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Terex Genie Z-60 DC Service Manual Download Page 162

Service and Repair Manual

 

 

August 2022

 

 

 

 

 

 

 

150 

Z

®

-60 DC • Z

®

-60 FE

 

Part No. 1307785GT 

 

Wiring Diagram - FE Models 

  [from Z60H-3000, Z60M-1000] 

 

 

 

 

D22

CR15A

GLOW 

PLUGS

CR15B

GLOW 

PLUGS

CR64

ENGINE 

FAULTS

CR2

 

ENGINE
IGNITION

CR4

ENGINE 

RPM

CR1

ENGINE 

START

F2

30A

F3

30A

F5

15A

BATT

STUD

VEC

12

V 

R

D

J2

8-

F

J2

9-

E

J2

9-

F

J2

9-

B

J2

8-

H

J2

9-

G

J2

8-

E

J2

8-

D

C

10

8E

SL

 W

H

/B

K

J2

9-

C

J2

9-

D

+12V RD

J2

8-

C

J2

8-

A

J2

9-

A

R

33

ST

R

 B

K/

W

H

R

34

SA

 R

D

R

34

SA

 R

D

C

10

7A

F 

R

D

R

21

IG

N

 W

H

J2

8-

G

J2

8-

B

S

TA

R

TE

R

F

U

EL

 S

O

LE

N

O

ID

G

LO

W

 P

LU

G

S

A

LT

ER

N

AT

O

R

O

IL

 P

R

ES

 S

W

IT

C

H

O

IL

 T

EM

P 

SW

IT

C

H

R

PM

 S

O

LE

N

O

ID

J2

9-

H

R

35

R

PM

 B

K

BATT

STUD

C

36

-1

C

36

-2

C

36

-3

C

36

-4

C

36

-5

C

36

-6

C

36

-7

C

36

-8

C

36

-9

C

36

-1

0

C

36

-1

1

C

36

-1

2

C

36

-1

3

C

36

-1

4

C

36

-1

5

C

36

-1

6

C

36

-1

7

C

36

-1

8

ECON AC 
MOTOR/GEN 
CONTROLLER

J2

4

1

2

3 4

5

6

7

8 9

11

13

19

20 24

26

31

32

R

18

1P

W

R

 O

R

V1

91

PC

E 

W

H

/R

D

C

24

1H

G

P 

O

R

/R

C

21

IG

N

 W

H

C

33

ST

R

 B

K

C

18

0R

ET

 B

K

P1

10

R

ET

-E

 B

K

C

26

TS

R

-E

 W

H

/R

D

R

10

8E

SL

 W

H

/B

K

C

18

3R

C

V 

BL

P1

81

R

ET

-E

 O

R

C

24

3H

M

L 

W

H

C

24

4B

M

L 

BL

C

23

9H

M

S 

BL

/W

H

P1

09

PW

R

-E

 R

D

D

18

5S

EN

-E

 W

H

D

18

6S

EN

-E

 B

L

KE

Y 

SW

_K

S1

PR

O

PE

L 

R

EL

IE

F 

H

V 

(H

YB

)

D

U

M

P 

LO

AD

 R

EL

AY

IG

N

IT

IO

N

 R

EL

AY

ST

AR

T 

R

EL

AY

PU

M

P/

G

EN

 C

O

N

T-

I/O

 G

N

D

TH

ER

M

 S

EN

SO

R

EN

G

IN

E 

ST

AT

U

S

R

EC

O

VE

R

Y 

TS

 (H

YB

) 

C

O

IL

 R

ET

U

R

N

H

YB

R

ID

 M

O

D

E 

LE

D

BA

T 

M

O

D

E 

LE

D

H

YB

 M

O

D

E 

SE

L

+5

V 

PW

R

EN

C

O

D

ER

 A

EN

C

O

D

ER

 B

J2

4

35

23

34

21

D

81

C

AN

0-

 G

R

D

82

C

AN

0+

 Y

L

D

81

C

AN

0-

 G

R

D

82

C

AN

0+

 Y

L

TR

2-

B

TR

2-

A

C

AN

0+

 

C

AN

0-

C

AN

0-

C

AN

0+

FUNC 

PUMP/GEN

  

  

 

  

-

 +

 B

 A

EN

C

O

D

ER

U

V

W

+

C37-5
C37-6
C37-4
C37-3
C37-1
C37-2

COLOR

U

V

W

G

N

D

48

VD

C

TO SHEET 1

2

1

87A 87

30

85

86

87A 87

30

85

86

87A 87

30

85

86

87A 87

30

85

86

87A 87

30

85

86

87A 87

30

85

86

12

0

O

H

M

CB1

15A

CB7

10A

G

N

D

 B

R

C

27

AU

X 

R

D

R

18

1P

W

R

 O

R

V1

91

PC

E 

W

H

/R

D

C

13

4P

W

R

 R

D

C

34

3S

A 

BK

/W

H

C

18

0R

ET

 B

K

C

18

3R

C

V 

BL

P1

81

R

ET

-E

 O

R

C

24

3H

M

L 

W

H

C

24

4B

M

L 

BL

C

23

9H

M

S 

BL

/W

H

C

35

R

PM

 B

K/

R

D

C

24

1H

G

P 

O

R

/R

D

D

81

C

AN

0-

 G

R

D

82

C

AN

0+

 Y

L

+12V

+

-

IND.

STA.

+

-

EXCT.

ES0625F

Summary of Contents for Genie Z-60 DC

Page 1: ...48 from Z60M 1000 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics Z 60 FE For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Original Instructions Part No 1307785GT Rev B August 2022 ...

Page 2: ...hine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encoura...

Page 3: ...on A 9 2021 Initial Release B 8 2022 Repair 11 1 Fault Codes All Sections Navigation Menus All Sections Schematics Electrical schematics Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...umber 4 Serial number stamped on chassis 5 Serial label located under cover Z60 H 12345 1 2 3 4 5 Model Serial number Electrical schematic number Year of manufacture Machine unladen weight Rated work load including occupants Maximum number of platform occupants Maximum allowable side force Maximum allowable inclination of the chassis Z60H 12345 ...

Page 5: ... operator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regul...

Page 6: ...l crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Be sure to keep sparks flames and lighted tobacco away from f...

Page 7: ... Section 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Manifold Component Specifications 5 Kubota D1105 Engine Specifications 6 Machine Torque Specifications 7 Machine Component Weights 7 Hydraulic Hose and Fitting Torque Specifications 8 Torque Procedure 9...

Page 8: ... Components 22 2 1 Platform Leveling Slave Cylinder 22 2 2 Platform Rotator 23 2 3 Platform Overload System 24 How to Perform a Zero Load Platform Calibration 24 How to Perform a Full Load Platform Calibration 25 How to Replace the Platform Overload Load Cell 27 How to Reset Overload Recovery Message 28 Jib Boom Components 29 3 1 Jib Boom 29 3 2 Jib Boom Lift Cylinder 30 Primary Boom Components 31...

Page 9: ...ow to Adjust the Primary Boom Extend Relief Valve 50 8 3 Jib Boom Platform Rotate Manifold Components 51 8 4 Turntable Rotation Manifold Components 52 8 5 Oscillate Directional Valve Manifold Components 53 8 6 How to Set Up the Oscillate Directional Valve 54 How to Adjust the Oscillate Reducing Valve 54 How to Test a Coil Diode 56 Turntable Rotation Components 58 9 1 Turntable Rotation Assembly 58...

Page 10: ...ontrols 68 Control System Fault Codes 70 Charger Fault Codes 91 Battery Charger 91 Charger Fault Codes 92 Charger Error Codes 93 Pump Control Fault Codes 97 Pump Controller Fault Handling 97 Drive Control Fault Codes 106 Drive Controller Fault Handling 106 Section 5 Navigation Menus 125 Top Menu 125 Faults Navigation Menu 126 Options Navigation Menu 127 Settings Navigation Menu 128 Advanced and Dr...

Page 11: ...Electrical Schematic Options 4WD from Z60H 2548 to 2999 146 Power Cable Wiring Diagram from Z60H 2548 to 2999 147 Wiring Diagram FE Models from Z60H 3000 Z60M 1000 150 Wiring Diagram DC Models from Z60H 3000 Z60M 1000 151 Electrical Schematics 153 Electrical Schematic from Z60H 2548 to 2999 154 Electrical Schematic from Z60H 2548 to 2999 155 Ground Control Box Wiring Diagram from Z60H 2548 to 2999...

