Page 1 Service and Repair Manual Serial Number Range -80/60 ® from Z8013-4592 This manual includes: to Z8016H-6399 Repair procedures from Z80H-6400 Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268556GT Rev C June 2020...
Page 2: Find A Manual For This Model
Copyright © 2015 by Terex Corporation 1268556GT Rev C, June 2020 Third Edition, Third Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -80/60 Part No. 1268556GT...
Page 3 June 2020 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 11/2015 Schematics Electrical Schematic (from Z8013-4592 to Z8015-5653) 9/2016 Introduction Serial Number Legend Specifications GM 3.0L engine Fault Codes GM 3.0L engine Schematics GM 3.0L engine;...
Page 4: Serial Number Legend
Service and Repair Manual June 2020 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code...
Page 5: Safety Rules
June 2020 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 June 2020 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
June 2020 Table of Contents Introduction Introduction ...................... ii Important Information ..................ii Find a Manual for this Model ................ii Serial Number Legend ..................iv Section 1 Safety Rules ...................... v General Safety Rules ..................v Section 2 Specifications ....................1 Machine Specifications ..................
Page 8 June 2020 Table of Contents Section 3 Repair Procedures ..................19 Introduction ...................... 19 Platform Controls ................... 21 Platform Controls ..................... 21 1-1 Platform Circuit Board ................22 How to Remove the LED Circuit Board ............23 1-2 Joysticks - How to Calibrate a Joystick ............24 How to Reset a Proportional Valve Coil Default ...........
Page 9 June 2020 Table of Contents Boom Components ..................44 4-1 Primary Boom Cable Track ................. 45 How to Repair the Primary Boom Cable Track ..........47 4-2 Primary Boom .................... 48 How to Shim the Primary Boom ..............48 How to Disassemble the Primary Boom ............50 4-3 Primary Boom Lift Cylinder .................
Page 10 June 2020 Table of Contents Ground Controls .................... 70 6-1 Bypass/Recovery Key Switch ..............70 How to Use the Recovery Mode ..............72 6-2 Circuit Boards .................... 73 6-3 Membrane Decal ..................74 Display Module....................75 Hydraulic Pumps .................... 83 7-1 Function Pump ...................
Page 11 June 2020 Table of Contents 8-9 Oil Diverter Manifold Components (welder option) ........109 8-10 Traction Manifold Components, 2WD ............110 8-11 Valve Adjustments, 2WD Traction Manifold..........112 8-12 Traction Manifold Components, 4WD ............114 8-13 Valve Adjustments, 4WD Traction Manifold..........116 8-14 Valve Coils .....................
Page 12 June 2020 Table of Contents Section 5 Schematics ....................174 Introduction ....................174 Wire Circuit Legend..................175 Wire Color Legend ..................179 Limit Switches and Angle Sensors..............184 Drive Chassis and Platform Controller Pin Legend ......... 186 Turntable Controller Pin Legend ..............187 Relay and Fuse Panel Legends ..............
Page 13: Specifications
June 2020 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Fluid capacities Fuel tank 35 gallons Tires and wheels 132.5 liters Tire size 18-625 FF LPG tank 33.5 lbs (foam filled and non-marking) 15.2 kg Tire size 445D50/70 Hydraulic tank 45 gallons...
Page 14: Performance Specifications
Service and Repair Manual June 2020 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications (models with rough terrain tires) Genie specifications require hydraulic oils which are Stowed position 40 ft / 8.7 - 9.3 sec designed to give maximum protection to hydraulic 12.2 m / 8.7 - 9.3 sec systems, have the ability to perform over a wide temperature range, and the viscosity index should...
Page 15 June 2020 Service and Repair Manual Specifications Do not top off with incompatible Chevron Rando HD Premium Oil hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
Page 16 Service and Repair Manual June 2020 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 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 15.0 cSt @ 104°F / 40°C...
Page 17: Hydraulic Component Specifications
June 2020 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Drive Pump Viscosity index Type: bi-directional variable displacement piston pump Kinematic Viscosity Displacement per revolution 2.8 cu in cSt @ 149°F / 65°C 46 cc cSt @ 104°F / 40°C Flow rate @ 2300 rpm...
Page 18 Service and Repair Manual June 2020 Specifications Function manifold Manifold Component Specifications System relief valve pressure, maximum 3200 psi Plug torque (measured at PTEST port) 220.6 bar SAE No. 2 36 in-lbs / 4 Nm Primary boom down relief valve pressure 1300 psi SAE No.
Page 19: Continental Tme27 Engine Specifications
June 2020 Service and Repair Manual Specifications Continental TME27 Engine Oil Pressure switch Installation torque 8 - 18 ft-lbs Displacement 164 cu. in 11 - 24 Nm 2.68 liters Pressure switch point 7 psi Number of cylinders 0.55 bar 3.58 x 4.06 inches Bore and Stroke Fuel Pump 91 x 103.2 mm...
Page 20: Gm 3.0L Engine Specifications
Service and Repair Manual June 2020 Specifications GM 3.0L Engine Fuel requirement For fuel requirements, refer to the engine Operator Displacement 183 cu. in Manual for your engine. 3.0 liters Battery – Engine starting and control system Number of cylinders Type 12V DC, Group 31 4.0 x 3.6 inches...
Page 21: Deutz Td2011L04I Engine Specifications
June 2020 Service and Repair Manual Specifications Deutz TD2011L04i Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 220.9 cu. in 11 - 24 Nm 3.62 liters Temperature switch point 275°F Number of cylinders 135°C 3.78 x 4.92 inches Bore and Stroke Oil Pressure switch 96 x 125 mm...
Page 22: Deutz Tcd 2.2 L3 Engine Specifications
Service and Repair Manual June 2020 Specifications Deutz TCD 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 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
Page 23: Deutz Td 2.9 Engine Specifications
June 2020 Service and Repair Manual Specifications Deutz TD 2.9 L4 Engine Oil temperature switch Installation torque 8 - 18 ft-lbs Displacement 177 cu. in 11 - 24 Nm 2.9 liters Temperature switch point 275°F Number of cylinders 135°C 3.6 x 4.3 inches Bore and Stroke Oil Pressure switch 92 x 110 mm...
Page 24: Perkins 404D-22T Engine Specifications
Service and Repair Manual June 2020 Specifications Perkins 404D-22T 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 3.31 x 3.94 inches Bore and Stroke For fuel requirements, refer to the engine Operator 84 x 100 mm Manual for your engine.
Page 25: Perkins 404F-22T Engine Specifications
June 2020 Service and Repair Manual Specifications Perkins 404F-E22TA Oil Pressure switch Installation torque 8 - 18 ft-lbs Displacement 134 cu. in 11 - 24 Nm 2.2 liters Pressure switch point 14.2 psi Number of cylinders 1 bar 3.31 x 3.94 inches Bore and Stroke Fuel injection system 84 x 100 mm...
Page 26: Perkins 804D-33 Engine Specifications
Service and Repair Manual June 2020 Specifications Perkins 804D-33 Injection system Injection pump make Zexel Displacement 201 cu. in Injection pump pressure 1707 to 1849 psi 3.3 liters 117.7 to 127.5 bar Number of cylinders Injector opening pressure ~2000 psi 3.70 x 4.72 inches Bore and Stroke ~138 bar...
