Terex Genie S-40 XC Service And Repair Manual
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Terex Genie S-40 XC Service And Repair Manual

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Service and Repair Manual
S
-40 XC
®
S
-40 HF
®
S
-40 TraX
®
S
-45 XC
®
S
-45 HF
®
S
-45 TraX
®
Serial Number Range
™
™
™
™
from S40XCH-101
to S40XCH-3290
from S45XCH-104
to S45XCH-3291
from S45XCD-167
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1286829GT
Rev C
February 2023

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  • Page 1 Service and Repair Manual Serial Number Range -40 XC ® ™ from S40XCH-101 This manual includes: to S40XCH-3290 Repair procedures -40 HF ® Fault Codes Electrical and -40 TraX ® ™ Hydraulic Schematics -45 XC ® ™ from S45XCH-104 to S45XCH-3291 -45 HF ®...

  • Page 2: Introduction

    Copyright © 2019 by Terex Corporation 1286829GT Rev C, February 2023 First Edition, Third Printing Genie and "S" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. "XC" and "TraX" are trademarks of Terex South Dakota, Inc.
  • Page 3 February 2023 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 2/2019 Initial Release 7/2019 Repair Display Menu 10/2019 Add S-40/45 HF Specifications Machine Specifications Repair 2-3, 7-6 Fault Codes Ford MSG-425 Schematics Limit Switch Legend 2/2023 All Sections Add Deutz TD 2.2 L3, D 2.9 L4 CN4 Engines...

  • Page 4: Serial Number Legend

    Service and Repair Manual February 2023 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label (located under cover) 5 Serial number (stamped on chassis) -40/45 XC • S -40/45 HF • S -40/45 TraX Part No.

  • Page 5: Safety Rules

    February 2023 Service and Repair Manual Safety Rules Section 1 Safety R ules 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 February 2023 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    February 2023 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 February 2023 Table of Contents Section 3 Repair Procedures ..................... 18 Introduction ......................18 Control System....................20 1-1 ALC-600 Platform Control Module ..............20 1-2 ALC-600 Service Mode .................. 20 1-3 Full Machine Calibration ................21 1-4 Machine Functions ..................22 How to Adjust the Machine Maximum Speed Setting........
  • Page 9 February 2023 Table of Contents Primary Boom Components ................46 4-1 Cable Track ....................46 How to Remove the Cable Track ..............46 How to Repair the Cable Track ............... 47 4-2 Boom ......................47 4-3 Boom Lift Cylinder ..................50 4-4 Boom Extension Cylinder ................
  • Page 10 February 2023 Table of Contents Turntable Rotation Components ..............76 8-1 Turntable Rotation Assembly ................. 76 How to Adjust the Turntable Rotation Gear Backlash ........77 How to Calibrate the Turntable Tilt Sensor ............. 78 Axle Components....................80 9-1 Oscillating Axle Cylinders ................80 Track Components ....................
  • Page 11 February 2023 Table of Contents Section 4 Fault Codes ......................83 Introduction ......................83 Control System Fault Codes ................84 How to Retrieve Control System Fault Codes ..........84 Control System Fault Codes ................85 Engine Fault Codes ..................101 Deutz D 2.9 L4 Tier IV Engine Fault Codes ............
  • Page 12 February 2023 Table of Contents Section 5 Schematics ....................... 130 Introduction ......................130 Electrical Symbol Legend .................. 131 Hydraulic Symbols Legend ................132 Limit Switch Location Legend ................133 Engine Relay Layout - All engines except Perkins 404F ........134 Engine Relay Layout - Perkins 404F-22T ............

  • Page 13: Specifications

    February 2023 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Track Components, TraX option Track material Rubber Tires and wheels Weight 480 lbs Tire size, rough terrain 315/55D20 (each) 218 kg (foam filled) 12 ply Fluid capacities 20 in x 11 in wheel 50.8 cm x 27.9 cm LPG tank...

  • Page 14: Performance Specifications

    Service and Repair Manual February 2023 Specifications Performance Specifications Hydraulic Oil Specifications Drive speeds, Hydraulic Fluid Specifications 2WD and 4WD Genie specifications require hydraulic oils which are 40 ft / 6.8 - 7.4 sec Stowed designed to give maximum protection to hydraulic 12.2 m / 6.8 - 7.4 sec systems, have the ability to perform over a wide temperature range, and the viscosity index should...
  • Page 15 February 2023 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index, maximum fluids are mixed, insoluble materials may form and deposit...
  • Page 16 Service and Repair Manual February 2023 Specifications Shell Tellus S4 VX Fluid Chevron 5606A Hydraulic Oil Properties Fluid Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.8...

  • Page 17: Hydraulic Component Specifications

    February 2023 Service and Repair Manual Specifications Hydraulic Component Function manifold Specifications Function relief valve 3200 psi / 220.6 bar pressure Drive Pump Boom extend 1950 psi Type: bi-directional variable displacement piston pump relief valve pressure 134 bar 0 - 28 gpm Steer regulator 2 gpm / 7.6 lpm Flow rate @ 2500 rpm...

  • Page 18: Manifold Component Specifications

    Service and Repair Manual February 2023 Specifications Manifold Component Specifications Plug torque SAE No. 4 13 ft-lbs / 18 Nm SAE No. 6 18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm SAE No.10 55 ft-lbs / 75 Nm SAE No.

  • Page 19: Ford Msg-425 Efi Engine Specifications

    February 2023 Service and Repair Manual Specifications Ford MSG-425 EFI Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 153 cu in Manual for your engine. 2,5 liters Ignition system Number of cylinders Spark plug type Motorcraft AYFS-32Y- Bore and Stroke 3.5 x 3.9 in 89 x 100 mm...

