Terex Genie Z-60 DC Service Manual
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Terex Genie Z-60 DC Service Manual

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Service and Repair Manual
Z
-60 DC
®
Z
-60 FE
®
Serial Number Range
from Z60H-2548
from Z60M-1000
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1307785GT
Rev B
August 2022

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Summary of Contents for Terex Genie Z-60 DC

  • Page 1 Service and Repair Manual Serial Number Range -60 DC ® from Z60H-2548 This manual includes: from Z60M-1000 Repair procedures -60 FE ® Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Original Instructions Part No.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation and scheduled maintenance. 1307785GT Rev B, August 2022 Second Edition, Second Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -60 DC • Z ®...
  • Page 3 August 2022 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2021 Initial Release 8/2022 Repair 11-1 Fault Codes All Sections Navigation Menus All Sections Schematics Electrical schematics Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual August 2022 Introduction Serial Number Legend Z60 H - 12345 Model: Serial number: Z60H-12345 Year of manufacture: Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model 2 Facility code...

  • Page 5: Safety Rules

    August 2022 Service and Repair Manual Safety Rules Secti on 1 Safety Rul es Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury.
  • Page 6 Service and Repair Manual August 2022 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    August 2022 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 Section 2 Specifications ....................
  • Page 8 August 2022 Table of Contents Section 3 Repair Procedures ..................11 Introduction ...................... 11 Cailbration Process Steps ................13 Platform Controls ................... 14 1-1 Platform Controls ..................14 How to Adjust the Joystick Threshold Setting ..........15 How to Adjust the Joystick Max-out Setting ..........16 How to Adjust the Joystick Ramp Rate Setting ..........
  • Page 9 August 2022 Table of Contents Secondary Boom Components ..............37 5-1 Secondary Boom Lift Cylinder..............38 Engines ......................40 6-1 RPM Adjustment ................... 40 Hydraulic Pumps .................... 41 7-1 Function Pump ................... 41 How to Check the Function Pump Calibration ..........42 Manifolds ......................
  • Page 10 August 2022 Table of Contents Section 4 Fault Codes ....................66 Introduction ...................... 66 Control System Fault Codes................67 Fault Codes Ground Controls ................67 How to Retrieve Control System Fault Codes - Platform Controls ..... 68 Control System Fault Codes ................70 Charger Fault Codes ..................
  • Page 11 August 2022 Table of Contents Section 6 Schematics ....................131 Introduction ....................131 Electrical Symbol Legend ................132 Hydraulic Symbols Legend ................133 Electrical Component and Wire Color Legends ..........134 Kubota Engine Fuse and Relay Module ............137 12V DC Charger Wiring (DC Option)............... 138 AC Input Wiring (DC Option) ................
  • Page 12 August 2022 Table of Contents Electrical Schematics .................. 169 Electrical Schematic, DCON [from Z60H-3000, Z60M-1000] ......170 Electrical Schematic, GCON [from Z60H-3000, Z60M-1000] ......171 Electrical Schematic, PCON [from Z60H-3000, Z60M-1000] ......174 Electrical Schematic, TCON [from Z60H-3000, Z60M-1000] ......175 Wiring Diagram, CAN BUS [from Z60H-3000, Z60M-1000] ......

  • Page 13: Specifications

    August 2022 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Batteries Type Lead acid L16G-AC Tires and Wheels Rough terrain EV Dry cell Tire size 355/55D625 Group 903-L16 (Rough terrain) Quantity Tire weight, foam-filled 426 lbs (minimum) (Rough terrain) 193 kg Capacity...

  • Page 14: Performance Specifications

    Service and Repair Manual August 2022 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications Stowed position Genie specifications require hydraulic oils which are 2WD/4WD models Stowed designed to give maximum protection to hydraulic 4.0 mph systems, have the ability to perform over a wide 6.44 km/h temperature range, and the viscosity index should 40 ft / 6.8 sec...
  • Page 15 August 2022 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index, maximum fluids are mixed, insoluble materials may form and deposit...
  • Page 16 Service and Repair Manual August 2022 Specifications Shell Tellus S4 VX Fluid Chevron 5606A Hydraulic Oil Properties Fluid Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.8...

  • Page 17: Hydraulic Component Specifications

    August 2022 Service and Repair Manual Specifications Hydraulic Component Manifold Component Specifications Specifications Function Pump Plug torque Type 2 section tandem gear SAE No. 4 13 ft-lbs / 18 Nm pump SAE No. 6 18 ft-lbs / 24 Nm SAE No. 8 50 ft-lbs / 68 Nm Displacement per revolution SAE No.10...

  • Page 18: Kubota D1105 Engine Specifications

    Service and Repair Manual August 2022 Specifications Kubota D1105 Engine Fuel injection system Injection pump make Bosch MD Displacement 68.53 cu in Injection pump pressure, 1991 psi 1.123 liters maximum 137 bar Number of cylinders Injection timing 16.5° BTDC Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm...

  • Page 19: Machine Torque Specifications

    August 2022 Service and Repair Manual Specifications Machine Torque Specifications Machine Component Weights Platform Rotator Tire and wheel assembly 429 lbs 195 kg 1-8 center bolt, GR 5 Drive motor and hub 160 lbs Lubricated 480 ft-lbs 73 kg 650 Nm Engine assembly 724 lbs 640 ft-lbs...

  • Page 20: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual August 2022 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...

  • Page 21: Torque Procedure

    August 2022 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
  • Page 22 Service and Repair Manual August 2022 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 23: Repair Procedures

    August 2022 Service and Repair Manual Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es Unless otherwise specified, perform each  repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
  • Page 24 Service and Repair Manual August 2022 Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 25: Cailbration Process Steps

    August 2022 Service and Repair Manual Repair Procedures Calibration Process Steps Verify pump efficiency calibration: Refer to Repair Procedures, How to Check the It is required to perform the calibration process if Function Pump Calibration. system defaults have been reset or if new software Set hydraulic valve thresholds for turntable has been installed.

  • Page 26: Platform Controls

    Service and Repair Manual August 2022 Platform Controls 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 27: How To Adjust The Joystick Threshold Setting

    August 2022 Service and Repair Manual Platform Controls How to Adju st th e Joys tick T hres hold S etting How to Adjust the Joystick Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE Threshold Setting TILT SENSOR is shown on the display.

