Terex Genie Z-51/30J Service And Repair Manual
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Terex Genie Z-51/30J Service And Repair Manual

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Service and Repair Manual
Z
-51/30J
®
Serial Number Range
from Z513014B-1201 to
Z513016M-1999
from Z5130M-2000
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. 1268553GT
Rev A2
November 2017

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Summary of Contents for Terex Genie Z-51/30J

  • Page 1 Service and Repair Manual Serial Number Range -51/30J ® This manual includes: from Z513014B-1201 to Repair procedures Z513016M-1999 Fault Codes from Z5130M-2000 Electrical and Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine. Part No. 1268553GT Rev A2 November 2017...

  • Page 2: Introduction

    Unrestricted with proper operation, inspection and scheduled maintenance. Copyright © 2015 by Terex Corporation 1268553 Rev A, September 2015 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®-51/31J Part No. 1268553GT...
  • Page 3 November 2017 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 9/2015 Initial Release 9/2016 Introduction Serial Number Legend Machine Specifications 11/2017 Specifications Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual November 2017 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

    November 2017 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 November 2017 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

    November 2017 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 November 2017 Table of Contents Platform Components ..................19 2-1 Platform Leveling Slave Cylinder ..............19 2-2 Platform Rotator ..................... 20 2-3 Platform Overload System ................21 Jib Boom Components ..................24 3-1 Jib Boom ......................24 3-2 Jib Boom Lift Cylinder ..................25 Primary Boom Components ................
  • Page 9 November 2017 Table of Contents Hydraulic Pumps ....................45 7-1 Lift/Steer Pump ....................45 7-2 Drive Pump..................... 46 Manifolds ......................48 8-1 Function Manifold Components ..............48 8-2 Valve Adjustments - Function Manifold ............52 How to Adjust the System Relief Valve ............52 How to Adjust the Secondary Boom Down Relief Valve .........
  • Page 10 November 2017 Table of Contents Section 5 Schematics ......................73 Introduction ......................73 Electrical Symbol Legend ..................74 Hydraulic Symbols Legend .................. 75 Electrical Component and Wire Color Legends ........... 76 Electrical Schematics – Options ..............79 Ground Control Box Terminal Strip Wiring Diagram, Options ......80 Platform Control Box Wiring Diagram, Options ...........

  • Page 11: Specifications

    November 2017 Service and Repair Manual Specifications Section 2 Specific ati ons Machine Specifications Performance Specifications Tires and wheels Drive speed, maximum Tire size 355/55 D625 Stowed position 5 mph 8 km/h Tire ply rating 40 ft/5.5 sec Tire weight, new foam-filled 390 lbs 12.2 m/5.5 sec (minimum) (Rough terrain)

  • Page 12: Hydraulic Specification

    Service and Repair Manual November 2017 Specifications Hydraulic Specification Do not top off with incompatible hydraulic fluids. Hydraulic fluids Hydraulic Oil Specifications may be incompatible due to the differences in base additive Hydraulic Fluid Specifications chemistry. When incompatible fluids are mixed, insoluble Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic materials may form and deposit...
  • Page 13 November 2017 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Petro-Canada Environ MV 46 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 14: Hydraulic Component Specifications

    Service and Repair Manual November 2017 Specifications Hydraulic Component Function manifold Specifications System relief valve pressure 3200 psi 220.6 bar Drive pump Secondary boom down relief 2100 psi valve pressure 145 bar Type: bi-directional, variable displacement piston Platform level relief valve 2500 psi pump pressure...
  • Page 15 November 2017 Service and Repair Manual Specifications Manifold Component Specifications Plug torque SAE No. 2 36 in-lbs / 4 Nm SAE No. 4 10 ft-lbs / 13 Nm SAE No. 6 14 ft-lbs / 19 Nm SAE No. 8 38 ft-lbs / 51 Nm SAE No.

  • Page 16: Deutz D2011 L03I Engine Specifications

    Service and Repair Manual November 2017 Specifications Deutz D2011 L03i Engine Lubrication system Oil pressure 20 to 44 psi 142 cu in Displacement 1.4 to 3 bar 2.33 liters Oil capacity 9.5 quarts Number of cylinders 9 liters (including filter) 3.7 x 4.4 inches Bore and stroke 94 x 112 mm...

