JIB UP V43JU-GR Proportional PWM valve drive (jib up)
P22-06 PM JIB DOWN V44JD-GR/BK Proportional PWM valve drive (jib down)
P22-07 PM PLAT LEVEL UP V14PLU-OR Proportional PWM valve drive (platform level up)
P22-08 PM PLAT LEVEL DOWN V15PLD-OR/BK Proportional PWM valve drive (platform level down)
P22-10 REF PROX KILL GND
P22-11 DI PROX Kill IN C90PXS-RD/BK Jib Stowed signal (from LSJ4SO)
P22-12 REF LOAD SNSR GND GR/YL Ground return for load sense switch
P22-13 DI LOAD SNSR IN OR Digital signal input for load sense switch (CE)
P22-14 PWR LOAD SNSR PWR BK 12V Power for load sense switch
P22-15 PWR SAFE PL TILT OUT C88PJTS-RD/BK Power for platform level up/down, jib up/down, and jib
bellcrank up/down in PCON mode (platform and Jib
bellcrank tilt sensor - safety)
P22-16 PWR LIMIT SWITCH PWR C64LS-OR/BK Power for footswitch, prox sensor, and limit switches
P22-17 CONT FOOT SW RTN C56FTS-RD Power from footswitch (P_7 circuit)
P22-18 DI JIB ROTATED CCW C215JRO-WH/RD Jib rotated CCW operational signal (from LSJ3RO)
P22-19 REF PL TILT SNSR GND P85RET-BR Ground for platform tilt sensor (operational)
P22-20 AI PL TILT SNSR C84TAY-GR/BK Analog signal input for platform tilt sensor
(operational)
P22-21 SNSR PL TILT SNSR PWR P85PTS-RD 5V Supply voltage for platform tilt sensor (operational)
P22-22 REF SAFE PL TILT GND P89RET-BR Ground for platform tilt sensor (safety)
P22-23 PWR SAFE PL TILT PWR P87PTS-RD 12V Supply voltage for platform tilt sensor (safety)
P22-24 PM JIB ROTATE CW V192JRL-WH Proportional PWM valve drive (jib rotate CW - left)
P22-27 PM JIB ROTATE CCW V193JRR-WH/BK Proportional PWM valve drive (jib rotate CCW - right)
P22-28 PM JIB BELLCRANK LEVEL UP V146JBU-BL Proportional PWM valve drive (jib bellcrank up)
P22-29 PM JIB BELLCRANK LEVEL V147JBD-BL/BK Proportional PWM valve drive (jib bellcrank down)
DOWN
P22-30 SNSR JIB SNSR PWR P109JBS-GR/WH 5V Supply voltage for jib bellcrank level sensor
P22-31 REF JIB SNSR GND P110JBS-BK Ground for jib bellcrank level sensor
P22-32 AI JIB SNSR IN C148JBS-BL/WH Analog signal input for jib bellcrank level sensor
P22-33 DI JIB ROTATED CCW C214JRS-RD/WH Jib rotated CCW signal (from LSJ2RS)
P22-35 NOT USED No Connection
212 SX-150 Part No. 1268496


Circuit Board Connector
J29-1 REF JOYSTICK_GND_2 JSGND2-BR Joystick signal ground (JC8)
J29-3 SNSR JOYSTICK_PWR_2 P162JPW2-OR Joystick power (JC8)
J29-5 NOT USED
J29-6 AI STEER - ROCKER C158STC-BL/RD Rocker steer signal from propel joystick (JC3)
J29-7 AI STEER - DUAL C159STC-BL/WH Dual axis steer signal from propel joystick (JC3)
AXIS
J29-8 AI PROPEL C160JPL-WH/RD Propel signal from propel joystick (JC3)
J29-9 AI SPARE AI
J29-10 AI PRIMARY EXT/RET C163PES-BL/WH Boom extend/retract signal from boom joystick (JC2)
J29-11 AI PRIMARY C164PLS-RD/WH Boom up/down signal from boom joystick (JC7)
UP/DOWN
J29-12 AI TT ROTATE C165TRS-WH/RD Turntable rotate CW/CCW signal from boom joystick
(JC7)
Part No. 1268496 SX-150 213


J169-1 AI JIB ROTATE C213JRS-RD/BK Jib rotate CW/CCW signal from jib joystick
(JC8)
J169-2 REF GND GND4-BR Joystick case ground (JC7)
J169-3 AI JIB UP/DOWN C156JUD-GR/WH Jib up/down signal from jib joystick (JC8)
J169-4 AI SPARE AI
J169-6 REF GND GND6-BR Return from platform level toggle switch (TS9)
J169-7 DI PLAT LVL UP PLAT LVL UP-OR Platform level up signal (TS9)
J169-8 DI PLAT LVL DOWN PLAT LVL DN-OR/BK Platform level down signal (TS9)
J169-10 PWR OUT PWR ENBL ESTOP RET-BK Return from PCON E-Stop (P2) - output power
enable circuit
J169-11 !BOOT
J169-12 REF GND GND12-BR PCON alarm ground
J169-14 DI SPARE DI
J169-15 DI SPARE DI
J169-16 REF GND
J169-17 DI PLAT ROT CCW PLAT ROT Platform Rotate CCW signal (TS7)
CCW-GR/BK
J169-18 DI PLAT ROT CW PLAT ROT CW-GR Platform Rotate CW signal (TS7)
J169-19 CONT ALARM ALARM(+)-RD/BK PCON alarm signal
J169-20 PWR PWR-PCON ESTOP PWR-RD/BK Power to PCON E-Stop (P2)
ESTOP
214 SX-150 Part No. 1268496


J1-1 DI PWR-HORN HORN PWR-RD Power for Service Horn button
J1-2 REF RET-HORN HORN RET-GR Return for Service Horn button
J1-3 DI GENERATOR ON/OFF GEN ON/OFF-GR/WH Generator toggle switch input
J1-4 DI AUXILIARY PUMP AUX PUMP-RD Auxiliary Pump toggle switch input
J1-5 DI START ASSIST START ASST-BK/WH Start Assist (Glow Plug) toggle switch input
J1-6 DI ENGINE START ENG START-BK Engine Start toggle switch input
J1-7 DI DRIVE ENABLE DRV ENBL-BL/WH Drive Enable toggle switch input
J1-8 NOT USED
J1-9 DI AXLE RETRACT AXLE RET-GR Axle Retract toggle switch input
J1-10 REF GND1 GND1-BR Ground for toggle switch inputs
J1-11 DI ENGINE SPEED ENG SPEED-BK/RD Engine Speed toggle switch input
SELECT
J1-12 DI AXLE EXTEND AXLE EXT-GR/WH Axle Extend toggle switch input
J1-13 DI DRIVE SPEED SELECT DRV SPEED-RD/WH Drive Speed toggle switch input
J1-14 DI STEER MODE SELECT STR MODE L-OR Steer Mode Select - Left toggle switch input
LEFT
J1-15 NOT USED
J1-16 NOT USED
J1-17 DI STEER MODE SELECT STR MODE R-OR/BK Steer Mode Select - Right toggle switch input
RIGHT
J1-18 DI SPARE Spare (option) toggle switch input
J1-19 NOT USED
J1-20 REF GND2 GND2-BR Ground for toggle switch inputs
Part No. 1268496 SX-150 215


P31-01 REF DCON ECU GND GNDDCON-BR DCON ground
P31-02 PWR DCON ECU PWR P21DCON-WH Power for DCON
P31-03 PWR P_6R1 P53LS-WH/BK Power for motor speed and brake valves
P31-04 NOT USED
P31-05 PWR P_7R S56PRV-RD Power for axle extend and steer valves
P31-06 PWR P_12 C61AXRT-GR Power for axle retract valve
P31-07 NOT USED
P31-08 REF AXLE NOT RET GND Not used
P31-09 DI AXLE NOT RET RTN Not used (active low)
P31-10 COM CAN SHIELD Not used
P31-11 COM RS232 RXD Not used
P31-12 COM RS232 TXD Not used
P31-13 !BOOT !BOOT
P31-14 NOT USED
P31-15 DI AXLE NOT EXT RTN Not used (active high)
P31-16 NOT USED
P31-19 COM RS232GND Not used
P31-20 AI FRONT AXLE C60FAP-GR/WH Analog signal input for front axle position sensor
POSITION SENSOR (RSFA1O)
P31-21 AI REAR AXLE POSITION C60RAP-GR/WH Analog signal input for rear axle position sensor
SENSOR (RSRA1O)
P31-22 AI SPARE Not used (0-5V Analog Input - Biased to 2.5V)
P31-23 PWR AXLE NOT EXT PWR P61LSA-GR Power to axle safety switches (LSFA1ES and
LSRA1ES)
216 SX-150 Part No. 1268496


P32-02 OM AXLE RETRACT V61AXRT-GR ON/OFF valve drive (axle retract)
P32-03 OM AXLE EXTEND V60AXEX-GR/WH ON/OFF valve drive (axle extend)
P32-04 OM MOTOR SPEED V29MS-RD/WH ON/OFF valve drive (motor speed)
P32-05 OM SPARE Not used
P32-06 OH SPARE Not used (paired with P32-07)
P32-07 OH SPARE Not used (paired with P32-06)
P32-08 OM RR STEER RIGHT V36RRS-BL ON/OFF valve drive (right rear steer right)
P32-09 OM RR STEER LEFT V37RRS-BL/BK ON/OFF valve drive (right rear steer left)
P32-10 AI RR STEER SNSR C111RRS-OR Analog signal input for right rear steer sensor
P32-11 AI LR STEER SNSR C111LRS-OR Analog signal input for left rear steer sensor
P32-12 AI RF STEER SNSR C111RFS-OR Analog signal input for right front steer sensor
P32-13 AI LF STEER SNSR C111LFS-OR Analog signal input for left front steer sensor
P32-15 OM BRAKE V32BRK-WH/RD ON/OFF valve drive (brake)
P32-16 OM LR STEER RIGHT V36LRS-BL ON/OFF valve drive (left rear steer right)
P32-17 OM LR STEER LEFT V37LRS-BL/BK ON/OFF valve drive (left rear steer left)
P32-18 OM RF STEER RIGHT V36RFS-BL ON/OFF valve drive (right front steer right)
P32-19 REF STEER SNSR GND P110RT-BK Ground to steer sensors
P32-20 SNSR STEER SNSR PWR (5.0 P109ANG-GR/WH Power to steer sensors (5.0VDC)
VDC)
P32-21 OM RF STEER LEFT V37RFS-BL/BK ON/OFF valve drive (right front steer left)
P32-22 OM LF STEER RIGHT V36LFS-BL ON/OFF valve drive (left front steer right)
P32-23 OM LF STEER LEFT V37LFS-BL/BK ON/OFF valve drive (left front steer left)
Part No. 1268496 SX-150 217


J121 Gray 12 Pin Connector
P121-01 DI LOAD SENSE S132LDS-BL/WH Digital input from load sense switch
P121-02 DI LSB3RS+LSB2RS S42BRT-OR/RD Digital input from LSB3RS+LSB2RS limit
(FULLY RETRACTED) switches
P121-03 COM RS232 TXD RS232 serial - connected through tee harness
P121-04 DI CALIBRATION IN C145CAL-RD/WH Digital input from calibration switch in TCON
P121-05 COM RS232 RXD RS232 serial - connected through tee harness
P121-08 OM P_12 C61AXRT-GR Safety circuit for axle retract (power)
P121-09 PWR P_7R S56PRV-RD Safety circuit power (from TCON)
P121-10 OM P_38 S137PLL-RD/WH Safety circuit for propel (power)
P121-11 OM P_39 S139TRF-WH/RD Safety circuit for turntable rotate (power)
P121-12 REF GND SCONGND-BR Ground for SCON ECU
P122-01 PWR ECU PWR P21DCON-WH Power for SCON/DCON ECU
P122-02 AI LTB1LS (BOOM C166PRS-OR Analog signal input for boom length (safety)
LENGTH)
P122-03 AI RSB1AS (BOOM C141PBS-RD Analog signal input for boom angle (safety)
ANGLE)
P122-04 DI AXLES EXTENDED C60AXEX-GR/WH Digital input from LSFA1ES and LSRA1ES
(power from DCON)
P122-05 DI LSB4ES (150FT S76BEX-BL Digital input from LSB4ES
EXTENDED)
P122-06 DI LST1S (DRIVE ENABLE) S13DE-BL/RD Digital input from LST1S limit switch
P122-07 PWR P_6R1 P53LS-WH/BK Safety circuit power (from TCON)
P122-08 OM P_11 S140ENL-OR/RD Safety circuit for boom up (power)
P122-09 PWR P_6R2 P54ENG-BK/WH Safety circuit power (from TCON)
P122-10 OM P_9B P58LS-RD/BK Safety circuit for fuel/ignition (power)
P122-11 PWR P_6R1 P53LS-WH/BK Safety circuit power (from TCON)
P122-12 OM P_9A+P_10 P57PBD-RD/WH Safety circuit for boom down and extend (power)
218 SX-150 Part No. 1268496

Engine Relay and Fuse Panel Legend- Deutz TD2011 and

Perkins 1104D Models
Deutz TD2011L04i and Perkins 1104D-44T Models
Number Component Description