  • Page 20: Deutz D2011 L03I Engine Specifications

    Service and Repair Manual February 2023 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 21: Deutz D 2.9 L4 Tier Iv Engine Specifications

    February 2023 Service and Repair Manual Specifications Deutz D 2.9 L4 Tier IV Engine Oil pressure switch Oil pressure switch point 20 psi Displacement 177 cu in 1,4 bar 2,9 liters Engine coolant Number of cylinders Capacity 10 quarts Bore and stroke 3.6 x 4.3 inches 9,4 liters 92 x 110 mm...

  • Page 22: Deutz D 2.9 L4 Stage Iv Engine Specifications

    Service and Repair Manual February 2023 Specifications Deutz D 2.9 L4 Stage IV Engine Engine coolant Capacity 10.7 quarts Displacement 177 cu in 10,1 liters 2,9 liters Fuel injection system Number of cylinders Injection pump make Bosch Bore and Stroke 3.6 x 4.3 in Injection pump pressure, 15000 psi...

  • Page 23: Deutz Td 2.2 L3 Engine Specifications

    February 2023 Service and Repair Manual Specifications Deutz TD 2.2 L3 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2,2 liters Temperature switch point 257°F Number of cylinders 125°C Bore and Stroke 3.6 x 4.3 inches Oil Pressure switch 92 x 110 mm...

  • Page 24: Perkins 404F-E22T Engine Specifications

    Service and Repair Manual February 2023 Specifications Perkins 404F-E22T Engine Fuel injection system Injection pump make Zexel Displacement 134 cu in Injection pressure 2133 psi 2,2 liters 147 bar Number of cylinders Fuel requirement Bore and Stroke 3.31 x 3.94 in For fuel requirements, refer to the engine Operator 84 x 100 mm Manual for your engine.

  • Page 25: Machine Torque Specifications

    February 2023 Service and Repair Manual Specifications Machine Torque Specifications TraX™ Torque Specifications Platform rotator Hub adapter to drive hub fasteners 1-8 center bolt, GR 5 Lug nut torque, lubricated 180 ft-lbs 244 Nm 615 ft-lbs 834 Nm Idler and bogey wheel fasteners 3/8 -16 bolts, GR 8 3/4-10 bolts, GR 8, lubricated 281 ft-lbs...

  • Page 26: Machine Component Weights

    Service and Repair Manual February 2023 Specifications Machine Component Weights 2000 lbs Primary boom assembly, S-40 XC/HF 907 kg Primary boom assembly, S-45 XC/HF 2370 lbs 1075 kg Turntable assembly 3050 lbs 1385 kg (does not include boom, jib or engine) 1750 lbs Counterweight, S-40 XC/HF 795 kg...

  • Page 27: Hydraulic Hose And Fitting Torque Specifications

    February 2023 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 28: Torque Procedure

    Service and Repair Manual February 2023 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 29 February 2023 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 30: Repair Procedures

    Service and Repair Manual February 2023 Repair Procedures Machine Configuration: Section 3 Repair Pr oc edures Unless otherwise specified, perform each  repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed Repair procedures shall be completed by a...
  • Page 31 February 2023 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 32: Control System

    Service and Repair Manual February 2023 Control System How to Enter ALC-600 Service ALC-600 Control Module Mode Platform Controls The platform control box contains the ALC- 600 platform Control Module. The platform Control Module receives all signals from the platform switches, joysticks and foot switch, and provides operator feedback through an Indicator Module.

  • Page 33: Service Mode

    February 2023 Service and Repair Manual Control System The Control System on this machine allows access to calibrations through the Service Mode. Full Machine Calibration The procedures that follow will require the operator to be in Service Mode. Service Mode can only be Full machine calibration must be completed in the entered at machine start up and requires a special proper sequence when the ALC-600 controller...

  • Page 34: Machine Functions

    Service and Repair Manual February 2023 Control System 10 Record the time it takes for that function to complete a full cycle (ie; boom up). Machine Functions 11 Compare the machine function time with the How to Adjust the Joystick How to Adj ust the Mac hine M axim um Speed Setti ng function times listed in Refer to Specifications, Performance Specifications.

  • Page 35: How To Adjust The Joystick Ramp Rate Setting

    February 2023 Service and Repair Manual Control System How to Adjust the Joystick Ramp How to Adj ust the Joystick Ram p R ate Setting Start the engine from the ground controls. Rate Setting Start a timer and activate the machine function that needs to be adjusted.

  • Page 36: How To Adjust The Joystick Threshold Setting

    Service and Repair Manual February 2023 Control System How to Adjust the Joystick How to Adj ust the Joystick Thr es hol d Setting Threshold Setting How to Enter ALC600 Software Update Mode The threshold setting of a joystick is the minimum output at which a function proportional valve can Go to the Genie website open and allow the function to operate.

  • Page 37: Display Module Menus

    February 2023 Service and Repair Manual Control System Display Module Menus Screen or Menu Item Selection Default Display Settings Backlight 0 - 100% Contrast 0 - 100% Display Inversion Off • On Screen or Menu Item Selection Default Model Configuration Model S-40 •...
  • Page 38 Service and Repair Manual February 2023 Control System Screen or Menu Item Selection Sensor Calibration Chassis Tilt Select OK to calibrate Load Sense Select OK to calibrate Boom Angle Select OK to calibrate Boom Length Select OK to calibrate Platform Angle Select OK to calibrate Screen or Menu Item...
  • Page 39 February 2023 Service and Repair Manual Control System Screen or Menu Item Default Deutz TD 2.9L T4 Threshold 2375 rpm Anti-Stall Drive Minimum XC / HF models Range 125 rpm Hysteresis 100 rpm Screen or Menu Item Default Deutz TD 2.9L T4 Threshold 2060 rpm Anti-Stall...
  • Page 40 Service and Repair Manual February 2023 Control System Screen or Menu Item Default Perkins 404F E22T Threshold 2300 rpm Anti-Stall Drive Minimum Trax models Range 275 rpm Hysteresis 100 rpm Screen or Menu Item Default Ford MSG425 Threshold 2350 rpm Anti-Stall Drive Minimum Range...
  • Page 41 February 2023 Service and Repair Manual Control System Screen or Menu Item Selection / Default Turntable Ramps CW Accelerating 1 - 10 sec / 3 sec CW Decelerating 0.5 - 2 sec / 2 sec CCW Accelerating 1 - 10 sec / 3 sec CCW Decelerating 0.5 - 2 sec / 2 sec Screen or Menu...
  • Page 42 Service and Repair Manual February 2023 Control System Maintenance Menu Item Selection / Units DISCON - Version OK to show DISCON Software version CAN Data Recording OK + Up/Down to set On/Off On: Starts recording Machine CAN bus Data Off: Converts and writes log data to USB storage if device is plugged in, or data is lost Real Time Data Tilt Pitch Op.

