Terex Genie Z-45 FE Service And Repair Manual
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Terex Genie Z-45 FE Service And Repair Manual

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1.
Service and Repair Manual
Z
®
-45 FE
Z
®
-45 DC
Serial Number Range
From Z45EM-101
This manual includes:
Repair procedures
Fault Codes
Electrical and Hydraulic
Schematics
For detailed maintenance
procedures, Refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1297714GT
Rev A1
July 2020

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  • Page 1 Service and Repair Manual Serial Number Range This manual includes: ® -45 FE From Z45EM-101 Repair procedures ® -45 DC Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, Refer to the appropriate Maintenance Manual for your machine. Part No. 1297714GT Rev A1 July 2020...

  • Page 2: Find A Manual For This Model

    Copyright © 2019 by Terex Corporation 1297714GT Rev A1 July 2020 First Edition, First Printing "Genie" and "Z" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. ® ® -45 DC • Z -45 FE Part No.

  • Page 3: Revision History

    July 2020 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 03/2020 Initial Release 07/2020 Section 6 Schematic page 120 REFERENCE EXAMPLES: Electronic Version Section – Repair Procedure, 4-2 Section – Fault Codes, All charts Click on any content or procedure in the Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual July 2020 Introduction Serial Number Legend Z45E Z45EM-001 2020 1 Model 2 Facility code 3 Sequence number 4 Serial number (stemped on chassis) 5 Serial label (located under cover) ® ® -45 DC • Z -45 FE Part No.

  • Page 5: Safety Rules

    July 2020 Service and Repair Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 6 Service and Repair Manual July 2020 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 7: Table Of Contents

    July 2020 Table of Contents Introduction Introduction ....................ii Important Information .................. ii Find a Manual for this Model ............... ii Revision History...................iii Serial Number Legend................iv Section 1 Safety Rules ....................v General Safety Rules .................. v Specifications .................... 1 Section 2 Machine Specifications ................
  • Page 8 July 2020 TABLE OF CONTENTS Section 3 Repair Procedures, continued Platform Components ................20 Platform Leveling Cylinder .............. 20 Platform Rotator ................21 Platform Overload System .............. 23 How to Reset Overload Recovery Fault .......... 24 Jib Boom Components ................25 Jib Boom ..................25 Boom Lift Cylinder ................
  • Page 9 July 2020 TABLE OF CONTENTS Section 3 Repair Procedures, continued Manifolds ....................48 Function Manifold Components............49 Valve Adjustments-Function Manifold ..........53 How to Adjust the Proportional Relief Valve and Hydraulic Pressure Sensor ..................... 53 How to Adjust the Secondary Boom Down Relief Valve ....54 Jib Boom / Platform Rotate Manifold Components ......
  • Page 10 July 2020 TABLE OF CONTENTS Section 4 Fault Codes ....................67 Introduction ....................67 Control System Fault Codes ..............68 Fault Codes Ground Controls ..............68 How to Retrieve Control System Fault Codes - Platform Controls .... 69 Control System Fault Codes..............70 Section 5 Navigation Menus ..................

  • Page 11: Specifications

    July 2020 Service and Repair Manual Specifications Machine Specifications Fluid capacities Fuel tank 17 gallons 64.4 liters Tires and wheels Rough terrain Hydraulic tank 10.5 gallons Tire size 315/55 D20 40 liters Tire ply rating Hydraulic system 17 gallons (including tank) 65 liters Tire and wheel weigh 290 lbs...

  • Page 12: Performance Specifications

    Service and Repair Manual July 2020 Specifications Performance Specifications Boom function speeds, maximum from platform controls Drive speed, maximum Jib boom up 13 to 17 seconds stowed position Jib boom down 13 to 17 seconds 2WD/4WD models Stowed 4.5 mph Primary boom up 26 to 30 seconds 7.2 km/h...

