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Terex Genie Z-45 DC Service And Repair Manual Download Page 6

vi 

Z

®

-45 DC • Z

®

-45 FE 

Part No. 1297714GT

July 2020

Service and Repair Manual

Personal Safety

Any person working on or around a machine must 
be aware of all known safety hazards. Personal 
safety and the continued safe operation of the 
machine should be your top priority.

 

Read each procedure thoroughly.  This

 

manual and the decals on the machine,

 

use signal words to identify the following:

 

 

Safety alert symbol—used to alert

 

 

personnel to potential personal

 

 

injury hazards. Obey all safety

 

 

messages that follow this symbol

 

 

to avoid possible injury or death.

 

 

Indicates an imminently

 

 

hazardous situation which, if not

 

 

avoided,  will result in death or

 

 

serious injury.

 

 

Indicates a potentially hazardous

 

 

situation which, if not avoided,

 

 

could result in death or serious

 

 

injury.

 

 

Indicates a potentially hazardous

 

 

situation which, if not avoided,

 

 

may cause minor or moderate

 

 

injury.

 

 

Indicates a potentially hazardous

 

 

situation which, if not avoided,

 

 

may result in property damage.

 

Be sure to wear protective eye wear and

 

other protective clothing if the situation

 

warrants it.

 

Be aware of potential crushing hazards

 

such as moving parts, free swinging or

 

unsecured components when lifting or

 

placing loads. Always wear approved

 

steel-toed shoes.

DANGER

WARNING

CAUTION

NOTICE

Workplace Safety

 

Be sure to keep sparks, flames and

 

lighted tobacco away from flammable and

 

combustible materials like battery gases

 

and engine fuels. Always have an

 

approved fire extinguisher within easy

 

reach.

 

Be sure that all tools and working areas

 

are properly maintained and ready for

 

use. Keep work surfaces clean and free of

 

debris that could get into machine

 

components and cause damage.

 

Be sure any forklift, overhead crane or

 

other lifting or supporting device is fully

 

capable of supporting and stabilizing the

 

weight to be lifted. Use only chains or

 

straps that are in good condition and of

 

ample capacity.

 

Be sure that fasteners intended for one

 

time use (i.e., cotter pins and self-locking

 

nuts) are not reused. These components

 

may fail if they are used a second time.

 

Be sure to properly dispose of old oil or

 

other fluids. Use an approved container.

 

Please be environmentally safe.

 

Be sure that your workshop or work area

 

is properly ventilated and well lit.

SAFETY RULES

Summary of Contents for Genie Z-45 DC

Page 1: ...v A1 July 2020 From Z45EM 101 Serial Number Range Z 45 FE Z 45 DC This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics For detailed maintenance procedures Refer to the appropriate Maintenance Manual for your machine ...

Page 2: ...nance and repair be performed at an authorized Genie dealer service center Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All co...

Page 3: ...edure Page Description A 03 2020 Initial Release A1 07 2020 Section 6 Schematic page 120 REFERENCE EXAMPLES Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics Electronic Version Click on any content or procedure in the Table of Contents to view the update Introduction ...

Page 4: ... 1297714GT July 2020 Service and Repair Manual Introduction Serial Number Legend Z45EM 001 2020 Z45E M 101 1 2 3 5 4 1 Model 2 Facility code 3 Sequence number 4 Serial number stemped on chassis 5 Serial label located under cover ...

Page 5: ...dentified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate t...

Page 6: ... clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes DANGER WARNING CAUTION NOTICE Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an a...

Page 7: ...s 5 Manifold Component Specifications 5 Kubota D1105 Engine Specificatios 6 Machine Torque Specifications 7 Machine Component Weights 7 Hydraulic Hose and Fitting Torque Specifications 8 Torque Procedure 9 Section 3 Repair Procedures 10 Introduction 10 Calibration Process Steps 11 Platform Controls 12 1 1 Platform Controls 12 How to Adjust the Joystick Treshold Setting 13 How to Adjust the Joystic...

Page 8: ...to Repair the Cable Track 30 4 2 Primary Boom 30 How to Disassemble the Primary Boom 32 4 3 Primary Boom Lift Cylinder 33 4 4 Primary Boom Extension Cylinder 34 4 5 Platform Leveling Master Cylinder 35 Secondary Boom Components 36 5 1 Secondary Boom Lift Cylinder 37 Engines 43 6 1 RPM Adjustment 43 How to Replace the Motor Tach Sensor 43 Ground Controls 44 7 1 Control System Fault Recovery Switch ...