Page 27: Machine Torque Specifications
June 2020 Service and Repair Manual Specifications Machine Torque Specifications Platform Rotator 1-8 center bolt, GR 5, dry 640 ft-lbs (before SN 15-5630) 867 Nm 1-8 center bolt, GR 5, dull gray 615 ft-lbs (from SN 15-5630) 834 Nm 3/8 -16 bolts, GR 8 35 ft-lbs* *(use blue thread locking compound) 47.5 Nm*...
Page 28: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual June 2020 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 29: Torque Procedure
June 2020 Service and Repair Manual Specifications JIC 37° fittings Torque Procedure 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 30 Service and Repair Manual June 2020 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 31: Repair Procedures
June 2020 Service and Repair Manual Repair Procedures Secti on 3 Repair P roce dur es Machine Configuration:  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
Page 32 Service and Repair Manual June 2020 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 33: Platform Controls
June 2020 Service and Repair Manual Platform Controls Platform Controls The platform controls contain two printed circuit boards: The LED circuit board is mounted to the underside of the control box lid which contains the LEDs. The LED circuit board sends the input from the operator to the platform controls circuit board (PCON).
Page 34: Platform Circuit Board
Service and Repair Manual June 2020 Platform Controls Platform Circuit Board Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Note: When the platform circuit board is replaced, the joystick controllers will need to be calibrated.
Page 35: How To Remove The Led Circuit Board
June 2020 Service and Repair Manual Platform Controls How to Re mov e th e LED Circ uit Boa rd How to Remove the LED Circuit Attach a grounded wrist strap to the ground screw inside the control box. Board Electrocution/burn hazard.
Page 36: Joysticks - How To Calibrate A Joystick
Service and Repair Manual June 2020 Platform Controls Drive functions: Joysticks Turn the key switch to the off position. Press and hold the enter button on the ground control panel while turning the key How to Calibrate a Joystick switch to platform controls. Hold the enter The joystick controllers on this machine utilize button for approximately 5 seconds.
Page 37 June 2020 Service and Repair Manual Platform Controls Steer functions: Secondary boom up/down and extend/retract functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the ground control panel while turning the key Press and hold the enter button on the switch to platform controls.
Page 38 Service and Repair Manual June 2020 Platform Controls Primary boom extend/retract functions: Primary boom up/down functions: Turn the key switch to the off position. Turn the key switch to the off position. Press and hold the enter button on the Press and hold the enter button on the ground control panel while turning the key ground control panel while turning the key...
Page 39: How To Reset A Proportional Valve Coil Default
June 2020 Service and Repair Manual Platform Controls How to Re set a Prop orti onal Valv e Coil De fault How to Reset a Proportional Turntable rotate functions: Valve Coil Default Turn the key switch to the off position. Note: Use the following chart to identify the Press and hold the enter button on the description of each LCD screen control button...
Page 40: How To Set The Function Thresholds And Default Functions Speeds
Service and Repair Manual June 2020 Platform Controls How to Set the Fu nction Th res holds and D efa ult F unctio ns Spe eds How to Set the Function Slowly move the joystick off center in the opposite direction just until the machine Thresholds and Default function starts to move, then move the Functions Speeds...
Page 41 June 2020 Service and Repair Manual Platform Controls Function speeds: 15 Once the function speeds have been set, press and hold the engine start button until Note: Be sure the machine is in the stowed the engine shuts off. Do not press the red position and the boom is rotated between the Emergency Stop button.
Page 42: How To Adjust The Function Speeds
Service and Repair Manual June 2020 Platform Controls How to Adju st th e F unctio n Spe eds How to Adjust the Function Press the enter button to save the setting in memory. Speeds Press the enter or previous button on the Note: Perform this procedure with the boom in the LCD screen until EXIT is displayed.
Page 43: How To Adjust The Function Ramp Rate Setting
June 2020 Service and Repair Manual Platform Controls How to Adju st th e F unctio n Ra mp R ate Set ting How to Adjust the Function Ramp Press the previous button until the function to be adjusted is displayed. Rate Setting Press the plus button to increase the ramp The ramp rate setting of a joystick controls the...
Page 44 Service and Repair Manual June 2020 Platform Controls Ramp Rate Specifications Ramp rate (factory settings) Turntable rotate accelerate 4 seconds decelerate 1.0 second Primary boom up/down accelerate 3 seconds decelerate 0.25 second Primary boom extend/retract accelerate 3 seconds decelerate 0.75 second Secondary boom up/down accelerate 7 seconds...
Page 45: Platform Components
June 2020 Service and Repair Manual Platform Components Platform Leveling Cylinder Platform The platform leveling cylinder keeps the platform How to Remove the Platform level through the entire range of boom motion. The platform is maintained level to the turntable. To Separate the foot switch quick disconnect accomplish this, the ECM at the ground controls plug.
Page 46: How To Bleed The Platform Leveling Cylinder
Service and Repair Manual June 2020 Platform Components Tag, disconnect and plug the hydraulic hoses 10 Use a soft metal drift to tap the platform level from the platform leveling cylinder at the cylinder rod-end pivot pin half way out and bulkhead fittings located inside the boom tube lower one of the leveling arms to the ground.
Page 47: Platform Rotator
June 2020 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the platform rotator manifold. Cap the Platform Rotator fittings on the manifold. The platform rotator is a hydraulically activated Bodily injury hazard. Spraying helical gear assembly used to rotate the platform hydraulic oil can penetrate and 160 degrees.
Page 48: How To Bleed The Platform Rotator
Service and Repair Manual June 2020 Platform Components How to Blee d th e Platf orm Rota tor How to Bleed the Platform 11 Remove the center bolt and slide the platform mounting weldment off of the platform rotator. Rotator Crushing hazard.
Page 49: Platform Overload System (If Equipped)
June 2020 Service and Repair Manual Platform Components How to Calibrate the Platform Overload System (if equipped) Platform Overload System (if equipped) Proper calibration of the platform overload system is essential to safe machine operation. Continued The platform overload system is designed to use of an improperly calibrated platform overload prevent the machine from continuing to operate system could result in the system failing to sense...
Page 50 Service and Repair Manual June 2020 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 51 June 2020 Service and Repair Manual Platform Components Move the platform up and down by hand, so it Test all machine functions from the platform bounces approximately 2.5 to 5 cm / 1 to controls. 2 inches. Allow the platform to settle. Result: All platform control functions should Result: The alarm should be off.
Page 52: Platform Overload Recovery Message
Service and Repair Manual June 2020 Platform Components Press the buttons on the ground controls in the following sequence: Platform Overload Recovery (plus)(minus)(minus)(plus). Message (software V2.04 and Press the enter or previous button on the later) LCD screen until CLEAR OVERLOAD RECOVERY is displayed.
Page 53: Jib Boom Components
June 2020 Service and Repair Manual Jib Boom Components Tag, disconnect and plug the jib boom lift cylinder hydraulic hoses. Cap the fittings on Jib Boom the cylinder. Bodily injury hazard. Spraying How to Remove the Jib Boom hydraulic oil can penetrate and burn skin.
Page 54 Service and Repair Manual June 2020 Jib Boom Components Use a soft metal drift to remove the pin and let 15 Attach a lifting strap from an overhead crane the cylinder hang down. to the lug on the rod end of the jib boom lift cylinder.
