Terex Genie Z-33/18 Service And Repair Manual
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Terex Genie Z-33/18 Service And Repair Manual

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1.
Service and Repair Manual
®
Z
-33/18
DC Power
Serial Number Range
From Z331815M-101 to
Z331816M-1299
From Z3318M-1300
to Z3318M-2668
From Z3318M-2669
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. 1268514GT
Rev A4
January 2020

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Summary of Contents for Terex Genie Z-33/18

  • Page 1 Service and Repair Manual Serial Number Range This manual includes: From Z331815M-101 to ® -33/18 Z331816M-1299 Repair procedures DC Power Fault Codes From Z3318M-1300 to Z3318M-2668 Electrical and Hydraulic Schematics From Z3318M-2669 For detailed maintenance procedures, Refer to the appropriate Maintenance Manual for your machine.
  • Page 2 Copyright © 2019 by Terex Corporation 1268514GT Rev A4 January 2020 First Edition, First Printing "Genie" and "Z" are registered trademarks of Terex South Dakota, Inc. in the USA and many other countries. Printed on recycled paper ®...

  • Page 3: Table Of Contents

    January 2020 Revision History Revision Date Section Procedure / Page / Description 09/2015 Initial Release 06/2016 Section 2 Specifications 2-3, 2-4 06/2016 Section 3 Repair Procedure 3-37, 3-40 06/2016 Section 4 Fault Codes 4-12 06/2016 Section 5 Schematics 5-4, 5-5, 5-6, 5-7, 5-8, 5-9, 5-10, 5-11, 5-12 09/2016 Introduction Serial Number Legend...

  • Page 4: Revision Date

    January 2020 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Section 2_Specifications, Machine Specifications Section 3_Repair Procedure, 3-2 Click on any procedure or page number Section 4_Fault Codes, 4-4 highlighted in blue to view the update. Section 5_Schematics, 5-7 ®...

  • Page 5: Serial Number Legend

    January 2020 Serial Number Legend To August 31, 2016 Z3318 15 M - 0101 Model: Serial number: Z331815M-0101 Manufacture date: 1/2/15 Model year: 2015 Electrical schematic number: Machine unladen weight: Rated work load (including occupants): Maximum number of platform occupants: Maximum allowable side force: Maximum allowable inclination of the chassis: 1 Model...
  • Page 6 January 2020 This page intentionally left blank. ® -33/18 Part No. 1268514GT...

  • Page 7: Safety Rules

    January 2020 Section 1 • Safety Rules Safety Rules 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 8 January 2020 Section 1 • Safety Rules SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.
  • Page 9 January 2020 Table of Contents Introduction Important Information .................. ii Revision History...................iii Serial Number Legend................. v Section 1 Safety Rules General Safety Rules .................vii Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications ..............2 - 2 Hydraulic Specifications .................2 - 3 Hydraulic Component Specifications ............2 - 5 Manifold Component Specifications ............2 - 5 Machine Torque Specifications ..............2 - 6...

  • Page 10: Repair Procedure

    January 2020 TABLE OF CONTENTS Section 3 Repair Procedures, continued Platform Components Platform Leveling Slave Cylinder ..........3 - 13 Platform ..................3 - 14 Platform Overload System ............3 - 14 Platform Overload Recovery Message........3 - 16 Primary Boom Components Cable Track ................3 - 17 Primary Boom................3 - 19 Primary Boom Lift Cylinder............3 - 22 Primary Boom Extension Cylinder..........3 - 23...

  • Page 11: Schematics

    January 2020 TABLE OF CONTENTS Section 3 Repair Procedures, continued Steer Angel Sensor ..............3 - 44 Non-steer Axle Components Drive Motots ................3 - 48 Drive Brake.................3 - 49 Motor Controller 10-1 Motor Controllers ................3 - 50 Section 4 Fault Codes Introduction .....................4 - 1 Control System Fault Codes..............4 - 2 Control System Fault Code Charts ............4 - 4...
  • Page 12 January 2020 This page intentionally left blank. ® -33/18 Part No. 1268514GT...