  • Page 43: How To Replace The Display Controller (Discon) Module

    February 2023 Service and Repair Manual Control System Open the ground box lid (1) and disconnect the wire harness going to the display How to Replace the Display controller (DISCON). Controller (DISCON) Module Remove the DISCON door from the back by loosening the four Torx head screws (8) and Push in the red Emergency Stop button to the remove the two ribbon cables (6) connecting...

  • Page 44: How To Replace The Ground Control Overlay

    Service and Repair Manual February 2023 Control System Install the new DISCON onto the ground box lid and fasten it using the new hex nuts and How to Replace the Ground Box washers. All five fastening points must be Control Overlay used.
  • Page 45 February 2023 Service and Repair Manual Control System Unscrew the nut holding the buttons and key Remove the ground box lid (1) from the switch and remove the key switch and ground box. buttons. Remove the old overlay and clean the ground Note the orientation of the key switch so it can be box lid surface from any dirt, oils or old reassembled in the same position.
  • Page 46 Service and Repair Manual February 2023 Control System 15 Reinstall the E-Stop button, function enable button and key switch and the contact assemblies. 16 Reinstall the wire harness from the ground box to the DISCON. Secure the harness to the ground box lid using zip ties. 17 Close and fasten the ground box lid.

  • Page 47: Platform Components

    February 2023 Service and Repair Manual Platform Components Tag, disconnect and cap the hydraulic hoses from the slave cylinder. Plug the union hoses Platform Leveling Cylinder from the master cylinder together using a connector. The slave cylinder and the rotator pivot are the two primary supports for the platform.

  • Page 48: Platform Rotator

    Service and Repair Manual February 2023 Platform Components How to Bleed the Slave Cylinder Platform Rotator Simultaneously activate the primary boom up The platform rotator is a hydraulically activated function and the platform level up function helical gear assembly used to rotate the platform until the boom is fully raised.
  • Page 49 February 2023 Service and Repair Manual Platform Components S-40 XC: Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Support the rod end of the platform level fittings on the manifold. cylinder. Bodily injury hazard. Spraying Remove the pivot pin retaining fasteners from hydraulic oil can penetrate and both the slave cylinder rod-end pivot pin and...
  • Page 50 Service and Repair Manual February 2023 Platform Components How to Bleed the Platform S-45 XC: Rotator 10 Remove the pin retaining fasteners from the jib boom and jib boom leveling arms to Note: This procedure will require two people. Do platform rotator pivot pins.

  • Page 51: Platform Overload System

    February 2023 Service and Repair Manual Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System Bodily injury hazard. Spraying Proper calibration of the platform overload system hydraulic oil can penetrate and is essential to safe machine operation.

  • Page 52: How To Perform A Full Load Platform Calibration

    Service and Repair Manual February 2023 Platform Components How to Perform a Full Load How to Per form a F ull Load Pl atform C alibration Platform Calibration Perform this procedure if the platform support or load cell sensor has been replaced, or if a zero load platform calibration does not return the machine to full load capacity.
  • Page 53 February 2023 Service and Repair Manual Platform Components Enter Service Mode. Refer to Repair 10 Place a test weight on the platform floor using a suitable lifting device. Place the weight near Procedure, How to Enter the Service Mode. the center entry point of the platform, as far Press the settings button above the display away from the operator controls as possible.

  • Page 54: How To Replace The Platform Overload Load Cell

    Service and Repair Manual February 2023 Platform Components How to Replace the Load Cell How to R eplac e the Platform Ov erload Load C ell 11 Follow the prompts to accept the weight. Sensor 12 Calibration is now complete. Note: The preload adjustment should only be 13 Exit Service Mode.

  • Page 55: Platform

    February 2023 Service and Repair Manual Platform Components Install the new Load Cell Sensor Platform Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out of the bottom of the sensor.The foot should How to Remove the Platform not contact the flex plate when assembling onto the platform support.

  • Page 56: Jib Boom Components

    Service and Repair Manual February 2023 Jib Boom Components Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. Jib Boom Remove the hose and cable cover from the side of the jib boom. Remove the hose and How to Remove the Jib Boom cable separators.

  • Page 57: Jib Boom Lift Cylinder

    February 2023 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin out enough to lower Jib Boom Lift Cylinder one of the leveling arms to the ground. Tap the pin the other direction and lower the How to Remove the Jib Boom Lift opposite leveling arm.

  • Page 58: Primary Boom Components

    Service and Repair Manual February 2023 Primary Boom Components Tag, disconnect and plug ports V1 and V2 on the platform rotate/jib manifold. Cap the Cable Track fittings. The primary boom cable track guides the cables Bodily injury hazard. Spraying and hoses running up the boom. It can be repaired hydraulic oil can penetrate and link by link without removing the cables and hoses burn skin.

