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

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Service and Repair Manual
Z
-45 DC
®
Z
-45 FE
®
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.
Original Instructions
Part No. 1297714GT
Rev B
October 2022

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Summary of Contents for Terex Genie Z-45 DC

  • Page 1 Service and Repair Manual Serial Number Range -45 DC ® from Z45EM-101 This manual includes: Repair procedures -45 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 © 2019 by Terex Corporation and scheduled maintenance. 1297714GT Rev B, October 2022 First Edition, Second Printing Genie and "Z" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. ® -45 DC • Z ®...
  • Page 3 October 2022 Service and Repair Manual Introduction Revision Hist ory Revision History Revision Date Section Procedure / Page / Description 3/2020 Initial Release 7/2020 Schematics Hydraulic schematics 10/2022 Specifications Kohler engine Repair Calibration process steps Procedure 2-3, 6-1, 9-2 Fault Codes Update fault codes Navigation Menus Update navigation menus...

  • Page 4: Safety Rules

    Service and Repair Manual October 2022 Safety Rules Gene ral Saf ety Rul es 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 5 October 2022 Service and Repair Manual 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 6: Table Of Contents

    October 2022 Table of Contents Introduction Introduction ...................... ii Important Information ..................ii Find a Manual for this Model ................ii Revision History ....................iii Section 1 Safety Rules ....................iv General Safety Rules ..................iv Section 2 Specifications....................1 Machine Specifications..................1 Performance Specifications ................
  • Page 7 October 2022 Table of Contents Section 3 Repair Procedures ..................12 Introduction ...................... 12 Cailbration Process Steps................. 14 Platform Controls ................... 15 1-1 Platform Controls ..................15 How to Adjust the Joystick Threshold Setting ..........16 How to Adjust the Maximum Speed Setting (Hydraulic Functions) ....17 How to Adjust the Function Ramp Rate Setting ..........
  • Page 8 October 2022 Table of Contents Secondary Boom Components ..............40 5-1 Secondary Boom ..................41 5-2 Secondary Boom Lift Cylinders ..............45 Engines......................46 6-1 RPM Adjustment ................... 46 How to Replace the Motor Tach Sensor ............46 Ground Controls .................... 47 7-1 Control System Fault Recovery Switch ............
  • Page 9 October 2022 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 ................71 Section 5 Navigation Menus ...................
  • Page 10 October 2022 Table of Contents Section 6 Schematics ....................101 Introduction ....................101 Electrical Symbol Legend ................102 Hydraulic Symbols Legend ................103 Electrical Component and Wire Color Legends ..........104 Kubota Engine Fuse and Relay Module ............108 Kohler Engine Fuse and Relay Module ............109 Limit Switch/Angle Sensor Legend ..............

  • Page 11: Specifications

    October 2022 Service and Repair Manual Specifications Secti on 2 Specificatio ns Machine Specifications Machin e Specific atio ns Batteries Type Tires and Wheels Group 903-L16 Tire size 315/55 D20 Quantity Wheel diameter 20 in 50,8 cm Ampere hour 370 AH Wheel width 11 in Reserve capacity @ 25A rate...

  • Page 12: Performance Specifications

    Service and Repair Manual October 2022 Specifications Perfor man ce Speci ficatio ns Performance Specifications Hydraulic Oil Specific ations Hydraulic Oil Specifications Drive speed - stowed Hydraulic Fluid Specifications 40 ft / 6.1 sec 12.2 m / 6,1 sec Genie specifications require hydraulic oils which are Drive speed - raised or 40 ft / 90 sec designed to give maximum protection to hydraulic...
  • Page 13 October 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 14 Service and Repair Manual October 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 15: Hydraulic Component Specifications

    October 2022 Service and Repair Manual Specifications Hydraulic Com pon ent Sp ecificati ons Hydraulic Component Manif old Co mpo nent Specifica tions Manifold Component Specifications Specifications Function Pump Plug torque Type gear pump SAE No. 4 14 ft-lbs / 19 Nm Displacement .40 cu in / 6,6 cc SAE No.

