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

Page 1: ...rom Z331815M 101 to Z331816M 1299 Serial Number Range 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 ...

Page 2: ...at maintenance and repair be performed at an authorized dealer service center Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All...

Page 3: ...ial Number Legend A3 12 2017 Section 5 Schematics 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 A4 01 2020 Section 3 Repair Procedure 3 37 A4 01 2020 Section 4 Fault Codes 4 13 4 14 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 A4 01 2020 Section 5 Schematics 5 15 5 16 REFERENCE EXAMPLES Section 2_Specifications Machine Specifications Section 3_Repair Procedure 3 2 Section 4_Fault...

Page 4: ...ction Procedure Schematic Page Description REFERENCE EXAMPLES Section 2_Specifications Machine Specifications Section 3_Repair Procedure 3 2 Section 4_Fault Codes 4 4 Section 5_Schematics 5 7 Electronic Version Click on any procedure or page number highlighted in blue to view the update ...

Page 5: ...del Serial number Model year Electrical schematic number Manufacture date Machine unladen weight Rated work load including occupants Maximum number of platform occupants Maximum allowable side force Maximum allowable inclination of the chassis Z331815M 0101 1 2 15 2015 1 2 3 4 5 Z3318 M 1300 Model Serial number Electrical schematic number Year of manufacture Machine unladen weight Rated work load ...

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Page 7: ...tified in the Operator s Manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tool...

Page 8: ...othing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes DANGER WARNING CAUTION NOTICE Workplace Safety Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an appr...

Page 9: ... 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 Hydraulic Hose and Fitting Torque Specifications 2 7 Torque Procedure 2 8 SAE and Metric Fasteners Torque Charts 2 9 Section 3 Repair Procedures Introduction 3 1 Platform Controls 1 1 Joystick 3 4 Table of Con...

Page 10: ...imary Boom Lift Cylinder 3 22 3 4 Primary Boom Extension Cylinder 3 23 3 5 Platform Leveling Master Cylinder 3 24 Secondary Boom Components 4 1 Secondary Boom 3 26 4 2 Secondary Boom Lift Cylinder 3 29 Hydraulic pumps 5 1 Auxiliary Pump 3 30 5 2 Function Pump 3 31 Manifolds 6 1 Function Manifold Components 3 33 6 2 Valve Adjustments Function Manifold 3 35 6 3 Valve Coils 3 39 Turntable Rotation Co...

Page 11: ...r 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 Motor Controller Fault Code Chart 4 27 Drive Motor Thermal Sensor 4 30 Section 5 Schematics Introduction 5 1 Electrical Symbol Legends 5 2 Hydraulic Symbol Legends 5 3 Electrical Schematic 5 4 Hydraulic Schematic 5 16 TABLE OF CONTENTS ...

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Page 13: ... 169 5 Nm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Fluid capacities Hydraulic tank 6 gallons 20 8 liters Hydraulic system including tank 8 gallons 28 4 liters Drive hubs 23 fl oz 0 68 liters Drive hub oil type EP 80 90W gear oil API service classification GL5 Batteries Type 6V DC Group size L16GH Quantity 8 Capacity 350 Ah...

Page 14: ...nual Boom function speeds from platform controls and one operator on the platform Primary boom up retracted 43 to 71 36 to 40 seconds Primary boom down retracted 43 to 71 46 to 50 seconds Primary boom up extended 43 to 71 48 to 52 seconds Primary boom down extended 43 to 71 55 to 59 seconds Secondary boom up 20 to 24 seconds Secondary boom down 20 to 24 seconds Primary boom extend 18 to 20 seconds...

Page 15: ...cations require additional equipment and special installation instructions for the approved optional fluids Consult the 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 range If the hydraulic fluid temperatur...

Page 16: ...on 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 200...

Page 17: ...mp Displacement 0 5 gpm 1 9 l min Manifold Component Specifications Plug Torque SAE No 2 36 in lbs 4 Nm SAE No 4 10 in lbs 13 Nm SAE No 6 14 in lbs 19 Nm SAE No 8 38 in lbs 51 Nm SAE No 10 41 in lbs 55 Nm SAE No 12 56 in lbs 76 Nm Valve Coil Resistance Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in ai...

