Terex Genie Z-40 Service And Repair Manual Download Page 2

Page: 2 / 287

Service and Repair Manual

June 2022

Introduction

-62/40

Part No. 1268555GT

Intro ductio n

Impo rtan t Inf or matio n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.
This manual provides troubleshooting and repair

procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills

are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance and repair be

performed at an authorized Genie dealer service

center.

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest

degree of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.
Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

Contact Us:

Internet: www.genielift.com

E-mail: [email protected]

Find a Manual for this Model

Go to

http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

Copyright © 2015 by Terex Corporation
1268555GT Rev B1, June 2022
First Edition, Second Printing
Genie and "Z" are registered trademarks of Terex South

Dakota, Inc. in the U.S.A. and many other countries.
"TraX" is a trademark of Terex South Dakota, Inc.

Summary of Contents for Genie Z-40

Page 1: ...9 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics from Z6216M 101 To Z6216M 399 from Z62D 150 from Z62H 3000 from Z62M 400 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Original Instructions Part No 1268555GT Rev B1 June 2022 ...

Page 2: ...e Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improve...

Page 3: ...2 11 2017 Specifications Machine Specifications A3 2 2020 Specifications Hydraulic Component Specifications B 5 2020 All Sections Add Deutz TD 2 2 L3 Engine Fault Codes Control System Fault Codes B1 6 2022 Repair 5 1 Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section...

Page 4: ...mber Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number stamped on chassis 6 Serial label located under cover From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover ...

Page 5: ... in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksit...

Page 6: ...shing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from flamma...

Page 7: ...ions 2 Hydraulic Component Specifications 5 Manifold Component Specifications 6 Ford MSG 425 EFI Engine Specifications 7 Deutz D2011 L03i Engine Specifications 8 Deutz TD2011 L04i Engine Specifications 9 Deutz TD 2 2 L3 Engine Specifications 10 Deutz D 2 9 L4 Engine Specifications 11 Perkins 404D 22 Engine Specifications 12 Perkins 404F 22 Engine Specifications 13 Machine Torque Specifications 14 ...

Page 8: ...omponents 26 2 1 Platform Leveling Slave Cylinder 26 2 2 Platform Rotator 28 2 3 Platform Overload System 30 Jib Boom Components 32 3 1 Jib Boom 32 3 2 Jib Boom Lift Cylinder 33 Primary Boom Components 34 4 1 Cable Track 34 How to Remove the Cable Track 34 How to Repair the Cable Track 35 4 2 Primary Boom 35 How to Disassemble the Primary Boom 36 4 3 Primary Boom Lift Cylinder 37 4 4 Primary Boom ...

Page 9: ...Adjust the System Relief Valve 60 How to Adjust the Platform Level Up Relief Valve 60 How to Adjust the Platform Level Down Relief Valve 61 8 3 Jib Boom Platform Rotate Manifold Components 62 8 4 Brake Two Speed Manifold Components 63 8 5 Brake Two Speed Steer Mode Manifold Components 64 8 6 Steer Select Manifold Components 65 8 7 Turntable Rotation Manifold Components 66 8 8 Oscillate Directional...

Page 10: ... Fault Codes Deutz D 2 9 L4 and Perkins 404F 22 Models 93 How to Retrieve Active Engine Fault Codes Deutz TD 2 2 L3 Models 94 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 and Perkins 404F 22 Models 95 Soft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 96 Soft Key Functions and Icons Deutz TD 2 2 L3 Models 97 Main Menu Structure Deutz D 2 9 L4 Models 98 Main Menu S...

Page 11: ...TD 2 2 L3 Engine Wire Harness 146 Electrical Schematic Options All Models 147 Perkins 404F 22 Engine Wire Harness 150 Electrical Schematic Options All Models 151 Wiring Diagram 3kW Hydraulic Generator 154 Wiring Diagram 12kW Hydraulic Generator Welder Option 155 Hydraulic Schematic 12kw Hydraulic Generator Welder Option 157 Wiring Diagram Lift Drive Option 160 Wiring Diagram Platform Overload Opti...

Page 12: ...I and CSA Models 185 Electrical Schematic Ford MSG 425 EFI Models ANSI CSA 186 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models ANSI CSA 190 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA 191 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models ANSI CSA 194 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI ...

Page 13: ... Control Box Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA 226 Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA 227 Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA 230 Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA 231 Electrical Schematic Perkins 404F 22 Models ANSI CSA 234 Ground Control Box Termi...

Page 14: ...E 254 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS CE 255 Electrical Schematic Deutz 2011 L03i Perkins 404D 22 Models AS CE 258 Ground Control Box Terminal Strip Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE 262 Ground Control Box Switch Panel Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE 263 Platform Control Box Wiring Diagram Deutz 2011 ...

Page 15: ...93 7 cm Overall tire diameter High flotation 40 3 in 102 4 cm Tire pressure Rough terrain 70 psi 4 92 bar Tire pressure High flotation 60 psi 4 13 bar Track Components Track material Rubber Tensioning system Pressurized grease Weight each 1500 lbs 680 kg Fluid capacities LPG tank 33 5 lbs 15 2 kg Fuel tank Gas LPG models 20 gallons 75 7 liters Fuel tank Diesel models 36 gallons 136 3 liters Hydrau...

Page 16: ...aulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ...

Page 17: ... 49 C Hydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375 F 1...

Page 18: ...m is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Shell ...

Page 19: ...variable displacement piston pump Flow rate 2500 rpm 32 4 gpm 122 6 L min Drive pressure maximum 3750 psi 259 bar Charge Pump Type gerotor Displacement per revolution 0 85 cu in 13 9 cc Flow rate 2500 rpm 9 gpm 34 L min Charge pressure 2500 rpm 310 psi 21 4 bar Function Pump Type 2 section tandem gear pump Displacement Pump 1 inner 1 3 cu in 21 cc Flow rate 2500 rpm 14 gpm 53 L min Displacement Pu...

Page 20: ...re 280 psi 19 3 bar Drive motors 4WD models Displacement per revolution variable 0 79 to 1 83 cu in 13 to 30 cc Drive motors 2WD models Displacement per revolution variable 1 28 to 2 14 cu in 20 9 to 35 cc Hydraulic Filters High pressure filter Beta 3 ˆ 200 High pressure filter bypass pressure 51 psi 3 5 bar Medium pressure filter Beta 3 ˆ 200 Medium pressure filter bypass pressure 51 psi 3 5 bar ...

Page 21: ...ssure switch point 7 5 psi 0 51 bar Normal engine cranking speedOil viscosity requirements Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Electronic fuel pump Fuel pressure static 60 psi 4 1 bar Fuel flow rate 0 58 gpm 2 2 L min Fuel requirement For fuel requirements refer to the engine Operat...

Page 22: ... 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Temperature switch point 300 F 149 C Oil pressure switch Oil pressure switch point 22 psi 1 5 bar Fuel injection system Injection ...

Page 23: ... F to 104 F 20 C to 40 C 10W 40 Above 5 F 15 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 275 F 135 C Oil pressure switch Installation torque 8 18 ft lbs 11 24 Nm Oil pres...

Page 24: ...0 C 10W 40 Above 5 F 15 C 15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Oil temperature switch Installation torque 8 18 ft lbs 11 24 Nm Temperature switch point 257 F 125 C Oil Pressure switch Installation torque 8 18 ft lbs 11 24 Nm Pressure switch point 17 4 psi ...

Page 25: ...to 32 C 10W 40 Above 23 F 5 C 20W 50 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil temperature switch Temperature switch point 257 F 125 C Oil pressure switch Oil pressure switch point 20 psi 1 4 bar Engine coolant Capacity 10 quarts 9 4 liters Fuel injection system...

Page 26: ...s Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel injection system Injection pump make Zexel In...

Page 27: ...iters Oil viscosity requirements Below 86 F 30 C 5W 20 4 F to 104 F 20 C to 40 C 10W 30 Above 14 F 10 C 15W 40 Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Oil pressure sending unit Oil pressure switch point 14 2 psi 1 bar Fuel injection system Injection pump make Zexe...