Page 9: ...te Manifold Components 55 9 4 Turntable Rotation Manifold Components 56 9 5 Directional Valve Manifold Components 57 9 6 How to Set Up the Oscillate Directional Valve 58 9 7 Valve Coils 59 How to Test a Coil Diode 59 Turntable Rotation Components 61 10 1 Turntable Rotation Assembly 61 10 2 How to Replace the Universal Tilt Sensor 62 How to Calibrate the Universal Tilt Sensor 62 Axle Components 63 ...

Page 10: ...Symbol Legends 101 Electrical Component and Wire Color Legends 102 Kubota Engine Fuse and Relay Module 105 12V DC Charger Wiring DC Option 106 AC Input Wiring DC Option 107 AC Input Wiring CE Option 108 CAN BUS Wiring Diagram DC Models 109 Limit Switch Angle Sensor Legend 110 Electrical Schematics Options 111 Wiring Diagram Options Schematics 111 Schematics Options DC and FE Models Schematics 115 ...

Page 11: ...llons 64 4 liters Hydraulic tank 10 5 gallons 40 liters Hydraulic system including tank 17 gallons 65 liters Drive hubs 24 fl oz 710 cc Turntable rotation drive hub 25 5 fl oz 750 cc Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Batteries Type L16G AC lead acid AGM dry cell Group 903 L16 Quantity 8 Capacity lead acid dry cell 390 AH 370 AH Reserve capacity 2...

Page 12: ...eeds maximum from platform controls Jib boom up 13 to 17 seconds Jib boom down 13 to 17 seconds Primary boom up 26 to 30 seconds Primary boom down 26 to 30 seconds Primary boom extend 12 to 20 seconds Primary boom retract 12 to 20 seconds Secondary boom up 26 to 30 seconds Secondary boom down 26 to 30 seconds Turntable rotate per 90 Stowed 67 to 80 seconds Turntable rotate per 90 Not stowed 105 to...

Page 13: ...fications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperat...

Page 14: ...vron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 2...

Page 15: ...00 Manifold Component Specifications Plug Torque SAE No 4 14 ft lbs 19 Nm SAE No 6 23 ft lbs 31 2 Nm SAE No 8 36 ft lbs 49 Nm SAE No 10 62 ft lbs 84 Nm SAE No 12 84ft lbs 114 Nm Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically incr...

Page 16: ...requirements Below 10 C 14 F SAE 10W 30 10 to 25 C 14 to 77 F SAE 10W 30 SAE 15W 40 Above 25 C 77 F SAE30 SAE10W 30 SAE15W 40 Unit ships with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Manual for your engine Engine coolant Capacity 3 3 quarts 3 1 liters Fuel injection system Injection pump make Bosch MD Inj...

Page 17: ...or leads square nuts requires 12 point socket 10 ft lbs 13 6 Nm Specifications Machine Component Weights Tire and wheel assembly 300 lbs 136 kg Drive motor and hub 114 6 lbs 52 kg Engine assembly 640 lbs 290 3 kg Primary boom 981 6 lbs 445 2 kg Primary boom cylinder 128 lbs 58 kg Primary boom extend cylinder 87 8 lbs 40 kg Secondary boom linkage 1668 6 lbs 757 kg Secondary boom cylinder 60 lbs 27 ...

Page 18: ...0 2 6 9 16 18 1 1 4 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 49 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm 1 SAE O ring Boss Port tube fitting installed ...

Page 19: ...e flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Using a permanent ink marker make a reference mark on one the flats of the hex nut and continue the mark onto the body of the hex fitting Refer to Illustration 1 3 Working clockwise on the body hex fitting make a second mark with a per...

Page 20: ...supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can...

Page 21: ...alibrate Booms Angle Sensors Note The one point calibration is optional It allows 2 MPH 3 2 Km h travel if machine needs to be immediately moved 5 Calibrate the steer angle sensor Refer to Repair Procedures How to Calibrate the Steer Angle Sensor 6 Complete calibrating the Primary and Secondary angle sensors stowed and elevated positions Refer to Repair Procedures How to Calibrate Booms Angle Sens...

Page 22: ... require no calibration Automatic calibration of center voltage occurs on power up if the signal value is in the valid range Each joystick controller should operate smoothly and provide proportional speed control over its entire range of motion The remaining boom functions operate by on off toggle switches Except for platform level the speed of these functions are controlled by a function speed co...

Page 23: ...The display will show FAULTS 6 Momentarily activate steer in the right direction until SETTINGS is shown on the display 7 Momentarily activate the drive enable toggle switch in the right direction until VALVE AND SENSOR SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSOR is shown on the display 9 Momentarily acti...

Page 24: ...rimary Extend Retract Secondary Up Down and Turntable rotate Low flow Functions Jib Up Down Jib rotate and Platform rotate Other Functions Steering is set by a fixed flow regulating valve non adjustable Platform level adjusted by a needle valve located on the function manifold and Hydraulic Valve Ramps Refer to How to Adjust Ramp Rate Setting Note Refer to Specifications Performance Specifications...

