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Terex Genie Z-45/25 Bi-Energy, Service And Repair Manual

The Terex Genie Z-45/25 Bi-Energy is a versatile and efficient aerial work platform designed for various construction and maintenance tasks. Ensure safe and proper usage of this impressive equipment with the comprehensive Operator's Manual, available for free download at manualshive.com. Get the most out of your Genie Z-45/25 Bi-Energy with this essential manual.

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July 2021

 

 

Service and Repair Manual

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part No. 1312350GT

 

Z

®

-45/25 • Z

®

-45/25J

 

115 

 

 

 

 

 

Functions, Electrical Schematic 

 

 

X109

LO

AD

 S

2 I

N

PU

T

5

SP

AR

E

1

X109

X109

X109 X109

X109

3

2

9

8

6

C41RPM OR/BK

5

X108

X108

C

7P

BE

 B

K

13

12

7

6

TB4

C

3B

-E

C

4T

R

L W

H

C

3P

-E

D9

P134BAT RD

C19JV RD

P24FS WH

10

9 5 4

C160JPL WH/RD

XOUT

GND

PWR

6

3

2

4

5

1 BR

P162JPW OR

YOUT

C159STC BL/WH

DRIVE FW/REV &

ROUT

ROCKER OPTION

STEER R/L

14

13

2

C165TRS WH/RD

YOUT

P162JPW OR
BR

1

5

4

2

3

6

PWR

GND

XOUT

C164PES RD/WH

1

TT ROTATE

PRI UP/DN & 

GND

PWR

3

11

12

6

3

2

4

5

1 BR

SECONDARY UP/DN

P162JPW OR

YOUT

C161SB WH/BK

TS61

6

14

7.5

R14

R4 20

R

D

/W

H

TS14

15

TS15

P22EST BK

P24FS WH

C

14

3D

EL

 B

L/R

D

8

16

6

7

C

13

D

E B

L/R

D

C

29

M

S

L1

R

IG

H

T

LE

FT

D

R

IV

E E

N

AB

LE

C28CAL RD/BK

16

15

C

7P

-3

C

1P

-E

C

1P

-F

19

20

C

1P

-G

C

1P

-D

9

14

C

1P

-M

C

1P

-L

C

7B

-3

C

1B

-E

C

1B

-F

C

1B

-G

C

1B

-D

C

1B

-M

C

1B

-L

BA

TG

N

D

C

30

FW

D

 W

H

C

32

BR

K W

H

/R

D

C

31

R

EV

 W

H

/B

K

C

36

SC

C

 B

L

C

29

M

S R

D

/W

H

C

37

SC

W

 B

L/B

K

X101

X101

2

1

BR

N

P2

4F

S W

H

4

3

P2

2E

ST

 B

K

P2

4F

S W

H

TS13

TS9

10

C

3P

-F

11

8

C

3P

-B

C

3P

-C

X102

TS62

TS61

9

4

C

3P

-M

C

3P

-L

3

4

C

3P

-R

C

1P

-P

U13  JOYSTICK CONTROL CARD

TS60

C40LSS OR

C

1B

-P

J2 BK

C

3B

-F

TB1

TB2

C

3B

-B

C

3B

-C

C

11

-2

C

6-2

7

W

H

-6

O

R

14

C

11

-3

C

3B

-M

C

3B

-L

TB11

TB10

C

3B

-R

BK

-4

13

C

5-1

8

C

11

-1

LS4

22

BK

-7

21

BK

-6

C

11

0-2

LS1

LE

FT

R

IG

H

T

TU

R

N

TA

BL

E R

O

TA

TE

C

1P

BU

 R

D

C

2P

BD

 R

D

/B

K

C

10

SB

U

 B

L

D

O

W

N

U

P

PR

IM

AR

Y B

O

O

M

C

11

SB

D

 B

L/B

K

C

16

D

R

E O

R

/R

D

D

O

W

N

U

P

BO

O

M

 S

EC

O

N

D

AR

Y

C

3P

-H

C

3P

-J

C

3P

-T

TS63

TS59

C

3P

-S

C

3B

-H

C

3B

-J

TB8

TB7

C

3B

-Q

C

3B

-P

TB15

C

3P

-T

TB14

C

3P

-S

TB17

TB18

C

8P

BR

 B

K/W

H

C

14

PL

U

 O

R

D

O

W

N

U

P

PL

AT

FR

O

M

 L

EV

EL

R

ET

R

AC

T

EX

TE

N

D

BO

O

M

C

15

PL

D

 O

R

/B

K

R

IG

H

T

PL

AT

 R

O

TA

TE

LE

FT

U

P

D

O

W

N

JIB

 B

O

O

M

X101

X101

X103

R

ET

R

AC

T

EX

TE

N

D

BO

O

M

R

IG

H

T

PL

AT

 R

O

TA

TE

LE

FT

C

5T

R

R

 W

H

/B

K

TB5

C

5-1

2

C

5-1

3

U4

BK

R

D

C

30

FW

D

 W

H

C

31

R

EV

 W

H

/B

K

C

5-1

4

C

5-1

1

C

6-2

5

C

6-2

6

C

32

BR

K W

H

/R

D

C

29

M

S R

D

/W

H