  • Page 13: Specifications

    January 2020 Section 2 • Specifications Specifications Machine Specifications Fluid capacities Hydraulic tank 6 gallons 20,8 liters Tires and wheels Hydraulic system 8 gallons Tire size (22x9x17 in) (including tank) 28,4 liters (solid rubber) 56x23x43 cm Drive hubs 23 fl oz Overall tire 22 in 0,68 liters...

  • Page 14: Performance Specifications

    January 2020 Section 2 • Specifications SPECIFICATIONS Performance Specifications Boom function speeds (from platform controls and one operator on the platform) Drive speed, stowed 3.23 mph Primary boom up, retracted 36 to 40 seconds 5,2 km/h (-43° to 71°) 40 ft / 8.5 sec Primary boom down, retracted 46 to 50 seconds 12,2 m / 8,5 sec...

  • Page 15: Hydraulic Specifications

    January 2020 Section 2 • Specifications SPECIFICATIONS Hydraulic Specifications Do not top off with incompatible NOTICE hydraulic fluids. Hydraulic fluids may be incompatible due to Hydraulic Oil Specification the differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 16 January 2020 Section 2 • Specifications SPECIFICATIONS Chevron Rando HD Premium Petro-Canada Environ MV 46 Oil MV 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 33.5 cSt @ 104°F / 40°C...

  • Page 17: Hydraulic Component Specifications

    January 2020 Section 2 • Specifications SPECIFICATIONS Hydraulic Components Manifold Component Specifications Specifications Functions Pump Plug Torque Type: fixed displacement gear SAE No. 2 36 in-lbs / 4 Nm pump SAE No. 4 10 in-lbs / 13 Nm Displacement 0.244 cu in SAE No.

  • Page 18: Machine Torque Specifications

    January 2020 Section 2 • Specifications SPECIFICATIONS Machine Torque Specifications Axles M16x2 mounting bolt, GR 166 ft-lbs 8.8 (dry) 226 Nm M16x2 mounting bolt, GR 125 ft-lbs 8.8 (lubricated) 170 Nm M20 x 2.5 steer link bolt, 180 ft-lbs GR 8.8 (dry) 244 Nm M20 x 2.5 steer link bolt, 140 ft-lbs...

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    January 2020 Section 2 • Specifications SPECIFICATIONS Hydraulic Hose and Fitting SAE O-ring Boss Port (tube fitting - installed into Aluminum) Torque Specifications (all types) SAE Dash size Torque Your machine is equipped with Parker Seal-Lok™ ORFS or 37° JIC fittings and hose ends. 14 ft-lbs / 19 Nm Genie specifications require that fittings and hose 23 ft-lbs / 31.2 Nm...

  • Page 20: Torque Procedure

    January 2020 Section 2 • Specifications SPECIFICATIONS Torque Procedure Seal-Lok fittings 1 Replace the O-ring. The O-ring must be replaced anytime the seal has been broken. The O-ring cannot be re-used if the fitting or hose end has been tightened beyond finger Figure 1 tight.
  • Page 21 January 2020 Section 2 • Specifications SPECIFICATIONS SAE FASTENER TO RQ UE C HART • Thi s chart i s t o be used as a gui de onl y unl ess not ed el sew here i n t hi s m anual • A 574 Hi gh St rengt h G r ade 5 G r ade 8...
  • Page 22 January 2020 Section 2 • Specifications This page intentionally left blank. 2-10 ® -33/18 Part No. 1268514GT...