Page 25: ...y increase 300 PSI and no audible alarm When the 300 PSI occurs proceed to the next step 14 Release the foot switch and momentarily activate steer in the right direction one time to increase the value by 10 milliamps Repeat releasing the foot switch and momentarily activating steer right until the function moves with no valve throttling and no audible alarm for the primary up down secondary up dow...

Page 26: ...ove and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode The ramp rate setting is an adjustment that controls the way boom function starts and stops There are two types of ramp rates to adjust on separate menus Ramp Up Time The amount of time it takes to accelerate to speed Ramp Down Time The amount of time it takes to decelerate to a stop Note Perfo...

Page 27: ...ng a parameter adjustment 12 Momentarily active steer to change the ramp up or ramp down value Each activation will change the value by 50 milliseconds Refer to the Ramp Rate chart for factory settings 13 Momentarily activate drive enable switch right to save the value Result The alarm will sound indicating the setting has been saved Continue to the next desired Ramp time adjustment Rampuptime fac...

Page 28: ...ivate the drive enable toggle switch in the right direction until you see the VALVE AND SENSOR SETTINGS screen 6 Momentarily activate the drive enable toggle switch in the right direction until you see the CALIBRATE TILT SENSOR screen 7 Momentarily activate steer in the right direction until BOOM ANGLE CALIBRATE is shown on the display 8 Momentarily activate the drive enable toggle switch in the r...

Page 29: ...d hold the drive enable toggle switch in the right direction while holding steer in the right direction 5 When the display leaves SYSTEM READY mode release the drive enable toggle switch and steer joystick Result The display will show FAULTS 6 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE FAULTS is shown on the display 7 Momentarily activate steer in the r...

Page 30: ...ng on the blocks just enough to support the platform Note Do not rest the entire weight of the jib boom on the blocks 4 Tag disconnect and cap the hydraulic hoses from the slave cylinder Plug the union hoses from the master cylinder together using a connector WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pr...

Page 31: ...r is disassembled proper alignment can be achieved by rotating the rotator all the way to the left and then installing the platform mounting weldment all the way in the left position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraul...

Page 32: ...not allow oil to squirt or spray 4 Move the function enable toggle switch to either side and hold the platform rotate toggle switch to the left position until the platform is fully rotated to the left Continue holding the toggle switch until air stops coming out of the bleed screw Close the bleed screw WARNING Crushing hazard Keep clear of the platform during rotation 5 Open the bottom bleed screw...

Page 33: ...D LOAD CALIBRATION Using a suitable lifting device place a test weight equal to the maximum platform capacity at the center of the platform floor Refer to the machine serial plate 7 Activate and hold the secondary boom up toggle switch until the full rated load calibration is done The smart hourmeter displays MAXRATED LOAD CAL OK Note There may be a 2 second delay before the platform overload indi...

Page 34: ...e switch and steer in the right direction 5 When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer joystick Result The display will show FAULTS 6 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE FAULTS is shown on the display 7 Activate steer in the right direction until RESET OVERLOAD RECOVERY is shown on the display 8...

Page 35: ...ener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 7 Remove the pin retaining fasteners from both platform rotator pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down 9 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 10 Remove the hose and cable cover fr...

Page 36: ... device Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the jib boom slightly and place blocks under the platform mo...

Page 37: ...ove the pin and let the cylinder hang down Remove the platform rotator from the machine WARNING Crushing hazard The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead lifting device 8 Attach a lifting strap from an overhead lifting device to the lug on the rod end of the jib boom lift cylinder 9 Use a soft metal drift to remo...

Page 38: ... counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 7 Tag and disconnect the hydraulic hoses from the platform leveling slave cylinder at the union an...

Page 39: ...ve the pin 17 Raise the primary boom slightly with the overhead lifting device to relieve the pressure on the primary boom lift cylinder rod end pivot pin 18 Use a soft metal drift to remove the primary boom lift cylinder rod end pivot pin WARNING Crushing hazard The primary boom lift cylinder could become unbalanced and fall if not properly supported by the lifting device 19 Lower the rod end of ...

Page 40: ...pment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections mus...

Page 41: ...oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 13 Remove the hose clamp at the pivot end of the boom 14 Attach a 5 ton 5 000 kg overhead lifting device to the center point of the primary boom 15 Attach a similar lifting device to the primary boom lift cylinder 16 Place support blocks unde...

Page 42: ...ionandamount of shims used with each wear pad 5 Support and slide the extension tube and extension cylinder assembly out of the boom tube WARNING Crushing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported Note During removal the overhead lifting device strap will need to be carefully adjusted for proper balanci...