Page 12: ...chematic DCON from Z60H 3000 Z60M 1000 170 Electrical Schematic GCON from Z60H 3000 Z60M 1000 171 Electrical Schematic PCON from Z60H 3000 Z60M 1000 174 Electrical Schematic TCON from Z60H 3000 Z60M 1000 175 Wiring Diagram CAN BUS from Z60H 3000 Z60M 1000 178 Hydraulic Schematics 179 Hydraulic Schematic 180 ...

Page 13: ...ugh terrain low profile tires 36 9 in 93 7 cm Fluid capacities Fuel tank 17 gallons 64 4 liters Hydraulic tank 18 gallons 68 liters Hydraulic system including tank 21 gallons 80 liters Drive hubs 24 fl oz 710 cc Turntable rotation drive hub 43 fl oz 1262 cc Drive hub oil type SAE 90 multipurpose hypoid gear oil API service classification GL5 Batteries Type Lead acid AGM L16G AC EV Dry cell Group 9...

Page 14: ...igned to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level minimum ISO 15 13 Water content maximum 250 ppm Recommended Hydraulic Fluid Hydrauli...

Page 15: ...ydraulic Fluid Temperature Range Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32 Viscosity index maximum 200 Kinematic Viscosity maximum cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity maximum cP 4 F 20 C cP 22 F 30 C 1040 3310 Fl...

Page 16: ...esult in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index maximum 154 Kinematic Viscosity maximum cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temperature 180 F 82 C Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index maximum 300 Kinematic Viscosity maximum cSt 200 F 100 C cSt...

Page 17: ...to 5 7 L min Hydraulic Filters High pressure filter Beta 5 ˆ 1000 Hydraulic tank return filter Beta 10 ˆ 200 Manifold Component Specifications Plug torque SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 56 ft lbs 75 9 Nm Valve coil resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C A...

Page 18: ...low 10 C 14 F SAE 10W 30 SAE 10W 40 10 to 25 C 14 to 77 F SAE 10W 30 SAE 10W 40 SAE 15W 40 Above 25 C 77 F SAE 10W 30 SAE 10W 40 SAE 15W 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 mak...

Page 19: ... leads square nuts requires 12 point socket 9 ft lbs 12 Nm Machine Component Weights Tire and wheel assembly 429 lbs 195 kg Drive motor and hub 160 lbs 73 kg Engine assembly 724 lbs 328 kg Primary boom 1277 lbs 579 kg Primary boom lift cylinder 283 lbs 128 kg Primary boom extend cylinder 234 lbs 106 kg Secondary boom linkage 3017 lbs 1368 kg Secondary boom lift cylinder 180 lbs 82 kg Jib boom asse...

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

Page 21: ...ted and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex n...

Page 22: ...ect number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex f...

Page 23: ...ual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a ...

Page 24: ...alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not...

Page 25: ...sal Tilt Sensor 4 Calibrate the platform overload Refer to Repair Procedures How to Calibrate the Platform Overload System 5 Calibrate the primary and secondary angle sensors Refer to Repair Procedures How to Calibrate Booms Angle Sensors 6 Calibrate the steer angle sensor Refer to Repair Procedures How to Calibrate the Steer Angle Sensor 7 Verify pump efficiency calibration Refer to Repair Proced...

Page 26: ...wer 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 control switch The platform controls VCON can be utilized to perform a number ...

Page 27: ...e toggle switch and the steer joystick Result 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 SEN...

Page 28: ...Down Primary 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 Specific...

Page 29: ...asing 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 down and primary boom extend and retract 15 Momentarily activate steer in the right direction two times to increase the value by 20 milliamps for the turntable function setting 16 Momentarily activate the drive enable toggle switch...

Page 30: ...ion until the display returns to SYSTEM READY mode How to Adju st th e Joys tick Ra mp Ra te Setti ng How to Adjust the Ramp Rate Setting 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 t...

Page 31: ...ed and ramp times can be measured Release the foot switch prior to making 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 the drive enable toggle switch in the right direction to save the value Result The alarm will sound ind...

Page 32: ... 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 VALVE AND SENSOR SETTINGS is shown on the display 6 Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE TILT SENSOR is shown on the display 7 Momentarily activate steer in the right direct...

Page 33: ... down the foot switch 4 Move and 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 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 ...

Page 34: ...eight 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 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 5 Remove the pin retaini...

Page 35: ...ons very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Support the platform rotator with a suitable lifting device Do not apply any lifting pressure Crushing hazard The platform rotator may become unbalanced and fall if not properly supported How to Bleed the Platform Rotator Note This procedure will require two people Do not start the engine Use aux...

Page 36: ...d system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over How to Pe rfor m a Ze ro Loa d Platfo rm C alibr ation How to Perform a Zero Load Platform Calibration Perform this procedure when platform overload is not operating within the calibration parameters This procedure will re calibrate the zero ...

Page 37: ...is procedure 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 1 Fully retract and lower the boom Level the platform 2 Remove all weight tools accessories and equipment from the platform Note Options and accessories that are considered integrated components...

Page 38: ...ain hoist 5 anchoring device 5 Activate and hold secondary boom up for 3 4 seconds Result Hour meter displays MAXRATED LOAD CAL OK Calibration is saved Result Hour meter displays MAXRATED LOAD OUT OF RANGE Calibration has not been saved Adjust the load cell and repeat this procedure 6 Push in the red Emergency Stop button to the off position Confirm calibration 7 Start the engine from the ground c...

Page 39: ...nsor and remove the sensor Install the new Load Cell Sensor 6 Screw the foot with jam nut into the top of the load cell sensor until the foot bolt extends out of the bottom of the sensor The foot should not contact the flex plate when assembling onto the platform support 7 Assemble the load cell and foot assembly to the platform and securely tighten the two mounting screws Torque the bolts to 101 ...

Page 40: ...t switch 4 Move and 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 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 stee...

Page 41: ...from the jib boom lift cylinder rod end pivot pin Do not remove the pin 6 Slide both of the jib boom leveling arms off of the jib boom cylinder rod end pivot pin 7 Remove the hose and cable cover from the side of the jib boom Remove the hose and cable separators 8 Attach a lifting strap from an overhead crane to the jib boom 9 Support the barrel end of the jib boom lift cylinder with a suitable li...

Page 42: ...e gradually Do not allow oil to squirt or spray 3 Remove the pin retaining fasteners from the jib boom lift cylinder rod end pivot pin Do not remove the pin 4 Use a soft metal drift to tap the jib boom lift cylinder rod end pivot pin out enough to lower one of the leveling arms to the ground Tap the pin the other direction and lower the opposite leveling arm Do not remove the pin 5 Support the jib...

Page 43: ...r of the connectors to those on the control box to be sure they are installed in the correct location 2 Disconnect the power to plat cable from the AC outlet box 3 Remove the hose and cable clamps from the platform support 4 Tag disconnect and plug the platform leveling slave cylinder hydraulic hoses from the bulkhead fittings on the top of the primary boom Cap the bulkhead fittings Bodily injury ...

Page 44: ...acement cable track section to the existing cable track using the pins and snap rings 8 Install the rollers onto the new section of cable track 9 Operate the boom extend retract function through a full cycle to ensure smooth operation of the new section of cable track 4 2 Primary Boom How to Remove the Primary Boom Bodily injury hazard This procedure requires specific repair skills lifting equipme...

Page 45: ...ay located under the primary boom and set it on a supporting device 13 Remove the retaining fasteners from the primary boom pivot pin 14 Remove the primary boom pivot pin with a soft metal drift then carefully remove the primary boom from the machine and place it on a structure capable of supporting it Crushing hazard The primary boom could become unbalanced and fall when removed from the machine ...

Page 46: ... the primary boom for support 5 Raise the primary boom with the overhead crane slightly to take the pressure off the primary boom lift cylinder pivot pins 6 Support the rod end and the barrel end of the primary boom lift cylinder with a second overhead crane or similar lifting device 7 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily in...

Page 47: ...ve the cover from the end of the the 1 boom tube 3 At the pivot end of the boom remove the retaining fasteners and blocks securing the extend cylinder to the 2 boom tube through the access holes in the 1 boom tube 4 At the pivot end of the boom remove the retaining fasteners and blocks securing the extend cylinder to the 1 boom tube 5 Tag disconnect and plug the primary boom extension cylinder hyd...

Page 48: ...oth the rod end and barrel end pivot pins on the master cylinder are accessible 2 Use an overhead supporting device to support the platform Do not apply lifting pressure 3 Tag disconnect and plug the master cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil press...