  • Page 28: How To Adjust The Joystick Max-Out Setting

    Service and Repair Manual August 2022 Platform Controls How to Adju st th e Joys tick M ax-o ut Setti ng How to Adjust the Maximum 14 Press down on the foot switch and select the toggle switch controlled boom function to be Speed Setting (Hydraulic adjusted.
  • Page 29 August 2022 Service and Repair Manual Platform Controls Momentarily activate the drive enable toggle 16 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE switch in the right direction to save the value. TILT SENSOR is shown on the display. Result: The alarm will sound indicating the Momentarily activate steer in the right setting has been saved.

  • Page 30: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual August 2022 Platform Controls How to Adju st th e Joys tick Ra mp Ra te Setti ng How to Adjust the Ramp Rate 20 Activate the boom function again by pressing the foot switch and moving the function switch Setting in the same direction.
  • Page 31 August 2022 Service and Repair Manual Platform Controls Momentarily activate the drive enable toggle 13 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND switch in the right direction to save the value. SENSOR SETTINGS is shown on the display. Result: The alarm will sound indicating the Momentarily activate the drive enable toggle setting has been saved.

  • Page 32: How To Calibrate Booms Angle Sensors

    Service and Repair Manual August 2022 Platform Controls Momentarily activate steer in the right direction until BOOM ANGLE CALIBRATE is How to Calibrate Booms Angle shown on the display. Sensors 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 33: How To Clear The Fault History

    August 2022 Service and Repair Manual Platform Controls How to Clear Fault History There are 1 - 16 fault codes shown in the fault history menu 1 being the most recent displayed. It may be necessary to clear the fault history in order to acquire the most recent fault codes.

  • Page 34: Platform Components

    Service and Repair Manual August 2022 Platform Components Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not Platform Leveling Cylinder remove the pin. Remove the external snap rings from the The slave cylinder and the rotator pivot are the two slave cylinder barrel-end pivot pin.

  • Page 35: Platform Rotator

    August 2022 Service and Repair Manual Platform Components Support the platform rotator with a suitable lifting device. Do not apply any lifting Platform Rotator pressure. Crushing hazard. The platform How to Remove the Platform rotator may become unbalanced Rotator and fall if not properly supported.

  • Page 36: Platform Overload System

    Service and Repair Manual August 2022 Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System Bodily injury hazard. Spraying Calibrating the platform overload system regularly hydraulic oil can penetrate and is essential to safe machine operation. Continued burn skin.

  • Page 37: How To Perform A Full Load Platform Calibration

    August 2022 Service and Repair Manual Platform Components How to Pe rfor m a Full Loa d Platf orm Calibr ation How to Perform a Full Load Platform Calibration Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Fully retract and lower the boom.
  • Page 38 Service and Repair Manual August 2022 Platform Components Place a test weight on the platform floor using Activate and hold secondary boom up for 3 - a suitable lifting device. Place the weight near 4 seconds. the center entry point of the platform, as far Result: Hour meter displays MAXRATED away from the operator controls as possible.

  • Page 39: How To Replace The Platform Overload Load Cell

    August 2022 Service and Repair Manual Platform Components How to Re place the Platfo rm O verlo ad Load Cell How to Replace the Load Cell Install the new Load Cell Sensor Sensor Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out Note: The preload adjustment should only be of the bottom of the sensor.The foot should...

  • Page 40: How To Reset Overload Recovery Message

    Service and Repair Manual August 2022 Platform Components How to Re set Ov erlo ad R ecove ry M essa ge How to Reset Overload Recovery Faults 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.

  • Page 41: Jib Boom Components

    August 2022 Service and Repair Manual Jib Boom Components Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. Jib Boom Remove the hose and cable cover from the How to Remove the Jib Boom side of the jib boom.

  • Page 42: Jib Boom Lift Cylinder

    Service and Repair Manual August 2022 Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin out enough to lower Jib Boom Lift Cylinder one of the leveling arms to the ground. Tap the pin the other direction and lower the How to Remove the Jib Boom Lift opposite leveling arm.

  • Page 43: Primary Boom Components

    August 2022 Service and Repair Manual Primary Boom Components Tag and disconnect the wire connectors from the bottom of the platform control box. Cable Track Note: When installing the wire connectors to the The primary boom cable track guides the cables bottom of the platform control box, match the color and hoses running up the boom.

  • Page 44: How To Repair The Cable Track

    Service and Repair Manual August 2022 Primary Boom Components How to Re pair the Cable Tr ack How to Repair the Cable Track Primary Boom Component damage hazard. The boom cable track can be damaged if it is twisted. How to Remove the Primary Boom Note: A cable track repair kit is available through the Genie Service Parts Department.

  • Page 45: How To Disassemble The Primary Boom

    August 2022 Service and Repair Manual Primary Boom Components Remove the retaining fasteners from the 13 Remove the retaining fasteners from the master cylinder rod-end pivot pin. Use a soft primary boom pivot pin. metal drift to remove the pin. Lower the 14 Remove the primary boom pivot pin with a master cylinder against the primary lift soft metal drift, then carefully remove the...

  • Page 46: Primary Boom Lift Cylinder

    Service and Repair Manual August 2022 Primary Boom Components Support the rod end and the barrel end of the primary boom lift cylinder with a second Primary Boom Lift Cylinder overhead crane or similar lifting device. The primary boom lift cylinder raises and lowers Tag, disconnect and plug the primary boom the primary boom.

  • Page 47: Primary Boom Extension Cylinder

    August 2022 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Primary Boom Extension fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.

  • Page 48: Platform Leveling Master Cylinder

    Service and Repair Manual August 2022 Primary Boom Components Remove the retaining fasteners from the master cylinder barrel-end pivot pin. Platform Leveling Master Cylinder Use a soft metal drift to remove the pin. Remove the retaining fastener from the rod- The master cylinder acts as a pump for the slave end pivot pin.

  • Page 49: Secondary Boom Components

    August 2022 Service and Repair Manual Secondary Boom Components Secondary Boom components 6 secondary boom lift cylinder 1 master cylinder 7 lower compression arm 2 primary boom lift cylinder 8 lower tension arms 3 upper compression arms 9 upper tension arm 4 mid-pivot 10 upper pivot 5 timing link...