  • Page 13: Hydraulic Specifications

    July 2020 Service and Repair Manual Specifications Hydraulic Specifications Do not top off with incompatible NOTICE hydraulic fluids. Hydraulic fluids may be incompatible due to Hydraulic Oil Specification the differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 14 Service and Repair Manual July 2020 Specifications Chevron Rando HD Premium Petro-Canada Environ MV 46 Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5 cSt @ 104°F / 40°C...

  • Page 15: Hydraulic Component Specifications

    July 2020 Service and Repair Manual Specifications Hydraulic Component Manifold Component Specifications Specifications Functions Pump Plug Torque Type: Single unit SAE No. 4 14 ft-lbs / 19 Nm gear pump SAE No. 6 23 ft-lbs / 31.2 Nm Displacement per revolution .40 cu in / 6.6 cc SAE No.

  • Page 16: Kubota D1105 Engine Specificatios

    Service and Repair Manual July 2020 Specifications Kubota D1105 Engine Engine coolant Displacement Capacity 3.3 quarts 68.53 cu in 1.123 liters 3.1 liters Number of cylinders Fuel injection system Bore and Stroke 3.07 x 3.09 Injection pump make Bosch MD inches Injection pump pressure, 1991 psi...

  • Page 17: Machine Torque Specifications

    July 2020 Service and Repair Manual Specifications Machine Torque Specifications Machine Component Weights Platform Rotator Tire and wheel assembly 300 lbs 136 1-8 center bolt, GR 5 Drive motor and hub 114.6 lbs 52 Lubricated 480 ft-lbs 650 Nm Engine assembly 640 lbs 547 ft-lbs 290.3 kg...

  • Page 18: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual July 2020 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port (tube fitting - installed into Aluminum) Torque Specifications (all types) SAE Dash size Torque Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. 14 ft-lbs / 19 Nm Genie specifications require that fittings and hose 23 ft-lbs / 31.2 Nm...

  • Page 19: Torque Procedure

    July 2020 Service and Repair Manual Specifications Torque Procedure Seal-Lok fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger Figure 1 tight.

  • Page 20: Repair Procedures

    Service and Repair Manual July 2020 Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Observe and Obey: Perform disassembly procedures to the point Repair procedures shall be completed by a...

  • Page 21: Calibration Process Steps

    July 2020 Service and Repair Manual Repair Procedures 6 Complete calibrating the Primary and Secondary angle sensors stowed and elevated positions: Refer to Repair It is required to perform the calibration process if Procedures, How to Calibrate Booms Angle system defaults have been reset or if new software Sensors.

  • Page 22: Platform Controls

    Service and Repair Manual July 2020 Platform Controls The platform control box contains two control modules; The VCON is a LCD screen mounted between the secondary boom and drive joysticks. The PCON (platform controller) inside the platform control box communicates with the VCON and controllers located on the turntable of the machine.

  • Page 23: How To Adjust The Joystick Treshold Setting

    July 2020 Service and Repair Manual Platform Controls 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND SENSOR SETTINGS is shown on the display. 8 Momentarily activate the drive enable toggle The threshold setting is the minimum output switch in the right direction until CALIBRATE current at which a function proportional valve can TILT SENSOR is shown on the display.

  • Page 24: How To Adjust The Joystick Max Speed Setting

    Service and Repair Manual July 2020 Platform Controls 14 Press down on the foot switch and select the toggle switch controlled boom function to be adjusted. Result: The display will indicate the parameter in milliamps while operating the function. There are three types of speed settings to adjust: High Flow Functions: Primary Up/Down Primary 15 Momentarily activate the speed select switch Extend/Retract, Secondary Up/Down and...
  • Page 25 July 2020 Service and Repair Manual Platform Controls 7 Momentarily activate the drive enable toggle 14 Release the foot switch and momentarily switch in the right direction until VALVE AND activate steer in the right direction one time to SENSOR SETTINGS is shown on the display. increase the value by 10 milliamps.

  • Page 26: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual July 2020 Platform Controls 19 Momentarily active a low flow boom function in one direction. Result: The display shows the name of the function, direction and current value The ramp rate setting is an adjustment that in milliamps for the function being moved.
  • Page 27 July 2020 Service and Repair Manual Platform Controls 8 Momentarily activate the drive enable toggle Ramp up time (factory settings) switch in the right direction until CALIBRATE Primary boom up/down TILT SENSOR is shown on the display. ramp accelerate (up) 2 seconds ramp decelerate (down) 0.6 second...