Page 43: ...he pressure off the primary boom lift cylinder pivot pins 5 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead lifting device or similar supporting device 6 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraul...

Page 44: ...boom to a horizontal position 2 Extend the primary boom until the primary boom extension cylinder rod end pivot pin is accessible in the primary boom extension tube 3 Remove the hose and cable guard from the upper pivot 4 Tag disconnect and plug the primary boom extension cylinder hydraulic hoses Cap the fittings on the cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and...

Page 45: ...Torque Specifications 1 Raise the primary and secondary booms until both the rod end and barrel end pivot pins on the master cylinder are accessible 2 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissip...

Page 46: ...al Secondary Boom Components Secondary Boom Components 1 upper secondary boom number 1 arm 2 upper tension link number 2 arm 3 lower tension link number 3 arm 4 mid pivot 5 compression link 6 secondary boom lift cylinder 2 7 lower secondary boom number 4 arm 8 upper pivot ...

Page 47: ...hen raise the primary boom lift cylinder with the lifting device to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or...

Page 48: ... mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid pivot and the upper pivot Do not remove the pins 19 Use a soft metal drift to drive both pins out Secondary Boom Components 20 Remove the number 1 arm from the machine WARNING Crushing hazard The number 1 arm could become unbalanced and fall when removed from the machine if not properly attached to the ove...

Page 49: ...ort Do not lift it 33 Remove the pin retaining fasteners from the number 2 3 and 4 arm pivot pins at the mid pivot Do not remove the pins 34 Use a soft metal drift to drive each pin out Then remove the mid pivot from the secondary boom assembly WARNING Crushing hazard The mid pivot could become unbalanced and fall when removed from the secondary boom assembly if not properly supported by the overh...

Page 50: ...wire between the machine and pump or container Note Be sure to only use a hand operated pump suitable for use with gasoline and diesel fuel 46 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled 47 Remove the fuel tank mounting fasteners Carefully remove the fuel tank from the machine NOTICE Component damage hazard The fuel tank is plastic and may beco...

Page 51: ...m could become unbalanced and fall when removed from the machine if not properly supported by the overhead lifting device There are two secondary boom lift cylinders incorporated in the structure of the secondary boom assembly These cylinders operate in parallel and require hydraulic pressure to extend and retract Each secondary boom lift cylinder is equipped with a counterbalance valve to prevent...

Page 52: ...head lifting device to the lug on the rod end of the secondary boom lift cylinder for support Do not apply any lifting pressure 6 Use a soft metal drift to drive the barrel end pivot pin half way out Lower the barrel end of the secondary boom lift cylinder and let it hang down 7 Use a soft metal drift to drive the rod end pivot pin half way out 8 Remove the secondary boom lift cylinder from the ma...

Page 53: ...the high idle solenoid from the bracket 1 tach sensor 2 high idle solenoid 3 Locate tag and disconnect the tach sensor harness 4 Loosen the jam nut and remove the tach sensor 5 Thread the new tach sensor until it stops Note Do not over tighten 6 Back the tach sensor off 1 2 turn and tighten the jam nut 7 Start the engine and check the high idle parameter Refer to Specifications Kubota D1105 Engine...

Page 54: ...ntrol system fault Recovery switch Bypass and Recovery mode is only intended for certain circumstances and is not part of normal machine operation If the Recovery function is required this indicates there may be faults with the machine Contact trained personnel immediately Recovery is only to be used as a last attempt to retract and lower the platform when control system failures or CAN communicat...

Page 55: ...e primary boom and lower the primary and secondary booms at the same time using the main pump at reduced speed to allow the operator to exit the platform 1 In case of CAN communication loss or control system failure only turn off the machine wait at least two seconds and turn the key switch in GROUND position 2 Press and hold the function enable button and move the Recovery switch backward to lowe...

Page 56: ...functions with hydraulic tank shut off valve closed Remove the key switch and tag the machine to inform personnel of the condition 2 Tag disconnect and plug function pump hydraulic hoses Cap the fittings on the pump WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow o...

Page 57: ...d hold the drive enable toggle switch in the right direction while holding steer in the right direction 3 When the display leaves SYSTEM READY mode release the drive enable toggle switch and the steer joystick 4 Momentarily activate steer in the right direction until SETTINGS is shown on the display 5 Momentarily activate the drive enable toggle switch in the right direction until you see the VALV...

Page 58: ...48 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Manifolds E F G H I J K L G M N L M N G O M J P P Q P L R N S P J M T ...

