Terex Genie Z-45/25J Service And Repair Manual
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Terex Genie Z-45/25J Service And Repair Manual

Terex Genie Z-45/25J Service And Repair Manual

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Service and Repair Manual
Z
-45/25
®
Z
-45/25J
®
Serial Number Range
from Z4525D-4536
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. 1312350GT
Rev A
July 2021

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Summary of Contents for Terex Genie Z-45/25J

  • Page 1 Service and Repair Manual Serial Number Range -45/25 ® from Z4525D-4536 This manual includes: Repair procedures -45/25J ® Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1312350GT Rev A July 2021...

  • Page 2: Find A Manual For This Model

    Copyright © 2015 by Terex Corporation 1312350GT Rev A, July 2021 Second Edition, First Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -45/25 • Z ®...

  • Page 3: Revision History

    July 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 7/2021 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual July 2021 Introduction Serial Number Legend Z4525 M - 12345 Model: Serial number: Z4525M-12345 Year of manufacture: Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model 4 Serial number (stamped on chassis)

  • Page 5: Safety Rules

    July 2021 Service and Repair Manual Safety Rules Secti on 1 Safety Rul 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...
  • Page 6 Service and Repair Manual July 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...

  • Page 7: Table Of Contents

    July 2021 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 ....................
  • Page 8 July 2021 Table of Contents Section 3 Repair Procedures ..................16 Introduction ...................... 16 Platform Controls ................... 18 1-1 ALC-500 Circuit Board ................18 1-2 Joysticks ....................19 How to Adjust the Joystick Max-out Setting ..........19 How to Adjust the Joystick Ramp Rate Setting ..........20 How to Adjust the Joystick Threshold Setting ..........
  • Page 9 July 2021 Table of Contents Primary Boom Components................32 4-1 Cable Track ....................32 How to Remove the Cable Track, Z-45/25 ........... 32 How to Remove the Cable Track, Z-45/25J ..........33 How to Repair the Primary Boom Cable Track ..........36 4-2 Primary Boom ....................
  • Page 10 July 2021 Table of Contents Manifolds ......................58 8-1 Function Manifold Components ..............58 8-2 Valve Adjustments - Function Manifold ............62 How to Adjust the System Relief Valve ............62 How to Adjust the Secondary Boom Down Relief Valve ....... 62 8-3 Jib Boom / Platform Rotate Manifold Components ........
  • Page 11 July 2021 Table of Contents Section 4 Fault Codes ..................... 79 Introduction ...................... 79 Control System Fault Codes ................80 How to Retrieve Control System Fault Codes ..........80 Control System Fault Codes ................ 81 Fault Code Display - Deutz Models ..............84 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models .....
  • Page 12 July 2021 Table of Contents Section 5 Schematics ..................... 99 Introduction ...................... 99 Electrical Symbol Legend ................100 Hydraulic Symbols Legend ................101 Electrical Component and Wire Color Legends ..........102 Engine Relay Layout - Deutz D 2.9 L4 ............106 Electrical Schematics - Options ..............

  • Page 13: Specifications

    July 2021 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Tires and wheels Hi-flotation (option) Tire size 33/16LL500 Tires and wheels rough terrain Tire ply rating Tire size 315/55 D20 Overall tire diameter 33 in Tire ply rating 84 cm Tire and wheel weight, air filled 140 lbs...

  • Page 14: Machine Component Weights

    Service and Repair Manual July 2021 Specifications Machine Component Weights Fuel capacities LPG tank 33.5 pounds Drive motor 26.7 lbs 15.2 kg 12.1 kg Fuel tank 17 gallons Drive hub 138.8 lbs 64.4 liters 63 kg Hydraulic tank 22 gallons Primary boom assembly 946.8 lbs 83 liters...

  • Page 15: Performance Specifications

    July 2021 Service and Repair Manual Specifications Performance Specifications Drive speed, maximum Stowed position (Deutz 4.5 mph D2.9L, D436, and D2011) 7.2 km/h 40 ft / 6.1 sec 12.2 m / 6.1 sec Stowed position (Kubota 3.1 mph D1105-E4B) 5 km/h 40 ft / 8.8 sec 12.2 m / 8.8 sec Raised or extended...

  • Page 16: Hydraulic Oil Specifications

    Service and Repair Manual July 2021 Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 17 July 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 15.0...
  • Page 18 Service and Repair Manual July 2021 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C cSt @ 104°F / 40°C 44.4...