  • Page 59: How To Repair The Cable Track

    February 2023 Service and Repair Manual Primary Boom Components How to Repair the Cable Track How to R epair the C abl e Tr ack Primary Boom Component damage hazard. The boom cable track can be damaged if it is twisted. How to Remove the Primary Boom Note: A cable track repair kit is available through...
  • Page 60 Service and Repair Manual February 2023 Primary Boom Components Remove the retaining fasteners from the 13 Remove the primary boom pivot pin with a master cylinder rod-end pivot pin. Use a soft soft metal drift, then carefully remove the metal drift to remove the pin. Lower the primary boom from the machine and place it master cylinder against the primary lift on a structure capable of supporting it.
  • Page 61 February 2023 Service and Repair Manual Primary Boom Components How to Disassemble the Primary Remove and label the wear pads from the top Boom side of the secondary boom tube at the platform end of the boom. Complete disassembly of the boom is only Remove the trunnion pin retaining fasteners necessary if the outer or inner boom tube must be at the base end of the secondary boom tube.

  • Page 62: Boom Lift Cylinder

    Service and Repair Manual February 2023 Primary Boom Components Remove the retaining fasteners from the primary boom lift cylinder rod-end pivot pin. Primary Boom Lift Cylinder Use a soft metal drift to remove the pin. Lower the lift cylinder onto the blocks. Protect the The primary boom lift cylinder raises and lowers cylinder rod from damage.

  • Page 63: Boom Extension Cylinder

    February 2023 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Primary Boom Extension fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.

  • Page 64: Platform Leveling Master Cylinder

    Service and Repair Manual February 2023 Primary Boom Components Remove the retaining fasteners from the master cylinder barrel-end pivot pin. Platform Leveling Master Cylinder Use a soft metal drift to remove the pin. Remove the retaining fastener from the rod- The master cylinder acts as a pump for the slave end pivot pin.

  • Page 65: Primary Boom Angle Sensor Calibration

    February 2023 Service and Repair Manual Primary Boom Components Press OK on the display to continue with the procedure to capture the maximum angle Primary Boom Angle Sensor point. The primary boom angle sensor is used to limit the Operate the boom up function until the boom angle of the primary boom relative to the angle of reaches its maximum angle.

  • Page 66: Boom Length Sensor

    Service and Repair Manual February 2023 Primary Boom Components Boom Length Sensor How to Calibrate the Primary Boom Length Sensor Note: The turntable level sensor, platform load sensor and primary boom angle sensor must be calibrated before calibrating the boom length sensor.

  • Page 67: Engines

    February 2023 Service and Repair Manual Engines Flex Plate RPM Adjustment - Deutz Models The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine Refer to Maintenance Procedure in the appropriate flywheel and has a splined center to drive the Service or Maintenance Manual for your machine, pump.
  • Page 68 Service and Repair Manual February 2023 Engines How to Install the Flex Plate Support the engine with an overhead crane or other suitable lifting device. Do not lift it. Install the flex plate onto the engine flywheel Remove the engine mounting plate to bell with the rubber vibration isolators towards the housing fasteners.
  • Page 69 February 2023 Service and Repair Manual Engines Ford Models Deutz Models Perkins Models Part No. 1286829GT -40/45 XC • S -40/45 HF • S -40/45 TraX ® ™ ® ® ™...

  • Page 70: How To Install The Pump And Bell Housing Assembly

    Service and Repair Manual February 2023 Engines How to i nstall the Pum p and Bell H ousing Ass embly 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 71: Diesel Particle Filter Regeneration - Deutz Td 2.2 L3

    February 2023 Service and Repair Manual Engines Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 Engine The combustion of diesel fuel results in soot, which is separated in the diesel particle filter (DPF). This must be regenerated as the contamination with soot increases.

  • Page 72: Hydraulic Pump

    Service and Repair Manual February 2023 Hydraulic Pump Tag, disconnect and plug the function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...

  • Page 73: Drive Pump

    February 2023 Service and Repair Manual Hydraulic Pump Locate the two hydraulic tank valves at the hydraulic tank. Close the valves. Drive Pump Component damage hazard. The drive pump is a bi-directional variable The engine must not be started displacement piston pump. The pump output is with the hydraulic tank shut-off controlled by the electro-proportional controller, valves in the closed position or...
  • Page 74 Service and Repair Manual February 2023 Hydraulic Pump How to Prime the Drive 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 75: Manifolds

    February 2023 Service and Repair Manual Manifolds Function Manifold Components The function manifold is located underneath the ground controls side turntable cover. Index Schematic Description Function Torque Item Solenoid Valve, 2 position 3 way Release brake when on 26-30 ft-lbs / 35-40 Nm Pressure reducing valve Oscillate circuit pressure 33-37 ft-lbs / 45-50 Nm...
  • Page 76 Service and Repair Manual February 2023 Manifolds -40/45 XC • S -40/45 HF • S -40/45 TraX Part No. 1286829GT ® ™ ® ® ™...
  • Page 77 February 2023 Service and Repair Manual Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Relief valve 1950 psi / 134 bar Limit boom extend pressure 20-25 ft-lbs / 27-34 Nm Flow control valve Compensate for pressure 33-37 ft-lbs / 45-50 Nm variation Differential sensing valve Compensate for pressure...
  • Page 78 Service and Repair Manual February 2023 Manifolds -40/45 XC • S -40/45 HF • S -40/45 TraX Part No. 1286829GT ® ™ ® ® ™...

  • Page 79: Valve Adjustments - Function Manifold

    February 2023 Service and Repair Manual Manifolds 7-2 Valve Adjustments - Function How to Adjust the Boom Extend How to Adj ust the Boom Ex tend R elief Valve Manifold Relief Valve Note: Perform this procedure with the machine in How to Adjust the System Relief the stowed position.