Page 18: ...GR 8 8 lubricated 180 ft lbs 244 Nm 140 ft lbs 189 Nm Turntable rotate assembly Rotate bearing mounting bolts lubricated 173 ft lbs 235 Nm Rotate bearing motor brake mounting bolts lubricated 87 ft lbs 110 Nm Drive motor and hubs Drive hub mounting bolts lubricated 180 ft lbs 244 Nm Drive motor mounting bolts lubricated 27 9 ft lbs 37 8 Nm Continuous improvement of our products is a Genie policy P...

Page 19: ...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 SAE O ring Boss Port tube fitting installed into Steel SAE Dash size Torque 4 ...

Page 20: ...1 Align the tube flare hex nut against the nose of the fitting body body hex fitting and tighten the hex nut to the body hex fitting to hand tight approximately 30 in lbs 3 4 Nm 2 Make a reference mark on one of the flats of the hex nut and continue it on to the body hex fitting with a permanent ink marker Refer to Figure 1 3 Working clockwise on the body hex fitting make a second mark with a perm...

Page 21: ...EAD i n l bs N m i n l bs N m i n l bs N m i n l bs N m i n l bs N m 20 80 9 100 11 3 110 12 4 140 15 8 130 14 7 28 90 10 1 120 13 5 120 13 5 160 18 140 15 8 ft l bs N m ft l bs N m ft l bs N m ft l bs N m ft l bs N m 18 13 17 6 17 23 18 24 25 33 9 21 28 4 24 14 19 19 25 7 20 27 1 27 36 6 24 32 5 16 23 31 2 31 42 33 44 7 44 59 6 38 51 5 24 26 35 2 35 47 4 37 50 1 49 66 4 43 58 3 14 37 50 1 49 66 4...

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Page 23: ...on with the key removed Wheels chocked All external AC power supply disconnected from the machine 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 Perform disassembly procedures to the point where repairs can be completed Then...

Page 24: ...lize Hall Effect technology and require no external adjustment The operating parameters of the joysticks are stored in memory at TCON If a joystick controller fault occurs or if a joystick is replaced it will need to be calibrated before that particular machine function will operate See 1 2 How to Calibrate a Joystick The platform control box also contains a liquid crystal display LCD screen The L...

Page 25: ...ow in accordance with the following instructions Written approval must be obtained from Genie Industries prior to making any change to configuration settings other than those listed below Consult Genie Service Department for additional information MOVING THE SWITCH IN THE LEFT DIRECTION EXITS THE CURRENT MENU EQUAL TO EXIT MOVING THE SWITCH IN THE RIGHT DIRECTION SELECTS THE MENU ITEM EQUAL TO ENT...

Page 26: ... Repair Procedures 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 PLATFORM CONTROLS ...

Page 27: ...RESHOLD CURRENT is shown on the display 9 Momentarily activate the drive enable toggle switch in the right direction to enter the threshold calibration mode Toggle switch controlled functions Begin this procedure with the rotary speed control at the plaform controls turned fully in the counterclockwise direction 10 Press down on the foot switch and activate the function in the direction to be corr...

Page 28: ...on while holding the steer rocker switch in the right direction 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 6 Momentarily activate the steer rocker switch in the right direction until SETTINGS is shown on the display 7 Momentarily activate the drive enable toggle switch in the r...

Page 29: ... should sound indicating the setting has been saved 18 Repeat steps 11 through 17 as needed for high flow functions Low flow functions 19 Momentarily activate one of the low flow functions full stroke Result The display will show the function direction and milliamps 20 Start a timer press down on the foot switch and activate the same function in the same direction again Record the time it takes fo...

Page 30: ...direction until VALVE AND PUMP SETTINGS is shown on the display 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 in the right direction until RAMP UP TIME is shown on the display 10 Momentarily activate the drive enable toggle switch in the right direction to enter R...

Page 31: ...p when returned to the neutral position The ramp down time of a function can be changed to compensate for hydraulic pump wear to maintain peak performance from the machine Begin this procedure with the rotary speed control at the platform turned fully in the clockwise direction 1 Turn the key switch to platform control 2 Pull out the red Emergency Stop button to the on position at both the ground ...

Page 32: ...and determine whether the ramp up time needs to increase or decrease 14 To adjust the ramp down time setting release the foot switch Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease Each time the steer rocker switch is momentarily pressed the time will change in 0 1 second increments Changing the ramp up time setting in on...