C

36

SC

C

 B

L

C

37

SC

W

 B

L/B

K

R

D

BK

BR

N

BR

N

G

R

O

U

N

D

D

R

IV

E E

D

C

 F

O

R

W

AR

D

D

R

IV

E E

D

C

 R

EV

ER

SE

ST

EE

R

 R

IG

H

T

ST

EE

R

 L

EF

T

M

O

TO

R

 S

TR

O

KE

BR

AK

E R

EL

EA

SE

 V

AL

VE

C

6-5

C

6-8

C

6-7

C

6-6

C

1P

BU

 R

D

C

15

-1

C

12

-1

C

14

-1

C

13

-1

C

2P

BD

 R

D

/B

K

C

5T

R

R

 W

H

/B

K

C

4T

R

L W

H

13

BK

-6

BK

-5

C

11

0-1

C

19

-1

C

18

-1

C

10

SB

U

 B

L

C

11

SB

D

 B

L/B

K

14

C

10

-1

W

H

-7

C

11

-4

BK

W

H

-6

C

10

-2

C

6-1

2

C

6-1

1

LS3

J1

 B

K

C

15

-2

C

12

-2

C

14

-2

C

13

-2

TU

R

N

TA

BL

E R

O

TA

TE

 L

EF

T

TU

R

N

TA

BL

E R

O

TA

TE

 R

IG

H

T

PR

IM

AR

Y D

O

W

N

PR

IM

AR

Y U

P

C

19

-2

C

18

-2

SE

C

O

N

D

AR

Y D

O

W

N

SE

C

O

N

D

AR

Y U

P

LIM

IT

 S

W

IT

C

H

LS

3-D

R

IV

E E

N

AB

LE

LS

2-P

R

IM

AR

Y U

P

D

R

IV

E L

IM

IT

 S

W

IT

C

H

LS

1-P

R

IM

AR

Y E

XT

EN

D

D

R

IV

E L

IM

IT

 S

W

IT

C

H

LS

4-S

EC

O

N

D

AR

Y U

P

W

H

-5

C

6-9

C

6-1

0

C

6-1

3

C

6-1

4

C

7P

BE

 B

K

C

17

-1

C

16

-1

C

8P

BR

 B

K/W

H

C

20

-1

C

21

-1

C

14

PL

U

 O

R

C

15

PL

D

 O

R

/B

K

C

6-1

6

C

6-1

5

C

17

PR

L G

R

C

23

-1

C

22

-1

C

18

PR

R

 G

R

/B

K

C

12

9D

A R

D

/B

K

C

17

-2

C

16

-2

C

20

-2

C

21

-2

PR

IM

AR

Y E

XT

EN

D

PL

AT

 L

EV

EL

 U

P

PL

AT

 L

EV

EL

 D

O

W

N

C

23

-2

C6-3

C

22

-2

H4

AL

AR

M

 O

PT

IO

N

S

PL

AT

FO

R

M

 R

O

TA

TE

 L

EF

T /

 JIB

 U

P

PL

AT

FO

R

M

 R

O

TA

TE

 R

IG

H

T /

 JIB

 D

O

W

N

PR

IM

AR

Y R

ET

R

AC

T

D

R

IV

E L

IM

IT

 S

W

IT

C

H

W

H

-4

P47FE RD

P174AUX RD

BRN

C28CAL RD/BK

C41RPM OR/BK

P22EST BK

D3

X109

G

N

D

R

TN

 B

R

C

15

PL

D

 O

R

/B

K

C

14

PL

U

 O

R

C

8P

BR

 B

K/W

H

C

7P

BE

 B

K

C

14

4D

ER

 B

L/W

H

C

3P

-Q

C

3P

-P

X102

X102

X102

X102

X102

X102

TB22

P22BAT BK

C

6-1

9

C

5-6

D

ES

C

EN

T A

LA

R

M

, T

R

AV

EL

 A

LA

R

M

(M

O

TIO

N

 A

LA

R

M

)

C129DA RD/BK

C129DA RD/BK

TB30

TB31

TB32

TB29

JC1

JC2

JC3

C

2-G

C

2-F

X102

X102

X101

X102

X103

P2

2L

S R

D

J8

7-1

J8

7-2

J8

7-4

11 10 7 5

C28TTA RD/BK

C171LDS WH/BK

R40LS OR

C

56

-6

C28TTA RD/BK

P4

7F

E O

R

/R

D

R

47

FE

 R

D

LS2

22

21

R

D

JIB

 V

AL

VE

BRN

C1

CR14

NO

-

+

R

19

JIB

 G

R

/W

H

JIB

 T

IM

E D

EL

AY

 C

IR

C

U

IT

JIB

 B

O

O

M

D

O

W

N

U

P

NC

CR13

TS8

TS7

CR13

WH

C

18

PR

R

 G

R

/B

K

C

3P

-U

TS58

TS57

C

17

PR

L G

R

C

3P

-U

C

19

JS

V G

R

/W

H

JIB

 V

AL

VE

S

TS8

GR/WH

D91

TB129

C

3B

-N

C

12

9D

A B

L/W

H

AL

AR

M

 O

U

TP

U

T

D29

D30

D27

C

3P

-N

D28

TB134

18

17

TO

 T

EL

EM

AT

IC

S

Summary of Contents for Genie Z-45/25 Bi-Energy

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

Page 2: ...O 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 suggestio...

Page 3: ...History Revision Date Section Procedure Page Description A 7 2021 Initial Release 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 Schematics Legends and schematics ...