  • Page 28: How To Calibrate Booms Angle Sensors

    Service and Repair Manual July 2020 Platform Controls 7 Momentarily activate steer in the right direction until BOOM ANGLE CALIBRATE is shown on the display. 8 Momentarily activate the drive enable toggle switch in the right direction to enter the BOOM Boom angle sensors are installed on the primary ANGLE CALIBRATE screen.

  • Page 29: How To Clear The Fault History

    July 2020 Service and Repair Manual Platform Controls 8 Momentarily activate the drive enable toggle switch in the right direction to activate the clear fault history function. Result: The display will read ENABLE at the There are 1 thru 16 fault codes shown in the fault bottom.

  • Page 30: Platform Components

    Service and Repair Manual July 2020 Platform Components 4 Tag, disconnect and cap the hydraulic hoses from the slave cylinder. Plug the union hoses from the master cylinder together using a connector. The slave cylinder and the rotator pivot are the Bodily injury hazard.

  • Page 31: Platform Rotator

    July 2020 Service and Repair Manual Platform Components 1 Simultaneously activate the primary boom up function and the platform level up function until the boom is fully raised. Component damage hazard. NOTICE Mark the platform mounting 2 Simultaneously activate the primary boom weldment and the rotator flange down function and the platform level down before removing the platform...
  • Page 32 Service and Repair Manual July 2020 Platform Components 3 Support the platform rotator with an appropriate 5 Open the bottom bleed screw on the rotator, lifting device. Do not apply any lifting pressure. but do not remove it. Crushing hazard. The platform Bodily injury hazard.

  • Page 33: Platform Overload System

    July 2020 Service and Repair Manual Platform Components 6 FULL RATED LOAD CALIBRATION: Using a suitable lifting device, place a test weight equal to the maximum platform capacity at the center of the platform floor. Refer to the machine serial plate.

  • Page 34: How To Reset Overload Recovery Fault

    Service and Repair Manual July 2020 Platform Components The message OVERLOAD RECOVERY will be displayed when a platform overload recovery occurs under auxiliary power. The message will persist until the reset overload recovery procedure is performed. Refer to Navigation Menus, Faults Menu.

  • Page 35: Jib Boom Components

    July 2020 Service and Repair Manual Jib Boom Components 7 Remove the pin retaining fasteners from both platform rotator 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.

  • Page 36: Boom Lift Cylinder

    Service and Repair Manual July 2020 Jib Boom Components 16 Remove the pin retaining fastener from the jib boom pivot pin. Use a soft metal drift to remove the pin, then remove the jib boom from the bellcrank. Crushing hazard. The jib boom WARNING may become unbalanced and fall when it is removed from...
  • Page 37 July 2020 Service and Repair Manual Jib Boom Components 4 Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.

  • Page 38: Primary Boom Components

    Service and Repair Manual July 2020 Primary Boom Components Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow The primary boom cable track guides the cables the oil pressure to dissipate and hoses running up the boom.
  • Page 39 July 2020 Service and Repair Manual Primary Boom Components 10 Tag, disconnect and plug the hydraulic hoses 18 Use a soft metal drift to remove the primary from the platform leveling master cylinder. Cap boom lift cylinder rod-end pivot pin. the fittings on the cylinder.

  • Page 40: How To Repair The Cable Track

    Service and Repair Manual July 2020 Primary Boom Components Component damage hazard. NOTICE The boom cable track can be damaged if it is twisted. Note: A 7 link repair section of cable track is Bodily injury hazard. This WARNING available through the Genie Service Parts procedure requires specific Department.
  • Page 41 July 2020 Service and Repair Manual Primary Boom Components 6 Remove the pin retaining fastener from the 14 Attach a 5 ton / 5,000 kg overhead lifting device master cylinder barrel-end pivot pin. Use a soft to the center point of the primary boom. metal drift to remove the pin.