Page 33: ...cker switch in the right direction until you see the AUTHORIZATION screen 8 Momentarily activate the drive enable toggle switch in the right direction to enter the authorization screen 9 Using the rocker switch on the drive joystick momentarily activate steer left left right and left Result The alarm will sound 10 Momentarily activate the steer rocker switch in the right direction until you see th...

Page 34: ...the drive speed 18 Momentarily move the steer rocker switch in the right direction to increase or momentarily in the left direction to decrease Repeat steps 16 and 17 Note Adjusting this setting will affect the stowed drive speed in forward and reverse 19 Momentarily activate the drive enable toggle switch to the right direction to save your changes Result The alarm should sound indicating the set...

Page 35: ...the platform is resting on the blocks 3 Tag and disconnect the hydraulic hoses to the slave cylinder at the union and connect them together with a connector Cap the fittings on the cylinder hoses WARNING 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 spra...

Page 36: ...shing hazard The platform could fall if not properly supported PLATFORM COMPONENTS 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 1 Level the platform 2 Determine t...

Page 37: ...own and allowed to settle between adjustments Confirm the setting 5 Turn the key switch to platform control 6 Lift the test weight off the platform floor using a suitable lifting device 7 Place the test weight back onto the center of the platform floor using a suitable lifting device Result The alarm should be off The platform overload indicator light should be off at both the ground and platform ...

Page 38: ...witch in the right direction 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 Result The display will show ACTIVE FAULTS 7 Momentarily activate the steer rocker switch in the right direction until RESET OVERLOAD MSG is shown ...

Page 39: ...eat step 1 for each link 3 To remove a single link open the lower clip Use a screwdriver to pry the link to the side a b H I J K L M N O H P H Q J R K O R J K Q S I R T N P U I J O Note 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 installation Refer to Section Two Hydraulic Hose and Fitting Torque Speci...

Page 40: ...lic 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 10 Tag disconnect and plug the hydraulic hoses at the mid pivot end of the cable tray Cap the fittings on the hydraulic lines Refer to YY in the illustration 11 Place blocks between the cable bridge and the primary boom Secure them togeth...

Page 41: ...significant component damage Dealer service is strongly recommended Perform this procedure with the boom in the stowed position 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 installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 2 How to Remove the Pl...

Page 42: ...rface 10 Remove the pin retaining fasteners from the primary boom lift cylinder rod end pivot pin Use a soft metal drift to remove the pin WARNING Crushing hazard The primary boom and primary boom lift cylinder could fall if not properly supported 11 Lower the rod end of the primary boom lift cylinder onto support blocks Protect the cylinder rod from damage 12 Remove the pin retaining fasteners fr...

Page 43: ...tension tube and extension cylinder assembly out of the boom tube WARNING Crushing hazard The primary boom extension tube could become unbalanced and fall when removed from the primary boom tube if not properly supported During removal the overhead crane strap will need to be carefully adjusted for proper balancing 7 Remove the external snap rings from the extension cylinder rod end pivot pin at t...

Page 44: ... of the primary boom lift cylinder with a second overhead crane or similar lifting device 5 Tag disconnect and plug the primary boom lift cylinder hydraulic hoses Cap the fittings on the cylinder WARNING 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 spra...

Page 45: ...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 extension cylinder hydraulic hoses barrel end Cap the fittings on the cylinder WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to d...

Page 46: ... pump for the slave cylinder It is part of the closedloop hydraulic circuit that keeps the platform level through the entire range of primary boom motion The platform leveling master cylinder is located at the base of the primary boom WARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills ...

Page 47: ...lifting device to the master cylinder 3 Remove the pin retaining fasteners from the master cylinder barrel end pivot pin Use a soft metal drift to remove the pin WARNING Crushing hazard The master cylinder could become unbalanced and fall if not properly attached to the overhead crane 4 Remove the pin retaining fastener from the rodend pivot pin 5 Place a rod through the rod end pivot pin and twis...

Page 48: ...ion 3 Tag disconnect and plug the hydraulic hoses of the primary boom lift cylinder Cap the fittings WARNING 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 NOTICE Component damage hazard Cables and hoses can be damaged if they are kinked or pinched ...

