Terex Genie Z-60/37 DC Service And Repair Manual
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Terex Genie Z-60/37 DC Service And Repair Manual

Serial number range from z6016n-101 to z6016n-599, from z60n-600
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Service and Repair Manual
Z
-60/37 DC
®
Z
-60/37 FE
®
Serial Number Range
from Z6016N-101 to
Z6016N-599
from Z60N-600
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1271125GT
Rev A6
December 2018

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Summary of Contents for Terex Genie Z-60/37 DC

  • Page 1 Service and Repair Manual Serial Number Range -60/37 DC ® from Z6016N-101 to This manual includes: Z6016N-599 Repair procedures from Z60N-600 Fault Codes -60/37 FE ® Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No.

  • Page 2: Find A Manual For This Model

    Copyright © 2016 by Terex Corporation 1271125GT Rev A, April 2016 First Edition, First Printing Genie and “Z” are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...
  • Page 3 December 2018 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 3/2016 Initial Release 6/2016 Repair Procedures How to Adjust Proportional Relief Valve and Hydraulic Pressure Sensor / Updated 9/2016 Introduction Serial number Legend 12/2016 Schematic Power Cable Wiring Diagram...

  • Page 4: Serial Number Legend

    Service and Repair Manual December 2018 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial number (stamped on chassis) 3 Facility code 6 Serial label (located under cover) From September 1, 2016 1 Model 4 Serial number (stamped on chassis) 2 Facility code...

  • Page 5: Safety Rules

    December 2018 Service and Repair Manual Safety Rules Section 1 Safety R ules 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.
  • Page 6 Service and Repair Manual December 2018 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    December 2018 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ...................
  • Page 8 December 2018 Table of Contents Section 3 Repair Procedures ..................... 12 Introduction ......................12 Cailbration Process Steps ..................14 Platform Controls ....................15 1-1 Platform Controls ................... 15 How to Adjust the Joystick Threshold Setting ..........16 How to Adjust the Joystick Max-out Setting ........... 17 How to Adjust the Joystick Ramp Rate Setting ..........
  • Page 9 December 2018 Table of Contents Secondary Boom Components ................. 36 5-1 Secondary Boom Lift Cylinder ................ 37 Engines ........................ 39 6-1 RPM Adjustment .................... 39 How to Replace the Motor Tach Sensor ............39 Hydraulic Pumps ....................40 7-1 Function Pump ....................40 How to Check the Function Pump Calibration ..........
  • Page 10 December 2018 Table of Contents Section 4 Fault Codes ......................63 Introduction ......................63 Control System Fault Codes ................64 Fault Codes Ground Controls ................64 How to Retrieve Control System Fault Codes - Platform Controls ...... 65 Control System Fault Codes ................66 Section 5 Navigation Menus ....................

  • Page 11: Specifications

    December 2018 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Batteries Type L16G-AC lead acid Tires and wheels Rough terrain AGM dry cell Tire size 355/55D625 Group 903-L16 (Rough terrain) Quantity Tire weight, foam-filled 426 lbs (minimum) (Rough terrain) 193 kg Capacity (lead acid)

  • Page 12: Performance Specifications

    Service and Repair Manual December 2018 Specifications Performance Specifications Hydraulic Oil Specifications Drive speed, maximum Hydraulic Fluid Specifications stowed position Genie specifications require hydraulic oils which are 2WD/4WD models Stowed 4.0 mph designed to give maximum protection to hydraulic 6.44 km/h systems, have the ability to perform over a wide temperature range, and the viscosity index should 40 ft / 6.8 sec...
  • Page 13 December 2018 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit...
  • Page 14 Service and Repair Manual December 2018 Specifications Chevron 5606A Hydraulic Oil Petro-Canada Environ MV 46 Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 15.0 cSt @ 104°F / 40°C...