Page 49: ...rt No 1307785GT Z 60 DC Z 60 FE 37 Secondary Boom components 1 master cylinder 2 primary boom lift cylinder 3 upper compression arms 4 mid pivot 5 timing link 6 secondary boom lift cylinder 7 lower compression arm 8 lower tension arms 9 upper tension arm 10upper pivot ...

Page 50: ...secondary lift cylinder clear the lower tension arms 2 Attach a lifting strap from an overhead supporting device 5 ton 5000 kg to the pivot end of the primary boom for support Do not apply lifting pressure Crushing hazard The boom assembly can fall if not properly supported by the overhead crane Component damage hazard Hoses and cables can be damaged if they are kinked or pinched 3 Remove the pin ...

Page 51: ...the center of the machine enough to lower it down through the lower compression arm Pull the cylinder towards the platform and remove it from the machine Crushing hazard The secondary boom lift cylinder could become unbalanced and fall when removed from the machine if not properly attached to the suitable lifting device Component damage hazard When removing a secondary boom lift cylinder from the ...

Page 52: ...l August 2022 Engines 40 Z 60 DC Z 60 FE Part No 1307785GT 6 1 RPM Adjust ment 6 1 RPM Adjustment Refer to Maintenance Procedure in the appropriate Service or Maintenance Manual for your machine Check and Adjust the Engine RPM ...

Page 53: ...ponent Damage hazard Do not perform any functions with hydraulic tank shut off valve closed Remove the key switch and tag the machine to inform personnel of the condition Open Closed 1 Tag disconnect and plug function pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pr...

Page 54: ...hine to DC mode 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 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 directi...

Page 55: ...August 2022 Service and Repair Manual Part No 1307785GT Z 60 DC Z 60 FE 43 This page intentionally left blank ...

Page 56: ...boom retract 30 35 ft lbs 41 47 Nm 7 Solenoid valve 3 position 4 way G Secondary boom extend retract 30 35 ft lbs 41 47 Nm 8 Shuttle valve H Pilots primary boom retract counterbalance valve 4 5 ft lbs 5 7 Nm 9 Solenoid valve 2 position 2 way normally open I P2 circuit 19 21 ft lbs 26 29 Nm 10 Pressure transducer J Monitors pressure 18 20 ft lbs 25 27 Nm 11 Diagnostic port TP1 K Testing 12 Check va...

Page 57: ...August 2022 Service and Repair Manual Manifolds Part No 1307785GT Z 60 DC Z 60 FE 45 ...

Page 58: ...24 Pressure reducing valve X Oscillate circuit 25 ft lbs 40 Nm 25 Needle valve Y Platform level up down 20 ft lbs 27 Nm 26 Solenoid valve 3 position 4 way Z Platform level up down 18 20 ft lbs 25 27 Nm 27 Solenoid operated proportional valve AA Boom functions 18 20 ft lbs 25 27 Nm 28 Relief valve 2800 PSI 193 bar AB Platform level up circuit 19 21 ft lbs 25 27 Nm 29 Check valve dual pilot operated...

Page 59: ...August 2022 Service and Repair Manual Manifolds Part No 1307785GT Z 60 DC Z 60 FE 47 ...

Page 60: ...gin flashing on the TCON controller Note The procedure will time out if any step is not completed within 90 seconds or terminate if the function 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 platf...

Page 61: ...ise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap 8 Repeat this procedure beginning with step 3 to confirm the relief valve pressure 9 Reinstall the proportional valve coil 10 Remove the pressure gauge Platform Level Down 11 Connect a 0 to 5000 PSI 0 to 350 bar pressure gauge to test port 4 on the bottom of the function manifold 12 Raise the jib...

Page 62: ...n Manifold Components 4 Press and hold the function enable button Activate and hold the primary boom extend switch with the boom fully extended 5 Observe the pressure reading on the pressure gauge Refer to Specifications Hydraulic Component Specifications 6 Locate and remove the cap from the primary boom extend relief valve Refer to Repair Procedures Function Manifold Components 7 Remove the press...

Page 63: ... Z 60 FE 51 8 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid Valve 2 position 3 way JA Platform rotate jib boom select 8 10 ft lbs 11 14 Nm ...

Page 64: ...onents The turntable rotation manifold is mounted to the turntable rotation motor located in the center of the turntable Index No Description Schematic Item Function 1 Counterbalance valve MM Turntable rotate right 2 Counterbalance valve NN Turntable rotate left 3 Shuttle valve OO Brake circuit 4 Orifice PP Brake circuit ...

Page 65: ...Z 60 FE 53 8 5 Oscillate Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non steer end Index No Description Schematic Item Function Torque 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve OA Directional control ...

Page 66: ...ing fastener hole in the bracket 7 Install the ball joint to the axle and tighten the jam nut 8 Check and make sure the drive chassis is completely level 9 Measure the distance between the drive chassis and non steer axle on both sides from inside of the drive chassis Note If the distance is not equal and the adjustment to the linkage was completed with ground and drive chassis level repeat steps ...

Page 67: ... Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification amperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function ov...

Page 68: ...oil 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 Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage Electrocution burn hazard Contact with electrically charged circuits could result in death or ser...

Page 69: ...ead to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good 7 Result If one or b...

Page 70: ...urface 1 Secure the turntable from rotating with the turntable rotation lock pin Note The turntable rotation lock pin is located next to the boom rest pad 2 Tag disconnect and plug the hydraulic hoses from the turntable rotation drive motor Cap the fittings on the drive motor Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow t...

Page 71: ...vot plate to specification Refer to Specifications Machine Torque Specifications 7 Adjust turntable rotation gear backlash Refer to Repair Procedure How to Adjust the Turntable Rotation Gear Backlash How to Adjust the Turntable Rotation Gear Backlash The turntable rotation drive hub is mounted on an adjustable plate that controls the gap between the rotation motor pinion gear and the turntable bea...

Page 72: ...djust if necessary 9 2 How to Replace the Universal Tilt Sensor UTS This machine has a dual axis angle sensing device called the Universal Tilt Sensor UTS It is mounted on the turntable to monitor and communicate ground angle relative to gravity via CAN bus Should the turntable be tilted at the Allowable Tilt Angle or greater an alarm will sound at both the turntable and the platform If not calibr...

Page 73: ...YSTEM READY mode release the drive enable toggle switch and the steer joystick Result The display will show FAULTS 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 VALVE AND SENSOR SETTINGS is shown on the display 6 Momentarily activate the drive enable toggle switch in the ...

Page 74: ... Hose and Fitting Torque Specifications 1 Rotate the turntable until 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 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 a...

Page 75: ...or pinched How to Cali brat e th e Stee r Angl e Sens or How to Calibrate the Steer Angle Sensor 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 controls 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Adjust the steer wheels s...

Page 76: ...te the drive enable toggle switch in the right direction to save calibrate steer center Result The alarm will sound and the mV value flashes to indicate the setting has been saved To exit programming mode 11 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode ...

Page 77: ...d in the internal memory when the battery type is selected using the machine software option settings When replacing the batteries with other brands or types not listed in the options settings battery type CUSTOM must be selected Charger status indicators 1 Error Fault USB indicator 2 AC power indicator 3 Battery charging indicator 4 USB port 5 Charging output indicator 6 Charger profile Error dis...

Page 78: ...hocked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all neces...

Page 79: ...ur meter will display unit hours and battery state of charge 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 defau...

Page 80: ...LTS is shown on the display 7 Momentarily activate the drive enable toggle switch in the right direction to access the active fault codes 8 Activate steer in the right direction to scroll through the fault codes Fault codes will be listed in order 1 through 16 To access component faults list 1 Turn the key switch to platform control 2 Pull out the red Emergency Stop button to the on position at bo...

Page 81: ...t to aid in troubleshooting the machine by pinpointing the area or component affected To clear fault history 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 Do not press down the foot switch 4 Move and hold the drive enable toggle switch in the right direction and hold steer in the right direction 5 Wh...

Page 82: ...tch B otherwise 18 PROPORTIONAL RELIEF VALVE 21 Fault Open or short circuit Warning Will cause poor operating efficiency Verify no open short circuit across C28 2 RRDCON C1 6 C3 3 V191PCE WH RD 19 AUX PUMP TOGGLE SWITCH 27 Active at startup Stuck ON on power up AUX functions disable d Verify when activated 24V created by AUX toggle switch TS1 at platform or ground controls they are wired in parall...

