Terex Genie Z-45 FE Installations- und Betriebsanleitung

Service and Repair Manual

Part No. 1297714GT

Rev 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.

ii Z®-45 DC • Z®-45 FE Part No. 1297714GT

July 2020

Service and Repair Manual

Compliance

Machine Classification

Group B/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical

skills are required to perform most procedures.

However, several procedures require specialized

skills, tools, lifting equipment and a suitable

workshop. In these instances, we strongly

recommend that maintenance 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

communications will be carefully considered for

future printings of this and all other manuals.

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

http://www.genielift.com

e-mail: [email protected]

Introduction

1297714GT Rev A1 July 2020

First Edition, First Printing

"Genie" and "Z" are registered trademarks of Terex

South Dakota, Inc. in the USA and many other countries.

July 2020

Part No. 1297714GT Z®-45 DC • Z®-45 FE iii

Service and Repair Manual

Revision History

Revision Date Section Procedure / 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

iv Z®-45 DC • Z®-45 FE Part No. 1297714GT

July 2020

Service and Repair Manual

Introduction

Serial Number Legend

Z45EM-001

2020

Z45E M101

123

1 Model

2 Facility code

3 Sequence number

4 Serial number (stemped on chassis)

5 Serial label (located under cover)

July 2020

Part No. 1297714GT Z®-45 DC • Z®-45 FE v

Service and Repair Manual

Danger

Failure to obey the instructions and safety rules

in this manual and the appropriate Operator's

Manual on your machine will result in death or

serious injury.

Many of the hazards identified in the

operator's manual are also safety hazards

when maintenance and repair procedures are

performed.

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 tools, lifting

equipment and a suitable workshop.

Safety Rules

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

July 2020

Part No. 1297714GT Z®-45 DC • Z®-45 FE vii

Introduction Introduction................................................................................................ii

Important Information .................................................................................. ii

Find a Manual for this Model ....................................................................... ii

Revision History...........................................................................................iii

Serial Number Legend................................................................................ iv

Section 1 Safety Rules............................................................................................... v

General Safety Rules .................................................................................. v

Section 2 Specifications ............................................................................................ 1

Machine Specifications................................................................................1

Performance Specifications.........................................................................2

Hydraulic Specifications ..............................................................................3

Hydraulic Component Specifications...........................................................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 Joystick Max Speed Setting ...............................14

How to Adjust the Joystick Ramp Rate Setting ...............................16

1-2 How to Calibrate Booms Angle Sensors .............................................18

1-3 How to Clear the fault History..............................................................19

Table of Contents

viii Z®-45 DC • Z®-45 FE Part No. 1297714GT

July 2020

Section 3 Repair Procedures, continued

Platform Components.............................................................................20

2-1 Platform Leveling Cylinder ..............................................................20

2-2 Platform Rotator ..............................................................................21

2-3 Platform Overload System ..............................................................23

2-4 How to Reset Overload Recovery Fault..........................................24

Jib Boom Components ...........................................................................25

3-1 Jib Boom .........................................................................................25

3-2 Boom Lift Cylinder...........................................................................26

Primary Boom Components...................................................................28

4-1 Cable Track.....................................................................................28

How 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...........................................44

How to use the Control System Fault Recovery Switch ..................45

Hydraulic pumps .....................................................................................46

8-1 Function Pump ................................................................................46

How to Check the Function Pump Calibration.................................47

TABLE OF CONTENTS

July 2020

Part No. 1297714GT Z®-45 DC • Z®-45 FE ix

Section 3 Repair Procedures, continued

Manifolds..................................................................................................48

9-1 Function Manifold Components.......................................................49

9-2 Valve Adjustments-Function Manifold.............................................53

How to Adjust the Proportional Relief Valve and Hydraulic Pressure

Sensor.............................................................................................53

How to Adjust the Secondary Boom Down Relief Valve .................54

9-3 Jib Boom / Platform Rotate 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

11-1 Oscillating Axle Cylinders................................................................63

11-2 How to Remove the Steer Cylinder.................................................64

How to Calibrate the Steer Angle Sensor........................................64

TABLE OF CONTENTS

x Z®-45 DC • Z®-45 FE Part No. 1297714GT

July 2020

Section 4 Fault Codes..............................................................................................67

Introduction................................................................................................67

Control System Fault Codes ..................................................................68

Fault Codes Ground Controls....................................................................68

How to Retrieve Control System Fault Codes - Platform Controls............69

Control System Fault Codes......................................................................70

Section 5 Navigation Menus....................................................................................95

Faults Navigation Menu.............................................................................95

Options Navigation Menu ..........................................................................96

Settings Navigation Menu..........................................................................97

Section 6 Schematics...............................................................................................99

Introduction................................................................................................99

Electrical Symbol Legends ......................................................................100

Hydraulic 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

Power Cable Wiring Diagram .................................................................117

Hydraulic Schematics ...........................................................................119

Hydraulic Schematic - DC and FE Models ..............................................120

Electrical Schematics............................................................................121

Electrical Schematic - DC and FE Models...............................................122

Ground Control Box Terminal Strip Wiring Dagram ................................127

TABLE OF CONTENTS

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