  • Page 42: How To Disassemble The Primary Boom

    Service and Repair Manual July 2020 Primary Boom Components 6 Remove the external snap rings from the extension cylinder rod-end pivot pins at the platform end of the extension tube. Use a soft Complete disassembly of the boom is only metal drift to remove the pins.

  • Page 43: Primary Boom Lift Cylinder

    July 2020 Service and Repair Manual Primary Boom Components 6 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. The primary boom lift cylinder raises and lowers Bodily injury hazard. Spraying the primary boom. The primary boom lift cylinder is WARNING hydraulic oil can penetrate and equipped with a counterbalance valve to prevent...

  • Page 44: Primary Boom Extension Cylinder

    Service and Repair Manual July 2020 Primary Boom Components accessible in the primary boom extension tube. Crushing hazard. The lift cylinder WARNING could become unbalanced and 3 Remove the hose and cable guard from the fall if not properly supported and upper pivot.

  • Page 45: Platform Leveling Master Cylinder

    July 2020 Service and Repair Manual Primary Boom Components Component damage hazard. Bodily injury hazard. Spraying NOTICE WARNING Hoses and cables can be hydraulic oil can penetrate and damaged if the primary boom burn skin. Loosen hydraulic extension cylinder is dragged connections very slowly to allow across them.

  • Page 46: Secondary Boom Components

    Service and Repair Manual July 2020 Secondary Boom Components Secondary Boom Components 5 compression link 6 secondary boom lift cylinder (2) 1 upper secondary boom (number 1 arm) 7 lower secondary boom (number 4 arm) 2 upper tension link (number 2 arm) 8 upper pivot 3 lower tension link (number 3 arm) 4 mid-pivot...

  • Page 47: Secondary Boom Lift Cylinder

    July 2020 Service and Repair Manual Secondary Boom Components 6 Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. Cap the fittings on the cylinder. Bodily injury hazard. Spraying WARNING How to Disassemble the hydraulic oil can penetrate and burn skin.
  • Page 48 Service and Repair Manual July 2020 Secondary Boom Components 12 Use a soft metal drift to drive the barrel-end 20 Remove the number 1 arm from the machine. pivot pin half way out. Lower the barrel end of Crushing hazard. The number 1 the secondary boom lift cylinder and let it hang WARNING arm could become unbalanced...
  • Page 49 July 2020 Service and Repair Manual Secondary Boom Components 25 Pull all of the hoses and cables out of the upper 34 Use a soft metal drift to drive each pin out. pivot and out through the mid-pivot. Lay the Then remove the mid-pivot from the secondary hoses and cables on the ground.
  • Page 50 Service and Repair Manual July 2020 Secondary Boom Components 40 Remove the number 2 arm from the machine. 46 Tag, disconnect and plug the fuel hoses from the fuel tank. Clean up any fuel that may have Crushing hazard. The number 2 spilled.
  • Page 51 July 2020 Service and Repair Manual Secondary Boom Components 54 Remove the number 3 arm from the machine. Crushing hazard. The number 3 WARNING arm could become unbalanced and fall when removed from There are two secondary boom lift cylinders the machine if not properly incorporated in the structure of the secondary supported by the overhead lifting...
  • Page 52 Service and Repair Manual July 2020 Secondary Boom Components 3 Tag, disconnect and plug the hydraulic hoses on the secondary boom lift cylinder. Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 53: Engines

    July 2020 Service and Repair Manual Engines 1 Remove the fastener under the engine tray and Refer to Maintenance Procedure in the appropriate pull the engine out. Maintenance Manual for your machine, Check and Adjust the Engine RPM. 2 Remove the high idle solenoid from the bracket.

  • Page 54: Ground Controls

    Service and Repair Manual July 2020 Ground Control The turntable control box (TCON) is the communication and operations center for the machine. The switch at the bottom of the control box is the control system fault Recovery switch. Bypass and Recovery mode is only intended for certain circumstances and is not part of normal machine operation.

