Terex SX135XCH-101 Installation and operating manual

Service and Repair Manual
Serial Number Range
SX™-135 XC™
SX135XCH-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1263383GT
Rev C5
December 2018

Service and Repair Manual December 2018
Introduction
ii SX™-135 XC™ Part No. 1263383GT
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 © 2016 by Terex Corporation
1263383GT Rev C, June 2017
First Edition, Third Printing
Genie is a registered trademark of Terex South Dakota, Inc. in
the U.S.A. and many other countries.
"SX" and "XC" are trademarks of Terex South Dakota, Inc.

December 2018 Service and Repair Manual
Introduction
Part No. 1263383GT SX™-135 XC™ iii
Revision History
Revision Date Section Procedure / Page / Description
A 10/2016 Initial Release
B 1/2017 Cover Changed part number from 1263382GT to 1263383GT
Repair How to Adjust Load Cell Pre-load
Update Function Manifold, Steer Manifold
B1 1/2017 Specifications Platform rotator torque
C 5/2017 Repair 1-2 Joysticks
2-5 Platform Overload System
3-6 Jib Boom Bellcrank Angle Sensor
4-6 Primary Boom Angle Sensor
4-7 Boom Length Sensor
6-4 Full Machine Calibration
9-2 Turntable Level Sensor
10-2 Axle Angle Sensors
Display Module - Boom Function Speeds
Display Module - Sensor Calibration
Display Module - Options
C1 7/2017 Repair Control System Numerical Fault Codes
Generator Manifold
Schematics Hydraulic Schematic
C2 11/2017 Fault Codes Updated references to LSB2RO
Schematics Updated references to LSB2RO
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 2018
Introduction
iv SX™-135 XC™ Part No. 1263383GT
Revision History
Revision Date Section Procedure / Page / Description
C3 8/2018 Fault Codes Added LSB1RS/LSJ1RO Cross-check, Jib Bellcrank Loop
Valve, Platform Level Loop Valve, Axle Retract Enable
Valve, Fuel Level Sensor
C4 12/2018 Specifications Rotate drive hub torque value
C5 12/2018 Repair 10-1 Cal. All Steer Sensors
Reference Examples:
Section – Maintenance, B-3
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

December 2018 Service and Repair Manual
Introduction
Part No. 1263383GT SX™-135 XC™ v
Serial Number Legend
1 Model
2 Facility code
3 Sequence number
4 Serial label (located under cover)
5 Serial number (stamped on chassis)

Service and Repair Manual December 2018
Safety Rules
vi SX™-135 XC™ Part No. 1263383GT
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.

December 2018 Service and Repair Manual
Safety Rules
Part No. 1263383GT SX™-135 XC™ vii
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 tho
roughly. 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.
Indicates 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 when 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 properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cau
se damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fas
teners 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 2018
Table of Contents
viii SX™-135 XC™ Part No. 1263383GT
Introduction Introduction...........................................................................................................ii
Important Information ............................................................................................. ii
Find a Manual for this Model .................................................................................. ii
Revision History..................................................................................................... iii
Serial Number Legend............................................................................................v
Section 1 Safety Rules .........................................................................................................vi
General Safety Rules ............................................................................................ vi
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 2018
Table of Contents
Part No. 1263383GT SX™-135 XC™ ix
Section 3 Repair Procedures .............................................................................................17
Introduction...........................................................................................................17
Platform Controls ...............................................................................................19
1-1 Platform Circuit Board ....................................................................................19
How to Remove the LED Circuit Board...........................................................20
1-2 Joysticks.........................................................................................................20
How to Reset a Proportional Valve Coil Default .............................................23
How to Set the Function Thresholds and Default Functions Speeds .............24
How to Adjust the Function Speeds ................................................................26
How to Adjust the Function Ramp Rate Setting..............................................27
Platform Components........................................................................................28
2-1 Platform ..........................................................................................................28
2-2 Platform Leveling Cylinder .............................................................................29
2-3 Platform Rotator .............................................................................................30
How to Bleed the Platform Rotator..................................................................31
2-4 Platform Level Sensor....................................................................................32
2-5 Platform Overload System .............................................................................33
How to Calibrate the Platform Overload System ............................................33
How to Perform a Zero Load Cell Calibration .................................................35
How to Replace the Platform Overload Load Cell ..........................................36
2-6 Platform Overload Recovery Message ..........................................................36
Jib Boom Components ......................................................................................38
3-1 Jib Boom ........................................................................................................39
3-2 Jib Boom Lift Cylinder ....................................................................................41
3-3 Jib Boom Level Cylinder ................................................................................42
3-4 Jib Boom Extension Cylinder .........................................................................43
3-5 How to Remove the Jib Boom Bellcrank........................................................45
3-6 Jib Boom Bellcrank Angle Sensor..................................................................46

December 2018
Table of Contents
x SX™-135 XC™ Part No. 1263383GT
Boom Components ............................................................................................49
4-1 Primary Boom Cable Track ............................................................................50
4-2 Primary Boom.................................................................................................53
How to Remove the Primary boom .................................................................54
How to Disassemble the Primary Boom..........................................................56
4-3 Primary Boom Lift Cylinder.............................................................................59
4-4 Extension Cylinder .........................................................................................61
4-5 Boom Extend and Retract Cables..................................................................63
How to Replace the Boom Extend/Retract Cables .........................................66
4-6 Primary Boom Angle Sensor ..........................................................................67
4-7 Boom Length Sensor......................................................................................69
Engines................................................................................................................71
5-1 RPM Adjustment ............................................................................................71
5-2 Flex Plate........................................................................................................71
How to Install the Flex Plate............................................................................72
Ground Controls.................................................................................................73
6-1 Bypass/Recovery Key Switch.........................................................................73
6-2 Circuit Boards .................................................................................................75
6-3 Membrane Decal ............................................................................................77
6-4 Full Machine Calibration.................................................................................78
Display Module ...................................................................................................79
Hydraulic Pumps ................................................................................................86
7-1 Function Pump ...............................................................................................86
How to Prime the Function Pump ...................................................................87
How to Adjust the Function Pump Standby Pressure .....................................87
How to Adjust the Function Pump Pressure Compensator.............................89
7-2 Drive Pump.....................................................................................................90
How to Prime the Drive Pump .........................................................................92