Page 55: Jib Boom Lift Cylinder
June 2020 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out and Jib Boom Lift Cylinder lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.
Page 56: Boom Components
Service and Repair Manual June 2020 Boom Components primary boom link arm pivot pin 13 secondary boom pivot pin primary boom lift cylinder link arm 14 secondary lift cylinder pivot pin - barrel end primary lift cylinder pivot pin - rod end 15 secondary boom lift cylinder primary boom lift cylinder 16 secondary lift cylinder pivot pin - rod end...
Page 57: Primary Boom Cable Track
June 2020 Service and Repair Manual Boom Components Remove the mounting fasteners from the power to platform outlet box. Remove the Primary Boom Cable Track outlet box and lay to the side. The primary boom cable track guides the cables Remove the hose clamp from the platform and hoses running up the boom.
Page 58 Service and Repair Manual June 2020 Boom Components 11 Tag, disconnect and plug the jib boom 18 Tag, disconnect and plug each hydraulic hose cylinder hydraulic hoses. Cap the fittings. from the bulkhead fittings that lead to the cable track. Cap the fittings. Bodily injury hazard.
Page 59: How To Repair The Primary Boom Cable Track
June 2020 Service and Repair Manual Boom Components How to Re pair the P rima ry Boo m Ca ble Track How to Repair the Primary Boom Remove the upper rollers from the replacement section of cable track. Cable Track Lift up the hoses and cables and carefully Component damage hazard.
Page 60: Primary Boom
Service and Repair Manual June 2020 Boom Components How to Remove the Primary Boom Primary Boom Bodily injury hazard. This How to Shi m th e Prim ary Bo om How to Shim the Boom procedure requires specific repair skills, lifting equipment and a Measure each wear pad.
Page 61 June 2020 Service and Repair Manual Boom Components Tag, disconnect and plug the primary boom 11 Use a soft metal drift to remove the upper extension cylinder hydraulic hoses. Cap the primary boom lift cylinder linkage arm pivot fittings on the cylinder. Tag, disconnect and pin.
Page 62: How To Disassemble The Primary Boom
Service and Repair Manual June 2020 Boom Components How to Disa ssem ble t he Pri mary Boom How to Disassemble the Primary Use a soft metal drift to remove the pin. Boom Crushing hazard. The primary boom could become unbalanced Bodily injury hazard.
Page 63: Primary Boom Lift Cylinder
June 2020 Service and Repair Manual Boom Components Use a soft metal drift to remove the pin. Primary Boom Lift Cylinder Crushing hazard. The extension cylinder could become unbalanced and fall The primary boom lift cylinder raises and lowers when removed from primary the primary boom.
Page 64: Primary Boom Extension Cylinder
Service and Repair Manual June 2020 Boom Components Place blocks under the primary boom lift cylinder linkage arms for support. Primary Boom Extension Tag, disconnect and plug the primary boom Cylinder lift cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom extension cylinder extends and retracts the primary boom extension tube.
Page 65 June 2020 Service and Repair Manual Boom Components Remove the access cover from the pivot end 10 Working at the pivot end of the boom, support of the primary boom. and slide the extension cylinder out of the boom extension. Place blocks under the barrel end of the primary boom extension cylinder for support.
Page 66: Primary Boom Angle Sensor
Service and Repair Manual June 2020 Boom Components Remove the angle sensor and bracket assembly. Primary Boom Angle Sensor Remove the sensor retaining fasteners from A properly functioning primary boom angle sensor the sensor bracket. Remove the angle sensor. (PBAS) is essential to safe machine operation. Install the new angle sensor onto the The primary boom angle sensor is used to limit the mounting bracket.
Page 67: How To Calibrate The Primary Boom Angle Sensor
June 2020 Service and Repair Manual Boom Components How to Cali brat e th e Prim ary Bo om A ngle Se nsor How to Calibrate the Primary Loosen the Primary Boom Angle Sensor (PBAS) assembly bracket fasteners attached Boom Angle Sensor to the primary boom.
Page 68 Service and Repair Manual June 2020 Boom Components 17 Press the previous button until EXIT is 25 Start the engine. shown on the display. Press the plus button 26 Activate the boom up function until the digital to select yes, then press the enter button to level reads 65°.
Page 69: Secondary Boom Cable Track
June 2020 Service and Repair Manual Boom Components Carefully remove the snap rings and pins from each end of the damaged section of cable Secondary Boom Cable Track track. The secondary boom cable track guides the Remove the retaining fasteners from the cables and hoses running up through the inside of upper black rollers from the 4-link section of the secondary boom.
Page 70: Secondary Boom
Service and Repair Manual June 2020 Boom Components Remove the primary boom. Refer to Repair Procedure, How to Remove the Primary Secondary Boom Boom. Tag, disconnect and plug the hydraulic hoses How to Disassemble the at the primary boom lift cylinder. Cap the Secondary Boom fittings on the cylinder.
Page 71: Secondary Boom Lift Cylinder
June 2020 Service and Repair Manual Boom Components Tag and disconnect the electrical cables from the turntable. Secondary Boom Lift Cylinder Remove the hose protector bracket. 10 Working at the platform end, place blocks How to Remove the Secondary under the barrel end of the secondary boom Boom Lift Cylinder extension cylinder for support.
Page 72 Service and Repair Manual June 2020 Boom Components Remove the engine pivot plate retaining Using an approved hand-operated pump, fastener. Swing the engine pivot plate out drain the fuel tank into a suitable container. away from the machine. Refer to Specifications, Machine Specifications.
Page 73: Secondary Boom Extension Cylinder
June 2020 Service and Repair Manual Boom Components 12 Tag, disconnect and plug the hydraulic hoses from the secondary boom lift cylinder. Cap the Secondary Boom Extension fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The secondary boom extension cylinder extends burn skin.
Page 74 Service and Repair Manual June 2020 Boom Components Remove the fasteners securing the cable 11 Tag, disconnect and plug the secondary track trays and cable track clamps to the boom extension cylinder hydraulic hoses. Cap secondary extension boom. the fittings on the cylinder. Remove the external snap rings from the Bodily injury hazard.
Page 75: Engines
June 2020 Service and Repair Manual Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Refer to Maintenance Procedure in the appropriate engine and the pump. It is bolted to the engine Service or Maintenance Manual for your machine, flywheel and has a splined center to drive the Check and Adjust the Engine RPM.
Page 76 Service and Repair Manual June 2020 Engines Deutz TD2011L04i models: Carefully pull the pump and bell housing assembly away from the engine and secure it Tag and disconnect the wiring from the bell from moving. housing. Component damage hazard. Remove the U-bolt from the exhaust flex pipe Hoses can be damaged if they at the muffler.
Page 77 June 2020 Service and Repair Manual Engines Perkins 404F-22T models: Continental model: Tag and disconnect the wiring from the bell Tag and disconnect the wire harness from the housing. oxygen sensor. Remove the fasteners supporting the muffler Remove the exhaust pipe heat shield assembly from the bell housing.
Page 78: How To Install The Flex Plate
Service and Repair Manual June 2020 Engines How to I nstall t he Flex Plat e How to Install the Flex Plate Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave Install the flex plate onto the engine flywheel the appropriate gap between coupler and with the raised spline towards the pump.