Page 28: ... ft lbs 50 Nm Drive motor and hubs Drive hub mounting bolts dry 200 ft lbs 271 Nm TRAX To rque Specific ations TraX Torque Specifications Sprocket to hub adapter fasteners 3 4 10 nuts GR 8 dry 317 ft lbs 430 Nm 3 4 10 nuts GR 8 lubricated 281 ft lbs 381 Nm 1 2 13 FHS screws dry 80 ft lbs 108 Nm 1 2 13 screws lubricated 60 ft lbs 81 Nm Hub adapter to drive hub fasteners Lug nut torque dry 240 ft lb...

Page 29: ...20 2 6 9 16 18 1 1 2 8 3 4 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 49 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable...

Page 30: ...is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare...

Page 31: ...umber of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fittin...

Page 32: ...Service and Repair Manual June 2022 Specifications 18 Z 62 40 Part No 1268555GT SAE and Me tric Fast ene rs Torq ue Ch arts ...

Page 33: ...anual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on ...

Page 34: ... personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoi...

Page 35: ...troller 1 1 ALC 50 0 Circui t Boa rd 1 1 ALC 500 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 ALC 500 circuit board is replaced the joystick controllers will need to be calibrated Refer to Repair Procedure How to Calibrate a Joystick How to Remove the ALC 500 Circu...

Page 36: ...ystick calibration Result The alarm does not sound Check the electrical connections or replace the joystick 8 Repeat this procedure for each joystick controlled machine function including the thumb rocker steer switch Note No machine function should operate while performing the joystick calibration procedure How to Adju st th e Joys tick Thres hold S etting How to Adjust the Joystick Threshold Set...

Page 37: ...tick controlled machine function Whenever a hydraulic cylinder drive motor or hydraulic pump is replaced the max out setting should be adjusted to maintain optimum performance The max out settings on the joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emer...

Page 38: ... the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to reach maximum output when moved out of the neutral position The ramp rate settings of a joystick can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Note Perform this procedure with the boom in the stowed position 1 Pull out the ...

Page 39: ... 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to be saved Result The alarm should sound indicating that the settings have been saved in memory Note Do not operate any machine function during the 10 second waiting time Ramp rate factory settings Primary boom up down accelerate 3 seconds decelerate 1 second Secondary boom up down accelera...

Page 40: ...and place blocks under the platform for support 3 Lower the jib boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the jib boom on the blocks 4 Tag disconnect and cap the hydraulic hoses from the slave cylinder Plug the union hoses from the master cylinder together using a connector Bodily injury hazard Spraying hydraulic oil ...

Page 41: ... 27 How to Bleed the Slave Cylinder 1 Simultaneously activate the primary boom up function and the platform level up function until the boom is fully raised 2 Simultaneously activate the primary boom down function and the platform level down function until the boom is fully lowered ...

Page 42: ... left position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform and platform support 2 Tag disconnect and plug the hydraulic hoses from the platform rotator manifold Ca...

Page 43: ... enable toggle switch to either side and activate the platform rotate toggle switch to the right then the left through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw on the rotator but do not remove it Bodily injury hazard Spraying hydrau...

Page 44: ...rews for leaks 2 3 Plat for m Ove rloa d Syste m 2 3 Platform Overload System if equipped How to Calibrate the Platform Overload System Calibrating the platform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromis...

Page 45: ...dicator light is flashing at both the ground and platform controls the alarm is sounding and the engine shuts down Proceed to step 8 Result The overload indicator lights are off at the platform and ground controls the alarm does not sound and the engine continues to run Slowly loosen the load spring adjustment nut in a counterclockwise direction in 10 increments until the overload indicator light ...

Page 46: ...ning fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 6 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 7 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 8 Attach a lifting strap from an overhead crane to the jib boom 9 Support the barrel end of the jib boom lift cylinder with...

Page 47: ...to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin out enough to lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Supp...

Page 48: ...ect the power to plat cable from the AC outlet box 3 Remove the hose and cable clamps from the platform support 4 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the top of the primary boom Cap the bulkhead fittings Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the...

Page 49: ...rack section to the existing cable track using the pins and snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 2 Pri mar y Boo m 4 2 Primary Boom How to Remove the Primary Boom Bodily injury hazard This procedure requires specific repair skills lifting eq...

Page 50: ...cated under the primary boom and set it on a supporting device 13 Remove the retaining fasteners from the primary boom pivot pin 14 Remove the primary boom pivot pin with a soft metal drift then carefully remove the primary boom from the machine and place it on a structure capable of supporting it Crushing hazard The primary boom could become unbalanced and fall when removed from the machine if no...

Page 51: ...head crane to the primary boom for support 5 Raise the primary boom with the overhead crane slightly to take the pressure off the primary boom lift cylinder pivot pins 6 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 7 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylin...

Page 52: ...ks securing the extend cylinder to the 2 boom tube through the access holes in the 1 boom tube 4 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube 5 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate a...

Page 53: ...dary boom until both the rod end and barrel end pivot pins on the master cylinder are accessible 2 Use an overhead supporting device to support the platform Do not apply lifting pressure 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to al...

Page 54: ...rt No 1268555GT Secondary B oom Components Secondary Boom components 1 master cylinder 2 primary boom lift cylinder 3 upper compression arms 4 mid pivot 5 timing link 6 secondary boom lift cylinder 7 lower compression arm 8 lower tension arms 9 upper tension arm 10upper pivot ...

Page 55: ... pins of the secondary lift cylinder clear the lower tension arms 2 Attach a lifting strap from an overhead supporting device 5 ton 5000 kg to the pivot end of the primary boom for support Do not apply lifting pressure Crushing hazard The boom assembly can fall if not properly supported by the overhead crane Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 3 Re...

Page 56: ...enter of the machine enough to lower it down through the lower compression arm Pull the cylinder towards the platform and remove it from the machine Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the suitable lifting device Component damage hazard When removing a secondary boom lift cylinder from the machi...

Page 57: ...Plate Deutz models 1 Remove the tailpipe bracket mounting fasteners from the engine bell housing 2 Support the drive pump assembly with an appropriate lifting device 3 Remove all of the engine bell housing fasteners 4 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 5 Remove t...

Page 58: ... of the engine bell housing fasteners 5 Carefully pull the pump and bell housing assembly away from the engine and secure it from moving Component damage hazard Hoses can be damaged if they are kinked or pinched 6 Remove the flex plate mounting fasteners 7 Remove the flex plate from the flywheel How to I nstall t he Flex Plat e How to Install the Flex Plate 1 Install the flex plate onto the engine...

Page 59: ...June 2022 Service and Repair Manual Engines Part No 1268555GT Z 62 40 45 Ford Models Deutz Models Perkins Models ...

Page 60: ...que the bell housing mounting bolts labeled A and B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled C to 70 ft lbs 95 Nm Perkins models Torque the bell housing mounting bolts labeled B in sequence to 28 ft lbs 38 Nm and the mounting bolts labeled A to 49 ft lbs 66 Nm Then torque the bell housing mounting bolts labeled B in sequence to 40 ft lbs 54 Nm and the mounting bolts labeled A ...

Page 61: ...quential fuel injection and make constant and instantaneous changes to ignition timing fuel delivery and throttle position to maintain the engine s running condition at its highest efficiency while at the same time keeping exhaust emissions to a minimum When a sensor fails or returns signals that are outside of set parameters the ECM will store a fault code in memory that relates to the appropriat...

Page 62: ...for your specific engine model Use the Fault Code Chart to aid in identifying the fault 6 6 En gine Faul t Cod es D eutz D 2 9 L4 and Perkins 40 4F 22 Mod els 6 6 Engine Fault Codes Deutz D 2 9 L4 and Perkins 404F 22 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine The ECM also uses signals from the sensors to initiate sequential ...

Page 63: ...does not need to perform any actions Standstill regeneration If passive regeneration does not attain an adequate reduction of the soot contamination the particle filter will continue to become contaminated with soot and a standstill regeneration will be required by the operator To perform standstill regeneration refer to the Operator s Manual on your machine Service regeneration If a fault occurs ...

Page 64: ... be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 2 Tag disconnect and plug the function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin...

Page 65: ...ed on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank Close the valves Component damage hazar...

