Terex SX15015H-101 Installation and operating manual

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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2015 by Terex Corporation
1268496GT Rev B, December 2019
First Edition, Second Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"SX" is a trademark of Terex South Dakota, Inc.

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