service genie z135
TRANSCRIPT
Service Manual
Part No. 106783
Rev D1
July 2009
Serial Number Range
from Z13505-101
Z-135/70
Z-135/70 Part No. 106783
April 2008
ii
Introduction
Important
Read, understand and obey the safety rules andoperating instructions in the Genie Z-135/70Operator's Manual before attempting anymaintenance or repair procedure.
This manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting faultcodes and repair procedures for qualified serviceprofessionals.
Basic mechanical, hydraulic and electrical skillsare required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealer servicecenter.
Technical Publications
Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specifications aresubject to change without notice.
Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.
Contact Us:
http://www.genieindustries.come-mail: [email protected]
Copyright © 2005 by Genie Industries
106783 Rev D April 2008First Edition, Fourth Printing
"Genie" and "Z" are registered trademarks ofGenie Industries in the USA and many othercountries.
Printed on recycled paper
Printed in U.S.A.
Introduction
Part No. 106783 Z-135/70
April 2008
INTRODUCTION
Serial Number Legend
iii
Z135 05 - 12345
Model
Year ofmanufacture
Sequencenumber
PN - 77055
Country of manufacture: USA
This machine complies with:
Genie Industries
18340 NE 76th Street
Redmond, WA 98052
USA
ANSI A92.5CAN B.354.4
Model: Z-135/70
Serial number: Z13505-12345
Electrical schematic number: ES0366
Machine unladen weight:
Rated work load (including occupants): 600 lb / 273 kg
Maximum allowable inclination of the chassis:
0 deg
Gradeability: 45%
Maximum allowable side force : 150 lb / 670 N
Maximum number of platfrm occupants: 2
Model year: Manufacture date: 04/12/052005
Maximum wind speed : 28 mph/ 12.5 m/s
Maximum platform height : 135 ft/ 41.15 m
Maximum platform reach : 69 ft 9 in/ 21.26 m
Serial numberstamped on chassis
Serial label(located under cover)
Z-135/70 Part No. 106783
April 2008
iv
This page intentionally left blank.
Part No. 106783 Z-135/70
April 2008
v
Safety Rules
Section 1 • Safety Rules
DangerFailure to obey the instructions and safety rules inthis manual, and the Genie Z-135/70 Operator'sManual will result in death or serious injury.
Many of the hazards identified in the operator'smanual are also safety hazards when maintenanceand repair procedures are performed.
Do Not Perform MaintenanceUnless:
You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.
Z-135/70 Part No. 106783
April 2008
SAFETY RULES
vi
Section 1 - Safety Rules
Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases
and engine fuels. Always have an approved fireextinguisher within easy reach.
Be sure that all tools and working areasare properly maintained and ready for use.Keep work surfaces clean and free of
debris that could get into machine components andcause damage.
Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the
weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.
Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These components
may fail if they are used a second time.
Be sure to properly dispose of old oil orother fluids. Use an approved container.Please be environmentally safe.
Be sure that your workshop or work area isproperly ventilated and well lit.
Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.
Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.
Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or
placing loads. Always wear approved steel-toedshoes.
Part No. 106783 Z-135/70
Juyl 2009
Table of Contents
vii
Introduction
Important Information ................................................................................................... ii
Serial Number Legend ................................................................................................. iii
Section 1 Safety Rules
General Safety Rules .................................................................................................. v
Section 2 Rev Specifications
G Machine Specifications .......................................................................................... 2 - 1
Performance Specifications ................................................................................... 2 - 1
Hydraulic Specifications ........................................................................................ 2 - 2
Manifold Component Specifications ....................................................................... 2 - 4
Deutz BF4L 2011 Engine ....................................................................................... 2 - 5
Deutz TD2011L04i Engine...................................................................................... 2 - 7
Cummins B4.5L Engine ......................................................................................... 2 - 9
Cummins B3.3T Engine ....................................................................................... 2 - 10
Perkins 1104C-44 Engine ..................................................................................... 2 - 11
Perkins 804D-33T Engine .................................................................................... 2 - 13
Machine Torque Specifications ............................................................................ 2 - 14
Hydraulic Hose and Fitting Torque Specifications ................................................ 2 - 15
SAE and Metric Fasteners Torque Charts ............................................................ 2 - 16
Z-135/70 Part No. 106783
July 2009
TABLE OF CONTENTS
viii
Section 3 Rev Scheduled Maintenance Procedures
Introduction ............................................................................................................ 3 - 1
Pre-delivery Preparation ......................................................................................... 3 - 3
Maintenance Inspection Report .............................................................................. 3 - 5
G Checklist A Procedures
A-1 Inspect the Manuals and Decals .................................................................. 3 - 7
A-2 Perform Pre-operation Inspection ................................................................. 3 - 8