Page 49: ...he machine 14 Remove the pin retaining fasteners securing the master cylinder pivot pin to the mid pivot 15 Using a soft metal drift remove the master cylinder pivot pin at the mid pivot Remove the secondary boom 16 Remove the pin retaining fasteners securing the secondary link pivot pin to the turntable 17 Using a soft metal drift remove the secondary link pivot pin WARNING Crushing hazard The se...

Page 50: ...air Procedures SECONDARY BOOM COMPONENTS 24 Remove the secondary boom from the machine letting the hydraulic hoses slide inside WARNING Crushing hazard The secondary boom could become unbalanced and fall if not properly supported when removed from the machine ...

Page 51: ...e fittings on the cylinder WARNING 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 3 Attach a lifting strap of suitable capacity from an overhead crane to the secondary boom lift cylinder 4 Remove the pin retaining fasteners from the secondary boom l...

Page 52: ...ould result in death or serious injury Remove all rings watches and other jewelry 4 Open the hydraulic tank side turntable cover 5 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications WARNING Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 6 Remove the drain plug from the hydraulic tank Completely drain the hydraulic tank into a c...

Page 53: ... the function pump WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Place a suitable container under the hydraulic tank Refer to Section 2 Specifications WARNING Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns HYDRAULIC PUMPS 4 Remove the drain plug fr...

Page 54: ...oggle switch and the steer rocker switch Result The display will show FAULTS 7 Momentarily activate the steer rocker switch in the right direction until SETTINGS is shown on the display 8 Momentarily activate the drive enable toggle switch in the right direction to enter the SETTINGS menu Result The display will show VALVE AND PUMP SETTINGS 9 Momentarily activate the drive enable toggle switch in ...

Page 55: ...E PLUG 5 VALVE RELIEF 130 BAR 1885 PSI BP Primary boom down 6 VALVE SOLENOID 3 POS 4 WAY BG Platform level up down 7 NIPPLE DIAGNOSTIC 4 8 CAP DIAGNOSTIC NIPPLE 9 VALVE PROPORTIONAL 3 POS 4 WAY BC Steer left right 10 VALVE PROPORTIONAL RELIEF BW System relief 11 VALVE PROPORTIONAL 3 POS 4 WAY BU Primary boom extend retract 12 VALVE RELIEF 130 bar 1885 PSI BP Secondary boom down 13 VALVE BL Turntab...

Page 56: ...3 34 Z 33 18 Part No 1268514GT January 2020 Section 3 Repair Procedures 10 9 6 3 4 1 2 11 14 BS BU BN BK BG BC BW BL BH 13 BM 8 7 15 BJ 5 12 17 16 4 BP BP MANIFOLDS ...

Page 57: ...s after the alarm sounds The function enable toggle switch must be activated within 2 seconds of the audible tone Result The green LED on the TCON should change from a slow blinking light to a rapid blinking light Result The green LED on the TCON does not blink rapidly Push in the red Emergency Stop button to the off position and repeat this procedure beginning with step 3 a green LED b red LED c ...

Page 58: ...p direction to increase the relief pressure or in the down direction to decrease the relief pressure Repeat this procedure beginning with step 6 Momentarily activating the platform level toggle switch will increase or decrease the relief pressure in increments of approximately 50 psi 3 bar 8 Move and hold the secondary boom toggle switch in the up direction Result The pressure gauge shows 2500 psi...

Page 59: ...eted within 90 seconds or terminate if the function enable switch is activated 4 Simultaneously activate the platform level toggle switch until the pressure gauge reads 1000 PSI 69 bar The platform level toggle up increases pressure platform level down decreases pressure 5 Simultaneously activate the platform rotate toggle switch to store the value Result The control system will continue to the ne...

Page 60: ...lief valve higher than specified 7 Turn the machine off Remove the pressure gauge and install the proportional relief valve coil 1 Turn the machine off Locate the proportional relief valve item BW on the function manifold Remove the coil nut and remove the coil from the valve cartridge and set aside Do not disconnect the coil electrical connector 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gau...

Page 61: ...ectrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table...

Page 62: ...should read 9V DC or more when measured across the terminals 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil Note If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil 5 Momentarily connect the po...