  • Page 15: Hydraulic Component Specifications

    December 2018 Service and Repair Manual Specifications UCON Hydrolube HP-5046 Fluid Hydraulic Component Properties Specifications ISO Grade Function pump Viscosity index Type 2 section tandem gear pump Kinematic Viscosity cSt @ 149°F / 65°C cSt @ 104°F / 40°C Displacement per revolution cSt @ 0°F / -18°C 1300 (inner pump)

  • Page 16: Manifold Component Specifications

    Service and Repair Manual December 2018 Specifications 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.

  • Page 17: Kubota D1105 Engine Specifications

    December 2018 Service and Repair Manual Specifications Kubota D1105 Engine Fuel injection system Injection pump make Bosch MD Displacement 68.53 cu in Injection pump pressure, 1991 psi 1.123 liters maximum 137 bar Number of cylinders Injection timing 18° BTDC Bore and Stroke 3.07 x 3.09 inches Fuel requirement 78 x 78.4 mm...

  • Page 18: Machine Torque Specifications

    Service and Repair Manual December 2018 Specifications Machine Torque Specifications Machine Component Weights Platform rotator Tire and wheel assembly 429 lbs 195 kg 1-8 center bolt, GR 5 Drive motor and hub 160 lbs Lubricated 480 ft-lbs 73 kg 650 Nm Engine assembly 724 lbs 640 ft-lbs...

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    December 2018 Service and Repair Manual Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed and...

  • Page 20: Torque Procedure

    Service and Repair Manual December 2018 Specifications JIC 37° fittings Torque Procedure Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
  • Page 21 December 2018 Service and Repair Manual Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 22: Repair Procedures

    Service and Repair Manual December 2018 Repair Procedures Section 3 Repair Pr oc edures Machine Configuration: Unless otherwise specified, perform each repair procedure with the machine in the following configuration: · Machine parked on a firm, level surface · Key switch in the off position with the key Observe and Obey: removed ·...

  • Page 23: About This Section

    December 2018 Service and Repair Manual Repair Procedures About This Section Most of the procedures in this section should only be performed by trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem. Perform disassembly procedures to the point where repairs can be completed.

  • Page 24: Cailbration Process Steps

    Service and Repair Manual December 2018 Repair Procedures Verify pump efficiency calibration: Refer to Calibration Process Steps Repair Procedures, How to Calibrate Function Pump. It is required to perform the calibration process if system defaults have been reset or if new software Set hydraulic valve thresholds for turntable has been installed.

  • Page 25: Platform Controls

    December 2018 Service and Repair Manual Platform Controls Platform Controls The platform control box contains two control modules; The VCON is a LCD screen mounted between the secondary boom and drive joysticks. The PCON (platform controller) inside the platform control box communicates with the VCON and controllers located on the turntable of the machine.

  • Page 26: How To Adjust The Joystick Threshold Setting

    Service and Repair Manual December 2018 Platform Controls How to Adj ust the Joystic k Thr eshol d Setting How to Adjust the Threshold Momentarily activate the drive enable toggle switch in the right direction until CALIBRATE Setting TILT SENSOR is shown on the display. The threshold setting is the minimum output current Momentarily activate steer in the right direction at which a function proportional valve can open and...

  • Page 27: How To Adjust The Joystick Max-Out Setting

    December 2018 Service and Repair Manual Platform Controls How to Adj ust the Joystic k Max- out Setting How to Adjust the Maximum 14 Press down on the foot switch and select the toggle switch controlled boom function to be Speed Setting (Hydraulic adjusted.
  • Page 28 Service and Repair Manual December 2018 Platform Controls 14 Release the foot switch and momentarily Momentarily activate the drive enable toggle activate steer in the right direction one time to switch in the right direction until CALIBRATE increase the value by 10 milliamps. Repeat TILT SENSOR is shown on the display.
  • Page 29 December 2018 Service and Repair Manual Platform Controls Low Flow Functions: 20 Activate the boom function again by pressing the foot switch and moving the function switch Hydraulic flow from the pump is fixed, and the in the same direction. Using a stop watch, function speed is controlled by the hydraulic record the full motion function and compare directional control valve.