  • Page 16: Kubota D1105 Engine Specifications

    Service and Repair Manual October 2022 Specifications Kubota D 110 5 Engin e Specific atio ns Kubota D1105-E4-GNI-1 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 18°...

  • Page 17: Kohler Kdw1404 Engine Specifications

    October 2022 Service and Repair Manual Specifications Kohler KDW1 404 En gine S pecifica tions Kohler KDW 1404 Engine Injection system Injection pump Bosch PDM Displacement 88.72 cu in Injection timing 11° BTDC 1,372 liters Injection pump pressure, 2030 - 2248 psi Number of cylinders maximum 140 - 155 bar...

  • Page 18: Machine Torque Specifications

    Service and Repair Manual October 2022 Specifications Machin e T orq ue Sp ecificati ons Machine Torque Specifications Machin e Co mpo nent Weigh ts Machine Component Weights Platform Rotator Tire and wheel assembly 343 lbs 156 kg 1-8 center bolt, GR 5 Drive motor and hub 120 lbs Lubricated...

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    October 2022 Service and Repair Manual Specifications Hydraulic Hose and Fitti ng Tor que Sp ecificati ons 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°...

  • Page 20: Torque Procedure

    Service and Repair Manual October 2022 Specifications Tor que P roce dur e 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 21 October 2022 Service and Repair Manual 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 22: Repair Procedures

    Service and Repair Manual October 2022 Repair Procedures Machine Configuration: Secti on 3 Repair P roce dur es Intro ductio n Unless otherwise specified, perform each  repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface •...
  • Page 23 October 2022 Service and Repair Manual 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 24: Cailbration Process Steps

    Service and Repair Manual October 2022 Repair Procedures Cailbrati on Pr ocess St eps 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 25: Platform Controls

    October 2022 Service and Repair Manual Platform Controls Platf or m Con tr ols 1-1 Plat for m Con trols 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 26: How To Adjust The Joystick Threshold Setting

    Service and Repair Manual October 2022 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 27: How To Adjust The Maximum Speed Setting (Hydraulic Functions)

    October 2022 Service and Repair Manual Platform Controls Switch Controlled Functions: How to Adju st th e M aximu m Spe ed Set ting (Hyd raulic Fun ctions ) How to Adjust the Maximum Speed Setting (Hydraulic 12 Perform steps 1 through 9 to enter the sub menu THRESHOLD CURRENT on the Functions) display.
  • Page 28 Service and Repair Manual October 2022 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 29: How To Adjust The Function Ramp Rate Setting

    October 2022 Service and Repair Manual Platform Controls How to Adju st th e F unctio n Ra mp R ate Set ting How to Adjust the Function Ramp 20 Activate the boom function again by pressing the foot switch and moving the function switch Rate Setting in the same direction.
  • Page 30 Service and Repair Manual October 2022 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 31: How To Calibrate Booms Angle Sensors

    October 2022 Service and Repair Manual Platform Controls 1-2 H ow to C alibra te Bo oms An gle Sen sors 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...

  • Page 32: How To Clear The Fault History

    Service and Repair Manual October 2022 Platform Controls 1-3 H ow to Cl ear the Fa ult Histo ry 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 33: Platform Components

    October 2022 Service and Repair Manual Platform Components Remove the pin retaining fastener from the Platf or m Com po ne nt s 2-1 Plat for m Le veling Slave Cylin der slave cylinder rod-end pivot pin. Do not Platform Leveling Cylinder remove the pin.

  • Page 34: Platform Rotator

    Service and Repair Manual October 2022 Platform Components 2-2 Plat for m Rot ato r 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...

  • Page 35: Platform Overload System

    October 2022 Service and Repair Manual Platform Components 2-3 Plat for m Ove rloa d Syste m 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.

  • Page 36: How To Perform A Full Load Platform Calibration

    Service and Repair Manual October 2022 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 37 October 2022 Service and Repair Manual 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 38: How To Replace The Platform Overload Load Cell

    Service and Repair Manual October 2022 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 39: How To Reset Overload Recovery Message

    October 2022 Service and Repair Manual 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 40: Jib Boom Components

    Service and Repair Manual October 2022 Jib Boom Components Jib B oom C om po ne nt s 3-1 Ji b Boo m 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...