Page 66: ...n the drive pump 2 Ford models Close the valve on the LPG tank then disconnect the hose from the tank Then move the fuel select switch to the LPG position Perkins 404D 22 models Disconnect the engine wiring harness from the fuel solenoid at the injector pump Deutz D2011 L03i models Hold the manual fuel shutoff valve clockwise to the closed position 1 manual fuel shutoff valve 3 Have another person...

Page 67: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 53 This page intentionally left blank ...

Page 68: ...Nm 8 Solenoid valve 2 position 2 way normally open C Function enable valve 33 37 ft lbs 45 50 Nm 9 Check valve S Differential sensing circuit secondary boom 8 10 ft lbs 10 15 Nm 10 Differential sensing valve 190 psi 13 bar AS Differential sensing circuit meters flow to functions 50 55 ft lbs 68 75 Nm 11 Differential sensing valve 150 psi 10 3 bar AO Differential sensing circuit secondary boom 30 3...

Page 69: ...June 2022 Service and Repair Manual Manifolds Part No 1268555GT Z 62 40 55 ...

Page 70: ... bar BN Platform level down circuit 20 25 ft lbs 27 34 Nm 26 Check valve AL Differential sensing circuit platform level down 8 10 ft lbs 10 15 Nm 27 Check valve AM Differential sensing circuit platform level up 8 10 ft lbs 10 15 Nm 28 Check valve BH Differential sensing circuit primary boom extend retract 8 10 ft lbs 10 15 Nm 29 Differential sensing valve 80 psi 5 5 bar AD Turntable rotate left ri...

Page 71: ...June 2022 Service and Repair Manual Manifolds Part No 1268555GT Z 62 40 57 ...

Page 72: ...nsing valves to tank 25 30 ft lbs 34 41 Nm 37 Check valve 100 psi 7 bar AX Primary boom and secondary boom circuit 35 40 ft lbs 47 54 Nm 38 Relief valve 1250 psi 86 bar M Primary boom retract 25 30 ft lbs 34 41 Nm 39 Check valve 30 psi 2 bar AW Platform rotate left and jib boom up 20 25 ft lbs 27 34 Nm 40 Check valve BM Platform level up circuit 20 25 ft lbs 27 34 Nm 41 Flow control valve H Platfo...

Page 73: ...June 2022 Service and Repair Manual Manifolds Part No 1268555GT Z 62 40 59 ...

Page 74: ... Do not adjust the relief valve higher than specified 7 Repeat this procedure beginning with step 2 to confirm the relief valve pressure 8 Remove the pressure gauge How to Adju st th e Platfo rm Lev el Up Reli ef Valve How to Adjust the Platform Level Up Relief Valve Note Perform this procedure with the machine in the stowed position 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the tes...

Page 75: ...rpm 4 Raise the jib to the horizontal position 5 Press and hold the function enable button Activate and hold the platform level down switch with the platform fully lowered 6 Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 7 Turn the engine off Use a wrench to hold the relief valve and remove the cap 8 Adjust the internal hex socket Turn...

Page 76: ...r m Rota te Manif old Co mpo nen ts 8 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way G Platform rotate jib boom select 8 10 ft lbs 11 14 Nm ...

Page 77: ...ponents The brake two speed manifold is located under the turntable cover at the platform end Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way KK Brake release 8 10 ft lbs 11 14 Nm 2 Solenoid Valve 2 position 3 way LL Two speed drive motor shift 3 Check valve II Brake circuit 4 Orifice JJ Brake and two speed circuit ...

Page 78: ...is located under the turntable cover at the platform end Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way MM Steer circuit 20 ft lbs 27 Nm 2 Solenoid Valve 2 position 3 way LL Two speed drive motor shift 20 ft lbs 27 Nm 3 Solenoid Valve 2 position 3 way KK Brake release 20 ft lbs 27 Nm 4 Orifice JJ Brake and two speed circuit 5 Check valve II Brake circuit 8 10...

Page 79: ...ct M anif old Co mpo nent s 8 6 Steer Select Manifold Components The brake two speed manifold is located under the turntable cover at the platform end Index No Description Schematic Item Function Torque 1 Pilot operated 2 position 4 way directional valve NN Steer circuit 30 35 ft lbs 41 47 Nm ...

Page 80: ...tation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the center of the turntable Index No Description Schematic Item Function 1 Counterbalance valve MM Turntable rotate right 2 Counterbalance valve NN Turntable rotate left 3 Shuttle valve OO Brake circuit 4 Orifice PP Brake circuit ...

Page 81: ...nts 8 8 Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description Schematic Item Function Torque 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve AA Directional control 3 Relief valve 800 psi 55 bar BB Oscillate relief 30 35 ft lbs 41 47 Nm ...

Page 82: ...ion Note The tires on some machines are foam filled and do not need air added to them 3 Remove the non steer end drive chassis cover and axle covers 4 Remove the ball joint retaining fastener from the bracket 5 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 6 Verify that the ground and drive chassis are completely leve...

Page 83: ...ngine idle toggle switch to the high idle position Activate the foot switch 5 With the engine running in high rpm manually activate the directional valve linkage in either direction Observe the pressure spike on the pressure gauge when the machine fully oscillates Refer to Specifications Hydraulic Component Specifications 6 Turn the engine off 7 Locate the relief valve on the directional valve and...

Page 84: ... machine Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 2 way CA Diverts oil from the drive circuit to the welder 35 40 ft lbs 47 54 Nm 2 Flow control valve CB Controls flow to the hydraulic motor 3 Check valve 65 psi 4 5 bar CC Flow control circuit 35 40 ft lbs 47 54 Nm 4 Relief valve 3500 psi 241 bar CD Charge pressure circuit 30 35 ft lbs 41 47 Nm 5 Check valve ...

Page 85: ...June 2022 Service and Repair Manual Manifolds Part No 1268555GT Z 62 40 71 ...

Page 86: ...ief valve 280 psi 19 3 bar UU Charge pressure circuit 30 35 ft lbs 41 47 Nm 2 Flow divider combiner valve XX Controls flow to drive motors in forward and reverse 80 90 ft lbs 108 122 Nm 3 Check valve SS Drive circuit 90 100 ft lbs 122 136 Nm 4 Check valve YY Drive circuit 30 35 ft lbs 41 47 Nm 5 Shuttle Valve 3 position 3 way VV Charge pressure circuit that directs hot oil out of low pressure side...

Page 87: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 73 This page intentionally left blank ...

Page 88: ...ice 0 040 inch 1 mm WW Equalizes pressure on both sides of divider combiner valve 1 6 Orifice 0 040 inch 1 mm AE Equalizes pressure on both sides of divider combiner valve 13 7 Orifice 0 040 inch 1 mm AC Equalizes pressure on both sides of divider combiner valve 4 8 Check valve SS Non steer end drive motor circuit 35 40 ft lbs 14 16 Nm 9 Check valve AF Non steer end drive motor circuit 60 70 ft lb...

Page 89: ...June 2022 Service and Repair Manual Manifolds Part No 1268555GT Z 62 40 75 ...

Page 90: ...nut 4 Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position Note the reading on the pressure gauge 5 Turn the engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 2WD models Hold the charge pressure relief valve and remove the cap item UU 4WD models Hold the ...

Page 91: ...Generator Manifold Components 3kW The generator manifold is mounted to the hydraulic generator located in the ground controls compartment Index No Description Schematic Item Function Torque 1 Proportional solenoid valve HH Controls generator speed 33 37 ft lbs 45 50 Nm 2 Relief valve 3000 psi 207 bar GG Generator relief valve 20 25 ft lbs 27 34 Nm ...

Page 92: ...rings watches and other jewelry 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 2...

Page 93: ...erminal on the coil Resistor 10Ω Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 m...

Page 94: ...o the stowed position 4 Secure the turntable from rotating with the turntable rotation lock Tip over hazard The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position 5 Raise the secondary boom until the upper pivot is 6 feet 2 m above the counterweight 6 Install a cylinder chock Genie part number 33484 onto the secondary...

Page 95: ...ust the Turntable Gear Backlash 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 Note Perform this procedure with the machine on a firm level surface and the boom rotated 90 to either side of the drive chassis 1 Push the backlash plat...