Page 4: ...ber 4 Serial number stamped on chassis 5 Serial label located under cover 5 4 Z4525 M 12345 Model Serial number Electrical schematic number Year of manufacture Machine unladen weight Rated work load including occupants Maximum number of platform occupants Maximum allowable side force Maximum allowable inclination of the chassis Z4525M 12345 1 2 3 ...

Page 5: ... 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 worksite regul...

Page 6: ... crushing 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 fl...

Page 7: ...eneral Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Machine Component Weights 2 Performance Specifications 3 Hydraulic Oil Specifications 3 Hydraulic Component Specifications 7 Deutz D2011 L03i Engine Specifications 9 Deutz D 2 9 L4 Engine Specifications 10 Kubota D1105 E4B Engine Specifications 11 Machine Torque Specifications 12 Hydraulic Hose and Fitting Torque Specificati...

Page 8: ...sticks 19 How to Adjust the Joystick Max out Setting 19 How to Adjust the Joystick Ramp Rate Setting 20 How to Adjust the Joystick Threshold Setting 22 Platform Components 23 2 1 Platform Leveling Slave Cylinder 23 How to Bleed the Slave Cylinder 24 2 2 Platform Rotator 25 2 3 Platform Overload System 26 Jib Boom Components 29 3 1 Jib Boom 29 3 2 Jib Boom Lift Cylinder 30 ...

Page 9: ...rimary Boom Lift Cylinder 39 4 4 Primary Boom Extension Cylinder 40 4 5 Platform Leveling Master Cylinder 41 Secondary Boom Components 43 5 1 Secondary Boom 44 5 2 Secondary Boom Lift Cylinders 49 Engines 50 6 1 RPM Adjustment Deutz D2011L03i and Kubota D1105 Models 50 6 2 Flex Plate 50 How to Install the Flex Plate 51 How to install the Pump and Bell Housing Assembly 52 6 3 Engine Fault Codes Deu...

Page 10: ...ifold Components 65 How to Set Up the Directional Valve Linkage 66 8 6 Traction Manifold Components 2WD 67 8 7 Valve Adjustments 2WD Traction Manifold 69 8 8 Traction Manifold Components 4WD 70 8 9 Valve Adjustments 4WD Traction Manifold 72 8 10 Hydraulic Generator Manifold Components 2 2kW 73 8 11 Valve Coils 74 How to Test a Coil Diode 74 Turntable Rotation Components 76 9 1 Turntable Rotation A...

Page 11: ...l System Fault Codes 80 Control System Fault Codes 81 Fault Code Display Deutz Models 84 How to Retrieve Active Engine Fault Codes Deutz D 2 9 L4 Models 84 Fault Code Display Flashing and Solid LED s Deutz D 2 9 L4 Models 85 Soft Key Functions and Icons Deutz D 2 9 L4 Models 85 Main Menu Structure Deutz D 2 9 L4 Models 86 Deutz D 2 9 L4 Engine Fault Codes 88 ...

Page 12: ...am Battery Hydraulic Oil and Engine Oil Heater Options 109 Wiring Diagram 2 2kW Hydraulic Generator 112 Electrical Schematics CE Models 113 Electrical Schematic Kubota D1105 Models 114 Functions Electrical Schematic 115 Electrical Schematic Deutz D2 9 Models 118 Deutz D2 9 L4 Engine Wire Harness 119 Electrical Schematic Deutz 2011 L03i Models 122 Electrical Schematic Deutz D436 CN3 Models 1 123 El...

Page 13: ...ameter 20 in 50 8 cm Wheel width 11 in 27 9 cm Wheel lugs 9 5 8 18 Lug nut torque lubricated 94 ft lbs 127 4 Nm Lug nut torque dry 125 ft lbs 169 5 Nm Tire pressure 60 psi 4 1 bar Tires and wheels Hi flotation option Tire size 33 16LL500 Tire ply rating 10 Overall tire diameter 33 in 84 cm Wheel diameter 19 5 in 49 5 cm Wheel width 14 in 35 6 cm Wheel lugs 9 5 8 18 Lug nut torque lubricated 94 ft ...

Page 14: ...oid gear oil API service classification GL5 Machine Component Weights Drive motor 26 7 lbs 12 1 kg Drive hub 138 8 lbs 63 kg Primary boom assembly 946 8 lbs 429 5 kg Primary boom lift cylinder 98 4 lbs 44 6 kg Primary boom extend cylinder 72 8 lbs 33 kg Secondary boom assembly 1679 6 lbs 761 9 kg Secondary boom lift cylinder each 56 2 lbs 25 5 kg Jib boom assembly 283 4 lbs 128 5 kg Jib boom lift ...

Page 15: ...6 mph 0 98 km h 40 ft 45 sec 12 2 m 45 sec Gradeability See Operator s Manual Braking distance maximum High range on paved surface 3 to 6 ft 0 9 to 1 8 m Joystick function speeds maximum from platform controls Primary boom up 24 to 28 seconds Primary boom down 24 to 28 seconds Primary boom extend 18 to 22 seconds Primary boom retract 18 to 22 seconds Secondary boom up 24 to 28 seconds Secondary bo...

Page 16: ...ube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond its maximum allowable range If the h...

Page 17: ...low 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 5606A hydr...

Page 18: ...ll Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C cS...

