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Genie SX-180 Service & Repair Manual 1300670GT – PDF DOWNLOAD
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Description
Genie SX-180 Service & Repair Manual 1300670GT – PDF DOWNLOAD
Language : English
Pages : 328
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie SX-180 Service & Repair Manual 1300670GT – PDF DOWNLOAD
Front Cover............................................................................... 1 Important Information..................................................................... 2 Find a Manual for this Model.............................................................. 2 Revision History.......................................................................... 3 Serial Number Legend...................................................................... 4 General Safety Rules...................................................................... 5 Table of Contents......................................................................... 7 Specifications............................................................................ 13 Machine Specifications................................................................ 13 Performance Specifications............................................................ 14 Hydraulic Oil Specifications.......................................................... 15 Hydraulic Component Specifications.................................................... 17 Manifold Component Specifications..................................................... 19 Deutz TD2011L04i Engine Specifications................................................ 20 Deutz TD 2.9 Engine Specifications.................................................... 21 Deutz TCD 2.2 L3 Engine Specifications................................................ 22 Perkins 1104D-44T Engine Specifications............................................... 23 Perkins 854F-34T Engine Specifications................................................ 25 Machine Torque Specifications......................................................... 26 Machine Component Weights............................................................. 27 Hydraulic Hose and Fitting Torque Specifications...................................... 28 Torque Procedure...................................................................... 29 Repair Procedures......................................................................... 31 Introduction.......................................................................... 31 Platform Controls..................................................................... 33 1-1 Platform Circuit Board........................................................ 33 How to Remove the LED Circuit Board........................................... 34 1-2 Joysticks..................................................................... 34 How to Reset a Proportional Valve Coil Default................................ 38 How to Set the Function Thresholds and Default Functions Speeds............... 38 How to Adjust the Function Speeds............................................. 40 How to Adjust the Function Ramp Rate Setting.................................. 41 Platform Components................................................................... 42 2-1 Platform...................................................................... 42 2-2 Platform Leveling Cylinder.................................................... 43 2-3 Platform Rotator.............................................................. 44 How to Bleed the Platform Rotator............................................. 45 2-4 Platform Level Sensor......................................................... 46 2-5 Platform Overload System...................................................... 47 How to Perform a Full Load Platform Calibration............................... 47 How to Perform a Zero Load Platform Calibration............................... 49 How to Replace the Platform Overload Load Cell................................ 51 2-6 Platform Overload Recovery Message............................................ 52 Jib Boom Components................................................................... 53 3-1 Jib Boom...................................................................... 54 3-2 Jib Boom Lift Cylinder........................................................ 55 3-3 How to Remove the Jib Boom Bellcrank.......................................... 56 3-4 Jib Boom Bellcrank Angle Sensor............................................... 57 Boom Components....................................................................... 60 4-1 Cable Track................................................................... 61 4-2 Primary Boom.................................................................. 63 4-3 Primary Boom Lift Cylinder.................................................... 71 4-4 Extension Cylinder............................................................ 73 4-5 Boom Extend and Retract Cables................................................ 77 How to Replace the Boom Extend/Retract Cables................................. 82 4-6 Boom Internal Cable Track..................................................... 85 4-7 Primary Boom Angle Sensor..................................................... 88 4-8 Boom Length Sensor............................................................ 91 Engines............................................................................... 94 5-1 RPM Adjustment................................................................ 94 5-2 Flex Plate.................................................................... 94 How to Install the Flex Plate................................................. 95 5-3 Diesel Particle Filter Regeneration - Deutz TCD 2.2 L3........................ 96 Ground Controls....................................................................... 97 6-1 Bypass/Recovery Key Switch.................................................... 97 6-2 Circuit Boards................................................................ 