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

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Service and Repair Manual

Serial Number Range

-51/30J

from Z513014B-1201 to

Z513016M-1999

This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics

from Z5130M-2000

For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.

Part No. 1268553GT
Rev A2
November 2017

Summary of Contents for Genie Z-51/30J

Page 1: ...014B 1201 to Z513016M 1999 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics from Z5130M 2000 For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1268553GT Rev A2 November 2017 ...

Page 2: ...6368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance 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 ...

Page 3: ...ription A 9 2015 Initial Release A1 9 2016 Introduction Serial Number Legend A2 11 2017 Specifications Machine Specifications Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ... Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial number stamped on chassis 6 Serial label located under cover From September 1 2016 1 Model 2 Facility code 3 Sequence number 4 Serial number stamped on chassis 5 Serial label located under cover ...

Page 5: ...ry 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 Yo...

Page 6: ...rushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace 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 Be sure to keep sparks flames and lighted tobacco away from flam...

Page 7: ...nce Specifications 1 Hydraulic Specification 2 Hydraulic Component Specifications 4 Deutz D2011 L03i Engine Specifications 6 Machine Torque Specifications 7 Hydraulic Hose and Fitting Torque Specifications 8 Torque Procedure 9 Section 3 Repair Procedures 11 Introduction 11 Platform Controls 13 1 1 ALC 500 Circuit Board 13 1 2 Joysticks 14 How to Adjust the Joystick Max out Setting 15 How to Adjust...

Page 8: ...1 Cable Track 27 How to Repair the Primary Boom Cable Track 29 4 2 Primary Boom 30 How to Disassemble the Primary Boom 31 4 3 Primary Boom Lift Cylinder 32 4 4 Primary Boom Extension Cylinder 33 4 5 Platform Leveling Master Cylinder 34 Secondary Boom Components 36 5 1 Secondary Boom 37 5 2 Secondary Boom Lift Cylinders 41 Engines 43 6 1 RPM Adjustment Deutz D2011L03i Models 43 6 2 Flex Plate 43 Ho...

Page 9: ...otate Manifold Components 53 8 4 Turntable Rotation Manifold Components 54 8 5 Directional Valve Manifold Components 55 How to Set Up the Directional Valve Linkage 56 8 6 Traction Manifold Components 58 8 7 Valve Adjustments Traction Manifold 60 8 8 Valve Coils 61 Turntable Rotation Components 63 9 1 Turntable Rotation Assembly 63 Axle Components 65 10 1 Oscillating Axle Cylinders 65 Section 4 Fau...

Page 10: ...cal Schematic Options 85 Electrical Schematics AS Models 87 Electrical Schematic AS 88 Ground Control Box Terminal Strip Wiring Diagram AS 92 Ground Control Box Switch Panel Wiring Diagram AS 93 Platform Control Box Wiring Diagram AS 96 Platform Control Box Switch Panel Wiring Diagram AS 97 Electrical Schematics CE Models 99 Electrical Schematic CE 100 Ground Control Box Terminal Strip Wiring Diag...

Page 11: ...503 cc Drive hubs with brake 57 1 Non steer end 24 fl oz 1242 cc Turntable rotation drive hub 25 5 fl oz 750 cc Performance Specifications Drive speed maximum Stowed position 5 mph 8 km h 40 ft 5 5 sec 12 2 m 5 5 sec Raised or extended position 0 6 mph 1 km h 40 ft 45 sec 12 2 m 45 sec Braking distance maximum High range on paved surface 3 to 6 ft 0 9 to 1 8 m Gradeability See Operator s Manual Bo...

Page 12: ...t UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable ...

Page 13: ...evron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic fluid or equivalent when ambient temperatures are consistently above 32 F 0 C may result in component damage Petro Canada Environ MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt ...