  • Page 50: Secondary Boom Lift Cylinder

    Service and Repair Manual August 2022 Secondary Boom Components Attach a lifting strap from an overhead supporting device (5 ton / 5000 kg) to the Secondary Boom Lift Cylinder pivot end of the primary boom for support. Do not apply lifting pressure. There is one secondary boom lift cylinder incorporated in the structure of the secondary Crushing hazard.
  • Page 51 August 2022 Service and Repair Manual Secondary Boom Components Remove the pin retaining fastener securing the rod-end pivot pin of the secondary boom lift cylinder. Remove the pivot pin securing the lift cylinder. 10 Lift and move the cylinder towards the center of the machine enough to lower it down through the lower compression arm.

  • Page 52: Engines

    Service and Repair Manual August 2022 Engines 6-1 RPM Adjust ment RPM Adjustment Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine, Check and Adjust the Engine RPM. ® -60 DC • Z ® -60 FE Part No.

  • Page 53: Hydraulic Pumps

    August 2022 Service and Repair Manual Hydraulic Pumps Support the pump with a suitable lifting device. Function Pump Remove the pump mounting bolts. Carefully remove the pump. How to Remove the Function Component damage hazard. Pump Be sure to open the hydraulic tank valve and prime the pump Note: When removing a hose assembly or fitting, after installation.

  • Page 54: How To Check The Function Pump Calibration

    Service and Repair Manual August 2022 Hydraulic Pumps How to Ch eck t he Functi on Pu mp C alibra tion How to Check the Function Pump Momentarily activate the drive enable toggle switch in the right direction until you see the Calibration VALVE AND SENSOR SETTINGS screen.
  • Page 55 August 2022 Service and Repair Manual This page intentionally left blank. Part No. 1307785GT ® -60 DC • Z ® -60 FE...

  • Page 56: Manifolds

    Service and Repair Manual August 2022 Manifolds Function Manifold Components The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Flow control valve, pressure compensated Oscillate circuit 33-37 ft lbs / 45-50 Solenoid valve, 3 position 4 way Primary boom extend/retract 24-26 ft lbs / 32-35...
  • Page 57 August 2022 Service and Repair Manual Manifolds Part No. 1307785GT ® -60 DC • Z ® -60 FE...
  • Page 58 Service and Repair Manual August 2022 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Primary boom up/down 18-20 ft lbs / 25-27 Nm Diagnostic port, (TP2) Testing Diagnostic port, (TP3) Testing Diagnostic port, (TP4) Testing Check valve...
  • Page 59 August 2022 Service and Repair Manual Manifolds Part No. 1307785GT ® -60 DC • Z ® -60 FE...

  • Page 60: Valve Adjustments - Function Manifold

    Service and Repair Manual August 2022 Manifolds Simultaneously activate the platform rotate toggle switch to store the value. Valve Adjustments - Function Manifold Result: The control system will continue to the next calibration procedure value - (3000 PSI / 207 bar). How to Adju st th e Pro porti onal R elief Valv e an d Hyd raulic P ressu re Se nsor How to Adjust the Proportional Simultaneously activate the platform level...

  • Page 61: How To Adjust The Platform Level Up Relief Valve

    August 2022 Service and Repair Manual Manifolds Locate and remove the cap from the platform How to Adju st th e Platfo rm Lev el Up Reli ef Valve How to Adjust the Platform Level level up relief valve. Refer to Repair Relief Valves Procedures, Function Manifold Components.

  • Page 62: How To Adjust The Primary Boom Extend Relief Valve

    Service and Repair Manual August 2022 Manifolds How to Adju st th e Prim ary Bo om Ext end R elief Valv e How to Adjust the Primary Boom Repeat this procedure beginning with step 4 to confirm the relief valve pressure. Extend Relief Valve 10 Reinstall the proportional valve coil.

  • Page 63: Jib Boom / Platform Rotate Manifold Components

    August 2022 Service and Repair Manual Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid Valve, 2 position Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm 3 way Part No.

  • Page 64: Turntable Rotation Manifold Components

    Service and Repair Manual August 2022 Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the center of the turntable. Index No. Description Schematic Item Function Counterbalance valve Turntable rotate right Counterbalance valve Turntable rotate left Shuttle valve...

  • Page 65: Oscillate Directional Valve Manifold Components

    August 2022 Service and Repair Manual Manifolds Oscillate 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 Breather 20-25 ft-lbs / 27-33 Nm Spool valve Directional control Part No.

  • Page 66: How To Set Up The Oscillate Directional Valve

    Service and Repair Manual August 2022 Manifolds How to Adju st th e Oscillat e Re ducin g Valve How to Adjust the Oscillate Relief How to Set Up the Oscillate Valve Directional Valve Linkage Note: Perform this procedure on a firm, level surface with the machine in the stowed position.
  • Page 67 August 2022 Service and Repair Manual Manifolds Adjust the internal hex socket. Turn it clockwise to increase the pressure or Valve Coils counterclockwise to decrease the pressure. Install the relief valve cap. How to Test a Coil Tip-over hazard. Do not adjust the relief valve higher than A properly functioning coil provides an specified.

  • Page 68: How To Test A Coil Diode

    Service and Repair Manual August 2022 Manifolds Valve Coil Resistance How to Test a Coil Dio de How to Test a Coil Diode Specification Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Note: The following coil resistance specifications Voltage spikes naturally occur within a function are at an ambient temperature of 68°F / 20°C.
  • Page 69 August 2022 Service and Repair Manual 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. 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 70: Turntable Rotation Components

    Service and Repair Manual August 2022 Turntable Rotation Components Loosen the backlash pivot plate and adjustment bolts. Turntable Rotation Assembly How to Remove a Turntable Rotation Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.
  • Page 71 August 2022 Service and Repair Manual Turntable Rotation Components How to Adjust the Turntable Remove the backlash pivot plate mounting Rotation Gear Backlash bolts. Carefully remove the drive hub assembly from the machine. The turntable rotation drive hub is mounted on an Crushing hazard.

  • Page 72: How To Replace The Universal Tilt Sensor

    Service and Repair Manual August 2022 Turntable Rotation Components Push the backlash pivot plate towards the turntable as far as possible (this will push the How to Replace the Universal Tilt rotation gear into the turntable bearing ring Sensor (UTS) gear).

  • Page 73: How To Calibrate The Universal Tilt Sensor

    August 2022 Service and Repair Manual Turntable Rotation Components How to Cali brat e th e Univ ersal Tilt Se nsor How to Calibrate the Universal Tilt Sensor (UTS) Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Note: The unit must be on a surface that is within 1 degree of level.