Page 59: ...uit 19 21 ft lbs 26 29 Nm 10 Valve Relief Size 8 3500 Psi J Platform level up circuit 19 21 ft lbs 26 29 Nm 11 Valve Relief Size 8 3500 Psi K Platform level down circuit 19 21 ft lbs 26 29 Nm 12 Valve Spool 4 Wy 3 Position Closed Center L Steer left right 19 21 ft lbs 26 29 Nm 13 Valve Pilot Operated 850 Psi M Oscillate circuit 24 26 ft lbs 33 35 Nm 14 Valve Solenoid 2pos 2way N o N P circuit 19 2...

Page 60: ... Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Manifolds B F G H D I J C L M O P K Q E R AA T U AC AB A S V W X Y Z N 2 17 18 28 15 27 3 8 6 7 4 9 10 12 13 16 11 5 20 21 29 1 19 22 23 24 25 26 14 ...

Page 61: ...Psi X Tank return circuit 19 21 ft lbs 26 29 Nm 25 Valve Check 25 Psi Y Secondary boom retract circuit 19 21 ft lbs 26 29 Nm 26 Valve Counterbalance Z Primary boom retract circuit 30 33 ft lbs 40 45 Nm 27 Nipple Diagnostic 4 AA Testing 28 Nipple Diagnostic 4 AB Testing 29 NIPPLE DIAGNOSTIC 4 AC Testing ...

Page 62: ... Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Manifolds B F G H D I J C L M O P K Q E R AA T U AC AB A S V W X Y Z N 2 17 18 28 15 27 3 8 6 7 4 9 10 12 13 16 11 5 20 21 29 1 19 22 23 24 25 26 14 ...

Page 63: ...nction enable switch is activated 4 Simultaneously activate the platform level toggle switch until the pressure gauge reads 1000 PSI 69 bar The platform level toggle up increases pressure platform level down decreases pressure 5 Simultaneously activate the platform rotate toggle switch to store the value Result The control system will continue to the next calibration procedure value 3000 PSI 207 b...

Page 64: ...ess and hold the function enable switch activate and hold the secondary boom down switch with the secondary boom fully lowered 3 Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Specifications 4 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap WARNING Tip over haza...

Page 65: ...Service and Repair Manual The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way G Platform rotate jib boom select 8 10 ft lbs 11 14 Nm Manifolds ...

Page 66: ...nual Manifolds The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment Index No Description Schematic Item Function 1 Counterbalance valve L Turntable rotate right 2 Counterbalance valve J Turntable rotate left ...

Page 67: ...Service and Repair Manual Manifolds The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description Schematic Item Function Torque 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve CH Directional control ...

Page 68: ...ers 3 Place a bubble type level across the drive chassis non steer end Verify the drive chassis is level to the working surface 4 Locate and remove the ball joint retaining fastener from the bracket 5 To level the chassis perform any boom function and push up or pull down the threaded rod until the machine is completely level 6 Verify that the ground and drive chassis are completely level 7 Adjust...

Page 69: ...or minus 30 replace the coil Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 10 C that your air temperature increases or decreases from 68 F 20 C Refer to Specifications Manifo...

Page 70: ...to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of...

Page 71: ...or Cap the fittings on the drive motor WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Turntable Rotation Components 5 Attach a lifting strap from an overhead lifting device to the turntable rotator assembly 6 Remove the turntable rotation as...

Page 72: ...n the stowed position Refer to Navigation Menus Settings Menu 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls Turn the key switch to platform control 2 Move and hold the drive enable toggle switch in the right direction while holding steer in the right direction 3 When the display leaves SYSTEM READY mode release the drive enable toggle switch a...

Page 73: ...l the boom is between the steer tires or tracks 2 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fast...

Page 74: ...ables can be damaged if they are kinked or pinched Note Perform this procedure on a firm level surface with the machine in the stowed position Refer to Navigation Menus Settings Menu 1 Turn the key switch to platform control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Adjust the steer wheels so they are pointing straight ahead in line with...

Page 75: ...le toggle switch in the right direction to save calibrate steer center Result The alarm will sound and the mV value flashes to indicate the setting has been saved To exit programming mode 11 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode Axle Components ...

Page 76: ...66 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual U V W X Y Z W W _ Z a b c Z d ...

Page 77: ...al AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and te...

Page 78: ...ge SOC whenever no faults are present on the system The value will cycle between unit hours and battery SOC every 5 seconds When the engine is running if equipped the display will cycle hours SOC and RPM Both Engine Hours and DC Function Enable Hours will be tracked DC Function enable hours will be displayed on the smart hour meter by default Engine Hours will be displayed if the hybrid mode selec...

Page 79: ...display from NO to YES 19 Activate the drive enable toggle switch in the right direction to accept the change Result The alarm will sound for one second All fault history listings and counters will be cleared At least one fault code is present when the alarm at the platform controls produces one short beep every 30 seconds Refer to Navigation Menus Faults Menu 1 Turn the key switch to platform con...