1 CR77A PCE#1
2 CR28 Engine / Fuel Relay
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 CR41 Flashing Beacon Relay
6 CR5 Horn Relay
7 F20 Fuse, 20A, RPM Solenoid
8 F23 Fuse, 30A, Eng / Start / Alt
9 F22 Fuse, 60A, Glow Plug
10 F7 Fuse, 20A, Hydraulic Oil Cooler / Horn
11 B3BAT Fused Power from B1
12 B1BAT Power from Battery
13 R21PIGN Ignition
14 02PGND Ground
15 CR1 Start Relay
16 CR15 Glow Plug Relay
Part No. 1268496 SX-150 219

Engine Relay and Fuse Panel Legend- Deutz TD2.9 Models
Deutz TD2.9 Models

1 CR39 Engine Shutdown
2 CR77A PCE #1
3 CR2 Engine Alt. Relay
4 CR17 Hydraulic Oil Cooler / Fan Relay
5 CR28 Fuel Pump
6 CR77B PCE #2
8 CR5 Horn Relay
10 F23 Fuse, 30A, Eng / Start/ Alt
11 F22 Fuse 60A, Glow Plug
15 R21PIGN Ignition
16 02PGND Ground
17 CR17 Glow Plug Relay
220 SX-150 Part No. 1268496

Engine Relay and Fuse Panel Legend- Perkins 854F

Models
Perkins 854F-34T Models

1 CR77A PCE#1
2 CR2 Engine Alt
3 CR17 Hydraulic Oil Cooler Fan Relay
4 CR77B PCE#2
5 FX1 Fuse, 30A, ECU Power
6 FX2 Fuse, 20A, Key Switch Power
8 CR5 Horn Relay
10 F23 Fuse, 30A, Eng / Start / Alt
11 F22 Fuse, 60A, Glow Plug
15 R21PIGN Ignition
16 02PGND Ground
17 CR1 Engine Starter
18 CR81 ECU Power
Part No. 1268496 SX-150 221

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
Pin Circuit Type Circuit Properties Genie Machine Function(s) Telematics Use Case
1 System Power 12 VDC Battery Positive – constant power Supply power to device
5 Amp Max. allowed
draw
2 System Ground 0 VDC Battery Negative Device Ground
3 Digital Output 1 12 VDC Engine Run Hour Meter Monitor Engine Hours
12V = engine run, 0V = engine off
4 Digital Output 2 12 VDC Key Switch Activation Monitor machine utilization
12V = key switch on, 0V = key switch off
5 Digital Output 3 12 VDC Foot switch Monitor machine utilization
12V = active, 0V = inactive
6 Digital Input 1 12 VDC Remote Disable Engine Start Remotely Prevent Engine Start
7* Databus H CAN HIGH Genie Databus J1939 Engine Messages, Receive
Proprietary Genie Telematics
Message
8* Databus L CAN LOW Genie Databus J1939 Engine Messages, Receive
Proprietary Genie Telematics
Message
* Tier IV engine models only, J1939 engine message available.
* Genie proprietary databus support.
Wireless Certifications
Telematic device(s) should comply with specific wireless carrier certifications where applicable and comply with the
following:
North America PTCRB, FCC/IC
Europe CE, R&TTE
222 SX-150 Part No. 1268496

Electrical Symbols Legend
Battery Motor Horn or alarm Flashing beacon Gauge
Diode Hour meter LED 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

Battery separator
terminal connection terminal amperage
Service Bypass Key

Main Key switch Steer sensor Auxiliary Pump Tilt sensor
switch
Emergency Stop Hydraulic oil cooling

Relay Power relay Gauge sending unit
button fan
Coolant temperature Diode starting aid,

Oil temperature Oil pressure switch Control relay contact
switch - normally glow plug or flame
switch normally open normally closed normally open
open ignitor
Part No. 1268496 SX-150 223

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
Filter with bypass relief Relief valve with pressure Solenoid operated
Priority flow regulator
valve setting proportional valve
Solenoid operated
Pilot operated 3 position,
Pressure reducing valve Flow divider/combiner valve 2 position, 3 way directional
3 way shuttle valve
valve
Solenoid operated
Counterbalance valve with Pilot operated 2 position, 2 position, 2 way solenoid
3 position 4 way directional
pressure and pilot ratio 2 way directional valve valve
valve
224 SX-150 Part No. 1268496

Control Circuits - Horn
225
Control Circuits - Horn
226 SX-150 Part No. 1268496

Control Circuits - Power
Part No. 1268496 SX-150 227

Control Circuits - Power
228
Control Circuits - Can Bus
229
Control Circuits - Can Bus
230 SX-150 Part No. 1268496

Control Circuits - Deutz TD2011L04i Engine
Part No. 1268496 SX-150 231

Control Circuits - Deutz TD2011L04i Engine
232
Control Circuits - Deutz 2.9 Engine
233
Control Circuits - Deutz 2.9 Engine
234 SX-150 Part No. 1268496

Control Circuits - Perkins 1104D-44T Engine
Part No. 1268496 SX-150 235

Control Circuits - Perkins 1104D-44T Engine
236
Control Circuits - Perkins 854 Engine
237
Control Circuits - Perkins 854 Engine
238 SX-150 Part No. 1268496

Control Circuits - Axle Extend/Retract
Part No. 1268496 SX-150 239

Control Circuits - Axle Extend/Retract
240
Control Circuits - Steering
241
Control Circuits - Steering
242 SX-150 Part No. 1268496

Control Circuits - Propel
Part No. 1268496 SX-150 243

Control Circuits - Propel
244
Control Circuits - Turntable Rotate
245
Control Circuits - Turntable Rotate
246 SX-150 Part No. 1268496

Control Circuits - Boom Up/Down
Part No. 1268496 SX-150 247

Control Circuits - Boom Up/Down
248
Control Circuits - Boom Extend/Retract
249
Control Circuits - Boom Extend/Retract
250 SX-150 Part No. 1268496

Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate
Part No. 1268496 SX-150 251

Control Circuits - Jib Up/Down, Jib Rotate and Platform Rotate
252
Control Circuits - Platform Level and Jib Bellcrank Level
253
Control Circuits - Platform Level and Jib Bellcrank Level
254 SX-150 Part No. 1268496

Control Circuits - Platform Load Sense
Part No. 1268496 SX-150 255

Control Circuits - Platform Load Sense
256
Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights
257
Control Circuits - Flashing Beacons, Oil Cooler and Drive/Work Lights
258 SX-150 Part No. 1268496

Control Circuits - Recovery PLD
Part No. 1268496 SX-150 259

Control Circuits - Recovery PLD
260
Control Circuits - Telematics
261
Control Circuits - Telematics
262 SX-150 Part No. 1268496

Generator Receptacle Wiring- ANSI/CSA
Part No. 1268496 SX-150 263

Generator Receptacle Wiring- ANSI/CSA
264
Generator Receptacle Wiring- CE
265
Generator Receptacle Wiring- CE
266 SX-150 Part No. 1268496

Perkins 1104D-44T Engine Electrical Schematic
Part No. 1268496 SX-150 267

Perkins 1104D-44T Engine Electrical Schematic
268
Perkins 854F-34T Engine Electrical Schematic
269
Perkins 854F-34T Engine Electrical Schematic
270 SX-150 Part No. 1268496

Perkins 854F-34T Engine Harness
Part No. 1268496 SX-150 271

Perkins 854F-34T Engine Harness
272
Deutz TD2.9 Engine Electrical Schematic
273
Deutz TD2.9 Engine Electrical Schematic
274 SX-150 Part No. 1268496

Deutz TD2.9 Engine Harness
Part No. 1268496 SX-150 275

Deutz TD2.9 Engine Harness
276
Hydraulic Schematic
to SN SX150H-518
277
Hydraulic Schematic
to SN SX150H-518
278 SX-150 Part No. 1268496

Hydraulic Schematic
from SX150H-519
Part No. 1268496 SX-150 279

Hydraulic Schematic
from SX150H-519
280
TCON MEMBRANE PANEL (MS2)
1
TO
uP
AC GENERATOR BYPASS VALVE P14-35 V150BV-GR/BK

2 PRESS COMP ENABLE VLV #1 P14-34 C155PCE1-OR/RD
TO
uP
TT ROTATE CW PRESS COMP ENABLE VLV #2 P14-33 C155PCE2-OR/BL

3 AUX RELAY P14-32 C27AUX-RD
PLAT ROT CW NOT USED P14-31
TO
uP
4 VALVE_RETURN_6 P14-30 VLVRET6-BR

JIB DOWN TO PLD NOT USED P14-29
5 NOT USED P14-28
Z
PLAT LVL DOWN VALVE_RETURN_7 P14-27 VLVRET7-BR

TO
uP
6
2
1
ROTATE CCW VLV P14-26 V05TRR-WH/BK Y53 TT ROT CCW VLV (J71) V150BV-GR/BK Y92 AC GENERATOR BYPASS VLV (J217)
2
PLAT LVL UP
1
ROTATE CW VLV P14-25 V04TRL-WH Y52 TT ROT CW VLV (J70) VLVRET6-BR

TO
uP
7
2
NOT USED P14-24

1
V45HG-GR/WH Y91 AC GENERATOR VLV (J216)

JIB UP MULTI FUNCT VLV P14-23 VLVRET3-BR
8
TO
NOT USED P14-22

uP
TO
uP
PLAT ROT CCW SPARE OM P14-21

9 TO PLD
SPARE OM P14-20
C155PCE1-OR/RD
C155PCE2-OR/BK
TO
uP
V150BV-GR/BK
TT ROTATE CCW SPARE OM P14-19

VLVRET6-BR
VLVRET6-BR
TO
10
uP
V45HG-GR/WH
BOOM OVERLOAD DI P14-18

VLVRET8-BR
TURTLE
86
87 85
TO PLD BOOM REVERSE LOAD DI P14-17 C155PCE1-OR/RD

11 TO PLD
2
FUNCTION
HYD_FILTER2 DI P14-16
1
30
R155PCE1-OR/RD Y74 FUNCTION ENABLE VALVE #1 (J166)

JIB ROT CCW
ENABLE
TO
uP
87a
TO
CR77B
uP
12
P_30
VALVE_RETURN_5 P14-14
#1
RABBIT DRIVE LIGHT RELAY P14-13

TO
uP
13
SPARE OM P14-12
86
87 85
BOOM EXT C155PCE2-OR/BK

Y
TO PLD NOT USED P14-11

2
1
14 R155PCE2-OR/BK Y74A FUNCTION ENABLE VALVE #2 (J166A)

30
2
1
FUNCTION
PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a
BOOM DOWN
ENABLE
2
TO PLD
1
TO
V07PBE-BK Y79 PRI EXT VLV (J62)

uP
PRI EXTEND VLV P14-09

CR77A
15
2
1
PRI DOWN VLV P14-08 V02PBD-RD/BK Y21 PRI DWN VLV (J60)
TO
uP
#2
BOOM RET
2
1
J9 PRI UP VLV P14-07 V01PBU-RD Y22 PRI UP VLV (J59) C26TSR-WH/RD OIL TEMP SENDER
TO
uP
J144-3
SPARE PM P14-06
R21IGN-WH
2
P P P P
1
PRI BM U/D FC VLV #1 P14-05 V03PUD1-RD/WH Y45 PRI BM UP/DWN F.C. #1 (J58)
2
C25PSR-WH/BK OIL PRESSURE

1
TT ROT FC VLV P14-04 V06TRF-WH/RD Y77 TT ROT CW/CCW F.C. (J69)

J144-5
TO
uP
2
1
PRI BM E/R FC VLV P14-03 V09PER-BK/RD Y76 PRI BM EXT/RET F.C. (J61)
TO
uP
2
1
PRI BM U/D FC VLV #2 P14-02 V03PUD2-GR/WH Y45A PRI BM UP/DWN F.C. #2 (J58A)
86
87 85
01GND-BR
TO
VALVE_RETURN_4 P14-01 VLVRET4-BR

uP
1
R21IGN-WH 06GND-BR
30
FUEL SOLENOID
FUNCTION HARNESS
J144-7
J144-8
B1ENG-RD
87a
ENG FUEL
TO PLD
J14 WHITE 35 PIN
2
C21IGN-WH
RELAY
CR28
TO
uP
3
J153
NOT USED
J172-2
TO PLD
HYDRAULIC
4
J172-1
87 87a
FAN
03GND-BR
4
X
NOT USED OIL COOLER FAN

30
3
COOLER
5 R116HYD-OR
RELAY
1 2
MULTI FUNCTION VLV RECOVERY SIGNAL
SEC BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP C116HYD-OR 03GND-BR

OTS1
BOOM EXT/RET FC RECOVERY SIGNAL
TEMP
86
BOOM UP/DWN FC RECOVERY SIGNAL
J171-2
85
N.O.
J171-1
FUNCTION ENGINE
SW
AUXILIARY HYD RECOVERY SIGNAL
6
COOLER
HARNESS HARNESS
SEC BOOM RET RECOVERY SIGNAL
JIB ROT CW
BOOM DWN RECOVERY SIGNAL
RELAY
BOOM RET RECOVERY SIGNAL
CR17
R21IGN-WH
C21IGN-WH
BK
OIL
7
C26TSR-WH/RD
C25PSR-WH/BK
AUXILIARY BK GLOW PLUGS