  • Page 55: How To Use The Control System Fault Recovery Switch

    July 2020 Service and Repair Manual Ground Control 3 If the recovery function has been used, this indicates major faults with the main control system and/or CAN bus. Tag and remove the machine from service until the faults have been Recovery is only to be used as a last attempt to fixed by trained personnel.

  • Page 56: Hydraulic Pumps

    Service and Repair Manual July 2020 Hydraulic Pumps 2 Tag, disconnect and plug function pump hydraulic hoses. Cap the fittings on the pump. Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 57: How To Check The Function Pump Calibration

    July 2020 Service and Repair Manual Hydraulic Pumps 6 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSOR is shown on the display. Pump efficiency is calibrated automatically but 7 Continue to momentarily active the steer in must be verified after a new pump installation and the right direction until PUMP EFFICIENCY before performing any boom speed calibrations.

  • Page 58: Manifolds

    Service and Repair Manual July 2020 Manifolds ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 59: Function Manifold Components

    July 2020 Service and Repair Manual Manifolds The function manifold is located on the turntable next to the ground controls Index Description Schematic Function Torque Item Valve, Check, Gs68 (Size8 8) Platform rotate left/right 19 - 21 ft lbs / 26 - 29 Nm Valve, Spool, 4 Way, 3 Position Platform rotate left/right 19 - 21 ft lbs / 26 - 29 Nm...
  • Page 60 Service and Repair Manual July 2020 Manifolds ® ® -45 DC • Z -45 FE Part No. 1297714GT...
  • Page 61 July 2020 Service and Repair Manual Manifolds Valve, Check 25 Psi Tank return circuit 19 - 21 ft lbs / 26 - 29 Nm Valve, Check 25 Psi Secondary boom retract 19 - 21 ft lbs / 26 - 29 Nm circuit Valve, Counterbalance Primary boom retract...
  • Page 62 Service and Repair Manual July 2020 Manifolds ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 63: Valve Adjustments-Function Manifold

    July 2020 Service and Repair Manual Manifolds 5 Simultaneously activate the platform rotate toggle switch to store the value Result: The control system will continue to the next calibration procedure value - (3000 PSI / 207 bar). 6 Simultaneously activate the platform level toggle switch until the pressure gauge reads 3000 PSI / 207 bar.

  • Page 64: How To Adjust The Secondary Boom Down Relief Valve

    Service and Repair Manual July 2020 Manifolds 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 valve. 1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the test1 port on the function manifold.

  • Page 65: Jib Boom / Platform Rotate Manifold Components

    July 2020 Service and Repair Manual Manifolds The jib boom / platform rotate manifold is mounted to the platform support. Index Description Schematic Function Torque Item Solenoid Valve, 2 position 3 way Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm Part No.

  • Page 66: Turntable Rotation Manifold Components

    Service and Repair Manual July 2020 Manifolds The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index Description Schematic Function Item Counterbalance valve Turntable rotate right Counterbalance valve Turntable rotate left ® ®...

  • Page 67: Directional Valve Manifold Components

    July 2020 Service and Repair Manual Manifolds The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index Description Schematic Item Function Torque Breather 20-25 ft-lbs / 27-33 Nm Spool valve Directional control Part No. 1297714GT ®...

  • Page 68: How To Set Up The Oscillate Directional Valve

    Service and Repair Manual July 2020 Manifolds 9 Verify that the ground and drive chassis are completely level. How to Set Up the Oscillate Directional Valve Linkage 10 Measure the distance between the drive chassis and non-steer axle on both sides (from inside of the drive chassis.

  • Page 69: Valve Coils

    July 2020 Service and Repair Manual Manifolds Valve Coil Resistance Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in A properly functioning coil provides an air temperature, the coil resistance will typically electromotive force which operates the solenoid...
  • Page 70 Service and Repair Manual July 2020 Manifolds 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 mA.

  • Page 71: Turntable Rotation Components

    July 2020 Service and Repair Manual Turntable Rotation Components 5 Attach a lifting strap from an overhead lifting device to the turntable rotator assembly. 6 Remove the turntable rotation assembly mounting fasteners. 7 Carefully remove the turntable rotation assembly from the machine. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Crushing hazard.