Page 19: ...cu in 11 cc Flow rate 2500 psi 172 bar 7 25 gpm 27 4 L min Auxiliary Pump Type gear fixed displacement Displacement per revolution 0 067 cu in 1 1 cc Auxiliary pump relief pressure 3200 psi 220 6 bar Function manifold System relief valve pressure maximum 3200 psi 220 6 bar Secondary boom down relief valve pressure 2100 psi 145 bar Platform level relief valve pressure 2500 psi 172 bar Steer flow re...

Page 20: ...2 to 30 cc Hydraulic Filters High pressure filter Beta 3 ˆ 200 High pressure filter bypass pressure 100 psi 6 89 bar Medium pressure filter Beta 3 ˆ 200 Medium pressure filter bypass pressure 50 psi 3 4 bar Hydraulic tank return filter 10 micron with 25 psi 1 7 bar bypass Manifold Component Specifications Plug torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 ft lbs 13 Nm SAE No 6 14 ft lbs 19 Nm SAE No ...

Page 21: ...ic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 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 Temperature switch point 300 F 149 C Oil Pressure switch Oil pressure switch point 22 psi 1 5 bar Fuel injection system Injection pump make Bosch ...

Page 22: ... Above 23 F 5 C 20W 50 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 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 Injection pump ...

Page 23: ...ers Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 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 Engine coolant Capacity 3 2 quarts 3 liters Fuel injection system Injection pump make Bosch MD Inje...

Page 24: ...60 Nm 3 8 16 bolts GR 8 dry ZAG coated 46 ft lbs 62 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated Zinc plated 180 ft lbs 244 Nm Rotate bearing mounting bolts lubricated ZAG coated 159 ft lbs 215 Nm Drive motor brake mounting bolts lubricated Zinc plated 105 ft lbs 142 Nm Drive motor brake mounting bolts lubricated ZAG coated 93 ft lbs 126 Nm Drive motors and hubs Drive hub ...

Page 25: ... 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 fitting 1 jam nut SAE...

Page 26: ...ted 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 hex n...

Page 27: ...ct number 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 fi...

Page 28: ...al 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 a f...

Page 29: ...lert 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 ...

Page 30: ...ystick controller 1 1 ALC 500 Circuit Board 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 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Ope...

Page 31: ...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 M ax o ut Setti ng How to Adjust the Joystick Max out Setting The max out setting of a joystick controls the maximum speed of a joystick control...

Page 32: ...tely 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 How to Adju st th e Joys tick Ra mp Ra te Setti ng How to Adjust the Joystick Ramp Rate Setting The ramp rate setting of a joystick controls the time at which it takes for the joystick to re...

Page 33: ...the drive enable toggle switch is momentarily moved the time will change in 10 increments 12 Repeat steps 9 through 11 for each joystick controlled machine function 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...

Page 34: ...nd the alarm should sound 8 times indicating that the machine is in threshold calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Select a boom function joystick to set the threshold 10 Slowly move the joystick off center in either direction just until the function begins to move 11 Slowly move the...

Page 35: ...slave cylinder barrel end pivot pin is accessible 2 Raise the primary boom slightly and place blocks under the platform for support 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them t...

Page 36: ...Use a soft metal drift and drive the barrel end pin out 11 Carefully pull the cylinder out of the primary boom How to Blee d th e Slave C ylinde r How to Bleed the Slave Cylinder Note This procedure will have to be preformed outside 1 Z45 25J Raise the jib to a horizontal postion and raise the secondary boom 3 feet Z45 25 Raise the secondary boom 4 feet 2 Move the function enable toggle switch to ...

Page 37: ... 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 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Move the function enable toggle switch to either...

Page 38: ...latform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note Perform this procedure with the machine on a firm level surface 1 Turn the key switch to...

Page 39: ...tform and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights ...

Page 40: ...a suitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate no...

Page 41: ...pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down 9 Use a soft metal drift to remove the platform rotator pivot pin and remove the platform rotator from the machine 10 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 11 Remove the hose and cable cover from the side of the jib bo...

Page 42: ...o specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mounting weldment Then 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 boom on the blocks 2 Tag disconnect and plug the jib boom lif...

Page 43: ...ard The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead lifting device 7 Attach a lifting strap from an suitable lifting device to the lug on the rod end of the jib boom lift cylinder 8 Use a soft metal drift to remove the jib boom lift cylinder rod end pin Remove the jib boom lift cylinder from the machine Crushing hazard...

Page 44: ...ary boom lift cylinder Cap the fittings on the unions Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Tag disconnect and plug the hydraulic hoses from the PR1 and PR2 ports on the counterbalance valve manifold located on the platform rotator Cap th...

Page 45: ...ed or pinched How to Re mov e th e Cabl e Track Z 45 25J How to Remove the Cable Track Z 45 25J 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 Locate the cables from the primary boom cab...

Page 46: ...l can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Tag disconnect and plug the hydraulic hoses from the platform leveling master cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow...

Page 47: ...away from the mounting ears for the rod end of the primary boom lift cylinder 21 Raise the rod end of the primary boom lift cylinder back into position and install the rod end pivot pin Install the pin retaining fasteners 22 Attach a strap from an suitable lifting device to the cable track 23 Remove the mounting fasteners from the upper cable track at the platform end of the extension boom 24 Remo...

Page 48: ...pair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be repl...

Page 49: ...d Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the hose clamp at the pivot end of the boom 14 Attach a 5 ton 5 000 kg capacity suitable lifting device to the center point of the primary boom 15 Attach a similar lifting device to the primary boom lift cylinde...