  • Page 23: Repair Procedures

    January 2020 Section 3 • Repair Procedures Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

  • Page 24: Platform Controls

    Section 3 • Repair Procedures January 2020 Platform Controls The control system consists of a platform controller (PCON) located inside the platform control box, a turntable controller (TCON) located below the ground control box and two AC inverter/ motor controllers. Input from the operator at the platform controls is communicated to the turntable controller (TCON) for processing via a CAN BUS connection.
  • Page 25 January 2020 Section 3 • Repair Procedures PLATFORM CONTROLS RESSING THE RESSING THE SWITCH OVING THE SWITCH IN THE LEFT OVING THE SWITCH IN THE LEFT IN THE RIGHT DIRECTION DIRECTION EXITS THE CURRENT SWITCH IN THE " ") DIRECTION SCROLLS SCROLLS FORWARD MENU EQUAL TO...
  • Page 26 Section 3 • Repair Procedures January 2020 PLATFORM CONTROLS The joysticks on this machine utilize digital Hall Effect technology for proportional control. If a joystick is disconnected or replaced, its calibration is calculated by control system following an automatic procedure. ®...
  • Page 27 January 2020 Section 3 • Repair Procedures PLATFORM CONTROLS Toggle switch controlled functions: Begin this procedure with the rotary speed control at the plaform controls turned fully in the counterclockwise direction. The threshold setting of a function is the minimum output at which a function proportional valve can 10 Press down on the foot switch and activate the open and allow the function to operate.
  • Page 28 Section 3 • Repair Procedures January 2020 PLATFORM CONTROLS 5 When the display leaves SYSTEM READY mode, release the drive enable toggle switch and the steer rocker switch. Result: The display will show FAULTS. The maximum speed setting of a joystick and toggle switch controls the maximum speed of a 6 Momentarily activate the steer rocker switch in machine function.
  • Page 29 January 2020 Section 3 • Repair Procedures PLATFORM CONTROLS 13 Release the footswitch. Momentarily activate Low flow functions: the steer rocker in the left direction to decrease the value shown on the display in small 19 Momentarily activate one of the low flow increments.
  • Page 30 Section 3 • Repair Procedures January 2020 PLATFORM CONTROLS 8 Momentarily activate the drive enable toggle switch in the right direction until THRESHOLD is shown on the display. 9 Momentarily activate the steer rocker switch The ramp up time setting of a function controls in the right direction until RAMP UP TIME is the time at which it takes for the function to reach shown on the display.
  • Page 31 January 2020 Section 3 • Repair Procedures PLATFORM CONTROLS 15 When ramp time has been achieved, activate the drive enable toggle switch to the right to save your changes. Result: The alarm should sound indicating the The ramp down time setting of a function controls setting has been saved.
  • Page 32 Section 3 • Repair Procedures January 2020 PLATFORM CONTROLS 8 Momentarily activate the drive enable toggle 15 When ramp time has been achieved, activate switch in the right direction until THRESHOLD the drive enable toggle switch to the right to is shown on the display.
  • Page 33 January 2020 Section 3 • Repair Procedures PLATFORM CONTROLS 9 Using the rocker switch on the drive joystick, momentarily activate steer left, left, right, and left. Result: The alarm will sound. Adjusting the max speed setting will only affect the stowed drive speed.
  • Page 34 Section 3 • Repair Procedures January 2020 PLATFORM CONTROLS 17 Continue at full speed and note the time when the machine reference point passes over the finish line. Release the foot switch. Refer to Section 2, Specifications. Result: The drive speed meets specification. Continue to step 19.

  • Page 35: Platform Components

    January 2020 Section 3 • Repair Procedures Platform Components Bodily injury hazard. Spraying WARNING 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 The slave cylinder and the platform mount are squirt or spray.

  • Page 36: Platform

    Section 3 • Repair Procedures January 2020 PLATFORM COMPONENTS 1 Raise the platform up to 5 ft / 1,5 m. Calibration of the platform overload system is 2 Tag and disconnect the harness clables from essential to safe machine operation. Continued the platform control box.
  • Page 37 January 2020 Section 3 • Repair Procedures PLATFORM COMPONENTS Determine the limit switch trigger point: Confirm the setting: 4 Gently move the platform up and down by 5 Turn the key switch to platform control. hand, so it bounces approximately 1 to 2 inches / 2,5 to 5 cm.
  • Page 38 Section 3 • Repair Procedures January 2020 PLATFORM COMPONENTS 5 When the display leaves SYSTEM READY mode, release the drive enable toggle switch and the steer rocker switch. Result: The display will show FAULTS. 6 Momentarily activate the drive enable toggle switch in the right direction.