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

    Service and Repair Manual December 2018 Platform Controls How to Adj ust the Joystic k Ramp R ate Setting How to Adjust the Ramp Rate Momentarily activate the drive enable toggle switch in the right direction until VALVE AND Setting SENSOR SETTINGS is shown on the display.

  • Page 31: How To Calibrate Booms Angle Sensors

    December 2018 Service and Repair Manual Platform Controls 13 Momentarily activate drive enable switch right to save the value. How to Calibrate Booms Angle Result: The alarm will sound indicating the Sensors setting has been saved. Continue to the next desired Ramp time adjustment.

  • Page 32: How To Clear The Fault History

    Service and Repair Manual December 2018 Platform Components Momentarily activate steer in the right direction until BOOM ANGLE CALIBRATE is shown on How to Clear Fault History the display. There are 1 thru 16 fault codes shown in the fault Momentarily activate the drive enable toggle history menu 1 being the most recent displayed.

  • Page 33: Bodily Injury Hazard. Spraying

    December 2018 Service and Repair Manual Platform Components Remove the pin retaining fastener from the slave cylinder rod-end pivot pin. Do not Platform Leveling Cylinder remove the pin. Remove the external snap rings from the slave The slave cylinder and the rotator pivot are the two cylinder barrel-end pivot pin.

  • Page 34: Platform Rotator

    Service and Repair Manual December 2018 Platform Components How to Bleed the Platform Rotator Platform Rotator Note: This procedure will require two people. Do not start the engine. Use auxiliary power for this How to Remove the Platform procedure. Rotator Move the function enable toggle switch to either side and activate the platform rotate Component damage hazard.

  • Page 35: Platform Overload System

    December 2018 Service and Repair Manual Platform Components Open the bottom bleed screw on the rotator, but do not remove it. Platform Overload System (if equipped) Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic How to Calibrate the Platform connections very slowly to allow the oil pressure to dissipate Overload System...
  • Page 36 Service and Repair Manual December 2018 Platform Components Move the platform up and down by hand, so it Using auxiliary power, test all machine bounces approximately 2.5 to 5 cm / 1 to functions from the ground controls. 2 inches. Allow the platform to settle. Result: All ground control functions should Result: The overload indicator lights are off operate.

  • Page 37: How To Reset Overload Recovery Message

    December 2018 Service and Repair Manual Platform Components How to Reset Overload Recovery Faults The message OVERLOAD RECOVERY will be displayed when a platform overload recovery occurs under auxiliary power. The message will persist until the reset overload recovery procedure is performed.

  • Page 38: Jib Boom Components

    Service and Repair Manual December 2018 Jib Boom Components Slide both of the jib boom leveling arms off of the jib boom cylinder rod-end pivot pin. Jib Boom Remove the hose and cable cover from the How to Remove the Jib Boom side of the jib boom.

  • Page 39: Jib Boom Lift Cylinder

    December 2018 Service and Repair Manual Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin out enough to lower Jib Boom Lift Cylinder one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite How to Remove the Jib Boom Lift leveling arm.

  • Page 40: Primary Boom Components

    Service and Repair Manual December 2018 Primary Boom Components Tag and disconnect the wire connectors from the bottom of the platform control box. Cable Track Note: When installing the wire connectors to the The primary boom cable track guides the cables bottom of the platform control box, match the color and hoses running up the boom.

  • Page 41: How To Repair The Cable Track

    December 2018 Service and Repair Manual Primary Boom Components How to R epair the C abl e Tr ac k How to Repair the Cable Track Primary Boom Component damage hazard. The boom cable track can be damaged if it is twisted. How to Remove the Primary Boom Note: A cable track repair kit is available through...