BK IN CYLINDER HEADS
8
J224 GREY 8 PIN
ENG SPEED CAN LOW (-) P224-08 D227CAN- GR

BK
8
TELEMATICS
CAN HIGH (+) P224-07 D22CAN+ YL P34SA-BK/WH R34SA-BK/WH

GLOW 86 30
85 87
9
7
NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6
FOOTSWITCH STATUS P224-05 RELAY

S56PRV-RD
RELAY
10
5
PLUG
CR15
+ BUTTON KEYSWITCH POWER P224-04 P23PCON-BK

J120
4
(TIER IV)
IGNITION STATUS P224-03 C21TEL-WH

11
A B C D
3
C31EDC(-)-WH/BK
P_11
- BUTTON GROUND P224-02 GND-BR DUAL

2
P_6R1
SYS_POWER P224-01 B1BAT-RD COIL

12
P_9A
EDC
1
W
B1ENG-RD
SCRL FWD/ENTER C30EDC(+)-WH

P_39

13 AC GENERATOR VALVE P13-22 V45HG-GR/WH 02GND-BR
SCROLL R
TT_TILT_Y_AXIS P13-21
P34SA-BK/WH
TO
B3BAT/14-RD
uP
BK-GND BK
TT_TILT_X_AXIS
6 AMP
14 PULL IN
3
P13-20 HI/LO SPEED

STRT ASST WH-PULL IN WH
P_39 PWR TO TT ROT FC P13-19 S139TRF-WH/RD HOLD SOLENOID
1 2
CB9
RD-HOLD RD
P_22R
C21TEL-WH
C226TEL-BL
P_7R
P_10
15
J57
ALTERNATOR RPM P13-18 C41RPM-OR/BK

P_30
START P_38 PWR TO PROPEL P13-17 S137PLL-RD/WH

RELAY
HORN
TO
J10
uP
D22
CR5
TO
TO
uP
uP
TT_TILT_SNSR_PWR P13-15 SERVICE

H2
HORN
DEUTZ TD2011L04i ENGINE SHOWN
86
TT_TILT_SNSR_GND P13-14
87 85
01GND-BR
OIL/WATER TEMP P13-13 C26TSR-WH/RD HORN
R46HRN-WH 01GND-BR
30
TO
uP
OIL PRESSURE P13-12 C25PSR-WH/BK B3BAT/14-RD RELAY

87a
OTHER ENGINE SCHEMATICS
EDC REV P13-11 C31EDC(-)-WH/BK BAT GND-BR

SEE SCHEMATIC PAGES FOR
(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP
WH-PULL IN
BUTTON STARTER RELAY P13-09 C33STR-BK C107AF-RD

J144-2
RD-HOLD
5V
LP P13-08
IND.
EXCT.
SERVICE HORN P13-07 C46HRN-WH

BAT.
STA.
ALTERNATOR
V
P_7R REV PWM P13-06

REGULATOR
TO uP
CB7
15A
P_7 FWD PWM P13-05 ALTERNATOR

P_6R1 START AID RLY P13-04 C34SA-BK/WH
AUX HYD (AH)
4 ~SLP MODE
FUEL/IGNITION P13-03 C21IGN-WH C21IGN-WH

P_7
BAT.
P34SA-BK/WH
C
B3BAT/14-RD
THROTTLE P13-02 C35RPM-BK/RD

+
(~SM)
FUNC ENABLE (FE)
TROMBETTA
TIME DELAY
100 OHM PULL UP
B3BAT+ STUD ON RELAY BLOCK
SUPPLIED S-500-A6
MOM N.O.
87a
82 OHM PULL UP
C27AUX-RD
30
NC
J13 WHITE 23 PIN
5
C229TEL IS CONNECTED TO
B1BAT-RD
NOTE: FOR ACTIVE LOW
85
86
ENGINE HARN
B1BAT-RD
PR1
B1ENG-RD
TELEMATICS SYSTEMS
(ACTIVE HIGH SHOWN)

TO
uP
(~SM)+(AH)
AUX+
BAT+
GND-
PUMP
F23 ENG/START/ALT
AUX.
CR80
TELEMATICS
RELAY
5V 12V
BY DEUTZ
C229TEL-BL/BK
(~SM)+(AH)
F19 DRIVE LIGHTS

GND
(OE)
F20 HI/LO SPEED

S137PLL-RD/WH
F22 GLOW PLUG

F7 OIL COOLER
AUX HYD
S139TRF-WH/RD
C35RPM-BK/RD PUMP
5 VOLT PR1
13
74HC08 10
12
SOLENOID
4
74HC08 1
9
2
74HC08 5
(OPTION)
74HC08
(~SM)+(AH)
PUMP
AUX.
FUSES
7
6
8
3
14
05GND-BR
14
86
87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)
C33STR-BK
74HC08
((~SM)+(AH))(P_7)
((~SM)+(AH))(OE)
STARTER
TO
uP
P_6R1
P_22R
P_22
B1ENG-RD
P_7R
R33STR-BK
30
(TM)(FE)
P16-04
STARTER
B1ENG-RD RELAY
U
BATECU GND P16-03 GND-BR F23

3
W/BAT CBL
30A
STARTER
INTEGRAL
SYS BAT GND P16-02 GND-BR

2
F20 STARTER
POWER
RELAY
P_7 SYS BAT PWR P16-01 B1BAT-RD B1BAT-RD

HARN
20A P35RPM-BK/RD
W/BAT CBL
CR1
INTEGRAL
1
J16 BLACK 4 PIN
20A
J15
CB
Vbb BTS621
Vbb BTS621
01GND-BR
ST OUT 2
IN1 OUT 1
IN1 OUT 1
ST OUT 2
POWER HARN
POWER
ENGINE BLOCK
BTS650
BTS650
BTS650
F22
OUT
OUT
P_1
OUT
P_6R2
HARN
HARN
ENG
-
GND
GND
GND
60A
B1
Vbb
Vbb
IN2
IN2
Vbb
AUX MAIN
IN
IN
IS
IS
IN
IS
F7
B1BAT-RD
20A
01GND-BR
B1BAT-RD START/CONT
B1BAT-RD B1BAT-RD ROL SYS
-
+
-
U32
B2
BATTERY
B2BAT-RD
SEPARATE
4 GA WIRE
SEPARATE TWO 6 VOLT

4 GA WIRE BATTERIES AUX HYD
BATTERY
(BM STOWED)
(~SM)+(AH)
U95
S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T
HARNESS
8
ENGINE
((~SM)+(AH))(BM STOWED)
J215

2
Vbb BTS621
LOWER LS
ST OUT 2
IN1 OUT 1
HARNESS
TO HORN BUTTON
PWR TO TCON ESTOP
GND
OUT PWR ENABLE
(P15)+(ECU POWER)
IN2
P_30
P_22
P_9B
P23PCON-BK
S56PRV-RD
B3BAT/14-RD
GND-BR
BOOM STOWED
S
5 VOLT
P_6R1
P_11
P_9A
PCON POWER
P_6R2
P_10
P_7
P_7R
TCON MODE
LSB4EO
NO
13
21
BK/WH
4321
150FT EXT OPER

NC
BK
J20 1 2
C64LS-OR/BK WH/BK BL J213

22
14
C71PBE-BL/BK
RED
C71PBE-BL/BK
BLU
BK BR
NO
13
21
BK/WH
432 1
NC
LSB3RO
10
BK
C64LS-OR/BK
OR/BK BL 3FT EXT OPER

22
14
BLU
C70PBE-BL/WH C70PBE-BL/WH GR/BK BR

J211
8 J208 9
WHT NO
13
21
BK/WH
NC
BK LSB1DO
ALL LIMIT SWITCHES SHOWN IN "STOWED" STATE
C64LS-OR/BK RD/BK BL 10 DEG ANGLE OPER

2 1
22
14
OUT PWR ENABLE
PWR TO TCON ESTOP
C68PBD-BL C68PBD-BL WH/BK BR

J210
7
TO HORN BUTTON
(P15)+(ECU POWER)
NO
13
21
P_22
P_9B
C64LS-OR/BK RD
4 32 1
LST2O
NC
C143DEL-BL/RD C143DEL-BL/RD
P_30
BR
R
BK DRV ENABLE LEFT

22
14
ORN
YEL
WH J125
ORN NO
13
21
C64LS-OR/BK RD LST1O
21
NC
C144DER-BL/WH C144DER-BL/WH BR DRV ENABLE RIGHT

BK
22
14
WH J124
A B J53
C65LOFL-BL/WH C65LOFL-BL/WH YL/WH

C64LS-OR/BK RD/WH FUEL
LEVEL
VLVRET BR VLVRET8-BR BK/WH SENSOR
C
LST1S
ORN NO
13
21
C64LS-OR/BK C64LS-OR/BK RD DRV ENABLE

4 321
NC
S13DE-BL/RD BR
BK SAFETY
22
14
RED
WH J126
J208
6 J199
P_30 P_30 P12-34

LTB1LO (BOOM LENGTH) P12-33 C167PRS-OR/BK C167PRS-OR/BK C167PRS-OR/BK BL YL LTB1LO
6
RSB1AO (BOOM ANGLE) P12-32 C123PBS-RD/BK P109ANG-GR/WH P109ANG-GR/WH GR BR BOOM LENGTH

4
OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q
OR
5
SPARE DI P12-30 C166PRS-OR RD BL

3
SPARE DI P12-29 P109ANG-GR/WH BK BK LTB1LS

1
DRV ENBL L - LST2O P12-28 C143DEL-BL/RD SNSRGND-BR WH RD BOOM LENGTH

2
SAFETY
TO
uP
AUX HYD PRESSURE IN P12-27

SNSR PWR (5V) P12-26 P109ANG-GR/WH
B3BAT/14-RD
S139TRF-WH/RD
S137PLL-RD/WH
4567
21
11
P57PBD-RD/WH RD BK/WH LSB3RS

4321
NC
NC
SNSR GND P12-25 SNSRGND-BR P63LS-OR/RD WH BK

TO
3.5FT EXT SAFETY

uP
C64LS-OR/BK OR RD/WH
RED
22
12
P2 SEQ VLV P12-24 S42BRT-OR GR RD J207

LOCKOUT VALVE #1 SIG
J20
TO PLD P1 SEQ VLV P12-23

6 J114
SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
SPARE DI P12-21 RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP
LSB4EO P12-20 C71PBE-BL/BK BOOM ANGLE

C123PBS-RD/BK C123PBS-RD/BK WH OPER
LSB3RO P12-19 C70PBE-BL/WH
4
PRI BOOM LENGTH 3' STATUS TO PLD C141PBS-RD YL

LSB2RO P12-18 C69PBR-BK
3
SNSRGND-BR BK RSB1AS
TO
uP
12V SIG TO PLD P12-17 C64LS-OR/BK BOOM ANGLE

P109ANG-GR/WH RD SAFETY
PRI BOOM LENGTH 151' STATUS LSB1DO P12-16
1
TO PLD C68PBD-BL
PRI BOOM DOWN STATUS DRV ENBL R - LST1O P12-15 C144DER-BL/WH
TO PLD
LOW FUEL - FST1S P12-14 C65LOFL-BL/WH
P
TO
uP
OUT PWR ENABLE
J222B
OPER SW PWR P12-13 C64LS-OR/BK

J20B
P_22
P_9B
P_18 P12-12
P_14 P12-11
2 1
2 1
S59CNBK-GR/WH S59CNBK-GR/WH GR/BK

P_12 P12-10 C61AXRT-GR SJ2-OR/BK RD/BK
11 12
P_11 P12-09 S140ENL-OR/RD

4 3 2 1
BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208
J222A
P_9B P_9B P12-07 P58LS-RD/BK

J122-BLACK 12
S59CNBK-GR/WH
P_9A P12-06 P57PBD-RD/WH

U32 PIN SCON

P_7R P_7R P12-05 S56PRV-RD MODULE

P63LS-OR/RD
U31
SJ2-OR/BK
SJ2-OR/BK
P_6R2 P_6R2 P12-04 P54ENG-BK/WH P57PBD-RD/WH P57PBD-RD/WH P122-12 P_9A+P_10

U30
P_6R1
P_6R1 P12-03 P53LS-WH/BK P53LS-WH/BK P122-11

DCON/SCON ECU PWR P12-02 P21DCON-WH P58LS-RD/BK P58LS-RD/BK P122-10 P_9B
PRI BOOM LENGTH 151' STATUS
P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL
SCON ECU GND P12-01 GNDSCON-BR P54ENG-BK/WH P122-09 P_6R2

OUT PWR ENABLE
PRI BOOM DOWN STATUS
PWR TO TCON ESTOP
S140ENL-OR/RD S140ENL-OR/RD P122-08 P_11 4 32 1 21

(P15)+(ECU POWER)
TO HORN BUTTON
BK
BK
BR
BR
BK/WH
BL
BL
BK/WH
P53LS-WH/BK P122-07 P_6R1

S13DE-BL/RD P122-06 LST1S (DRIVE ENABLE)
LIMIT SWITCH HARN
P_22
P122-05 LSB4ES (150FT EXTENDED)