  • Page 17: Machine Torque Specifications

    November 2017 Service and Repair Manual Specifications Machine Torque Specifications Deutz D2011 L03i Engine, continued Fuel injection system Platform rotator Injection pump make Bosch 3/4 -10 center bolt, GR 8 380 ft-lbs Injection pump pressure, 15000 psi 515 Nm maximum 1034 bar 3/8 -16 bolts, GR 8 44 ft-lbs...

  • Page 18: Hydraulic Hose And Fitting Torque Specifications

    Service and Repair Manual November 2017 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...

  • Page 19: Torque Procedure

    November 2017 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings 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 20 Service and Repair Manual November 2017 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 21: Repair Procedures

    November 2017 Service and Repair Manual Repair Procedures Section 3 Machine Configuration: Repair Pr oc edures  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 22 Service and Repair Manual November 2017 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 23: Platform Controls

    November 2017 Service and Repair Manual Platform Controls Platform Controls ALC-500 Circuit Board The platform control box contains one printed circuit board. The ALC-500 circuit board inside the Note: When the ALC-500 circuit board is replaced, platform control box controls all proportional the joystick controllers will need to be calibrated.

  • Page 24: Joysticks

    Service and Repair Manual November 2017 Platform Controls Return the joystick to the neutral position, pause for a moment, then move the joystick Joysticks full stroke in the opposite direction. Hold for 5 seconds and return the joystick to the How to Calibrate a Joystick neutral position.

  • Page 25: How To Adjust The Joystick Max-Out Setting

    November 2017 Service and Repair Manual Platform Controls How to Adj ust the Joystick Max- out Setting How to Adjust the Joystick Start the engine from the platform controls and press down the foot switch. Max-out Setting Start a timer and activate the machine function The max-out setting of a joystick controls the that needs to be adjusted.

  • Page 26: How To Adjust The Joystick Ramp Rate Setting

    Service and Repair Manual November 2017 Platform Controls How to Adj ust the Joystick Ram p R ate Setting How to Adjust the Joystick Ramp Start the engine from the platform controls and press down the foot switch. Rate Setting Start a timer and simultaneously move the The ramp rate setting of a joystick controls the time joystick in either direction full stroke.

  • Page 27: How To Adjust The Joystick Threshold Setting

    November 2017 Service and Repair Manual Platform Controls How to Adj ust the Joystick Thr es hol d Setting How to Adjust the Joystick 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the Threshold Setting settings to be saved.
  • Page 28 Service and Repair Manual November 2017 Platform Controls Select a boom function joystick to set the threshold. 10 Slowly move the joystick off center in either direction just until the function begins to move. 11 Slowly move the joystick back towards the neutral position.

  • Page 29: Platform Components

    November 2017 Service and Repair Manual Platform Components Tag, disconnect and plug the hydraulic hoses from the slave cylinder at the unions and Platform Leveling Slave Cylinder connect them together using a connector. Connect the hoses from the cylinder together The slave cylinder and the rotator pivot are the two using a connector.

  • Page 30: Platform Rotator

    Service and Repair Manual November 2017 Platform Components How to Bleed the Slave Cylinder Platform Rotator Simultaneously activate the boom up function and the platform level up function until the boom is fully raised. How to Bleed the Platform Simultaneously activate the boom down Rotator function and the platform level down function until the boom is fully lowered.

  • Page 31: Platform Overload System

    November 2017 Service and Repair Manual Platform Components Bodily injury hazard. Spraying hydraulic oil can penetrate and Platform Overload System burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate How to Calibrate the Platform gradually. Do not allow oil to Overload System squirt or spray.
  • Page 32 Service and Repair Manual November 2017 Platform Components Move the platform up and down by hand, so it Move the platform up and down by hand, so it bounces approximately 2.5 to 5 cm / 1 to bounces approximately 2.5 to 5 cm / 1 to 2 inches.
  • Page 33 November 2017 Service and Repair Manual Platform Components Test all machine functions from the platform controls. Result: All platform control functions should not operate. 10 Turn the key switch to ground control. 11 Test all machine functions from the ground controls.