Page 96: ...cifications Hydraulic Hose and Fitting Torque Specifications 1 Rotate the turntable until the boom is between the steer tires or tracks 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipa...

Page 97: ...rocket retaining fasteners from the hub adapter 8 Carefully remove the track assembly from the drive hub and set aside Crushing hazard The track assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane How to Replace the Track Note Perform this procedure on a firm level surface with the machine in the stowed position 1 Remove the track...

Page 98: ...idler wheels 2 bogey wheels 9 Rotate the sprocket half until the split tooth of the sprocket is lower than the other side 1 split tooth 10 Using an overhead supporting device lift up on the rubber track to create enough room to install the other sprocket half 11 Install the sprocket half removed in step 3 while engaging the sprocket teeth with the rubber track Note Be sure to align the split tooth...

Page 99: ...e track assembly could become unbalanced and fall when installed onto the machine if not properly supported by the overhead crane 17 Adjust the track tension Locate the grease plug on the track tension cylinder Loosen the plug but do not remove it 18 Locate the grease zerk fitting on the other side of the track tension cylinder 1 grease zerk 2 grease plug 19 Pump grease into the grease zerk fittin...

Page 100: ...the grease plug on the cylinder to remove grease and loosen the track 22 Raise the machine remove the jack stands and lower the machine 23 Drive the machine in either direction just until the remaining sprocket retaining fasteners can be installed onto the drive hub adapter Turn the machine off 24 Install the remaining sprocket retaining fasteners to the drive hub adapter and torque to specificati...

Page 101: ...purge wire with the male spade connector from the MTE generator harness 2 Connect a jumper wire of sufficient length from the positive battery terminal to the spade connector on the purge wire 3 Start the engine and turn on the generator Allow the generator to run for three minutes 4 Turn off the generator and turn off the engine 5 Remove the jumper wire from the positive battery terminal and disc...

Page 102: ...s chocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option 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 ne...

Page 103: ...onent damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the tw...

Page 104: ...ot Calibrated Normal function except threshold for one or both directions is zero Calibrate valve threshold 18 Just calibrated Initiate 1 second beep of Alarm Self clearing transient 24 Angle sensor 11 Value at 5 0 V Reduced function speed Retract before lowering required Dual capacity models Power up controller with problem corrected 12 Value too high 15 Value too low 16 Value at 0 V 17 Not Calib...

Page 105: ...ited Speed and Direction frozen at zero and neutral Alarm sounds Power up controller with problem corrected 12 Value too high 15 Value too low 16 Value at 0 V 17 Not Calibrated Initiate 1 second beep of Alarm Calibrate Joystick 18 Just calibrated Initiate 1 second beep of Alarm Self clearing transient 42 Turntable Rotate Directional Valves 21 Fault Limited Speed and Direction frozen at zero and ne...

Page 106: ...with problem corrected 55 Propel High Motor Speed Valve 21 Fault Motor speed frozen in the low state Power up controller with problem corrected 56 Platform Level Valve 21 Fault Direction frozen at zero and neutral Power up controller with problem corrected 57 Foot switch ECU Power Crosscheck 12 Value too high Direction frozen at zero and neutral Power up controller with problem corrected 15 Value ...

Page 107: ...s 404F 22 is equipped with an engine fault LED located at the platform control box If an engine fault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm When operating from the platform if the red Emergency Stop button is pushed in the active fault code s will be erased from the display Start the engine from the ground con...

Page 108: ...ault occurs that does not result in an engine shutdown the engine rpm will go into limp home mode resulting in the loss of high rpm When operating from the platform if the red Emergency Stop button is pushed in the active fault code s will be erased from the display Start the engine from the ground control box and operate various boom functions to verify that an active engine fault occurs and is s...

Page 109: ...vice Flashing with right flashing amber LED engine soot level over 140 Engine shut down Contact service 4 Right green LED Flashing engine fault detected Contact service Solid fault acknowledged Contact service 5 Right amber LED Perkins models Solid with left amber LED on solid regeneration has been inhibited and engine soot level is between 80 100 Regeneration is required Flashing with left amber ...

Page 110: ...ft Key Functions and Icons Deutz D 2 9 L4 and Perkins 404F 22 Models 1 Next menu Exit Back one screen Decrease brightness 2 Brightness Contrast Scroll up Increase Increase brightness 3 Regeneration forced Scroll down Decrease Decrease contrast 4 Regeneration inhibited Select Next Main menu Increase contrast Note Regeneration initiate inhibit and soot only apply to the Perkins 404F 22 models ...

Page 111: ...Decrease brightness 3 Scroll down Decrease Time Date Increase brightness 4 Main menu Select Main Screen Icons Engine Warning Icons Engine RPM Voltage Oil pressure Coolant temperature Regen required DPF service required Replace DPF Change oil Soot load Engine torque Hour meter Time since last regen Low coolant Fuel Water separator Engine stop Engine start Exit Back one screen Scroll up Scroll down ...

Page 112: ...Service and Repair Manual June 2022 Fault Codes 98 Z 62 40 Part No 1268555GT Main Men u Struc tur e D eutz D 2 9 L4 Mod els Main Menu Structure Deutz D 2 9 L4 Models ...

Page 113: ...June 2022 Service and Repair Manual Fault Codes Part No 1268555GT Z 62 40 99 Main Men u Struc tur e D eutz TD 2 2 L 3 M odels Main Menu Structure Deutz TD 2 2 L3 Models ...

Page 114: ...Service and Repair Manual June 2022 Fault Codes 100 Z 62 40 Part No 1268555GT Main Men u Struc tur e Pe rkins 404 F 22 Mod els Main Menu Structure Perkins 404F 22 Models ...

Page 115: ...e measured differential pressure 1075 411 2 Engine exhaust gas recirculation Positive measured differential pressure DTC SPN FMI Description 1077 411 3 Engine exhaust gas recirculation Signal value above maximum limit 1078 411 4 Engine exhaust gas recirculation Signal value below maximum limit 1079 108 0 Ambient air pressure sensor above normal operational range 1080 108 1 Ambient air pressure sen...

Page 116: ... normal or shorted to high 1131 1209 4 Engine exhaust pressure sensor voltage below normal or shorted to low DTC SPN FMI Description 1134 3251 3 DPF voltage above normal or shorted to high 1135 3251 4 DPF voltage below normal or shorted to low 1136 3251 14 DPF reporting communication error 1137 3251 14 DPF reporting data error 1138 3251 14 DPF reporting fast channel 1 error 1139 3251 14 DPF report...

Page 117: ... Maximum rail pressure exceeded in limp home mode 1208 157 3 Engine fuel injector metering rail pressure voltage above normal or shorted to high DTC SPN FMI Description 1209 157 4 Engine fuel injector metering rail pressure voltage below normal or shorted to low 121 520252 2 Wrong checksum in the CAN message EAT Control 1212 629 12 ECU Keep alive error during runtime at an external device 1213 629...

Page 118: ...U below normal operational range 1306 677 3 Engine starter motor relay voltage above normal or shorted to high 1307 677 4 Engine starter motor relay voltage below normal or shorted to low DTC SPN FMI Description 1308 677 5 Engine starter motor relay current below normal or shorted to low 1310 677 3 Engine starter motor relay voltage above normal or shorted to high 1311 677 4 Engine starter motor r...

Page 119: ... valve 1 position 1 mechanical system not responding or out of adjustment Valve stuck open 1391 51 3 Engine throttle valve 1 position 1 voltage above normal or shorted to high DTC SPN FMI Description 1392 51 4 Engine throttle valve 1 position 1 voltage below normal or shorted to low 1397 105 0 Engine intake manifold 1 temperature above normal operational range 1398 105 1 Engine intake manifold 1 t...

Page 120: ...or of CAN receive frame TSC1AR Retarder 365 3349 0 Timeout error of CAN receive frame TSC1TE Setpoint DTC SPN FMI Description 367 3349 0 Timeout Error of CAN receive frame TSC1TR control signal 38 1485 3 ECM main relay voltage above normal or shorted to high 39 1485 3 ECM main relay voltage above normal or shorted to high of actuator relay 2 40 1485 3 ECM main relay voltage above normal or shorted...