Page 63: ...4 Remove the counterweight bottom screw to disassembly it from the swing chassis NOTE At the end of the following procedure make sure to apply an even coat of Loctite 243 retaining compound on the thread of the screw before reinstalling it into the counterweight 5 Attach a lifting strap from a suitable lifting device to the eyebolt 6 Carefully lift up and remove the counterweight from the turntabl...

Page 64: ...ice to the two turntable s handles and to the counterweight handle bar 13 Remove the turntable rotation assembly mounting fasteners 14 Carefully remove the turntable rotation assembly from the machine WARNING Crushing hazard The machine could tip over when the turntable rotation assembly is removed if the turntable rotation lock is not in the locked position WARNING Crushing hazard The turntable r...

Page 65: ... seal When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 1 Be sure that both bearings are packed with clean fresh grease 2 Place the large inner bearing into the rear of the hub 3 Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Always replace the bearing grease seal when removing the h...

Page 66: ... minimize turning radius Drive speed is also reduced proportionately depending on the steer angle to minimize lateral platform acceleration 1 Adjust the steer tires so they are in a straight driving position 2 Turn the key switch to the off position 3 Push in the red Emergency Stop buttons to the off position at both the ground and platform controls 4 Remove the drive chassis cover at the steer en...

Page 67: ...er fasteners 15 Install the cable clamp to secure the steer sensor cable to the drive chassis 16 Install the drive chassis cover 17 Calibrate the steer sensor See 9 2 How to Calibrate the Steer Angle Sensor 1 Turn the key switch to platform control 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Using the thumb rocker switch on the drive joyst...

Page 68: ...rection until you see the CALIBRATE RIGHT screen 12 Adjust the steer wheels fully in the right direction 13 Momentarily activate the drive enable toggle switch in the right direction to enter the CALIBRATE RIGHT screen Result The display will show OUT OF RANGE or IN RANGE according to the wheels position 14 Momentarily activate the drive enable toggle switch in the right direction to save the sett...

Page 69: ...oggle 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 To exit programming mode 19 Move and hold the drive enable toggle in the left position until the display returns to SYSTEM READY mode STEER AXLE COMPONENTS ...

Page 70: ...e drive motor if it becomes excessively hot 1 Disconnect the battery packs from the machine WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Remove the chassis cover fasteners from the non steer end of the chassis Remove the cover 3 Tag and disconnect the power cables from the drive mot...

Page 71: ... the non steer end of the chassis Remove the cover 4 Tag and disconnect the electrical connector from the brake 5 Loosen the brake mounting fasteners in an even pattern until all spring tension has been relieved Remove the fasteners 6 Remove the brake from the drive motor Some parts may fall loose from the brake assembly during removal Refer to the following illustrations to be sure the spring pat...

Page 72: ...convert the voltage to AC power for the drive motors The motor controllers are in communication with the turntable controller TCON and the platform controller PCON which are able to communicate operating or fault information to the LCD display at the platform controls The motor controllers also control the valve outputs and machine options such as flashing beacon travel alarm etc Refer to Section ...

Page 73: ...ine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices DANGER Crushing hazard When testing or replacing any hydraulic component always...

Page 74: ...ctivate the steer rocker switch in the right direction to scroll through the fault codes To access motor controller faults 9 Momentarily activate the drive enable toggle switch in the right direction until ACTIVE FAULTS is shown on the display 10 Activate the steer rocker switch in the right direction until MOTOR CONTROLLER FAULTS is shown on the display 11 Momentarily activate the drive enable to...

Page 75: ...appear as three quick red flashes followed by a short pause then three more quick red flashes followed by a long pause 7 Determine the error type The flashing green LED when combined with short or long pauses between the flash tells the service technician the specific error type Error type code 12 for example would appear as one quick green flash followed by a short pause of almost two seconds the...

Page 76: ...too high All functions disabled Check for voltage at main contactor coil with machine in the on position 24V DC on red wire 48V DC on orange wire Replace main contactor 15 Value too low All functions disabled Check for voltage at main contactor coil with machine in the on position 24V DC on red wire 48V DC on orange wire Replace main contactor 14 RELIEF_VALVE 12 Value too high Auxiliary functions ...