Page 83: ...o Calibrate Stowed mV must be between 2600 3400 mV Elevated mV must be between 400 1200 mV 16 Value at 0 V 0V 17 Not Calibrated Calibration Not Completed 19 Out of Range Reported angle sensor value out outside normal range more than 3 degrees 26 PRIMARY EXTEND VALVE 25 Value too high Open Circuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across TCON C20 3 BK B...

Page 84: ...Circuit or Ohms 60 Associated Function disabled Check Ohms Verify no open short circuit across PCON C47 3 BK or C10 1 B C19JSV GR WH 26 Value too low Short or Ohms 5 41 TURNTABLE JOYSTICK 11 Shorted to Supply 5V Turntable rotate functions disabled Verify 5V at JC7 2 P162PJW OR B at JC7 1 JSGND BR 500 to 4500 mV at JC7 4 PCON C46 12 C165TRS WH RD through joystick motion 16 Value at 0 V 0V 17 Not Ca...

Page 85: ... 56 TELEMATICS DEVICE 13 Not Detected Genie Telematics Device not detected when option is enabled Only basic telematics functionality Verify CAN bus wiring Telematics device is functioning 61 STEER JOYSTICK 11 Shorted to Supply 5V Steer function disabled Verify 5V at JC3 2 P162JW OR B at JC3 1 JSGND BR 500 to 4500 mV at JC3 3 JC3 5 for dual axis joystick PCON C46 11 C159STC BL WH through joystick ...

Page 86: ...24 SBS RD WH Cycle Power with problem corrected to clear fault To Calibrate Stowed mV must be between 3600 4400 mV Elevated mV must be between 600 1400 mV 16 Value at 0 V 0V 17 Not Calibrated Calibration not completed 19 Out of Range Reported angle sensor value out outside normal range more than 3 degrees 68 FUNCTION ENABLE TOGGLE SWITCH Ground controls 27 Active at startup Stuck ON on power up Gr...

Page 87: ... disabled Verify CAN connection at the load cell 14 Cross check fault Cross check between controllers failed Check load cell mounting Repeat calibration Replace load cell 15 Value too low Negative load detected while boom up activated Check load cell mounting Repeat calibration 17 Not Calibrated Load cell not calibrated or only zero load calibrated No calibration Partial calibration Perform full c...

Page 88: ...ons allowed from ground controls Verify 24V supply on C48 1 B at C48 2 60 Ohm resistance across CAN C49 1 and C49 2 78 PCON CONTROLLER Platform controls 13 No Response No CAN communication All functions disabled Verify 24V supply on C47 11 C47 12 and C46 2 B at C46 1 60 Ohm resistance across CAN C46 3 and C46 4 29 Software Version Mismatch Wrong software version 79 ROUND LCD DISPLAY Ground control...

Page 89: ... command All functions disabled or drive speed reduced or lift speed reduced Contact machine owner to have functionality restored 84 LEVEL SENSOR 13 No Response No CAN communication 2WD or 4WD limited to 2 5 MPH ANSI 3 2WD or 4WD Elevated Drive disabled CE Tilt Alarm ON Sensor or calibration fault latches loss of CAN does not Verify 24V supply on C21 1 B at C1 2 60 Ohm resistance across CAN C21 3 ...

Page 90: ... path to the relay coil unplug oil pressure switch for this test C108SEL WH BK Oil Pressure Switch contacts open to B after engine start C108SEL WH BK Relay CR64 is operable Output of relay CR64 87 is connected to C27 4 LRDCON through C35 1 R108SEL WH BK 96 LOW OIL PRESSURE OR ENGINE OVERTEMP 19 Value out of range Either the over temperature or low oil pressure switch provided a ground to relay CR...

Page 91: ...ATFORM LEVEL DOWN VALVE 25 Value too high Open circuit or 60 ohms Associated Function Disabled Verify no open circuit between controller B V14PLD OR BK 26 Value too low Short circuit or 5 ohms Verify no short circuit between controller B V14PLD OR BK 104 STEER ANGLE SENSOR 11 Shorted to Supply 12V High Speed Drive disabled Verify 12V supply Pin A RRDCON C28 25 P198SEN RD in relation to C28 7 RRDCO...

Page 92: ...has been corrected 135 WALL POWERED CHARGER 08 Component fault Fault without a specific Genie fault code occurred Refer to Charger Faults 13 No Response detected by TCON not reported by charger No CAN signal from charger Display fault Verify 24V on terminal Ground on terminal 60 ohms across with power off Charger is connected to the machine 28 Charger timeout Battery pack not reaching required vol...

Page 93: ...without a specific Genie fault code occurred Refer too Drive Controller Faults 13 No Response See left front motor controller Drive disabled 138 RIGHT FRONT MOTOR CONTROLLER 08 Component fault Fault without a specific Genie fault code occurred Refer too Drive Controller Faults 13 No Response See left front motor controller Drive disabled 139 LEFT REAR MOTOR CONTROLLER 08 Component fault Fault with...

Page 94: ...lems with power supply for the motor encoder Main contactor open No lift functions Check encoder wiring Confirm motor rotates freely 25 Value too high Motor phase is open Bad crimps or faulty wiring Main contactor open Check motor power U V W cables Check power cable connections Check motor phase to phase resistance 190 RIGHT REAR DRIVE MOTOR 21 Fault Stalled motor Motor encoder failure Bad crimps...

Page 95: ...talled motor Motor encoder failure Bad crimps or faulty wiring Problems with power supply for the motor encoder Brake set Main contactor open No drive functions Verify brakes release Check encoder wiring Confirm motor rotates freely 25 Value too high Motor phase is open Bad crimps or faulty wiring Brake set Main contactor open No drive of failed motor Reduced drive speed Check motor power U V W ca...

Page 96: ...t Brake motor coil failure Open or short circuit Reduced drive speed Affected wheel locked Check brake coil Check wiring C32BRK WH BK P181RET OR 198 RIGHT REAR SPEED SENSOR 21 Fault Motor Sin Cos encoder feedback signal fault Reduced drive speed Affected wheel locked Check motor encoder Sin Cos Check wiring D185SEN WH D186SEN BL P109PWR P110RET BK 199 LEFT REAR SPEED SENSOR 21 Fault Motor Sin Cos ...

Page 97: ... Check main contactor contacts 233 BATTERY TEMPERATURE CHARGER 19 Out of Range Battery temperature too high Battery temperature too low Battery temperature sensor error Charging disabled Check temperature sensor Check wiring Reset charger Self clearing when condition has been corrected 21 Fault Battery temperature sensor is required by charge profile Charging disabled Verify sensor is connected co...

Page 98: ...perature exceeded maximum rated temperature limit of 293 F 145 C No drive functions Allow motor to cool down Check gearbox and motor for damage Check temperature sensor wiring 256 LEFT REAR DRIVE MOTOR TEMPERATURE 20 Warning Motor temperature exceeded warning temperature limit of 248 F 120 C Reduced drive speed Allow motor to cool down Check gearbox and motor for damage 21 Fault Motor temperature ...

Page 99: ... warmer location 23 Value too high Motor controller temperature exceeded the maximum temperature limit 205 F 95 C No drive functions Allow motor controller to cool down Check mechanical connection to heat dissipation plate Check for component damage Verify brakes release 24 Value too low Motor controller temperature below the minimum temperature limit 40 F 40 C No drive functions Move unit to warm...

Page 100: ...40 C No drive functions Move unit to warmer location 262 LEFT FRONT DRIVE CONTROLLER TEMPERATURE 20 Warning Motor controller temperature exceeded or is below the warning temperature limit Reduced drive speed Allow motor controller to cool down Move unit to warmer location 23 Value too high Motor controller temperature exceeded the maximum temperature limit 205 F 95 C No drive functions Allow motor...

Page 101: ... 266 CHARGE PROFILE 21 Fault Selected charge profile is incompatible with charger software Charging disabled Update charger software Select different charge profile 31 Invalid setup Charge profile not selected Select charge profile 267 CHARGER AC VOLTAGE 23 Value too high AC voltage is too high 270 VAC Charging disabled Connect charger to an AC source that provides stable AC between 85 270 VAC 45 ...

Page 102: ...wn Check temperature sensor wiring Check for component damage 23 Value too high Motor temperature exceeded warning temperature limit of 248 F 120 C Limited pump speed Allow motor to cool down Check for component damage 272 PUMP CONTROLLER TEMPERATURE 23 Value too high Motor controller temperature exceeded the maximum temperature limit 205 F 95 C No drive functions Allow motor controller to cool do...