Page 121: ...threshold Overrun Mode 610 171 15 Environment temperature sensor temperature above upper physical threshold DTC SPN FMI Description 613 171 3 Ambient air temperature sensor voltage above normal or shorted to high 614 171 4 Ambient air temperature sensor voltage below normal or shorted to low 615 723 8 Camshaft speed sensor abnormal frequency or pulse width or period 616 723 14 Camshaft sensor dete...

Page 122: ...ngine cylinder 4 fuel injection quantity current below normal or open circuit 820 5362 5 Engine cylinder 5 fuel injection quantity current below normal or open circuit DTC SPN FMI Description 821 5363 5 Engine cylinder 6 fuel injection quantity current below normal or open circuit 822 2797 6 Engine fuel 1 injector Group 1 current above normal or grounded circuit 823 2798 6 Engine fuel 1 injector G...

Page 123: ...ramming injector 1 839 2798 14 Engine fuel 1 injector group 2 missing injector adjustment value programming injector 2 DTC SPN FMI Description 840 4257 14 Engine fuel 1 injector group 3 missing injector adjustment value programming injector 3 854 7103 5 Engine fuel metering rail pump current below normal or open circuit 855 7103 3 Engine fuel metering rail pump voltage above normal or shorted to h...

Page 124: ...rs Diagnostic fault check to report the error due to injection quantity correction 884 5442 2 Engine fuel injection pressure error for multiple cylinders 885 29 2 Accelerator pedal 2 position 886 677 2 Engine starter motor relay Function monitoring Fault of ECU power train active DTC SPN FMI Description 887 513 2 Actual engine percent torque DFC to report the fault in energizing time comparison 88...

Page 125: ...ctuator error EGR Valve Overload by short circuit 51 7 1016 Actuator position for EGR Valve not plausible SPN FMI KWP Description 51 11 1231 Actuator error EGR Valve Power stage over temp due to high current 51 12 1018 Actuator EGR Valve powerstage over temperature 51 12 1021 Mechanical actuator defect EGR Valve 51 12 1225 Actuator EGR Valve over temperature 94 1 474 Low fuel pressure warning thre...

Page 126: ...d correction factor exceeding the maximum drift limit 157 3 877 Sensor error rail pressure signal range check high 157 4 878 Sensor error rail pressure signal range check low SPN FMI KWP Description 168 0 1180 Physical range check high for battery voltage 168 1 1181 Physical range check low for battery voltage 168 2 47 High battery voltage warning threshold exceeded 168 2 48 Low battery voltage wa...

Page 127: ... 4 381 Physical range check low for EGR differential pressure 411 4 796 Sensor error differential pressure Venturiunit EGR signal range check low SPN FMI KWP Description 412 3 1007 Sensor error EGR cooler downstream temperature signal range check high 412 4 1008 Sensor error EGR cooler downstream temperature signal range check low 520 9 306 Timeout Error of CAN Receive Frame TSC1TR Setpoint 597 2 ...

Page 128: ...out Error of CAN Receive Frame TSC1TE Setpoint 1079 13 946 Sensor supply voltage monitor 1 error ECU 1080 13 947 Sensor supply voltage monitor 2 error ECU SPN FMI KWP Description 1109 2 121 Engine shut off demand ignored 1136 0 1398 Physikal range check high for ECU temperature 1136 1 1399 Physikal range check low for ECU temperature 1136 3 1400 Sensor error ECU temperature signal range check high...

Page 129: ...5 Physical range check low for EGR exhaust gas mass flow 2659 2 1523 Exhaust gas recirculation AGS sensor plausibility error SPN FMI KWP Description 2659 2 1527 AGS sensor temperature exhaust gas mass flow plausibility error 2659 12 1526 Exhaust gas recirculation AGS sensor has burn off not performed 2797 4 1337 Injector diagnostics timeout error of short circuit to ground measurement cyl Bank 0 2...

Page 130: ...09 9 825 Pressure Relief Valve PRV reached maximun allowed opening count 523009 10 833 Pressure relief valve PRV reached maximun allowed open time SPN FMI KWP Description 523212 9 171 Timeout Error of CAN Receive Frame ComEngPrt Engine Protection 523216 9 198 Timeout Error of CAN Receive Frame PrHtEnCmd pre heat command engine command 523240 9 179 Timeout CAN message FunModCtl Function Mode Contro...

Page 131: ...tion reported error 523612 12 628 Internal ECU monitoring detection reported error SPN FMI KWP Description 523612 12 637 Internal ECU monitoring detection reported error 523612 12 1170 Internal software error ECU 523612 14 973 Softwarereset CPU SWReset_0 523612 14 974 Softwarereset CPU SWReset_1 523612 14 975 Softwarereset CPU SWReset_2 523613 0 856 Maximum positive deviation of rail pressure exce...

Page 132: ... Description 523788 12 299 Timeout Error of CAN Transmit Frame TrbCH Status Wastegate 523793 9 202 Timeout Error of CAN Receive Frame UAA10 AGS sensor service message 523794 9 203 Timeout Error of CAN Receive Frame UAA11 AGS sensor data 523895 13 559 Check of missing injector adjustment value programming IMA injector 1 in firing order 523896 13 560 check of missing injector adjustment value progra...

Page 133: ...6 12 169 Timeout Error of CAN Transmit Frame EEC3VOL2 Engine send messages 523946 0 1158 Zero fuel calibration injector 1 in firing order maximum value exceeded SPN FMI KWP Description 523946 1 1164 Zero fuel calibration injector 1 in firing order minimum value exceeded 523947 0 1159 Zerofuel calibration injector 2 in firing order maximum value exceeded 523947 1 1165 Zerofuel calibration injector ...

Page 134: ...alue downstream DOC too high 524028 2 1431 CAN message PROEGRActr plausibility error 524029 2 1432 Timeout Error of CAN Receive Frame ComEGRActr exhaust gas recirculation positioner 524030 7 1440 EGR actuator internal error 524031 13 1441 EGR actuator calibration error SPN FMI KWP Description 524032 2 1442 EGR actuator status message EGRCust is missing 524033 7 1443 EGR actuator due to overload in...

Page 135: ...t error of CAN Transmit Frame ComETVActr 524111 9 1680 Timeout error of CAN Receive Frame ComRxETVActr 524112 9 1671 Timeout ComITVActr 524113 9 1681 Timeout error of CAN Receive Frame ComRxITVActr SPN FMI KWP Description 524114 9 1659 Timeout error of CAN Transmit Frame A1DOC 524115 9 1660 Timeout error of CAN Transmit Frame AT1S 524116 9 1661 Timeout error of CAN Transmit Frame SCR2 524117 9 166...

Page 136: ...ove Normal 558 4 Accelerator Pedal1 Low Idle Switch Voltage Below Normal 638 6 Engine Fuel Rack Actuator Current Above Normal 639 14 J1939 Network 1 Special Instruction SPN FMI Description 723 3 Engine Speed Sensor 2 Voltage Above Normal 723 4 Engine Speed Sensor 2 Voltage Below Normal 723 8 Engine Speed Sensor 2 Abnormal Frequency Pulse Width or Period 723 10 Engine Speed Sensor 2 Abnormal Rate o...

Page 137: ... Timeout 3719 0 Particulate Trap 1 Soot Load Percent High most severe 3 3719 16 Particulate Trap 1 Soot Load Percent High moderate severity 2 4016 6 High Current Auxiliary Power Relay 1 Current Above Normal 4201 3 Engine Speed Sensor 1 Voltage Above Normal SPN FMI Description 4201 4 Engine Speed Sensor 1 Voltage Below Normal 4201 8 Engine Speed Sensor 1 Abnormal Frequency Pulse Nidth or Period 420...

Page 138: ...engine light should begin to blink 4 Continue to hold the run test toggle switch in the test position and count the blinks Note Before the fault codes are displayed the check engine light will blink a code 1 6 5 4 three times After the fault codes the check engine light will blink a code 1 6 5 4 three times again indicating the end of the stored codes Note If any fault codes are present the ECM wi...