Page 50: ... wear pads from the platform end of the primary boom Note Pay careful attention to the location and amount of shims used with each wear pad 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube Crushing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported Note During removal t...

Page 51: ...ry boom to a horizontal position 2 Raise the secondary boom until the primary boom lift cylinder barrel end pivot pin is above the turntable covers 3 Attach a 5 ton 5000 kg capacity suitable lifting device to the primary boom for support 4 Raise the primary boom with a suitable lifting device slightly to take the pressure off the primary boom lift cylinder pivot pins 5 Support the rod end and the ...

Page 52: ...om extension tube The primary boom extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure How to Remove the Primary Boom Extension Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or seri...

Page 53: ...rimary boom extension cylinder is dragged across them Note Note the length of the cylinder after removal The cylinder must be at the same length for installation 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom motion The master cylinder is lo...

Page 54: ... pivot pin and twist to remove the pin 6 Remove the pin retaining fastener from the rod end pivot pin 7 Place a rod through the rod end pivot pin and twist to remove the pin 8 Remove the master cylinder from the machine Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the lifting device ...

Page 55: ...5 Z 45 25J 43 Secondary Boom components 1 upper secondary boom number 1 arm 2 upper tension link number 2 arm 3 lower tension link number 3 arm 4 mid pivot 5 compression link 6 secondary boom lift cylinder 2 7 lower secondary boom number 4 arm 8 turntable pivot 9 boom rest 10upper pivot ...

Page 56: ...y Boom 4 Remove the master cylinder Refer to Repair Procedure How to Remove the Master Cylinder 5 Attach a lifting strap from an suitable lifting device to the lug on the rod end of the primary boom lift cylinder Then raise the primary boom lift cylinder with the crane to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cyl...

Page 57: ... not to damage the counterbalance valve at the barrel end of the cylinder 16 Attach a lifting strap from an suitable lifting device to the upper pivot for support Do not lift it 17 Attach a lifting strap from a second suitable lifting device to the number 1 arm at the mid point between the upper pivot and mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid p...

Page 58: ...per pivot end 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch 10 x 10 x 28 cm block 30 Lower the number 2 arm onto the boom rest pad 31 Insert a 4 x 4 x 8 1 2 inch 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid pivot end 32 Attach a lifting strap from a suitable lifting device to the mid pivot for support Do not lift it 33 Remove the pin retaining ...

Page 59: ...mage hazard Cables and hoses can be damaged if they are kinked or pinched 43 Open the ground controls side turntable cover 44 Remove the fuel tank filler cap 45 Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Specifications Machine Specifications Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ven...

Page 60: ...t through the access hole behind the ground control box 54 Remove the number 3 arm from the machine Crushing hazard The number 3 arm could become unbalanced and fall when removed from the machine if not properly supported by the lifting device 55 Remove the upper and lower hose and cable covers from the number 3 arm 56 Remove the secondary boom drive speed limit switch mounting fasteners from the ...

Page 61: ...tion 2 Raise the primary boom so that it is above the secondary boom lift cylinder rod end pivot pin 3 Tag disconnect and plug the hydraulic hoses on the secondary boom lift cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Remove the pin re...

Page 62: ... 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 the flex plate mounting fasteners then remove the flex plate from the eng...

Page 63: ...nd loosely install the fasteners 3 Deutz models Torque the flex plate mounting bolts in sequence to 28 ft lbs 38 Nm Then torque the flex plate mounting bolts in sequence to 40 ft lbs 54 Nm Kubota models Pre torque to 13 ft lbs 17 5 Nm Then torque the flex plate mounting fasteners in sequence to 36 ft lbs 49 Nm 4 Apply a high viscosity coupling grease Genie part number 128025 to the splines of the ...

Page 64: ...torque the bell housing mounting fasteners labeled A in sequence to 5 ft lbs 7 Nm Pre torque the bell housing mounting fasteners labeled B in sequence to 10 ft lbs 13 Nm Then torque the bell housing mounting fasteners labeled A in sequence to 15 ft lbs 20 Nm Then torque the bell housing mounting fasteners labeled B in sequence to 29 ft lbs 40 Nm Component damage hazard When installing the pump do ...

Page 65: ...cy 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 appropriate sensor One or more fault LED s will illuminate on the display located at the ground control box The active fault code will also be displayed on the LCD screen If a fault occurs that does ...

Page 66: ...nt damage hazard The engine must not 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 lift steer pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hyd...

Page 67: ... 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 through the access hole underneath the turntable Close the valves Compon...

Page 68: ...r Component damage hazard Be sure to open the two hydraulic tank valves and prime the pump after installing the pump How to Pri me t he Pu mp How to Prime the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin from the engine pivot plate latch Note The engine pivot plate latch is located under the engine turntable pivot plate at the ...

Page 69: ...person crank the engine with the starter motor for 15 seconds wait 15 seconds then crank the engine an additional 15 seconds or until the pressure reaches 320 psi 22 bar 6 Deutz and Kubota models Release the manual fuel shutoff valve 7 Start the engine from the ground controls and check for hydraulic leaks ...

Page 70: ...BG Meters flow to functions 25 ft lbs 34 Nm 7 Proportional directional solenoid valve 3 position 4 way BP Turntable rotate left right 16 20 ft lbs 22 27 Nm 8 Proportional directional solenoid valve 3 position 4 way BU Secondary boom up down 16 20 ft lbs 22 27 Nm 9 Solenoid valve 3 position 4 way BF Steer left right 25 ft lbs 34 Nm 10 Relief valve 2100 psi 145 bar BV Secondary boom down 20 ft lbs 2...