Page 77: ... Replace motor 19 AUX_PUMP Auxiliary pump 12 Value too high Auxiliary functions disabled Check fuse F1 200A Check for 24V DC to Aux pump Replace Aux pump Replace left slave AC motor controller 15 Value too low Auxiliary functions disabled Check for 24V DC to Aux pump Replace Aux pump Replace left slave AC motor controller 21 PRI_UD_JYSTK Primary up down joystick 11 12 15 16 Shorted high 5V Value t...

Page 78: ...t coil 32 SEC_UP_VALVE Secondary boom up valve 12 15 Value too high Value too low Secondary up function disabled Check for open or short from TCON P2 7 to the secondary up coil Replace coil 33 SEC_DN_ VALVE Secondary boom down valve 12 15 Value too high Value too low Secondary down function disabled Check for open or short from TCON P2 8 to the secondary down coil Replace coil 41 TT_ROT_JYSTK Turn...

Page 79: ...52 AC_R_MOTOR Right side drive motor 12 Value too high Drive function disabled Do not operate machine with batteries charging Check cable connections Check for 33V AC across any two legs on drive motor at full stick Replace right drive motor Replace right master AC motor controller 15 Value too low Drive function disabled Check cable connections Check for 33V AC across any two legs on drive motor ...

Page 80: ...6 wire deustch plug on motor Check resistance on thermal sensor 54 BRAKE_RIGHT Right side AC motor brake 15 Value too low Drive function disabled Check for 48V DC to brake Check for 48V DC on R 1 Replace brake Replace right master AC motor controller 55 BRAKE_LEFT Left side motor brake screen 15 Value too low Drive function disabled Check for 48V DC to brake Check for 48V DC on R 1 Replace brake R...

Page 81: ...CTRLR Left side Slave AC motor controller 21 Fault All functions disabled or limited Cycle power off and back on If fault persist replace left slave AC motor controller See motor controller fault code chart 61 STEER_JYSTK Joystick steer 11 12 15 16 Shorted high 5V Value too high Value too low Value at 0V Steering function disabled Repair Joystick wire connections or replace Joystick 17 Not calibra...

Page 82: ...controller 66 AC_L_OUTPUT Left side AC motor controller output 15 Value too low Hour meter brake relay and tilt sensor alarm disabled Platform overload alarm disabled option Check wiring and coil for function causing fault Fault at power up replace left slave AC motor controller 16 Value at 0V Output shorted to B 67 DENA_SW_ PBOX Platform control box drive enable switch 12 19 21 Value too high Out...

Page 83: ... only Extend disabled Do not exceed maximum platform weight Check for 24V DC black input to load sensor Check for 24V DC red output from load sensor Check for 0V DC on right master AC motor controller on R 19 Replace load sensor 77 VCON_PBOX Platform display screen 13 No response Platform functions disabled Ground controls operative Check can bus circuit for open Check can bus resistor Isolate all...

Page 84: ...BY OWNER 21 Lift and Drive functions disabled or slowed remotely by GTM Request from Telematics Device Lift and Drive functions disabled remotely according to the machine configuration by Track Trace device contact machine owner 90 Z33 WIRE CONNECTION 21 Fault Only fault code on the display All functions are enabled Check wire connection AC motor controller left pin 7 ...

Page 85: ...er rheostat 17 AUX_PUMP Auxiliary Pump 25 RESISTANCE TOO HIGH Pump motor output is too low with respect to PWM applied Auxiliary functions disabled Check Fuse F1 200A Check for 24V DC to AUX pump If OK check pump winding resistance Replace AUX pump Replace Left slave AC controller 26 RESISTANCE TOO LOW Pump motor output is too high with respect to PWM applied Main Lift Pump and Drive Disabled P Co...

Page 86: ...y CR3 86 CR3 85 DC units only 20 Primary Extend Retract Joystick Rocker 11 Shorted to supply 5V Primary Boom Extend Retract Disabled Inspect and repair joystick 5V at JC7 2 P162JPW OR B at JC7 1 JSGND BR 1050 to 3750 mV at JC7 5 PCON C28 5 C163PLS BL WH through joystick motion Replace joystick 16 Sensor at Zero 0V 17 Not calibrated Not between 2000 3000 mV at startup 21 Primary Up Down Joystick 11...