A-3 Perform Function Tests ................................................................................ 3 - 8
A-4 Perform Engine Maintenance - Deutz Models ............................................... 3 - 9
A-5 Perform Engine Maintenance - Cummins Models ......................................... 3 - 9
A-6 Perform Engine Maintenance - Perkins Models .......................................... 3 - 10
A-7 Check the Hydraulic Return Filter Condition Indicator ................................. 3 - 10
A-8 Inspect the Fuel Filter/Water Separator Element - Perkins Models ............. 3 - 11
A-9 Drain the Fuel Filter/Water Separator Element -Deutz and Cummins Models ...................................................................... 3 - 12
A-10 Perform 30 Day Service ............................................................................. 3 - 13
A-11 Grease the Turntable Rotation Bearing and Rotate Gear ............................ 3 - 13
A-12 Replace the Drive Hub Oil .......................................................................... 3 - 14
D Checklist B Procedures
B-1 Inspect the Batteries .................................................................................. 3 - 15
B-2 Inspect the Electrical Wiring ....................................................................... 3 - 16
B-3 Test the Key Switches ............................................................................... 3 - 18
B-4 Check the Exhaust System ....................................................................... 3 - 20
B-5 Check the Engine Oil Cooler and Cooling Fins - Deutz Models ................... 3 - 21
B-6 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 22
Part No. 106783 Z-135/70
Juyl 2009
TABLE OF CONTENTS
ix
Section 3 Rev Scheduled Maintenance Procedures, continued
B-7 Confirm the Proper Brake Configuration...................................................... 3 - 22
B-8 Check the Drive Hub Oil Level and Fastener Torque .................................. 3 - 23
B-9 Test the Ground Control Override ............................................................... 3 - 24
B-10 Test the Platform Self-leveling ................................................................... 3 - 25
B-11 Test the Engine Idle Select Operation ........................................................ 3 - 26
B-12 Test the Drive Brakes ................................................................................ 3 - 27
B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 27
B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 28
B-15 Test the Alarm and Optional Flashing Beacon ............................................ 3 - 29
B-16 Perform Hydraulic Oil Analysis ................................................................... 3 - 29
B-17 Replace the Inline Fuel Filter/WaterSeparator Element - Perkins Models .......................................................... 3 - 30
B-18 Check and Adjust the Engine RPM ............................................................ 3 - 31
B-19 Test the Safety Envelope Limit Switches ................................................... 3 - 34
B-20 Test the Primary Boom Angle Sensor ........................................................ 3 - 37
B-21 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ....................... 3 - 38
B-22 Perform Engine Maintenance - Cummins Models ....................................... 3 - 39
D Checklist C Procedures
C-1 Perform Engine Maintenance - Deutz Models ............................................. 3 - 40
C-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 40
C-3 Perform Engine Maintenance - Perkins Models .......................................... 3 - 41
C-4 Grease the Platform Overload Mechanism (if equipped) ............................. 3 - 41
C-5 Test the Platform Overload Mechanism (if equipped) ................................. 3 - 42
Z-135/70 Part No. 106783
July 2009
Section 3 Rev Scheduled Maintenance Procedures, continued
D Checklist D Procedures
D-1 Check the Boom Wear Pads ...................................................................... 3 - 44
D-2 Check the Free-wheel Configuration ........................................................... 3 - 45
D-3 Replace the Drive Hub Oil .......................................................................... 3 - 46
D-4 Adjust the Turntable Rotation Backlash...................................................... 3 - 48
D-5 Replace the Hydraulic Filter Elements ........................................................ 3 - 49
D-6 Perform Engine Maintenance - Deutz Models ............................................. 3 - 51
D-7 Perform Engine Maintenance - Cummins Models ....................................... 3 - 51
D-8 Perform Engine Maintenance - Perkins Models .......................................... 3 - 52
D-9 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 52
D-10 Inspect for Turntable Bearing Wear ............................................................ 3 - 54
D Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 55
E-2 Perform Engine Maintenance - Cummins Models ....................................... 3 - 57
E-3 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 57
E-4 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 58
E-5 Perform Engine Maintenance -Deutz TD2011L04i and Perkins 804D-33T Models ...................................... 3 - 58
E-6 Perform Engine Maintenance - Deutz TD2011L04i Models ......................... 3 - 59
E-7 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 59
E-8 Perform Engine Maintenance - Perkins 1104C-44 Models .......................... 3 - 60
E-9 Perform Engine Maintenance - Perkins 804D-33T Models .......................... 3 - 60
x
TABLE OF CONTENTS
Part No. 106783 Z-135/70
Juyl 2009
TABLE OF CONTENTS
xi
Section 4 Rev Repair Procedures
Introduction ............................................................................................................ 4 - 1
C Display Module ...................................................................................................... 4 - 2
C Platform Controls