Page 80: ...unctions operate at 50 speed Verify 24V supply on toggle switch center RD C134PWR 24V on pos 3 C48 11 VCON C194DEC WH BK when pressing down on the swtich 24V on C48 10 C194INC WH RD when pressing up on the switch B otherwise 18 Proportional Relief Valve 21 Fault Open or Shorted Warning Will cause poor operating efficiency Verify no open short circuit across C28 2 RRDCON C1 6 C3 3 V191PCE WH RD 19 ...

Page 81: ...Resistance Too Lowt Short or Ohms 5 24 Primary Boom Angle Sensor 11 Shorted to supply 4850 mV Act as if in Out of Stowed position elevated drive speed no elevated drive due to tilt drive cutout on CE units Driving at 2 MPH is allowed if primary and secondary angle sensors are calibrated and the mV value is close to the calibrated stowed value Verify 5V from C27 5 to C12 C P109PWR GR WH B at Pin C1...

Page 82: ...erify no open short circuit across TCON C20 7 BK B V10SBU BL 26 Resistance Too Low Short or Ohms 5 33 Secondary Down Valve 25 Resistance Too High Open Circuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across TCON C20 8 BK B V11SBD BL BK 26 Resistance Too Low Short or Ohms 5 36 Jib Up or Platform Rotate Left Valve 25 Resistance Too High Open Circuit or Ohms 60 ...

Page 83: ...p 42 Turntable CW Valve 25 Resistance Too High Open Circuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across TCON C20 9 TCON BK B V04TRL WH 26 Resistance Too Low Short or Ohms 5 43 Turntable CCW Valve 25 Resistance Too High Open Circuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across TCON C20 10 BK B V05TRR WH BK 26 Resis...

Page 84: ...ify CAN bus wiring Telematics Device is functioniong 61 Steer Joystick 11 Shorted to supply 5V Steer Disabled Verify 5V at JC3 2 P162JW OR B at JC3 1 JSGND BR 500 4500 mV at JC3 3 JC3 5 for dual axis joystick PCON C46 11 C159STC BL WH through joystick motion Note 1500 to 3500 mV for rocker style joystick at JC3 5 16 Sensor at 0v 0V 17 Not calibrated Not between 2000 3000 mV at startup 64 Hydraulic...

Page 85: ...problem corrected to clear fault To Calibrate Stowed mV must be between 3600 4400 mV Elevated mV must be between 600 16 Sensor at Zero 0V 17 Not calibrated Calibration Not Completed 19 Out of Range Reported angle sensor value out outside normal range more than 3 degrees 68 Func Enable Toggle Switch ground controls 27 Active at Startup Stuck ON on power up Ground controlled functions disabled Verif...

Page 86: ...12 Overload Overload condition detected All functions disabled Unload the exceeding weight on the Platform 13 Not Detected No CAN communication All functions disabled Verify CAN connection to LC 15 Anti Tampering Negative load detected while boom up triggered All functions disabled Check LC mounting and repeat calibration 17 Not Calibrated Load Sense not calibrated All functions disabled Perform f...

Page 87: ...ommunication Warning Verify 24V supply on C61 5 B at C61 8 60 Ohm restance across CAN C61 1 and C62 2 82 Load Sense Recovery 21 Fault Overload was tripped and AUX was used to lower the platform while overloaded All functions disabled Enter LCD menu at Platform Navigate to RESET OVERLOAD RECOVERY Enter Enter reset pass code 83 Telematics Remote Shutdown 21 Fault Unit shut down via remote telematics...

Page 88: ...temperature or low oil pressure switch provided a ground to relay CR64 to shut down the engine A time delay of 5 seconds gives the oil pressure time to build after the engine is started Verify Over temperature switch is not activating Relay CR64 by providing a ground path to the relay coil unplug oil pressure switch for this test C108SEL WH BK Oil Pressure Switch contacts open to B after engine st...

Page 89: ...RD in relation to C28 7 RRDCON Sensor Ground 500 4500mV through steer motion at PIN B C28 24 C111LFS OR and has no open short circuit to either pin A or pin C When wheels are straight signal 16 Sensor at Zero 0V 17 Not calibrated Calibration Not Completed 135 Wall Powered Charger Faults 51 DC DC failure LLC excessive leakage fault Charger Fault 1 offset by 50 Internal charger fault Remove AC and b...

Page 90: ...eck battery size condition This error will automatically clear once the condition has been corrected 2 Low battery voltage error detected prior to starting a charge cycle Battery Voltage is too low to charge Check the battery voltage and cable connections Check battery size condition This error willautomatically clear once the condition has been corrected 3 Charge timeout Charge Timeout caused by ...