  • Page 34: Jib Boom Components

    Service and Repair Manual November 2017 Jib Boom Components Remove the pin retaining fasteners from both platform rotator pivot pins. Do not remove the Jib Boom pins. Use a soft metal drift to remove the leveling How to Remove the Jib Boom arm pivot pin and let the leveling arms hang down.

  • Page 35: Jib Boom Lift Cylinder

    November 2017 Service and Repair Manual Jib Boom Components 16 Use a soft metal drift to remove the pin and let the cylinder hang down. Jib Boom Lift Cylinder Crushing hazard. The jib boom could fall when the barrel-end How to Remove the Jib Boom Lift pivot pin is removed if not Cylinder properly supported by the...
  • Page 36 Service and Repair Manual November 2017 Jib Boom Components Use a soft metal drift to tap the jib boom lift cylinder rod-end pivot pin half way out. Then lower one of the leveling arms to the ground. Tap the pin the other direction and lower the opposite leveling arm.

  • Page 37: Primary Boom Components

    November 2017 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the hydraulic hoses from the "V1" and "V2" ports on the Cable Track counterbalance valve manifold located on the platform rotator. Cap the fittings on the The primary boom cable track guides the cables manifold.
  • Page 38 Service and Repair Manual November 2017 Primary Boom Components Tag, disconnect and plug the platform rotator 13 Attach a lifting strap from an overhead 5 ton / hydraulic hoses at the union located above the 5,000 kg capacity crane to the platform end of primary boom lift cylinder.

  • Page 39: How To Repair The Primary Boom Cable Track

    November 2017 Service and Repair Manual Primary Boom Components How to R epair the Primary Boom C abl e Tr ack How to Repair the Primary Boom 22 Attach a strap from an overhead crane to the cable track. Cable Track 23 Remove the mounting fasteners from the Component damage hazard.

  • Page 40: Primary Boom

    Service and Repair Manual November 2017 Primary Boom Components Remove the pin retaining fastener from the master cylinder barrel-end pivot pin. Use a soft Primary Boom metal drift to remove the pin. Then lower the cylinder and let it hang down. How to Remove the Primary Component damage hazard.

  • Page 41: How To Disassemble The Primary Boom

    November 2017 Service and Repair Manual Primary Boom Components How to Dis ass embl e the Primary Boom How to Disassemble the Primary 14 Attach a 5 ton / 5,000 kg overhead crane to the center point of the primary boom. Boom 15 Attach a similar lifting device to the primary Complete disassembly of the boom is only...

  • Page 42: Primary Boom Lift Cylinder

    Service and Repair Manual November 2017 Primary Boom Components Remove the external snap rings from the extension cylinder rod-end pivot pin at the Primary Boom Lift Cylinder platform end of the extension tube. Use a soft metal drift to remove the pin. The primary boom lift cylinder raises and lowers the primary boom.

  • Page 43: Primary Boom Extension Cylinder

    November 2017 Service and Repair Manual Primary Boom Components Tag, disconnect and plug the primary boom lift cylinder hydraulic hoses. Cap the fittings on Primary Boom Extension the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The primary boom extension cylinder extends and burn skin.

  • Page 44: Platform Leveling Master Cylinder

    Service and Repair Manual November 2017 Primary Boom Components Tag, disconnect and plug the primary boom extension cylinder hydraulic hoses. Cap the Platform Leveling Master fittings on the cylinder. Cylinder Bodily injury hazard. Spraying hydraulic oil can penetrate and The master cylinder acts as a pump for the slave burn skin.
  • Page 45 November 2017 Service and Repair Manual Primary Boom Components Remove the pin retaining fasteners from the master cylinder barrel-end pivot pin. Place a rod through the barrel-end pivot pin and twist to remove the pin. Remove the pin retaining fastener from the rod-end pivot pin.

  • Page 46: Secondary Boom Components

    Service and Repair Manual November 2017 Secondary Boom Components Secondary Boom components 6 secondary boom lift cylinder (2) 1 upper secondary boom (number 1 arm) 7 lower secondary boom (number 4 arm) 2 upper tension link (number 2 arm) 8 turntable pivot 3 lower tension link (number 3 arm) 9 boom rest 4 mid-pivot...

  • Page 47: Secondary Boom

    November 2017 Service and Repair Manual Secondary Boom Components Tag, disconnect and plug the hydraulic hoses at the primary boom lift cylinder. Cap the Secondary Boom fittings on the cylinder. Bodily injury hazard. Spraying How to Disassemble the hydraulic oil can penetrate and Secondary Boom burn skin.
  • Page 48 Service and Repair Manual November 2017 Secondary Boom Components 10 Remove the pin retaining fasteners from both 17 Attach a lifting strap from a second overhead sides of the secondary boom lift cylinder crane to the number 1 arm at the mid-point rod-end pivot pin and barrel-end pivot pin.
  • Page 49 November 2017 Service and Repair Manual Secondary Boom Components 23 Pull all of the cables and hoses out through 32 Attach a lifting strap from the overhead crane the upper pivot. to the mid-pivot for support. Do not lift it. 33 Remove the pin retaining fasteners from the Component damage hazard.
  • Page 50 Service and Repair Manual November 2017 Secondary Boom Components 39 Use a soft metal drift to remove the upper 45 Using an approved hand-operated pump, compression link pivot pin from the number drain the fuel tank into a container of suitable 2 arm.

  • Page 51: Secondary Boom Lift Cylinders

    November 2017 Service and Repair Manual Secondary Boom Components 51 Remove the mounting fasteners from the cover located in the boom storage area to Secondary Boom Lift Cylinders access the number 3 and number 4 arm pivot pin retaining fasteners at the turntable riser. There are two secondary boom lift cylinders incorporated in the structure of the secondary 52 Remove the pin retaining fasteners from the...
  • Page 52 Service and Repair Manual November 2017 Secondary Boom Components Tag, disconnect and plug the hydraulic hoses on the secondary boom lift cylinder. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually.

  • Page 53: Engines

    November 2017 Service and Repair Manual Engines Flex Plate RPM Adjustment - Deutz D2011L03i Models The flex plate acts as a coupler between the engine and the pump. It is bolted to the engine flywheel Refer to Maintenance Procedure in the appropriate and has a splined center to drive the pump.

  • Page 54: How To Install The Flex Plate

    Service and Repair Manual November 2017 Engines How to Ins tall the Fl ex Plate How to i nstall the Pum p and Bell H ousing Ass embly How to Install the Flex Plate How to install the Pump and Bell Housing Assembly Install the flex plate onto the engine flywheel with the rubber vibration isolators towards the...

  • Page 55: Hydraulic Pumps

    November 2017 Service and Repair Manual Hydraulic Pumps Tag, disconnect and plug the lift/steer pump hydraulic hoses. Cap the fittings on the pump. Lift/Steer Pump Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Lift/Steer burn skin. Loosen hydraulic Pump connections very slowly to allow the oil pressure to dissipate...

  • Page 56: Drive Pump

    Service and Repair Manual November 2017 Hydraulic Pumps Locate the two hydraulic tank valves at the hydraulic tank through the access hole Drive Pump underneath the turntable. Close the valves. The drive pump is a bi-directional variable Component damage hazard. displacement piston pump.
  • Page 57 November 2017 Service and Repair Manual Hydraulic Pumps How to Prime the Pump Carefully pull the drive pump out until the pump coupler separates from the flex plate. Connect a 0 to 600 psi / 0 to 41 bar pressure Remove the drive pump from the machine.

  • Page 58: Manifolds

    Service and Repair Manual November 2017 Manifolds 8-1 Function Manifold Components The function manifold is located next to the hydraulic tank underneath the ground controls side cover. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Platform level up/down 25 ft-lbs / 34 Nm Solenoid valve, 3 position 4 way Platform rotate left/right and jib...
  • Page 59 November 2017 Service and Repair Manual Manifolds Part No. 1268553GT Z®-51/31J...
  • Page 60 Service and Repair Manual November 2017 Manifolds Function Manifold Components, continued Index Schematic Description Function Torque Item Check valve, 5 psi / 0.3 bar Differential sensing circuit, turntable 12-14 ft-lbs / 16-19 rotate Check valve, 5 psi / 0.3 bar Differential sensing circuit, primary 12-14 ft-lbs / 16-19 boom retract...
  • Page 61 November 2017 Service and Repair Manual Manifolds Part No. 1268553GT Z®-51/31J...

  • Page 62: Valve Adjustments - Function Manifold

    Service and Repair Manual November 2017 Manifolds How to Adj ust the Sec ondary Boom D own R elief Valv e 8-2 Valve Adjustments - Function How to Adjust the Secondary Manifold Boom Down Relief Valve Note: Perform this procedure with the boom in the How to Adj ust the Sy stem Reli ef Valve stowed position.

  • Page 63: Jib Boom / Platform Rotate Manifold Components

    November 2017 Service and Repair Manual 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 3 way Platform rotate/jib boom select 8-10 ft-lbs / 11-14 Nm Part No.

  • Page 64: Turntable Rotation Manifold Components

    Service and Repair Manual November 2017 Manifolds Turntable Rotation Manifold Components The turntable rotation manifold is mounted to the turntable rotation motor located in the boom storage compartment. Index No. Description Schematic Item Function Counterbalance valve Turntable rotate right Counterbalance valve Turntable rotate left Z®-51/31J Part No.

  • Page 65: Directional Valve Manifold Components

    November 2017 Service and Repair Manual Manifolds 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 Part No.

  • Page 66: How To Set Up The Directional Valve Linkage

    Service and Repair Manual November 2017 Manifolds How to Set U p the Direc tional Valve Li nk age How to Set Up the Directional Adjust the ball joint until the hole lines up with the retaining fastener hole in the bracket. Valve Linkage 10 Install the ball joint to the axle and tighten the Note: Adjustment of the oscillate directional valve...
  • Page 67 November 2017 Service and Repair Manual This page intentionally left blank. Part No. 1268553GT Z®-51/31J...

  • Page 68: Traction Manifold Components

    Service and Repair Manual November 2017 Manifolds Traction Manifold Components The traction manifold is mounted inside the drive chassis at the non-steer end. Index Schematic Description Function Torque Item Flow divider/combiner valve Controls flow to flow divider/combiner 25-30 ft-lbs / 34-41 valves 2 and 4 Flow divider/combiner valve Controls flow to non-steer end drive motors...
  • Page 69 November 2017 Service and Repair Manual Manifolds Part No. 1268553GT Z®-51/31J...

  • Page 70: Valve Adjustments,Traction Manifold

    Service and Repair Manual November 2017 Manifolds Valve Adjustments,Traction Manifold How to Adjust the Charge Pressure Relief Valve Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to the test port on the drive pump. Hold the charge pressure relief valve and remove the cap (item AH).

  • Page 71: Valve Coils

    November 2017 Service and Repair Manual Manifolds How to Test a Coil Diode Valve Coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function How to Test a Coil circuit following the interruption of electrical current to a coil.
  • Page 72 Service and Repair Manual November 2017 Manifolds At the battery or coil terminals, reverse the connections. Note and record the current reading. Result: Both current readings are greater than 0 mA and are different by a minimum of 20%. The coil is good. Result: If one or both of the current readings are 0 mA, or if the two current readings do not differ by a minimum of 20%, the coil and/or its...

  • Page 73: Turntable Rotation Components

    November 2017 Service and Repair Manual Turntable Rotation Components Secure the turntable from rotating with the turntable rotation lock. Turntable Rotation Assembly Tip-over hazard. The machine could tip over when the turntable How to Remove the Turntable rotation assembly is removed if Rotation Assembly the turntable rotation lock is not in the locked position.
  • Page 74 Service and Repair Manual November 2017 Turntable Rotation Components Remove the safety pin from the engine pivot Remove the turntable rotation assembly plate latch. mounting fasteners. Note: The engine pivot plate latch is located under Carefully remove the turntable rotation the engine turntable pivot plate at the assembly from the machine.

  • Page 75: Axle Components

    November 2017 Service and Repair Manual 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 76 Service and Repair Manual November 2017 This page intentionally left blank. Z®-51/31J Part No. 1268553GT...

  • Page 77: Fault Codes

    November 2017 Service and Repair Manual Fault Codes Section 4 Before Troubleshooting: Faul t Codes  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 78: Control System Fault Codes

    Service and Repair Manual November 2017 Control System Fault Codes How to R etrieve Contr ol Sy stem F ault Codes Control System Determine the error source: The red LED indicates the error source and will flash two separate codes. The first code will indicate the How to Retrieve Control System first digit of the two digit code, flashing once per second.

  • Page 79: Control System Fault Codes

    November 2017 Service and Repair Manual Control System Fault Codes Control System F ault C odes Error Source Error Type Condition Solution Name Name Primary Up / Value at 5V Function is inoperative.Alarm sounds Cycle power off, then on Down Joystick indicating a fault.
  • Page 80 Service and Repair Manual November 2017 Control System Fault Codes Error Source Error Type Condition Solution Name Name Secondary Up / Fault Valve is operating outside of limits. Cycle power off, then on Down. Directional Alarm sounds indicating a fault. after problem has been Valves corrected.
  • Page 81 November 2017 Service and Repair Manual Control System Fault Codes Error Source Error Type Condition Solution Name Name Platform Level Fault Platform level frozen at neutral Power up controller with Switch problem corrected Primary Fault Platform Ext/Ret frozen at neutral Power up controller with Extend/Retract problem corrected Switch...
  • Page 82 Service and Repair Manual November 2017 Control System Fault Codes Error Source Error Type Condition Solution Name Name Drive Brake Valve 21 Fault Drive frozen at zero and neutral. Cycle power off, then on after problem has been corrected. Alarm sounds indicating a fault. High Drive Motor Fault Motor speed in the low state.

  • Page 83: Schematics

    November 2017 Service and Repair Manual Schematics Section 5 About This Section Schem atics 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.

  • Page 84: Electrical Symbol Legend

    Service and Repair Manual November 2017 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 85: Hydraulic Symbols Legend

    November 2017 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 86: Electrical Component And Wire Color Legends

    Service and Repair Manual November 2017 Electrical Component and Wire Color Legends Item Description Item Description Battery Horn or Alarm Engine Start - 12V DC Tilt/load sense alarm Descent (ground) Connector Load sense (ground) Power to platform, 12v cable connector Joystick Footswitch input connector Options connector...
  • Page 87 November 2017 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Item Description Motor Toggle Switch Auxiliary pump Auxiliary pump switch Engine starter Start engine switch Fuel pump Fuel select switch (ford efi only) Hi/low rpm switch Button Glow plug switch Red emergency stop button...
  • Page 88 Service and Repair Manual November 2017 Electrical Component and Wire Color Legends Item Description Wire Color Legend Module Item Description Ignition start module Blue EDC - drive pump Black Alc 500 joystick controller card Brown Control module Green Load sense module Orange Time delay relay - 2 seconds, 10A Purple...

  • Page 89: Electrical Schematics - Options

    November 2017 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram, Options...

  • Page 90: Ground Control Box Terminal Strip Wiring Diagram, Options

    Service and Repair Manual November 2017 Ground Control Box Terminal Strip Wiring Diagram, Options Z®-51/31J Part No. 1268553GT...

  • Page 91: Platform Control Box Wiring Diagram, Options

    November 2017 Service and Repair Manual Platform Control Box Wiring Diagram, Options Part No. 1268553GT Z®-51/31J...
  • Page 92 Service and Repair Manual November 2017 Platform Control Box Wiring Diagram, Options...
  • Page 93 November 2017 Service and Repair Manual Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options...

  • Page 94: Wiring Diagram - Battery, Hydraulic Oil And Engine Oil Heater Options

    Service and Repair Manual November 2017 Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options Z®-51/31J Part No. 1268553GT...

  • Page 95: Electrical Schematic, Options

    November 2017 Service and Repair Manual Electrical Schematic, Options Part No. 1268553GT Z®-51/31J...
  • Page 96 Service and Repair Manual November 2017 Electrical Schematic, Options...