Page 103: ... P code Indicates charger programming mode is active This will occur when the charger profile is being configured Type USB code Indicates the USB interface is active and the USB should not be removed This will occur when the charger firmware is being updated Solid red Internal fault condition Type F fault code Flashing amber External fault condition Type E error code Flashing green USB interface i...

Page 104: ...s Charger Fault Code Genie Fault ID Genie Fault Type Description Possible Causes Solution F 0 0 1 135 8 DC DC failure LLC excessive leakage fault Internal charger fault Disconnect AC input and battery pack for 30 seconds If fault does not clear replace charger F 0 0 2 135 8 PFC failure PFC excessive leakage fault F 0 0 3 135 8 PFC taken too long to boost F 0 0 4 135 8 Charger unable to calibrate c...

Page 105: ... required voltage within safe time limit Charge output reduced due to high temperature Charge at lower temperature Check battery condition Replace damaged battery Check battery connections Battery pack deep discharge Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 0 4 204 21 Defective battery Battery pack could not be trickle charged up to the minimum vo...

Page 106: ...file for battery type Installed from a different machine with different battery type Disconnect battery pack for 30 seconds to clear fault when condition has been corrected E 0 1 6 135 8 Software update failed Software update failed Confirm USB Flash Drive is formatted with correct software If software update continues to fail contact Genie Product support E 0 1 7 265 21 USB error USB not connecte...

Page 107: ...e AC source between 85 270 VAC 45 65 Hz Self clearing when condition has been corrected E 0 2 4 135 8 Failure to initialize Charger failed to turn on correctly Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 2 5 267 24 Low AC voltage oscillation AC voltage unstable Connect to a stable AC source between 85 270 VAC 45 65 Hz Using an undersized generator Self cle...

Page 108: ...surements triggered alarm Internal charger error Disconnect AC input and battery pack for 30 seconds Contact Genie Product Support E 0 3 2 135 13 CAN Bus heartbeat error CAN Bus heartbeat error CAN Bus devices not functioning correctly E 0 3 6 233 21 Battery temperature sensor charge profile Battery temperature sensor is required by charger profile but is not installed Check battery temperature se...

Page 109: ...LED s The controller status LED s produce flash code ID s displaying all the currently set faults in a repeating cycle Each code ID consists of two digits The red LED flashes once to indicate that the first digit of the code ID will follow the yellow LED then flashes the appropriate number of times for the first digit The red LED flashes twice to indicate that the second digit of the code ID will ...

Page 110: ...ected by the Supervisor or Primary microprocessor Missing or corrupt software Interrupting a software download may cause corruption of the software Cycle the key switch to clear Reload software or replace controller if necessary Alternating red and yellow flash pattern Active fault When a fault is detected and no wiring or component failure can be found cycle the key switch off and back on to see ...

Page 111: ...t Precharge failed to charge the capacitor bank from the external precharge resistor Clear Cycle Interlock input or use VCL function Enable_Precharge 1 5 Controller Severe Undertemp 1 See Monitor menu Controller Temperature 2 Controller is operating in an extreme environment ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Heatsink temperature below 40 C Clear Bri...

Page 112: ...s are misadjusted 3 Non controller system drain on battery 4 Battery resistance too high 5 Battery disconnected while driving 6 See Monitor menu Battery Capacitor Voltage 7 Blown B fuse or main contactor did not close Reduced drive torque Set Capacitor bank voltage dropped below the Undervoltage limit with the FET bridge enabled Clear Bring capacitor voltage above the Undervoltage limit 2 5 5V Sup...

Page 113: ...V or 10 V Clear Bring the motor thermistor input voltage within range 3 1 Main Open Short 1 Open or short on driver load 2 Dirty connector pin 3 Bad crimps or faulty wiring ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Main contactor driver pin 6 is either open or shorted This fault can be set only when Main Enable On Clear Correct open or short and cycle drive...

Page 114: ...Power to KSI 3 9 Main Contactor Did Not Close 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 4 Blown B fuse ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Just prior to the main contactor closing the capacitor ba...

Page 115: ...ller fault detected Clear Cycle Power to KSI 7 2 PDO Timeout Time between CAN PDO messages received exceeded the PDO Timeout Period ShutdownThrottle CAN NMT State set to Pre operational Set Time between CAN PDO messages received exceeded the PDO Timeout Period Clear Cycle KSI or receive CAN NMT message 7 3 Stall Detected 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Probl...

Page 116: ...tor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake Set Internal controller fault detection Clear Cycle Power to KSI 8 4 Following Error Fault 1 vThe Following Error Limit has been exceeded for the Following Error Time 2 Incorrect or overly restrictive Following Error Limit and Following Error Time parameter settings 3 Motor or drive train rotation obstruction or degradation Shutd...

Page 117: ... has been commanded to set 2 EM Brake will not hold the motor from rotating ShutdownEMBrake ShutdownThrottle Position Hold is engaged when Interlock On Set After the EM Brake was commanded to set time has elapsed to allow the brake to fully engage vehicle movement sensed Clear Activate the Interlock 9 8 Illegal Model Number 1 Model_Number variable contains illegal value 2 Software and hardware do ...

Page 118: ...ed including the fault type Cause Effect and Solution are also listed Effect is what the controller will do when the fault is active Diagnostics information can be obtained by observing the flash pattern issued by the status LED The controller status LED produces flash code ID s displaying all the currently set faults in a repeating cycle Each code ID consists of two digits The LED flashes red ind...

Page 119: ...ardware fault detected by the Supervisor or Primary microprocessor Missing or corrupt software Interrupting a software download may cause corruption of the software Cycle the key switch to clear Reload software or replace controller if necessary Red LED flashing Non production device profile software When a fault is detected and no wiring or component failure can be found cycle the key switch off ...

Page 120: ... An external load on the capacitor bank B connection terminal that prevents the capacitor bank from charging See Programmer System Monitor menu Controller Capacitor Voltage ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set The precharge failed to charge the capacitor bank Clear Cycle Interlock or Reset Controller 2141 1 5 Controller Sev...

Page 121: ... KSI voltage above Brownout Voltage 2130 1 8 Severe B Overvoltage 1 Battery parameters are misadjusted 2 Battery resistance too high for given regen current 3 Battery disconnected while regen braking See Programmer System Monitor menu Controller Capacitor Voltage ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Capacitor bank voltage e...

Page 122: ... is too old to fully support the FOS version Clear 100 Internal Fault 100 Update CIT version re package the project and re flash the application package 210A 1 12 OS General 2 Fault Program execution within the controller encountered a serious problem and could not recover from this 100 Internal Fault kindly contact your Curtis representative immediately 100 Ill formed or corrupted application pac...

Page 123: ... regen braking Controller is performance limited at this voltage 2 Battery parameters are mis adjusted 3 Battery resistance too high for given regen current 4 Battery disconnected while regen braking See Programmer System Monitor menu Controller Currents OverVoltageCutback See Programmer System Monitor menu Controller Capacitor Voltage Reduced brake torque Note This fault is declared only when the...

Page 124: ...On then Regen Braking Torque is reduced Fault Action None unless a fault action is programmed in VCL Set Motor temperature is at or above the Temperature Hot parameter setting Clear Bring the motor temperature within range 2150 2 9 Motor Temp Sensor 1 Motor thermistor is not connected properly 2 Sensor polarity between Pin 8 and Pin 18 is incorrect 3 The motor temperature and sensor parameters are...

Page 125: ...Contactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Motor position speed Sin Cos sensor fault Clear Either Reset Controller or if parameter LOS Upon Encoder Fault On and Interlock has been cycled then the Encoder Fault is cleared and Encoder LOS fault flash code 9 3 is set allowing limited motor control 2230 3 6 Encoder Fault Fault Type s 1 Loss of regulation 2 Over Current trips...

Page 126: ...or not making good contact 3 An external load on the capacitor bank B connection terminal is preventing the capacitor bank from charging 4 Blown B fuse 5 Main contactor parameters mis tuned 6 Main Pull in Voltage 7 Main Holding Voltage Type 2 1 Main contactor opened during operation while commanded closed 2 Driver wiring to contactor s coil e g pin 3 wiring removed during operation 3 Contactor coi...

Page 127: ...troller and Reset Controller 2211 4 7 HPD Sequencing 1 Incorrect sequence in application of Keyswitch Interlock Direction or Throttle 2 Faulty wiring crimps or switches at KSI Interlock Direction or Throttle 3 Moisture in above noted digital input switches causing invalid real On Off state Verify input switch status See Programmer System Monitor menu Inputs Switch Status Verify Throttle See Progra...