  • Page 19: Hydraulic Component Specifications

    July 2021 Service and Repair Manual Specifications Hydraulic Component Auxiliary Pump Specifications Type gear, fixed displacement Drive Pump Displacement per revolution 0.067 cu in 1.1 cc Type: bi-directional variable displacement piston pump Auxiliary pump relief pressure 3200 psi Flow rate @ 2500 psi / 172 bar 32 gpm 220.6 bar 121 L/min...
  • Page 20 Service and Repair Manual July 2021 Specifications Non-steer end drive motors Manifold Component Specifications Displacement per revolution 0.54 to 1.53 cu in Plug torque variable 4WD (2 speed motor) 8.85 to 25.1 cc SAE No. 2 36 in-lbs / 4 Nm Displacement per revolution 0.99 to 1.83 cu in SAE No.

  • Page 21: Deutz D2011 L03I Engine Specifications

    July 2021 Service and Repair Manual Specifications Deutz D2011 L03i Engine Oil temperature switch Temperature switch point 300°F Displacement 142 cu in 149°C 2,33 liters Oil Pressure switch Number of cylinders Oil pressure switch point 22 psi Bore and Stroke 3.7 x 4.4 inches 1,5 bar 94 x 112 mm...

  • Page 22: Deutz D 2.9 L4 Engine Specifications

    Service and Repair Manual July 2021 Specifications Deutz D2.9 L4 Engine Engine coolant Capacity 10 quarts Displacement 177 cu in 9,4 liters 2,9 liters Fuel injection system Number of cylinders Injection pump make Bosch Bore and Stroke 3.6 x 4.3 inches Injection pump pressure, 15000 psi 92 x 110 mm...

  • Page 23: Kubota D1105-E4B Engine Specifications

    July 2021 Service and Repair Manual Specifications Kubota D1105-E4B Engine Fuel injection system Injection pump make Bosch MD Displacement 68.53 cu in Injection pump pressure, 1991 psi 1,123 liters maximum 137 bar Number of cylinders Injection timing 18° BTDC Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78,4 mm...

  • Page 24: Machine Torque Specifications

    Service and Repair Manual July 2021 Specifications Machine Torque Specifications Platform Rotator 3/4 -10 center bolt, GR 8, dry 380 ft-lbs Zinc plated 515 Nm 3/4 -10 center bolt, GR 8, dry 265 ft-lbs ZAG coated 359 Nm 3/8 -16 bolts, GR 8, Dry 44 ft-lbs Zinc plated 60 Nm...

  • Page 25: Hydraulic Hose And Fitting Torque Specifications

    July 2021 Service and Repair Manual Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...

  • Page 26: Torque Procedure

    Service and Repair Manual July 2021 Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
  • Page 27 July 2021 Service and Repair Manual Specifications 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.

  • Page 28: Repair Procedures

    Service and Repair Manual July 2021 Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es Unless otherwise specified, perform each  repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...

  • Page 29: About This Section

    July 2021 Service and Repair Manual 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.

  • Page 30: Platform Controls

    Service and Repair Manual July 2021 Platform Controls Platform Controls ALC-500 Circuit Board The platform control box contains one printed circuit board. The ALC-500 circuit board inside the Note: When the ALC-500 circuit board is replaced, platform control box controls all proportional the joystick controllers will need to be calibrated.

  • Page 31: Joysticks

    July 2021 Service and Repair Manual Platform Controls How to Adju st th e Joys tick M ax-o ut Setti ng How to Adjust the Joystick Max- Joysticks out Setting The max-out setting of a joystick controls the How to Calibrate a Joystick maximum speed of a joystick-controlled machine function.

  • Page 32: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual July 2021 Platform Controls How to Adju st th e Joys tick Ra mp Ra te Setti ng How to Adjust the Joystick Ramp Start the engine from the platform controls and press down the foot switch. Rate Setting Start a timer and activate the machine The ramp rate setting of a joystick controls the...
  • Page 33 July 2021 Service and Repair Manual Platform Controls Start the engine from the platform controls 13 Return the joystick to the neutral position and and press down the foot switch. wait for approximately 10 seconds to allow the settings to be saved. Start a timer and simultaneously move the joystick in either direction full stroke.