1-1 ALC-1000 Circuit Board ................................................................................ 4 - 9
1-2 Membrane Decal ........................................................................................ 4 - 10
1-3 Joysticks ................................................................................................... 4 - 11
D Platform Components
2-1 Platform Leveling Cylinder .......................................................................... 4 - 19
2-2 Platform Rotator ......................................................................................... 4 - 20
2-3 Platform Level Sensor ................................................................................ 4 - 21
2-4 Platform Overload System (if equipped) ..................................................... 4 - 23
E Jib Boom Components
3-1 Jib Boom Cable Track ................................................................................ 4 - 27
3-2 Jib Boom.................................................................................................... 4 - 29
3-3 Jib Boom Lift Cylinder ................................................................................ 4 - 31
3-4 Jib Boom Level Cylinder ............................................................................. 4 - 32
3-5 Jib Boom Extension Cylinder ..................................................................... 4 - 33
3-6 Jib Boom Bellcrank Angle Sensor .............................................................. 4 - 34
Z-135/70 Part No. 106783
July 2009
xii
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued
F Boom Components
4-1 Primary Boom Cable Track ........................................................................ 4 - 41
4-2 Secondary Boom Cable Track .................................................................... 4 - 44
4-3 Primary Boom ............................................................................................ 4 - 47
4-4 Primary Boom Lift Cylinder ......................................................................... 4 - 49
4-5 Secondary Boom Lift Cylinder .................................................................... 4 - 50
4-6 Primary Boom Extension Cylinder .............................................................. 4 - 53
4-7 Secondary Boom Extension Cylinders ....................................................... 4 - 54
4-8 Primary Boom Angle Sensor ...................................................................... 4 - 55
4-9 Secondary Boom Angle Sensor .................................................................. 4 - 61
C Engines
5-1 RPM Adjustment ........................................................................................ 4 - 66
5-2 Flex Plate................................................................................................... 4 - 66
D Ground Controls
6-1 Service Bypass / Recovery Keyswitch ....................................................... 4 - 69
6-2 Circuit Boards ............................................................................................ 4 - 71
6-3 Membrane Decal ........................................................................................ 4 - 72
C Hydraulic Pumps
7-1 Function Pump .......................................................................................... 4 - 73
7-2 Drive Pump ................................................................................................ 4 - 76
Part No. 106783 Z-135/70
Juyl 2009
xiii
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued
E Manifolds
8-1 Function Manifold - View 1 (before serial number 440) ................................ 4 - 78
8-2 Function Manifold - View 2 (before serial number 440) ................................ 4 - 80
8-3 Function Manifold - View 1 (after serial number 439) .................................. 4 - 82
8-4 Function Manifold - View 2 (after serial number 439) .................................. 4 - 84
8-5 Valve Adjustments - Function Manifold ...................................................... 4 - 86
8-6 Platform Manifold ....................................................................................... 4 - 88
8-7 Jib Boom Manifold ..................................................................................... 4 - 90
8-8 Function Enable Valve ............................................................................... 4 - 92
8-9 Turntable Rotation Manifolds ...................................................................... 4 - 93
8-10 Steer and Axle Manifold ............................................................................. 4 - 94
8-11 Valve Adjustments - Steer and Axle Manifold ............................................ 4 - 98
8-12 Traction Manifold - View 1 .........................................................................4 - 100
8-13 Traction Manifold - View 2 .........................................................................4 - 102
8-14 Valve Adjustments, Traction Manifold .......................................................4 - 104
8-15 Drive Oil Diverter Manifold (welder option) .................................................4 - 105
8-16 Valve Coils ................................................................................................4 - 106
E Turntable Rotation Components
9-1 Turntable Rotation Assembly ....................................................................4 - 108
9-2 Turntable Level Sensor .............................................................................4 - 109
F Axle Components
10-1 Steer Sensors ........................................................................................... 4 - 112
10-2 Steer Cylinders..........................................................................................4 - 117
10-3 Axle Extension Cylinders ..........................................................................4 - 118
10-4 Axle Angle Sensors...................................................................................4 - 119
Z-135/70 Part No. 106783
July 2009
xiv
Section 5 Rev Fault Codes
Introduction ............................................................................................................ 5 - 1