Page 14: ...i 220 6 bar Function manifold System relief valve pressure 3200 psi 220 6 bar Secondary boom down relief valve pressure 2100 psi 145 bar Platform level relief valve pressure 2500 psi 172 bar Steer flow regulator 1 5 gpm 5 7 L min Boom extend flow regulator 2 gpm 7 6 L min Jib boom platform rotate flow regulator 0 4 gpm 1 5 L min Drive manifold Hot oil relief pressure 250 psi 17 2 bar Steer end dri...

Page 15: ...AE No 6 14 ft lbs 19 Nm SAE No 8 38 ft lbs 51 Nm SAE No 10 41 ft lbs 55 Nm SAE No 12 56 ft lbs 76 Nm Valve coil resistance specifications Proportional directional solenoid valve 10V DC schematic items BP BU and BY 6 to 8Ω 3 position 4 way directional valve 10V DC schematic items BF BM and CG 6 to 8Ω 2 position 3 way solenoid valve 10V DC schematic items CA CC G AF and AG 6 to 8Ω ...

Page 16: ...ugal mechanical Valve clearance cold Intake 0 012 in 0 3 mm Exhaust 0 020 in 0 5 mm Lubrication system Oil pressure 20 to 44 psi 1 4 to 3 bar Oil capacity including filter 9 5 quarts 9 liters Oil viscosity requirements 22 F to 86 F 30 C to 30 C 5W 30 synthetic 4 F to 90 F 20 C to 32 C 10W 40 Above 23 F 5 C 20W 50 Units ship with 15W 40 Extreme operating temperatures may require the use of alternat...

Page 17: ...0 27 in 7 mm Battery Type 12V DC Group 34 78 Quantity 1 Cold cranking ampere 900A Reserve capacity 25A rate 200 minutes Alternator output 60A 14V DC Fan belt deflection 3 8 to 1 2 inch 9 to 12 mm Machine Torque Specifications Platform rotator 3 4 10 center bolt GR 8 380 ft lbs 515 Nm 3 8 16 bolts GR 8 44 ft lbs 60 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 180 ft lbs 244...

Page 18: ...8 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm Adjustable Fitting Non adjustable fitting 1 jam nut SAE O ri...

Page 19: ... and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the tube flare hex nut ...

Page 20: ... number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitt...

Page 21: ...on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm...

Page 22: ...rt personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a 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 av...

Page 23: ...tick controller 1 1 ALC 500 Circuit Board Note When the ALC 500 circuit board is replaced the joystick controllers will need to be calibrated Refer to Repair Procedure How to Calibrate a Joystick How to Remove the ALC 500 Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open ...

Page 24: ...ols 3 Turn the key switch to platform control Do not start the engine 4 Select a joystick to calibrate 5 Disconnect the wire harness connector from the joystick for approximately 10 seconds or until the alarm sounds Connect the wire harness connector to the joystick 6 Move the joystick full stroke in either direction and hold for 5 seconds 7 Return the joystick to the neutral position pause for a ...

Page 25: ... and the alarm should sound 4 times indicating that the machine is in max out calibration mode Result The alarm does not sound Repeat steps 3 through 7 8 Start the engine from the platform controls and press down the foot switch 9 Start a timer and activate the machine function that needs to be adjusted Record the time it takes for that function to complete a full cycle ie boom up 10 Compare the m...

Page 26: ...mergency Stop button to the on position 6 When the alarm sounds release the drive enable toggle switch 7 Momentarily activate the drive enable toggle switch in the right direction 6 times Result There should be a pause and the alarm should sound 6 times indicating that the machine is in ramp rate calibration mode 8 Start the engine from the platform controls and press down the foot switch 9 Start ...

Page 27: ...ol d Setting How to Adjust the Joystick Threshold Setting The threshold setting of a joystick is the minimum output at which a function proportional valve can open and allow the function to operate Note Perform this procedure with the boom in the stowed position 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform co...

Page 28: ...e alarm should sound indicating a successful calibration Note For each joystick axis the threshold must be set for both directions 12 Repeat steps 9 through 11 for each direction of boom joystick controlled machine function boom up down boom extend retract and turntable rotate left right 13 Return the joystick to the neutral position and wait for approximately 10 seconds to allow the settings to b...