  • Page 39: Primary Boom Components

    January 2020 Section 3 • Repair Procedures Primary Boom Components The primary boom cable track guides the cables Note: When removing a hose assembly or fitting, and hoses running up the boom. It can be repaired the O-ring on the fitting and/or hose end must be link by link without removing the cables and replaced and then torqued to specification during hoses that run through it.

  • Page 40: Primary Boom

    Section 3 • Repair Procedures January 2020 PRIMARY BOOM COMPONENTS 3 At the rear of the chassis, open the AC plug. 10 Tag, disconnect and plug the hydraulic hoses Tag and disconnect the wiring from the plug. at the mid pivot end of the cable tray. Cap the Remove the wiring from the clamp.
  • Page 41 January 2020 Section 3 • Repair Procedures PRIMARY BOOM COMPONENTS Bodily injury hazard. This WARNING procedure requires specific repairskills, lifting equipment and a suitable workshop. 1 Extend the boom until the wear pads are Attempting this procedure accessible. without these skills and tools could result in death or serious 2 Loosen the wear pad mounting fasteners.

  • Page 42: Primary Boom Lift Cylinder

    Section 3 • Repair Procedures January 2020 PRIMARY BOOM COMPONENTS 5 Tag, disconnect and plug the primary boom 13 Remove the primary boom pivot pin with a soft extension cylinder hydraulic hoses. Cap the metal drift. Carefully remove the primary boom fittings on the cylinder.

  • Page 43: Primary Boom Extension Cylinder

    January 2020 Section 3 • Repair Procedures PRIMARY BOOM COMPONENTS 7 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin. Complete disassembly of the boom is only necessary if the outer or inner boom tube must be 8 Support and slide the extension cylinder out of...
  • Page 44 Section 3 • Repair Procedures January 2020 PRIMARY BOOM COMPONENTS 5 Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying WARNING The primary boom lift cylinder raises and lowers hydraulic oil can penetrate and the primary boom.
  • Page 45 January 2020 Section 3 • Repair Procedures PRIMARY BOOM COMPONENTS 3 Completely extend the extension cylinder. 4 Support the extension tube with an overhead crane at the platform end of the boom. 5 Tag, disconnect and plug the primary boom The extension cylinder extends and retracts the extension cylinder hydraulic hoses, barrel-end.
  • Page 46 Section 3 • Repair Procedures January 2020 PRIMARY BOOM COMPONENTS 8 Remove the external snap rings from the extension cylinder rod-end pivot pin at the platform end of the extension tube. Use a soft metal drift to remove the pin. 9 Support and slide the extension cylinder out of The platform leveling master cylinder acts as the base end of the extension tube.
  • Page 47 January 2020 Section 3 • Repair Procedures PRIMARY BOOM COMPONENTS 1 Tag, disconnect and plug the master cylinder hydraulic hoses. Cap the fittings on the cylinder. Bodily injury hazard. Spraying WARNING hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 48: Secondary Boom Components

    Section 3 • Repair Procedures January 2020 Secondary Boom Components Remove the mid-pivot 2 Attach a lifting strap of suitable capacity from an overhead crane to the primary lift cylinder. Raise the cylinder to an horizontal position. 3 Tag, disconnect and plug the hydraulic hoses of the primary boom lift cylinder.

  • Page 49: Secondary Boom

    January 2020 Section 3 • Repair Procedures SECONDARY BOOM COMPONENTS Remove the secondary boom Component damage hazard. NOTICE Cables and hoses can be 16 Remove the pin retaining fasteners securing damaged if they are kinked or the secondary link pivot pin to the turntable. pinched.
  • Page 50 Section 3 • Repair Procedures January 2020 SECONDARY BOOM COMPONENTS 24 Remove the secondary boom from the machine letting the hydraulic hoses slide inside. Crushing hazard. The secondary WARNING boom could become unbalanced and fall if not properly supported when removed from the machine.