  • Page 72: How To Replace The Universal Tilt Sensor

    Service and Repair Manual July 2020 Turntable Rotation Components 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls. Turn the key switch to platform control. 2 Move and hold the drive enable toggle switch This machine has a dual axis angle-sensing in the right direction while holding steer in the device called the Universal Tilt Sensor (UTS).

  • Page 73: Axle Components

    July 2020 Service and Repair Manual Axle Components 4 Attach a lifting strap from an overhead lifting device to the barrel end of the oscillating cylinder. 5 Remove the pin retaining fasteners from the The oscillating axle cylinders extend and retract barrel-end pivot pin.

  • Page 74: How To Remove The Steer Cylinder

    Service and Repair Manual July 2020 Axle Components Note: Perform this procedure on a firm, level surface with the machine in the stowed position. 1 Adjust the steer tires so they are in a straight Refer to Navigation Menus, Settings Menu. driving position.
  • Page 75 July 2020 Service and Repair Manual Axle Components 10 Momentarily activate the drive enable toggle switch in the right direction to save calibrate steer center. Result: The alarm will sound and the mV value flashes to indicate the setting has been saved. To exit programming mode: 11 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM...
  • Page 76 Service and Repair Manual July 2020 ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 77: Fault Codes

    July 2020 Service and Repair Manual Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Read each appropriate fault code thoroughly.

  • Page 78: Control System Fault Codes

    Service and Repair Manual July 2020 Control System Fault Codes Both Engine Hours and DC Function Enable Hours will be tracked. DC Function enable hours will be displayed on the smart hour meter by default. Standard Genie fault codes shall be displayed and Engine Hours will be displayed if the hybrid mode the red LED will illuminate when any faults are select switch is held for three (3) seconds.

  • Page 79: How To Retrieve Control System Fault Codes - Platform Controls

    July 2020 Service and Repair Manual Control System Fault Codes 10 Activate the steer rocker switch in the right direction until FAULT HISTORY is shown on the display. 11 Momentarily activate the drive enable toggle switch in the right direction to access the fault At least one fault code is present when the alarm history list codes.