Page 128: ...ication between left and right motor control sections Clear Repower with CAN wiring problem corrected or replace controller 2712 5 3 User 3 Fault Invalid Motor Type Selection Incompatible motor selected See User 1 fault above Set Invalid Motor Type Selection Clear Select valid Motor Type 2713 5 4 User 4 Fault Front to Back CAN bus fault 1 CAN wiring 2 Damaged Controller See User 1 fault above Set ...

Page 129: ... or Reset Controller 2231 7 3 Stall Detected 1 Stalled motor 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Problems with power supply for the motor encoder See Programmer System Monitor menu AC Motor Motor RPM ShutdownEMBrake ShutdownThrottle ShutdownMotor Control Mode changed to LOS Limited Operating Strategy Set No motor encoder movement detected Clear Either Reset Controller Or if par...

Page 130: ...set Controller 2835 8 3 Internal Hardware Fault Internal controller fault detected ShutdownVehicle ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump Set Internal controller fault detected Clear Reset Controller 2850 8 7 Motor Characterization Error Motor characterization failed during characterization process The fault type indicates the cause ShutdownVehi...

Page 131: ...Set 1 Vehicle movement sensed after the EM Brake has been commanded to set 2 EM Brake will not hold the motor from rotating Position Hold is engaged when Interlock ON Fault Action None unless a fault action is programmed in VCL Set After the EM Brake was commanded to set and time has elapsed to allow the brake to fully engage vehicle movement has been sensed Clear 1 Activate the Throttle EM Brake ...

Page 132: ...eters ShutdownAll ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 to 7 ShutdownPD FullBrake ShutdownPump ShutdownCoilSupply ShutdownVehicle ShutdownLower ShutdownLift Clear Fix parameter mismatch and reset the controller 2332 9 10 Interlock Braking Supervision Fault Type s 1 Motor speed is outside the Interlock Brake Supervision Speed Limit 2 ...

Page 133: ...downDriver1 Set Driver 1 is either open or shorted or Driver 1 exceeded its overcurrent setting Clear Correct the open or short and then Reset Controller 2161 10 2 Driver 2 Fault Fault Type s See Driver 1 Fault See Driver 1 Fault ShutdownDriver2 See Driver 1 Fault 2162 10 3 Driver 3 Fault Fault Type s See Driver 1 Fault See Driver 1 Fault ShutdownDriver3 See Driver 1 Fault 2163 10 4 Driver 4 Fault...

Page 134: ... ShutdownDriver1 to 7 ShutdownPD FullBrake ShutdownPump ShutdownCoilSupply ShutdownVehicle ShutdownLower ShutdownLift Set Short detected after the startup check has passed A low side driver short is detected and the respective fault action fails to cut off driver current Coil supply startup test fails Clear Reset Controller 2620 11 1 Analog 1 Out of Range Fault Type s 1 above High limit 2 below Lo...

Page 135: ... Analog 1 Out of Range 262A 11 11 See Analog 1 Out of Range See Analog 1 Out of Range See Analog 1 Out of Range See Analog 1 Out of Range 2631 11 12 Analog Assignment Fault Fault Type s 13 X Analog Input number that caused the fault X 1 9 14 18 19 31 1 An Analog Input is used for two or more functions 2 An Analog Input is outside the range of analog inputs See Programmer Controller Setup IO Assign...

Page 136: ... Out of Range 2108 12 9 VCL Watchdog The time interval of the VCL watchdog WD exceeded the timeout value See the associated VCL Functions Set_Watchdog_Timeout Set_Watchdog_Fault_Action Kick_Watchdog The fault actions can be defined by the User OEM in the application specific VCL software ShutdownAll Clear Kick_Watchdog Starts and reset the specified watchdog timer 2111 12 10 Autobaud Failure on li...

Page 137: ... Navigation Menus Part No 1307785GT Z 60 DC Z 60 FE 125 Secti on 5 Navigatio n M enus Navigation Menu Top Menus Drive enable switch Drive Joystick Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right ...

Page 138: ...Service and Repair Manual August 2022 Faults Navigation Menu 126 Z 60 DC Z 60 FE Part No 1307785GT Faults Navigation Menu ...

Page 139: ...T EXIT EXIT EXIT SVENSKA NEDERLANDS ITALIANO PORTUGUES LANGUAGE ENGLISH DEUTSCH FRANCAIS ESPANOL OPTIONS DESCENT ALARM EXIT EXIT EXIT EXIT LOW VOLTAGE CUTOUT TRAVEL ALARM MOTION ALARM EXIT POWER SAVE ALARM SELECT BATTERY TYPE EXIT REVISION LEVEL hold 4 SEC 3 SEC 3 SEC POWER UP FAULTS SYSTEM READY GENIE LOGO EXIT ENT SETTINGS FAULTS FUEL LEVEL SENSING EXIT ...

Page 140: ...IT ENT RESET GEN PARAMETER Y N RESET CALIBRATION Y N EXECUTE PARAMETERS RESET Y N RAMP UP TIME MAX FUNCT SPEED MA THRESHOLD CURRENT VALVE SENSOR SETTINGS RESET TO RESET TO DEFAULTS DEFAULTS hold 4 SEC 3 SEC 3 SEC POWER UP SETTINGS FAULTS SYSTEM READY GENIE LOGO EXIT EXIT ANG SENSOR CALIBRATE UTS CALIBRATE hold 4 SEC PUMP EFFICIENCY EXIT RAMP DOWN TIME EXIT AUTHORIZATION EXIT ENT ENTER AUTH CODE DR...

Page 141: ...RAMP EXIT REVERSE DELAY EXIT CENTER ENT ENT ENT ENT ENT ENT EXIT EXIT EXIT LIFT DRIVE PRIORITY MODE PLATFORM LEVEL CUTOUT EXIT EXIT FOOTSWITCH TIME OUT LVI LEVEL CUT OFF MARKET SELECTION EXIT MACHINE TYPE CONFIGURATION EXIT ENT DRIVE LOCKOUT ENT EXIT ENT EXIT CE ENT EXIT ANSI CSA ENT EXIT AUSTRALIA ENT EXIT ENT EXIT NONE LIFT TILT CUTOUT DRIVETILT CUTOUT DRIVE LIFT CUTOUT ENT EXIT ENT EXIT ENT EXI...

Page 142: ...022 Advanced and Drive Navigation Menu 130 Z 60 DC Z 60 FE Part No 1307785GT Advanced and Drive Navigation Menu cont EXIT ENT EXIT ENT EXIT EXIT EXIT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT EXIT ENT EXIT ENT EXIT ENT EXIT ENT EXIT EXIT ...

Page 143: ...the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings w...

Page 144: ...terminal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle Switch DPDT Toggle Switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency Stop button normally closed Resistor with ohm value Battery separator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally...

Page 145: ...sition 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoi...

Page 146: ...ont 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 Drive enab...

Page 147: ... F2 F3 Glow plugs 30A F5 Spare 15A F8 Charger 40A F18 Work lights 7A FS1 Foot switch G Gauge G1 Battery Charge Indicator G2 Engine oil pressure G3 Engine coolant temp G4 Engine oil temp G6 Hour meter Item Description H Horn or Alarm H2 Horn H5 Alarm multifunction JC Joystick JC1 Boom proportional joystick secondary boom up down JC3 Drive steer proportional joystick JC7 Boom proportional joystick p...

Page 148: ... option TS51 Auxiliary pump TS52 Model select TS56 Proximity switch 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 TS69 Recovery 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 c...

Page 149: ...se 3 30A glow plug 3 Circuit breaker 1 15A Engine start Fuel pump 4 Control Relay 64 Engine fault 5 Control Relay 2 Fuel pump 6 Circuit breaker 7 10A Engine RPM 7 Control Relay 1 Engine start 8 Control Relay 15A glow plug 1 9 Fuse 5 15A spare 10Control Relay 15B glow plug 2 11Diode 6A 12Control Relay 4 Engine RPM 13Connector 1 Blue 14Connector 2 Orange ...

Page 150: ... Repair Manual August 2022 12V DC Charger Wiring DC Option 138 Z 60 DC Z 60 FE Part No 1307785GT 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 151: ...August 2022 Service and Repair Manual AC Input Wiring DC Option Part No 1307785GT Z 60 DC Z 60 FE 139 1 AC input wall plug 2 AC input to 48V charger 3 Charger Control IN 4 To 12V charger ...