B Control System Fault Codes .................................................................................. 5 - 2
A SCON Fault Matrix ............................................................................................... 5 - 20
Section 6 Rev Schematics
Introduction ............................................................................................................ 6 - 1
C Wire Circuit Legend ................................................................................................ 6 - 2
B Limit Switches and Angle Sensors ......................................................................... 6 - 9
B Drive Chassis and Platform Controller Pin Legend ............................................... 6 - 11
B Safety Controller Pin Legend................................................................................ 6 - 12
B Turntable Controller Pin Legend ........................................................................... 6 - 13
B Engine Relay and Fuse Panel Legend .................................................................. 6 - 14
A Electrical Symbols Legend .................................................................................. 6 - 15
A Hydraulic Symbols Legend .................................................................................. 6 - 16
A Electrical Schematic Layout ................................................................................ 6 - 18
B Electrical Connector and Circuit Legend ............................................................... 6 - 19
B Electrical Schematic - View 1, Drive Chassis Controller (DCON) ......................... 6 - 22
D Electrical Schematic - View 2, Platform Controls (PCON) .................................... 6 - 23
C Electrical Schematic - View 3, Ground Controls (TCON) ...................................... 6 - 26
B Electrical Schematic - View 4, Ground Controls (TCON) ...................................... 6 - 27
A Electrical Schematic - View 5, Ground Controls (TCON) ...................................... 6 - 30
C Electrical Schematic - View 6, Ground Controls (TCON) ...................................... 6 - 31
TABLE OF CONTENTS
Part No. 106783 Z-135/70
Juyl 2009
Section 6 Rev Schematics, continued
B Electrical Schematic - View 7 .............................................................................. 6 - 34
D Electrical Schematic - View 8 .............................................................................. 6 - 35
B Electrical Schematic - View 9 .............................................................................. 6 - 38
D Electrical Schematic - View 10, Limit Switches ................................................... 6 - 39
A Electrical Schematic - View 10A, Limit Switches ................................................. 6 - 41
D Electrical Schematic - View 11,Deutz BF4L 2011 Engine and Deutz TD2011L04i Engine ........................... 6 - 44
B Electrical Schematic - View 12 ............................................................................ 6 - 45
B Electrical Schematic - View 13,Perkins 1104C-44 Engine and Perkins 804D-33T ....................................... 6 - 48
B Electrical Schematic - View 14,Cummins B4.5L Engine and Cummins B3.3T Engine ................................. 6 - 49
B Generator Wiring .................................................................................................. 6 - 51
D Hydraulic Schematic (before serial number 180, except for serial number 102) .... 6 - 54
B Hydraulic Schematic (serial number 102 and from serial number 180 to 534) ....... 6 - 55
A Hydraulic Schematic (from serial number 535) ..................................................... 6 - 57
TABLE OF CONTENTS
xv
Z-135/70 Part No. 106783
July 2009
This page intentionally left blank.
xvi
Part No. 106783 Z-135/70 2 - 1
Section 2 • SpecificationsJuly 2009
REV G Specifications
Machine Specifications
Tires and wheels
Tire size 445/65D22.5, FF
Tire ply rating 18
Overall tire diameter 46.5 in118.1 cm
Wheel diameter 22.5 in57.2 cm
Wheel width 13 in33 cm
Wheel lugs 10 @ 3/4 -16
Lug nut torque, dry 420 ft-lbs569.4 Nm
Lug nut torque, lubricated 320 ft-lbs433.9 Nm
Fluid capacities
Fuel tank 40 gallons151.4 liters
Hydraulic tank 65 gallons246 liters
Hydraulic system 123 gallons(including tank) 466 liters
Drive hubs 47 fl oz1.4 liters
Turntable rotation drive hub 40 fl oz1.18 liters
Drive hub oil type:SAE 90 multipurpose hypoid gear oil API serviceclassification GL5
For operational specifications, refer to theOperator's Manual.
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Performance Specifications
Drive speeds, maximum
Stowed position, high speed 2.8 mph4.5 km/h
40 ft / 9.7 sec12.2 m / 9.7 sec
Raised or extended 0.7 mph1.1 km/h
40 ft / 40 sec12.2 m / 40 sec
Raised and extended 0.4 mph0.64 km/h
40 ft / 68.5 sec12.2 m / 68.5 sec
Braking distance, maximum
High range on paved surface 3 to 6 ft1 to 2 m
Gradeability See Operator's Manual
Boom function speeds, maximumfrom platform controls
Jib boom up/down 38 to 43 seconds
Jib boom extend/retract 38 to 42 seconds
Primary boom up/down-60° to +70° 88 to 105 seconds
Primary boom extend/retract 35 to 48 seconds
Secondary boom up/down 80 to 95 seconds
Secondary boom extend/retract 88 to 98 seconds
Turntable rotate, 360° 88 to 92 secondsfully stowed
Turntable rotate, 360° 160 to 180 secondsjib or primary booms extended
Turntable rotate, 360° 280 to 350 secondsjib and primary booms extended
2 - 2 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalentViscosity grade Multi-viscosityViscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and the viscosity index shouldexceed 140. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Environ MV 46Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046Quintolubric 822
Mineral based Shell Tellus T32Shell Tellus T46
Chevron Aviation A
Component damage hazard.Continued use of Chevron AviationA hydraulic fluid when ambienttemperatures are consistentlyabove 32°F / 0°C may result incomponent damage.
Note: Use Chevron Aviation A hydraulic oil when inambient temperatures consistently below 0°F / -18°C.