Page 79: How To Install The Pump And Bell Housing Assembly
June 2020 Service and Repair Manual Engines How to ins tall th e Pum p a nd Bell Ho using Assem bly Deutz Pump Mounting Plate 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 80: How To Access Perkins 404F Engine Regeneration Service
Service and Repair Manual June 2020 Engines How to Force or Inhibit DPF How to Access Perkins 404F Regeneration Engine Regeneration Service There are three modes available for DPF regeneration. Machines equipped with Perkins 404F-22T Diesel The default, AUTOMATIC MODE, allows for ECU engines will have a regeneration mode that should run automatically when soot levels in the Diesel controlled regeneration.
Page 81: 5-4 Diesel Particle Filter Regeneration - Deutz Tcd 2.2 L3
June 2020 Service and Repair Manual Engines Press the enter button until FORCE DPF REGENERATION or INHIBIT DPF Diesel Particle Filter REGENERATION is displayed. Regeneration - Deutz TCD 2.2 L3 Press the plus button or the minus button to Engine select YES to change the regeneration mode from the default automatic mode.
Page 82: Ground Controls
Service and Repair Manual June 2020 Ground Controls Bypass/Recovery Key Switch The ground control box contains two key switches. The main key switch towards the top of the control box is for selection of ground or platform controls. The key switch at the bottom of the control box is the Bypass/Recovery key switch.
Page 83 June 2020 Service and Repair Manual Ground Controls How to Use the Bypass Mode Turn the bypass/recovery key switch to the bypass position. Tip-over hazard. Operating the Using auxiliary power, operate the ground machine outside of the operating control buttons to level the platform. envelope while in Bypass mode will result in death or serious Note: Only the auxiliary power unit can be used to...
Page 84: How To Use The Recovery Mode
Service and Repair Manual June 2020 Ground Controls How to Us e the Recov ery Mod e How to Use the Recovery Mode Turn the main key switch to ground controls. Remove the key from the main key switch and Recovery is only to be used as a last attempt to insert the key into the bypass/recovery key lower the platform when the operator in the...
Page 85: Circuit Boards
June 2020 Service and Repair Manual Ground Controls How to Determine the Revision Circuit Boards Level The ground control box (TCON) is the communication and operations center for the Turn the key switch to ground controls and machine. The ground control box contains two key pull out the red Emergency Stop buttons to switches.
Page 86: Membrane Decal
Service and Repair Manual June 2020 Ground Controls Carefully disconnect the two ribbon cables from the membrane decal at the ECM circuit Membrane Decal board. The membrane decal is a special decal that Electrocution/burn hazard. consists of a decal with an electronic membrane Contact with electrically charged on the backside.
Page 87: Display Module
June 2020 Service and Repair Manual Display Module This table lists the various screens and menu options of the operating software. Some display menus are for informational purpose only, while others can be used to change the machine operating parameters. Tip-over hazard.
Page 88 Service and Repair Manual June 2020 Display Module Screen or Procedure Description Range or Selection Menu Machine Status With key switch on, press the Hydraulic pressure PSI 0-4500 PSI (plus)(minus) buttons at the same (English) time. Hydraulic pressure kPa 0-31000 kPa (metric) DPF Soot 0-150%...
Page 89 June 2020 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Forward not stowed drive 120% (default) 50% (min) Drive Functions and hold the enter button speed % and turn key switch to on Forward low drive speed % 120% (default) 50% (min) position.
Page 90 Service and Repair Manual June 2020 Display Module Screen or Menu Procedure Description Range or Selection Boom Function With key switch , press Primary boom up speed stowed 120% max, 50% min, Speeds and hold the enter button 100% (default) and turn key switch to on Primary boom up speed not stowed position.
Page 91 June 2020 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection Lift Functions With key switch , press and Primary boom up/down ramp 150% max and 50% min Ramps hold the enter button and turn key acceleration % 100% (default), switch to on position.
Page 92 Service and Repair Manual June 2020 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press and Reset drive valve defaults YES/NO Valve Calibration hold the enter button and turn Reset primary boom up/down key switch to on position. valve defaults Release the enter button and Reset primary boom ext/ret...
Page 93 June 2020 Service and Repair Manual Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Set unit levels to gravity YES/NO Sensor Calibration and hold the enter button Unit Level Y-axis millivolts per and turn key switch to on degree position.
Page 94 Service and Repair Manual June 2020 Display Module Screen or Menu Procedure Description Range or Selection With key switch , press Boom Length Limit: No Limit (NO Options and hold the enter button LT), and turn key switch to on Secondary Extend disabled (EXT position.
Page 95: Hydraulic Pumps
June 2020 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the hydraulic hoses at the function pump. Cap the fittings on the Function Pump pump. Bodily injury hazard. Spraying How to Remove the Function hydraulic oil can penetrate and burn skin.
Page 96: Drive Pump
Service and Repair Manual June 2020 Hydraulic Pumps Models without hydraulic tank shutoff valves: Remove the drain plug from the Drive Pump hydraulic tank and completely drain the tank into a container of suitable capacity. Refer to The drive pump is a bi-directional variable Specifications, Machine Specifications.
Page 97: How To Prime The Drive Pump
June 2020 Service and Repair Manual Hydraulic Pumps How to Pri me t he D rive Pu mp Support the pump with a lifting device and How to Prime the Drive Pump remove the pump mounting fasteners. Component damage hazard. Carefully pull the drive pump out until the The engine must not be started pump coupler separates from the flex plate.
Page 98: Manifolds
Service and Repair Manual June 2020 Manifolds Function Manifold Components - View 1 The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Differential sensing valve Secondary boom up/extend and 30-35 ft-lbs / 41-47 Nm down/retract Relief valve, 2500 psi / 172 bar Secondary boom up...
Page 99 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 100: Function Manifold Components - View 2
Service and Repair Manual June 2020 Manifolds Function Manifold Components - View 2 The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Secondary boom extend circuit 20-25 ft-lbs / 27-34 Nm Relief valve, 2600 psi / 179 bar Secondary boom extend...
Page 101 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 102: Valve Adjustments - Function Manifold
Service and Repair Manual June 2020 Manifolds Simultaneously push and hold the function enable/high speed button and the primary Valve Adjustments - Function boom retract button with the primary boom Manifold fully retracted. Observe the reading on the pressure gauge. Refer to Specifications, How to Adju st th e Syste m Relie f Valve Hydraulic Specifications.
Page 103: How To Adjust The Primary Boom Down Relief Valve
June 2020 Service and Repair Manual Manifolds How to Adju st th e Prim ary Bo om D own Reli ef Valve How to Adjust the Primary Boom Adjust the internal hex socket. Turn it clockwise to increase the pressure or Down Relief Valve counterclockwise to decrease the pressure.
Page 104: How To Adjust The Primary Boom Extend Relief Valve
Service and Repair Manual June 2020 Manifolds How to Adju st th e Prim ary Bo om Ext end R elief Valv e How to Adjust the Primary Boom Turn the engine off. Use a wrench to hold the relief valve and remove the cap. Extend Relief Valve 10 Adjust the internal hex socket.
Page 105: How To Adjust The Secondary Boom Up Relief Valve
June 2020 Service and Repair Manual Manifolds How to Adju st th e Seco nda ry Boo m Up R elief Valv e How to Adjust the Secondary Continue holding the function enable/high speed button and the secondary boom Boom Up Relief Valve up/extend button while observing the reading Note: Refer to Function Manifold Component list to on the pressure gauge.