  • Page 42: How To Disassemble The Primary Boom

    Service and Repair Manual December 2018 Primary Boom Components Remove the retaining fasteners from the 13 Remove the retaining fasteners from the master cylinder rod-end pivot pin. Use a soft primary boom pivot pin. metal drift to remove the pin. Lower the master 14 Remove the primary boom pivot pin with a soft cylinder against the primary lift cylinder.

  • Page 43: Primary Boom Lift Cylinder

    December 2018 Service and Repair Manual Primary Boom Components Support the rod end and the barrel end of the primary boom lift cylinder with a second Primary Boom Lift Cylinder overhead crane or similar lifting device. The primary boom lift cylinder raises and lowers the Tag, disconnect and plug the primary boom lift primary boom.

  • Page 44: Primary Boom Extension Cylinder

    Service and Repair Manual December 2018 Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Primary Boom Extension Cylinder fittings on the cylinder. Bodily injury hazard. Spraying The primary boom extension cylinder extends and hydraulic oil can penetrate and retracts the primary boom extension tube.The primary boom extension cylinder is equipped with...

  • Page 45: Platform Leveling Master Cylinder

    December 2018 Service and Repair Manual Primary Boom Components Remove the retaining fasteners from the master cylinder barrel-end pivot pin. Platform Leveling Master Cylinder Use a soft metal drift to remove the pin. The master cylinder acts as a pump for the slave Remove the retaining fastener from the cylinder.

  • Page 46: Secondary Boom Components

    Service and Repair Manual December 2018 Secondary Boom Components Secondary Boom components 6 secondary boom lift cylinder 1 master cylinder 7 lower compression arm 2 primary boom lift cylinder 8 lower tension arms 3 upper compression arms 9 upper tension arm 4 mid-pivot 10 upper pivot 5 timing link...

  • Page 47: Secondary Boom Lift Cylinder

    December 2018 Service and Repair Manual Secondary Boom Components Attach a lifting strap from an overhead crane (5 ton / 5000 kg) to the pivot end of the primary Secondary Boom Lift Cylinder boom for support. Do not apply lifting pressure. There is one secondary boom lift cylinder Crushing hazard.
  • Page 48 Service and Repair Manual December 2018 Secondary Boom Components Lower the cylinder onto the lower compression arm. Remove the six fasteners securing the cap on the rod-end of the lift cylinder through the access hole of the lower compression arm. Note: When installing the lift cylinder, torque the cap fasteners to 110 ft-lbs / 149 Nm dry.

  • Page 49: Engines

    December 2018 Service and Repair Manual Engines How to R eplac e the M otor Tach Sens or How to Replace the Motor Tach Sensor RPM Adjustment Remove the fastener under the engine tray Refer to Maintenance Procedure in the appropriate and pull the engine out.

  • Page 50: Hydraulic Pumps

    Service and Repair Manual December 2018 Hydraulic Pumps 2 Tag, disconnect and plug function pump hydraulic hoses. Cap the fittings on the pump. Function Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Function burn skin. Loosen hydraulic connections very slowly to allow Pump the oil pressure to dissipate...

  • Page 51: How To Check The Function Pump Calibration

    December 2018 Service and Repair Manual Hydraulic Pumps How to C hec k the F unction Pump C alibr ati on Momentarily activate the drive enable toggle How to Check the Function Pump switch in the right direction until you see the Calibration VALVE AND SENSOR SETTINGS screen.

  • Page 52: Manifolds

    Service and Repair Manual December 2018 Manifolds This page intentionally left blank Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 53: Function Manifold Components

    December 2018 Service and Repair Manual Manifolds Function Manifold Components The function manifold is located on the turntable next to the ground controls. Index Schematic Description Function Torque Item Flow control valve, pressure compensated Oscillate circuit 33-37 ft lbs / 45-50 Nm Solenoid valve, 3 position 4 way Primary boom extend/retract 24-26 ft lbs / 32-35 Nm...
  • Page 54 Service and Repair Manual December 2018 Manifolds Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...
  • Page 55 December 2018 Service and Repair Manual Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Primary boom up/down 18-20 ft lbs / 25-27 Nm Diagnostic port, (TP2) Testing Diagnostic port, (TP3) Testing Diagnostic port, (TP4) Testing Check valve...
  • Page 56 Service and Repair Manual December 2018 Manifolds Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 57: Valve Adjustments - Function Manifold