Note: Use Shell Tellus T46 hydraulic oil when oiltemperatures consistently exceed 205°F / 96°C.
Note: Genie specifications require additionalequipment and special installation instructions forthe approved optional fluids. Consult the GenieIndustries Service Department before use.
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 3
Section 2 • SpecificationsJuly 2009
REV G SPECIFICATIONS
Drive pump
Type: bi-directional variable displacement piston pump
Displacement 2.8 cu in46 cc
Flow rate @ 2350 rpm 28.5 gpm108 L/min
Drive pressure, maximum 3625 psi250 bar
Charge pump
Type: gerotor
Displacement 0.85 cu in13.9 cc
Flow rate @ 2350 rpm 9 gpm34 L/min
Charge pressure @ 2350 rpm 315 psiNeutral position 21.7 bar
Function pumps
Type: variable displacement piston pump
Displacement 0 to 2.75 cu in0 to 45 cc
Flow rate @ 2350 rpm 0 to 28 gpm0 to 106 L/min
Pressure, maximum 2900 psi200 bar
Pressure compensator 2900 psi200 bar
Standby pressure 250 psi17 bar
Auxiliary pumps
Type: fixed displacement gear pump
Displacement 0.15 cu in2.47 cc
Function manifold
Function relief pressure 3100 psi(measured at TEST port) 213.7 bar
Primary boom extend relief pressure 2600 psi(measured at PTEST port) 179 bar
Jib and platform manifolds
Platform rotate and platform level 0.2 gpmflow regulator 0.76 L/min
Jib manifold flow regulator 2 gpm7.6 L/min
Steer/Axle manifold
Axle extend relief pressure 2400 psi165 bar
Drive manifold
Hot oil relief pressure 250 psi17.2 bar
Hydraulic filters
High pressure filter Beta 3 ≥ 200
High pressure filter 102 psibypass pressure 7 bar
Medium pressure filter Beta 3 ≥ 200
Medium pressure filter 51 psibypass pressure 3.5 bar
Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass
Drive motor case drain Beta 10 ≥ 2return filter
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
2 - 4 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Brakes
Brake release pressure 190 psi13 bar
Drive motors(before serial number 180) (see note below)
Displacement per revolution, 0.8 cu inhigh speed 13.3 cc
Displacement per revolution, 2.7 cu inlow speed 45 cc
Drive motors(after serial number 179)
Displacement per revolution, 0.8 cu inhigh speed 13.3 cc
Displacement per revolution, 2.7 cu inlow speed (square end) 45 cc
Displacement per revolution, 1.5 cu inlow speed (circle end) 25 cc
Note: Serial number 102 is equipped with drivemotors equal to those used on machines afterserial number 179.
Manifold ComponentSpecifications
Plug torque
SAE No. 2 36 in-lbs / 4 Nm
SAE No. 4 10 ft-lbs / 13 Nm
SAE No. 6 14 ft-lbs / 19 Nm
SAE No. 8 38 ft-lbs / 51 Nm
SAE No. 10 41 ft-lbs / 55 Nm
SAE No. 12 56 ft-lbs / 76 Nm
Valve coil resistance specifications
Proportional solenoid valve 3.5 to 5.5Ω(schematic items N, P, R, T, V)
3 position 4 way solenoid valve 4 to 6Ω(schematic item B)
3 position 4 way solenoid valve 7 to 9Ω(schematic items BN, BO, BP and BQ)
3 position 4 way solenoid valve 8 to 10Ω(schematic item AH)
3 position 4 way proportional 8 to 10Ωsolenoid valve(schematic items Y and AI)
2 position 3 way solenoid valve 5.5 to 7.5Ω(schematic items F and AD)
2 position 3 way solenoid valve 8 to 10Ω(schematic items AE and AF)
2 position 3 way solenoid valve 3.5 to 5.5Ω(schematic items H and J)
2 position 3 way solenoid valve 7.5 to 9.5Ω(schematic items C, D, G, I, K, AX, AY, BU and BT)
2 position 2 way solenoid valve 3.5 to 5.5Ω(schematic item A)
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 5
Section 2 • SpecificationsJuly 2009
REV G SPECIFICATIONS
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 ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Oil temperature switch
Installation torque 8-18 ft-lbs11-24 Nm
Oil temperature switch point 275°F135°C
Oil pressure switch
Installation torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 7 psi0.48 bar
Fuel injection system
Injection pump make Motorpal
Injection pump pressure, maximum 15,000 psi1034 bar
Injector opening pressure 3046 psi210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Starter motor
Current draw, normal load 140-200A
Cranking speed 200-250 rpm
Deutz BF4L 2011 Engine
Displacement 189.6 cu in3.1 liters
Number of cylinders 4
Bore and stroke 3.7 x 4.409 inches94 x 112 mm
HorsepowerContinuous @ 2500 rpm 69 / 51 kWNet intermittent @ 2500 rpm 73 / 54 kW
Firing order 1 - 3 - 4 - 2
Low idle 1500 rpm383 Hz