  • Page 34: How To Adjust The Joystick Threshold Setting

    Service and Repair Manual July 2021 Platform Controls How to Adju st th e Joys tick T hres hold S etting How to Adjust the Joystick Select a boom function joystick to set the threshold. Threshold Setting 10 Slowly move the joystick off center in either The threshold setting of a joystick is the minimum direction just until the function begins to output at which a function proportional valve can...

  • Page 35: Platform Components

    July 2021 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the unions and Platform Leveling Slave Cylinder connect them together using a connector. Connect the hoses from the cylinder together The slave cylinder and the rotator pivot are the two using a connector.

  • Page 36: How To Bleed The Slave Cylinder

    Service and Repair Manual July 2021 Platform Components How to Blee d th e Slave C ylinde r How to Bleed the Slave Cylinder Use a soft metal drift to drive the rod-end pivot pin out. Note: This procedure will have to be preformed outside.

  • Page 37: Platform Rotator

    July 2021 Service and Repair Manual Platform Components While still holding the function enable toggle switch, simultaneously activate the primary Platform Rotator boom down and platform level down toggle switches until the primary boom is fully lowered. How to Bleed the Platform The platform should be facing in a down Rotator position.

  • Page 38: Platform Overload System

    Service and Repair Manual July 2021 Platform Components Move the function enable toggle switch to either side and hold the platform rotate toggle Platform Overload System switch to the right position until the platform is fully rotated to the right. Continue holding the toggle switch until air stops coming out of the How to Calibrate the Platform bleed screw.
  • Page 39 July 2021 Service and Repair Manual Platform Components Move the platform up and down by hand, so it Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to bounces approximately 2.5 to 5 cm / 1 to 2 inches.
  • Page 40 Service and Repair Manual July 2021 Platform Components Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls.

  • Page 41: Jib Boom Components

    July 2021 Service and Repair Manual Jib Boom Components Use a soft metal drift to remove the platform rotator pivot pin and remove the platform Jib Boom rotator from the machine. 10 Slide both of the jib boom leveling arms off of How to Remove the Jib Boom the jib boom cylinder rod-end pivot pin.

  • Page 42: Jib Boom Lift Cylinder

    Service and Repair Manual July 2021 Jib Boom Components 18 Attach a lifting strap from an suitable lifting device to the lug on the rod end of the jib Jib Boom Lift Cylinder boom lift cylinder. 19 Use a soft metal drift to remove the jib boom How to Remove the Jib Boom Lift lift cylinder rod-end pivot pin, then remove the jib boom lift cylinder from the bellcrank.
  • Page 43 July 2021 Service and Repair Manual Jib Boom Components Support the jib boom lift cylinder with a suitable lifting device. Remove the pin retaining fastener from the jib boom lift cylinder barrel-end pivot pin. Use a soft metal drift to remove the barrel-end pin and let the cylinder hang down.

  • Page 44: Primary Boom Components

    Service and Repair Manual July 2021 Primary Boom Components Tag, disconnect and plug the hydraulic hoses from the "PR1" and "PR2" ports on the Cable Track counterbalance valve manifold located on the platform rotator. Cap the fittings on the The primary boom cable track guides the cables manifold.

  • Page 45: How To Remove The Cable Track, Z-45/25J

    July 2021 Service and Repair Manual Primary Boom Components 10 Place blocks in between the upper and lower How to Re mov e th e Cabl e T rack, Z- 45/ 25J How to Remove the Cable Track, cable tracks and secure the upper and lower Z-45/25J tracks together.
  • Page 46 Service and Repair Manual July 2021 Primary Boom Components Tag and disconnect the hydraulic hoses from 10 Tag, disconnect and plug the hydraulic hoses the platform leveling slave cylinder at the from the platform leveling master cylinder. union and connect them together using a Cap the fittings on the cylinder.
  • Page 47 July 2021 Service and Repair Manual Primary Boom Components 17 Raise the primary boom slightly with the 25 Remove the cable track from the machine and suitable lifting device to relieve the pressure place it on a structure capable of supporting it. on the primary boom lift cylinder rod-end pivot Crushing hazard.