  • Page 80: Jib Boom And Platform Rotate Manifold Components

    Service and Repair Manual February 2023 Manifolds Jib Boom / Platform Rotate and Generator Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid Valve, 2 position Platform rotate/jib boom select 18-20 ft-lbs / 25-27 Nm 3 way Counterbalance valve...

  • Page 81: Traction Manifold Components, 4Wd

    February 2023 Service and Repair Manual Manifolds Traction Manifold Components, 4WD 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 Divides flow between diagonal pairs of 80-90 ft-lbs / 108-122 motors: LF+RR=50%, LR+RF=50% Check valve, 5 psi /...
  • Page 82 Service and Repair Manual February 2023 Manifolds -40/45 XC • S -40/45 HF • S -40/45 TraX Part No. 1286829GT ® ™ ® ® ™...

  • Page 83: Valve Adjustments, Traction Manifold

    February 2023 Service and Repair Manual Manifolds Valve Adjustments - Traction Valve Adjustments - Oscillate Manifold Relief Valve How to Adjust the Charge How to Adjust the Oscillate Relief Pressure Relief Valve Valve Connect a 0 to 600 psi / 0 to 50 bar pressure Connect a 0 to 1500 psi / 0 to 100 bar pressure gauge to the diagnostic nipple gauge to the test port on the drive pump.

  • Page 84: How To Set Up The Oscillate Directional Valve

    Service and Repair Manual February 2023 Manifolds How to Set Up the Directional How to Set U p the Oscillate Directional Valv e Measure the gap between the drive chassis and the non-steer axle on both sides (from the Valve Linkage inside of the drive chassis).

  • Page 85: Generator Manifold Components

    February 2023 Service and Repair Manual Manifolds Generator Manifold The generator manifold is mounted on the turntable tray by the fuel tank. Index Schematic Description Function Torque Item Relief valve Generator relief valve 50 ft-lbs / 67 Nm Solenoid Valve Charge pressure circuit 60-65 ft lbs / 81-88 Nm Needle valve...

  • Page 86: Valve Coils

    Service and Repair Manual February 2023 Manifolds Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...

  • Page 87: How To Test A Coil Diode

    February 2023 Service and Repair Manual Manifolds How to Test a Coil Diode How to T est a Coil Di ode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 88: Turntable Rotation Components

    Service and Repair Manual February 2023 Turntable Rotation Components Attach a suitable lifting device to the turntable rotator assembly. Turntable Rotation Assembly How to Remove the Turntable Rotation Drive Hub Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.

  • Page 89: How To Adjust The Turntable Rotation Gear Backlash

    February 2023 Service and Repair Manual Turntable Rotation Components When installing the drive hub assembly: How to Adjust the Turntable How to Adj ust the Tur ntabl e R otati on Gear Backlash Rotation Gear Backlash Install the turntable rotator assembly. Apply removable thread locking compound to The turntable rotation drive hub is mounted on an fastener threads.Torque the backlash pivot...

  • Page 90: How To Calibrate The Turntable Tilt Sensor

    Service and Repair Manual February 2023 Turntable Rotation Components How to Calibrate the Turntable How to C alibr ate the T urntable Tilt Sensor Push the backlash pivot plate towards the turntable as far as possible (this will push the Tilt Sensor rotation gear into the turntable bearing ring gear).
  • Page 91 February 2023 Service and Repair Manual Turntable Rotation Components A graphic of the machine pitch will now be 13 A graphic of the machine roll will now be shown on the display. By pressing the UP or shown on the display. By pressing the UP and DOWN buttons, the graphic will change to DOWN buttons, the graphic will change to show the counterweight being uphill or...

  • Page 92: Axle Components

    Service and Repair Manual February 2023 Axle Components Attach a lifting strap from an overhead lifting device to the barrel end of the oscillating Oscillating Axle Cylinders cylinder. The oscillating axle cylinders extend and retract Remove the pin retaining fasteners from the between the drive chassis and the oscillating axle.

  • Page 93: Track Components

    February 2023 Service and Repair Manual Track Components How to Replace the Track 10-1 Track Assembly Remove the track assembly from the machine. See How to Remove a Track Assembly. How to Remove a Track Note: The sprocket is comprised of two halves. Assembly Before removing the track assembly from the machine and to ease the removal of the sprocket,...
  • Page 94 Service and Repair Manual February 2023 Track Components Install the new track onto the undercarriage. 12 Insert a pin or rod through the wheel stud hole closest to the split tooth to hold the sprocket Attach a lifting strap from an overhead crane in place.

  • Page 95: Fault Codes

    February 2023 Service and Repair Manual Fault Codes Before Troubleshooting: Section 4 Faul t Codes 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 96: Control System Fault Codes

    Service and Repair Manual February 2023 Control System Fault Codes Control System How to R etrieve Contr ol Sy stem F ault Codes How to Retrieve Control System Fault Codes The machine control system contains two different types of fault codes Active Faults: These faults have been detected in the current operating session.