Page 87: ...bled Check for open or short from TCON C14 4 to the up coil Replace coil 26 Resistance Too Low Short or Ohms 5 32 Secondary Up Valve 25 Resistance Too High Open Circuit or Ohms 60 Associated Function disabled Check for open or short from TCON C14 7 to the up coil Replace coil 26 Resistance Too Low Short or Ohms 5 33 Secondary Down Valve 25 Resistance Too High Open Circuit or Ohms 60 Associated Fun...

Page 88: ...and repair joystick 5V at JC3 2 P162JW OR B at JC3 1 JSGND BR 500 4500 mV at JC3 4 PCON C47 2 C160JPL WH RD through joystick motion 16 Sensor at 0v 0V 17 Not calibrated Not between 2000 3000 mV at startup 56 Telematics Device 13 Not Detected Genie Telematics Device not detected when option is enabled Only basic telematics functionality Verify CAN bus wiring Telematics Device is functioning 61 Stee...

Page 89: ...ne RPM don t match by more than 100 RPM for 2 5 seconds Primary Up and Secondary Up are disabled Check 3 wire plug on lift pump motor verify 5V DC to pin B at pin C Check Replace lift pump motor encoder and wiring 71 Estop Relay 21 Fault Relay Contact Stuck Platform Estop detected when Key Switch is in Ground Position or Platform Estop not detected when Key Switch is in platform position All platf...

Page 90: ...CAN communication Lift functions disabled Verify 24V supply on C35 1 C35 2 B at C28 1 60 Ohm resistance across CAN C34 1 and C34 2 Replace Right master AC controller 78 PCON controller platform controls 13 Not Detected No CAN communication All functions disabled Verify 24V supply on C28 2 C29 11 C29 12 B at C28 1 60 Ohm resistance across CAN C28 3 and C28 4 29 Sotware Version Mismatch Wrong softwa...

Page 91: ...rt circuit across RDCON C16 11 B V14PLU OR 104 Steer Angle Sensor 11 Shorted to supply 5V High Speed Drive disabled Check for 5V DC at steer sensor GR WH Check for 0 5V DC output at steer sensor orange Check for 0 5V DC at right AC motor controller C16 30 Replace steer sensor 12 VALUE TOO HIGH 4 5V 15 VALUE TOO LOW 0 5V Re calibrate steer sensor Replace steer sensor 16 Sensor at Zero 0V 17 Not cal...

Page 92: ...otor Controller 21 Fault Internal fault not mapped to a specific Genie fault code has occurred Functions disabled or limited per AC motor controller internal fault handling Refer to MOTOR CONTROLLER FAULT CODES screen on platform display and MOTOR CONTROLLER FAULT CODE CHART in service manual If fault persist replace Right AC Motor Controller 160 Steer Left Valve 21 Fault Open or shorted Associate...

Page 93: ...per airflow to lift pump motor Ensure that hydraulic pressure settings are correct If motor cools and problem remains check temperature switch and wiring 25 RESISTANCE TOO HIGH Pump motor output is too low with respect to PWM applied Lift pump disabled Auxiliary functions only Check cables going to the Lift Motor 26 RESISTANCT TOO LOW Pump motor output is too high with respect to PWM applied Lift ...

Page 94: ...lugs when joystick fully deflected Replace right drive motor Replace right AC motor controller 15 VALUE TOO LOW Motor Windings Shorted Drive Disabled Functions allowed Do not operate machine with batteries charging Check for shorted motor cable connections Check for 33V AC across 2 motor lugs when joystick fully deflected Replace right drive motor Replace right AC motor controller 21 FAULT Tempera...

Page 95: ...orted Drive Disabled AUX Lift Functions allowed Do not operate machine with batteries charging Check for shorted motor cable connections Check for 33VAC across 2 motor lugs when joystick fully deflected Replace right drive motor Replace right AC motor controller 21 FAULT Temperature or speed sensor failure Drive Current Reduced to 50 Check wires to thermal speed sensor at 6 pin Deustch connector C...

Page 96: ...R Encoder AC Motor Left Side 21 FAULT Loss of speed sensor encoder signal Drive Functions disabled Check wiring at 6 pin deutsch connector on motor Check for 12V DC on pins 1 2 Replace motor encoder is inside Replace left slave AC motor controller 202 AC_R_CTRLR AC Motor Controller Right Side 26 RESISTANCE TOO LOW Coil shorted or lower than expected resistance Steering Platform Level and Flashing ...