  • Page 74: Axle Components

    Service and Repair Manual August 2022 Axle Components 10-1 Attach a lifting strap from an overhead lifting device to the barrel end of the oscillating Oscillating Axle Cylinders cylinder. The oscillating axle cylinders extend and retract Remove the pin retaining fasteners from the between the drive chassis and the oscillating axle.

  • Page 75: How To Remove The Steer Cylinder

    August 2022 Service and Repair Manual Axle Components 10-2 How to Cali brat e th e Stee r Angl e Sens or How to Calibrate the Steer Angle How to Remove the Steer Sensor Cylinder Note: Perform this procedure on a firm, level surface with the machine in the stowed position.
  • Page 76 Service and Repair Manual August 2022 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.

  • Page 77: Battery Charger

    August 2022 Service and Repair Manual Battery Charger 11-1 Battery Charger The charger contains selectable charging profiles stored in its internal memory to charge batteries. These profiles are specific to each battery type. The charging profile must be programmed to match the specific battery type on the machine.

  • Page 78: Fault Codes

    Service and Repair Manual August 2022 Fault Codes Before Troubleshooting: Secti on 4 Fault C odes 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 ...

  • Page 79: Control System Fault Codes

    August 2022 Service and Repair Manual Control System Fault Codes Both Engine Hours and DC Function Enable Hours Fault Codes Ground Controls 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 80: How To Retrieve Control System Fault Codes - Platform Controls

    Service and Repair Manual August 2022 Control System Fault Codes How to Retrieve Control System To access component faults list: Fault Codes from the Platform Turn the key switch to platform control. Controls Pull out the red Emergency Stop button to the on position at both the ground and platform At least one fault code is present when the alarm controls.
  • Page 81 August 2022 Service and Repair Manual Control System Fault Codes To access fault history list: To clear fault history: Turn the key switch to platform control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out the red Emergency Stop button to the on position at both the ground and platform on position at both the ground and platform...

  • Page 82: Control System Fault Codes

    Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component Name Cause Effect Solution Stuck ON Release foot switch and Fault recycle power (on @ power up) Verify: (when activated) • 24V supply on C11-1 Platform controlled FOOT SWITCH (P22PWR WH)
  • Page 83 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit or · Check Ohms 25 Value too high Ohms > 60 · Verify no open/short PRIMARY DOWN Associated circuit across PCON C20-...
  • Page 84 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit or · Check Ohms Value too high Ohms > 60 SECONDARY DOWN Associated Function ·...
  • Page 85 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit or · Check Ohms 25 Value too high Ohms > 60 · Verify no open/short LARGE PUMP Associated Function circuit across PCON C47-6...
  • Page 86 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution 11 Shorted to Supply 5V Act as if in Out of Verify: Stowed position · 5V from TCON C19- 16 Value at 0 V ·...
  • Page 87 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Verify: *When switch is not activated: · -0V on N.O. switch NO/NC switch output and at C247LS LIFT GUARD contacts not OR/BK...
  • Page 88 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution All functions Verify: disabled from · 24V supply on C48-1 VCON LCD platform controls No CAN ·...
  • Page 89 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Enter LCD menu at Platform, Overload was Navigate to RESET tripped and AUX OVERLOAD RECOVERY All functions LOAD SENSE 21 Fault...
  • Page 90 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Verify: · Proper operation engine hi RPM solenoid Engine Speed · Proper engine RPM 23 Value too high higher than setting: setting...
  • Page 91 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: Open circuit or · no open circuit between 25 Value too high >60 ohms controller & B- Associated PLATFORM (V14PLU OR)
  • Page 92 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution · Check battery voltage · Check battery condition · Check battery size Battery voltage 23 Value too high ·...
  • Page 93 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 136 PUMP / 08 Component fault Fault without a Refer too Pump GENERATOR specific Genie Controller fault MOTOR fault code codes...
  • Page 94 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 160 STEER LEFT 21 Fault Open or short Associated Verify: VALVE circuit Function · No open/short circuit disabled between controller and B- (V37SCC BL/BK)
  • Page 95 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution LEFT REAR DRIVE Fault Stalled motor Brake set • Verify brakes release MOTOR • Check encoder wiring Motor encoder Main contactor •...
  • Page 96 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 194 RIGHT REAR 21 Fault Brake motor coil Reduced drive • Check brake coil BRAKE COIL failure speed •...
  • Page 97 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution MAIN BATTERY Fault Voltage detected but • Check for shorted battery (CHARGER) the charger is cells unable to charge the •...
  • Page 98 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 254 BATTERY 23 Value too high Battery voltage • Check battery voltage CHARGE too high as and cable connections.
  • Page 99 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution LEFT FRONT DRIVE Warning Motor temperature Reduced drive • Check battery voltage and MOTOR exceeded warning speed cable connections.
  • Page 100 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 261 RIGHT FRONT 20 Warning Motor controller Reduced drive • Allow motor controller to DRIVE temperature speed cool down CONTROLLER...
  • Page 101 August 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 265 CHARGER USB 21 Fault Issue inserting or • Remove and re-insert removing USB USB Flash Drive flash drive If issue persist, disconnect AC power and...
  • Page 102 Service and Repair Manual August 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution 270 PUMP POWER 21 Fault Main contactor Shut down • Check main contactor CONTACTOR does not close motor, main wiring correctly...

  • Page 103: Charger Fault Codes

    August 2022 Service and Repair Manual Charger Fault Codes Battery Charger The charger continuously monitors internal and external conditions. Fault and Error codes are generated by the charger to indicate that an internal or external malfunction has been detected in the electrical system.

  • Page 104: Charger Fault Codes

    Service and Repair Manual August 2022 Charger Fault Codes Charger status indicators Remote charger status indicators 1 Error / Fault / USB indicator 2 Charger profile / Error display 3 Error / Fault Charg er Fault Cod es Charger Fault Codes Genie Genie Description...