  • Page 80: Control System Fault Codes

    Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Release foot switch and recycle power. Stuck ON Verify: (when activated) Fault (on @ power up) *24V supply on C11-1 Platform controlled (P22PWR WH) Foot Switch...
  • Page 81 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: Shorted to *5V at JC7-2 supply (P162PJW OR) *B- at JC7-1 (JSGND Primary Up/Down Primary Boom Disabled Sensor at Zero Joystick *500 to 4500 mV at...
  • Page 82 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Resistance Too Open Circuit or *Check Ohms High Ohms > 60 Verify no open/short Primary Retract Associated Function circuit across Valve disabled...
  • Page 83 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name *Check Ohms Resistance Too Open Circuit or *Verify no open/short High Ohms > 60 Associated Function circuit across Jib Select Valve disabled PCON C47-3 BK or...
  • Page 84 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: Shorted to *5V at JC3-2 (P162JW supply *B- at JC3-1 (JSGND Drive Joystick Drive Disabled BR), Sensor at 0v * 500-4500 mV at JC3- 4 &...
  • Page 85 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: *5V from TCON C19-8 Act as if in Out of thru Shorted to Stowed C3-15 to sensor C15-C supply position *Verify B- from C19-9...
  • Page 86 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: *Relay in operable Relay Contact Stuck condition -Platform Estop *LRDCON C27-22 detected when Key detects Platform Switch is in Ground Estop when All plagorm functions...
  • Page 87 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: *24V supply on C48-1 VCON LCD Display No CAN *B- at C48-2 Not Detected Lift functions disabled (platform controls) communication *60 Ohm resitance...
  • Page 88 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Shorted to Verify: Signal > 4975 mV supply *24V supply on pin A of sensor Sensor too Fuel Level Sensor display fault code only Signal >...
  • Page 89 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name *Verify no open/short Platform Level Down Associated Function circuit across Fault Open or Shorted Valve Disabled ECON C34-4 & B- (V14PLD OR/BK) Verify: *12V supply Pin A &...
  • Page 90 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Verify: *24V supply on (+) Terminal No Response *B- on (-) Terminal (Detected by Display fault, but battery Loss of CAN from *60 Ohm restance TCON not...
  • Page 91 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name *Check for shorted or damaged cells *Replace battery pack *Check DC Battery Battery could not be trickle charged up to the connections defective minimum voltage.
  • Page 92 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Battery voltage is detected but the charger is Ensure the charger is unable to charge the battery. This can be due properly connected to to a Battery does...
  • Page 93 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Check the battery voltage and cable Low battery connections. voltage error Battery voltage is too low as detected by the (This error will detected while algorithm.
  • Page 94 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Check the physical CAN connector, electrical bus conditions & other modules for correct CAN Bus error CANbus network error. function.
  • Page 95 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name 48V on C28-1, C28-11 No CAN No Response Drive disabled (R181PWR), 0V on communication Left Front Drive C28-12 Controller 12..9...
  • Page 96 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Heatsink temperature below - Controller Severe Undertemp ShutdownMotor; 40°C. 1. See Monitor menu » Controller: ShutdownMainContactor; Temperature.
  • Page 97 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Heatsink Controller Overtemp Cutback temperature exceeded 1. See Monitor menu » Controller: 85°C. Temperature. 2. Controller is performance-limited at Reduced drive and brake Clear: Bring heatsink this temperature.
  • Page 98 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Motor thermistor Motor Temp Sensor Fault MaxSpeed reduced input (pin 8) is 1. Motor thermistor is not connected (LOS, at the voltage rail (0 V properly.
  • Page 99 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Motor encoder phase failure detected. Clear: Either cycle KSI, or if parameter LOS Encoder Fault Upon Encoder Fault= 1.
  • Page 100 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Adjustment of a Parameter Change Fault ShutdownMotor; parameter setting that 1. This is a safety fault caused by a ShutdownMainContactor;...
  • Page 101 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Supervisor Fault ShutdownMotor; Set: Mismatched 1. The Supervisor has detected a ShutdownMainContactor; redundant readings; mismatch in redundant readings. ShutdownEMBrake;...
  • Page 102 Service and Repair Manual July 2020 Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Motor lost IFO control and ShutdownMotor; accelerated without ShutdownMainContactor; throttle Encoder Pulse Count Fault ShutdownEMBrake; command. 1.
  • Page 103 July 2020 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Cause Effect Solution Component Name Set: Illegal Model_ Number variable; when KSI cycles, a check is made to confirm a legal Model_ Number, and a fault Pump &...
  • Page 104 Service and Repair Manual July 2020 Control System Fault Codes Navigation Menu - Top Menus ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 105: Navigation Menus

    July 2020 Service and Repair Manual Faults Navigation Menu Faults Navigation Menu Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 106: Options Navigation Menu

    Service and Repair Manual July 2020 Options Navigation Menu Options Navigation Menu ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 107: Settings Navigation Menu

    July 2020 Service and Repair Manual Settings Navigation Menu Settings Navigation Menu Part No. 1297714GT ® -45 DC • Z ® -45 FE...
  • Page 108 Service and Repair Manual July 2020 ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 109: Schematics

    July 2020 Service and Repair Manual Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. WARNING Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 110: Electrical Symbol Legends

    Service and Repair Manual July 2020 Electrical Symbols Legends ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 111: Hydraulic Symbol Legends

    July 2020 Service and Repair Manual Hydraulic Symbols Legends Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 112: Electrical Component And Wire Color Legends

