Terex Genie Z-45 FE Installation and operating manual

1.
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.

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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.
Contact Us:
http://www.genielift.com
e-mail: [email protected]
Introduction
Copyright © 2019 by Terex Corporation
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.

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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

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Service and Repair Manual
Introduction
Serial Number Legend
Z45EM-001
2020
Z45E M101
123
54
1 Model
2 Facility code
3 Sequence number
4 Serial number (stemped on chassis)
5 Serial label (located under cover)

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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

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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

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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

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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

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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

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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