  • Page 51: Secondary Boom Lift Cylinder

    January 2020 Section 3 • Repair Procedures SECONDARY BOOM COMPONENTS 5 Using a soft metal drift, remove the secondary boom lift cylinder pins. Crushing hazard. The cylinder WARNING could fall if not properly The secondary boom lift cylinder raises and lowers supported when the pivot pins the secondary boom.

  • Page 52: Hydraulic Pumps

    Section 3 • Repair Procedures January 2020 Hydraulic Pumps 6 Remove the drain plug from the hydraulic tank. Completely drain the hydraulic tank into a container of suitable capacity. 7 Tag, disconnect and plug the hydraulic hoses from the auxiliary pump. Cap the fittings on the pump.

  • Page 53: Function Pump

    January 2020 Section 3 • Repair Procedures HYDRAULIC PUMPS 4 Remove the drain plug from the hydraulic tank. Completely drain the hydraulic tank into a container of suitable capacity. 5 Tag, disconnect and plug the hydraulic hoses from the function pump. Cap the fittings on the pump.
  • Page 54 Section 3 • Repair Procedures January 2020 HYDRAULIC PUMPS 8 Momentarily activate the drive enable toggle switch in the right direction to enter the SETTINGS menu. Result: The display will show VALVE AND Calibration of the function pump is essential to PUMP SETTINGS.

  • Page 55: Manifolds

    January 2020 Section 3 • Repair Procedures Manifolds The function manifold is located inside the ground controls side turntable cover. Pos. Description Schematic Function VALVE, PROPORTIONAL, 3 POS, 4-WAY Primary boom up/down VALVE, PROPORTIONAL, 3 POS, 4-WAY Secondary boom up/down VALVE, PROPORTIONAL, 3 POS, 4 WAY Turntable rotate curcuit SAE PLUG...
  • Page 56 Section 3 • Repair Procedures January 2020 MANIFOLDS 3-34 ® -33/18 Part No. 1268514GT...
  • Page 57 January 2020 Section 3 • Repair Procedures MANIFOLDS This procedure must be performed at the ground controls. 1 Turn the key switch to the off position, and push in the red Emergency Stop button to the off position. 2 Connect a 0 to 3000 psi / 0 to 207 bar pressure a green LED gauge to test port TP1 on the function manifold.
  • Page 58 Section 3 • Repair Procedures January 2020 MANIFOLDS 5 Move and hold the primary boom toggle switch 8 Move and hold the secondary boom toggle in the extended direction. Momentarily activate switch in the up direction. the platform level toggle switch in the up direction to increase the relief pressure or in the Result: The pressure gauge shows 2500 psi / down direction to decrease the relief pressure.
  • Page 59 January 2020 Section 3 • Repair Procedures MANIFOLDS 6 Simultaneously activate the platform level toggle switch until the pressure gauge reads 3000 PSI / 207 bar. The platform level toggle up increases pressure, platform level down decreases pressure. 7 Simultaneously activate the platform rotate toggle switch to save the value.
  • Page 60 Section 3 • Repair Procedures January 2020 MANIFOLDS 1 Turn the machine off. Locate the proportional 1 Turn the machine off. Locate the proportional relief valve (item BW) on the function manifold. relief valve (item BW) on the function manifold. Remove the coil nut and remove the coil from Remove the coil nut and remove the coil from the valve cartridge and set aside.

  • Page 61: Valve Coils

    January 2020 Section 3 • Repair Procedures MANIFOLDS Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically A properly functioning coil provides an increase or decrease by 4% for each 18°F / 20°C...
  • Page 62 Section 3 • Repair Procedures January 2020 MANIFOLDS How to Test a Coil Diode COIL Genie incorporates spike suppressing diodes in all MULTI- of its coils. Properly functioning coil diodes protect METER 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 63: Turntable Rotation Components

    January 2020 Section 3 • Repair Procedures Turntable Rotation Components When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during 4 Remove the counterweight bottom screw to installation.