    December 2018 Service and Repair Manual Manifolds Simultaneously activate the platform rotate toggle switch to store the value. Valve Adjustments - Result: The control system will continue to the Function Manifold next calibration procedure value - (3000 PSI / 207 bar). How to Adj ust the Pr oportional Reli ef Val ve and H ydraulic Pr ess ure Sensor How to Adjust the Proportional Simultaneously activate the platform level...

  • Page 58: How To Adjust The Platform Level Up Relief Valve

    Service and Repair Manual December 2018 Manifolds How to Adj ust the Pl atfor m Level U p R elief Val ve Locate and remove the cap from the platform How to Adjust the Platform Level level up relief valve. Refer to Repair Relief Valves Procedures, Function Manifold Components.

  • Page 59: How To Adjust The Primary Boom Extend Relief Valve

    December 2018 Service and Repair Manual Manifolds How to Adj ust the Pri mar y Boom Extend R elief Val ve How to Adjust the Primary Boom Repeat this procedure beginning with step 4 to confirm the relief valve pressure. Extend Relief Valve 10 Reinstall the proportional valve coil.

  • Page 60: Jib Boom / Platform Rotate Manifold Components

    Service and Repair Manual December 2018 Manifolds Jib Boom / Platform Rotate Manifold Components The jib boom / platform rotate manifold is mounted to the platform support. Index Schematic Description Function Torque Item Solenoid Valve, 2 position Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm 3 way Z®-60/37 DC •...

  • Page 61: Turntable Rotation Manifold Components

    December 2018 Service and Repair Manual Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the center of the turntable. Index No. Description Schematic Item Function Counterbalance valve Turntable rotate right Counterbalance valve Turntable rotate left Shuttle valve...

  • Page 62: Oscillate Directional Valve Manifold Components

    Service and Repair Manual December 2018 Manifolds Oscillate Directional Valve Manifold Components The directional valve manifold is mounted inside the drive chassis at the non-steer end. Index No. Description Schematic Item Function Torque Breather 20-25 ft-lbs / 27-33 Spool valve Directional control Z®-60/37 DC •...

  • Page 63: How To Set Up The Oscillate Directional Valve

    December 2018 Service and Repair Manual Manifolds How to Adj ust the Oscill ate R educing Val ve How to Adjust the Oscillate How to Set Up the Oscillate Reducing Valve Directional Valve Linkage Note: Perform this procedure on a firm, level surface with the machine in the stowed position.

  • Page 64: Electrocution/Burn Hazard

    Service and Repair Manual December 2018 Manifolds Adjust the internal hex socket. Turn it clockwise to increase the pressure or Valve Coils counterclockwise to decrease the pressure. Install the relief valve cap. How to Test a Coil Tip-over hazard. Do not adjust the relief valve higher than A properly functioning coil provides an specified.

  • Page 65: How To Test A Coil Diode

    December 2018 Service and Repair Manual Manifolds How to T est a Coil Di ode How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 66: Turntable Rotation Components

    Service and Repair Manual December 2018 Turntable Rotation Components Loosen the backlash pivot plate and adjustment bolts. Turntable Rotation Assembly How to Remove the Turntable Rotation Assembly Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.
  • Page 67 December 2018 Service and Repair Manual Turntable Rotation Components How to Adjust the Turntable Remove the backlash pivot plate mounting bolts. Carefully remove the drive hub assembly Rotation Gear Backlash from the machine. The turntable rotation drive hub is mounted on an Crushing hazard.

  • Page 68: How To Replace The Universal Tilt Sensor

    Service and Repair Manual December 2018 Turntable Rotation Components Push the backlash pivot plate towards the turntable as far as possible (this will push the How to Replace the Universal Tilt rotation gear into the turntable bearing ring Sensor (UTS) gear).