High idle 2350 rpm599 Hz
Compression ratio 17.5:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in0.3 mm
Exhaust 0.020 in0.5 mm
Lubrication system
Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity 11 quarts(including filter) 10.4 liters
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
2 - 6 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV G
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Alternator output 80A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch9 to 12 mm
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 7
Section 2 • SpecificationsJuly 2009
REV G
Lubrication system
Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity 12.8 quarts(including filter) 12.1 liters
Oil viscosity requirements
-22°F to 86°F / -30°C to 30°C 5W-30(synthetic)
-4°F to 104°F / -20°C to 40°C 10W-40
Above 5°F / -15°C 15W-40
Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Oil temperature switch
Installation torque 8-18 ft-lbs11-24 Nm
Oil temperature switch point 275°F135°C
Oil pressure switch
Installation torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 22 psi1.5 bar
Deutz TD2011L04i Engine
Displacement 220.9 cu in3.62 liters
Number of cylinders 4
Bore and stroke 3.78 x 4.92 inches96 x 125 mm
HorsepowerNet intermittent @ 2400 rpm 74 / 55 kW
Induction system turbocharged
Firing order 1 - 3 - 4 - 2
Low idle 1500 rpm383 Hz
High idle 2350 rpm599 Hz
Compression ratio 17.5:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.012 in0.3 mm
Exhaust 0.020 in0.5 mm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
SPECIFICATIONS
2 - 8 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Fuel injection system
Injection pump make Motorpal
Injection pump pressure, maximum 15,000 psi1034 bar
Injector opening pressure 3046 psi210 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Starter motor
Current draw, normal load 140-200A
Cranking speed 250-350 rpm
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Alternator output 80A @ 14V DC
Fan belt deflection 3/8 to 1/2 inch9 to 12 mm
Part No. 106783 Z-135/70 2 - 9
Section 2 • SpecificationsJuly 2009
REV G
Cummins B4.5L Engine
Displacement 275 cu in4.5 liters
Number of cylinders 4
Bore and stroke 4.02 x 5.42 inches102 x 138 mm
Horsepower 80 @ 2200 rpm60 kW @ 2200 rpm
Firing order 1 - 3 - 4 - 2
Low idle 1300 rpm368 Hz
High idle 2350 rpm666 Hz
Compression ratio 18:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Valve clearance, cold
Intake 0.010 in0.254 mm
Exhaust 0.020 in0.508 mm
Lubrication system
Oil pressure, hot 50 psi(at 2000 rpm) 3.45 bar
Oil capacity 9.5 quarts(including filter) 9 liters
Oil viscosity requirements
Below 68°F / 20°C 5W-30
-10° to 68°F / -23° to 20°C 10W-30
Above 15°F / -9°C 15W-40
Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Fuel injection system
Injection pump make Delphi
Injection pump pressure 3480 to 3680 psi240 to 254 bar
Injector opening pressure 3480 psi240 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Starter motor
Current draw, no load 125A
Brush length, minimum 0.72 in18.3 mm
Engine coolant
Capacity 17 quarts16 liters
Coolant temperature sending unit
Installation torque 8-18 ft-lbs11-24 Nm
Temperature switch point 230°F 110°C
Alternator output 95A, 12V DC
Fan belt deflection 3/8 to 1/2 inch10 to 12.5 mm
SPECIFICATIONS
2 - 10 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV G
Cummins B3.3T Engine
Displacement 199 cu in3.26 liters
Number of cylinders 4
Bore and stroke 3.74 x 4.53 inches95 x 115 mm
Horsepower 80 @ 2200 rpm60 kW @ 2200 rpm
Firing order 1 - 2 - 4 - 3
Low idle 1300 rpm368 Hz
High idle 2350 rpm666 Hz
Compression ratio 17:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Valve clearance, cold
Intake 0.014 in0.35 mm
Exhaust 0.020 in0.5 mm
Lubrication system
Oil pressure, hot 31 to 72 psi(at 2000 rpm) 2 to 5 bar
Oil capacity 9 quarts(including filter) 8.5 liters
Oil viscosity requirements
Below 68°F / 20°C 5W-30
-10° to 68°F / -23° to 20°C 10W-30
Above 14°F / -10°C 15W-40
Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Fuel injection system
Injection pump make Zexel
Injection pressure 12,000 psi827 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Starter motor
Current draw, maximum 550A
Engine cranking speed, minimum 130 rpm
Engine coolant
Capacity 9.1 quarts8.6 liters
Alternator output 120A, 12V DC