  • Page 41: Jib Boom Lift Cylinder

    October 2022 Service and Repair Manual Jib Boom Components 3-2 Ji b Boo m Lift C ylinde r 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.

  • Page 42: Primary Boom Components

    Service and Repair Manual October 2022 Primary Boom Components Tag, disconnect and plug the hydraulic hoses Pr im ar y Boom Com p o nen ts 4-1 C able Tra ck from the cable track to the bulkhead union at Cable Track platform end of the boom.
  • Page 43 October 2022 Service and Repair Manual Primary Boom Components 10 Raise the boom to a horizontal position. 20 Raise the rod end of the primary boom lift cylinder back into position and install the rod- 11 Place blocks between the upper and lower end pivot pin.

  • Page 44: How To Repair The Cable Track

    Service and Repair Manual October 2022 Primary Boom Components How to Re pair the Cable Tr ack How to Repair the Cable Track 4-2 Pri mar y Boo m Primary Boom Component damage hazard. The boom cable track can be damaged if it is twisted.
  • Page 45 October 2022 Service and Repair Manual Primary Boom Components 17 Remove the pin retaining fasteners from the Locate the primary boom drive speed limit switch inside of the upper pivot. primary boom lift cylinder rod-end pivot pin. Use a soft metal drift to remove the pin. Remove the primary boom drive speed limit switch mounting fasteners.

  • Page 46: How To Disassemble The Primary Boom

    Service and Repair Manual October 2022 Primary Boom Components How to Disassemble the Primary Remove the external snap rings from the Boom 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 47: Primary Boom Lift Cylinder

    October 2022 Service and Repair Manual Primary Boom Components 4-3 Pri mar y Boo m Lift C ylinde r Support the rod end and the barrel end of the primary boom lift cylinder with a second Primary Boom Lift Cylinder overhead supporting device.

  • Page 48: Primary Boom Extension Cylinder

    Service and Repair Manual October 2022 Primary Boom Components Tag, disconnect and plug the primary boom 4-4 Pri mar y Boo m Extensi on Cylin der extension cylinder hydraulic hoses. Cap the Primary Boom Extension fittings on the cylinder. Cylinder Bodily injury hazard.

  • Page 49: Platform Leveling Master Cylinder

    October 2022 Service and Repair Manual Primary Boom Components 4-5 Plat for m Le veling Mas ter Cyli nde r 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 50: Secondary Boom Components

    Service and Repair Manual October 2022 Secondary Boom Components Seco ndar y B o om Com p on en ts 1 upper secondary boom (number 1 arm) 2 upper tension link (number 2 arm) 3 lower tension link (number 3 arm) 4 mid-pivot 5 compression link 6 secondary boom lift cylinder (2)

  • Page 51: Secondary Boom

    October 2022 Service and Repair Manual Secondary Boom Components Tag, disconnect and plug the hydraulic hoses 5-1 Sec ond ary Bo om at the primary boom lift cylinder. Cap the Secondary Boom fittings on the cylinder. Bodily injury hazard. Spraying How to Disassemble the hydraulic oil can penetrate and Secondary Boom...
  • Page 52 Service and Repair Manual October 2022 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 the secondary boom lift cylinder and let it 1 arm could become unbalanced hang down.
  • Page 53 October 2022 Service and Repair Manual Secondary Boom Components 25 Pull all of the hoses and cables out of the 35 Attach the lifting strap from an overhead lifting upper pivot and out through the mid-pivot. Lay device to the center point of the number 2 arm the hoses and cables on the ground.
  • Page 54 Service and Repair Manual October 2022 Secondary Boom Components 50 Attach a lifting strap from an overhead lifting 43 Open the ground controls side turntable cover. device to the center point of the number 3 arm for support. Do not lift it. 44 Remove the fuel tank filler cap.