Page 29: ...ort 3 Lower the primary boom until the platform is resting on the blocks just enough to support the platform Note Do not rest the entire weight of the boom on the blocks 4 Tag disconnect and plug the hydraulic hoses from the slave cylinder at the unions and connect them together using a connector Connect the hoses from the cylinder together using a connector Bodily injury hazard Spraying hydraulic...

Page 30: ...through two platform rotation cycles then hold the switch to the right position until the platform is fully rotated to the right 2 Place a suitable container underneath the platform rotator 3 Open the top bleed screw on the rotator but do not remove it Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissi...

Page 31: ... inspect the bleed screws for leaks 2 3 Platform Overload System How to Calibrate the Platform Overload System Calibration of the platform overload system is essential to safe machine operation Continued use of an improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note P...

Page 32: ...orm and ground controls and the alarm sounds Proceed to step 7 Result The overload indicator lights are flashing at the platform and ground controls and the alarm is sounding Repeat this procedure beginning with step 5 Note The platform will need to be moved up and down and allowed to settle between each adjustment Note There may be a 2 second delay before the platform overload indicator lights an...

Page 33: ...suitable lifting device lift the test weight off the platform floor Result The platform overload indicator light should be off at both the ground and platform controls and the alarm should not sound Note There may be a 2 second delay before the overload indicator lights and alarm turn off 13 Test all machine functions from the ground controls Result All ground control functions should operate norm...

Page 34: ... Attach a lifting strap from an overhead crane to the platform rotator for support 6 Remove the pin retaining fastener from the jib boom lift cylinder rod end pivot pin Do not remove the pin 7 Remove the pin retaining fasteners from both platform rotator pivot pins Do not remove the pins 8 Use a soft metal drift to remove the leveling arm pivot pin and let the leveling arms hang down 9 Use a soft ...

Page 35: ...moved from the machine if it is not properly supported by the overhead crane 3 2 Jib Boom Lift Cylinder How to Remove the Jib Boom Lift Cylinder Note Perform this procedure with the boom in the stowed position Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refe...

Page 36: ...inder barrel end pivot pin Use a soft metal drift to remove the barrel end pin and let the cylinder hang down Crushing hazard The jib boom may become unbalanced and fall when it is removed from the machine if it is not properly supported by the overhead crane 7 Attach a lifting strap from an overhead crane to the lug on the rod end of the jib boom lift cylinder 8 Use a soft metal drift to remove t...

Page 37: ...mp on the primary boom bellcrank 5 Pull all of the electrical cables out of the plastic cable track Do not pull out the hydraulic hoses 6 Tag disconnect and plug the hydraulic hoses from the V1 and V2 ports on the counterbalance valve manifold located on the platform rotator Cap the fittings on the manifold Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic co...

Page 38: ...er the cable track could become unbalanced and fall when removed from the machine 13 Attach a lifting strap from an overhead 5 ton 5 000 kg capacity crane to the platform end of the primary boom for support Do not lift it 14 Remove all hose and cable clamps from the underside of the primary boom 15 Support the rod end of the primary boom lift cylinder with a suitable lifting device 16 Remove the p...

Page 39: ...le track could become unbalanced and fall if not properly attached to the overhead crane Component damage hazard Cables and hoses can be damaged if they are kinked or pinched How to R epair the Primary Boom C abl e Tr ack How to Repair the Primary Boom Cable Track Component damage hazard The boom cable track can be damaged if it is twisted Note A 7 link repair section of cable track is available t...

Page 40: ...Remove the hose and cable cover from the upper pivot 6 Remove the pin retaining fastener from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin Then lower the cylinder and let it hang down Component damage hazard When lowering the master cylinder down be sure not to damage the master cylinder hoses or fittings 7 Locate the primary boom drive speed limit switch insid...