  • Page 105: Charger Error Codes

    August 2022 Service and Repair Manual Charger Fault Codes Charg er Er ror Cod es Charger Error Codes Charger Error Genie Genie Description Condition Possible Causes Code Fault ID Fault Type E-0-0-1 High battery voltage Battery voltage too high to Check battery voltage and cable charge.
  • Page 106 Service and Repair Manual August 2022 Charger Fault Codes Charger Error Codes Charger Error Genie Genie Description Condition Possible Causes Code Fault ID Fault Type E-0-0-8 Battery temperature out of Battery temperature sensor. Check temperature sensor and range electrical connections. Rest charger.
  • Page 107 August 2022 Service and Repair Manual Charger Fault Codes Charger Error Codes Charger Error Genie Genie Description Condition Possible Causes Code Fault ID Fault Type E-0-2-1 High battery voltage detected Battery voltage too high as Check battery voltage and cable while charging detected by charger connections.
  • Page 108 Service and Repair Manual August 2022 Charger Fault Codes Charger Error Codes Charger Error Genie Genie Description Condition Possible Causes Code Fault ID Fault Type E-0-2-9 CAN Bus error CAN Bus network error. Check CAN Bus connections. CAN modules not functioning correctly.

  • Page 109: Pump Control Fault Codes

    August 2022 Service and Repair Manual Pump Control Fault Codes Pump Controller Fault Handling The pump controller is located on the engine side of the machine and mounted to the battery compartment. The pump controller can detect faults or error conditions. Faults can also be detected by the machine control system and PCON display.
  • Page 110 Service and Repair Manual August 2022 Pump Control Fault Codes LED Display Format: The LEDs have five different display modes, indicating the type of information they are providing. Display Status Neither LED illuminated • Controller is not powered on. • Faulty battery. •...
  • Page 111 August 2022 Service and Repair Manual Pump Control Fault Codes Flash Name Cause Effect Solution Pattern 1. External short of phase U,V, or W motor connections ShutdownMotor; Set: Phase current exceeded the 2. Motor parameters are ShutdownMainContactor; current measurement limit Controller miss-tuned ShutdownEMBrake;...
  • Page 112 Service and Repair Manual August 2022 Pump Control Fault Codes Flash Name Cause Effect Solution Pattern 1. See Monitor menu » Battery: Set: Capacitor bank voltage Capacitor Voltage ShutdownMotor; exceeded the Severe Overvoltage 2. Battery parameters are ShutdownMainContactor; limit with FET bridge enabled Severe B+ misadjusted ShutdownEMBrake;...
  • Page 113 August 2022 Service and Repair Manual Pump Control Fault Codes Flash Name Cause Effect Solution Pattern 1. Motor temperature is at or above the programmed Temperature Hot setting, and the current is being cut back 2. Motor Temperature Control Set: Motor temperature is at or Menu parameters are miss-tuned above the Temperature Hot Motor Temp Hot...
  • Page 114 Service and Repair Manual August 2022 Pump Control Fault Codes Flash Name Cause Effect Solution Pattern Proportional Driver Set: Proportional driver (pin 2) is 1. Open or short on driver load Open/Short either open or shorted 2. Dirty connector pins ShutdownPD (Proportional Relief Clear: Correct open or short, and...
  • Page 115 August 2022 Service and Repair Manual Pump Control Fault Codes Flash Name Cause Effect Solution Pattern 1. VCL code encountered a runtime ShutdownMotor; VCL error Set: Runtime VCL code error ShutdownMainContactor; condition ShutdownEMBrake; 2. See Monitor menu » Controller: ShutdownThrottle; VCL Error Module and VCL Error.
  • Page 116 Service and Repair Manual August 2022 Pump Control Fault Codes Flash Name Cause Effect Solution Pattern ShutdownMotor; ShutdownMainContactor; ShutdownEMBrake; Set: Incompatible software Supervisor The main OS is not compatible ShutdownThrottle; Clear: Load properly matched OS code or with the Supervisor OS ShutdownInterlock;...
  • Page 117 August 2022 Service and Repair Manual Pump Control Fault Codes Flash Name Cause Effect Solution Pattern ShutdownMotor; ShutdownMainContactor; Motor Type The Motor_Type parameter value is ShutdownEMBrake; Cycle Power Fault out of range ShutdownThrottle; FullBrake ShutdownMotor; Set: VCL & OS software do not match; ShutdownMainContactor;...

  • Page 118: Drive Control Fault Codes

    Service and Repair Manual August 2022 Drive Control Fault Codes Drive Controller Fault Handling The drive controllers are located on the ground controls side of the machine and mounted to the bulkhead. The drive controller can detect faults or error conditions. Faults can also be detected by the machine control system and PCON display.
  • Page 119 August 2022 Service and Repair Manual Drive Control Fault Codes LED Display Format: The LED has six different display modes, indicating the type of information it is providing. Display Status LED not illuminated • Controller is not powered on. • Faulty battery. •...
  • Page 120 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type Controller 1. External short of phase U, Overcurrent V, or W motor connections ShutdownVehicle: 1 = Controller Over 2. Speed encoder noise ShutdownMotor Current Phase U problems...
  • Page 121 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type 1. Non-controller system Set: When Main is closed drain on battery No drive torque. and the FET Bridge is 2. Battery resistance too enabled, either the high Fault Action:...
  • Page 122 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type 1. With the vehicle in the stopped state, the detected motor frequency and/or ShutdownVehicle: Set: The motor frequency phase current exceeds the and/or and phase-current limit set by the Travel ShutdownMotor...
  • Page 123 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type 1. Batteries need recharging. Controller is performance limited at this voltage 2. Battery parameters are mis-adjusted. Reduced drive Non-controller system- torque drain on battery Set: Capacitor bank voltage...
  • Page 124 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Cause Effect Solution Object Pattern Fault Type Set: (1) The 12V supply (pin Ext 12V Supply External load 23) is outside 12V ± Failure impedance on the +12V supply is too low Disables the 12V Supply (2) The current is outside...
  • Page 125 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type Set: Electromagnetic brake EM Brake Driver driver (pin 4) is either open 1. Open or short on driver or shorted Fault Type(s): load ShutdownEMBrake...
  • Page 126 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type Set: Just prior to the main 1. Main contactor tips are contactor closing, the welded closed ShutdownVehicle: capacitor bank voltage (B+ 2.
  • Page 127 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type Motor offset has shifted so Clear: Motor Misalignment controller is producing 2102 3-11 Shudown Vehicle; Error torque in an Reset Controller uncommanded direction ShutdownAll: NV Memory Failure...
  • Page 128 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type While the Interlock was ON, ShutdownVehicle: a safety-based parameter Parameter Change Set: Adjustment of a was changed ShutdownMotor parameter setting that Fault Type(s): ShutdownMainContactor requires cycling of KSI...
  • Page 129 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type ShutdownAll: ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock 1. Physical damage from Internal Controller Clear: 2831 ShutdownDriver1 to 7 external sources/events Fault Reset Controller ShutdownPD FullBrake...
  • Page 130 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type ShutdownAll: ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle Set: Damaged Controller ShutdownInterlock Supervision Input 2841 Internal controller fault ShutdownDriver1 to 7 Check Clear: ShutdownPD Reset Controller FullBrake...
  • Page 131 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type ShutdownVehicle: 1. Parameter value Parameter Out of detected outside of the Set: Parameter detected Range ShutdownMotor limits outside of limits ShutdownMainContactor 2811 Use CIT or the 1313HHP...
  • Page 132 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type 1. External short of pump Clear: motor 2520 Pump Overcurrent Shutdown Pump Reset Controller 2. Controller defective Set: Pump activated when 1.
  • Page 133 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type 1. Open or short on driver Driver 1 Fault load Fault Type(s): Dirty connector pins at 1 = Driver Short controller or contactor coil Set: Driver 1 is either open 2 = Driver Overcurrent...
  • Page 134 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type A Driver Output is used for Set: Driver assignment Driver Assignment two or more functions Fault Action: conflict (i.e., duplicate items See Programmer »...
  • Page 135 August 2022 Service and Repair Manual Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type See Analog 1 Out of See Analog 1 Out of See Analog 1 Out of 2624 11-5 See Analog 1 Out of Range Range Range Range...
  • Page 136 Service and Repair Manual August 2022 Drive Control Fault Codes Flash Description & Fault Cause Effect Solution Object Pattern Type Set: Software / hardware Software and hardware ShutdownVehicle: incompatibly branding mismatch ShutdownMotor Clear: As applicable: For technical support on this ShutdownMainContactor fault, contact the Curtis Load Branded software, or...