  • Page 69: How To Calibrate The Universal Tilt Sensor

    December 2018 Service and Repair Manual Turntable Rotation Components How to C alibr ate the Uni vers al Tilt Sens or How to Calibrate the Universal Tilt Sensor (UTS) Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Refer to Navigation Menus, Settings Menu.

  • Page 70: Axle Components

    Service and Repair Manual December 2018 Axle Components 10-1 Attach a lifting strap from an overhead crane to the barrel end of the oscillating cylinder. Oscillating Axle Cylinders Remove the pin retaining fasteners from the The oscillating axle cylinders extend and retract barrel-end pivot pin.

  • Page 71: How To Remove The Steer Cylinder

    December 2018 Service and Repair Manual Axle Components How to C alibr ate the Steer Angle Sensor 10-2 How to Calibrate the Steer Angle How to Remove the Steer Sensor Cylinder Note: Perform this procedure on a firm, level surface with the machine in the stowed position. Adjust the steer tires so they are in a straight Refer to Navigation Menus, Settings Menu.
  • Page 72 Service and Repair Manual December 2018 This page intentionally left blank. Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 73: Fault Codes

    December 2018 Service and Repair Manual Fault Codes Section 4 Faul t Codes 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 test equipment are available and ready for use.

  • Page 74: Control System Fault Codes

    Service and Repair Manual December 2018 Control System Fault Codes Both Engine Hours and DC Function Enable Hours Fault Codes Ground Controls will be tracked. DC Function enable hours will be displayed on the smart hour meter by default. Standard Genie fault codes shall be displayed and Engine Hours will be displayed if the hybrid mode the red LED will illuminate when any faults are select switch is held for three (3) seconds.

  • Page 75: How To Retrieve Control System Fault Codes - Platform Controls

    December 2018 Service and Repair Manual Control System Fault Codes How to Retrieve Control System To access fault history list: Fault Codes from the Platform Momentarily activate the drive enable toggle Controls switch in the right direction until ACTIVE FAULTS is shown on the display. At least one fault code is present when the alarm at 10 Activate the steer rocker switch in the right the platform controls produces one short beep...

  • Page 76: Control System Fault Codes

    Service and Repair Manual December 2018 Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Stuck ON Release foot switch and recycle power 21 Fault (on @ power Verify: (when activated) Platform controlled · 24V supply on C11-1 15 FOOT SWITCH functions disabled (P22PWR WH)
  • Page 77 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Open Circuit or · Check Ohms 12 Value too high Ohms > 35 PRIMARY DOWN Associated ·...
  • Page 78 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component Name Cause Effect Solution Open Circuit or · Check Ohms Value too high Ohms > 35 SECONDARY Associated · Verify no open/short circuit DOWN VALVE function disabled across TCON C20-8 BK &...
  • Page 79 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component Name Cause Effect Solution Open Circuit or · Check Ohms Value too high Ohms > 35 · Verify no open/short LARGE PUMP Associated circuit across PCON...
  • Page 80 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution 59 Right Rear Drive Verify: Controller No CAN 48V on C25-1, C25-11, No response Drive disabled communication C25-12 (R181PWR Note: Left Rear, Left...
  • Page 81 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Type Error Source ID Component Name Cause Effect Solution 59 Right Rear Drive Verify: Controller No CAN 48V on C25-1, C25-11, No response Drive disabled communication C25-12 (R181PWR Note: Left Rear, Left...
  • Page 82 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution 11 Shorted to supply Verify: · 5V at Jc3-2 (P162PJW OR) 16 Value at 0V ·...
  • Page 83 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution 11 Shorted to supply >4850 mV · elevated drive Verify: speed · 5V from TCON 16 Value at 0v ·...
  • Page 84 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Relay Contact Verify: Stuck · Relay is in operable · Platform Estop condition detected when ·...
  • Page 85 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Verify: · 24V supply on (+) Charger Terminal No CAN No response configuration not · B- on (-) Terminal communication possible ·...
  • Page 86 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution · Replace battery pack Safety limit exceeded, possible · Check DC connections causes: · Disconnect parasitic ·...
  • Page 87 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution · Remove and re-insert the USB Drive There has been a problem · If the condition persists 17 USB error mounting or unmounting the then remove AC and...
  • Page 88 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Connect charger to an AC source that provides AC source is unstable. Could stable AC between 85 - Low AC voltage oscillation be caused by undersized 270 VAC / 45-65 HZ.
  • Page 89 December 2018 Service and Repair Manual Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Check if sensor is Battery temperature sensor connected correctly if is required by charge profile alarm is shown or ensure Battery Temperature (battery temperature...
  • Page 90 Service and Repair Manual December 2018 Control System Fault Codes Control System Fault Codes Error Source Error Type ID Component ID Name Cause Effect Solution Verify: · Proper operation engine hi RPM solenoid Engine Speed · Proper engine RPM 12 Value too high higher than setting: setting...