  • Page 97: Control System Fault Codes

    February 2023 Service and Repair Manual Control System Fault Codes Control System F ault C odes ID Component ID Name Cause Effect Solution Engine Can 13 Not Engine CANBUS CAN+ Disable engine start for * Verify with a voltmeter that CAN+ and detected or CAN- shorted to tier 4F engines.
  • Page 98 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 14 Alternator 15 Fault Fault occurs if voltage None. * Release foot switch and cycle power. is below 12.3 VDC for * Test / Replace alternator. 10 seconds while engine is running.
  • Page 99 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 22 Pri Boom Shorted TCON detected that Boom Up function will * With a voltmeter, measure Y22. Proper not operate. resistance should be between 5 - 60 ohms. Up coil to GND C1PBU circuit is...
  • Page 100 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 26 Pri Boom Shorted TCON detected that Boom Extend function * With a voltmeter, measure Y26. Proper will not operate. resistance should be between 5 - 60 ohms. Ext Coil to GND C7PBE circuit is...
  • Page 101 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 41 Turntable Shorted Circuit C165TTR is Turntable Rotate * Leave joystick in neutral position and to GND below 4.5 V or shorted functions will not cycle power.
  • Page 102 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 46 Platform Shorted PCON detected that Platform Rotate CW * With a voltmeter, measure Y70. Proper to GND V17PRL circuit is function will not operate. resistance should be between 5 - 60 ohms.
  • Page 103 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 52 Drive Shorted TCON detected that Drive forward and brake * With a voltmeter, measure Y6. Proper to GND C30FWD circuit is release will not operate. resistance should be between 5 - 60 ohms.
  • Page 104 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 62 Prox 27 Active at Toggle switch input Override will not * Verify with a voltmeter that the Jib startup was detected as HIGH operate.
  • Page 105 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 74 Engine 15 Sensor Engine temperature Engine will not operate. * With a voltmeter, check that C26TSR sensor is shorted to ( WH/RD, TCON J6P8) is not shorted to Temperature value too ground.
  • Page 106 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 78 Platform 13 Not TCON has not Controls from the * Verify PCON is receiving power. Check detected detected the PCON platform will not operate. for 12 V on J15-2 (+) and J15-1 (-).
  • Page 107 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 80 Turntable 13 Not The DISCON has not Machine limited to * Verify TCON is receiving power. Check recovery functions. for 12 V on J5-2 (+) and J5-1 (-). Controller detected detected the TCON on...
  • Page 108 Service and Repair Manual February 2023 Control System Fault Codes ID Component ID Name Cause Effect Solution 88 Function Shorted TCON detected that Only Auxiliary Power is * With a voltmeter, measure Y74. Proper Enable Coil to GND C155PCE circuit is available.
  • Page 109 February 2023 Service and Repair Manual Control System Fault Codes ID Component ID Name Cause Effect Solution 95 Engine 13 Not Control system has Engine start disabled. * Verify wiring at the alternator. detected detected no or too low * Check tach signal at alternator while RPM.
  • Page 110 Service and Repair Manual February 2023 Control System Fault Codes Component ID Name Cause Effect Solution 100 Platform Shorted PCON detected that Platform Level Up * With a voltmeter, measure Y20. Proper function will not resistance should be between 5 - Level Up Coil to GND V14PLU circuit is...
  • Page 111 February 2023 Service and Repair Manual Control System Fault Codes Component ID Name Cause Effect Solution 160 LF Steer Shorted TCON detected that Steer Left function will * With a voltmeter, measure Y3. Proper not operate. resistance should be between 5 - Coil to GND C37STL circuit is...
  • Page 112 Service and Repair Manual February 2023 Control System Fault Codes Component ID Name Cause Effect Solution 206 TCON / 13 TCON The bank power on the None. * Check J1, Bank Power, on TCON is PCON Bank TCON is no longer making a good connection.

  • Page 113: Engine Fault Codes

    February 2023 Service and Repair Manual Engine Fault Codes Engine Fault Codes Some engine options have their own Electronic Control Module that contains more detailed fault information that is specific to the engine. This system can be accessed by using the engine's dedicated service tool.

  • Page 114: Deutz D 2.9 L4 Tier Iv Engine Fault Codes

    Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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 115 February 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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...
  • Page 116 Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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...
  • Page 117 February 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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...
  • Page 118 Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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 119 February 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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...
  • Page 120 Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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 121 February 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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-...
  • Page 122 Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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);...
  • Page 123 February 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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 124 Service and Repair Manual February 2023 Deutz D 2.9 L4 Tier IV 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-...

  • Page 125: Deutz Td 2.2 L3, D/Td 2.9 L4 Stage Iv Engine Fault Codes

    February 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1077 411 Engine exhaust gas recirculation. SPN = Suspect Parameter Number Signal value above maximum limit.
  • Page 126 Service and Repair Manual February 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1134 3251 3 DPF voltage above normal or SPN = Suspect Parameter Number shorted to high.
  • Page 127 February 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1209 157 Engine fuel injector metering rail SPN = Suspect Parameter Number pressure voltage below normal or shorted to low.
  • Page 128 Service and Repair Manual February 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1308 677 Engine starter motor relay current SPN = Suspect Parameter Number below normal or shorted to low.
  • Page 129 February 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1392 51 Engine throttle valve 1, position SPN = Suspect Parameter Number 1 voltage below normal or shorted to low.
  • Page 130 Service and Repair Manual February 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 3349 Timeout Error of CAN receive SPN = Suspect Parameter Number frame TSC1TR;...
  • Page 131 February 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier Ambient air temperature sensor SPN = Suspect Parameter Number voltage above normal or shorted to high.
  • Page 132 Service and Repair Manual February 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 5363 5 Engine cylinder 6 fuel injection SPN = Suspect Parameter Number quantity current below normal or open circuit.
  • Page 133 February 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 4257 14 Engine fuel 1 injector, group SPN = Suspect Parameter Number 3 missing injector adjustment value programming injector 3.
  • Page 134 Service and Repair Manual February 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier Actual engine percent torque. SPN = Suspect Parameter Number DFC to report the fault in energizing time comparison.

  • Page 135: Perkins 404F-E22T Engine Fault Codes

    February 2023 Service and Repair Manual Perkins 404F-E22T Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Engine Speed Sensor #2: Voltage Above Normal Description Engine Speed Sensor #2: Voltage Accelerator Pedal Position 2: Voltage Below Normal Above Normal Engine Speed Sensor#2: Abnormal...
  • Page 136 Service and Repair Manual February 2023 Perkins 404F-E22T Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Below Normal Description 4201 Engine Speed Sensor #1: Abnormal 3251 Particulate Trap Differential Pressure: Frequency, Pulse \Nidth, or Period Voltage Above Normal 4201...