Page 41: ...d to the overhead crane How to Disassembl e the Primary Boom How to Disassemble the Primary Boom Complete disassembly of the boom is only necessary if the outer or inner boom tube must be replaced The extension cylinder can be removed without completely disassembling the boom Refer to Repair Procedure How to Remove the Primary Boom Extension Cylinder 1 Remove the primary boom Refer to Repair Proce...

Page 42: ... to Remove the Primary Boom Lift Cylinder Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fit...

Page 43: ... barrel end pivot pin Carefully remove the primary boom lift cylinder from the machine Crushing hazard The lift cylinder could become unbalanced and fall if not properly supported and secured to the lifting device 4 4 Primary Boom Extension Cylinder The primary boom extension cylinder extends and retracts the primary boom extension tube The primary boom extension cylinder is equipped with counterb...

Page 44: ...d cables can be damaged if the primary boom extension cylinder is dragged across them Note Note the length of the cylinder after removal The cylinder must be at the same length for installation 4 5 Platform Leveling Master Cylinder The master cylinder acts as a pump for the slave cylinder It s part of the closed circuit hydraulic loop that keeps the platform level through the entire range of boom ...

Page 45: ...pin 5 Place a rod through the barrel end pivot pin and twist to remove the pin 6 Remove the pin retaining fastener from the rod end pivot pin 7 Place a rod through the rod end pivot pin and twist to remove the pin 8 Remove the master cylinder from the machine Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the overhead crane ...

Page 46: ...o 1268553GT Secondary Boom components 1 upper secondary boom number 1 arm 2 upper tension link number 2 arm 3 lower tension link number 3 arm 4 mid pivot 5 compression link 6 secondary boom lift cylinder 2 7 lower secondary boom number 4 arm 8 turntable pivot 9 boom rest 10 upper pivot ...

Page 47: ...Boom 4 Remove the master cylinder Refer to Repair Procedure How to Remove the Master Cylinder 5 Attach a lifting strap from an overhead crane to the lug on the rod end of the primary boom lift cylinder Then raise the primary boom lift cylinder with the crane to a vertical position 6 Tag disconnect and plug the hydraulic hoses at the primary boom lift cylinder Cap the fittings on the cylinder Bodil...

Page 48: ... be careful not to damage the counterbalance valve at the barrel end of the cylinder 16 Attach a lifting strap from an overhead crane to the upper pivot for support Do not lift it 17 Attach a lifting strap from a second overhead crane to the number 1 arm at the mid point between the upper pivot and mid pivot 18 Remove the pin retaining fasteners from the number 1 arm pivot pins at the mid pivot an...

Page 49: ...pper pivot end 29 Raise the number 2 arm slightly and remove the 4 x 4 x 11 inch 10 x 10 x 28 cm block 30 Lower the number 2 arm onto the boom rest pad 31 Insert a 4 x 4 x 81 2 inch 10 x 10 x 22 cm block between the number 3 arm and the number 4 arm at the mid pivot end 32 Attach a lifting strap from the overhead crane to the mid pivot for support Do not lift it 33 Remove the pin retaining fastene...

Page 50: ...g an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Specifications Machine Specifications Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Explosion and fire hazard When transferr...

Page 51: ...the number 4 arm from the turntable riser through the ground controls side bulkhead 60 Remove the number 4 arm from the machine Crushing hazard The number 4 arm could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 5 2 Secondary Boom Lift Cylinders There are two secondary boom lift cylinders incorporated in the structure of the secondary boo...

Page 52: ...rom an overhead crane to the lug on the rod end of the secondary boom lift cylinder for support Do not apply any lifting pressure 6 Use a soft metal drift to drive the barrel end pivot pin half way out Lower the barrel end of the secondary boom lift cylinder and let it hang down 7 Use a soft metal drift to drive the rod end pivot pin half way out 8 Remove the secondary boom lift cylinder from the ...