  • Page 137: Navigation Menus

    August 2022 Service and Repair Manual Navigation Menus Secti on 5 Navigatio n M enus Navigation Menu - Top Menus Drive enable Drive Joystick switch Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right Part No. 1307785GT ®...

  • Page 138: Faults Navigation Menu

    Service and Repair Manual August 2022 Faults Navigation Menu Faults Navigation Menu ® -60 DC • Z ® -60 FE Part No. 1307785GT...

  • Page 139: Options Navigation Menu

    August 2022 Service and Repair Manual Options Navigation Menu Options Navigation Menu GENIE LOGO POWER UP REVISION LEVEL & SYSTEM (hold) FAULTS FAULTS READY EXIT SETTINGS LANGUAGE ENGLISH OPTIONS EXIT MOTION EXIT DEUTSCH EXIT ALARM TRAVEL FRANCAIS EXIT EXIT ALARM DESCENT ESPANOL EXIT...

  • Page 140: Settings Navigation Menu

    Service and Repair Manual August 2022 Settings Navigation Menu Settings Navigation Menu GENIE LOGO EXIT EXIT POWER UP REVISION DRIVE SETTINGS AUTHORIZATION LEVEL NEXT PAGE & SYSTEM (hold) FAULTS READY EXIT ENTER AUTH CODE - - + - < >< >< >< > (hold) RESET TO RESET TO...

  • Page 141: Advanced And Drive Navigation Menu

    August 2022 Service and Repair Manual Advanced and Drive Navigation Menu Advanced and Drive Navigation Menu PREVIOUS PAGE DRIVE SETTINGS ADVANCED SETUP LVI LEVEL ENT/ NONE EXIT EXIT CUT OFF% CALIBRATE EXIT CENTER DRIVE PRIORITY FOOTSWITCH ENT/ EXIT ONLY EXIT TIME OUT *MAX EXIT...
  • Page 142 Service and Repair Manual August 2022 Advanced and Drive Navigation Menu Advanced and Drive Navigation Menu (cont.) ENT/ EXIT EXIT ENT/ EXIT EXIT ENT/ EXIT EXIT ENT/ EXIT ENT/ EXIT EXIT ENT/ EXIT EXIT EXIT ENT/ EXIT ENT/ EXIT ENT/ EXIT ENT/ EXIT...

  • Page 143: Schematics

    August 2022 Service and Repair Manual Schematics About This Section Secti on 6 Schematic s There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury.

  • Page 144: Electrical Symbol Legend

    Service and Repair Manual August 2022 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing no Quick disconnect...

  • Page 145: Hydraulic Symbols Legend

    August 2022 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed bi- Pump, fixed displacement Motor, bi-directional variable displacement directional Pump, prime mover Shuttle valve. 2 position, Cylinder, double acting Differential sensing valve (engine or motor) 3 way...

  • Page 146: Electrical Component And Wire Color Legends

    Service and Repair Manual August 2022 Electrical Component and Wire Color Legends Drive enable limit switch Item Description Left front AC motor to front MC harness Battery Right front AC motor to front MC harness Engine start, 12V DC Left rear AC motor to rear MC harness Left/Right side battery packs, 48V DC Right rear AC motor to rear MC harness Connector...
  • Page 147 August 2022 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Circuit Breaker Horn or Alarm Fuel pump, 15A Horn Controls power, 24V DC, 15A Alarm (multifunction) Charger box 12V, 10A Joystick Engine RPM, 10A Boom proportional joystick: secondary boom up/down Telematics, 5A (option)
  • Page 148 Service and Repair Manual August 2022 Electrical Component and Wire Color Legends Item Description Module DCON, RR, AC motor controller Button DCON, LR AC motor controller Red emergency stop (ground) DCON, RF AC motor controller (4WD Red emergency stop (platform) option) Horn DCON LF AC motor controller (4WD)

  • Page 149: Kubota Engine Fuse And Relay Module

    August 2022 Service and Repair Manual Kubota Engine Fuse and Relay Module Kubota D1105-E4B 1 Fuse 1 - 15A (spare) 2 Fuse 3 - 30A glow plug 3 Circuit breaker 1 - 15A Engine start / Fuel pump 4 Control Relay 64 Engine fault 5 Control Relay 2 Fuel pump 6 Circuit breaker 7 - 10A Engine RPM 7 Control Relay 1 Engine start...

  • Page 150: Dc Charger Wiring (Dc Option)

    Service and Repair Manual August 2022 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 ® -60 DC •...

  • Page 151: Ac Input Wiring (Dc Option)

    August 2022 Service and Repair Manual AC Input Wiring (DC Option) 1 AC input wall plug 2 AC input to 48V charger 3 Charger Control IN 4 To 12V charger Part No. 1307785GT ® -60 DC • Z ® -60 FE...