  • Page 64: Turntable Rotation Assembly

    Section 3 • Repair Procedures January 2020 TURNTABLE ROTATION COMPONENTS 10 Tag and disconnect the harness both from the control box and manifold. 11 Tag and disconnect the power cables from the main and auxiliary pumps. 12 Attach a lifting strap from an overhead crane or other suitable lifting device to the two turntable's handles and to the counterweight handle bar.

  • Page 65: Steer Axle Components

    January 2020 Section 3 • Repair Procedures Steer Axle Components When replacing a wheel bearing, both the inner and outer bearings, including the pressed-in races, must be replaced. 1 Loosen the wheel lug nuts. Do not remove 1 Be sure that both bearings are packed with them.
  • Page 66 Section 3 • Repair Procedures January 2020 STEER AXLE COMPONENTS 10 Install a new cotter pin. Bend the cotter pin to lock it in place. Note: Always use a new cotter pin when installing a castle nut. 11 Install the dust cap, then the tire and wheel assembly.
  • Page 67 January 2020 Section 3 • Repair Procedures STEER AXLE COMPONENTS 8 Install the new steer sensor assembly to the yoke pivot pin. Loosely install the cover retaining fasteners. Be sure the sensor activator pin is engaged into 1 Turn the key switch to platform control. the sensor.
  • Page 68 Section 3 • Repair Procedures January 2020 STEER AXLE COMPONENTS 8 Momentarily activate the steer rocker switch in 13 Momentarily activate the drive enable toggle the right direction until you see the CALIBRATE switch in the right direction to enter the CENTER screen.
  • Page 69 January 2020 Section 3 • Repair Procedures STEER AXLE COMPONENTS 18 Momentarily activate the drive enable toggle switch in the right direction to save the setting (if steer sensor mV value is IN RANGE). Result: The alarm should sound indicating the setting has been saved.

  • Page 70: Non-Steer Axle Components

    Section 3 • Repair Procedures January 2020 Non-steer Axle Components The drive motors are AC powered and are a brushless design requiring very little maintenance. They have built-in speed and temperature sensors which are monitored by the turntable controller (TCON) and the platform controller (PCON). The speed sensor is a Hall-effect type and is part of the rear motor shaft bearing.
  • Page 71 January 2020 Section 3 • Repair Procedures NON-STEER AXLE COMPONENTS Proper brake action is essential to safe machine operation. The machine uses drive motor regenerative braking to slow and stop the machine. Spring applied electrically released individual wheel brakes hold the machine once it has stopped.

  • Page 72: Motor Controller

    Section 3 • Repair Procedures January 2020 Motor Controller The motor controllers also control the valve outputs and machine options such as flashing beacon, travel alarm, etc. Refer to Section 5, Fault Codes for a list of fault There are two drive motor controllers located codes and additional information.

  • Page 73: Fault Codes

    January 2020 Section 4 Fault Codes Fault 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 Observe and Obey: equipment are available and ready for use. Be aware of the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices.

  • Page 74: Fault Codes

    Section 4 • Fault Codes January 2020 FAULT CODES To access motor controller faults: 9 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE At least one fault code is present when the service FAULTS is shown on the display. icon is shown on the display.

  • Page 75: Fault Codes

    January 2020 Section 4 Fault Codes FAULT CODES 8 Use the fault code table on the following pages to aid in troubleshooting the machine by pinpointing the area or component affected. Only control system fault codes can be retrieved from TCON. Motor controller fault codes can only 1 Turn the key switch to platform control.