Page 53: ...y Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 3 Support the drive pump with an appropriate lifting device Then remove all of the bell housing to engine mounting bolts Leave the pump con...

Page 54: ...ng grease Genie part number 128025 to the splines of the pump shaft and flex plate Grease Specification Shell Alvania Grease CG NLGI 0 1 or equivalent How to i nstall the Pum p and Bell H ousing Assembly How to install the Pump and Bell Housing Assembly 1 Install the pump and bell housing assembly 2 Torque the bell housing mounting bolts labeled C in sequence to 28 ft lbs 38 Nm Then torque the bel...

Page 55: ... damage hazard The engine must not be started with the hydraulic tank shut off valves in the closed position or component damage will occur If the tank valves are closed remove the key from the key switch and tag the machine to inform personnel of the condition open closed 2 Tag disconnect and plug the lift steer pump hydraulic hoses Cap the fittings on the pump Bodily injury hazard Spraying hydra...

Page 56: ...ust be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Disconnect the electrical connectors at the electrical proportional controller located on the drive pump 2 Locate the two hydraulic tank valves at the hydraulic tank through the access hole underneath the turntable Close the valves Componen...

Page 57: ...me the Pump 1 Connect a 0 to 600 psi 0 to 41 bar pressure gauge to the test port on the drive pump 2 Remove the safety pin from the engine pivot plate latch Note The engine pivot plate latch is located under the engine turntable pivot plate at the counterweight end of the machine 3 Open the engine pivot plate latch and swing the engine pivot plate out and away from the machine 4 Hold the manual fu...

Page 58: ... Meters flow to functions 25 ft lbs 34 Nm 7 Proportional directional solenoid valve 3 position 4 way BP Turntable rotate left right 16 20 ft lbs 22 27 Nm 8 Proportional directional solenoid valve 3 position 4 way BU Secondary boom up down 16 20 ft lbs 22 27 Nm 9 Solenoid valve 3 position 4 way BF Steer left right 25 ft lbs 34 Nm 10 Relief valve 2100 psi 145 bar BV Secondary boom down 20 ft lbs 27 ...

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Page 60: ...e 3000 psi 207 bar CD Primary boom down circuit 30 35 ft lbs 45 50 Nm 24 Pressure compensator valve 80 psi 5 5 bar BR Turntable rotate circuit 25 ft lbs 34 Nm 25 Shuttle valve CE Differential sensing circuit primary boom up down 12 14 ft lbs 16 19 Nm 26 Flow regulator valve 0 4 gpm 1 5 L min BE Jib boom and platform rotate circuit 20 ft lbs 27 Nm 27 Needle valve BN Platform level flow control 20 f...

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Page 62: ...ot adjust the relief valve higher than specified 7 Repeat steps 2 through 5 and recheck relief valve pressure 8 Remove the pressure gauge How to Adj ust the Secondary Boom D own R elief Valve How to Adjust the Secondary Boom Down Relief Valve Note Perform this procedure with the boom in the stowed position Note Refer to Function Manifold Component list to locate the secondary boom down relief valv...

Page 63: ...51 31J 53 8 3 Jib Boom Platform Rotate Manifold Components The jib boom platform rotate manifold is mounted to the platform support Index No Description Schematic Item Function Torque 1 Solenoid valve 2 position 3 way G Platform rotate jib boom select 8 10 ft lbs 11 14 Nm ...

Page 64: ...table 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 1 Counterbalance valve L Turntable rotate right 2 Counterbalance valve J Turntable rotate left ...

Page 65: ... Z 51 31J 55 8 5 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 1 Cap Breather 20 25 ft lbs 27 33 Nm 2 Spool valve CH Directional control ...

Page 66: ...chassis cover and the non steer axle covers 5 Place a bubble type level across the drive chassis non steer end Check to be sure the drive chassis is completely level 6 Remove the ball joint retaining fastener from the bracket 7 To level the drive chassis start the engine and push up or pull down on the threaded rod until the machine is completely level 8 Verify that the ground and drive chassis ar...