Page 71: ...July 2021 Service and Repair Manual Manifolds Part No 1312350GT Z 45 25 Z 45 25J 59 ...

Page 72: ...lve 3000 psi 207 bar CD Primary boom down circuit 30 35 ft lbs 45 50 Nm 24 Pressure compensator valve 80 psi 5 5 bar BR Turntable rotate circuit 25 ft lbs 34 Nm 25 Shuttle valve CE Differential sensing circuit primary boom up down 12 14 ft lbs 16 19 Nm 26 Flow regulator valve 0 4 gpm 1 5 L min BE Jib boom and platform rotate circuit 20 ft lbs 27 Nm 27 Needle valve BN Platform level flow control 20...

Page 73: ...July 2021 Service and Repair Manual Manifolds Part No 1312350GT Z 45 25 Z 45 25J 61 ...

Page 74: ...not adjust the relief valve higher than specified 7 Repeat steps 2 through 5 and recheck relief valve pressure 8 Remove the pressure gauge How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate the secondary boom down relief ...

Page 75: ...Z 45 25J 63 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 76: ...rntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index No Description Schematic Item Function 1 Counterbalance valve L Turntable rotate right 2 Counterbalance valve J Turntable rotate left ...

Page 77: ... Z 45 25J 65 8 5 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 CH Directional control 1 2 ...

Page 78: ...ve chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Remove the ball joint retaining fastener from the bracket 7 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and drive chassis...

Page 79: ...ition 3 way AC Charge pressure circuit that directs hot oil out of low pressure side of drive pump and allows low pressure flow path for brake release and 2 speed motor shift 15 18 ft lbs 20 24 Nm 4 Check valve AD Drive circuit 25 30 ft lbs 34 41 Nm 5 Relief valve 250 psi 17 2 bar AE Charge pressure circuit 10 12 ft lbs 14 16 Nm 6 Solenoid valve 2 position 3 way AF 2 speed motor shift 10 12 ft lbs...

Page 80: ...Service and Repair Manual July 2021 Manifolds 68 Z 45 25 Z 45 25J Part No 1312350GT ...

Page 81: ... 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 Hold the charge pressure relief valve and remove the cap 8 Start the engine and move and hold the function enable rpm select toggle switch t...

Page 82: ...7 Solenoid valve 2 position 3 way AG Braking 10 12 ft lbs 14 16 Nm 8 Relief valve 250 psi 17 2 bar AH Charge pressure circuit 10 12 ft lbs 14 16 Nm 9 Solenoid valve 2 position 3 way AI 2 speed motor shift 10 12 ft lbs 14 16 Nm 10 Check valve AJ Steer end drive motor circuit 10 12 ft lbs 14 16 Nm 11 Check valve AK Steer end drive motor circuit 10 12 ft lbs 14 16 Nm 12 Check valve AL Non steer end d...

Page 83: ...July 2021 Service and Repair Manual Manifolds Part No 1312350GT Z 45 25 Z 45 25J 71 ...

Page 84: ... 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 Hold the charge pressure relief valve and remove the cap 8 Start the engine and move and hold the function enable rpm select toggle switch t...

Page 85: ...fold Components 2 2kW The generator manifold is mounted to the hydraulic generator located in the engine compartment Index No Description Schematic Item Function Torque 1 Proportional solenoid valve HH Generator speed 33 37 ft lbs 45 50 Nm 2 Relief valve 3000 psi 207 bar GG Generator circuit 20 25 ft lbs 27 34 Nm ...

Page 86: ... position 4 way directional valve 10V DC 6 to 8Ω schematic items BF BM and CG 2 position 3 way solenoid valve 10V DC 6 to 8Ω schematic items CA CC AF AG and AI How to Test a Coil Dio de 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 electric...

Page 87: ...ead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or bot...

Page 88: ... turntable pivot plate at the counterweight end of the machine 4 Remove the center turntable cover retaining fasteners Remove the center turntable cover from the machine 5 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine 6 Tag disconnect and plug the hydraulic hoses from the turntable rotation motor manifold Cap the fittings on the manifold Bodily in...

Page 89: ...emove the rear bearing How to I nstall t he Hu b a nd Bea rings How to Install the Hub and Bearings 2WD Models Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Press the bearing seal evenly into the hub until...

Page 90: ... to Specifications Hydraulic Hose and Fitting Torque Specifications 1 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 dissipate gradually Do not allow oil to squirt or spray 2 Remove the pin re...

Page 91: ...hocked 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 neces...

Page 92: ...e 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 two digit cod...

Page 93: ... 17 Not 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 ...

Page 94: ...V Limited 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 a...

Page 95: ...ller 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 V...

Page 96: ...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 shown ...

Page 97: ...wledged Contact service 2 Left red LED Flashing engine fault detected Contact service Flashing with right flashing amber LED engine soot level over 140 Engine shut down Contact service 3 Right green LED Flashing engine fault detected Contact service Solid fault acknowledged Contact service 4 Right red LED Flashing engine fault detected Contact service Flashing with right flashing amber LED engine ...