  • Page 76: Control System Fault Code Charts

    Section 4 • Fault Codes January 2020 Control System Fault Code Chart (from S/N Z331815M- 101 to Z3318M-2668) Error Source Error Type Condition Solution Name Name Do not operate machine with Main contactor batteries charging. open or will not Batteries overcharged, exceeds close.
  • Page 77 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Check for 48V DC to main Auxiliary Value too high function pump. Replace right functions only. (master) AC motor controller. Do not operate machine with batteries charging.
  • Page 78 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Shorted high (5V) Primary extend/ Inspect and repair joystick wiring. Value too high retract function PRI_ER_JYSTK Replace joystick. Value too low disabled.
  • Page 79 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Shorted high (5V) Drive function Inspect and repair joystick wiring. Value too high disabled. Replace joystick. DRIVE_JYSTK Value too low Drive joystick. Value at 0V Drive function Calibrate joystick.
  • Page 80 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Do not operate machine with batteries charging. Check cable connections. Drive function Check for 33V AC across any two Value too high disabled.
  • Page 81 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Check can bus circuit for open. Check can bus resistor. All functions No response Isolate all other modules disabled. simultaneously. Replace right AC_R_CTRLR (Master) AC motor controller.
  • Page 82 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Check for 5V DC (GR/WH) at steer sensor. Shorted high Wheel speed Check for 0-5V DC (orange) (5V) correction is output at steer sensor.
  • Page 83 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name With Red Emergency Stop pulled out at ground control, CR62 ESTOP_RELAY should close. Shorted High All functions Emergency Stop Check for 24V DC on 30 and 87 (24V) disabled.
  • Page 84 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Condition Solution Name Name Lift and Drive functions disabled or slowed remotely by GTM Request from Telematics Device. DISABLED BY Lift and Drive contact machine owner OWNER functions disabled...
  • Page 85 January 2020 Section 4 Fault Codes Control System Fault Code Chart (from s/n Z3318M-2669) Error Source Error Type Component Name Cause Effect Solution *Release foot switch and Stuck ON 21 Fault (on @ power up) Platform re-power. controlled *Check for power to PCON Foot Switch functions at C28-6 with foot switch...
  • Page 86 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution Verify: (when activated) *24V created by AUX toggle switch TS1 at platform or ground controls(they are wired in parallel) Aux Pump Active at Stuck ON...
  • Page 87 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution Resistance Open Circuit or *Check for open or short Associated Too High Ohms > 60 Primary Up from TCON (C14-5) to Function Valve the up coil.
  • Page 88 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution Resistance Open Circuit *Check for open or short Associated Too High orOhms > 60 Turntable CCW from TCON (C29-7) to Function Valve the up coil.
  • Page 89 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Verify no open/short circuit across C14-2 (C47FE WH/BK) to Function Ground either 24VDC or B-. Enable Toggle Active at Stuck ON(on @ controlled *Check for 24VDC or Switch (Ground...
  • Page 90 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution Verify: *B- at C16-9, C28-7 (S132LDS BL/WH NO) Voltage on both Cross Check All functions (C175LDS WH/BK NC) or none, or not Failure disabled.
  • Page 91 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution All functions disabled Unit shut down -or- drive Telematics Contact machine owner via remote speed Remote 21 Fault to have functionality telematics reduced Shutdown...
  • Page 92 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Check CAN bus circuit for open or short. *Check CAN bus resistor. Should be 120 *Ohms from CAN High Loss of CAN Functions to CAN Low.
  • Page 93 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution Allow motor to cool down.Ensure proper airflow to lift pump Lift pump Motor Too Hot or motor.Ensure that disabled. there is an issue hydraulic pressure 21 FAULT Auxiliary...
  • Page 94 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Do not operate machine with batteries charging. *Check for loose motor cable connections. Drive Motor Windings *Check for 33V AC disabled.
  • Page 95 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Do not operate machine with batteries charging. *Check for loose motor cable connections. Drive *Check for 33 VAC Motor Windings disabled.
  • Page 96 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Check for 48V DC to brake (WH/RD) *Check for 48V DC at BRAKE_LEFT Drive C23-4 VALUE TOO Brake Coil Brake AC Motor functions *(48V is brake set, 0V is...
  • Page 97 January 2020 Section 4 Fault Codes CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *If occurs on function activation check wiring Coil shorted and valve coil for the RESISTANCE or lower than Drive output function activated when TOO LOW expected...
  • Page 98 Section 4 • Fault Codes January 2020 CONTROL SYSTEM FAULT CODE CHART Error Source Error Type Component Name Cause Effect Solution *Check connections between right motor controller and contactor coil. VALUE TOO Coil Shorted *Check diode on main contactor. If OK replace contactor or right AC motor controller if contactor is OK...