  • Page 91: Navigation Menus

    December 2018 Service and Repair Manual Control System Fault Codes Section 5 Navigati on Menus Navigation Menu - Top Menus Drive enable Drive Joystick switch Drive enable switch left Drive enable switch right Drive joystick left Drive joystick right Part No. 1271125GT Z®-60/37 DC •...

  • Page 92: Faults Navigation Menu

    Service and Repair Manual December 2018 Faults Navigation Menu Faults Navigation Menu Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 93: Options Navigation Menu

    December 2018 Service and Repair Manual Options Navigation Menu Options Navigation Menu Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...

  • Page 94: Settings Navigation Menu

    Service and Repair Manual December 2018 Settings Navigation Menu Settings Navigation Menu Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 95: Schematics

    December 2018 Service and Repair Manual Schematics Section 6 Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall be watches and other jewelry.

  • Page 96: Electrical Symbol Legend

    Service and Repair Manual December 2018 Electrical Symbol Legend Battery Coil, solenoid or relay Horn or alarm Flashing beacon Gauge Diode Hour meter Fuse with amperage Foot switch T-circuits connect Limit Switch Power relay Coil with suppression Fuel or RPM solenoid T-circuits connect at Circuits crossing - no Quick disconnect...

  • Page 97: Hydraulic Symbols Legend

    December 2018 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Shut off valve Brake Pump, bi-directional Motor, 2 speed Pump, fixed displacement Motor, bi-directional variable displacement bi-directional Pump, prime mover (engine Shuttle valve. 2 position, Double acting cylinder Differential sensing valve or motor) 3 way...

  • Page 98: Electrical Component And Wire Color Legends

    Service and Repair Manual December 2018 Electrical Component and Wire Color Legends Item Drive enable limit switch Description Left front AC motor to front MC harness Battery Right front AC motor to front MC harness Engine Start - 12V DC Left rear AC motor to rear MC harness Left/Right side battery packs, 48V DC Right rear AC motor to rear MC harness...
  • Page 99 December 2018 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Circuit Breaker Horn or Alarm Engine power, 15A Tilt / Platform overload Controls power, 24V DC, 15A Horn Charger box 12V, 10A Alarm (multifunction) Master, 48V DC, 10A Joystick Telematic, 5A (option)
  • Page 100 Service and Repair Manual December 2018 Electrical Component and Wire Color Legends TS58 Jib boom up/down Item Description TS59 Platform level up/down Motor TS60 Secondary boom up/down Function pump motor/generator TS61 Primary boom up/down Auxiliary pump TS62 Turntable rotate Engine starter TS63 Primary boom extend/retract Button...