99 6-3 Membrane Decal................................................................101 6-4 Full Machine Calibration......................................................102 Display Module........................................................................103 Hydraulic Pumps.......................................................................110 7-1 Function Pump.................................................................110 How to Prime the Function Pump................................................111 How to Adjust the Function Pump Standby Pressure..............................111 How to Adjust the Function Pump Pressure Compensator..........................113 7-2 Drive Pump....................................................................114 How to Prime the Drive Pump...................................................116 Manifolds.............................................................................117 8-1 Function Manifold.............................................................117 8-2 Valve Adjustments - Function Manifold.........................................123 8-3 Platform Level and Rotation Manifold from SN SX180H-613......................125 8-4 Jib Boom Manifold from SN 613.................................................126 8-5 Function Enable Manifold......................................................127 8-6 Steer and Axle Manifold Components............................................129 8-7 Valve Adjustments - Steer and Axle Manifold...................................133 8-8 Traction Manifold Components..................................................135 8-9 Valve Adjustments - Traction Manifold.........................................139 8-10 Generator Manifold Component.................................................140 8-11 Valve Coils..................................................................141 Turntable Rotation Components.........................................................143 9-1 Turntable Rotation Assembly...................................................143 How to Adjust the Turntable Rotation Gear Backlash............................144 9-2 Turntable Level Sensor........................................................145 Axle Components.......................................................................148 10-1 Steer Sensors................................................................148 How to Calibrate a Replacement Steer Sensor...................................150 How to Calibrate All Steer Sensors............................................150 10-2 Steer Cylinders..............................................................153 10-3 Axle Extension Cylinders.....................................................153 10-4 Axle Angle Sensors...........................................................154 Generators............................................................................157 11-1 Welder Generator.............................................................157 Fault Codes...............................................................................158 Introduction..........................................................................158 Control System Fault Codes............................................................159 Fault Matrix......................................................................178 Fault Code Source.....................................................................179 Deutz TCD 2.2 L3 Engine Fault Codes...................................................182 Deutz TD 2.9 L4 Engine Fault Codes....................................................192 Perkins 854F-34T Engine Fault Code....................................................207 Schematics................................................................................216 Introduction..........................................................................216 Wire Circuit Legend...................................................................217 Wire Color Legend.....................................................................221 Limit Switches and Angle Sensors......................................................226 Circuit Connector Legend..............................................................230 Connector Pin Legend..................................................................233 Engine Relay and Fuse Panel Legend - Deutz TD2011L04i and Perkins 1104D-44T Models....247 Engine Relay and Fuse Panel Legend - Deutz TCD 2.2 L3, TD 2.9 L4 Models...............248 Engine Relay and Fuse Panel Legend - Perkins 854F-34T Models..........................249 Electrical Symbols Legend.............................................................250 Hydraulic Symbols Legend..............................................................251 Electrical Schematics – Control Circuits..............................................253 Control Circuit, Horn.............................................................254 Control Circuit, Power............................................................255 Control Circuit, Can Bus..........................................................258 Control Circuit, Axle Extend/Retract..............................................259 Control Circuit, Steer............................................................262 Control Circuit, Propel...........................................................263 Control Circuit, Turntable Rotate.................................................266 Control Circuit, Boom Up/Down.....................................................267 Control Circuit, Boom Extend/Retract..............................................270 Control Circuit, Jib Up/Down, Jib Rotate, Platform Rotate.........................271 Control Circuit, Platform Level, Jib Bellcrank Level..............................274 Control Circuit, Flashing Beacons, Oil Cooler, Drive/Work Lights..................275 Control Circuit, Recovery PLD.....................................................278 Control Circuit, Telematics.......................................................279 Control Circuit, Deutz TD2011L04i Engine..........................................282 Control Circuit, Deutz TD 2.9 L4 Engine...........................................283 Control Circuit, Perkins 1104D-44T Engine.........................................286 Control Circuit, Perkins 854F-34T Engine..........................................287 Electrical Schematics.................................................................289 Elecrical Schematic, Perkins 1104D-44T Engine.....................................290 Electrical Schematic, Perkins 854F-34T Engine.....................................294 Electrical Schematic, Deutz TCD 2.2 L3 Tier IV Engine.............................299 Electrical Schematic, Deutz TCD 2.2 L3 Stage V Engine.............................306 Deutz TD2011L04i Engine...........................................................311 Electrical Schematic, Generator Receptacle Wiring - ANSI / CSA....................315 Electrical Schematic, Generator Receptacle Wiring - EU............................318 Electrical Schematic, Generator Receptacle Wiring - UK............................319 Electrical Schematic, Generator Receptacle Wiring - AUS...........................322 Electrical Schematic, Generator Receptacle Wiring - S. Korea......................323 Hydraulic Schematics..................................................................325 Hydraulic Schematic...............................................................326 Full Electrical Schematic with Deutz TD 2.9 L4........................................327 Back Cover................................................................................328
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