Terex Genie Z-51/30J Installation and operating manual

Service and Repair Manual
Serial Number Range
Z®-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. 1268553
GT
Rev A2
November 2017

Service and Repair Manual November 2017
Introduction
ii Z®-51/31J Part No. 1268553GT
Intr od ucti o n Intr od ucti o n
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
procedure.
This manual provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group B/Type 3 as defined by ISO 16368
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 for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
Find a Manual for this Model
Go to http://www.genielift.com
Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's Manuals.
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.

November 2017 Service and Repair Manual
Introduction
Part No. 1268553GT Z®-51/31J iii
Revision History
Revision Date Section Procedure / Page / Description
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

Service and Repair Manual November 2017
Introduction
iv Z®-51/31J Part No. 1268553GT
Serial 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)

November 2017 Service and Repair Manual
Safety Rules
Part No. 1268553GT Z®-51/31J v
Section 1 Safet y R ul es
Danger
Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in death or serious
injury.
Many of the hazards identified in the operator's
manual are also safety hazards when maintenance
and repair procedures are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
•manufacturer's instructions and safety rules
•employer's safety rules and worksite
regulations
•applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.

Service and Repair Manual November 2017
Safety Rules
vi Z®-51/31J Part No. 1268553GT
Personal Safety
Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Safety alert symbol
—
used to alert
personnel
to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potential
ly hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not
avoided,
may result in property damage.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
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 flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.
Be sure that all tools and working areas
are properly mainta
ined and ready for
use. Keep work surfaces clean and free of
debris that could get into machine
components and cause damage.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
we
ight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.
Be sure that fasteners intended for one
time use (i.e., cotter pins and self
-locking
nuts) are not reused. These components
may fail if they are used a second
time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.
Be sure that your workshop or work area
is properly ventilated and well lit.

November 2017
Table of Contents
Part No. 1268553GT Z®-51/31J vii
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 2Specifications .......................................................................................................1
Machine Specifications...........................................................................................1
Performance 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 the Joystick Ramp Rate Setting...............................................16
How to Adjust the Joystick Threshold Setting.................................................17

November 2017
Table of Contents
viii Z®-51/31J Part No. 1268553GT
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 ............................................................................. 27
4-1 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
How to Install the Flex Plate ........................................................................... 44
How to install the Pump and Bell Housing Assembly ..................................... 44

November 2017
Table of Contents
Part No. 1268553GT Z®-51/31J ix
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.................................52
8-3 Jib Boom / Platform Rotate 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 Fault Codes .........................................................................................................67
Introduction...........................................................................................................67
Control System Fault Codes .............................................................................68
How to Retrieve Control System Fault Codes ................................................68
Control System Fault Codes ...........................................................................69

November 2017
Table of Contents
x Z®-51/31J Part No. 1268553GT
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 ................................................... 81
Wiring Diagram - Battery, Hydraulic Oil and Engine Oil Heater Options ............. 84
Electrical 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 Diagram (CE) ................................. 104
Ground Control Box Switch Panel Wiring Diagram (CE) ................................... 105
Platform Control Box Wiring Diagram (CE) ....................................................... 108
Platform Control Box Switch Panel Wiring Diagram (CE).................................. 109
Hydraulic Schematics...................................................................................... 111
Hydraulic Schematic, 4WD Models.................................................................... 112