  • Page 48: How To Repair The Primary Boom Cable Track

    Service and Repair Manual July 2021 Primary Boom Components How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom Cable Track Primary Boom Component damage hazard. How to Remove the Primary The boom cable track can be damaged if it is twisted.
  • Page 49 July 2021 Service and Repair Manual Primary Boom Components 17 Remove the pin retaining fasteners from the Remove the pin retaining fastener from the primary boom lift cylinder rod-end pivot pin. master cylinder barrel-end pivot pin. Use a Use a soft metal drift to remove the pin. soft metal drift to remove the pin.

  • Page 50: How To Disassemble The Primary Boom

    Service and Repair Manual July 2021 Primary Boom Components Remove the external snap rings from the How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary extension cylinder rod-end pivot pin at the Boom platform end of the extension tube. Use a soft metal drift to remove the pin.

  • Page 51: Primary Boom Lift Cylinder

    July 2021 Service and Repair Manual Primary Boom Components Raise the primary boom with a suitable lifting device slightly to take the pressure off the Primary Boom Lift Cylinder primary boom lift cylinder pivot pins. Support the rod end and the barrel end of the The primary boom lift cylinder raises and lowers primary boom lift cylinder with a second the primary boom.

  • Page 52: Primary Boom Extension Cylinder

    Service and Repair Manual July 2021 Primary Boom Components Lower the rod end of the lift cylinder onto the block. Protect the cylinder rod from damage. Primary Boom Extension Crushing hazard. The primary Cylinder boom lift cylinder could become unbalanced and fall if not The primary boom extension cylinder extends and properly supported by the lifting retracts the primary boom extension tube.The...

  • Page 53: Platform Leveling Master Cylinder

    July 2021 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Platform Leveling Master fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The master cylinder acts as a pump for the slave burn skin.
  • Page 54 Service and Repair Manual July 2021 Primary Boom Components Place a rod through the barrel-end pivot pin and twist to remove the pin. Remove the pin retaining fastener from the rod-end pivot pin. Place a rod through the rod-end pivot pin and twist to remove the pin.

  • Page 55: Secondary Boom Components

    July 2021 Service and Repair Manual Secondary Boom Components Secondary Boom components 6 secondary boom lift cylinder (2) 1 upper secondary boom (number 1 arm) 7 lower secondary boom (number 4 arm) 2 upper tension link (number 2 arm) 8 turntable pivot 3 lower tension link (number 3 arm) 9 boom rest 4 mid-pivot...

  • Page 56: Secondary Boom

    Service and Repair Manual July 2021 Secondary Boom Components Attach a lifting strap from an suitable lifting device to the lug on the rod end of the primary Secondary Boom boom lift cylinder. Then raise the primary boom lift cylinder with the crane, to a vertical position.
  • Page 57 July 2021 Service and Repair Manual Secondary Boom Components 10 Remove the pin retaining fasteners from both 17 Attach a lifting strap from a second suitable sides of the secondary boom lift cylinder rod- lifting device to the number 1 arm at the mid- end pivot pin and barrel-end pivot pin.
  • Page 58 Service and Repair Manual July 2021 Secondary Boom Components 23 Pull all of the cables and hoses out through 31 Insert a 4 x 4 x 8 1/2 inch / 10 x 10 x 22 cm the upper pivot. block between the number 3 arm and the number 4 arm at the mid-pivot end.
  • Page 59 July 2021 Service and Repair Manual Secondary Boom Components 39 Use a soft metal drift to remove the upper 44 Remove the fuel tank filler cap. compression link pivot pin from the number 45 Using an approved hand-operated pump, 2 arm. Remove the compression link from the drain the fuel tank into a container of suitable machine.
  • Page 60 Service and Repair Manual July 2021 Secondary Boom Components 48 Remove the retaining fastener from the 58 Attach a lifting strap from the lifting device to ground control box and function manifold pivot the center point of the number 4 arm. Do not plate.

  • Page 61: Secondary Boom Lift Cylinders

    July 2021 Service and Repair Manual Secondary Boom Components Remove the pin retaining fasteners from the secondary boom lift cylinder rod-end pivot pin Secondary Boom Lift Cylinder and barrel-end pivot pin. Do not remove the pins. There are two secondary boom lift cylinders Attach a strap from an suitable lifting device to incorporated in the structure of the secondary the lug on the rod end of the secondary boom...

  • Page 62: Engines

    Service and Repair Manual July 2021 Engines Flex Plate RPM Adjustment - Deutz D2011L03i and Kubota D1105 The flex plate acts as a coupler between the Models engine and the pump. It is bolted to the engine flywheel and has a splined center to drive the Refer to Maintenance Procedure in the appropriate pump.