J12 BLACK 35 PIN
O
22 21 22 21
C60AXEX-GR/WH P122-04 LSFA1ES & LSRA1ES (AXLES EXTENDED)
NC NC
P53LS-WH/BK C141PBS-RD P122-03 RSB1AS (BOOM ANGLE) 14 13 14 13
PUR
GRN
NO NO
B3BAT/14-RD C166PRS-OR P122-02 LTB1LS (BOOM LENGTH)
P21DCON-WH P21DCON-WH P122-01 SCON PWR
LSB5S
CABLE
TENSION #1
J192A
LSB6S
CABLE
TENSION #2
J192B
GNDSCON-BR GNDSCON-BR P121-12 SCON GND

S139TRF-WH/RD P121-11 P_39
S137PLL-RD/WH P121-10 P_38
S56PRV-RD S56PRV-RD P121-09 P_7R
C61AXRT-GR P121-08 P_12
D81CAN(-)-GR P121-07 CAN LOW
D82CAN(+)-YL P121-06 CAN HIGH
P121-05 RS232 RxD
C145CAL-RD/WH P121-04 CALIBRATION IN
P121-03 RS232 TxD
TO MICRO
S42BRT-OR P121-02 LSB3RS+LSB2RS (FULLY RETRACTED)

S132LDS-BL/WH LOAD SENSE
P121-01
SCON
N
C60AXEX-GR/WH
P53LS-WH/BK
C61AXRT-GR
C145CAL-RD/WH
S132LDS-BL/WH
P57PBD-RD/WH
J121-GRAY 12
S56PRV-RD
D81CAN(-)-GR
P117FB-RD
D82CAN(+)-YL
P63LS-OR/RD
BM U/D FC O
C61AXRT-GR
PIN SCON
ECU POWER
GND-BR
BM E/R FC O PLD MODULE

BM DWN O
P_15
BM RET O SEC BM E/R FC O

MLT FNC VLV O SEC BM RET O
AUX HYD O
BYPASS OR
BM DWN ST I OPER. REC. OPER. REC.
BM 100' I PWR IN BYPASS OR
BM 3' I RECOVERY
RECOVERY MODE
PROVIDES PWR TO
PRI LO#1 O MINIMAL HARDWARE
OUT PWR ENABLE
PWR TO TCON ESTOP
TO HORN BUTTON
PCON POWER
ECU POWER
OPER. REC.
TCON MODE
P_22
P_15
P_6R1
P_7
P_7R
P_11
TO WORKLIGHT OPTION
C60AXEX-GR/WH
P57PBD-RD/WH
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
CLOSED
CLOSED
CLOSED
SERVICE RECOVERY
GNDDCON-BR
P21DCON-WH
M
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE
S56PRV-RD
KEYSWITCH POSITION
RECOVERY KEYSWITCH TRUTH-TABLE
GROUND PLATFORM
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH
KEYSWITCH POSITION
2
E 1
OPEN
OPEN
OPEN
1
3
NC
J155/6C
W
Z
1
X 3 3
2
NC
4
NC
NO
V
Y
D
4
U
2
B 1
NO
NC
2
1
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC
NC
C
D81CAN(-)-GR
4
P117FB-RD
D82CAN(+)-YL
NC
NO
PANEL
01GND-BR
FLASHING BEACON
NC
OPEN
OPEN
OPEN
OFF
A
CONTACT
PANEL
J152B
W
U
V
X
Y
Z
CONTACT
85
30
C
D
A
B
RELAY
CR41
BC BC
86
TO FLASHING BEACONS 87a
87
GND-OR/WH
P20BAT-OR
BB BB
R117FB-RD
ESTOP
BA BA
C145CAL-RD/WH
S132LDS-BL/WH
C117FB-RD
GNDDCON-BR
NC 1
2
AC
AA
AB
GND-BR
TCON E-STOP (P1)

L
PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS
BL/BK
CALIBRATION
CALIBRATE)
SWITCH TO
J142
1 SWITCH
(CLOSE
G/P MODE-WH/BK
1
2
J17
WH/BK
AC
AA
AB
1
1
C
D
E
1 PWR TO TCON ESTOP

C145CAL-RD/WH
S132LDS-BL/WH
2 NOT USED NOT USED P11-23

PLAT
PLAT
PLAT
PLAT
2
PLAT
OFF
OFF
OFF
OFF
2
2
GROUND
OFF
GRND
GROUND
GRND
BA
GRND
J152A
WH 3 SERV/CAL MODE DIAG PWR (12V) P11-22

BB
J173-1
C47OUT WH/BK C47OUT-WH/BK 4 ECU POWER DIAG GND P11-21

BA
P23PCON-BK P23PCON-BK 5 PCON MODE NOT USED P11-20
WH/BK
TCON MODE C47OUT-WH/BK 6 OUTPUT PWR ENABLE NOT USED P11-19

BC
BA
BB
P53LS-BK/WH 7 P_6R1 CAN HIGH P11-18 D82CAN(+)-YL

NOTE: J152C
TIER IV ENGINES
ONLY
S56PRV-RD/BK 8 P_7R CAN LOW P11-17 D81CAN(-)-GR

SRV REC-WH 9 SERV OR OPER RECOVERY CAL FREQ 2 P11-16
C117FB-RD
AC
AA
AB
P56PRV-RD 10 P_22 NOT USED P11-15

K
OR/BK 11 OPER RECOVERY CAL FREQ 1 P11-14

P_7 BA
J152C
GR/WH 12 !BOOT P11-13

OR/RD 13 P_11 NOT USED P11-12 BB
BA
W
1
RD/WH 14 TCON MODE SERV/CAL MODE P11-11 C145CAL-RD/WH

U
V
Z
BL 15 ALARM PWR CAN SHIELD (1939-11) P11-10

BC
BA
BB
16 ALARM GND FLASHING BEACON RLY P11-09

2
C117FB-RD
RECOVERY
SERV BYPASS
RUN
SPARE RLY OUT P11-08

S140ENL-OR/RD P_22 P11-07 P56PRV-RD/WH
J4 ON CIRCUIT BOARD
U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR
RS232_RXD
RS232_TXD
C47OUT-WH/BK PWR-PCON ESTOP P11-05 P23PCON-BK

P_15-OR/BK OUT PWR ENBL P11-04 C47OUT-WH/BK
CKT #
HORN RELAY COIL P11-03 C46HRN-WH

ALARM
TCON
ALARM PWR-BL
H5
PCON ECU POWER P11-02 P52PCON-WH

ALARM GND-BR
PIN
PCON ECU GND P11-01 GNDPCON-BR

MOLEX
J147B-1
2
3
5
8PIN
J223
GNDDCON-BR
ENGINE CAN
TCON J147B-1
120Ω GNDPCON-BR
GROUND P223-01 ALM-GND-BR BUS TO
J
CAN GATEWAY
TELEMATICS
J151-C
J151-A
J151-B
C
B
A
CAN SHIELD P223-02

J155/6B-1
J155/6B-2
J148A-1
J147A-1
& TCON LCD
ENGINE CAN HIGH P223-03 D228CAN+ YL

J150-4
J150-1
J150-2
J149-1
J149-2
J150-3
J228-1 ENGINE CAN BUS

D227CAN- GR TO ENGINE HARNESS
ENGINE CAN LOW P223-04
C60AXEX-GR/WH
J228-2
P57PBD-RD/WH
D82CAN+ -YL
GNDDCON-BR
P53LS-WH/BK
MACHINE CAN HIGH P223-05
P63LS-OR/RD
P21DCON-WH
D81CAN(-)-GR
D82CAN(+)-YL
J228-3 J155/6A
C61AXRT-GR
S132LDS-BL/WH
C47OUT-WH/BK
P56PRV-RD/WH
S56PRV-RD
GNDPCON-BR
D81CAN(-)-GR
P223-06 D81CAN- -GR

D82CAN(+)-YL
P52PCON-WH
MACHINE CAN LOW 1

P23PCON-BK
J228-4
GND-OR/WH
C46HRN-WH
S56PRV-RD
P20BAT-OR
DIGITAL IN 1 P223-07 P20BAT-OR

TO WORKLIGHT OPTION
TIER IV ENG
GND-OR/WH
OPT GBOX
DIGITAL IN 2 P223-08 2
HARN
PWR-PCON ESTOP P21-23 P23PCON-BK

SPARE
NOT USED P21-22

TSx
#1
SPARE-WH NOT USED P21-21

LED/TOGGLE SWITCH INTERFACE BOARD
NOT USED P21-20

STEER MODE
STR MODE R-OR/BK NOT USED P21-19 P23PCON-BK

SELECT
TS22
CAN HIGH P21-18 D82CAN(+)-YL D82CAN(+)-YL

STR MODE L-OR CAN LOW P21-17 D81CAN(-)-GR D81CAN(-)-GR
HRN RLY CNTRL P21-16 C46HRN-WH C46HRN-WH
SPEED
OUT PWR ENBL P21-15 C47OUT-WH/BK C47OUT-WH/BK

DRIVE
I
TS5
NOT USED P21-14

DRV SPEED-RD/WH
!BOOT P21-13
NOT USED P21-12
S132LDS-BL/WH
ENGINE
SPEED
NOT USED P21-11

TS4
GND2-BR 20 CAN SHIELD P21-10
J34-LIMIT SW HARN
J35-LIMIT SW HARN
ENG SPEED-BK/RD
J1 20PIN
J33-BOOM HARN
NOT USED 19 NOT USED P21-09
AXLE EXT-GR/WH NOT USED P21-08
EXT/RET
SPARE-WH 18
AXLE
TS23
U21
U22
STR MODE R-OR/BK 17 P_22 P21-07 P56PRV-RD/WH P56PRV-RD/WH

Vbb BTS621
ST OUT 2
IN1 OUT 1
BTS650
OUT
AXLE RET-GR 16 NOT USED P21-06

P_7R
NOT USED
P_6
GND
NOT USED P21-05

IN2
NOT USED 15
Vbb
IN
IS
ENABLE
STR MODE L-OR 14 P_7 P21-04 S56PRV-RD S56PRV-RD

DRIVE
6
2
3
5
TS15
4
C
1
2
A
B
DRV SPEED-RD/WH 13 NOT USED P21-03
DRV ENBL-BL/WH
6
2
3
5
4
PCON PWR P21-02 P52PCON-WH P52PCON-WH
C
AXLE EXT-GR/WH 12
A
B
1
2
ENG SPEED-BK/RD 11 PCON GND P21-01 GNDPCON-BR GNDPCON-BR
ENGINE
J24 10PIN
GR
START
YL
WH
OR
GR
DCON PWR RD
BR
10
BK
GND1-BR
TS2
BL
YL
AXLE RET-GR 9
J21 23 PIN
HARNESS
H
ENG START-BK
P_9A+P_10
DCON GND
SLIP RING
C60AXEX
CAN HIGH
CAN LOW
NOT USED 8
BLACK
RS232_GND
BOOM
RS232_RXD
RS232_TXD
P_6R1
P_10
P_12
P_7R
DRV ENBL-BL/WH 7
ASSIST
START
TS6
6
CKT #
ENG START-BK
START ASST-BK/WH START ASST-BK/WH 5
88
88
88
88
88
88
88
88
88
88
88
AUX PUMP-RD 4
74HC08
74HC08
GENERATOR AUXILIARY
DB9 CONNECTOR PIN
GEN ON/OFF-GR/WH 3
PUMP
TS1
2
3
5
WH
GR
RD
OR
BR
BK
BL
YL
HORN RET-GR
ON CIRCUIT BOARD
GR
YL
2
1
5
AUX PUMP-RD
4
1
S132LDS-BL/WH
HORN PWR-RD
6
2
3
5
4
1
2
B
A
C
ON/OFF
6
2
3
5
4
TS17
B
J36-DRIVE CHASSIS HARN A
1
2
SLP_MODE
GEN ON/OFF-GR/WH
J38-DRIVE CHASSIS HARN

P_7R
ECU
P_22
J157-1
P_6
HORN RTN-GR
P_7
J162
SERVICE
HORN
BN5
C88PJTS-RD/WH
6
G
TILT SENSOR
POWER FET POWER FET
HORN PWR-RD C88PTS-RD/BK
BELLCRANK
5
ASSEMBLY
- -
P89RET-BR + 10 DEG 10 DEG
MANIFOLD
+
4
J22 35 PIN
HARNESS
SAFETY CUTOUT
P109JBS-GR/WH
WH
3
0-20 DEG Y AXIS
WHITE
-
PCON
S21
C148JBS-BL/WH
JIB
DRIVE & STEERING
2
+
P110JBS-BK PLAT TILT SNSR
6
JOYSTICK (JC3)
1
GND1-BR
5 C158STC-BL/RD NOT USED P22-35
4 C160JPL-WH/RD VALVE_RETURN_2 P22-34 VLVRET2-BR VLVRET2-BR
3 C159STC-BL/WH JIB ROTATED CW P22-33 C214JRL-RD/WH
2 P
1
2
2 P162JPW1-OR V147JBD-BL/BK Y86 JIB BELLCRANK DOWN (J136)
JIB TILT SNSR IN P22-32 C148JBS-BL/WH
P
1
1 JSGND1-BR V146JBU-BL Y85 JIB BELLCRANK UP (J135)
JIB TILT SNSR GND P22-31 P110JBS-BK
J25
2 P
1
2
JIB TILT SNSR PWR P22-30 P109JBS-GR/WH V193JRR-WH/BK Y90 JIB ROTATE CCW (J203)
P
JIB UP/DOWN AND
1
JSGND1-BR 16 JOYSTICK_GND_1 JIB BELLCRANK LEVEL DOWN P22-29 V147JBD-BL/BK V192JRL-WH Y89 JIB ROTATE CW (J202)
6 GND2-BR
JOYSTICK (JC8)
JSGND4-BR 15 JOYSTICK_GND_4 JIB BELLCRANK LEVEL UP P22-28 V146JBU-BL