Page 139: ... voltage 217 ECT higher than expected 2 219 Max govern speed override 221 TPS1 higher than TPS2 222 TPS2 low voltage 223 TPS2 high voltage 236 TIP Active Code Description 237 TIP Low Voltage 238 TIP High Voltage 261 Injector Loop Open or Low side short to Ground 262 Injector Coil Shorted 264 Injector Loop Open or Low side short to Ground 265 Injector Coil Shorted 267 Injector Loop Open or Low side...

Page 140: ...trol ground short 617 Start relay coil short to power 627 Fpump relay coil open 628 FPump motor loop open or high side shorted to ground 628 Fpump relay control ground short 629 FPump motor high side shorted to power 629 Fpump relay coil short to power Code Description 642 5VE1 low voltage 643 5VE1 high voltage 650 MIL open 652 5VE2 low voltage 653 5VE2 high voltage 685 Relay Coil Open 686 Relay C...

Page 141: ... low 1517 AUX analog PU3 high 1518 AUX analog PU3 low 1521 CHT higher than expected 1 1522 CHT higher than expected 2 1531 IVS Brake Trans Park interlock failure 1541 AUX analog PUD1 high 1542 AUX analog PUD1 low 1543 AUX analog PUD2 high 1544 AUX analog PUD2 low 1545 AUX analog PUD3 high Code Description 1551 AUX DIG1 high 1552 AUX DIG1 low 1553 AUX DIG2 high 1554 AUX DIG2 low 1555 AUX DIG3 high ...

Page 142: ...er than IVS limit 2116 FPP2 higher than IVS limit 2120 FPP1 invalid voltage and FPP2 disagrees with IVS 2121 FPP1 lower than FPP2 2122 FPP1 high voltage 2123 FPP1 low voltage 2125 FPP2 invalid voltage and FPP1 disagrees with IVS 2126 FPP1 higher than FPP2 2127 FPP2 low voltage 2128 FPP2 high voltage Code Description 2130 IVS stuck at idle FPP1 2 match 2131 IVS stuck off idle FPP1 2 match 2135 TPS1...

Page 143: ...pen or Low side Short to Ground 2313 Primary Coil Shorted 2315 Primary Loop Open or Low side Short to Ground 2316 Primary Coil Shorted 2318 Primary Loop Open or Low side Short to Ground 2319 Primary Coil Shorted 2321 Primary Loop Open or Low side Short to Ground 2322 Primary Coil Shorted 2618 Tach output ground short 2619 Tach output short to power Ford MSG 425 EFI Diagnostic Manual Genie part num...

Page 144: ...ey 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all ring...

Page 145: ...ction no terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch...

Page 146: ...alve 2 position 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot rati...

Page 147: ...3 Oil cooler 15A CB4 Drive lights 10A option CB7 Engine rpm 10A CR Control Relay CR1 Engine start CR2 Ignition power CR2A Ignition power CR4 High idle CR5 Horn CR13 Jib jib option CR14 Jib jib option CR17 Hydraulic oil cooling fan option CR18 Platform level cutout CE models CR23 Drive lights CR27 Brake circuit lift drive option CR30 Limit switch lift drive option CR39 High idle CR51 Aircraft packa...

Page 148: ...lt alarm led ANSI CSA models LS Limit Switch LS1 Primary boom extend LS2 Primary boom up LS3 Drive enable LS4 Secondary boom up LS18 Platform overload AS CE models LS18A Platform overload AS CE models Item Description M Motor M1 Oil cooler fan M2 Auxiliary pump M3 Engine starter M4 Fuel pump P Button P1 Red emergency stop ground P2 Red emergency stop platform P3 Horn P4 Function enable PR Power Re...

Page 149: ... Jib boom up down option TS59 Platform level up down TS60 Secondary boom up down TS61 Primary boom up down TS62 Turntable rotate TS63 Primary boom extend retract TS64 Run test Ford TS74 Run test Deutz Item Description U Module U1 Ignition start module U4 EDC drive pump U13 ALC 500 joystick controller card U33 Load sense module U34 Time delay relay 2 seconds 10A U35 Time delay relay 2 seconds 30A U...

Page 150: ...on BL Blue BK Black BR Brown GR Green OR Orange PP Purple RD Red WH White YL Yellow BL BK Blue Black BL RD Blue Red BL WH Blue White BK RD Black Red GR BK Green Black GR WH Green White OR BK Orange Black OR RD Orange Red OR WH Orange White RD BK Red Black RD WH Red White WH BK White Black WH RD White Red WH YL White Yellow YL BK Yellow Black ...

Page 151: ...l Ford Engine Relay Layout Part No 1268555GT Z 62 40 137 For d Engin e Relay Lay out Ford MSG 425 EFI 1 Power Relay 2 Fuel Pump Relay 3 Starter Relay 4 Starter 20A 5 Empty 6 Fuse 1 10A 7 Fuse 2 5A 8 Fuse 3 10A 9 Fuse 4 15A 10Fuse 5 15A ...

Page 152: ...Pump Diode D22 6A Alternator Ext Relays CR2B Ignition on CR5B Horn CR6 Fuel pump CR17B Hydraulic oil cooler option CR23B Engine accessory CR39B Auxiliary pump Perkins 404F 22 Fuses F10 15A Relay power F11A 15A ARD Injector 1 F11B 15A ARD Injector 2 F11C 5A Linear solenoid F12 7 5A Engine start F17 10A Fuel Alternator Ext F22A 15A Glow plug 1 F22B 20A Glow plug 2 F22C 20A ARD Glow plug Diode D22 6A...

Page 153: ...June 2022 Service and Repair Manual Limit Switch Legend Part No 1268555GT Z 62 40 139 Limit Switch Leg end 1 LS4 Secondary boom up 2 LS2 Primary boom up 3 LS1 Primary boom extend 4 LS3 Drive enable ...

Page 154: ...Service and Repair Manual June 2022 140 Z 62 40 Part No 1268555GT This page intentionally left blank ...

Page 155: ...June 2022 Service and Repair Manual 141 Electrica l Schemati cs Options Ford MSG 425 Engine Wire Harness ...

Page 156: ...Service and Repair Manual June 2022 142 Z 62 40 Part No 1268555GT For d MSG 42 5 EFI En gine Wi re H arn ess Ford MSG 425 EFI Engine Wire Harness ...

Page 157: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 143 Deutz D 2 9 L 4 Engi ne Wir e Har ness Deutz D 2 9 L4 Engine Wire Harness ...

Page 158: ...Service and Repair Manual June 2022 144 Deutz D 2 9 L4 Engine Wire Harness ...

Page 159: ...June 2022 Service and Repair Manual 145 Deutz TD 2 2 L3 Engine Wire Harness ...

Page 160: ...Service and Repair Manual June 2022 146 Z 62 40 Part No 1268555GT Deutz TD 2 2 L3 E ngine Wire H arn ess Deutz TD 2 2 L3 Engine Wire Harness ...

Page 161: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 147 Electrical Sch emati c Op tions All Mo dels Perkins 404F E22T Engine Wire Harness ...

Page 162: ...Service and Repair Manual June 2022 148 Perkins 404F E22T Engine Wire Harness ...

Page 163: ...June 2022 Service and Repair Manual 149 Perkins 404F 22 Engine Wire Harness ...

Page 164: ...Service and Repair Manual June 2022 150 Z 62 40 Part No 1268555GT Perkins 4 04 F 2 2 Engin e Wire Har ness Perkins 404F 22 Engine Wire Harness ...

Page 165: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 151 Electrical Sch emati c Op tions All Mo dels Electrical Schematic Options All Models ...

Page 166: ...Service and Repair Manual June 2022 152 Electrical Schematic Options All Models ...

Page 167: ...June 2022 Service and Repair Manual 153 Wiring Diagram 3kW Hydraulic Generator ...

Page 168: ...Service and Repair Manual June 2022 154 Z 62 40 Part No 1268555GT Wiring Dia gra m 3kW Hydr aulic G ene rato r Wiring Diagram 3kW Hydraulic Generator ...

Page 169: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 155 Wiring Dia gra m 1 2kW Hyd raulic Gen erat or Weld er O ption Wiring Diagram 12kW Hydraulic Generator Welder Option ...