  • Page 63: How To Install The Flex Plate

    July 2021 Service and Repair Manual Engines How to I nstall t he Flex Plat e How to Install the Flex Plate Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the pump. Apply Loctite removable thread sealant to ®...

  • Page 64: How To Install The Pump And Bell Housing Assembly

    Service and Repair Manual July 2021 Engines How to ins tall th e Pum p a nd Bell Ho using Assem bly How to Install the Pump and Bell Housing Assembly Install the pump and bell housing assembly. Deutz models: Torque the bell housing mounting bolts labeled "C"...

  • Page 65: Engine Fault Codes - Deutz D 2.9 L4 Models

    July 2021 Service and Repair Manual Engines Engine Fault Codes - Deutz D 2.9 L4 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle...

  • Page 66: Hydraulic Pumps

    Service and Repair Manual July 2021 Hydraulic Pumps Tag, disconnect and plug the lift/steer pump hydraulic hoses. Cap the fittings on the pump. Lift/Steer Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Lift/Steer burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...

  • Page 67: Drive Pump

    July 2021 Service and Repair Manual Hydraulic Pumps Locate the two hydraulic tank valves at the hydraulic tank through the access hole Drive Pump underneath the turntable. Close the valves. The drive pump is a bi-directional variable Component damage hazard. displacement piston pump.

  • Page 68: How To Prime The Pump

    Service and Repair Manual July 2021 Hydraulic Pumps How to Pri me t he Pu mp How to Prime the Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Connect a 0 to 600 psi / 0 to 41 bar pressure Remove the drive pump from the machine.
  • Page 69 July 2021 Service and Repair Manual Hydraulic Pumps 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 320 psi / 22 bar. Deutz and Kubota models: Release the manual fuel shutoff valve.

  • Page 70: Manifolds

    Service and Repair Manual July 2021 Manifolds 8-1 Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform level up/down 25 ft-lbs / 34 Nm Solenoid valve, 3 position 4 way Platform rotate left/right and jib...
  • Page 71 July 2021 Service and Repair Manual Manifolds Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 72 Service and Repair Manual July 2021 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Differential sensing circuit, turntable 12-14 ft-lbs / 16-19 rotate Check valve, 5 psi / 0.3 bar Differential sensing circuit, primary 12-14 ft-lbs / 16-19 boom retract...
  • Page 73 July 2021 Service and Repair Manual Manifolds Part No. 1312350GT ® -45/25 • Z ® -45/25J...

  • Page 74: Valve Adjustments - Function Manifold

    Service and Repair Manual July 2021 Manifolds 8-2 Valve Adjustments - Function How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Manifold Boom Down Relief Valve Note: Perform this procedure with the boom in the How to Adju st th e Syste m Relie f Valve How to Adjust the System Relief stowed position.

  • Page 75: Jib Boom / Platform Rotate Manifold Components

    July 2021 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid valve, 2 position 3 way Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm Part No.

  • Page 76: Turntable Rotation Manifold Components

    Service and Repair Manual July 2021 Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No. Description Schematic Item Function Counterbalance valve Turntable rotate right Counterbalance valve Turntable rotate left ®...

  • Page 77: Directional Valve Manifold Components

    July 2021 Service and Repair Manual Manifolds Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index No. Description Schematic Item Function Torque Breather 20-25 ft-lbs / 27-33 Spool valve Directional control Part No.

  • Page 78: How To Set Up The Directional Valve Linkage

    Service and Repair Manual July 2021 Manifolds How to Set Up th e Dir ection al Valve Linka ge How to Set Up the Directional Adjust the ball joint until the hole lines up with the retaining fastener hole in the bracket. Valve Linkage 10 Install the ball joint to the axle and tighten the Note: Adjustment of the oscillate directional valve...

  • Page 79: Traction Manifold Components, 2Wd

    July 2021 Service and Repair Manual Manifolds Traction Manifold Components, 2WD The traction manifold is mounted inside the drive chassis at the non-steer end of the machine. Index Schematic Description Function Torque Item Flow divider/combiner valve Controls flow to drive motors in forward and 25-30 ft-lbs / 34-41 reverse Orifice, 0.067 in / 1.70 mm...
  • Page 80 Service and Repair Manual July 2021 Manifolds ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 81: Valve Adjustments, 2Wd Traction Manifold

    July 2021 Service and Repair Manual Manifolds Valve Adjustments, 2WD Traction Manifold How to Adjust the Charge Pressure Relief Valve Note: Refer to 2WD Traction Manifold Component list to locate the charge pressure relief valve. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to the test port on the drive pump.