  • Page 55: Secondary Boom Lift Cylinders

    October 2022 Service and Repair Manual Secondary Boom Components Remove the pin retaining fasteners from the 5-2 Sec ond ary Bo om Lift Cylin ders secondary boom lift cylinder rod-end pivot pin Secondary Boom Lift Cylinder and barrel-end pivot pin. Do not remove the pins.

  • Page 56: Engines

    Service and Repair Manual October 2022 Engines Engi nes How to Re place the Mot or Tac h Sens or How to Replace the Motor Tach 6-1 RPM Adjust ment Sensor RPM Adjustment Remove the fastener under the engine tray Refer to Maintenance Procedure in the appropriate and pull the engine out.

  • Page 57: Ground Controls

    October 2022 Service and Repair Manual Ground Controls Gr oun d C on tr ols How to Us e Cont rol Syst em Faul t Reco very Switc h How to use Control System Fault 7-1 C ontr ol Syste m F ault R ecove ry Switch Recovery Switch Control System Fault Recovery Switch...

  • Page 58: Hydraulic Pumps

    Service and Repair Manual October 2022 Hydraulic Pumps Tag, disconnect and plug function pump Hydr au lic Pum ps 8-1 Func tion Pu mp hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin.

  • Page 59: How To Check The Function Pump Calibration

    October 2022 Service and Repair Manual 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 60: Manifolds

    Service and Repair Manual October 2022 Manifolds Mani fo lds 9-1 Func tion Manif old C omp one nts Function Manifold Components The function manifold is mounted to the turntable next to the ground controls. Index Schematic Description Function Torque Item Check valve Platform rotate left/right...
  • Page 61 October 2022 Service and Repair Manual Manifolds Part No. 1297714GT ® -45 DC • Z ® -45 FE...
  • Page 62 Service and Repair Manual October 2022 Manifolds Function Manifold Components, continued Index Description Schematic Item Function Torque Diagnostic port System relief Pressure transducer Monitors pressure 18-20 ft-lbs / 25-27 Nm Shuttle valve Turntable rotate left/right 4-5 ft-lbs / 5-6 Nm circuit Needle valve Platform level circuit...
  • Page 63 October 2022 Service and Repair Manual Manifolds Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 64: Valve Adjustments - Function Manifold

    Service and Repair Manual October 2022 Manifolds Activate the platform level toggle switch up or 9-2 Valv e Adjust men ts - Fu nction Ma nifold down until the pressure gauge reads 3000 psi Valve Adjustments - Function / 207 bar. The platform level toggle up Manifold increases pressure, platform level down decreases pressure.

  • Page 65: How To Adjust The Secondary Boom Down Relief Valve

    October 2022 Service and Repair Manual Manifolds How to Adju st th e Seco nda ry Boo m Dow n Relief Valve How to Adjust the Secondary Boom Down Relief Valve Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Note: Refer to Function Manifold Component list to locate the secondary boom down relief valve.

  • Page 66: Jib Boom / Platform Rotate Manifold Components

    Service and Repair Manual October 2022 Manifolds 9-3 Ji b Boo m / Platf or m Rota te Manif old Co mpo nen ts Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description...

  • Page 67: Turntable Rotation Manifold Components

    October 2022 Service and Repair Manual Manifolds 9-4 Tur nta ble Rot ation Ma nifold Com pon ents Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No. Description Schematic Item Function...

  • Page 68: Directional Valve Manifold Components

    Service and Repair Manual October 2022 Manifolds 9-5 Dir ectio nal Valve Ma nifold C om pon ents 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...

  • Page 69: How To Set Up The Directional Valve Linkage

    October 2022 Service and Repair Manual Manifolds Verify that the ground and drive chassis are How to Set Up th e Dir ection al Valve Linka ge How to Set Up the Oscillate completely level. Directional Valve Linkage 10 Measure the distance between the drive Note: Adjustment of the oscillate directional valve chassis and the non-steer axle on both sides linkage is only necessary when the linkage or...
  • Page 70 Service and Repair Manual October 2022 Manifolds Valve Coil Resistance Valve Coils 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 air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...