  • Page 137: Ford Msg-425 Engine Fault Codes

    February 2023 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description TIP Low Voltage Never crank synced at start TIP High Voltage FP low voltage Injector Loop Open or Low-side short to FP high voltage Ground MAP Low Voltage Injector Coil Shorted MAP High Pressure...
  • Page 138 Service and Repair Manual February 2023 Ford MSG-425 Engine Fault Codes Code Description Code Description Emissions/catalyst damaging misfire 5VE1 low voltage Emissions/catalyst damaging misfire 5VE1 high voltage Emissions/catalyst damaging misfire MIL open Emissions/catalyst damaging misfire 5VE2 low voltage Emissions/catalyst damaging misfire 5VE2 high voltage Emissions/catalyst damaging misfire Relay Coil Open...
  • Page 139 February 2023 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description 1173 Megajector comm lost 1551 AUX DIG1 high 1174 Megajector voltage supply high 1552 AUX DIG1 low 1175 Megajector voltage supply low 1553 AUX DIG2 high 1176 Megajector internal actuator fault detection 1554...
  • Page 140 Service and Repair Manual February 2023 Ford MSG-425 Engine Fault Codes Code Description Code Description 1629 J1939 TSC1 message receipt lost 2130 IVS stuck at-idle, FPP1/2 match 1630 J1939 ETC message receipt lost 2131 IVS stuck off-idle, FPP1/2 match 1631 PWM1-Gauge1 open / ground short 2135 TPS1/2 simultaneous voltages out of range...
  • Page 141 February 2023 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description 2309 Primary Loop Open or Low-side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low-side Short to Ground 2313 Primary Coil Shorted 2315 Primary Loop Open or Low-side Short to Ground 2316...

  • Page 142: Schematics

    Service and Repair Manual February 2023 Schematics About This Section Section 5 Schem atics 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 143: Electrical Symbol Legend

    February 2023 Service and Repair Manual 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 144: Hydraulic Symbols Legend

    Service and Repair Manual February 2023 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 145: Limit Switch Location Legend

    February 2023 Service and Repair Manual Limit Switch Location Legend 1 LSB1RS 2 String Potentiometer 3 LST3S 4 S17 5 S8O, S8S 6 LST1O 7 S24 Limit Switches and Sensors LSB1RS Limit switch boom fully retracted - safety String pot Measures boom extension LST3S Limit switch boom angle - safety...

  • Page 146: Engine Relay Layout - All Engines Except Perkins 404F

    Service and Repair Manual February 2023 Engine Relay Layout - All engines except Perkins 404F All engines Fuses Drive light Telematic option Engine control power System control logic power CB8A Glow plug 1 CB8B Glow plug 2 Engine run / options/ acc CB10 System control driver power Diode...

  • Page 147: Engine Relay Layout - Perkins 404F-22T

    February 2023 Service and Repair Manual Engine Relay Layout - Perkins 404F-22T Perkins 404F-22T only (second relay box) Fuses Hyd / Start Relay power Eng ECU power Spare Fuel / Alt exct Heater Circuit Breakers CB8C Glow plug 1 CB8D Glow plug 2 CB31A Eng ECU 1...

  • Page 148: Kw Generator Receptacle Wiring

    Service and Repair Manual February 2023 3 kW Generator Receptacle Wiring -40/45 XC • S -40/45 HF • S -40/45 TraX Part No. 1286829GT ® ™ ® ® ™...

  • Page 149: Kw Generator Receptacle Wiring

    February 2023 Service and Repair Manual 7 kW Generator Receptacle Wiring Part No. 1286829GT -40/45 XC • S -40/45 HF • S -40/45 TraX ® ™ ® ® ™...

  • Page 150: 12 Kw Generator Receptacle Wiring

    Service and Repair Manual February 2023 12 kW Generator Receptacle Wiring -40/45 XC • S -40/45 HF • S -40/45 TraX Part No. 1286829GT ® ™ ® ® ™...

  • Page 151: Connector Pin Legend

    February 2023 Service and Repair Manual Connector Pin Legend VEC - blue - 8 pin Number Description VEC - green - 8 pin Boom cable - Controls VEC- gray - 2 pin Boom cable - Power VEC - black - 2 pin Boom sensors Function enable Function manifold...
  • Page 152 Service and Repair Manual February 2023 Connector Pin Legend Number Description TCON power TCON engine TCON functions TCON functions TCON logic TCON limit switches TCON limit switches TCON unused TCON communication DISCON PCON power PCON functions PCON functions PCON logic PCON toggles PCON toggles PCON joysticks...

  • Page 153: Electrical Schematics

    February 2023 Service and Repair Manual Electrical Schematic, Turntable Controller Models without Recovery Module...

  • Page 154: Models Without Recovery Module

    Service and Repair Manual February 2023 Electrical Schematic, Turntable Controller Models without Recovery Module P20DRV RD C2-1 P20DRV RD DRV_GND BR C2-4 DRV_GND BR P20LOG RD/WH C2-2 P20LOG RD/WH LOG_GND BR C2-3 LOG_GND BR C1-6 C46HRN WH S8_O VCC 1 C1-1 P23PWR RD CHASSIS...

  • Page 155: Electrical Schematic, Turntable Controller, Models With Recovery Module

    February 2023 Service and Repair Manual Electrical Schematic, Turntable Controller Models with Recovery Module P20DRV RD C2-1 P20DRV RD DRV_GND BR DRV_GND BR C2-4 P20LOG RD/WH C2-2 P20LOG RD/WH LOG_GND BR C2-3 LOG_GND BR C1-6 C46HRN WH S8_O VCC 1 C1-1 P23PWR RD CHASSIS...
  • Page 156 Service and Repair Manual February 2023 Electrical Schematic, Turntable Controller Models with Recovery Module...
  • Page 157 February 2023 Service and Repair Manual Electrical Schematic, Platform Controller...