5
CCW SAFETY
JIB ROTATED
JIB ROTATE
P162JPW1-OR 14 JOYSTICK_PWR_1 JIB ROTATE CCW P22-27
NO
V193JRR-WH/BK
13
21
4 C156JUD-GR/WH BK/WH
43 2 1
NC
P162JPW4-OR 13 JOYSTICK_PWR_4 SPARE OM P22-26 BK
LSJ2RS
3 C213JRS-RD/BK BL
14
TT ROTATE
22
C165TRS-WH/RD 12
GRN
SPARE OM P22-25 C214JRL-RD/WH
BLU
BR
J55
2 P162JPW2-OR
J205
C164PLS-RD/WH 11 PRIMARY UP/DOWN
PLATFORM
ASSEMBLY
1 JSGND2-BR JIB ROTATE CW P22-24 V192JRL-WH
6
F
SENSOR
C163PES-BL/WH 10 PRIMARY EXT/RET POWER FET
CCW (RIGHT)
JIB ROTATED
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD POWER FET
NO
13
21
BK/WH
5
EXTEND/RETRACT
9
-
SPARE AI SAFE PL/JB TILT GND P22-22 10 DEG
-
10 DEG
NC
U20 P89RET-BR BK
TILT
+
LSJ3RO
4 +
PRIMARY BOOM
BL
S6
JOYSTICK (JC2)
6 GND3-BR C160JPL-WH/RD 8 PROPEL SAFETY CUTOUT
14
22
PL TILT SNSR PWR P22-21
21
GRN
P85PTS-GR
RED
BR
3
-
STEER - DUAL AXIS
J206
5 C159STC-BL/WH 7 PL TILT SNSR IN P22-20 C84TAY-GR/BK + 0-20 DEG Y AXIS
2
4 C163PES-BL/WH C158STC-BL/RD 6 STEER - ROCKER PL TILT SNSR GND P22-19 P85RET-BR PLAT TILT SNSR
1
P_7R
P_22
5
P_6
3 JIB ROTATED CCW P22-18 C215JRR-WH/RD C215JRR-WH/RD
FOOTSW (FS1)
2 P162JPW3-OR P162JPW3-OR 4 JOYSTICK_PWR_3
2
FOOT SW RTN P22-17 C56FTS-RD C56FTS-RD
C60AXEX-GR/WH
1 JSGND3-BR P162JPW2-OR 3 JOYSTICK_PWR_2 LIMIT SWITCH PWR P22-16 C64LS-OR/BK C64LS-OR/BK
P57PBD-RD/WH
D81CAN(-)-GR
D82CAN(+)-YL
GNDDCON-BR
P21DCON-WH
J26
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
JSGND3-BR 2 JOYSTICK_GND_3
OVERLOAD
SAFE PL/JB TILT OUT P22-15 C88PJTS-RD/WH
S56PRV-RD
1
RD
LIMIT SW
J84
JSGND2-BR 1 JOYSTICK_GND_2 LOAD SNSR PWR P22-14 BK BK BK
LSP1LS
6
NO
GND4-BR
AND TURNTABLE
PRIMARY BOOM
J29
JOYSTICK (JC7)
LOAD SNSR IN P22-13 OR OR
NC
5
WH
4 C164PLS-RD/WH LOAD SNSR GND P22-12 GR/YL
UP/DOWN
PROX KILL IN P22-11

ROTATE
3 C165TRS-WH/RD
PROX GND P22-10
2 P162JPW4-OR
1 JSGND4-BR SPARE OM P22-09 P57PBD-RD/WH
2 P
1
2
J127 PLAT LEVEL DOWN P22-08 V15PLD-OR/BK Y19 PLAT LEVEL DOWN (J81) P63LS-OR/RD
1 P
1
PLAT LEVEL UP P22-07 V14PLU-OR Y20 PLAT LEVEL UP (J80)
C60AXEX-GR/WH
E
2 P
2
JIB DOWN P22-06 V44JD-GR/BK Y73 JIB DOWN (J79)
P
1
JIB UP P22-05 V43JU-GR Y72 JIB UP(J78)
13
23
C60AXEX-GR/WH RD
NO
NO
4 3 2 1
LSRA1ES
2
PLAT ROT CW P22-04 V17PRL-GR Y70 PLAT ROTATE CW (J76) J2-GR/BK BR
P63LS-OR/RD BK REAR AXLE SAFETY
24
14
1
2
ESTOP PWR-RD/BK 20 PWR-PCON ESTOP PLAT ROT CCW P22-03 V18PRR-GR/BK Y71 PLAT ROTATE CCW (J77) J1-OR/BK WH SW
ALARM(+)-RD/BK 19 ALARM SPARE OM P22-02 J138
PLAT ROT CW-GR 18 PLAT ROT CW VALVE_RETURN_1 P22-01 VLVRET1-BR
ESTOP PWR-RD
PLAT ROT CCW-GR/BK 17 PLAT ROT CCW
13
E-STOP
23
J2-GR/BK RD
NO
NO
PCON
4 3 2 1
GND5-BR 16 GND P61LSA-GR BR LSFA1ES
P2
J1-OR/BK BK FRONT AXLE
24
14
15 SPARE DI SAFETY SW
P57PBD-RD/WH WH
14 SPARE DI J137
ESTOP RET-BK
GND1-BR 13 GND
PLATFORM PLATFORM
GND12-BR 12 GND BL
ROTATE
6
TS7
PLAT ROT CCW-GR/BK 11 !BOOT GR

NOT USED
5
GND5-BR ESTOP RET-BK 10 OUT PWR ENBL WH
4
PLAT ROT CW-GR GND2-BR 9 GND AXLE NOT EXT PWR P31-23 P61LSA-GR P61LSA-GR YL RSRA1O
3
PLAT LVL DN-OR/BK 8 PLAT LVL DOWN SPARE AI (BIASED TO 2.5V) P31-22 BK REAR AXLE SENSOR
2
(S16)
PLAT LVL DN-OR/BK PLAT LVL UP-OR 7 PLAT LVL UP PCON REAR AXLE POSITION SENSOR P31-21 C60RAP-GR/WH C60RAP-GR/WH RD
LEVEL
J161
1
GND6-BR
TS9
GND6-BR 6 GND
D
FRONT AXLE POSITION SENSOR P31-20 C60FAP-GR/WH C60FAP-GR/WH

PLAT LVL UP-OR GND3-BR 5 GND RS232 GND P31-19
4 SPARE AI
CAN HIGH P31-18 D82CAN(+)-YL
C156JUD-GR/WH 3 JIB UP/DOWN
CAN LOW P31-17 D81CAN(-)-GR
GND4-BR 2 GND
NOT USED P31-16
C213JRS-RD/BK 1 JIB ROTATE
AXLE NOT EXT RTN P31-15
ALARM
J169
PCON
ALARM(+)-RD/BK NOT USED P31-14

H8
GND12-BR BL
!BOOT P31-13
6
GR NOT USED
RS232 TxD P31-12
5
RS232 RxD P31-11 WH
4
YL RSFA1O
CAN SHIELD P31-10
3
BK FRONT AXLE SENSOR
AXLE NOT RET RTN P31-09
2
(S15)
RD J160
AXLE NOT RET GND P31-08
1
SX-150 ELECTRICAL SCHEMATIC
NOT USED P31-07

P_12 P31-06 C61AXRT-GR
P_7R P31-05 S56PRV-RD
with Deutz TD2011L04i Engine
NOT USED P31-04

C
P_6R1 P31-03 P53LS-WH/BK

DCON PWR P31-02 P21DCON-WH
DCON GND P31-01 GNDDCON-BR
J31 23 PIN BLACK

DRIVE CHASSIS
FROM SERIAL NUMBER 228 TO 518
HARNESS
VLVRET2-BR
2
V37LFS-BL/BK Y62-LF STEER LEFT (J98)
2
V36LFS-BL Y61-LF STEER RIGHT (J97)
2
V37RFS-BL/BK Y60-RF STEER LEFT (J96)
2
J32 23 PIN WHITE
V36RFS-BL Y59-RF STEER RIGHT (J95)
DRIVE CHASSIS
P_6R1
P_12
P_7R
2
V37LRS-BL/BK Y58-LR STEER LEFT (J94)
2
V36LRS-BL Y57-LR STEER RIGHT (J93)
HARNESS
2
ES0554D
V37RRS-BL/BK Y56-RR STEER LEFT (J92)
2
V36RRS-BL Y55-RR STEER RIGHT (J91)
LF STEER LEFT P32-23 V37LFS-BL/BK
V36LFS-BL BK
B
LF STEER RIGHT P32-22
C
RF STEER LEFT P32-21 V37RFS-BL/BK C111LFS-OR BL RSLF1SO
B
LF STEER
STEER SNSR PWR (5.0 VDC) P32-20 P109ANG-GR/WH P109ANG-GR/WH RD
SNSR (S14)
A
STEER SNSR GND P32-19 P110RT-BK P110RT-BK J110
RF STEER RIGHT P32-18 V36RFS-BL
LR STEER LEFT P32-17 V37LRS-BL/BK BK
C
LR STEER RIGHT P32-16 V36LRS-BL C111RFS-OR BL RSRF1SO
B
RF STEER
BRAKE P32-15 V32BRK-WH/RD RD
SNSR (S13)
A
VALVE_RETURN_2 P32-14 VLVRET2-BR J109
LF STEER SNSR P32-13 C111LFS-OR
RF STEER SNSR P32-12 C111RFS-OR BK
C
LR STEER SNSR P32-11 C111LRS-OR C111LRS-OR BL RSLR1SO
B
LR STEER
RR STEER SNSR P32-10 C111RRS-OR RD
SNSR (S12)
A
RR STEER LEFT P32-09 V37RRS-BL/BK J108
RR STEER RIGHT P32-08 V36RRS-BL
SPARE OM P32-07 BK
C
SPARE OM P32-06 C111RRS-OR BL RSRR1SO
B
A
RR STEER SNSR
SPARE OM P32-05 RD
(S11)
A
MOTOR SPEED P32-04 V29MS-RD/WH J107
AXLE EXTEND P32-03 V60AXEX-GR/WH
AXLE RETRACT P32-02 V61AXRT-GR
DCON
2
V32BRK-WH/RD Y2-BRAKE RELEASE (J106)
2
V29MS-RD/WH Y27-TWO SPEED MOTOR STROKE (J87)
2
V60AXEX-GR/WH Y99-AXLE EXTEND (J99)
2
V61AXRT-GR Y100-AXLE RETRACT (J100)
VLVRET1-BR
10
12
13
14
15
16
11
1
9
TCON MEMBRANE PANEL (MS2)
1
TO
uP
AC GENERATOR BYPASS VALVE P14-35 V150BV-GR/BK

2 PRESS COMP ENABLE VLV #1 P14-34 C155PCE1-OR/RD
TO
uP
TT ROTATE CW PRESS COMP ENABLE VLV #2 P14-33 C155PCE2-OR/BL

3 AUX RELAY P14-32 C27AUX-RD
PLAT ROT CW NOT USED P14-31
TO
uP
4 VALVE_RETURN_6 P14-30 VLVRET6-BR

JIB DOWN TO PLD NOT USED P14-29
5 NOT USED P14-28
Z
PLAT LVL DOWN VALVE_RETURN_7 P14-27 VLVRET7-BR

TO
uP
6
2
1
ROTATE CCW VLV P14-26 V05TRR-WH/BK Y53 TT ROT CCW VLV (J71) V150BV-GR/BK Y92 AC GENERATOR BYPASS VLV (J217)
2
PLAT LVL UP
1
ROTATE CW VLV P14-25 V04TRL-WH Y52 TT ROT CW VLV (J70) VLVRET6-BR