Fan belt deflection 3/8 to 1/2 inch10 to 12.5 mm
SPECIFICATIONS
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 11
Section 2 • SpecificationsJuly 2009
REV G SPECIFICATIONS
Perkins 1104C-44 Engine
Displacement 268.5 cu in4.4 liters
Number of cylinders 4
Bore and stroke 4.13 x 5 inches105 x 127 mm
Horsepower
Gross intermittent @ 2400 rpm 86 / 64 kWNet intermittent @ 2400 rpm 83 / 62 kW
Firing order 1 - 3 - 4 - 2
Low idle 1300 rpm316 Hz
High idle 2350 rpm572 Hz
Compression ratio 18.2:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.008 in0.2 mm
Exhaust 0.018 in0.45 mm
Lubrication system
Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity 7.3 quarts(including filter) 6.9 liters
Oil viscosity requirements
Below 68°F / 20°C 5W-20
10°F to 104°F / -12°C to 40°C 10W-30
Above 14°F / -10°C 15W-40
Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Oil pressure sending unit
Installation torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 8 psi0.55 bar
Fuel injection system
Injection pump make Bosch
Injector opening pressure 2200 psi152 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
2 - 12 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Starter motor
Current draw, normal load 140-200A
Cranking speed 200-250 rpm
Engine coolant
Capacity 14 quarts13.2 liters
Coolant temperature sending unit
Installation torque 8-18 ft-lbs11-24 Nm
Temperature switch point 230°F 110°C
Alternator output 85A @ 13.8V DC
Fan belt deflection 3/8 in10 mm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 13
Section 2 • SpecificationsJuly 2009
REV G SPECIFICATIONS
Perkins 804D-33T Engine
Displacement 203 cu in3.33 liters
Number of cylinders 4
Bore and stroke 3.7 x 4.72 inches94 x 120 mm
Horsepower
Gross intermittent @ 2500 rpm 83 / 62 kW
Induction system turbocharged
Firing order 1 - 3 - 4 - 2
Low idle 1300 rpm316 Hz
High idle 2350 rpm572 Hz
Compression ratio 19.5:1
Compression pressurePressure (psi or bar) of the lowest cylinder must be atleast 75% of the highest cylinder.
Governor centrifugal mechanical
Valve clearance, cold
Intake 0.0098 in0.25 mm
Exhaust 0.0098 in0.25 mm
Lubrication system
Oil pressure, hot 40 to 60 psi(at 2000 rpm) 2.8 to 4.1 bar
Oil capacity 10.6 quarts(including filter) 10 liters
Oil viscosity requirements
Below 86°F / 30°C 5W-30
-4°F to 104°F / -20°C to 40°C 10W-30
Above 14°F / -10°C 15W-40
Units ship with 15W-40.Extreme operating temperatures may require the use ofalternative engine oils. For oil requirements, refer to theEngine Operator Handbook on your machine.
Oil pressure sending unit
Installation torque 8-18 ft-lbs11-24 Nm
Oil pressure switch point 8 psi0.55 bar
Fuel injection system
Injection pump make Bosch
Injector opening pressure 2200 psi152 bar
Fuel requirement
For fuel requirements, refer to the engine Operator'sManual on your machine.
Battery - Auxiliary power units
Type 6V DCQuantity 2AH rating 285AHReserve capacity @ 25A rate 745 minutes
Battery - Engine starting and control system
Type 12V DC, Group 31Quantity 1Cold cranking ampere 1000AReserve capacity @ 25A rate 200 minutes
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
2 - 14 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Machine Torque Specifications
Platform rotator
1-8 center bolt, GR 5 480 ft-lbs651 Nm
3/8 -16 bolts, GR 8 44 ft-lbs60 Nm
Turntable rotate assembly
Rotate bearing mounting bolts, lubricated 320 ft-lbs(3/4 -10 SHC) 434 Nm
Rotate bearing mounting bolts, lubricated 180 ft-lbs(5/8 -11 SHC) 244 Nm
Rotate drive hub mounting bolts, lubricated 80 ft-lbs108 Nm
Drive motor mounting bolts, dry 75 ft-lbs102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs76 Nm
Backlash plate mounting bolts, lubricated 320 ft-lbs434 Nm
Drive motors and hubs
Drive hub mounting bolts, lubricated 180 ft-lbs217 Nm
Drive motor mounting bolts, dry 75 ft-lbs102 Nm
Drive motor mounting bolts, lubricated 56 ft-lbs76 Nm
Engine vibration isolators
Mounting bolts, dry 60 ft-lbs81 Nm
Mounting bolts, lubricated 45 ft-lbs61 Nm
Starter motor
Current draw, normal load 200A
Cranking speed 250 rpm
Engine coolant
Capacity 12.5 quarts11.8 liters
Coolant temperature sending unit
Installation torque 8-18 ft-lbs11-24 Nm
Temperature switch point 230°F 110°C
Alternator output 90A @ 12V DC
Fan belt deflection 3/8 to 1/2 in9 to 12 mm
Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.