  • Page 71: How To Test A Coil Diode

    October 2022 Service and Repair Manual Manifolds How to Test a Coil Dio de How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 72: Turntable Rotation Components

    Service and Repair Manual October 2022 Turntable Rotation Components Carefully remove the turntable rotation Tur n ta ble R ota tio n C om p one nt s 10-1 10-1 Tu rnt able R otatio n Asse mbly assembly from the machine. Turntable Rotation Assembly Crushing hazard.

  • Page 73: How To Replace The Universal Tilt Sensor

    October 2022 Service and Repair Manual Turntable Rotation Components 10-2 How to Repla ce t he Univ ersal Tilt Se nsor 10-2 How to Cali brat e th e Univ ersal Tilt Se nsor How to Calibrate the Universal How to Replace the Universal Tilt Tilt Sensor (UTS) Sensor (UTS) Note: Perform this procedure on a firm, level...

  • Page 74: Axle Components

    Service and Repair Manual October 2022 Axle Components Axle C om po ne nts 11-1 11-1 Oscillatin g Axle Cylin ders Attach a lifting strap from an overhead lifting device to the barrel end of the oscillating Oscillating Axle Cylinders cylinder.

  • Page 75: How To Remove The Steer Cylinder

    October 2022 Service and Repair Manual Axle Components 11-2 How to Rem ove t he Ste er Cyli nde r 11-2 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...
  • Page 76 Service and Repair Manual October 2022 Axle Components To exit programming mode: 11 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode. ® -45 DC • Z ® -45 FE Part No.

  • Page 77: Fault Codes

    October 2022 Service and Repair Manual Fault Codes Before Troubleshooting: Secti on 4 Fault C odes Intro ductio n 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 78: Control System Fault Codes

    Service and Repair Manual October 2022 Control System Fault Codes Both Engine Hours and DC Function Enable Hours Contr ol Sys tem F au lt C ode s Fault Codes Ground Controls Fault C odes Gr oun d Cont rols will be tracked.

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

    October 2022 Service and Repair Manual Control System Fault Codes How to Re triev e Con trol Syst em Fa ult Cod es - Platfo rm C ontr ols How to Retrieve Control System To access component faults list: Fault Codes from the Platform Turn the key switch to platform control.
  • Page 80 Service and Repair Manual October 2022 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 81: Control System Fault Codes