  • Page 99: Motor Controller Fault Code Chart

    January 2020 Section 4 Fault Codes Motor Controller Fault Code Chart AC Motor controller Error Type Condition Solution code 24592 W atchdog No functions or drive. Replace the AC motor controller. 65297 Logic failure #3 No functions or drive. Replace the AC motor controller. 65298 Logic failure #2 No functions or drive.
  • Page 100 Section 4 • Fault Codes January 2020 MOTOR CONTROLLER FAULT CODE CHART AC Motor controller Error Type Condition Solution code 13912 High temperature Functions and drive Let the AC motor controllers cool start to degrade and off. quit. One or both If fault persist with AC motor motor controllers have controllers cooled, replace faulty AC...
  • Page 101 January 2020 Section 4 Fault Codes MOTOR CONTROLLER FAULT CODE CHART AC Motor controller Error Type Condition Solution code 65280 Tiller mismatch No functions or drive. Replace the AC motor controller. 16913 Current sensor time No functions or drive. Replace the AC motor controller. 21776 EEPROM warning No functions or drive.

  • Page 102: Drive Motor Thermal Sensor

    Section 4 • Fault Codes January 2020 Drive Motor Thermal Sensor The thermal sensor is monitored by the motor Te m pe ra ture Re sista nce controllers to maintain optimum performance and °F / °C as a thermal shutdown protection device. -40 / -40 -22 / -30 Normal safe operating range is between -40°F /...
  • Page 103 January 2020 Section 5 • Schematics Schematics About This Section There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. WARNING 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 104: Electrical Symbol Legends

    Section 5 • Schematics January 2020 Electrical Symbols Legends ® -33/18 Part No. 1268514GT...

  • Page 105: Hydraulic Symbol Legends

    January 2020 Section 5 • Schematics Hydraulic Symbols Legends ® Part No. 1268514GT -33/18...
  • Page 106 Section 5 • Schematics January 2020 Electrical Schematic...
  • Page 107 Section 5 • Schematics January 2020 Electrical Schematic, up to S/N Z331815M-306 GROUND BOX PLATFORM BOX VCON VCON PCON DCON - RIGHT AC MOTOR CONTROLLER PCON DCON - LEFT AC MOTOR CONTROLLER AP2/1 TCON POWER TO PLATFORM (opt) AC POWER (NC) (NO) (NO)
  • Page 108 Section 5 • Schematics January 2020 Electrical Schematic...
  • Page 109 Section 5 • Schematics January 2020 Electrical Schematic, from S/N Z331815M-307 to S/N Z331816M-946 Z-33/18 Part No. 1268514GT...
  • Page 110 Section 5 • Schematics January 2020 Electrical Schematic...
  • Page 111 Section 5 • Schematics January 2020 Electrical Schematic, from S/N Z331815M-947 to S/N Z3318M-1782 and for S/N Z331815M-919, 923, 926, 929, 933, 934, 937, 938 5-10 Z-33/18 Part No. 1268514GT...
  • Page 112 Section 5 • Schematics January 2020 Electrical Schematic 5-11...

  • Page 113: Electrical Schematic

    Section 5 • Schematics January 2020 Electrical Schematic, from S/N Z3318M-1783 to Z3318M-2668 5-12 Z-33/18 Part No. 1268514GT...
  • Page 114 Section 5 • Schematics January 2020 Electrical Schematic 5-13...
  • Page 115 Section 5 • Schematics January 2020 Electrical Schematic, from S/N Z3318M-2669 5-14 Z-33/18 Part No. 1268514GT...
  • Page 116 Section 5 • Schematics January 2020 Electrical Schematic, from S/N Z3318M-2669 5-15 Z-33/18 Part No. 1268514GT...

  • Page 117: Hydraulic Schematic

    Section 5 • Schematics January 2020 Hydraulic Schematic 5-16 Z-33/18 Part No. 1268514GT...

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