Page 170: ...Service and Repair Manual June 2022 156 Wiring Diagram 12kW Hydraulic Generator Welder Option ...

Page 171: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 157 Hydraulic Schem atic 12kw Hy dra ulic Ge ner ator Wel der Optio n Hydraulic Schematic 12kw Hydraulic Generator Welder Option ...

Page 172: ...Service and Repair Manual June 2022 158 Hydraulic Schematic 12kw Hydraulic Generator Welder Option ...

Page 173: ...June 2022 Service and Repair Manual 159 Wiring Diagram Lift Drive Option ...

Page 174: ...Service and Repair Manual June 2022 160 Z 62 40 Part No 1268555GT Wiring Dia gra m Lif t Driv e Op tion Wiring Diagram Lift Drive Option ...

Page 175: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 161 Wiring Dia gra m Platf or m Ove rloa d Opti on Wiring Diagram Platform Overload Option ...

Page 176: ...Service and Repair Manual June 2022 162 Wiring Diagram Platform Overload Option ...

Page 177: ...June 2022 Service and Repair Manual 163 Wiring Diagram Platform Overload and Lift Drive Option ...

Page 178: ...Service and Repair Manual June 2022 164 Z 62 40 Part No 1268555GT Wiring Dia gra m Platf or m Ove rloa d an d Lift Driv e Opti on Wiring Diagram Platform Overload and Lift Drive Option ...

Page 179: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 165 Wiring Dia gra m Wo rk Lig hts O ption Wiring Diagram Work Lights Option ...

Page 180: ...Service and Repair Manual June 2022 166 Wiring Diagram Work Lights Option ...

Page 181: ...June 2022 Service and Repair Manual 167 Wiring Diagram Aircraft Protection Option ...

Page 182: ...Service and Repair Manual June 2022 168 Z 62 40 Part No 1268555GT Wiring Dia gra m Airc raft P rotec tion Optio n Wiring Diagram Aircraft Protection Option ...

Page 183: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 169 Wiring Dia gra m Platf or m Cont rol Box Heat er Optio n Wiring Diagram Platform Control Box Heater Option ...

Page 184: ...Service and Repair Manual June 2022 170 Wiring Diagram Platform Control Box Heater Option ...

Page 185: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 171 Wiring Dia gra m Fuel Level Se nsing Opti on Fuel Level Sensing Option ...

Page 186: ...Service and Repair Manual June 2022 172 Fuel Level Sensing Option ...

Page 187: ...June 2022 Service and Repair Manual 173 Hydraulic Sc hema tics Hydraulic Schematic 2WD 2 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 188: ...Z 62 40 Part No 1268555GT Hydraulic Schem atic 2WD 2 Whe el Stee r M odels to s erial num bers Z62D 546 Z6 2H 4 484 fro m Z62 M 1 01 Hydraulic Schematic 2WD 2 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 189: ...Repair Manual Part No 1268555GT Z 62 40 175 Hydraulic Schem atic 2WD 2 Whe el Stee r M odels fro m se rial n um bers Z6 2D 5 47 Z6 2H 4 485 Hydraulic Schematic 2WD 2 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 190: ...Service and Repair Manual June 2022 176 Hydraulic Schematic 2WD 2 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 191: ...June 2022 Service and Repair Manual 177 Hydraulic Schematic 4WD 2 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 192: ...Z 62 40 Part No 1268555GT Hydraulic Schem atic 4WD 2 Whe el Stee r M odels to s erial num bers Z62D 546 Z6 2H 4 484 fro m Z62 M 1 01 Hydraulic Schematic 4WD 2 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 193: ...Repair Manual Part No 1268555GT Z 62 40 179 Hydraulic Schem atic 4WD 2 Whe el Stee r M odels fro m se rial n um bers Z6 2D 5 47 Z6 2H 4 485 Hydraulic Schematic 4WD 2 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 194: ...Service and Repair Manual June 2022 180 Hydraulic Schematic 4WD 2 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 195: ...June 2022 Service and Repair Manual 181 Hydraulic Schematic 4WD 4 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 196: ...Z 62 40 Part No 1268555GT Hydraulic Schem atic 4WD 4 Whe el Stee r M odels to s erial num bers Z62D 546 Z6 2H 4 484 fro m Z62 M 1 01 Hydraulic Schematic 4WD 4 Wheel Steer Models to serial numbers Z62D 546 Z62H 4484 from serial number Z62M 101 ...

Page 197: ...Repair Manual Part No 1268555GT Z 62 40 183 Hydraulic Schem atic 4WD 4 Whe el Stee r M odels fro m se rial n um bers Z6 2D 5 47 Z6 2H 4 485 Hydraulic Schematic 4WD 4 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 198: ...Service and Repair Manual June 2022 184 Hydraulic Schematic 4WD 4 Wheel Steer Models from serial numbers Z62D 547 Z62H 4485 ...

Page 199: ...June 2022 Service and Repair Manual 185 Electrica l Schemati cs ANSI andCSA Models Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 200: ...Service and Repair Manual June 2022 186 Z 62 40 Part No 1268555GT Electrical Sch emati c Ford MSG 425 EFI Mod els ANSI CSA Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 201: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 187 Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 202: ...Service and Repair Manual June 2022 188 Electrical Schematic Ford MSG 425 EFI Models ANSI CSA ...

Page 203: ...June 2022 Service and Repair Manual 189 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 204: ...Manual June 2022 190 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m For d MSG 42 5 EFI Mo dels ANSI CSA Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 205: ... and Repair Manual Part No 1268555GT Z 62 40 191 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m For d MSG 42 5 EFI Mo dels ANSI CSA Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 206: ...Service and Repair Manual June 2022 192 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 207: ...June 2022 Service and Repair Manual 193 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 208: ...ice and Repair Manual June 2022 194 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Fo rd MSG 425 E FI M odels ANSI CSA Platform Control Box Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 209: ... and Repair Manual Part No 1268555GT Z 62 40 195 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Ford MSG 425 EFI Mod els ANSI CSA Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 210: ...Service and Repair Manual June 2022 196 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models ANSI CSA ...

Page 211: ...June 2022 Service and Repair Manual 197 Electrical Schematic Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 212: ...e and Repair Manual June 2022 198 Z 62 40 Part No 1268555GT Electrical Sch emati c Deu tz D20 11 L03i Perkin s 40 4D 2 2 M odels ANSI CSA Electrical Schematic Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 213: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 199 Electrical Schematic Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 214: ...Service and Repair Manual June 2022 200 Electrical Schematic Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 215: ...June 2022 Service and Repair Manual 201 Ground Control Box Terminal Strip Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 216: ...202 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m De utz D2 011 L03i Perki ns 4 04D 22 Models ANSI CSA Ground Control Box Terminal Strip Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 217: ... Part No 1268555GT Z 62 40 203 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m D eutz D 201 1 L0 3i Pe rkins 4 04D 22 Mod els ANSI CSA Ground Control Box Switch Panel Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 218: ...Service and Repair Manual June 2022 204 Ground Control Box Switch Panel Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 219: ...June 2022 Service and Repair Manual 205 Platform Control Box Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 220: ...anual June 2022 206 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Deutz D20 11 L 03i P erkins 404D 22 Mo dels ANSI CSA Platform Control Box Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 221: ...Part No 1268555GT Z 62 40 207 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Deu tz D2 011 L03i Perkin s 40 4D 2 2 M odels ANSI CSA Platform Control Box Switch Panel Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 222: ...Service and Repair Manual June 2022 208 Platform Control Box Switch Panel Wiring Diagram Deutz D2011 L03i Perkins 404D 22 Models ANSI CSA ...

Page 223: ...June 2022 Service and Repair Manual 209 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 224: ...Service and Repair Manual June 2022 210 Z 62 40 Part No 1268555GT Electrical Sch emati c Deu tz D 2 9 L 4 M odels ANSI CSA Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 225: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 211 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 226: ...Service and Repair Manual June 2022 212 Electrical Schematic Deutz D 2 9 L4 Models ANSI CSA ...