Page 98: ...2350GT Soft Key Functions and Icons Deutz D 2 9 L4 Models 1 Next menu Exit Back one screen Decrease brightness 2 Brightness Contrast Scroll up Increase Increase brightness 3 Scroll down Decrease Decrease contrast 4 Select Next Main menu Increase contrast Main Men u Struc tur e D eutz D 2 9 L4 Mod els ...

Page 99: ...July 2021 Service and Repair Manual Fault Code Display Deutz Models Part No 1312350GT Z 45 25 Z 45 25J 87 Main Menu Structure Deutz D 2 9 L4 Models ...

Page 100: ...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 threshold exceeded...

Page 101: ... load 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 voltag...

Page 102: ... 411 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 59...

Page 103: ...Timeout 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 ...

Page 104: ... 1525 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...

Page 105: ...523009 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 Co...

Page 106: ...etection 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 ...

Page 107: ... SPN 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 pr...

Page 108: ...23936 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 injec...

Page 109: ...al value 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 overloa...

Page 110: ...meout 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...

Page 111: ...he 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 rings wa...

Page 112: ...erminal 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 normally ...

Page 113: ...sition 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 ratio Solenoi...

Page 114: ... controls 10A engine throttle solenoid CB9 Circuit breaker 6A CR Control Relay CR1 Start relay CR2 Ignition power relay CR4 High idle relay CR5 Horn relay CR6 Fuel pump relay CR7 Secondary boom up down CR8 Primary boom up down CR9 Primary boom extend retract CR13 Jib relay jib option CR14 Jib relay jib option CR17 Hydraulic oil cooling fan option CR18 Platform level up down CR23 Drive work lights ...

Page 115: ...eck engine led L4 Platform overload led ce only L29 Drive lights L45 Load sense led L48 Tilt alarm led LS Limit Switch LS1 Primary boom extend LS2 Primary boom up LS3 Drive enable LS4 Secondary boom up LS18 CE limit switch Item Description M Motor M1 Cooling Fan option M2 Auxiliary pump M3 Engine starter P Button P1 Red emergency stop button P2 Emergency stop button P3 Horn Button P4 Function enab...

Page 116: ...ch TS54 Rpm select toggle switch TS56 Glow plug toggle switch TS57 Platform rotate toggle switch TS58 Jib boom up down toggle switch option TS59 Platform level up down toggle switch TS60 Secondary boom up down toggle switch TS61 Primary boom up down toggle switch TS62 Turntable rotate toggle switch TS63 Primary boom extend retract toggle switch Item Description U Module U1 Ignition start module U4...

Page 117: ... 25J 105 Wire Color Legend Item Description BL Blue BK Black BR Brown GN Green OR Orange PP Purple RD Red WH White YL Yellow BL RD Blue Red BL WH Blue White BK RD Black Red OR WH Orange White RD BK Red Black RD WH Red White WH BL White Blue WH BK White Black WH RD White Red WH YL White Yellow YL BK Yellow Black ...

Page 118: ... No 1312350GT Deutz D 2 9 L4 Fuses F7 20A Horn Hydraulic Oil Cooler F8 30A ECU Power F17 15A Ignition F19 10A Engine accessory F20 20A Fuel 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 ...

Page 119: ...July 2021 Service and Repair Manual 107 Electrical Schematic Options ...

Page 120: ... 1 BK P2 CB2 C7P 1 R22BAT BK C7B 1 15AMP RD P1 TB22 PLAT GRND KS1 PLAT GRND KS1 CB1 15AMP RD TB24 TB134 12 6 4 5 7 8 C32 PLUG C32 8 3 1 P20BAT RD TB20 TB21 CB3 15A CB8 15A P20BAT RD CR17 P116HYD RD 86 85 30 87A 87 P116HYD OR C116TS WH C5 5 C5 27 SW3 NO M1 FB1 P134FB WH C6 29 12V DC B1 J196 7 J196 12 J196 11 J196 1 J196 2 J196 10 J196 9 WH BK RD J196 CONTROLMODULE HOLD COIL PULLRELAY GND PULLIN REL...

Page 121: ...July 2021 Service and Repair Manual Part No 1312350GT Z 45 25 Z 45 25J 109 Wiring Diagram Battery Hydraulic Oil and Engine Oil Heater Options ...

Page 122: ...Service and Repair Manual July 2021 110 Wiring Diagram Battery Hydraulic Oil and Engine Oil Heater Options ...

Page 123: ...July 2021 Service and Repair Manual 111 Wiring Diagram 2 2kW Hydraulic Generator ...

Page 124: ...Service and Repair Manual July 2021 112 Z 45 25 Z 45 25J Part No 1312350GT Wiring Diagram 2 2kW Hydraulic Generator ...

Page 125: ...July 2021 Service and Repair Manual 113 Electrical Schematic Kubota D1105 ...

Page 126: ...H BK C132PLI GR C3P G WH C3B G GR P26BAT BK NO C9P 1 COM WH R20 4 7K RD D89 D88 BK P26BAT NO CR76 86 85 87 30 87A C7P 2 BK P22EST BK RD P22BAT C171LS WH BK BRN TS54 TS4 NO CR4 CR4 HIGH RPM HIGH IDLE C1P K C35RPM BK RD ENGINE SPEED LOW_RPM HIGH_RPM C5 17 Q3 C35RPM BK RD BK RD FOOTSW HIGH TB35 10A CB7 D13 D12 LED ENGINE CHECK L2 C5 8 TB25 C108ESL WH BK SW2 NC SW3 NO CHECK ENGINE LED OIL PRESSURE OIL...