Page 106: How To Adjust The Secondary Boom Down Relief Valve
Service and Repair Manual June 2020 Manifolds How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Adjust the internal hex socket. Turn it clockwise to increase the pressure or Boom Down Relief Valve counterclockwise to decrease the pressure.
Page 107: How To Adjust The Secondary Boom Extend Relief Valve
June 2020 Service and Repair Manual Manifolds How to Adju st th e Seco nda ry Boo m Exte nd Reli ef Valve How to Adju st th e Platfo rm Ma nifold R elief Valv e How to Adjust the Secondary How to Adjust the Platform Boom Extend Relief Valve Manifold Relief Valve...
Page 108: Platform Manifold
Service and Repair Manual June 2020 Manifolds Platform Manifold The platform manifold is mounted to the platform mounting weldment. Index Schematic Description Function Torque Item Check valve, 5 psi Platform load sense/level 12-14 ft-lbs / 16-19 Nm circuit Differential sensing valve, N.C. Directs flow to functions 19-21 ft-lbs / 26-29 Nm Jib load sense/up/down...
Page 109 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 110: Turntable Rotation Manifold
Service and Repair Manual June 2020 Manifolds Turntable Rotation Manifold The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index Schematic Description Function Torque Item Shuttle valve. 2 position, 3 way Turntable rotation brake release 10-13 ft-lbs / 14-18 Nm Counterbalance valve Turntable rotate right...
Page 111: Platform Rotate Manifold
June 2020 Service and Repair Manual Manifolds Platform Rotate Manifold The platform rotate manifold is mounted on the platform rotator. Index Schematic Description Function Torque Item Counterbalance valve Turntable rotation brake release 35-40 ft-lbs / 47-54 Nm Counterbalance valve Turntable rotate left 35-40 ft-lbs / 47-54 Nm ®...
Page 112: Two Wheel Steer And Oscillate Manifold
Service and Repair Manual June 2020 Manifolds Two Wheel Steer and Oscillate Manifold The Two Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the machine. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Steer left/right, yellow side steer 26-30 ft-lbs / 35-41 Nm cylinder...
Page 113 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 114: How To Adjust The Oscillate Relief Valve
Service and Repair Manual June 2020 Manifolds How to Adju st th e Oscillat e Relie f Valve How to Adjust the Oscillate Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Two people will be required to perform this procedure.
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Page 116: Four Wheel Steer And Oscillate Manifold
Service and Repair Manual June 2020 Manifolds Four Wheel Steer and Oscillate Manifold The Four Wheel Steer and Oscillate manifold is mounted inside the drive chassis at the square-end of the machine. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Steer left/right, square end 26-30 ft-lbs / 35-41 Nm yellow side steer cylinder...
Page 117 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 118 Service and Repair Manual June 2020 Manifolds Four Wheel Steer and Oscillate Manifold, continued Index Schematic Description Function Torque Item Steer left/right, circle end blue Solenoid valve, 3 position 4 way 26-30 ft-lbs / 35-41 Nm side steer cylinder Solenoid valve, 3 position 4 way Steer left/right, circle end yellow 26-30 ft-lbs / 35-41 Nm side steer cylinder...
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Page 120: How To Adjust The Oscillate Relief Valve
Service and Repair Manual June 2020 Manifolds How to Adju st th e Oscillat e Relie f Valve How to Adjust the Oscillate Relief Valve Note: Perform this procedure with the boom in the stowed position. Note: Two people will be required to perform this procedure.
Page 121: Oil Diverter Manifold Components (Welder Option)
June 2020 Service and Repair Manual Manifolds Oil Diverter Manifold Components (welder option) The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment. Index Schematic Description Function Torque Item Pilot Operated Directional valve, Activates generator 80-90 ft-lbs / 108-122 Nm 2 position 3 way Orifice disc, 0.031 inch / 0.79 mm...
Page 122: Traction Manifold Components, 2Wd
Service and Repair Manual June 2020 Manifolds 8-10 Traction Manifold Components, 2WD The 2WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Drive motor anti-cavitation 30-35 ft-lbs / 41-47 Nm Check valve, 5 psi / 0.34 bar...
Page 123 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 124: Valve Adjustments, 2Wd Traction Manifold
Service and Repair Manual June 2020 Manifolds 8-11 Move rpm select switch to high rpm (rabbit symbol). Valve Adjustments, 2WD Traction Begin driving the machine forward at a Manifold medium speed while one person monitors the pressure gauge. Continue driving until the How to Adjust the Charge pressure stabilizes.
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Page 126: Traction Manifold Components, 4Wd
Service and Repair Manual June 2020 Manifolds 8-12 Traction Manifold Components, 4WD The 4WD traction manifold is mounted inside the drive chassis at the circle-end of the machine. Index Schematic Description Function Torque Item Check valve, 5 psi / 0.34 bar Drive motor anti-cavitation 30-35 ft-lbs / 41-47 Nm Solenoid Valve, 2 position 3 way...
Page 127 June 2020 Service and Repair Manual Manifolds ® Part No. 1268556GT -80/60...
Page 128: Valve Adjustments, 4Wd Traction Manifold
Service and Repair Manual June 2020 Manifolds 8-13 Move rpm select switch to high rpm (rabbit symbol). Valve Adjustments, 4WD Traction Begin driving the machine forward at a Manifold medium speed while one person monitors the pressure gauge. Continue driving until the How to Adjust the Charge pressure stabilizes.
Page 129: Valve Coils
June 2020 Service and Repair Manual Manifolds 8-14 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 130 Service and Repair Manual June 2020 Manifolds How to Test a Coil Diode 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. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 131: Turntable Rotation Components
June 2020 Service and Repair Manual Turntable Rotation Components Remove the drive hub mounting bolts and remove the turntable rotation assembly from Turntable Rotation Assembly the machine. Repeat steps 3 through 5 for the other How to Remove a Turntable turntable rotation assembly.
Page 132: How To Adjust The Turntable Rotation Gear Backlash
Service and Repair Manual June 2020 Turntable Rotation Components How to Adju st th e T urn table Rota tion G ear Backlas h How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bearing ring gear.
Page 133: Axle Components
June 2020 Service and Repair Manual Axle Components 10-1 Measure the distance between the inside of one circle-end tire and the chassis side plate Steer Sensors on both sides of the axle. The steer sensor measures steer angle and Result: Both measurements should be the communicates that information to the ground same to indicate that the tires are parallel with controls ECM.
Page 134: How To Adjust A Steer Sensor
Service and Repair Manual June 2020 Axle Components How to Adju st a St eer S enso r How to Adjust a Steer Sensor Circle-end steer sensors: 10 At the platform controls, press the square-end Start the engine from the platform controls. steer mode button.
Page 135: How To Calibrate The Steer Sensors
June 2020 Service and Repair Manual Axle Components How to Cali brat e th e Stee r Sen sors How to Calibrate the Steer Angle Enter sensor calibration mode by pressing the buttons at the ground controls in the following Sensor sequence: (plus)(enter)(enter)(plus).