  • Page 82: Traction Manifold Components, 4Wd

    Service and Repair Manual July 2021 Manifolds Traction Manifold Components, 4WD The traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Flow divider/combiner valve Controls flow to flow divider/combiner 25-30 ft-lbs / 34-41 valves 2 and 4 Flow divider/combiner valve Controls flow to non-steer end drive motors...
  • Page 83 July 2021 Service and Repair Manual Manifolds Part No. 1312350GT ® -45/25 • Z ® -45/25J...

  • Page 84: Valve Adjustments, 4Wd Traction Manifold

    Service and Repair Manual July 2021 Manifolds Valve Adjustments, 4WD Traction Manifold How to Adjust the Charge Pressure Relief Valve Note: Refer to 4WD Traction Manifold Component list to locate the charge pressure relief valve. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to the test port on the drive pump.

  • Page 85: 8-10 Hydraulic Generator Manifold Components, 2.2Kw

    July 2021 Service and Repair Manual Manifolds 8-10 Hydraulic Generator Manifold Components, 2.2kW The generator manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Proportional solenoid valve Generator speed 33-37 ft-lbs / 45-50 Relief valve, 3000 psi / 207 bar Generator circuit 20-25 ft-lbs / 27-34...

  • Page 86: Valve Coils

    Service and Repair Manual July 2021 Manifolds 8-11 How to Test a Coil Dio de How to Test a Coil Diode Valve Coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function How to Test a Coil circuit following the interruption of electrical current to a coil.
  • Page 87 July 2021 Service and Repair Manual Manifolds 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note: Dotted lines in illustration indicate a reversed connection as specified in step 6. Set a multimeter to read DC current. Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA.

  • Page 88: Turntable Rotation Components

    Service and Repair Manual July 2021 Turntable Rotation Components Remove the safety pin from the engine pivot plate latch. Turntable Rotation Assembly Note: The engine pivot plate latch is located under the engine turntable pivot plate at the How to Remove the Turntable counterweight end of the machine.

  • Page 89: Axle Components

    July 2021 Service and Repair Manual Axle Components How to I nstall t he Hu b a nd Bea rings 10-1 How to Install the Hub and Hub and Bearings, 2WD Models Bearings, 2WD Models How to Re mov e th e Hub and Beari ngs Note: When replacing a wheel bearing, both the inner and outer bearings including the pressed-in How to Remove the Hub and...

  • Page 90: Oscillating Axle Cylinders

    Service and Repair Manual July 2021 Axle Components Remove the pin retaining fasteners from the 10-2 barrel-end pivot pin. Use a soft metal drift to Oscillating Axle Cylinders remove the pin. The oscillating axle cylinders extend and retract Crushing hazard. The oscillate cylinder may become between the drive chassis and the oscillating axle.

  • Page 91: Fault Codes

    July 2021 Service and Repair Manual Fault Codes Before Troubleshooting: Secti on 4 Fault C odes Read, understand and obey the safety rules  and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test ...

  • Page 92: Control System Fault Codes

    Service and Repair Manual July 2021 Control System Fault Codes Control System How to Re triev e Con trol Syst em Fa ult Cod es Determine the error source: The red LED indicates the error source and will flash two separate codes.

  • Page 93: Control System Fault Codes

    July 2021 Service and Repair Manual Control System Fault Codes Contr ol System Fa ult Co des Error Source Error Type Condition Solution Name Name Primary Up / Value at 5.0 V Limited Speed and Direction frozen at Power up controller with Down Joystick zero and neutral, Alarm sounds.
  • Page 94 Service and Repair Manual July 2021 Control System Fault Codes Error Source Error Type Condition Solution Name Name Secondary Up / Fault Limited Speed and Direction frozen at Power up controller with Down. Directional zero and neutral, Alarm sounds. problem corrected. Valves Secondary Up / Value too high...
  • Page 95 July 2021 Service and Repair Manual Control System Fault Codes Error Source Error Type Condition Solution Name Name Drive Joystick Value at 5.0 V Limited Speed and Direction frozen at Power up controller with zero and neutral, Alarm sounds. problem corrected. Value too high Value too low Value at 0 V...