TO
uP
7
2
NOT USED P14-24

1
V45HG-GR/WH Y91 AC GENERATOR VLV (J216)

JIB UP MULTI FUNCT VLV P14-23 VLVRET3-BR
8
TO
NOT USED P14-22

uP
TO
uP
PLAT ROT CCW SPARE OM P14-21

9 TO PLD
SPARE OM P14-20
C155PCE1-OR/RD
C155PCE2-OR/BK
TO
uP
V150BV-GR/BK
TT ROTATE CCW SPARE OM P14-19

VLVRET6-BR
VLVRET6-BR
TO
10
uP
V45HG-GR/WH
BOOM OVERLOAD DI P14-18

VLVRET8-BR
TURTLE
86
87 85
TO PLD BOOM REVERSE LOAD DI P14-17 C155PCE1-OR/RD

11 TO PLD
2
FUNCTION
1
30
R155PCE1-OR/RD Y74 FUNCTION ENABLE VALVE #1 (J166)

JIB ROT CCW
ENABLE
TO
uP
87a
TO
CR77B
uP
12
P_30
#1
RABBIT DRIVE LIGHT RELAY P14-13

TO
uP
13
SPARE OM P14-12
86
87 85
BOOM EXT C155PCE2-OR/BK

Y
TO PLD NOT USED P14-11

2
1
14 R155PCE2-OR/BK Y74A FUNCTION ENABLE VALVE #2 (J166A)

30
2
1
FUNCTION
PRI RETRACT VLV P14-10 V08PBR-BK/WH Y80 PRI RET VLV (J63)
87a
BOOM DOWN
ENABLE
2
TO PLD
1
TO
V07PBE-BK Y79 PRI EXT VLV (J62)

uP
PRI EXTEND VLV P14-09

CR77A
15
2
1
PRI DOWN VLV P14-08 V02PBD-RD/BK Y21 PRI DWN VLV (J60)
TO
uP
#2
BOOM RET
2
1
J9 PRI UP VLV P14-07 V01PBU-RD Y22 PRI UP VLV (J59) C26TSR-WH/RD OIL TEMP SENDER
TO
uP
J144-3
SPARE PM P14-06
R21IGN-WH
2
P P P P
1
PRI BM U/D FC VLV #1 P14-05 V03PUD1-RD/WH Y45 PRI BM UP/DWN F.C. #1 (J58)
2
C25PSR-WH/BK OIL PRESSURE

1
TT ROT FC VLV P14-04 V06TRF-WH/RD Y77 TT ROT CW/CCW F.C. (J69)

J144-5
TO
uP
2
1
PRI BM E/R FC VLV P14-03 V09PER-BK/RD Y76 PRI BM EXT/RET F.C. (J61)
TO
uP
2
1
PRI BM U/D FC VLV #2 P14-02 V03PUD2-GR/WH Y45A PRI BM UP/DWN F.C. #2 (J58A)
86
87 85
01GND-BR
TO

uP
1
R21IGN-WH 06GND-BR
30
FUEL SOLENOID
FUNCTION HARNESS
J144-7
J144-8
B1ENG-RD
87a
ENG FUEL
TO PLD
J14 WHITE 35 PIN
2
C21IGN-WH
RELAY
CR28
TO
uP
3
J153
NOT USED
J172-2
TO PLD
HYDRAULIC
4
J172-1
87 87a
FAN
03GND-BR
4
X
NOT USED OIL COOLER FAN

30
3
COOLER
5 R116HYD-OR
RELAY
1 2
BOOM UP C116HYD-OR 03GND-BR

OTS1
TEMP
86
J171-2
85
N.O.
J171-1
FUNCTION ENGINE
SW
6
COOLER
HARNESS HARNESS
JIB ROT CW
RELAY
CR17
R21IGN-WH
C21IGN-WH
BK
OIL
7
C26TSR-WH/RD
C25PSR-WH/BK
AUXILIARY BK GLOW PLUGS

BK IN CYLINDER HEADS
8
J224 GREY 8 PIN
ENG SPEED CAN LOW (-) P224-08 D227CAN- GR

BK
8
TELEMATICS
CAN HIGH (+) P224-07 D22CAN+ YL P34SA-BK/WH R34SA-BK/WH

GLOW 86 30
85 87
9
7
NOT USED REMOTE DISABLE P224-06 C226TEL-BL C34SA-BK/WH 01GND-BR GLOW PLUG
TO CAN GATEWAY
ENGINE CAN BUS
6
FOOTSWITCH STATUS P224-05 RELAY

S56PRV-RD
RELAY
10
5
PLUG
CR15
+ BUTTON KEYSWITCH POWER P224-04 P23PCON-BK

J120
4
(TIER IV)
IGNITION STATUS P224-03 C21TEL-WH

11
A B C D
3
C31EDC(-)-WH/BK
P_11
- BUTTON GROUND P224-02 GND-BR DUAL

2
P_6R1
SYS_POWER P224-01 B1BAT-RD COIL

12
P_9A
EDC
1
W
B1ENG-RD
SCRL FWD/ENTER C30EDC(+)-WH

P_39

13 AC GENERATOR VALVE P13-22 V45HG-GR/WH 02GND-BR
SCROLL R
TT_TILT_Y_AXIS P13-21
P34SA-BK/WH
TO
B3BAT/14-RD
uP
BK-GND BK
TT_TILT_X_AXIS
6 AMP
14 PULL IN
3
P13-20 HI/LO SPEED

STRT ASST WH-PULL IN WH
P_39 PWR TO TT ROT FC P13-19 S139TRF-WH/RD HOLD SOLENOID
1 2
CB9
RD-HOLD RD
P_22R
C21TEL-WH
C226TEL-BL
P_7R
P_10
15
J57
ALTERNATOR RPM P13-18 C41RPM-OR/BK

P_30
START P_38 PWR TO PROPEL P13-17 S137PLL-RD/WH

RELAY
HORN
TO
J10
uP
D22
CR5
TO
TO
uP
uP
TT_TILT_SNSR_PWR P13-15 SERVICE

H2
HORN
DEUTZ TD2011L04i ENGINE SHOWN
86
TT_TILT_SNSR_GND P13-14
87 85
01GND-BR
OIL/WATER TEMP P13-13 C26TSR-WH/RD HORN
R46HRN-WH 01GND-BR
30
TO
uP
OIL PRESSURE P13-12 C25PSR-WH/BK B3BAT/14-RD RELAY

87a
OTHER ENGINE SCHEMATICS
EDC REV P13-11 C31EDC(-)-WH/BK BAT GND-BR

SEE SCHEMATIC PAGES FOR
(P15)+(ECU POWER)
EDC FWD P13-10 C30EDC(+)-WH C41RPM-OR/BK
TO HORN
J144-1
TO
uP
WH-PULL IN
BUTTON STARTER RELAY P13-09 C33STR-BK C107AF-RD

J144-2
RD-HOLD
5V
LP P13-08
IND.
EXCT.
SERVICE HORN P13-07 C46HRN-WH

BAT.
STA.
ALTERNATOR
V
P_7R REV PWM P13-06

REGULATOR
TO uP
CB7
15A
P_7 FWD PWM P13-05 ALTERNATOR

P_6R1 START AID RLY P13-04 C34SA-BK/WH
AUX HYD (AH)
4 ~SLP MODE
FUEL/IGNITION P13-03 C21IGN-WH C21IGN-WH

P_7
BAT.
P34SA-BK/WH
C
B3BAT/14-RD
THROTTLE P13-02 C35RPM-BK/RD

+
(~SM)
FUNC ENABLE (FE)
TROMBETTA
TIME DELAY
100 OHM PULL UP
B3BAT+ STUD ON RELAY BLOCK
SUPPLIED S-500-A6
MOM N.O.
87a
82 OHM PULL UP
C27AUX-RD
30
NC
J13 WHITE 23 PIN
5
C229TEL IS CONNECTED TO
B1BAT-RD
NOTE: FOR ACTIVE LOW
85
86
ENGINE HARN
B1BAT-RD
PR1
B1ENG-RD
TELEMATICS SYSTEMS
(ACTIVE HIGH SHOWN)

TO
uP
(~SM)+(AH)
AUX+
BAT+
GND-
PUMP
F23 ENG/START/ALT
AUX.
CR80
TELEMATICS
RELAY
5V 12V
BY DEUTZ
C229TEL-BL/BK
(~SM)+(AH)
F19 DRIVE LIGHTS

GND
(OE)
F20 HI/LO SPEED

S137PLL-RD/WH
F22 GLOW PLUG

F7 OIL COOLER
AUX HYD
S139TRF-WH/RD
C35RPM-BK/RD PUMP
5 VOLT PR1
13
74HC08 10
12
SOLENOID
4
74HC08 1
9
2
74HC08 5
(OPTION)
74HC08
(~SM)+(AH)
PUMP
AUX.
FUSES
7
6
8
3
14
05GND-BR
14
86
87 85
((~SM)+(AH))(P_22)
OUT PWR ENABLE (OE)
C33STR-BK
74HC08
((~SM)+(AH))(P_7)
((~SM)+(AH))(OE)
STARTER
TO
uP
P_6R1
P_22R
P_22
B1ENG-RD
P_7R
R33STR-BK
30
(TM)(FE)
P16-04
STARTER
B1ENG-RD RELAY
U
BATECU GND P16-03 GND-BR F23

3
W/BAT CBL
30A
STARTER
INTEGRAL
SYS BAT GND P16-02 GND-BR

2
F20 STARTER
POWER
RELAY
P_7 SYS BAT PWR P16-01 B1BAT-RD B1BAT-RD

HARN
20A P35RPM-BK/RD
W/BAT CBL
CR1
INTEGRAL
1
J16 BLACK 4 PIN
20A
J15
CB
Vbb BTS621
Vbb BTS621
01GND-BR
ST OUT 2
IN1 OUT 1
IN1 OUT 1
ST OUT 2
POWER HARN
POWER
ENGINE BLOCK
BTS650
BTS650
BTS650
F22
OUT
OUT
P_1
OUT
P_6R2
HARN
HARN
ENG
-
GND
GND
GND
60A
B1
Vbb
Vbb
IN2
IN2
Vbb
AUX MAIN
IN
IN
IS
IS
IN
IS
F7
B1BAT-RD
20A
01GND-BR
B1BAT-RD START/CONT
B1BAT-RD B1BAT-RD ROL SYS
-
+
-
U32
B2
BATTERY
B2BAT-RD
SEPARATE
4 GA WIRE
SEPARATE TWO 6 VOLT

4 GA WIRE BATTERIES AUX HYD
BATTERY
(BM STOWED)
(~SM)+(AH)
U95
S139TRF-WH/RD
S137PLL-RD/WH
74HC08 10
T
HARNESS
8
ENGINE
((~SM)+(AH))(BM STOWED)
J215

2
Vbb BTS621
LOWER LS
ST OUT 2
IN1 OUT 1
HARNESS
TO HORN BUTTON
PWR TO TCON ESTOP
GND
OUT PWR ENABLE
(P15)+(ECU POWER)
IN2
P_30
P_22
P_9B
P23PCON-BK
S56PRV-RD
B3BAT/14-RD
GND-BR
BOOM STOWED
S
5 VOLT
P_6R1
P_11
P_9A
PCON POWER
P_6R2
P_10
P_7
P_7R
TCON MODE
LSB4EO
NO
13
21
BK/WH
4321
150FT EXT OPER

NC
BK
J20 1 2
C64LS-OR/BK WH/BK BL J213

22
14
C71PBE-BL/BK
RED
C71PBE-BL/BK
BLU
BK BR
NO
13
21
BK/WH
432 1
NC
LSB3RO
10
BK
C64LS-OR/BK
OR/BK BL 3FT EXT OPER

22
14
BLU
C70PBE-BL/WH C70PBE-BL/WH GR/BK BR

J211
8 J208 9
WHT NO
13
21
BK/WH
NC
BK LSB1DO
ALL LIMIT SWITCHES SHOWN IN "STOWED" STATE
C64LS-OR/BK RD/BK BL 10 DEG ANGLE OPER

2 1
22
14
OUT PWR ENABLE
PWR TO TCON ESTOP
C68PBD-BL C68PBD-BL WH/BK BR

J210
7
TO HORN BUTTON
(P15)+(ECU POWER)
NO
13
21
P_22
P_9B
C64LS-OR/BK RD
4 32 1
LST2O
NC
C143DEL-BL/RD C143DEL-BL/RD
P_30
BR
R
BK DRV ENABLE LEFT

22
14
ORN
YEL
WH J125
ORN NO
13
21
C64LS-OR/BK RD LST1O
21
NC
C144DER-BL/WH C144DER-BL/WH BR DRV ENABLE RIGHT

BK
22
14
WH J124
LST1S
ORN NO
13
21
C64LS-OR/BK C64LS-OR/BK RD DRV ENABLE

4 321
NC
S13DE-BL/RD BR
BK SAFETY
22
14
RED
WH J126
J208
6 J199
P_30 P_30 P12-34

LTB1LO (BOOM LENGTH) P12-33 C167PRS-OR/BK C167PRS-OR/BK C167PRS-OR/BK BL YL LTB1LO
6
RSB1AO (BOOM ANGLE) P12-32 C123PBS-RD/BK P109ANG-GR/WH P109ANG-GR/WH GR BR BOOM LENGTH