Page 136: How To Adjust The Oscillate Limit Switches
Service and Repair Manual June 2020 Axle Components How to Adju st th e Oscillat e Li mit Switche s How to Adjust the Oscillate Limit Carefully hold the position of each limit switch and tighten the limit switch mounting Switches fasteners.
Page 137: Oscillating Axle Cylinders
June 2020 Service and Repair Manual Axle Components 10-2 Remove the pin retaining fasteners from the oscillate cylinder rod-end pivot pin. Use a soft Oscillating Axle Cylinders metal drift to remove the pin. The oscillating axle cylinders extend and retract Attach a lifting strap from an overhead crane between the drive chassis and the oscillating axle.
Page 138: Fault Codes
Service and Repair Manual June 2020 Fault Codes Secti on 4 Fault C odes Before Troubleshooting:  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 equipment are available and ready for use.
Page 139: Control System Fault Codes
June 2020 Service and Repair Manual Control System Fault Codes How to Read Control System Using Web GPI Fault Codes Connect the device containing the WEB GPI software to the TCON with an RS-232 cable. Note: Initial fault testing occurs at power-up. Select the Secondary Boom, then the Safety Faults are abnormal conditions that exist due to Switch Status Flags screen.
Page 140 Service and Repair Manual June 2020 Control System Fault Codes Error Source Error Type Effects Recovery Actions Primary Up/Down Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 141 June 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Display message on LCD and allow Primary Up/Down Speed Not Calibrated Perform auto calibrate procedure. operation at default speed Primary Extend/Retract Not Calibrated Display message on LCD and allow Perform auto calibrate procedure.
Page 142 Service and Repair Manual June 2020 Control System Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 143 June 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Secondary Boom Up/Down Display message on LCD and allow See service manual on how to perform Not calibrated Speed operation at default speed this procedure.
Page 144 Service and Repair Manual June 2020 Control System Fault Codes Error Source Error Type Effects Recovery Actions Steer Joystick Value at 5.0 V Limited Speed and Direction frozen at Check for damaged wiring to the zero and neutral, Alarm sounds. joystick.
Page 145 June 2020 Service and Repair Manual Control System Fault Codes Error Source Error Type Effects Recovery Actions Limited Speed and Direction frozen at Check for defective or damaged Motor Valve Speed Fault Check zero and neutral, Alarm sounds. wiring. Check for an open or shorted valve coil.
Page 146 Service and Repair Manual June 2020 Control System Fault Codes Error Source Error Type Effects Recovery Actions Safety Switch P3 Fault Check Display message on LCD Power up controller with problem P3 SAFETY SWITCH FAULT corrected. Safety Switch P6R1 Fault Check Display message on LCD Power up controller with problem P6R1 SAFETY SWITCH FAULT...
Page 147: Fault Code Source
June 2020 Service and Repair Manual Control System Fault Codes Fault Source and Type will display as: Fault Source Description Source Type SCON Controller Area Network “ ID XXX_xx FAULT “ Primary Boom Angle Zone Where XXX is the one to three digit Fault Source Primary Boom Length Switches Cross-Check and xx is the two digit Fault Type.
Page 148 Service and Repair Manual June 2020 Control System Fault Codes Fault Source Fault Source Description Description Turntable Level Sensor X-Direction Enable Output Power P7R Turntable Level Snesor Y-Direction Primary Down Power P9A Boom Length Sensors Cross-Check (SCON) IGN/Fuel Power P9B Boom Safety Envelope (SCON) Primary Extend Power P10 Turntable Controller - Platform Controller...
Page 149 June 2020 Service and Repair Manual Control System Fault Codes Fault Source Description Brake Valve Motor Shift Valve Chassis Tilt Sensors Cross-Check (SCON) Jib Bellcrank Level Sensor Jib Bellcrank Level Flow Valve AUX Relay Platform Level Toggle Switch Platform Rotate Toggle Switch Platform Level Flow Valve Platform Rotate Valve Boom Length Sensor...
Page 150: Fault Code Display - Deutz And Perkins Models
Service and Repair Manual June 2020 Fault Code Display - Deutz and Perkins Models How to Re triev e Active En gine Fa ult Cod es De utz D 2.9 L4 a nd Pe rkins 4 04 F-2 2 M odels How to Retrieve Active Engine Fault Codes - Deutz TCD 2.2 L3, TD 2.9 L4 and Perkins 404F-...
Page 151: Deutz Td 2.9 L4 Engine Fault Codes
June 2020 Service and Repair Manual Deutz TD 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 152 Service and Repair Manual June 2020 Deutz TD 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 153 June 2020 Service and Repair Manual Deutz TD 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 154 Service and Repair Manual June 2020 Deutz TD 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description ECU temperature...
Page 155 June 2020 Service and Repair Manual Deutz TD 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 156 Service and Repair Manual June 2020 Deutz TD 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 157 June 2020 Service and Repair Manual Deutz TD 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 158 Service and Repair Manual June 2020 Deutz TD 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 159 June 2020 Service and Repair Manual Deutz TD 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 160 Service and Repair Manual June 2020 Deutz TD 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 161 June 2020 Service and Repair Manual Deutz TD 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 162: Deutz Tcd 2.2 L3 Engine Fault Codes
Service and Repair Manual June 2020 Deutz TCD 2.2 L3 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. DTC SPN FMI Description 1078 411...
Page 163 June 2020 Service and Repair Manual Deutz TCD 2.2 L3 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 164 Service and Repair Manual June 2020 Deutz TCD 2.2 L3 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 165 June 2020 Service and Repair Manual Deutz TCD 2.2 L3 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. DTC SPN FMI Description 1310 677...
Page 166 Service and Repair Manual June 2020 Deutz TCD 2.2 L3 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 167 June 2020 Service and Repair Manual Deutz TCD 2.2 L3 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; control signal. DTC SPN Description 1485...
Page 168 Service and Repair Manual June 2020 Deutz TCD 2.2 L3 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 169 June 2020 Service and Repair Manual Deutz TCD 2.2 L3 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 170 Service and Repair Manual June 2020 Deutz TCD 2.2 L3 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 171 June 2020 Service and Repair Manual Deutz TCD 2.2 L3 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 172: Perkins 404F-E22Ta Engine Fault Codes
Service and Repair Manual June 2020 Perkins 404F-E22TA Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Accelerator Pedal Position 2: Voltage Above Normal Accelerator Pedal Position 2: Voltage Below Normal Accelerator Pedal Position 1: Voltage Above Normal Accelerator Pedal Position 1: Voltage Below Normal...
Page 173 June 2020 Service and Repair Manual Perkins 404F-E22TA Engine Fault Codes Description Engine Speed Sensor #2: Voltage Above Normal Engine Speed Sensor #2: Voltage Below Normal Engine Speed Sensor#2: Abnormal Frequency, Pulse Width or Period" Engine Speed Sensor #2: Abnormal Rate of Change Engine Rack Position Sensor: Voltage Above Normal...
Page 174 Service and Repair Manual June 2020 Perkins 404F-E22TA Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Engine Speed Sensor #1: Voltage Description Below Normal 3251 Particulate Trap Differential Pressure: 4201 Engine Speed Sensor #1: Abnormal Voltage Above Normal Frequency, Pulse \Nidth, or Period 3251...
Page 175: Continental Tme27 Engine Fault Codes
June 2020 Service and Repair Manual Continental TME27 Engine Fault Codes How to Re triev e Con tinen tal Engi ne Fault Cod es Note: Once a fault code has been retrieved and How to Retrieve Active Engine the repair has been completed, the ECM memory Fault Codes - Continental Models must be reset to clear the fault code from the ECM.
Page 176: Continental Tme27 Engine Fault Codes
Service and Repair Manual June 2020 Continental TME27 Engine Fault Codes Contine ntal TME2 7 Engin e F ault C odes System Code Fault Name 2 3 4 5 6 Fault Conditions MAP Pressure High MAP pressure > 16 psi and TPS < 10% and RPM >...
Page 177 June 2020 Service and Repair Manual Continental TME27 Engine Fault Codes System Code Fault Name 3 4 5 6 Fault Conditions 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc 2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc Engine Max Govern Speed Override RPM >...
Page 178 Service and Repair Manual June 2020 Continental TME27 Engine Fault Codes System Code Fault Name 3 4 5 6 Fault Conditions 2122 FPP1 High Voltage Y FPP1 voltage > 4.8 vdc 2123 FPP1 Low Voltage Y FPP1 voltage < 0.2 vdc Engine Max Govern Speed Override RPM >...
Page 179 June 2020 Service and Repair Manual Continental TME27 Engine Fault Codes System Code Fault Name 1 2 3 4 5 6 Fault Conditions EGO Open/Lazy Pre-cat 1 EGO cold persistently > 120 seconds Sensors EGO Open/Lazy Post-cat EGO cold persistently > 120 seconds Injectors Injector Loop Open or n Y Y Y...
Page 180 Service and Repair Manual June 2020 Continental TME27 Engine Fault Codes System Code Fault Name 1 2 3 4 5 Fault Conditions Cam Crank Cam Loss No cam pulse in 4 cycles and RPM > 1000 Sensors Crank Loss Cam pulses without crank activity > 6 cam pulses Cam Sync Noise Number of invalid cam re-syncs = 1 within a...
Page 181: Gm 3.0L Engine Fault Codes
June 2020 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2/FMI-2 SPN-2/FMI-2 DTC 11: Intake cam / distributor position DTC 221: TPS1-2 higher than expected 520800 / 7 653/6 error DTC 16: Crank and/or cam no sync during DTC 222: TPS2 voltage low 636 / 8 520251 / 4...
Page 182 Service and Repair Manual June 2020 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-2 / FMI- DTC 420: Catalyst inactive on gasoline (Bank DTC 1111: RPM above fuel rev limit level 520211 / 10 515 / 16 DTC 430: Catalyst inactive on gasoline (Bank...
Page 183 June 2020 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-2 / FMI-2 DTC 1315: Cylinder 5 misfire detected 1327 / 11 DTC 1543: AUX analog Pull-Up/Down 2 high voltage 520220 / 3 DTC 1316: Cylinder 6 misfire detected 1328 / 11...
Page 184 Service and Repair Manual June 2020 GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-2 / FMI-2 DTC 1517: AUX analog Pull-Up 3 high voltage 520218 / 3 DTC 1626: CAN-J1939 Tx fault 639 / 12 DTC 1518: AUX analog Pull-Up 3 low voltage 520218 / 4 DTC 1627: CAN-J1939 Rx fault...
Page 185 June 2020 Service and Repair Manual GM 3.0L Engine Fault Codes DTC Set 2 DTC Set 2 Description Description SPN-2 / FMI- SPN-2 / FMI-2 DTC 2123: FPP1 voltage low 91 / 4 DTC 2328: Spark coil 10 primary shorted 1277 / 6 DTC 2125: FPP2 invalid voltage and 520250 / 31 DTC 2428: EGT temperature high...
Page 186: Schematics
Service and Repair Manual June 2020 Schematics Secti on 5 Schematic s About This Section 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 187: Wire Circuit Legend
June 2020 Service and Repair Manual Wire Circuit Legend Circuit numbering Circuit prefix Circuit numbers consist of three parts: the Control circuit prefix, circuit number and circuit suffix. Data The circuit prefix indicates the type of circuit. Engine The circuit number describes the function of Gauges the circuit.
Page 188 Service and Repair Manual June 2020 Wire Circuit Legend Suffix Definition Suffix Definition Auxiliary Boom Valve Engine Speed Select Alternator Field Axle Front Position Auxiliary Forward Valve Flashing Beacon Auxiliary Hydraulic Pump Function Enable Angle Fuel Select (gas/LP) Auxiliary Platform Valve Filter Restricted Auxiliary Reverse Valve Filter Switch...
Page 189 June 2020 Service and Repair Manual Wire Circuit Legend Suffix Definition Suffix Definition Jib Select Valve Platform Level Flow Control Jib Up Propel Lockout Jib Up/Down Control Primary Boom Extend/Retract Signal Load Sensor Platform Level Up Left Front Platform Rotate Control Left Front Steer Sensor Platform Rotate Flow Control Lockout...
Page 190 Service and Repair Manual June 2020 Wire Circuit Legend Suffix Definition Suffix Definition Right Rear Steer Sensor Starter Rotary Sensor Sec Boom Up/Down Flow Control Start Aid (Glow Plug or choke) Tilt Alarm X axis Secondary Boom Tilt Alarm Y axis Sec Boom Down Ground Control Sec Boom Extend...
Page 191: Wire Color Legend
June 2020 Service and Repair Manual Wire Color Legend Wire Coloring Color Circuit # Primary Function Primary boom up drive All cylinder extension colors are solid and all RD/BK Primary boom down drive retract functions are striped black. When RD/WH Primary boom up/dwn FC using black wire, the stripe shall be white.
Page 192 Service and Repair Manual June 2020 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Auxiliary power Axle retract RD/BK Platform level alarm Boom stowed (safety) RD/WH Drive motor shift (speed) OR/RD Power to boom envelope safety switch Forward/EDC-A OR/BK...
Page 193 June 2020 Service and Repair Manual Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function Tether power WH/BK Secondary boom lockout (Riser Down Enable) Tether ESTOP power ECU test switch J1708 + (high) OR/RD Low engine speed J1708 - (low) RD/BK Descent alarm...
Page 194 Service and Repair Manual June 2020 Wire Color Legend Color Circuit # Primary Function Color Circuit # Primary Function BL/RD Spare Encode A BL/WH Steer joystick signal Encode B WH/RD Propel joystick signal Bootstrap or program enable WH/BK Sec boom joystick signal Safety cross check Joystick 5 VDC power Data receive...
Page 195 June 2020 Service and Repair Manual Wire Color Legend Types of Limit Switches Types of Limit Switches There are two types of limit switches, found in LSP1AO Primary boom angle stowed various locations throughout the machine: LSP1RO Primary boom length retracted mechanical-type operational or safety switches.
Page 196: Limit Switches And Angle Sensors
Service and Repair Manual June 2020 Limit Switches and Angle Sensors Limit Switch Legend LSP1RO LSS2AS LSS2AO 10 LSA1OS LSP1EO 11 LSA2OS LSP1AO 12 LST1O LSJ1EO 13 Turntable Angle Sensor Platform Angle Sensor 14 LSS1AO LSS1RO 15 LSS1RS LSS3AO 16 Primary Boom angle Sensor ®...
Page 197 June 2020 Service and Repair Manual Schematics Limit Switch Functions LSS2AS: Limit switch, Secondary Boom #2 Angle Safety Switch. Secondary boom angle full LSA1OS: Limit switch, Axle #1 Oscillating extension, angle up all the way (secondary boom Operational. Activates the axle oscillate circuit on extend allowed).
Page 198: Drive Chassis And Platform Controller Pin Legend
Service and Repair Manual June 2020 Drive Chassis and Platform Controller Pin Legend Pin Numbering - 23 pin connector Plat Controller Plat Controller Drive Chassis J32 Drive Chassis GND PCON - BR VLVRET7 - BR GND-DCON - BR VLVRET - BR P52PCON - BL/RD (UNUSED) P21DCON - WH...
Page 199: Turntable Controller Pin Legend
June 2020 Service and Repair Manual Turntable Controller Pin Legend Pin Numbering - 35 pin connector Pin Numbering - 23 pin connector Pin Numbering - 4 pin connector ® Part No. 1268556GT -80/60...
Page 200 Service and Repair Manual June 2020 Turntable Controller Pin Legend J11 Turntable Turntable Controller Turntable J14 Turntable Controller Controller Controller GNDDCON - BR GNDPCON - BR Vl.VRET1 - BR VLVRET4 - BR P21DCON - RD P52PCON - BL/RD C35RPM – BK/RD C03PBF - RD/WH P53LS - WH/BK C46HN - WH...
Page 201: Relay And Fuse Panel Legends
June 2020 Service and Repair Manual Relay and Fuse Panel Legends ® Part No. 1268556GT -80/60...
Page 202 Service and Repair Manual June 2020 Relay and Fuse Panel Legends ® -80/60 Part No. 1268556GT...
Page 203: Electrical Symbol Legend
June 2020 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 204: Hydraulic Symbols Legend
Service and Repair Manual June 2020 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 205: Electrical Schematics
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine...
Page 206: Electrical Schematic - Engine Options, Deutz Td 2.9 L4 Engine
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine ® -80/60 Part No. 1268556GT...
Page 207: Electrical Schematic - Engine Options, Deutz Td 2.9 L4 Engine Harness
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine Harness ® Part No. 1268556GT -80/60...
Page 208 Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Deutz TD 2.9 L4 Engine Harness...
Page 209 June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine...
Page 210: Electrical Schematic - Engine Options, Deutz Tcd 2.2 L3 Engine
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine ® -80/60 Part No. 1268556GT...
Page 211: Electrical Schematic - Engine Options, Deutz Tcd 2.2 L3 Engine Harness, Tier Iv Models
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Tier IV Models ® Part No. 1268556GT -80/60...
Page 212 Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Tier IV Models...
Page 213 June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Stage V Models...
Page 214: Electrical Schematic - Engine Options, Deutz Tcd 2.2 L3 Engine Harness, Stage V Models
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Deutz TCD 2.2 L3 Engine Harness, Stage V Models ® -80/60 Part No. 1268556GT...
Page 215: Electrical Schematic - Engine Options, Perkins 404D-22T Engine
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 404D-22T Engine ® Part No. 1268556GT -80/60...
Page 216 Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Perkins 404D-22T...
Page 217 June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 404F-E22TA Engine...
Page 218: Electrical Schematic - Engine Options,Perkins 404F-E22Ta Engine
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Perkins 404F-E22TA Engine ® -80/60 Part No. 1268556GT...
Page 219: Electrical Schematic - Engine Options, Perkins 404F-E22Ta Engine Harness
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 404F-E22TA Engine Harness ® Part No. 1268556GT -80/60...
Page 220 Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Perkins 404F-E22TA Engine Harness...
Page 221 June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Perkins 804D Engine...
Page 222: Electrical Schematic - Engine Options, Perkins 804D Engine
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Perkins 804D Engine ® -80/60 Part No. 1268556GT...
Page 223: Electrical Schematic - Engine Options, Continental Tme27 Engine
June 2020 Service and Repair Manual Electrical Schematic - Engine Options, Continental TME27 Engine ® Part No. 1268556GT -80/60...
Page 224 Service and Repair Manual June 2020 Electrical Schematic - Engine Options, Continental TME27 Engine...
Page 225 June 2020 Service and Repair Manual Electrical Schematic - Engine Options, GM 3.0 Engine...
Page 226: Electrical Schematic - Engine Options, Gm 3.0 Engine
Service and Repair Manual June 2020 Electrical Schematic - Engine Options, GM 3.0 Engine ® -80/60 Part No. 1268556GT...
Page 227: Electrical Schematic - Safety Circuits
June 2020 Service and Repair Manual Electrical Schematic - Safety Circuits ® Part No. 1268556GT -80/60...
Page 228 Service and Repair Manual June 2020 Electrical Schematic - Safety Circuits...
Page 229 June 2020 Service and Repair Manual Electrical Schematic - Generator Options...
Page 230: Electrical Schematic - Generator Options
Service and Repair Manual June 2020 Electrical Schematic - Generator Options ® -80/60 Part No. 1268556GT...
Page 231: Electrical Schematic - Welder Generator Option
June 2020 Service and Repair Manual Electrical Schematic - Welder Generator Option ® Part No. 1268556GT -80/60...
Page 232 Service and Repair Manual June 2020 Electrical Schematic - Welder Generator Option...
Page 233: Hydraulic Schematics
June 2020 Service and Repair Manual Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer)
Page 234: Hydraulic Schematic - 2 Wheel Drive (2 And 4 Wheel Steer)
Service and Repair Manual June 2020 Hydraulic Schematic - 2 Wheel Drive (2 and 4 Wheel Steer) ® -80/60 Part No. 1268556GT...
Page 235: Hydraulic Schematic - 4 Wheel Drive (2 And 4 Wheel Steer)
June 2020 Service and Repair Manual Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer) ® Part No. 1268556GT -80/60...
Page 236 Service and Repair Manual June 2020 Hydraulic Schematic - 4 Wheel Drive (2 and 4 Wheel Steer)
Page 237 June 2020 Service and Repair Manual Hydraulic Schematic - Hydraulic Generator Options...
Page 238: Hydraulic Schematic - Hydraulic Generator Options
Service and Repair Manual June 2020 Hydraulic Schematic - Hydraulic Generator Options ® -80/60 Part No. 1268556GT...
Page 239: Electrical Schematic - (From Z8013-4592 To Z8016H-6187)
(~SM)+(AH) MICRO GBOX HARN BTS621 BOOM RET RECOVERY SIGNAL OUT 1 P22R P22R BOOM DWN RECOVERY SIGNAL OUT 2 Genie Z-80 GROUND BTS621 P22R BOOM EXT/RET FC RECOVERY SIGNAL OUT 1 ((~SM)+(AH))(P_22) BOOM UP/DWN FC RECOVERY SIGNAL PLAT OUT 2...
Page 240: Electrical Schematic - (From Z8016H-6188)
PRI BOOM LENGTH 100' STATUS PCON PLATFORM PLATFORM JOYSTICK (JC1) GENERATOR AUXILIARY START ENGINE DRIVE ENGINE STEER MODE STEER MODE SPARE FUEL PLAT Genie Z-80 ALARM ROTATE LEVEL ENABLE DRIVE SELECT PRI BOOM DOWN STATUS ON/OFF PUMP ASSIST START SPEED SPEED SELECT SELECT...

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