    October 2022 Service and Repair Manual Control System Fault Codes Contr ol System Fa ult Co des Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Stuck ON Release foot switch and 21 Fault recycle power (on @ power up) Verify: (when activated)
  • Page 82 Service and Repair Manual October 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 25 Value too high Ohms > 60 · Verify no open/short PRIMARY DOWN Associated circuit across PCON C20-...
  • Page 83 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component Name Cause Effect Solution Open Circuit or 25 Value too high Ohms > 60 SECONDARY DOWN Associated Function VALVE disabled Short or 26 Value too low Ohms <...
  • Page 84 Service and Repair Manual October 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 25 Value too high Ohms > 60 · Verify no open/short LARGE PUMP Associated Function circuit across PCON C47-6...
  • Page 85 October 2022 Service and Repair Manual 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 86 Service and Repair Manual October 2022 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 contacts not OR/BK Platform functions...
  • Page 87 October 2022 Service and Repair Manual 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 88 Service and Repair Manual October 2022 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 89 October 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: · Proper operation engine hi RPM solenoid Engine Speed · Proper engine RPM 23 Value too high higher than setting: setting...
  • Page 90 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: Associated PLATFORM · No open/short circuit 21 Fault Open or Shorted Function LEVEL UP VALVE across ECON C34-3 &...
  • Page 91 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution DC-DC failure: Remove AC and battery Internal charger LLC excessive for minimum 30 seconds fault leakage fault and retry charger WALL POWERED 52 PFC failure: PFC excessive leakage fault...
  • Page 92 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution · Replace battery pack Safety limit exceeded, possible · Check DC causes: connections · Poor battery health. ·...
  • Page 93 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution · Remove and re-insert the USB Drive There has been a problem · If the condition 17 USB error mounting or unmounting the persists then remove...
  • Page 94 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Connect charger to an AC source that provides AC source is unstable. Could stable AC between 85 - Low AC voltage be caused by undersized 270 VAC / 45-65 HZ.
  • Page 95 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component Name Cause Effect Solution Check if sensor is Battery temperature sensor connected correctly if is required by charge profile alarm is shown or ensure Battery Temperature (battery temperature the charge profile...
  • Page 96 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Verify: No CAN 48V on C25-1, C25- No Response Drive disabled communication 11, C25-12 (R181PWR OR) Controller Overcurrent 1.
  • Page 97 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Severe B+ Undervoltage Set: Capacitor bank 1. Battery parameters are mis- voltage dropped adjusted. below the Severe 2.
  • Page 98 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution '+5V Supply Failure 1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking. Set: +5V supply (pin Controller is performance limited at this voltage.
  • Page 99 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Set: Main contactor Main Open/Short ShutdownMotor; driver (pin 6) is either (RRDCON & ECON only) ShutdownMainContactor; open or shorted.
  • Page 100 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Set: Motor phase U, ShutdownMotor; V, or W detected ShutdownMainContactor; Motor Open open. ShutdownEMBrake; 1. Motor phase is open. ShutdownThrottle;...
  • Page 101 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Set: Runtime VCL VCL Runtime Error code error condition. ShutdownMotor; 1. VCL code encountered a Clear: Edit VCL ShutdownMainContactor;...
  • Page 102 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Set: Mismatched Supervisor Fault ShutdownMotor; redundant readings; 1. The Supervisor has detected a ShutdownMainContactor; damaged Supervisor; mismatch in redundant readings.
  • Page 103 October 2022 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Set: Motor lost IFO ShutdownMotor; control and ShutdownMainContactor; accelerated without Encoder Pulse Count Fault ShutdownEMBrake; throttle command. ShutdownThrottle;...
  • Page 104 Service and Repair Manual October 2022 Control System Fault Codes Control System Fault Codes Error Source Error Type Component ID Name Cause Effect Solution Pump & Drive Parameter Mismatch Controllers: 1. Dual drive enabled on one ShutdownMotor; 136=Pump [ECON] Clear: Adjust controller.

  • Page 105: Navigation Menus

    October 2022 Service and Repair Manual Navigation Menus Secti on 5 Navigatio n M enus Navigation Menu - Top Menus Top Men u Drive enable Drive Joystick switch Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right Part No.

  • Page 106: Faults Navigation Menu

    Service and Repair Manual October 2022 Faults Navigation Menu Faults Naviga tion Men u Faults Navigation Menu ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 107: Options Navigation Menu

    October 2022 Service and Repair Manual Options Navigation Menu Options Naviga tion Men u Options Navigation Menu Part No. 1297714GT ® -45 DC • Z ® -45 FE...

  • Page 108: Settings Navigation Menu

    Service and Repair Manual October 2022 Settings Navigation Menu Settings N avigati on Menu Settings Navigation Menu ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 109: Advanced And Drive Navigation Menu

    October 2022 Service and Repair Manual Advanced and Drive Navigation Menu Advance d an d Driv e Navig ation Me nu Advanced and Drive Navigation Menu Part No. 1297714GT ® -45 DC • Z ® -45 FE...
  • Page 110 Service and Repair Manual October 2022 Advanced and Drive Navigation Menu Advanced and Drive Navigation Menu (cont.) ® -45 DC • Z ® -45 FE Part No. 1297714GT...

  • Page 111: Schematics

    October 2022 Service and Repair Manual Schematics About This Section Secti on 6 Schematic s Intro ductio n 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 112: Electrical Symbol Legend

    Service and Repair Manual October 2022 Electrical Symbol Legend Electrical Sym bol L ege nd 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...

  • Page 113: Hydraulic Symbols Legend

    October 2022 Service and Repair Manual Hydraulic Symbols Legend Hydraulic Symbols Le gen d 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.