4
OPER
BOOM STOWED P12-31 SNSRGND-BR SNSRGND-BR OR
Q
OR
5
SPARE DI P12-30 C166PRS-OR RD BL

3
SPARE DI P12-29 P109ANG-GR/WH BK BK LTB1LS

1
DRV ENBL L - LST2O P12-28 C143DEL-BL/RD SNSRGND-BR WH RD BOOM LENGTH

2
SAFETY
TO
uP
AUX HYD PRESSURE IN P12-27

SNSR PWR (5V) P12-26 P109ANG-GR/WH
B3BAT/14-RD
S139TRF-WH/RD
S137PLL-RD/WH
4567
21
11
P57PBD-RD/WH RD BK/WH LSB3RS

4321
NC
NC
SNSR GND P12-25 SNSRGND-BR P63LS-OR/RD WH BK

TO
3.5FT EXT SAFETY

uP
C64LS-OR/BK OR RD/WH
RED
22
12
P2 SEQ VLV P12-24 S42BRT-OR GR RD J207

LOCKOUT VALVE #1 SIG
J20
TO PLD P1 SEQ VLV P12-23

6 J114
SPARE DI P12-22
P109ANG-GR/WH P109ANG-GR/WH BL
LSB2RS P12-21 RSB1A0
SNSRGND-BR SNSRGND-BR GR
TO
uP
LSB4EO P12-20 C71PBE-BL/BK BOOM ANGLE

C123PBS-RD/BK C123PBS-RD/BK WH OPER
LSB3RO P12-19 C70PBE-BL/WH
4
PRI BOOM LENGTH 3' STATUS TO PLD C141PBS-RD YL

LSB2RO P12-18 C69PBR-BK
3
SNSRGND-BR BK RSB1AS
TO
uP
12V SIG TO PLD P12-17 C64LS-OR/BK BOOM ANGLE

P109ANG-GR/WH RD SAFETY
PRI BOOM LENGTH 151' STATUS LSB1DO P12-16
1
TO PLD C68PBD-BL
PRI BOOM DOWN STATUS DRV ENBL R - LST1O P12-15 C144DER-BL/WH
TO PLD
LOW FUEL - FST1S P12-14 C65LOFL-BL/WH
P
TO
uP
OUT PWR ENABLE
J222B
OPER SW PWR P12-13 C64LS-OR/BK

J20B
P_22
P_9B
P_18 P12-12
P_14 P12-11
2 1
2 1
S59CNBK-GR/WH S59CNBK-GR/WH GR/BK

P_12 P12-10 C61AXRT-GR SJ2-OR/BK RD/BK
11 12
P_11 P12-09 S140ENL-OR/RD

4 3 2 1
BK/WH
P_10 P_10 P12-08 S59CNBK-GR/WH P63LS-OR/RD BL/BK
J208
J222A
P_9B P_9B P12-07 P58LS-RD/BK

J122-BLACK 12
S59CNBK-GR/WH
P_9A P12-06 P57PBD-RD/WH

U32 PIN SCON

P_7R P_7R P12-05 S56PRV-RD MODULE

P63LS-OR/RD
U31
SJ2-OR/BK
SJ2-OR/BK
P_6R2 P_6R2 P12-04 P54ENG-BK/WH P57PBD-RD/WH P57PBD-RD/WH P122-12 P_9A+P_10

U30
P_6R1
P_6R1 P12-03 P53LS-WH/BK P53LS-WH/BK P122-11

DCON/SCON ECU PWR P12-02 P21DCON-WH P58LS-RD/BK P58LS-RD/BK P122-10 P_9B
P54ENG-BK/WH
LOCKOUT VALVE #1 SIGNAL
SCON ECU GND P12-01 GNDSCON-BR P54ENG-BK/WH P122-09 P_6R2

OUT PWR ENABLE
PRI BOOM DOWN STATUS
PWR TO TCON ESTOP
S140ENL-OR/RD S140ENL-OR/RD P122-08 P_11 4 32 1 21

(P15)+(ECU POWER)
TO HORN BUTTON
BK
BK
BR
BR
BK/WH
BL
BL
BK/WH
P53LS-WH/BK P122-07 P_6R1

S13DE-BL/RD P122-06 LST1S (DRIVE ENABLE)
LIMIT SWITCH HARN
P_22
P122-05 LSB4ES (150FT EXTENDED)

J12 BLACK 35 PIN
O
22 21 22 21
C60AXEX-GR/WH P122-04 LSFA1ES & LSRA1ES (AXLES EXTENDED)
NC NC
P53LS-WH/BK C141PBS-RD P122-03 RSB1AS (BOOM ANGLE) 14 13 14 13
PUR
GRN
NO NO
B3BAT/14-RD C166PRS-OR P122-02 LTB1LS (BOOM LENGTH)
P21DCON-WH P21DCON-WH P122-01 SCON PWR
LSB5S
CABLE
TENSION #1
J192A
LSB6S
CABLE
TENSION #2
J192B
GNDSCON-BR GNDSCON-BR P121-12 SCON GND

S139TRF-WH/RD P121-11 P_39
S137PLL-RD/WH P121-10 P_38
S56PRV-RD S56PRV-RD P121-09 P_7R
C61AXRT-GR P121-08 P_12
D81CAN(-)-GR P121-07 CAN LOW
D82CAN(+)-YL P121-06 CAN HIGH
P121-05 RS232 RxD
C145CAL-RD/WH P121-04 CALIBRATION IN
P121-03 RS232 TxD
TO MICRO
S42BRT-OR P121-02 LSB3RS+LSB2RS (FULLY RETRACTED)

S132LDS-BL/WH LOAD SENSE
P121-01
SCON
N
C60AXEX-GR/WH
P53LS-WH/BK
C61AXRT-GR
C145CAL-RD/WH
S132LDS-BL/WH
P57PBD-RD/WH
J121-GRAY 12
S56PRV-RD
D81CAN(-)-GR
P117FB-RD
D82CAN(+)-YL
P63LS-OR/RD
BM U/D FC O
C61AXRT-GR
PIN SCON
ECU POWER
GND-BR
BM E/R FC O PLD MODULE

BM DWN O
P_15
BM RET O SEC BM E/R FC O

MLT FNC VLV O SEC BM RET O
AUX HYD O
BYPASS OR
BM DWN ST I OPER. REC. OPER. REC.
BM 100' I PWR IN BYPASS OR
BM 3' I RECOVERY
RECOVERY MODE
PROVIDES PWR TO
PRI LO#1 O MINIMAL HARDWARE
OUT PWR ENABLE
PWR TO TCON ESTOP
TO HORN BUTTON
PCON POWER
ECU POWER
OPER. REC.
TCON MODE
P_22
P_15
P_6R1
P_7
P_7R
P_11
TO WORKLIGHT OPTION
C60AXEX-GR/WH
P57PBD-RD/WH
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
CLOSED
CLOSED
CLOSED
SERVICE RECOVERY
GNDDCON-BR
P21DCON-WH
M
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
GROUND/PLATFORM KEYSWITCH TRUTH-TABLE
S56PRV-RD
KEYSWITCH POSITION
RECOVERY KEYSWITCH TRUTH-TABLE
GROUND PLATFORM
CLOSED CLOSED
CLOSED CLOSED
CLOSED CLOSED
RECOVERY
CLOSED CLOSED OPEN
CLOSED CLOSED OPEN
KEY SWITCH
KEYSWITCH POSITION
2
E 1
OPEN
OPEN
OPEN
1
3
NC
J155/6C
W
Z
1
X 3 3
2
NC
4
NC
NO
V
Y
D
4
U
2
B 1
NO
NC
2
1
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
RUN
NC
NC
C
D81CAN(-)-GR
4
P117FB-RD
D82CAN(+)-YL
NC
NO
PANEL
01GND-BR
FLASHING BEACON
NC
OPEN
OPEN
OPEN
OFF
A
CONTACT
PANEL
J152B
W
U
V
X
Y
Z
CONTACT
85
30
C
D
A
B
RELAY
CR41
BC BC
86
TO FLASHING BEACONS 87a
87
GND-OR/WH
P20BAT-OR
BB BB
R117FB-RD
ESTOP
BA BA
C145CAL-RD/WH
S132LDS-BL/WH
C117FB-RD
GNDDCON-BR
NC 1
2
AC
AA
AB
GND-BR
TCON E-STOP (P1)

L
PANEL
BOOM LOWER LS
CABLE HARNESS
J11 BLACK 23 PIN
BOOM HARNESS
BL/BK
CALIBRATION
CALIBRATE)
SWITCH TO
J142
1 SWITCH
(CLOSE
G/P MODE-WH/BK
1
2
J17
WH/BK
AC
AA
AB
1
1
C
D
E
1 PWR TO TCON ESTOP

C145CAL-RD/WH
S132LDS-BL/WH
2 NOT USED NOT USED P11-23

PLAT
PLAT
PLAT
PLAT
2
PLAT
OFF
OFF
OFF
OFF
2
2
GROUND
OFF
GRND
GROUND
GRND
BA
GRND
J152A
WH 3 SERV/CAL MODE DIAG PWR (12V) P11-22

BB
J173-1
C47OUT WH/BK C47OUT-WH/BK 4 ECU POWER DIAG GND P11-21

BA
P23PCON-BK P23PCON-BK 5 PCON MODE NOT USED P11-20
WH/BK
TCON MODE C47OUT-WH/BK 6 OUTPUT PWR ENABLE NOT USED P11-19

BC
BA
BB
P53LS-BK/WH 7 P_6R1 CAN HIGH P11-18 D82CAN(+)-YL

NOTE: J152C
TIER IV ENGINES
ONLY
S56PRV-RD/BK 8 P_7R CAN LOW P11-17 D81CAN(-)-GR

SRV REC-WH 9 SERV OR OPER RECOVERY CAL FREQ 2 P11-16
C117FB-RD
AC
AA
AB
P56PRV-RD 10 P_22 NOT USED P11-15

K
OR/BK 11 OPER RECOVERY CAL FREQ 1 P11-14

P_7 BA
J152C
GR/WH 12 !BOOT P11-13

OR/RD 13 P_11 NOT USED P11-12 BB
BA
W
1
RD/WH 14 TCON MODE SERV/CAL MODE P11-11 C145CAL-RD/WH

U
V
Z
BL 15 ALARM PWR CAN SHIELD (1939-11) P11-10

BC
BA
BB
16 ALARM GND FLASHING BEACON RLY P11-09

2
C117FB-RD
RECOVERY
SERV BYPASS
RUN
SPARE RLY OUT P11-08

S140ENL-OR/RD P_22 P11-07 P56PRV-RD/WH
J4 ON CIRCUIT BOARD
U30
P_7 PLAT-GR/WH P_7 P11-06 S56PRV-RD
RS232_GND
DB9 CONNECTOR
RS232_RXD
RS232_TXD
C47OUT-WH/BK PWR-PCON ESTOP P11-05 P23PCON-BK

P_15-OR/BK OUT PWR ENBL P11-04 C47OUT-WH/BK
CKT #
HORN RELAY COIL P11-03 C46HRN-WH

ALARM
TCON
ALARM PWR-BL
H5
PCON ECU POWER P11-02 P52PCON-WH

ALARM GND-BR
PIN
PCON ECU GND P11-01 GNDPCON-BR

MOLEX
J147B-1
2
3
5
8PIN
J223
GNDDCON-BR
ENGINE CAN
TCON J147B-1
120Ω GNDPCON-BR
GROUND P223-01 ALM-GND-BR BUS TO
J
CAN GATEWAY
TELEMATICS
J151-C
J151-A
J151-B
C
B
A
CAN SHIELD P223-02

J155/6B-1
J155/6B-2
J148A-1
J147A-1
& TCON LCD
ENGINE CAN HIGH P223-03 D228CAN+ YL

J150-4
J150-1
J150-2
J149-1
J149-2
J150-3
J228-1 ENGINE CAN BUS

D227CAN- GR TO ENGINE HARNESS
ENGINE CAN LOW P223-04
C60AXEX-GR/WH
J228-2
P57PBD-RD/WH
D82CAN+ -YL
GNDDCON-BR
P53LS-WH/BK
MACHINE CAN HIGH P223-05
P63LS-OR/RD
P21DCON-WH
D81CAN(-)-GR
D82CAN(+)-YL
J228-3 J155/6A
C61AXRT-GR
S132LDS-BL/WH
C47OUT-WH/BK
P56PRV-RD/WH
S56PRV-RD
GNDPCON-BR
D81CAN(-)-GR
P223-06 D81CAN- -GR

D82CAN(+)-YL
P52PCON-WH
MACHINE CAN LOW 1

P23PCON-BK
J228-4
GND-OR/WH
C46HRN-WH
S56PRV-RD
P20BAT-OR
DIGITAL IN 1 P223-07 P20BAT-OR

TO WORKLIGHT OPTION
TIER IV ENG
GND-OR/WH
OPT GBOX
DIGITAL IN 2 P223-08 2
HARN
PWR-PCON ESTOP P21-23 P23PCON-BK

SPARE
NOT USED P21-22

TSx
#1
SPARE-WH NOT USED P21-21

LED/TOGGLE SWITCH INTERFACE BOARD
NOT USED P21-20

STEER MODE
STR MODE R-OR/BK NOT USED P21-19 P23PCON-BK

SELECT
TS22
CAN HIGH P21-18 D82CAN(+)-YL D82CAN(+)-YL

STR MODE L-OR CAN LOW P21-17 D81CAN(-)-GR D81CAN(-)-GR
HRN RLY CNTRL P21-16 C46HRN-WH C46HRN-WH
SPEED
OUT PWR ENBL P21-15 C47OUT-WH/BK C47OUT-WH/BK