  • Page 97: Electrical Schematics - As Models

    November 2017 Service and Repair Manual Electrical Schematic (AS)

  • Page 98: Electrical Schematic (As)

    Service and Repair Manual November 2017 Electrical Schematic (AS) Z®-51/31J Part No. 1268553GT...
  • Page 99 November 2017 Service and Repair Manual Electrical Schematic (AS) Part No. 1268553GT Z®-51/31J...
  • Page 100 Service and Repair Manual November 2017 Electrical Schematic (AS)
  • Page 101 November 2017 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram (AS)

  • Page 102: Ground Control Box Terminal Strip Wiring Diagram (As)

    Service and Repair Manual November 2017 Ground Control Box Terminal Strip Wiring Diagram (AS) Z®-51/31J Part No. 1268553GT...

  • Page 103: Ground Control Box Switch Panel Wiring Diagram (As)

    November 2017 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram (AS) Part No. 1268553GT Z®-51/31J...
  • Page 104 Service and Repair Manual November 2017 Ground Control Box Switch Panel Wiring Diagram (AS)
  • Page 105 November 2017 Service and Repair Manual Platform Control Box Wiring Diagram (AS)

  • Page 106: Platform Control Box Wiring Diagram (As)

    Service and Repair Manual November 2017 Platform Control Box Wiring Diagram (AS) Z®-51/31J Part No. 1268553GT...

  • Page 107: Platform Control Box Switch Panel Wiring Diagram (As)

    November 2017 Service and Repair Manual Platform Control Box Switch Panel Wiring Diagram (AS) Part No. 1268553GT Z®-51/31J...
  • Page 108 Service and Repair Manual November 2017 Platform Control Box Switch Panel Wiring Diagram (AS)

  • Page 109: Electrical Schematics - Ce Models

    November 2017 Service and Repair Manual Electrical Schematic (CE)

  • Page 110: Electrical Schematic (Ce)

    Service and Repair Manual November 2017 Electrical Schematic (CE) Z®-51/31J Part No. 1268553GT...
  • Page 111 November 2017 Service and Repair Manual Electrical Schematic (CE) Part No. 1268553GT Z®-51/31J...
  • Page 112 Service and Repair Manual November 2017 Electrical Schematic (CE)
  • Page 113 November 2017 Service and Repair Manual Ground Control Box Terminal Strip Wiring Diagram (CE)

  • Page 114: Ground Control Box Terminal Strip Wiring Diagram (Ce)

    Service and Repair Manual November 2017 Ground Control Box Terminal Strip Wiring Diagram (CE) Z®-51/31J Part No. 1268553GT...

  • Page 115: Ground Control Box Switch Panel Wiring Diagram (Ce)

    November 2017 Service and Repair Manual Ground Control Box Switch Panel Wiring Diagram (CE) Part No. 1268553GT Z®-51/31J...
  • Page 116 Service and Repair Manual November 2017 Ground Control Box Switch Panel Wiring Diagram (CE)
  • Page 117 November 2017 Service and Repair Manual Platform Control Box Wiring Diagram (CE)

  • Page 118: Platform Control Box Wiring Diagram (Ce)

    Service and Repair Manual November 2017 Platform Control Box Wiring Diagram (CE) Z®-51/31J Part No. 1268553GT...

  • Page 119: Platform Control Box Switch Panel Wiring Diagram (Ce)

    November 2017 Service and Repair Manual Platform Control Box Switch Panel Wiring Diagram (CE) Part No. 1268553GT Z®-51/31J...
  • Page 120 Service and Repair Manual November 2017 Platform Control Box Switch Panel Wiring Diagram (CE)

  • Page 121: Hydraulic Schematics

    November 2017 Service and Repair Manual Hydraulic Schematic...

  • Page 122: Hydraulic Schematic, 4Wd Models

    Service and Repair Manual November 2017 Hydraulic Schematic Z®-51/31J Part No. 1268553GT Servic e and R epair M anual Novem ber 2017 Z®-51/31J Part No. 1268553GT...

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