    Service and Repair Manual July 2020 Electrical Component and Wire Color Legends Jumper plug LR/RR motor controller Item Description to ECON Battery Jib select hydraulic manifold Engine Start - 12V DC Steer sensor extender Battery pack, 48V DC Function pump motor / Generator Connector ECON, AC motor / Generator controller GCON box to rear motor controller...
  • Page 113 July 2020 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Circuit Breaker Engine oil temp. Engine power, 15A Hour meter Controls power, 24V DC, 15A Horn or Alarm Charger box 12V, 10A Tilt / Platform overload Master, 48V DC, 10A Horn Telematic, 5A (option)
  • Page 114 Service and Repair Manual July 2020 Electrical Component and Wire Color Legends TS63 Primary boom extend/retract Item Description Module Power Relay DCON, RR, AC motor controller Main contactor DCON, LR AC motor controller Pump / Generator contactor DCON, RF AC motor controller (4WD Resistor option) DCON LF AC motor controller (4WD)

  • Page 115: Kubota Engine Fuse And Relay Module

    July 2020 Service and Repair Manual Kubota Engine Fuse and Relay Module Kubota D1105-E4B Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 116: Dc Charger Wiring (Dc Option)

    Service and Repair Manual July 2020 12V DC Charger Wiring (DC Option) 1 Control Relay 3 - 24V auxiliary 2 Circuit breaker 4 - 10A 3 Battery charger - 12V 4 To relay AC input box 5 Connector 14 ® ®...

  • Page 117: Ac Input Wiring (Dc Option)

    July 2020 Service and Repair Manual AC Input Wiring, ANSI/CSA version (DC Option) 1 AC input wall plug 2 AC input to 48V charger 3 Charger Control IN 4 To 12V charger Part No. 1297714GT ® -45 DC • Z ®...

  • Page 118: Ac Input Wiring Ce Option

    Service and Repair Manual July 2020 AC Input Wiring, AS/CE version (DC Option) 1 AC input wall plug 2 AC input to 48V charger 4 To 12V charger ® ® -45 DC • Z -45 FE Part No. 1297714GT...

  • Page 119: Can Bus Wiring Diagram - Dc Models

    July 2020 Service and Repair Manual CAN BUS Wiring Diagram Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 120: Limit Switch/Angle Sensor Legend

    Service and Repair Manual July 2020 Limit Switch/Angle Sensor Legend 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS3 Drive enable 4 S13 Steer Angle sensor (inside steer cylinder) 5 S19 Secondary angle sensor ® ® -45 DC •...

  • Page 121: Electrical Schematics - Options

    Service and Repair Manual July 2020 Wiring Diagram - Options...
  • Page 122 Service and Repair Manual July 2020 Wiring Diagram - Options ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 123 Service and Repair Manual July 2020 Wiring Diagram - Options ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 124 Service and Repair Manual July 2020 Wiring Diagram - Options...

  • Page 125: Schematics - Options, Dc And Fe Models Schematics

    Service and Repair Manual July 2020 Schematics - Options, DC and FE Models...
  • Page 126 Service and Repair Manual July 2020 Schematics - Options, DC and FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 127: Power Cable Wiring Diagram

    Service and Repair Manual July 2020 Power Cable Wiring Diagram...
  • Page 128 Service and Repair Manual July 2020 Wiring Diagram - Options ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 129: Hydraulic Schematics

    Service and Repair Manual July 2020 Hydraulic Schematic...

  • Page 130: Hydraulic Schematic - Dc And Fe Models

    Service and Repair Manual July 2020 Hydraulic Schematic, DC/FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 131: Electrical Schematics

    Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models...

  • Page 132: Electrical Schematic - Dc And Fe Models

    Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 133 Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 134 Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models...
  • Page 135 Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 136 Service and Repair Manual July 2020 Electrical Schematic, DC/FE Models...

  • Page 137: Ground Control Box Terminal Strip Wiring Dagram

    Service and Repair Manual July 2020 Ground Control Box Terminal Strip Wiring Diagram, DC/FE Models...
  • Page 138 Service and Repair Manual July 2020 Ground Control Box Terminal Strip Wiring Diagram, DC/FE Models ® -45 DC • Z ® -45 FE Part No. 1297714GT...
  • Page 139 Service and Repair Manual July 2020 Ground Control Box Terminal Strip Wiring Diagram, DC/FE Models...
  • Page 140 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

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