Page 152: ...ngle Sensor Legend 140 Z 60 DC Z 60 FE Part No 1307785GT 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS18 Platform overload 4 LS3 Drive enable 5 S13 Steer angle sensor inside steer cylinder 6 S19 Secondary angle sensor outside upper pivot ...

Page 153: ...August 2022 Service and Repair Manual 141 Wiring Diagram Options from Z60H 2548 to 2999 ...

Page 154: ...9 10 11 12 12VDC RD C35 CLUTCH P GENERATOR ENGINE CONNECTOR HYBRID MODEL D22 R108ESL WH BK C35RPM BK RD C34SA BK WH C41RPM OR BK C21IGN WH R181PWR OR C33STR BK P181RET OR C222CLU GR WH C27AUX RD BATGND BR 1 2 3 4 5 6 7 8 9 10 11 12 C35 DC MODEL ONLY L LINE N NEUTRAL C60 AUX RLY 24VDC BATTERY CHARGER 12V 5 5A TO CR88 CHARGER SELECT RLY PIN 3 AND 6 PAGE 1 12VDC AUXGND F3 30A F2 30A CONN 1 ORANGE CON...

Page 155: ... BK G2 C26TS RD 53758 D 53760 53761 P F 53759 G1 C25PS BK G2 C26TS RD ENGGND BR C21IGN WH G3 WH BK WH RD WH BR PRES SENSOR TEMP SENSOR 12V BATTERY ENG GND GAUGE OPTION C29 P182BAT RD BATGND BR D82CAN1 YL D81CAN1 GR C56FTS RD C134PWR WH C226TEL BL TELEMATICS C29B P182BAT RD BATGND BK D82CAN1 YL D81CAN1 GR C56FTS RD C134PWR WH C197FE OR C226TEL BL CAN GATEWAY BATGND BK 01 02 03 04 05 06 07 08 01 02 ...

Page 156: ...Service and Repair Manual August 2022 144 Wiring Diagram Options from Z60H 2548 to 2999 ...

Page 157: ...August 2022 Service and Repair Manual 145 Electrical Schematic Options 4WD from Z60H 2548 to 2999 ...

Page 158: ...GR 21 CANTM_H YL 35 CAN0_L 23 CAN0_H DCON RF AC MOTOR CONTROLLER C26 C26 ENCODER BRAKE RIGHT AC MOTOR C39 W V U U V W C26 A B C26 SENGND BK C26TSR WH RD D185SEN WH D186SEN BL P198SEN RD SENGND BK P181RET OR C32BRK WH RD U3A 7 I O GND 8 THERM SENSOR 31 ENCODER A 32 ENCODER B 25 12V PWR 13 COIL RETURN 5 EM BRAKE R181PWR OR SP 9 SP 10 SP 4 SP 3 SP 17 SP 2 D82CAN0 YL D81CAN0 GR SENGND BK C26TSR WH RD ...

Page 159: ...180RET BK 6 12V BATTERY RIGHT REAR CONTROLLER LEFT REAR CONTROLLER RIGHT FRONT CONTROLLER LEFT FRONT CONTROLLER RIGHT REAR DRIVE MOTOR RIGHT FRONT DRIVE MOTOR LEFT REAR DRIVE MOTOR LEFT FRONT DRIVE MOTOR MOTOR CONTROLLER MOTOR GEN 2 FROM 12V BATTERY CHARGER CLUTCH ENGINE STARTER ALT FUSE RELAY MODULE 175A INVERTOR OPTION 1 1 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 10 4 4 2 8 10 10 48766 ...

Page 160: ...Service and Repair Manual August 2022 148 Power Cable Wiring Diagram from Z60H 2548 to 2999 ...

Page 161: ...August 2022 Service and Repair Manual 149 Wiring Diagram FE Models from Z60H 3000 Z60M 1000 ...

Page 162: ...WR OR V191PCE WH RD C241HGP OR R C21IGN WH C33STR BK C180RET BK P110RET E BK C26TSR E WH RD R108ESL WH BK C183RCV BL P181RET E OR C243HML WH C244BML BL C239HMS BL WH P109PWR E RD D185SEN E WH D186SEN E BL KEY SW_KS1 PROPEL RELIEF HV HYB DUMP LOAD RELAY IGNITION RELAY START RELAY PUMP GEN CONT I O GND THERM SENSOR ENGINE STATUS RECOVERY TS HYB COIL RETURN HYBRID MODE LED BAT MODE LED HYB MODE SEL 5...

Page 163: ...IEF HV HYB DUMP LOAD RELAY PUMP GEN CONT I O GND THERM SENSOR RECOVERY TS HYB COIL RETURN 5V PWR ENCODER A ENCODER B D81CAN0 GR D82CAN0 YL D81CAN0 GR D82CAN0 YL TR2 B TR2 A CAN0 CAN0 CAN0 CAN0 FUNC PUMP GEN B A ENCODER U V W C37 5 C37 6 C37 4 C37 3 C37 1 C37 2 COLOR U V W C36 1 C36 2 C36 3 C36 4 C36 5 C36 6 C36 7 C36 8 C36 9 C36 10 C36 11 C36 12 C36 13 C36 14 C36 15 C36 16 C36 17 C36 18 GND 48VDC ...

Page 164: ...Service and Repair Manual August 2022 152 Wiring Diagram DC Models from Z60H 3000 Z60M 1000 ...

Page 165: ...August 2022 Service and Repair Manual 153 Electrical Schematic from Z60H 2548 to 2999 ...

Page 166: ... C26TSR WH RD D185SEN WH D186SEN BL P198SEN RD SENGND BK U1A 7 I O GND 8 THERM SENSOR 31 ENCODER A 32 ENCODER B 25 12V PWR 13 COIL RETURN 6 MAIN CONTACT 34 CAN0TM_L 21 CAN0TM_H 35 CAN0_L GR 23 CAN0_H YL 1 KEY SW_KS1 16 PLAT LEV UD TS 24 HYB MODE SEL 02 HOUR METER ECON AC MOTOR GEN CONTROLLER C34 LS3 DRIVE ENAB C22PWR BK PR1 MAIN CONTACTOR P182BAT RD 14 C134PWR RD C22PWR BK C22PWR BK B7 GND V37SCC ...

Page 167: ... RLY 3 1 TS51 AUX DN TS59 PLAT LEVEL UP BAT ENG TS52 HYBRID MODE DN UP TS58 JIB CW CCW TS62 TT ROTATE P22BAT BK 14 C134PWR RD 14 BATGND BR 14 SPARE 1 2 3 4 P23PWR WH C41RPM OR C22PWR BK C134PWR RD C171LDS WH BK C27AUX RD BATGND BR R181PWR OR P181PWR OR P182BAT RD P181PWR OR 16 BATGND BR P109PWR GR WH C196PWR YL CR47 GEN KS1 RLY C45GEN GR WH CCW TS57 PLAT ROT CW GROUND BOX GROUND BOX A TELEMATIC C2...

Page 168: ...Service and Repair Manual August 2022 156 Electrical Schematic from Z60H 2548 to 2999 ...

Page 169: ...August 2022 Service and Repair Manual 157 Ground Control Box Wiring Diagram from Z60H 2548 to 2999 ...

Page 170: ...S62 3 C164PES RD WH C3 6 C163PLS BL WH C3 5 C156JUD GR WH C1 3 C16PLF OR RD C2 2 C239HMF BL WH C2 3 C27AUX RD TB 27C C18PRR GR BK C1 12 C165TRS WH RD C1 14 C134PWR RD C47FE WH BK C3 14 C243HML WH C2 9 YL GR P182PWR RD U61 2 MODE SELECT ENG BAT TS52 L44 LED ENGINE L5 LED BATTERY EXT RET C134PWR RD P4 2 TS52 3 P109PWR GR WH C244BML BL C2 10 C174PWR WH TS51 2 C134PWR RD 14 TS57 2 P181PWR OR 14 TB181 ...

Page 171: ...SP4 SP3 SP2 SP1 TB 191 D TB 134 C TB 134 D BASE BOX HARNESS TO SWITCH PANNEL C2 4 FB REF ONLY C29 3 C29 5 C29 6 C5 2 RD 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 R181PWR C171LDS C156JUD C133PLA C45GEN V191PCE C134PWR C22PWR C27AUX C197FE C17PRL C18PRR C174PWR C165TRS D82CAN0 C P23PWR D81CAN0 C BATGND OR 16 WH BK GR WH GR WH GR WH WH RD RD BK RD WH GR GR BK WH WH RD YL WH GR BR 14 PIN 1 2 3 4...