  • Page 96: Fault Code Display - Deutz Models

    Service and Repair Manual July 2021 Fault Code Display - Deutz Models How to Retrieve Active Engine How to Re triev e Active En gine Fa ult Cod es De utz D 2.9 L4 M odels With an active fault and the engine running: (preferred method) Fault Codes - Deutz D 2.9 L4 At the ground controls, activate the auxiliary...

  • Page 97: Fault Code Display - Flashing And Solid Led's - Deutz D 2.9 L4 Models

    July 2021 Service and Repair Manual Fault Code Display - Deutz Models Fault C ode Display - Fl ashin g an d Solid LED's - De utz D 2.9 L 4 M odels Flashing and Solid LED's - Deutz D 2.9 L4 Models 1 Left green LED: Flashing, engine fault detected.

  • Page 98: Soft Key Functions And Icons - Deutz D 2.9 L4 Models

    Service and Repair Manual July 2021 Fault Code Display - Deutz Models Soft Key Functions and Icons - Deutz D 2.9 L4 Models Next menu • Exit / Back one screen • Decrease brightness (-) Brightness / Contrast • Scroll up • Increase • Increase brightness (+) Scroll down •...

  • Page 99: Main Menu Structure - Deutz D 2.9 L4 Models

    July 2021 Service and Repair Manual Fault Code Display - Deutz Models Main Menu Structure - Deutz D 2.9 L4 Models Part No. 1312350GT ® -45/25 • Z ® -45/25J...

  • Page 100: Deutz D 2.9 L4 Engine Fault Codes

    Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1231 Actuator error EGR-Valve; KWP = Keyword Protocol Power stage over temp due to high current SPN FMI Description...
  • Page 101 July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
  • Page 102 Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
  • Page 103 July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
  • Page 104 Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature KWP = Keyword Protocol exhaust gas mass flow; plausibility error SPN FMI Description...
  • Page 105 July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of CAN-Receive- KWP = Keyword Protocol Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of CAN-Receive-...
  • Page 106 Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
  • Page 107 July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI SPN Description FMI = Failure Mode Identifier 523788 Timeout Error of CAN-Transmit- KWP = Keyword Protocol Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of CAN-Receive- Frame UAA10;...
  • Page 108 Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value exceeded FMI KWP Description 523947...
  • Page 109 July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
  • Page 110 Service and Repair Manual July 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of CAN-Transmit- KWP = Keyword Protocol Frame A1DOC KWP Description 524115 9 1660 Timeout error of CAN-Transmit- Frame AT1S...

  • Page 111: Schematics

    July 2021 Service and Repair Manual Schematics About This Section Secti on 5 Schematic s There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 112: Electrical Symbol Legend

    Service and Repair Manual July 2021 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...

  • Page 113: Hydraulic Symbols Legend

    July 2021 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...

  • Page 114: Electrical Component And Wire Color Legends

    Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Gauge Description Volt meter (option) Battery Engine oil pressure Engine Start - 12V DC Water temperature sender (option) Connector Gauge display Control cables connector Fuse Control cables connector Fuse, 20A, horn/hydraulic oil cooler Engine control connector Fuse, 30A, ECU power...
  • Page 115 July 2021 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Horn or Alarm Motor Tilt/load sense alarm Cooling Fan (option) Descent (ground) Auxiliary pump Load sense (ground) Engine starter Joystick Button Boom proportional joystick: secondary Red emergency stop button boom up/down Emergency stop button...
  • Page 116 Service and Repair Manual July 2021 Electrical Component and Wire Color Legends Item Description Item Description Toggle Switch Module Auxiliary pump switch Ignition start module Start engine switch EDC - drive pump Fuel select switch (ford efi only) Alc 500 joystick controller card Hi/low rpm switch Load sense module Glow plug switch...
  • Page 117 July 2021 Service and Repair Manual Electrical Component and Wire Color Legends Wire Color Legend Item Description Blue Black Brown Green Orange Purple White Yellow BL/RD Blue/Red BL/WH Blue/White BK/RD Black/Red OR/WH Orange/White RD/BK Red/Black RD/WH Red/White WH/BL White/Blue WH/BK White/Black WH/RD White/Red...