  • Page 152: Limit Switch/Angle Sensor Legend

    Service and Repair Manual August 2022 Limit Switch/Angle Sensor Legend 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS18 Platform overload 4 LS3 Drive enable 5 S13 Steer angle sensor (inside steer cylinder) 6 S19 Secondary angle sensor (outside upper-pivot) ®...

  • Page 153: Electrical Schematics - Options

    August 2022 Service and Repair Manual Wiring Diagram - Options [from Z60H-2548 to 2999]...

  • Page 154: Wiring Diagrams - Options [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Wiring Diagram - Options [from Z60H-2548 to 2999] DC MODEL ONLY HYBRID MODEL ENGINE CONNECTOR TO CR88; CHARGER SELECT RLY; PIN 3 AND 6. PAGE 1 P20BAT RD BATTERY 30 86 AUX. RLY CHARGER 12V 5.5A 24VDC L LINE 87 85...

  • Page 155: Wiring Diagram, Options [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual Wiring Diagram, Options [from Z60H-2548 to 2999] G1 C25PS BK WH/BK PRES. SENSOR G2 C26TS RD WH/RD TEMP. SENSOR GAUGE OPTION C21IGN WH G3(+) ENGINE 12V BATTERY G1 C25PS BK ENGGND BR ENG. GND G2 C26TS RD WATER &...
  • Page 156 Service and Repair Manual August 2022 Wiring Diagram - Options [from Z60H-2548 to 2999]...
  • Page 157 August 2022 Service and Repair Manual Electrical Schematic - Options, 4WD [from Z60H-2548 to 2999]...

  • Page 158: Electrical Schematic - Options, 4Wd [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Electrical Schematic - Options, 4WD [from Z60H-2548 to 2999] TO DCON - LR AC MOTOR CONTROLLER TB134 SP 10 SENGND BK 7 I/O GND C26TSR WH/RD 8 THERM SENSOR D185SEN WH 31 ENCODER A SP 17 RIGHT D186SEN BL...

  • Page 159: Power Cable Wiring Diagram [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual Power Cable Wiring Diagram [from Z60H-2548 to 2999] POWER CABLE DIAGRAM 48773 94652 48773 RIGHT LEFT LEFT RIGHT REAR CONTROLLER REAR CONTROLLER FRONT CONTROLLER FRONT CONTROLLER 48766 48 V CHARGER LEFT REAR LEFT FRONT RIGHT REAR RIGHT FRONT DRIVE MOTOR...
  • Page 160 Service and Repair Manual August 2022 Power Cable Wiring Diagram [from Z60H-2548 to 2999]...
  • Page 161 August 2022 Service and Repair Manual Wiring Diagram - FE Models [from Z60H-3000, Z60M-1000]...

  • Page 162: Wiring Diagram - Fe Models [From Z60H-3000, Z60M-1000]

    Service and Repair Manual August 2022 Wiring Diagram - FE Models [from Z60H-3000, Z60M-1000] TO SHEET 1 BATT STUD C37-5 COLOR FUNC C37-6 PUMP/GEN BATT C37-4 STUD C37-3 C37-1 C37-2 CR15A CR15B CR64 GLOW GLOW ENGINE ENGINE ENGINE ENGINE 87A 87 87A 87 87A 87 87A 87...

  • Page 163: Wiring Diagram - Dc Models [From Z60H-3000, Z60M-1000]

    August 2022 Service and Repair Manual Wiring Diagram - DC Models [from Z60H-3000, Z60M-1000] TO SHEET 1 TO SHEET 1 C37-5 COLOR FUNC LINE C 3 r C37-6 PUMP/GEN NEUTRAL C37-4 C37-3 C37-1 C37-2 +12V ES0625F ECON AC MOTOR/GEN CONTROLLER Part No.
  • Page 164 Service and Repair Manual August 2022 Wiring Diagram - DC Models [from Z60H-3000, Z60M-1000]...

  • Page 165: Electrical Schematics

    August 2022 Service and Repair Manual Electrical Schematic [from Z60H-2548 to 2999]...

  • Page 166: Electrical Schematic [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Electrical Schematic [from Z60H-2548 to 2999] P181BAT(A) OR/14 P181BAT OR/14 DC/DC C2-11 CONVERTER 48/26V P182BAT RD/14 P182BAT RD/14 C2-8 SHT 11 C171LDS WH/BK C171LDS WH/BK N.C. DRIVE MORE C22PWR BK C22PWR BK ENAB. DETAIL C134PWR RD C134PWR RD C3-2...

  • Page 167: Electrical Schematic [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual Electrical Schematic [from Z60H-2548 to 2999] GROUND BOX TB P181 P181BAT OR/14 P181PWR OR P182BAT RD P182BAT RD/14 DLITE TB181 P181PWR OR/16 C171LDS WH/BK GCON ESTOP HORN P181BAT OR/14 C22PWR BK SWITCH P182BAT RD/14 P182PWR RD/14 C134PWR RD C174PWR WH...
  • Page 168 Service and Repair Manual August 2022 Electrical Schematic [from Z60H-2548 to 2999]...
  • Page 169 August 2022 Service and Repair Manual Ground Control Box Wiring Diagram [from Z60H-2548 to 2999]...

  • Page 170: Ground Control Box Wiring Diagram [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Ground Control Box Wiring Diagram [from Z60H-2548 to 2999] BATGND BB C161SBE WH/BK C3-9 C47FE WH/BK C3-14 C134PWR RD L45(+) (OPT) C164PES RD/WH C3-6 C196PWR YL TB2.5V C163PLS BL/WH C3-5 TS52-3 P109PWR GR/WH P109PWR GR/WH TB-5V TS52-1 C196PWR YL C156JUD GR/WH C1-3 P-BOX...

  • Page 171: Ground Control Box Wiring Diagram [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual Ground Control Box Wiring Diagram [from Z60H-2548 to 2999] 1263723 1263729 1263730 1263725 C4 - TO PLAT DT12 C3 - GBOX C2 - ECON/LS/ ANGLE/ 1263720 DTV02-18PB MANIFOLD ENGINE CIRCUIT # COLOR CIRCUIT # COLOR C5: DTP06-4S COLOR...
  • Page 172 Service and Repair Manual August 2022 Ground Control Box Wiring Diagram [from Z60H-2548 to 2999]...
  • Page 173 August 2022 Service and Repair Manual Platform Control Box Wiring Diagram [from Z60H-2548 to 2999]...