Page 172: ...Service and Repair Manual August 2022 160 Ground Control Box Wiring Diagram from Z60H 2548 to 2999 ...

Page 173: ...August 2022 Service and Repair Manual 161 Platform Control Box Wiring Diagram from Z60H 2548 to 2999 ...

Page 174: ...OR SP12 SGND BR SP12 JSGND BR SP13 162JPW OR JC1 BATGND SP19 BATGND BR C48 14 C13DEL BL RD TS14 TS3 C134PWR RD L1 C18PRR GR BK C48 8 C134PWR RD TS5 2 C196PWR YL TB 2 5V C16PLF OR RD C48 5 P162JPW OR TB 5V SP12 JSGND BR JC1 1 JC3 1 JC7 1 TB0V SP17 D82CAN1 YL SP18 D81CAN1 GR C46HRN BK RD C9 1 P26PWR BK C11 1 BK P2 1 P23PWR WH C9 4 TS1 2 P22BAT BK C8 1 BK P3 3 P23PWR WH P2 2 C163PLS BL WH C46 5 C156J...

Page 175: ...2BAT BK 14 P2 1 C8 2 C134PWR RD 14 TB 134 C9 1 C46HRN BK RD P3 4 C9 2 C27AUX RD TS1 2 C9 3 C171LDS WH BK C10 7 C9 4 P23PWR WH P2 2 C9 5 P182PWR RD F18 C9 12 P48LPS WH RD TS18 3 C9 14 V242HGP WH BK C47 7 C9 9 D82CAN1 YL SP14 C9 10 D81CAN GR SP15 C9 17 V17PRL GR C47 4 C8 3 BATGND BR 14 TB GND C9 13 V241HGP OR RD C47 6 C9 18 V18PRR GR BK C47 5 C10 C11 C8 C9 GND BAT 5V 2 5V 0V 0V SP19 BATGND BR 16 C8 ...

Page 176: ...Service and Repair Manual August 2022 164 Platform Control Box Wiring Diagram from Z60H 2548 to 2999 ...

Page 177: ...August 2022 Service and Repair Manual 165 Electrical Schematic PCON from Z60H 2548 to 2999 ...

Page 178: ...VE JOYSTICK VCON PCON C47 C49 JC1 SECONDARY JOYSTICK DN RIGHT C9 NC NC C46HRN BK RD C27AUX RD P23PWR WH P182PWR RD C56FTS RD D82CAN1 YL D81CAN1 GR NC P49LPS WH RD V241HGP OR RD V242HGP WH BK C45GEN GR WH NC V17PRL GR V18PRR GR BK 6 7 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 C5 C8 P22BAT BK 14 C134PWR RD 14 BATGND BR 14 1 2 3 4 RET TS13 EXT RET TS14 MOTOR SHIFT LOW F18 7A C196PWR YL C46 C10 SW30 PR...

Page 179: ... BATGND BR 14 P181BAT B OR 14 MOLEX 4 DTP 4 1 2 3 01 OUT 02 OUT 03 IN 04 IN 05 ENABLE P182BAT RD 14 BATGND BR 14 BATGND BR 14 P181BAT B OR 14 MOLEX 5 1 2 3 4 C18 C18 C18 01 OUT 02 OUT 03 IN 04 IN 05 ENABLE P182BAT RD 14 BATGND BR 14 BATGND BR 14 P181BAT B OR 14 MOLEX 4 MOLEX 5 1 2 3 4 ENABLE C18 P181BAT B OR 14 1 2 3 4 5 LOAD CELL GTPL GTPL TERMINATOR 120 OHM GATEWAY C17 B C17 A C49 2 C49 1 C46 4 ...

Page 180: ...Service and Repair Manual August 2022 168 CAN BUS Wiring Diagram from Z60H 2548 to 2999 ...

Page 181: ...August 2022 Service and Repair Manual 169 Electrical Schematic DCON from Z60H 3000 Z60M 1000 ...

Page 182: ...OR R181PWR OR D82CAN0 YL D81CAN0 GR C134PWR RD C27AUX RD V191PCE WH RD GND BR R181PWR OR TR4 B TR4 A STEER SENSOR GR YL C35 A C35 C C35 B J26 14 5 13 12 10 6 48V CHARGER J26 7 9 BAT INTLCK2 REAR MOTOR CONTROLLER FRONT MOTOR CONTROLLER CAN0 DC DC CONVERTER 48 26V BR C179RET GR R181PWR OR C35RPM BK RD C16PLF OR RD V191PCE_DC WH RD C183RCV_DC BL D82CAN0 YL D81CAN0 GR C34SA BK WH P198PWR R RD C111LFS ...

Page 183: ... C4 7 C4 8 C4 9 C4 10 C4 11 C4 12 C4 13 C4 14 C4 15 C4 16 C4 17 C4 18 C46HRN WH C27AUX RD C42LS OR RD P23PWR WH P182PWR RD D82CAN1 YL D81CAN1 GR C48LPS WH RD V241HGP OR RD V242HGP WH BK C45GEN GR WH V17PRL GR V18PRR GR BK C7 A C7 B C7 C C7 D C7 E C134PWR RD GND BR D82CAN1 GR D81CAN1 YL P22PWR BK C134PWR RD GND BR BK WH BR BK RD WH BK BL OR BK WH BL BK RD BK YL GR RD WH WH RD OR BK GR WH BL WH BL R...

Page 184: ...Service and Repair Manual August 2022 172 Electrical Schematic GCON from Z60H 3000 Z60M 1000 ...

Page 185: ...August 2022 Service and Repair Manual 173 Electrical Schematic PCON from Z60H 3000 Z60M 1000 ...

Page 186: ... TS DRV ENABLE TS PLAT LVL TS SEC UP DN JY MOTOR SHIFT TS PLAT ROT R TS PLAT ROT L TS HYD FSD INC TS HYD FSD DEC TS CTA PROX N O KEY SWITCH DRV ENABLE LED OVERLOAD LED TILT ALARM LED LCD HEATER DIM CONTROL VCON J14 1 2 3 4 5 6 CAN CAN CAN SHIELD CAN SHIELD CAN CAN J11 1 2 3 4 5 6 7 8 9 10 11 12 GND 24V CAN CAN PRI EXT RET TS FOOT SWITCH CTA PROX N C 5V 0V TT ROT JY STEER JY PRI UP DN JY PCON J12 1...

Page 187: ...D C134PWR RD TO SHEET 2 TO SHEET 1 V8PBR V BK WH V2PBD V RD BK J27 1 2 3 4 24V B CAN CAN TILT SENSOR C134PWR RD GND BR D81CAN1 GR D82CAN1 YL FUEL LEVEL SENSOR C41 A C41 B C41 C RD WH YL WH BK WH C134PWR RD C65FP BL WH GND BR TR3 B TR3 A RD YL BK PRIMARY BOOM ANGLE SENSOR C28 1 C28 2 C28 3 C28 4 GR YL C29 A C29 C C29 B RD WH BK P109PWR GR WH C123PBS RD BK P110RET BK RD YL BK SECONDARY BOOM ANGLE SE...

Page 188: ...Service and Repair Manual August 2022 176 Electrical Schematic TCON from Z60H 3000 Z60M 1000 ...

Page 189: ...August 2022 Service and Repair Manual 177 Wiring Diagram CAN BUS from Z60H 3000 Z60M 1000 ...

Page 190: ...RMETER J1 1 2 CAN0 CAN0 YL GR D82CAN0 YL D81CAN0 GR D82CAN1 YL D81CAN1 GR J21 3 4 20 21 GR YL D81CAN1 GR D82CAN1 YL TR3 B TR3 A J27 3 4 TILT SENSOR TR4 B TR4 A GR YL GR YL J26 10 6 CAN0 CAN0 ECON AC MOTOR GEN CONTROLLER J23 23 35 YL GR FRONT MOTOR CONTROLLER J22 1 23 REAR MOTOR CONTROLLER TCON D82CAN1 YL D82CAN1 GR C49 1 2 VCON PCON C11 4 C11 5 D82CAN1 YL D81CAN1 GR LOAD CELL C157 4 C157 5 C157 3 ...

Page 191: ...August 2022 Service and Repair Manual 179 Hydraulic Schematic ...

Page 192: ...Service and Repair Manual August 2022 180 Z 60 DC Z 60 FE Part No 1307785GT Hydraulic Schematic Z 6 0 DC Z 60 FE Part No 130 778 5GT Service a nd Re pair Ma nual August 2 022 ...

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