  • Page 118: Engine Relay Layout - Deutz D 2.9 L4

    Service and Repair Manual July 2021 Engine Relay Layout - Deutz D 2.9 L4 Deutz D 2.9 L4 Fuses Horn, Hydraulic Oil Cooler ECU Power Ignition Engine accessory Fuel Pump Diode Alternator Ext. Relays CR2B Ignition on CR5B Horn Fuel pump CR17B Hydraulic oil cooler (option) CR23B...

  • Page 119: Electrical Schematics - Options

    July 2021 Service and Repair Manual Electrical Schematic, Options...

  • Page 120: Electrical Schematic, Options [Alc500-2]

    Service and Repair Manual July 2021 Electrical Schematic, Options P25FS RD RD (FS) C9P-3 C9P-1 BK BK (FS) WH (FS) P24FS WH C9P-2 P22BATBK R26FS WH TO ALC500 - X103-3 AND TS15 P26FS WH TS47 LIFT/DRIVE OPTION TS43 C90PXS RD/BK TS46 U13, X103 #1 CR78...

  • Page 121: Wiring Diagram - Battery, Hydraulic Oil And Engine Oil Heater Options

    July 2021 Service and Repair Manual Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 122 Service and Repair Manual July 2021 Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options...
  • Page 123 July 2021 Service and Repair Manual Wiring Diagram, 2.2kW Hydraulic Generator...

  • Page 124: Wiring Diagram, 2.2Kw Hydraulic Generator

    Service and Repair Manual July 2021 Wiring Diagram, 2.2kW Hydraulic Generator ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 125: Electrical Schematics - Ce Models

    July 2021 Service and Repair Manual Electrical Schematic, Kubota D1105...

  • Page 126: Electrical Schematic, Kubota D1105 Models

    Service and Repair Manual July 2021 Electrical Schematic, Kubota D1105 Models CR76 ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 127: Functions, Electrical Schematic

    July 2021 Service and Repair Manual Functions, Electrical Schematic TB22 Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 128 Service and Repair Manual July 2021 Functions, Electrical Schematic...
  • Page 129 July 2021 Service and Repair Manual Electrical Schematic, Deutz D2.9...

  • Page 130: Electrical Schematic, Deutz D2.9 Models

    Service and Repair Manual July 2021 Electrical Schematic, Deutz D2.9 Models CR76 ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 131: Deutz D2.9 L4 Engine Wire Harness

    July 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Wire Harness Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 132 Service and Repair Manual July 2021 Deutz D2.9 L4 Engine Wire Harness...
  • Page 133 July 2021 Service and Repair Manual Electrical Schematic, Deutz 2011 L03i...

  • Page 134: Electrical Schematic, Deutz 2011 L03I Models

    Service and Repair Manual July 2021 Electrical Schematic, Deutz 2011 L03i Models CE D2011 CR76 ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 135: Electrical Schematic, Deutz D436 Cn3 Models 1

    July 2021 Service and Repair Manual Electrical Schematic, Deutz D436 Models - 1 CR76 Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 136 Service and Repair Manual July 2021 Electrical Schematic, Deutz D436 - 1...
  • Page 137 July 2021 Service and Repair Manual Electrical Schematic, Deutz D436 - 2...

  • Page 138: Electrical Schematic, Deutz D436 - 2

    Service and Repair Manual July 2021 Electrical Schematic, Deutz D436 - 2 Electrical Schematic, Deutz D436 Models - 2 ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 139: Hydraulic Schematics - All Models

    July 2021 Service and Repair Manual Hydraulic Schematic, 2WD Models...

  • Page 140: Hydraulic Schematic, 2Wd Models

    Service and Repair Manual July 2021 Hydraulic Schematic, 2WD Models ® -45/25 • Z ® -45/25J Part No. 1312350GT...

  • Page 141: Hydraulic Schematic, 4Wd Models

    July 2021 Service and Repair Manual Hydraulic Schematic, 4WD Models Part No. 1312350GT ® -45/25 • Z ® -45/25J...
  • Page 142 Service and Repair Manual July 2021 Hydraulic Schematic, 4WD Models Z®-4 5/25 • Z®- 45/2 5J Part No. 131 235 0GT Service a nd Re pair Ma nual July 20 21...

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Genie z-45/25

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