  • Page 114: Electrical Component And Wire Color Legends

    Service and Repair Manual October 2022 Electrical Component and Wire Color Legends Electrical Co mpo nen t an d Wire Colo r Le gen ds Item Jumper plug LR/RR motor controller to Description ECON Battery Jib select hydraulic manifold Engine start, 12V DC Steer sensor extender Left / Right side battery packs, 48V DC Function pump motor / Generator...
  • Page 115 October 2022 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Circuit breaker Gauge Fuel pump, 15A Battery charge indicator Controls power, 24V DC, 15A Engine oil pressure Charger box 12V, 10A Engine coolant temp. Engine RPM, 10A Engine oil temp.
  • Page 116 Service and Repair Manual October 2022 Electrical Component and Wire Color Legends TS51 Auxiliary pump Item Description TS52 Model select Button TS57 Platform rotate Red emergency stop (ground) TS58 Jib boom up/down Red emergency stop (platform) TS59 Platform level up/down Horn TS60 Secondary boom up/down...
  • Page 117 October 2022 Service and Repair Manual Electrical Component and Wire Color Legends Wire Color Legend Item Description Blue Black Brown Green Orange Purple White Yellow BL/BK Blue / Black BL/RD Blue / Red BL/WH Blue / White BK/RD Black / Red BK/WH Black / White GR/BK...

  • Page 118: Kubota Engine Fuse And Relay Module

    Service and Repair Manual October 2022 Kubota Engine Fuse and Relay Module Kubota En gine Fus e a nd Rel ay M odule 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...

  • Page 119: Kohler Engine Fuse And Relay Module

    October 2022 Service and Repair Manual Kohler Engine Fuse and Relay Module Kohler En gine Fus e an d Relay Mo dule Kohler KDW 1404 1 CR1 Engine start 2 CR4 High rpm 3 CR6 Fuel pump 4 CR15A Engine status 5 CR64 Fault alarm 6 CR15B Engine status 7 CR15 Glow plug...

  • Page 120: Limit Switch/Angle Sensor Legend

    Service and Repair Manual October 2022 Limit Switch/Angle Sensor Legend Limit Switch/An gle Se nsor Leg end 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 ®...

  • Page 121: Electrical Schematics

    October 2022 Service and Repair Manual Electr ica l Sch em ati cs Electrical Schematic, Chassis and Turntable...

  • Page 122: Electrical Schematic, Chassis And Turntable

    Service and Repair Manual October 2022 Electrical Sch emati c, Cha ssis an d T urn table Electrical Schematic, Chassis and Turntable LS1 PRIMARY RETRACTED P181BAT(A) OR/14 P181BAT OR/14 C2-11 P182BAT RD/14 P182BAT RD/14 C2-8 N.C. DRIVE C22PWR BK C22PWR BK ENABLE C134PWR RD C134PWR RD...

  • Page 123: Electrical Schematic, Tcon

    October 2022 Service and Repair Manual Electrical Sch emati c, TC ON Electrical Schematic, TCON GROUND BOX TB P181 C2-4 P181PWR OR P181PWR OR P48LPS WH/RD P181BAT OR/14 P182BAT RD P182BAT RD/14 P181PWR OR/16 TB181 P181BAT OR/14 C22PWR BK P182BAT RD/14 P182PWR RD/14 TELEMATICS C134PWR RD...
  • Page 124 Service and Repair Manual October 2022 Electrical Schematic, TCON...
  • Page 125 October 2022 Service and Repair Manual Electrical Schematic, PCON...

  • Page 126: Electrical Schematic, Pcon

    Service and Repair Manual October 2022 Electrical Sch emati c, PCON Electrical Schematic, PCON CONTACT ALARM POWER RD/BK C249CTA BK/RD C249CTA BK/RD BATGND BR BATGND BR SYNC. C250CTA YL P23PWR WH C247CTA OR/BK C248CTA OR POWER RD/BK C249CTA BK/RD BATGND BR SYNC.

  • Page 127: Electrical Schematic, Kubota Engine Models

    October 2022 Service and Repair Manual Electrical Sch emati c, Kub ota En gine Mod els Electrical Schematic, Kubota Engine Models ENGINE CONNECTOR TO CR88; CHARGER SELECT RLY; PIN 3 AND 6. P20BAT RD LINE N NEUTRAL R181PWR OR P20BAT RD 12VDC AUXGND P20BAT RD...
  • Page 128 Service and Repair Manual October 2022 Electrical Schematic, Kubota Engine Models...
  • Page 129 October 2022 Service and Repair Manual Electrical Schematic, Kohler Engine Models...