DRIVE
I
TS5
NOT USED P21-14

DRV SPEED-RD/WH
!BOOT P21-13
NOT USED P21-12
S132LDS-BL/WH
ENGINE
SPEED
NOT USED P21-11

TS4
GND2-BR 20 CAN SHIELD P21-10
J34-LIMIT SW HARN
J35-LIMIT SW HARN
ENG SPEED-BK/RD
J1 20PIN
J33-BOOM HARN
NOT USED 19 NOT USED P21-09
AXLE EXT-GR/WH NOT USED P21-08
EXT/RET
SPARE-WH 18
AXLE
TS23
U21
U22
STR MODE R-OR/BK 17 P_22 P21-07 P56PRV-RD/WH P56PRV-RD/WH

Vbb BTS621
ST OUT 2
IN1 OUT 1
BTS650
OUT
AXLE RET-GR 16 NOT USED P21-06

P_7R
NOT USED
P_6
GND
NOT USED P21-05

IN2
NOT USED 15
Vbb
IN
IS
ENABLE
STR MODE L-OR 14 P_7 P21-04 S56PRV-RD S56PRV-RD

DRIVE
6
2
3
5
TS15
4
C
1
2
A
B
DRV SPEED-RD/WH 13 NOT USED P21-03
DRV ENBL-BL/WH
6
2
3
5
4
PCON PWR P21-02 P52PCON-WH P52PCON-WH
C
AXLE EXT-GR/WH 12
A
B
1
2
ENG SPEED-BK/RD 11 PCON GND P21-01 GNDPCON-BR GNDPCON-BR
ENGINE
J24 10PIN
GR
START
YL
WH
OR
GR
DCON PWR RD
BR
10
BK
GND1-BR
TS2
BL
YL
AXLE RET-GR 9
J21 23 PIN
HARNESS
H
ENG START-BK
P_9A+P_10
DCON GND
SLIP RING
C60AXEX
CAN HIGH
CAN LOW
NOT USED 8
BLACK
RS232_GND
BOOM
RS232_RXD
RS232_TXD
P_6R1
P_10
P_12
P_7R
DRV ENBL-BL/WH 7
ASSIST
START
TS6
6
CKT #
ENG START-BK
START ASST-BK/WH START ASST-BK/WH 5
88
88
88
88
88
88
88
88
88
88
88
AUX PUMP-RD 4
74HC08
74HC08
GENERATOR AUXILIARY
DB9 CONNECTOR PIN
GEN ON/OFF-GR/WH 3
PUMP
TS1
2
3
5
WH
GR
RD
OR
BR
BK
BL
YL
HORN RET-GR
ON CIRCUIT BOARD
GR
YL
2
1
5
AUX PUMP-RD
4
1
S132LDS-BL/WH
HORN PWR-RD
6
2
3
5
4
1
2
B
A
C
ON/OFF
6
2
3
5
4
TS17
B
J36-DRIVE CHASSIS HARN A
1
2
SLP_MODE
GEN ON/OFF-GR/WH

P_7R
ECU
P_22
J157-1
P_6
HORN RTN-GR
P_7
J162
SERVICE
HORN
WH
BN5
C88PJTS-RD/WH
6
G
TILT SENSOR
POWER FET POWER FET
HORN PWR-RD C88PTS-RD/BK
BELLCRANK
5
ASSEMBLY
- -
P89RET-BR + 10 DEG 10 DEG
MANIFOLD
+
4
J22 35 PIN
HARNESS
SAFETY CUTOUT
P109JBS-GR/WH
3
0-20 DEG Y AXIS
WHITE
-
PCON
S21
C148JBS-BL/WH
JIB
DRIVE & STEERING
2
+
P110JBS-BK PLAT TILT SNSR
6
JOYSTICK (JC3)
1
GND1-BR
5 C158STC-BL/RD NOT USED P22-35 VLVRET2-BR
4 C160JPL-WH/RD VALVE_RETURN_2 P22-34 VLVRET2-BR
2
3 C159STC-BL/WH V238JLV-WH/RD Y102 JIB BELLCRANK LOOP VLV (J235)
JIB ROTATED CW P22-33 C214JRL-RD/WH
2 P
1
2
2 P162JPW1-OR V147JBD-BL/BK Y86 JIB BELLCRANK DOWN (J136)
JIB TILT SNSR IN P22-32 C148JBS-BL/WH
P
1
1 JSGND1-BR V146JBU-BL Y85 JIB BELLCRANK UP (J135)
JIB TILT SNSR GND P22-31 P110JBS-BK
J25
2 P
1
2
JIB TILT SNSR PWR P22-30 P109JBS-GR/WH V193JRR-WH/BK Y90 JIB ROTATE CCW (J203)
P
JIB UP/DOWN AND
1
JSGND1-BR 16 JOYSTICK_GND_1 JIB BELLCRANK LEVEL DOWN P22-29 V147JBD-BL/BK V192JRL-WH Y89 JIB ROTATE CW (J202)
6 GND2-BR
JOYSTICK (JC8)
JSGND4-BR 15 JOYSTICK_GND_4 JIB BELLCRANK LEVEL UP P22-28 V146JBU-BL

5
CCW SAFETY
JIB ROTATED
JIB ROTATE
P162JPW1-OR 14 JOYSTICK_PWR_1 JIB ROTATE CCW P22-27
NO
V193JRR-WH/BK
13
21
4 C156JUD-GR/WH BK/WH
43 2 1
NC
P162JPW4-OR 13 JOYSTICK_PWR_4 PLAT LEVEL LOOP P22-26 BK
LSJ2RS
3 C213JRS-RD/BK BL
14
TT ROTATE
22
C165TRS-WH/RD 12
GRN
SPARE OM P22-25 C214JRL-RD/WH
BLU
BR
J55
2 P162JPW2-OR
J205
C164PLS-RD/WH 11 PRIMARY UP/DOWN JIB ROTATE CW P22-24 V192JRL-WH
PLATFORM
ASSEMBLY
1 JSGND2-BR
6
F
C163PES-BL/WH 10 PRIMARY EXT/RET POWER FET
CCW (RIGHT)
JIB ROTATED
SENSOR
J218 SAFE PL/JB TILT PWR P22-23 P87PTS-RD POWER FET
NO
13
21
BK/WH
5
EXTEND/RETRACT
9
-
SPARE AI SAFE PL/JB TILT GND P22-22 10 DEG
-
10 DEG
NC
U20 P89RET-BR + BK
LSJ3RO
4 +
TILT
PRIMARY BOOM
BL
JOYSTICK (JC2)
6 GND3-BR C160JPL-WH/RD 8 PROPEL SAFETY CUTOUT
14
22
S6
PL TILT SNSR PWR P22-21
21
GRN
P85PTS-GR
RED
BR
3
-
STEER - DUAL AXIS
J206
5 C159STC-BL/WH 7 PL TILT SNSR IN P22-20 C84TAY-GR/BK + 0-20 DEG Y AXIS
2
4 C163PES-BL/WH C158STC-BL/RD 6 STEER - ROCKER PL TILT SNSR GND P22-19 P85RET-BR PLAT TILT SNSR
1
P_7R
P_22
5
P_6
3 JIB ROTATED CCW P22-18 C215JRR-WH/RD C215JRR-WH/RD
FOOTSW (FS1)
2 P162JPW3-OR P162JPW3-OR 4 JOYSTICK_PWR_3
2
FOOT SW RTN P22-17 C56FTS-RD C56FTS-RD
C60AXEX-GR/WH
1 JSGND3-BR P162JPW2-OR 3 JOYSTICK_PWR_2 LIMIT SWITCH PWR P22-16 C64LS-OR/BK C64LS-OR/BK
P57PBD-RD/WH
D81CAN(-)-GR
D82CAN(+)-YL
GNDDCON-BR
P21DCON-WH
J26
P53LS-WH/BK
P63LS-OR/RD
C61AXRT-GR
JSGND3-BR 2 JOYSTICK_GND_3
OVERLOAD
SAFE PL/JB TILT OUT P22-15 C88PJTS-RD/WH
S56PRV-RD
1
RD
LIMIT SW
J84
JSGND2-BR 1 JOYSTICK_GND_2 LOAD SNSR PWR P22-14 BK BK BK
LSP1LS
6
NO
GND4-BR
AND TURNTABLE
PRIMARY BOOM
J29
JOYSTICK (JC7)
LOAD SNSR IN P22-13 OR OR
NC
5
WH
4 C164PLS-RD/WH LOAD SNSR GND P22-12 GR/YL
UP/DOWN
PROX KILL IN P22-11

ROTATE
3 C165TRS-WH/RD
PROX GND P22-10
2 P162JPW4-OR
P
1
2 P 2
1 JSGND4-BR JIB BELLCRANK LOOP P22-09 V238JLV-WH/RD Y101 PLAT LEVEL LOOP VLV (J236) P57PBD-RD/WH
2
J127 PLAT LEVEL DOWN P22-08 V15PLD-OR/BK Y19 PLAT LEVEL DOWN (J81) P63LS-OR/RD
1 P
1
PLAT LEVEL UP P22-07 V14PLU-OR Y20 PLAT LEVEL UP (J80)
C60AXEX-GR/WH
E
2 P
2
JIB DOWN P22-06 V44JD-GR/BK Y73 JIB DOWN (J79)
P
1
JIB UP P22-05 V43JU-GR Y72 JIB UP(J78)
13
23
C60AXEX-GR/WH RD
NO
NO
4 3 2 1
LSRA1ES
2
PLAT ROT CW P22-04 V17PRL-GR Y70 PLAT ROTATE CW (J76) J2-GR/BK BR
P63LS-OR/RD BK REAR AXLE SAFETY
24
14
1
2
ESTOP PWR-RD/BK 20 PWR-PCON ESTOP PLAT ROT CCW P22-03 V18PRR-GR/BK Y71 PLAT ROTATE CCW (J77) J1-OR/BK WH SW
ALARM(+)-RD/BK 19 ALARM SPARE OM P22-02 J138
PLAT ROT CW-GR 18 PLAT ROT CW VALVE_RETURN_1 P22-01 VLVRET1-BR
ESTOP PWR-RD
PLAT ROT CCW-GR/BK 17 PLAT ROT CCW
13
E-STOP
23
J2-GR/BK RD
NO
NO
PCON
4 3 2 1
GND5-BR 16 GND P61LSA-GR BR LSFA1ES
P2

This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Uploaded by

Copyright:

Available Formats

This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

This Manual Includes: Repair Procedures Fault Codes Electrical and Hydraulic Schematics

Uploaded by

Copyright:

Available Formats

What components are covered in the service manual?

What components are covered in the service manual?

What safety procedures are outlined?

What safety procedures are outlined?

Service and Repair Manual

Serial Number Range

SX™-150 from SX15015H-101 to

For detailed maintenance

Part No. 1268496

Important Technical Publications

Compliance Find a Manual for this Model

Copyright © 2015 by Terex Corporation

Genie is a registered trademark of Terex South Dakota, Inc. in

ii SX-150 Part No. 1268496

Part No. 1268496 SX-150 iii

Serial Number Legend

1 Model 1 Sequence number

1 Model 1 Serial label (located under cover)

iv SX-150 Part No. 1268496

Do Not Perform Maintenance

Part No. 1268496 SX-150 v

Personal Safety Workplace Safety

vi SX-150 Part No. 1268496

Section 1 Safety Rules .......................................................................................................... v

Section 2 Specifications ....................................................................................................... 1

Section 3 Repair Procedures ............................................................................................. 17

Platform Controls ............................................................................................... 19

Part No. 1268496 SX-150 vii

Platform Components ........................................................................................29

Jib Boom Components ......................................................................................38

Boom Components ............................................................................................45

viii SX-150 Part No. 1268496

Ground Controls ................................................................................................. 76

Display Module ................................................................................................... 83

Hydraulic Pumps ................................................................................................ 90

Turntable Rotation Components .................................................................... 125

Part No. 1268496 SX-150 ix

Axle Components .............................................................................................130

Section 4 Fault Codes .......................................................................................................140

Control System Fault Codes ...........................................................................141

Section 5 Schematics ........................................................................................................188

x SX-150 Part No. 1268496

Electrical Schematics – Control Circuits ....................................................... 225

Hydraulic SchematicsH ................................................................................... 277

Part No. 1268496 SX-150 xi

For operational specifications, refer to the

Part No. 1268496 SX-150 1

Performance Specifications Boom function speeds, maximum from platform

Braking distance, maximum Primary boom up/down 26 - 31 sec / 5°

2 SX-150 Part No. 1268496

Hydraulic Oil Specifications Do not top off with incompatible

Note: Extended machine operation can cause the

Part No. 1268496 SX-150 3

Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil

4 SX-150 Part No. 1268496

Petro-Canada Environ MV 46 Hydraulic Component

Viscosity index 300 Charge pressure @ 2450 rpm 315 psi

Part No. 1268496 SX-150 5

Function pump - End Pump Brakes