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Page 68: ...lenoid valve 2 position 3 way AG Braking 10 12 ft lbs 14 16 Nm 8 Relief valve 250 psi 17 2 bar AH Charge pressure circuit 10 12 ft lbs 14 16 Nm 9 Solenoid valve 2 position 3 way AI 2 speed motor shift 10 12 ft lbs 14 16 Nm 10 Check valve AJ Steer end drive motor circuit 10 12 ft lbs 14 16 Nm 11 Check valve AK Steer end drive motor circuit 10 12 ft lbs 14 16 Nm 12 Check valve AL Non steer end drive...

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Page 70: ...gh rpm rabbit symbol position Note the reading on the pressure gauge 5 Turn the engine off 6 Remove the pressure gauge from the drive pump Connect the gauge to the test port located on the traction manifold 7 Hold the charge pressure relief valve and remove the cap item AH 8 Start the engine and move and hold the function enable rpm select toggle switch to the high rpm rabbit symbol position 9 Adj...

Page 71: ...tems BP BU and BY 3 position 4 way directional valve 10V DC 6 to 8Ω schematic items BF BM and CG 2 position 3 way solenoid valve 10V DC 6 to 8Ω schematic items CA CC AF AG and AI 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 curr...

Page 72: ...d to the other terminal on the coil 5 Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 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 ...

Page 73: ...All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Raise the secondary boom until the upper pivot is above the turntable covers Turn the machine off 2 Secure the turntable from rotating with the turntable rotation lock Tip over hazard The machine could tip over when the turntable rotation assembly is remov...

Page 74: ... the fittings on the manifold Bodily injury hazard Spraying 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 squirt or spray 7 Attach a lifting strap from and overhead crane or other suitable lifting device to the turntable rotator assembly 8 Remove the turntable rotation assembly mounting fasten...

Page 75: ...fer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the oscillating axle cylinder hydraulic hoses Cap the fittings on the oscillate 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 Do not allow oil to squirt or spray 2 Remove the pin...

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Page 77: ...ked All external AC power supply disconnected from the machine Boom in the stowed position Turntable secured with the turntable rotation lock Welder disconnected from the machine if equipped with the weld cable to platform option 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 necessar...

Page 78: ...zard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 3 Determine the error source The red LED indicates the error source and will flash two separate codes The first code will indicate the first digit of the two digit code fl...

Page 79: ...blem has been corrected 15 Value too low Alarm sounds indicating a fault 17 Not calibrated Normal function except threshold for one or both directions is zero Calibrate valve threshold 24 Angle sensor 11 Value at 5V Reduced speed function Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not calibrated Cali...

Page 80: ...ring Check and service ext ret and fully stowed switches 500lb Mode Operates normally 41 Turntable Rotate Joystick 11 Value at 5V Limited speed and direction frozen at zero and neutral Cycle power off then on after problem has been corrected 12 Value too high Alarm sounds indicating a fault 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 42 Turntable Rotate Directional Valves ...

Page 81: ...cted 51 Drive Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after problem has been corrected 12 Value too high 15 Value too low 16 Value at 0V 17 Not calibrated Calibrate joystick 53 Drive Flow Valve EDC 12 Value too high Limited speed and direction Frozen at zero and neutral ALarm sounds indicating a fault Cy...

Page 82: ...e 21 Fault Direction frozen at zero and neutral AB Power up controller with problem corrected 57 Foot switch ECU Power Crosscheck 12 Value too high Direction frozen at zero and neutral AB Power up controller with problem corrected 15 Value too low 61 Steer Joystick 11 Value at 5V Limited speed and direction Frozen at zero and neutral Alarm sounds indicating a fault Cycle power off then on after pr...

Page 83: ... 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watc...

Page 84: ...minal T circuits connect at terminal Circuits crossing no connection Quick disconnect terminal Circuit breaker with amperage Key switch Toggle switch DPDT Toggle switch SPDT Pump or Motor Tilt sensor Horn button normally open Emergency stop button normally closed Resistor with ohm value Battery seperator Gauge sending unit Oil temperature switch normally open Coolant temperature switch normally op...

Page 85: ...ion 3 way Differential sensing valve Filter with bypass relief valve Relief valve with pressure setting Priority flow regulator valve Solenoid operated proportional valve Directional valve mechanically activated Flow divider combiner valve Pilot operated 3 position 3 way shuttle valve Solenoid operated 2 position 3 way directional valve Counterbalance valve with pressure and pilot ratio Solenoid o...

Page 86: ...le CR27 Brake circuit relay lift drive option CR30 Limit switch relay lift drive option CR76 Load sense aux recovery AS models CR51 Aircraft package option G Gauge G1 Battery Charge Indicator G2 Engine oil pressure G3 Engine coolant temp G4 Engine oil temp G6 Hour meter Item Description H Horn or Alarm H1 Tilt load sense alarm H4 Descent ground H6 Load sense ground JC Joystick JC1 Boom proportiona...

Page 87: ...l select switch ford efi only TS4 Hi low rpm switch TS6 Glow plug switch TS7 Platform rotate switch TS8 Jib rotate switch jib option TS9 Platform level switch TS13 Primary boom extend retract switch TS14 Drive speed switch TS15 Drive enable switch TS43 Heater switch option TS46 Proximity kill switch option TS47 Generator switch option TS51 Auxiliary pump toggle switch TS52 Engine start toggle swit...

Page 88: ...r X101 ALC500 input out connectors X102 ALC500 input out connectors X103 ALC500 input out connectors X104 ALC500 input out connectors X105 ALC500 input out connectors X106 ALC500 input out connectors X107 ALC500 input out connectors X108 ALC500 input out connectors X109 ALC500 input out connectors X1 4 Circuit splice Wire Color Legend Item Description BL Blue BK Black BR Brown GN Green OR Orange P...

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Page 93: ...November 2017 Service and Repair Manual 83 Wiring Diagram Battery Hydraulic Oil and Engine Oil Heater Options ...

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Page 103: ...November 2017 Service and Repair Manual Part No 1268553GT Z 51 31J 93 Ground Control Box Switch Panel Wiring Diagram AS ...

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Page 111: ...November 2017 Service and Repair Manual Part No 1268553GT Z 51 31J 101 Electrical Schematic CE ...

Page 112: ...Service and Repair Manual November 2017 102 Electrical Schematic CE ...

Page 113: ...November 2017 Service and Repair Manual 103 Ground Control Box Terminal Strip Wiring Diagram CE ...

Page 114: ...Service and Repair Manual November 2017 104 Z 51 31J Part No 1268553GT Ground Control Box Terminal Strip Wiring Diagram CE ...

Page 115: ...November 2017 Service and Repair Manual Part No 1268553GT Z 51 31J 105 Ground Control Box Switch Panel Wiring Diagram CE ...

Page 116: ...Service and Repair Manual November 2017 106 Ground Control Box Switch Panel Wiring Diagram CE ...

Page 117: ...November 2017 Service and Repair Manual 107 Platform Control Box Wiring Diagram CE ...

Page 118: ...Service and Repair Manual November 2017 108 Z 51 31J Part No 1268553GT Platform Control Box Wiring Diagram CE ...

Page 119: ...November 2017 Service and Repair Manual Part No 1268553GT Z 51 31J 109 Platform Control Box Switch Panel Wiring Diagram CE ...

Page 120: ...Service and Repair Manual November 2017 110 Platform Control Box Switch Panel Wiring Diagram CE ...

Page 121: ...November 2017 Service and Repair Manual 111 Hydraulic Schematic ...

Page 122: ...Service and Repair Manual November 2017 112 Z 51 31J Part No 1268553GT Hydraulic Schematic Z 51 31J Part No 1268553GT Service and R epair M anual Novem ber 2017 ...

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