Page 91: ...health Very deeply discharged battery Poorly connected battery High parasitic loads on battery while charging Replace battery pack Check DC connections Disconnect parasitic loads This error will automatically clear once the charger is reset by cycling DC 8 Battery temperature out of range error Could be battery temperature sensor error Check temperature sensor and connections Reset charger This er...

Page 92: ...etry the update by reinserting the USB Flash Drive into the charger 17 USB error There has been a problem mounting or unmounting the USB Flash Drive Remove and re insert the USB Drive If the condition persists then remove AC and battery for minimum 30 seconds and retry charger 18 Slot CRC error The software update failed Ensure the USB Flash Drive is properly formatted and retry the update by rein...

Page 93: ...to turn on properly Disconnect AC input and battery for 30 seconds before retrying 25 Low AC voltage oscillation error AC source is unstable Could be caused by undersized generator and or severely undersized input cables Connect charger to an AC source that provides stable AC between 85 270 VAC 45 65 Hz This error will automatically clear once the condition has been corrected 26 Script Failure The...

Page 94: ...rtbeat error CANbus heartbeat error Check the networked CANbus device s for correct functioning 36 Battery Temperature Sensor Error Battery temperature sensor is required by charge profile battery temperature compensated algorithm by it is not installed Check if sensor is connected correctly if alarm is shown or ensure thecharge profile installed does not require temperature compensation 37 CANOpe...

Page 95: ...Front RF 139 Left Rear LR 140 Right Rear RR 0 No Response No CAN communication Drive disabled 48V on C25 1 C25 11 C25 12 R181PWR OR 12 Controller Overcurrent 1 External short of phase U V or W motor connections 2 Motor parameters are miss tuned 3 Controller defective ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Phase current exceeded the current measurement li...

Page 96: ...llBrake Set Heatsink temperature above 95 C Clear Bring heatsink temperature below 95 C and cycle interlock or KSI 17 Severe B Undervoltage 1 Battery parameters are misadjusted 2 Non controller system drain on battery 3 Battery resistance too high 4 Battery disconnected while driving 5 See Monitor menu Battery Capacitor Voltage 6 Blown B fuse or main contactor did not Reduced drive torque Set Capa...

Page 97: ...tor voltage above the Undervoltage limit 25 5V Supply Failure 1 Normal operation Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is None Set 5V supply pin 26 outside the 5 V 10 range Clear Bring voltage within range 26 Digital Out 6 Open Short 1 External load impedance on Digital Output 6 driver pin 19 is too low Digital Output 6 driver will not...

Page 98: ...shorted This fault can be set only when Main Enable On Clear Correct open or short and cycle driver 32 EMBrake Open Short DCON Only 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring ShutdownEMBrake ShutdownThrottle FullBrake Will drag tire with the bad brake Set Electromagnetic brake driver pin 5 is either open or shorted Thisfault can be set only when EM Brake Ty...

Page 99: ...MBrake Motor disabled Set Motor encoder phase failure detected Clear Cycle Power to KSI 39 Main Contactor Did Not Close RRDCON ECON only 1 Main contactor did not close 2 Main contactor tips are oxidized burned or not making good contact 3 External load on capacitor bank B connection terminal that prevents capacitor bank from charging ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThro...

Page 100: ...r ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 2 3 4 ShutdownPD FullBrake Set Runtime VCL code error condition Clear Edit VCL application software to fix this error condition flash the new compiled software and matching parameter defaults cycle KSI 71 OS General 1 Internal controller fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrot...

Page 101: ...MainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 2 3 4 ShutdownPD FullBrake Set Incompatible software Clear Load properly matched OS code or update the Supervisor code cycle KSI 82 Bad Calibrations 1 Internal controller fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Internal controller fault detection Clear Cycle Power to KS...

Page 102: ... out of range ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Cycle Power 91 VCL OS Mismatch 1 The VCL software in the controller does not match the OS software in the controller ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 2 3 4 ShutdownPD FullBrake Set VCL OS software do not match when KSI cycles a check is ...

Page 103: ...heck is made to confirm a legal Model_ Number and a fault is issued if one is not found Clear Download appropriate software for controller model 99 Parameter Mismatch 1 Dual drive enabled on one controller 2 Incorrect position feedback type chosen for motor technology in use 3 Dual drive is enabled in torque mode ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Clear ...

Page 104: ...94 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Navigation Menu Top Menus Control System Fault Codes ...

Page 105: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 95 Service and Repair Manual Faults Navigation Menu Faults Navigation Menu ...

Page 106: ...96 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Options Navigation Menu Options Navigation Menu ...

Page 107: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 97 Service and Repair Manual Settings Navigation Menu Settings Navigation Menu ...