  • Page 130: Electrical Schematic, Kohler Engine Models

    Service and Repair Manual October 2022 Electrical Sch emati c, Kohle r Engi ne Mod els Electrical Schematic, Kohler Engine Models TO CR88; P20BAT RD CHARGER SELECT RLY; PIN 3 AND 6 P20BAT RD L LINE N NEUTRAL + 12VDC - AUXGND RD/16 AUXGND BK...

  • Page 131: Electrical Schematic, Front Motor Controllers

    October 2022 Service and Repair Manual Electrical Sch emati c, F ron t Mo tor Cont rolle rs Electrical Schematic, Front Motor Controllers TO BATTERY FROM DCON - LR PACK 48V AC MOTOR CONTROLLER 175A SP 9 SP 10 7 I/O GND SP 4 8 THERM SENSOR SP 3...
  • Page 132 Service and Repair Manual October 2022 Electrical Schematic, Front Motor Controllers...
  • Page 133 October 2022 Service and Repair Manual CAN Bus Wiring Diagram...

  • Page 134: Can Bus Wiring Diagram

    Service and Repair Manual October 2022 CAN Bus Wiring Dia gr am CAN Bus Wiring Diagram LOAD CELL SP18 SP15 SP25 SP27 D81CAN1- GR D82CAN1+ YL SP17 SP14 SP26 SP28 PCON VCON SP13 SP14 D82CAN1+ YL C3-11 D82CAN1+ YL C74-D D81CAN1- GR C3-12 D81CAN1- GR...

  • Page 135: Power Cable Wiring Diagram

    October 2022 Service and Repair Manual Power Ca ble Wirin g Dia gra m Power Cable Wiring Diagram INVERTER 48V / AC OPTION CHARGER P181RET(C) OR[5] C180RET BK[6] C179RET GR[4] P181RET(B) OR[3] TRACTION P181BAT(B) OR(14GA)[2]TO DC/DC AC MOTOR P181BAT(A) OR(14GA)[1]TO GBOX CONTROLLER BATTERY PACK FROM 12V...
  • Page 136 Service and Repair Manual October 2022 Power Cable Wiring Diagram...
  • Page 137 October 2022 Service and Repair Manual AC / DC Junction Box Wiring Diagram...

  • Page 138: Ac / Dc Junction Box Wiring Diagram

    Service and Repair Manual October 2022 AC / DC Juncti on Box Wi ring Di agr am AC / DC Junction Box Wiring Diagram 12V CHARGER BOX WIRING P20BAT RD (BK) (BK) AUX RLY 24VDC R27AUX RD 13.8V CHARGER BOX BATGND BR TO RELAY AC INPUT BOX...

  • Page 139: Rcbo Option Wiring Diagram

    October 2022 Service and Repair Manual RCBO Option Wiring Diag ram RCBO Option Wiring Diagram RCBO OPTION PLATFORM RCBO OPTION PLATFORM WITH INVERTER SOCKET WITH POWER SOCKET TO PLATFORM GROUND TO GROUND TO PLATFORM CHASSIS PLATFORM CHASSIS RCBO BOX RCBO BOX 110/220VAC INVERTER GROUND TO...
  • Page 140 Service and Repair Manual October 2022 RCBO Option Wiring Diagram...

  • Page 141: Hydraulic Schematics

    October 2022 Service and Repair Manual Hydr au lic Sc hem a tics Hydraulic Schematic...

  • Page 142: Hydraulic Schematic

    Service and Repair Manual October 2022 Hydraulic Schem atic Hydraulic Schematic COUNTERBALANCE VALVES psi / bar RATIO 3500 / 241 4.25:1 3626 / 250 3000 / 207 10:1 3250 / 224 1000 / 69 1500 / 103 3300 / 228 3800 / 262 1.5:1 3500 / 241...

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