Page 227: ...June 2022 Service and Repair Manual 213 Ground Control Box Terminal Strip Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 228: ...r Manual June 2022 214 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m De utz D 2 9 L4 M odels ANSI CSA Ground Control Box Terminal Strip Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 229: ...ice and Repair Manual Part No 1268555GT Z 62 40 215 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m D eutz D 2 9 L4 Mod els ANSI CSA Ground Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 230: ...Service and Repair Manual June 2022 216 Ground Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 231: ...June 2022 Service and Repair Manual 217 Platform Control Box Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 232: ...ervice and Repair Manual June 2022 218 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Deutz D 2 9 L4 Mo dels ANSI CSA Platform Control Box Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 233: ...e and Repair Manual Part No 1268555GT Z 62 40 219 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Deu tz D 2 9 L 4 M odels ANSI CSA Platform Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 234: ...Service and Repair Manual June 2022 220 Platform Control Box Switch Panel Wiring Diagram Deutz D 2 9 L4 Models ANSI CSA ...

Page 235: ...June 2022 Service and Repair Manual 221 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 236: ...Service and Repair Manual June 2022 222 Z 62 40 Part No 1268555GT Electrical Sch emati c Perki ns 40 4F 22 Mo dels ANSI CSA Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 237: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 223 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 238: ...Service and Repair Manual June 2022 224 Electrical Schematic Perkins 404F 22 Models ANSI CSA ...

Page 239: ...June 2022 Service and Repair Manual 225 Ground Control Box Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 240: ...Manual June 2022 226 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m Pe rkins 4 04 F 2 2 M odels ANSI CSA Ground Control Box Terminal Strip Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 241: ...e and Repair Manual Part No 1268555GT Z 62 40 227 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m Pe rkins 404 F 2 2 M odels ANSI CSA Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 242: ...Service and Repair Manual June 2022 228 Ground Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 243: ...June 2022 Service and Repair Manual 229 Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 244: ...rvice and Repair Manual June 2022 230 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Perkins 40 4F 22 Mod els ANSI CSA Platform Control Box Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 245: ... and Repair Manual Part No 1268555GT Z 62 40 231 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Perki ns 4 04F 22 Mo dels ANSI CSA Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 246: ...Service and Repair Manual June 2022 232 Platform Control Box Switch Panel Wiring Diagram Perkins 404F 22 Models ANSI CSA ...

Page 247: ...June 2022 Service and Repair Manual 233 Electrical Schematic Perkins 404F E22T Models ANSI CSA ...

Page 248: ...Service and Repair Manual June 2022 234 Z 62 40 Part No 1268555GT Electrical Sch emati c Perki ns 40 4F 22 Mo dels ANSI CSA Electrical Schematic Perkins 404F E22T Models ANSI CSA ...

Page 249: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 235 Electrical Schematic Perkins 404F E22T Models ANSI CSA ...

Page 250: ...Service and Repair Manual June 2022 236 Electrical Schematic Perkins 404F E22T Models ANSI CSA ...

Page 251: ...June 2022 Service and Repair Manual 237 Ground Control Box Terminal Strip Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 252: ...anual June 2022 238 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m Pe rkins 4 04 F 2 2 M odels ANSI CSA Ground Control Box Terminal Strip Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 253: ... and Repair Manual Part No 1268555GT Z 62 40 239 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m Pe rkins 404 F 2 2 M odels ANSI CSA Ground Control Box Switch Panel Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 254: ...Service and Repair Manual June 2022 240 Ground Control Box Switch Panel Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 255: ...June 2022 Service and Repair Manual 241 Platform Control Box Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 256: ...vice and Repair Manual June 2022 242 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Perkins 40 4F 22 Mod els ANSI CSA Platform Control Box Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 257: ...and Repair Manual Part No 1268555GT Z 62 40 243 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Perki ns 4 04F 22 Mo dels ANSI CSA Platform Control Box Switch Panel Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 258: ...Service and Repair Manual June 2022 244 Platform Control Box Switch Panel Wiring Diagram Perkins 404F E22T Models ANSI CSA ...

Page 259: ...June 2022 Service and Repair Manual 245 Electrica l Schemati cs AS andCE M odels Electrical Schematic Ford MSG 425 EFI Models AS CE ...

Page 260: ...Service and Repair Manual June 2022 246 Z 62 40 Part No 1268555GT Electrical Sch emati c Ford MSG 425 EFI Mod els AS CE Electrical Schematic Ford MSG 425 EFI Models AS CE ...

Page 261: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 247 Electrical Schematic Ford MSG 425 EFI Models AS CE ...

Page 262: ...Service and Repair Manual June 2022 248 Electrical Schematic Ford MSG 425 EFI Models AS CE ...

Page 263: ...June 2022 Service and Repair Manual 249 Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 264: ...ir Manual June 2022 250 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m For d MSG 42 5 EFI Mo dels AS CE Ground Control Box Terminal Strip Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 265: ...ice and Repair Manual Part No 1268555GT Z 62 40 251 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m For d MSG 42 5 EFI Mo dels AS CE Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 266: ...Service and Repair Manual June 2022 252 Ground Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 267: ...June 2022 Service and Repair Manual 253 Platform Control Box Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 268: ...ervice and Repair Manual June 2022 254 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Fo rd MSG 425 E FI M odels AS CE Platform Control Box Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 269: ...ice and Repair Manual Part No 1268555GT Z 62 40 255 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Ford MSG 425 EFI Mod els AS CE Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 270: ...Service and Repair Manual June 2022 256 Platform Control Box Switch Panel Wiring Diagram Ford MSG 425 EFI Models AS CE ...

Page 271: ...June 2022 Service and Repair Manual 257 Electrical Schematic Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 272: ...rvice and Repair Manual June 2022 258 Z 62 40 Part No 1268555GT Electrical Sch emati c Deu tz 20 11 L03i Perkin s 40 4D 2 2 M odels AS CE Electrical Schematic Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 273: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 259 Electrical Schematic Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 274: ...Service and Repair Manual June 2022 260 Electrical Schematic Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 275: ...June 2022 Service and Repair Manual 261 Ground Control Box Terminal Strip Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 276: ...022 262 Z 62 40 Part No 1268555GT Grou nd Co ntr ol Box Ter minal St rip Wiri ng Dia gra m De utz 2 011 L03i Perki ns 4 04D 22 Models AS CE Ground Control Box Terminal Strip Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 277: ...anual Part No 1268555GT Z 62 40 263 Grou nd Co ntr ol Box Switch Pa nel Wiri ng Dia gra m D eutz 201 1 L0 3i Pe rkins 4 04D 22 Mod els AS CE Ground Control Box Switch Panel Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 278: ...Service and Repair Manual June 2022 264 Ground Control Box Switch Panel Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 279: ...June 2022 Service and Repair Manual 265 Platform Control Box Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 280: ...ir Manual June 2022 266 Z 62 40 Part No 1268555GT Platfor m Cont rol Box Wiring Diagr am Deutz 20 11 L 03i P erkins 404D 22 Mo dels AS CE Platform Control Box Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 281: ...ual Part No 1268555GT Z 62 40 267 Platfor m Cont rol Box Switch Pan el Wirin g Diag ra m Deu tz 2 011 L03i Perkin s 40 4D 2 2 M odels AS CE Platform Control Box Switch Panel Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 282: ...Service and Repair Manual June 2022 268 Platform Control Box Switch Panel Wiring Diagram Deutz 2011 L03i Perkins 404D 22 Models AS CE ...

Page 283: ...June 2022 Service and Repair Manual 269 Electrical Schematic Deutz TD 2 2 L3 Models CE ...

Page 284: ...Service and Repair Manual June 2022 270 Z 62 40 Part No 1268555GT Electrical Sch emati c Deu tz TD 2 2 L3 Mod els CE Electrical Schematic Deutz TD 2 2 L3 Models CE ...

Page 285: ...June 2022 Service and Repair Manual Part No 1268555GT Z 62 40 271 Electrical Schematic Deutz TD 2 2 L3 Models CE ...

Page 286: ...Service and Repair Manual June 2022 272 Electrical Schematic Deutz TD 2 2 L3 Models CE Z 6 2 40 Part No 126 855 5GT Service a nd Re pair Ma nual June 2022 ...

Page 287: ......

Search results

Summary of Contents for Genie Z-40

Reviews:

Terex Genie Z-40, Service And Repair Manual, Page: 2 / 287

Search results

Summary of Contents for Genie Z-40

Reviews: