Terex Z4525XCM-101 Manuals

Manuals and User Guides for Terex Z4525XCM-101. We have 1 Terex Z4525XCM-101 manual available for free PDF download: Service And Repair Manual

Terex Z4525XCM-101 Service And Repair Manual (197 pages)

Brand: Terex | Category: Lifting Systems | Size: 8 MB

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2
Safety Rules
4
Table of Contents
6
Specifications
13
Machine Specifications
13
Performance Specifications
14
Hydraulic Oil Specifications
14
Hydraulic Component Specifications
17
Deutz D 2.9 L4 Engine Specifications
19
Deutz TD 2.2 L3 Engine Specifications
20
Deutz D2011 L03I Engine Specifications
21
Perkins 404D-22 Engine Specifications
22
Perkins 404F-E22T Engine Specifications
23
Ford MSG-425 EFI Engine Specifications
24
Machine Torque Specifications
25
Hydraulic Hose and Fitting Torque Specifications
25
Torque Procedure
27
Repair Procedures
29
Introduction
29
Platform Controls
31
Circuit Board
31
Joysticks
32
How to Adjust the Joystick Max-Out Setting
32
How to Adjust the Joystick Ramp Rate Setting
33
How to Adjust the Joystick Threshold Setting
35
Platform Components
36
Platform Leveling Slave Cylinder
36
How to Bleed the Slave Cylinder
37
Platform Rotator
37
Platform Overload System
38
How to Replace the Platform Overload Load Cell
41
Platform Overload Recovery Fault
41
Jib Boom Components
42
Jib Boom
42
Jib Boom Lift Cylinder
43
Primary Boom Components
45
Cable Track
45
How to Remove the Cable Track
45
How to Repair the Primary Boom Cable Track
47
Primary Boom
47
How to Disassemble the Primary Boom
49
Primary Boom Lift Cylinder
50
Primary Boom Extension Cylinder
51
Platform Leveling Master Cylinder
52
Secondary Boom Components
53
Secondary Boom
54
Secondary Boom Lift Cylinders
58
Engines
59
RPM Adjustment - Deutz D2011L03I Models
59
RPM Adjustment - Perkins 404D-22 Models
59
Flex Plate
59
How to Install the Flex Plate
61
How to Install the Pump and Bell Housing Assembly
62
Engine Fault Codes
63
Diesel Particle Filter Regeneration - Deutz TD 2.2 L3
64
Hydraulic Pumps
65
Lift/Steer Pump
65
Drive Pump
66
How to Prime the Pump
67
Manifolds
68
Function Manifold Components - CE (to Z4525XCM-1500)
68
8-1.1 Function Manifold Components - ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501)
72
Valve Adjustments - Function Manifold
76
How to Adjust the System Relief Valve
76
How to Adjust the Secondary Boom down Relief Valve
76
Jib Boom / Platform Rotate Manifold Components
77
Turntable Rotation Manifold Components
78
Directional Valve Manifold Components
79
How to Set up the Directional Valve Linkage
80
Traction Manifold Components, 4WD
82
Valve Adjustments, 4WD Traction Manifold
84
Hydraulic Generator Manifold Components, 2.2Kw
85
8-8.1 Generator Manifold Components
86
Valve Coils
87
How to Test a Coil Diode
87
Turntable Rotation Components
89
Turntable Rotation Assembly
89
Axle Components
90
Oscillating Axle Cylinders
90
Fault Codes
91
Introduction
91
Control System Fault Codes
92
How to Retrieve Control System Fault Codes
92
Control System Fault Codes
93
How to Retrieve Platform Overload System Fault Codes - Deutz D2011L03I, Perkins 404D-22 and Ford MSG-425 Models
96
Platform Overload System Fault Codes
97
Fault Code Display - Deutz and Perkins Models
99
How to Retrieve Active Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-E22T Models
99
How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3 Models
100
Deutz D 2.9 L4 and Perkins 404F-E22T Models
101
Soft Key Functions and Icons - Deutz D 2.9 L4 and Perkins 404F-E22T Models
102
Soft Key Functions and Icons - Deutz TD 2.2 L3 Models
103
Main Menu Structure - Deutz D 2.9 L4 Models
104
Main Menu Structure - Deutz TD 2.2 L3 Models
105
Main Menu Structure - Perkins 404F-E22T Models
106
Deutz TD 2.2 L3 Engine Fault Codes
107
Deutz D 2.9 L4 Engine Fault Codes
117
Perkins 404F-E22T Engine Fault Codes
128
Ford MSG-425 Engine Fault Codes
130
How to Retrieve Ford MSG-425 Engine Fault Codes
130
Schematics
135
Introduction
135
Electrical Symbol Legend
136
Hydraulic Symbols Legend
137
Limit Switch Location Legend
138
Electrical Component and Wire Color Legends
139
Hour Meter Legend
142
Electrical Schematics
143
Electrical Schematic, Ford MSG425
144
Electrical Schematic, Deutz D2011L03I and Perkins 404D-22
145
Electrical Schematic, Deutz D 2.9 L4
148
Engine Wire Harness, Deutz D 2.9 L4
149
Electrical Schematic, Deutz TD 2.2 L3
152
Engine Wire Harness, Deutz TD 2.2 L3
153
Engine Wire Harness, Deutz TD 2.2 L3
155
Electrical Schematic, Perkins 404F-22T
158
Perkins 404F-E22T Engine Wire Harness
159
Electrical Schematic, Function Controls - ANSI / CSA
162
Electrical Schematic, Function Controls - CE
163
Electrical Schematic, Platform Overload
166
Electrical Schematic, Options Wiring Diagram
167
Ground Control Box Switch Panel Wiring Diagram
169
Deutz D2011L03I and Perkins 404D-22 - ANSI / CSA
170
Ground Control Box Terminal Strip Wiring Diagram, Deutz D2011L03I and Perkins 404D-22 - ANSI / CSA
171
Ground Control Box Switch Panel Wiring Diagram, Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA
174
Ground Control Box Terminal Strip Wiring Diagram, Deutz D 2.9 L4 and Perkins 404F-E22T - ANSI / CSA
175
Ground Control Box Switch Panel Wiring Diagram, Ford MSG425 - ANSI / CSA
178
Ground Control Box Terminal Strip Wiring Diagram, Ford MSG425 - ANSI / CSA
179
Ground Control Box Switch Panel Wiring Diagram - CE
182
Ground Control Box Terminal Strip Wiring Diagram - CE
183
Platform Control Box Switch Panel Wiring Diagram
186
Platform Control Box Terminal Strip Wiring Diagram
187
Platform Control Box Relayl Wiring Diagram - ANSI / CSA
190
Platform Control Box Relay Wiring Diagram- CE
191
Hydraulic Schematics
193
Hydraulic Schematic - CE (to Z4525XCM-1500)
194
Hydraulic Schematic - ANSI / CSA / CE (from Z4525XCF-101, Z4525XCM-1501)
195

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Terex Z4525XCM-101 Service And Repair Manual (197 pages)

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