Page 108: ...98 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual e f g h i j k l g m n l m n g o m j p p q p l r n s p j m t ...

Page 109: ...operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and ot...

Page 110: ...100 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Electrical Symbols Legends ...

Page 111: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 101 Service and Repair Manual Hydraulic Symbols Legends ...

Page 112: ...Left front AC motor controller C26 DCON Right front AC motor controller C27 DCON Left rear AC motor controller C28 DCON Right rear AC motor controller C29 Telematics C30 Jumper plug LR RR motor controller to ECON C31 Jib select hydraulic manifold C32 Steer sensor extender C33 Function pump motor Generator C34 ECON AC motor Generator controller C35 DC or Engine option C36 Battery status LED C37 Dri...

Page 113: ...s 5A F33 Telematics 6A FS1 Foot switch G Gauge G1 Battery Charge Indicator G2 Engine oil pressure G3 Engine coolant temp Item Description G4 Engine oil temp G6 Hour meter H Horn or Alarm H1 Tilt Platform overload H2 Horn H5 Alarm multifunction JC Joystick JC1 Boom proportional joystick secondary boom up down JC3 Drive steer proportional joystick JC7 Boom proportional joystick primary up down turnt...

Page 114: ...mity kill option TS47 Inverter option TS51 Auxiliary pump TS52 Model select TS57 Platform rotate TS58 Jib boom up down TS59 Platform level up down TS60 Secondary boom up down TS61 Primary boom up down TS62 Turntable rotate TS63 Primary boom extend retract U Module U3A DCON RR AC motor controller U3B DCON LR AC motor controller U3C DCON RF AC motor controller 4WD option U3D DCON LF AC motor control...

Page 115: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 105 Service and Repair Manual Kubota Engine Fuse and Relay Module ª µ Kubota D1105 E4B ...

Page 116: ...C Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual 12V DC Charger Wiring DC Option 1 Control Relay 3 24V auxiliary 2 Circuit breaker 4 10A 3 Battery charger 12V 4 To relay AC input box 5 Connector 14 ...

Page 117: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 107 Service and Repair Manual AC Input Wiring ANSI CSA version DC Option 1 AC input wall plug 2 AC input to 48V charger 3 Charger Control IN 4 To 12V charger ...

Page 118: ...108 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual AC Input Wiring AS CE version DC Option 1 AC input wall plug 2 AC input to 48V charger 4 To 12V charger ...

Page 119: ...July 2020 Part No 1297714GT Z 45 DC Z 45 FE 109 Service and Repair Manual CAN BUS Wiring Diagram ...

Page 120: ...4GT July 2020 Service and Repair Manual Limit Switch Angle Sensor Legend 4 3 1 2 5 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: ...July 2020 Service and Repair Manual 111 Wiring Diagram Options ...

Page 122: ...112 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Wiring Diagram Options ...

Page 123: ...July 2020 Service and Repair Manual Wiring Diagram Options 113 Z 45 DC Z 45 FE Part No 1297714GT ...

Page 124: ...July 2020 Service and Repair Manual 114 Wiring Diagram Options ...

Page 125: ...July 2020 Service and Repair Manual 115 Schematics Options DC and FE Models ...

Page 126: ...116 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Schematics Options DC and FE Models ...

Page 127: ...July 2020 Service and Repair Manual 117 Power Cable Wiring Diagram ...

Page 128: ...118 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Wiring Diagram Options ...

Page 129: ...July 2020 Service and Repair Manual 119 Hydraulic Schematic ...

Page 130: ...120 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Hydraulic Schematic DC FE Models ...

Page 131: ...July 2020 Service and Repair Manual 121 Electrical Schematic DC FE Models ...

Page 132: ...122 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Electrical Schematic DC FE Models ...

Page 133: ...123 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Electrical Schematic DC FE Models ...

Page 134: ...July 2020 Service and Repair Manual 124 Electrical Schematic DC FE Models ...

Page 135: ...125 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Electrical Schematic DC FE Models ...

Page 136: ...July 2020 Service and Repair Manual 126 Electrical Schematic DC FE Models ...

Page 137: ...July 2020 Service and Repair Manual 127 Ground Control Box Terminal Strip Wiring Diagram DC FE Models ...

Page 138: ...128 Z 45 DC Z 45 FE Part No 1297714GT July 2020 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram DC FE Models ...

Page 139: ...July 2020 Service and Repair Manual 129 Ground Control Box Terminal Strip Wiring Diagram DC FE Models ...

Page 140: ...ia to cause cancer and birth defects or other reproductive harm These chemicals can be emitted from or contained in othervariouspartsandsystems fluidsandsome component wear by products To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your equipment and vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your ...

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