Page 127: ...PLAT ROTATE LEFT C5TRR WH BK TB5 C5 12 C5 13 U4 BK RD C30FWD WH C31REV WH BK C5 14 C5 11 C6 25 C6 26 C32BRK WH RD C29MS RD WH C36SCC BL C37SCW BL BK RD BK BRN BRN GROUND DRIVE EDC FORWARD DRIVE EDC REVERSE STEER RIGHT STEER LEFT MOTOR STROKE BRAKE RELEASE VALVE C6 5 C6 8 C6 7 C6 6 C1PBU RD C15 1 C12 1 C14 1 C13 1 C2PBD RD BK C5TRR WH BK C4TRL WH 13 BK 6 BK 5 C110 1 C19 1 C18 1 C10SBU BL C11SBD BL ...

Page 128: ...Service and Repair Manual July 2021 116 Functions Electrical Schematic ...

Page 129: ...July 2021 Service and Repair Manual 117 Electrical Schematic Deutz D2 9 ...

Page 130: ...C5 28 C6 21 GR BK C7B 2 WH KS1 4 6 12 8 7 5 1 3 C32 P174BAT WH P174AUX RD P22BAT BK C2 J C5 16 GR YL C5 23 C5 20 D82CAN YL D81CAN GN C2 W C2 X D10 C1P R C128RPM OR RD C1B R FOOTSW LOW D11 TB34 YL GR C2 B C2 H C33STR BK STARTER B BIBAT RD P23PWR WH C5 7 C5 15 P23PWR WH C33STR BK START RELAY C21RET WH BK GND BR GND BR CR39A NO C2 S C5 24 R27AUX GN C2 A C5 3 P110RET WH P110RET BK GND BR NO CR1 R164PW...

Page 131: ...July 2021 Service and Repair Manual Part No 1312350GT Z 45 25 Z 45 25J 119 Deutz D 2 9 L4 Engine Wire Harness ...

Page 132: ...Service and Repair Manual July 2021 120 Deutz D2 9 L4 Engine Wire Harness ...

Page 133: ...July 2021 Service and Repair Manual 121 Electrical Schematic Deutz 2011 L03i ...

Page 134: ...2 D64 BR WH OR BK RD WH BK C132PLI GR C3P G WH C3B G GR P26BAT BK NO C9P 1 COM WH R20 4 7K RD D89 D88 BK P26BAT NO CR76 86 85 87 30 87A C7P 2 BK P22EST BK RD P22BAT C171LS WH BK BRN TS54 TS4 NO CR4 CR4 HIGH RPM HIGH IDLE C1P K C35RPM BK RD ENGINE SPEED C1B K C5 17 Q3 C35RPM BK RD BK RD FOOTSW HIGH TB35 10A CB7 D13 D12 LED ENGINE CHECK L2 C5 8 TB25 C108ESL WH BK SW2 NC SW3 NO CHECK ENGINE LED OIL P...

Page 135: ...H R20 4 7K RD D89 D88 BK P26BAT NO CR76 86 85 87 30 87A C7P 2 BK P22EST BK RD P22BAT C171LS WH BK BRN TS54 TS4 NO CR4 CR4 HIGH IDLE C1P K C35RPM BK RD ENGINE SPEED C1B K C35RPM BK RD FOOTSW HIGH TB35 D13 D12 P4 FUNC ENABLE P47FE OR RD P174AUX RD P174AUX RD P22BAT BK 3MF C1B Q C1P N C34SA C2 U C2 E C2 P P134BAT RD C41RPM OR BK P22BAT BK P174BAT WH RELAY WH BK R34SA RD FUSE 70A BK WH C2 J NO PR3 C5 ...

Page 136: ...Service and Repair Manual July 2021 124 Electrical Schematic Deutz D436 1 ...

Page 137: ...July 2021 Service and Repair Manual 125 Electrical Schematic Deutz D436 2 ...

Page 138: ...16 GND_SPEED BRN 14 OIL_PS SIG ORG 14 D O3 16 PWR5 RD 14 RPM_ALT OR BK SW_OIL 16 GND_TEMP BRN 14 FIELD WH 16 SW_AIR 16 RACKREF BR 16 OIL TEMP BL 14 SW AIR 16 STARTER BK 14 GND_SPEED 16 ACTOR WH 12 E D A B H G P21IGN2 WH 16 GND 16 SPARE 16 SPARE 16 CAN 16 CAN 16 X23 12 X23 11 X23 9 X23 8 X23 6 X23 7 X23 10 X23 5 X23 3 X23 4 X23 2 X23 1 SW_OIL 16 C41RPM OR BK 16 D I5 16 D O6 16 D O4 16 GND 16 SW_AIR...

Page 139: ...July 2021 Service and Repair Manual 127 Hydraulic Schematic 2WD Models ...

Page 140: ...Service and Repair Manual July 2021 128 Z 45 25 Z 45 25J Part No 1312350GT Hydraulic Schematic 2WD Models ...

Page 141: ...July 2021 Service and Repair Manual Part No 1312350GT Z 45 25 Z 45 25J 129 Hydraulic Schematic 4WD Models ...

Page 142: ...Service and Repair Manual July 2021 130 Hydraulic Schematic 4WD Models Z 4 5 25 Z 45 2 5J Part No 131 235 0GT Service a nd Re pair Ma nual July 20 21 ...

Page 143: ......

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