Page 97: ...he function activated when fault occurs Look for short to B in wire from faulted function to right AC motor controller 204 BATTERY_ PWR Battery Power Notes AUX is available Drive is locked out 19 OUT OF RANGE Battery Voltage Too High Main Contactor Opens or will not close Check that batteries are not being charged while attempting to operate Voltage must be below 65V Ensure that batteries are not ...

Page 98: ...f OK replace contactor or right AC motor controller if contactor is OK 12 VALUE TOO HIGH Contacts detected closed when contactor not commanded Check for voltage at main contactor coil with machine in the ON position 24V DC on red wire 48V DC on orange wire Replace main contactor 13 VALUE TOO LOW Contacts Stuck Open won t close when commanded Check for voltage at main contactor coil with machine in...

Page 99: ...ng to the right brake coil Replace the AC motor controller 8785 Hardware coil short time out No functions or drive Replace the AC motor controller 65512 W rong set point No functions or drive Replace the AC motor controller 6513 Power MOS shorted No functions or drive Replace the AC motor controller 65515 Tiller errror No functions or drive Check for 48V DC R 1 OR RD on master motor controller Che...

Page 100: ...unctions or drive Replace the AC motor controller 65509 Wrong zero No functions or drive Replace the AC motor controller 65510 Output mismatch No functions or drive Replace the AC motor controller 65530 Input mismatch No functions or drive Replace the AC motor controller 65511 Safety feedback No functions or drive Replace the AC motor controller 65512 Wrong setpoint No functions or drive Replace t...

Page 101: ...CHART AC Motor controller code Error Type Condition Solution 65280 Tiller mismatch No functions or drive Replace the AC motor controller 16913 Current sensor time out No functions or drive Replace the AC motor controller 21776 EEPROM warning No functions or drive Replace the AC motor controller ...

Page 102: ...ction device Normal safe operating range is between 40 F 40 C and 131 F 55 C at an 85 duty cycle Thermal faults will occur when the temperature exceeds its threshold of 302 F 150 C Then drive speeds will be reduced by 50 Thermal shut down occurs at 392 F 200 C 1 Disconnect the battery packs from the machine WARNING Electrocution burn hazard Contact with electrically charged circuits could result i...

Page 103: ...at 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 WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics WARNING Bodily injury hazard Spraying hydraulic oil c...

Page 104: ...5 2 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Electrical Symbols Legends ...

Page 105: ...January 2020 Part No 1268514GT Z 33 18 5 3 Section 5 Schematics Hydraulic Symbols Legends ...

Page 106: ...January 2020 Section 5 Schematics 5 4 5 5 Electrical Schematic ...

Page 107: ... PRIMARY COLLISION CONTROL LS3 DRIVE ENABLE LS28 COLLISION ZONE LS27 FAST MAST LS1 PRIMARY RETRACT LS LS2 PRIMARY DOWN LS LS4 SECONDARY DOWN LS PTIMARY EXTENDED HV PRIMARY RETRACT HV PRIMARY UP HV PRIMART DOWN HV SECONDARY UP HV SECONDARY DOWN HV TURRET CW HV TURRET CCW HV PLATFORM BOX GROUND BOX B B1 1 1 2 2 3 1 2 4 1 2 2 1 3 2 1 1 2 2 2 2 1 1 1 3 3 3 C16 C16 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1...

Page 108: ...January 2020 Section 5 Schematics 5 7 Electrical Schematic ...

Page 109: ...5 8 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Electrical Schematic from S N Z331815M 307 to S N Z331816M 946 ...

Page 110: ...January 2020 Section 5 Schematics 5 9 Electrical Schematic ...

Page 111: ...5 10 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics 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 ...

Page 112: ...January 2020 Section 5 Schematics 5 11 Electrical Schematic ...

Page 113: ...5 12 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Electrical Schematic from S N Z3318M 1783 to Z3318M 2668 ...

Page 114: ...January 2020 Section 5 Schematics 5 13 Electrical Schematic ...

Page 115: ...5 14 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Electrical Schematic from S N Z3318M 2669 ...

Page 116: ...5 15 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Electrical Schematic from S N Z3318M 2669 ...

Page 117: ...5 16 Z 33 18 Part No 1268514GT January 2020 Section 5 Schematics Hydraulic Schematic ...