  • Page 174: Platform Control Box Wiring Diagram [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Platform Control Box Wiring Diagram [from Z60H-2548 to 2999] PLATFORM CONTROL HARNESS (TO CONTROL BOX) SP19 BATGND BR TB-BATGND/16 C48-2 JC7-STUD HIGH/LOW MODE SELECT SP11 C134PWR RD DC / HYBRID MOTOR SHIFT DRV.ENA TB-134/16 C48-1 L1(+) C48-13...

  • Page 175: Platform Control Box Wiring Diagram [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual Platform Control Box Wiring Diagram [from Z60H-2548 to 2999] PLATFORM CONTROL HARNESS (TO CONTROL BOX) PCON BATGND BR BATGND C46-4 C11-4 C46 (GY) SP15 D81CAN1-GR C46-4 SP18 C9-10 SP14 D82CAN1+ YL C46-3 SP17 C9-9 C47 (BK) SP17 D82CAN1+YL C49-1...
  • Page 176 Service and Repair Manual August 2022 Platform Control Box Wiring Diagram [from Z60H-2548 to 2999]...
  • Page 177 August 2022 Service and Repair Manual Electrical Schematic, PCON [from Z60H-2548 to 2999]...

  • Page 178: Electrical Schematic, Pcon [From Z60H-2548 To 2999]

    Service and Repair Manual August 2022 Electrical Schematic, PCON [from Z60H-2548 to 2999] P23PWR WH TB134 VCON C134PWR RD C134PWR RD BATT + POWER CABLE 3C/12 C5/C8 GND BR BATT - P22BAT BK/14 HYBRID MODE TS C239HMS BL/WH HYBRID MD LS1 PRIMARY C134PWR RD/14 TB134...

  • Page 179: Can Bus Wiring Diagram [From Z60H-2548 To 2999]

    August 2022 Service and Repair Manual CAN BUS Wiring Diagram [from Z60H-2548 to 2999] MOLEX (4) MOLEX (4) DTP (4) LOAD CELL 01 OUT - 04 OUT - BATGND BR/14 BATGND BR/14 BATGND BR/14 P182BAT RD/14 02 OUT+24V 03 IN- PBOX - PLATFORM BOX BATGND BR/14 03 IN-...
  • Page 180 Service and Repair Manual August 2022 CAN BUS Wiring Diagram [from Z60H-2548 to 2999]...
  • Page 181 August 2022 Service and Repair Manual Electrical Schematic, DCON [from Z60H-3000, Z60M-1000]...

  • Page 182: Electrical Schematic, Dcon [From Z60H-3000, Z60M-1000]

    Service and Repair Manual August 2022 Electrical Schematic, DCON [from Z60H-3000, Z60M-1000] 48VDC P181BAT OR C5-1 24VDC P182BAT RD C5-2 C5-3 DC/DC CONVERTER 48/26V C22-5 C22-6 C22-7 U2 V2 W2 C22-8 C22-1 C26TSR-RF WH/BK THERM SENSOR RIGHT C22-2 D185SEN-RF WH C243HML WH C1-2 ENCODER A...

  • Page 183: Electrical Schematic, Gcon [From Z60H-3000, Z60M-1000]

    August 2022 Service and Repair Manual Electrical Schematic, GCON [from Z60H-3000, Z60M-1000] C5-1 P181BAT OR 48VDC P1 GBOX ESTOP P182TEL RD P182TEL RD C6-1 C5-2 P182BAT RD 24VDC GND BR C6-2 C5-3 P181PWR OR C6-3 C6-4 P182PWR RD C134PWR WH C6-5 C6-6 D82CAN0+ YL...
  • Page 184 Service and Repair Manual August 2022 Electrical Schematic, GCON [from Z60H-3000, Z60M-1000]...
  • Page 185 August 2022 Service and Repair Manual Electrical Schematic, PCON [from Z60H-3000, Z60M-1000]...

  • Page 186: Electrical Schematic, Pcon [From Z60H-3000, Z60M-1000]

    Service and Repair Manual August 2022 Electrical Schematic, PCON [from Z60H-3000, Z60M-1000] CONTACT ALARM OPTION TS3 HYBRID MODE C115-1 R249CTA BK/WH C11-1 C249CTA BK/RD VCON C115-2 GND BR C11-2 GND BR C134PWR RD +24V C11-3 P23PWR WH GROUND BR C116-1 R249CTA BK/WH C11-4 C247LS OR/BK...

  • Page 187: Electrical Schematic, Tcon [From Z60H-3000, Z60M-1000]

    August 2022 Service and Repair Manual Electrical Schematic, TCON [from Z60H-3000, Z60M-1000] TO SHEET 1 TO SHEET 2 TO SHEET 1 FLASHING BEACONS C118-1 C118-2 C117-1 C117-2 TCON GND BR BATT- C134PWR RD DRIVE LIGHTS BATT+ D82CAN0+ YL C120-1 C120-2 CAN0+ D81CAN0- GR CAN0-...
  • Page 188 Service and Repair Manual August 2022 Electrical Schematic, TCON [from Z60H-3000, Z60M-1000]...
  • Page 189 August 2022 Service and Repair Manual Wiring Diagram, CAN BUS [from Z60H-3000, Z60M-1000]...

  • Page 190: Wiring Diagram, Can Bus [From Z60H-3000, Z60M-1000]

    Service and Repair Manual August 2022 Wiring Diagram, CAN BUS [from Z60H-3000, Z60M-1000] HOURMETER ECON AC MOTOR/GEN CONTROLLER TR2-B C1-6 D82CAN0+ YL TR2-A C1-7 D81CAN0- GR C1-8 D82CAN0+ YL D82CAN0+ YL C6-11 C1-9 D81CAN0- GR D81CAN0- GR C6-12 LOAD CELL VCON C157-4 C11-4...
  • Page 191 August 2022 Service and Repair Manual Hydraulic Schematic...

  • Page 192: Hydraulic Schematic

    Service and Repair Manual August 2022 Hydraulic Schematic Z®-6 0 DC • Z® -60 FE Part No. 130 778 5GT Service a nd Re pair Ma nual August 2 022 ® -60 DC • Z ® -60 FE Part No. 1307785GT...

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