  • Page 101: Kubota Engine Fuse And Relay Module

    December 2018 Service and Repair Manual Kubota Engine Fuse and Relay Module Kubota D1105-E4B 1 Fuse 1 - 15A (spare) 2 Fuse 3 - 30A glow plug 3 Circuit breaker 1 - 15A Engine start / Fuel pump 4 Control Relay 64 Engine fault 5 Control Relay 2 Fuel pump 6 Circuit breaker 7 - 10A Engine RPM 7 Control Relay 1 Engine start...

  • Page 102: Dc Charger Wiring (Dc Option)

    Service and Repair Manual December 2018 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 Z®-60/37 DC • Z®-60/37 FE Part No.

  • Page 103: Ac Input Wiring (Dc Option)

    December 2018 Service and Repair Manual AC Input Wiring (DC Option) 1 AC input wall plug 2 AC input to 48V charger 3 Charger Control IN 4 To 12V charger Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...

  • Page 104: Can Bus Wiring Diagram - Dc Models

    Service and Repair Manual December 2018 CAN BUS Wiring Diagram - DC Models Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 105: Limit Switch/Angle Sensor Legend

    December 2018 Service and Repair Manual Limit Switch/Angle Sensor Legend 1 S17 Primary angle sensor 2 LS1 Boom extend limit switch 3 LS18 overload 4 LS3 Drive enable 5 S13 Steer Angle sensor (inside steer cylinder) 6 S19 Secondary angle sensor (inside upper-pivot) Part No.
  • Page 106 Service and Repair Manual December 2018 This page intentionally left blank. Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 107: Electrical Schematics - Options

    December 2018 Service and Repair Manual Wiring Diagram - Options...

  • Page 108: Wiring Diagram - Options

    Service and Repair Manual December 2018 Wiring Diagram - Options Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 109: Schematics - Options, 4Wd, Dc And Fe Models

    December 2018 Service and Repair Manual Schematics - Options, 4WD, DC and FE Models Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...
  • Page 110 Service and Repair Manual December 2018 Schematics – Options 4WD, DC and FE Models...
  • Page 111 December 2018 Service and Repair Manual Power Cable Wiring Diagram...

  • Page 112: Power Cable Wiring Diagram

    Service and Repair Manual December 2018 Power Cable Wiring Diagram Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 113: Hydraulic Schematics

    December 2018 Service and Repair Manual Hydraulic Schematic, DC and FE Models...
  • Page 114 Service and Repair Manual December 2018 Hydraulic Schematic, DC/FE Models Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 115: Electrical Schematics

    December 2018 Service and Repair Manual Electrical Schematic, DC/FE Models...

  • Page 116: Electrical Schematics, Dc/Fe Models

    Service and Repair Manual December 2018 Electrical Schematic, DC/FE Models Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...
  • Page 117 December 2018 Service and Repair Manual Electrical Schematic, DC/FE Models Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...
  • Page 118 Service and Repair Manual December 2018 Electrical Schematic, DC/FE Models...
  • Page 119 December 2018 Service and Repair Manual Electrical Schematic, DC/FE Models Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...
  • Page 120 Service and Repair Manual December 2018 Electrical Schematic, DC/FE Models...
  • Page 121 December 2018 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram, DC/FE Models...

  • Page 122: Ground Control Box Terminal Strip Wiring Diagram

    Service and Repair Manual December 2018 Ground Control Box Terminal Strip Wiring Diagram, DC/FE Models Z®-60/37 DC • Z®-60/37 FE Part No. 1271125GT...

  • Page 123: Platform Control Box Wiring Diagram

    December 2018 Service and Repair Manual Platform Control Box Wiring Diagram, DC/FE Models Part No. 1271125GT Z®-60/37 DC • Z®-60/37 FE...
  • Page 124 Service and Repair Manual December 2018 Platform Control Box Wiring Diagram, DC/FE Models Z®-60/37 DC • Z®-60/37 F E Part No. 1271125GT Ser vic e and R epair M anual December 2018...

This manual is also suitable for:

Genie z-60/37 feGenie z-60 dcGenie z-60 fe

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