Terex SX15015H-101 Installations- und Betriebsanleitung

Service and Repair Manual

Serial Number Range

SX™-150

from SX15015H-101

to SX15016H-

499

This manual includes:

Repair

procedures

Fault Codes

Electrical and

Hydraulic Schematics

from SX150H-500

to SX150H-

611

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1268496GT

Rev B

December 2019

Service and Repair Manual December 2019

Introduction

ii SX™-150 Part No. 1268496GT

Intr od ucti o n Intr od ucti o n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1268496GT Rev B, December 2019

First Edition, Second Printing

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

the U.S.A. and many other countries.

"SX" is a trademark of Terex South Dakota, Inc.

December 2019 Service and Repair Manual

Introduction

Part No. 1268496GT SX™-150 iii

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, 8-4, 8-5

Fault Codes Fault Code Source

A3 10/2018 Repair 8-3A, 8-4A

Schematics Electrical schematics

A4 12/2018 Specifications Machine Torque Specifications

B 12/2019 Cover Add ending serial break

Reference Examples:

Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual December 2019

Introduction

iv SX™-150 Part No. 1268496GT

Serial Number Legend

To August 31,

2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label (located under cover)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (located under cover)

5 Serial number (stamped on chassis)

December 2019 Service and Repair Manual

Safety Rules

Part No. 1268496GT SX™-150 v

Section 1 Safet y R ul es

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:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

•manufacturer's instructions and safety rules

•employer's safety rules and worksite

regulations

•applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Service and Repair Manual December 2019

Safety Rules

vi SX™-150 Part No. 1268496GT

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Read each procedure thoroughly. This

manual and the decals on the machine,

use signal words to identify the following:

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

result in death or serious injury.

Indica

tes a potentially hazardous

situation which, if not avoided,

could result in death or serious

injury.

Indicates a potentially hazardous

situation which, if not avoided,

may cause minor or moderate

injury.

Indicates a potentially hazardous

situation

which, if not avoided,

may result in property damage.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components w

hen lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your top priority.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Always have an

approved fire extinguisher within easy

reach.

Be sure that all tools and working areas

are p

roperly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine

components and cause damage.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stab

ilizing the

weight to be lifted. Use only chains or

straps that are in good condition and of

ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self

-locking

nuts) are not reused. These components

may fail if they are

used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe.

Be sure that your workshop or work area

is properly ventilated and well lit.

December 2019

Table of Contents

Part No. 1268496GT SX™-150 vii

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......................................................................6

Manifold Component Specifications .......................................................................7

Deutz TD2011L04i Engine Specifications ..............................................................8

Deutz TD 2.9 Engine Specifications.......................................................................9

Perkins 1104D-44T Engine Specifications ...........................................................10

Perkins 854F-34T Engine Specifications .............................................................12

Machine Torque Specifications ............................................................................13

Hydraulic Hose and Fitting Torque Specifications ...............................................14

Torque Procedure ................................................................................................15

December 2019

Table of Contents

viii SX™-150 Part No. 1268496GT

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..............................................27

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 ..........................................................35

Jib Boom Components ......................................................................................37

3-1 Jib Boom.........................................................................................................38

3-2 Jib Boom Lift Cylinder ....................................................................................39

3-3 How to Remove the Jib Boom Bellcrank........................................................40

3-4 Jib Boom Bellcrank Angle Sensor ..................................................................41

December 2019

Table of Contents

Part No. 1268496GT SX™-150 ix

Boom Components ............................................................................................43

4-1 Primary Boom Cable Track ............................................................................44

4-2 Primary Boom.................................................................................................46

How to Remove the Primary Boom.................................................................47

How to Disassemble the Primary Boom .........................................................49

4-3 Primary Boom Lift Cylinder ............................................................................52

4-4 Extension Cylinder .........................................................................................54

4-5 Boom Extend and Retract Cables..................................................................56

How to Replace the Boom Extend/Retract Cables .........................................61

4-6 Primary Boom Angle Sensor..........................................................................64

4-7 Boom Length Sensor .....................................................................................67

Engines................................................................................................................69

5-1 RPM Adjustment ............................................................................................69

5-2 Flex Plate .......................................................................................................69

How to Install the Flex Plate............................................................................70

Ground Controls.................................................................................................71

6-1 Bypass/Recovery Key Switch ........................................................................71

How to Use the Recovery Mode .....................................................................72

6-2 Circuit Boards.................................................................................................73

6-3 Membrane Decal............................................................................................75

6-4 Full Machine Calibration.................................................................................76

Display Module ...................................................................................................77

Hydraulic Pumps ................................................................................................84

7-1 Function Pump ...............................................................................................84

How to Prime the Function Pump ...................................................................85

How to Adjust the Function Pump Standby Pressure .....................................85

How to Adjust the Function Pump Pressure Compensator ............................87

7-2 Drive Pump.....................................................................................................88

How to Prime the Drive Pump.........................................................................90

December 2019

Table of Contents

x SX™-150 Part No. 1268496GT

Manifolds .............................................................................................................92

8-1 Function Manifold Components......................................................................92

8-2 Valve Adjustments - Function Manifold..........................................................98

8-3 Platform Level and Rotation Manifold Components, to SX150H-518 ..........100

8-3A Platform Level and Rotation Manifold Components, from SX150H-519 ...101

8-4 Jib Boom Manifold Components, to SX150H-518 .......................................102

8-4A Jib Boom Manifold Components, from SX150H-519.................................103

8-5 Function Enable Manifold.............................................................................104

8-6 Steer and Axle Manifold Components, to SX150H-507...............................106

8-6A Steer and Axle Manifold Components, from SX150H-508 ........................110

8-7 Valve Adjustments - Steer and Axle Manifold ..............................................114

8-8 Traction Manifold Components ....................................................................116

8-9 Valve Adjustments - Traction Manifold.........................................................120

8-10 Generator Manifold Component.................................................................121

8-11 Valve Coils .................................................................................................122

Turntable Rotation Components.....................................................................124

9-1 Turntable Rotation Assembly .......................................................................124

How to Adjust the Turntable Rotation Gear Backlash...................................125

9-2 Turntable Level Sensor ................................................................................126

Axle Components .............................................................................................129

10-1 Steer Sensors.............................................................................................129

How to Calibrate a Replacement Steer Sensor ............................................131

How to Calibrate All Steer Sensors ...............................................................132

10-2 Steer Cylinders ...........................................................................................134

10-3 Axle Extension Cylinders............................................................................134

10-4 Axle Angle Sensors ....................................................................................135

Generators.........................................................................................................138

11-1 Welder Generator .......................................................................................138

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