  • Page 158: Electrical Schematic, Platform Controller

    Service and Repair Manual February 2023 Electrical Schematic, Platform Controller P20DRV RD C17-1 DRV_GND BR C17-4 P20LOG RD/WH C17-2 LOG_GND BR C17-3 C46HRN WH C12-6 P23PWR RD C12-1 P23RET BK C12-2 D81CAN- GR C12-4 D82CAN+ YL C12-3 SPARE BL/WH C12-5 SPARE WH/BL C12-8 C10-5...

  • Page 159: Electrical Schematic, Deutz D2011 L03I Engine

    February 2023 Service and Repair Manual Electrical Schematic, Deutz D2011 L03i Engine TO TCON TO TCON C43F C43G C43B C43A C42D CR23 C41B C43C C42G SPL3 C42C C42B C41G CR17 C41H C41A C42A C42E C42F C43H C44A C44F C44C C44B C44H C41D CR15A...
  • Page 160 Service and Repair Manual February 2023 Electrical Schematic, Deutz D2011 L03i Engine...
  • Page 161 February 2023 Service and Repair Manual Electrical Schematic, Deutz TD 2.2 L3 Engine...

  • Page 162: Electrical Schematic, Deutz Td 2.2 L3 Engine

    Service and Repair Manual February 2023 Electrical Schematic, Deutz TD 2.2 L3 Engine TO TCON TO TCON P134PWR RD GND BR D227CAN- GR D228CAN+ YL C43F C43G P20PWR RD C43B C43A C42D C41B CR23 C43C C135PWR BL/WH C42G C135RET BL/RD C42C R135PWR BL C42B...
  • Page 163 February 2023 Service and Repair Manual Electrical Schematic, Deutz TD 2.2 L3 Engine ENGINE INTERFACE CONNECTOR C37 (DIAGNOSTIC) P134PWR RD P134PWR RD GND BR GND BR D227CAN- GR D227CAN- GR D228CAN+ YL D104CAN- GR D105CAN+ YL D228CAN+ YL 120Ω P20PWR RD P20PWR RD GND BR INJ2- GR/BK...
  • Page 164 Service and Repair Manual February 2023 Electrical Schematic, Deutz TD 2.2 L3 Engine...
  • Page 165 February 2023 Service and Repair Manual Electrical Schematic, Deutz D 2.9 L4 Stage IV Engine...

  • Page 166: Electrical Schematic, Deutz D 2.9 L4 Stage Iv Engine

    Service and Repair Manual February 2023 Electrical Schematic, Deutz D 2.9 L4 Stage IV Engine TO TCON TO TCON P134PWR RD GND BR D227CAN- GR D228CAN+ YL C43F C43G P20PWR RD C43B C43A C42D C41B CR23 C43C C135PWR BL/WH C42G C135RET BL/RD C42C R135PWR BL...
  • Page 167 February 2023 Service and Repair Manual Electrical Schematic, Deutz D 2.9 L4 Stage IV Engine ENGINE INTERFACE CONNECTOR C37 (DIAGNOSTIC) P134PWR RD P134PWR RD GND BR GND BR D227CAN- GR D227CAN- GR D228CAN+ YL D104CAN- GR D105CAN+ YL D228CAN+ YL J29 94PINS J30 60PINS D2.2(K)
  • Page 168 Service and Repair Manual February 2023 Electrical Schematic, Deutz D 2.9 L4 Stage IV Engine...
  • Page 169 February 2023 Service and Repair Manual Electrical Schematic, Deutz D 2.9 L4 Tier IV Engine...

  • Page 170: Electrical Schematic, Deutz D 2.9 L4 Tier Iv Engine

    Service and Repair Manual February 2023 Electrical Schematic, Deutz D 2.9 L4 Tier IV Engine TO TCON TO TCON C43F C43G C43B C43A C42D C41B CR23 C43C C42G SPL3 C42C C42B C41G C41H CR17 C41A SPL20 C42A 120Ω C42E SPL18 C42F SPL7 C43H...

  • Page 171: Electrical Schematic, Perkins 404F-E22T Engine

    February 2023 Service and Repair Manual Electrical Schematic, Perkins 404F-E22T Engine TO TCON TO TCON C43F C43G CR1B C43B C43A C42D C41B CR23 C43C PERKINS ENGINE CONNECTOR C42G SPL12 F-C2 C42C J31-47 WAY C42B INJ SH BK J31-38 F-C1 C41G SPL33 J30-96 WAY C41H...
  • Page 172 Service and Repair Manual February 2023 Electrical Schematic, Perkins 404F-E22T Engine...
  • Page 173 February 2023 Service and Repair Manual Electrical Schematic, Ford MSG-425 EFI Engine...

  • Page 174: Electrical Schematic, Ford Msg-425 Efi Engine

    Service and Repair Manual February 2023 Electrical Schematic, Ford MSG-425 EFI Engine TO TCON TO TCON R46HRN WH/RD C43F C43G C43B C43A C42D SLP9 CR23 C41B C43C C42G SPL3 C42C C42B C41G CR17 C41H C41A C42A C42E C42F C43H C44A C44F CR4/17B C44C...

  • Page 175: Hydraulic Schematics

    February 2023 Service and Repair Manual Hydraulic Schematic Part No. 1286829GT -40/45 XC • S -40/45 HF • S -40/45 TraX ® ™ ® ® ™...
  • Page 176 Service and Repair Manual February 2023 Hydraulic Schematic S®-40/45 XC ™ • S®-40/45 HF • S®- 40/45 Tr aX™ Part No. 1286829GT Servic e and R epair M anual Febr uary 2023...

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