Part No. 106783 Z-135/70 2 - 15
Section 2 • SpecificationsJuly 2009
REV G
Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok® Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 25 Nm
-6 30 ft-lbs / 40 Nm
-8 40 ft-lbs / 55 Nm
-10 60 ft-lbs / 80 Nm
-12 85 ft-lbs / 115 Nm
-16 110 ft-lbs / 150 Nm
-20 140 ft-lbs / 190 Nm
-24 180 ft-lbs / 245 Nm
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must be replacedanytime the seal has been broken. The O-ringcannot be re-used if the fitting or hose end hasbeen tightened beyond finger tight.
Note: The O-rings used in the Parker Seal Lok®fittings and hose ends are custom-size O-rings.They are not standard SAE size O-rings. They areavailable in the O-ring field service kit (Genie partnumber 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated andretained properly.
4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.
5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
SPECIFICATIONS
2 - 16 Z-135/70 Part No. 106783
Section 2 • Specifications July 2009
REV GSPECIFICATIONS
Size(mm)
in- lbs N m in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m5 16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.36 19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.67 45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4
f t - lbs N m ft-lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m8 5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6
10 10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.412 18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 14714 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 23416 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 36518 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 50320 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71322 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 97024 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6DRYLUBED
METRIC FASTENER TORQUE CHART• This chart is to be used as a guide only unless noted elsewhere in this manual •
LUBED DRY
Class 10.9Class 8.8DRY
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm20 80 9 100 11.3 110 12.4 140 15.8 130 14.728 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm18 13 17.6 17 23 18 24 25 33.9 21 28.424 14 19 19 25.7 20 27.1 27 36.6 24 32.516 23 31.2 31 42 33 44.7 44 59.6 38 51.524 26 35.2 35 47.4 37 50.1 49 66.4 43 58.314 37 50.1 49 66.4 50 67.8 70 94.7 61 82.720 41 55.5 55 74.5 60 81.3 80 108.4 68 92.113 57 77.3 75 101.6 80 108.4 110 149 93 12620 64 86.7 85 115 90 122 120 162 105 14212 80 108.4 110 149 120 162 150 203 130 17618 90 122 120 162 130 176 170 230 140 18911 110 149 150 203 160 217 210 284 180 24418 130 176 170 230 180 244 240 325 200 27110 200 271 270 366 280 379 380 515 320 43316 220 298 300 406 310 420 420 569 350 4749 320 433 430 583 450 610 610 827 510 69114 350 474 470 637 500 678 670 908 560 7598 480 650 640 867 680 922 910 1233 770 104412 530 718 710 962 750 1016 990 1342 840 11397 590 800 790 1071 970 1315 1290 1749 1090 147712 670 908 890 1206 1080 1464 1440 1952 1220 16547 840 1138 1120 1518 1360 1844 1820 2467 1530 207412 930 1260 1240 1681 1510 2047 2010 2725 1700 23046 1460 1979 1950 2643 2370 3213 3160 4284 2670 362012 1640 2223 2190 2969 2670 3620 3560 4826 3000 4067
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5DRYLUBED
• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide BoltsGrade 8
LUBED
1/4
LUBED DRY LUBED DRY
1 1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
5/16
3/8
7/16
1/2
10.9 12.98.84.6
Part No. 106783 Z-135/70 3 - 1
April 2008 Section 3 • Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted daily, quarterly, six months, annuallyand every two years as specified on theMaintenance Inspection Report.
Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial machine damage.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating machine.
Use only Genie approved replacement parts.
Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:
• Machine parked on a firm, level surface
• Boom in the stowed position
• Turntable rotated with the boom betweenthe circle-end (yellow arrow) wheels
• Turntable secured with the turntablerotation lock pin
• Key switch in the off position with thekey removed
• Wheels chocked
• All external AC power supply disconnectedfrom the machine
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
3 - 2 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
Maintenance Symbols Legend
Note: The following symbols have been used in thismanual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will be requiredto perform this procedure.
Indicates that a cold engine will berequired to perform this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service is requiredto perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report containschecklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.
Maintenance Schedule
There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, semi-annually, annual andtwo years. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D and E. Use the following chart to determine whichgroup(s) of procedures are required to perform ascheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A + B
Semi-annually or every 500 hours A + B + C
Annual or every 1000 hours A + B + C + D
Two years or every 2000 hours A + B + C + D + E
Maintenance Inspection Report
The maintenance inspection report containschecklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Reportto use for each inspection. Maintain completedforms for a minimum of 4 years or in compliancewith employer, jobsite and governmental regulationsand requirements.
SCHEDULED MAINTENANCE PROCEDURES
Part No. 106783 Z-135/70 3 - 3
April 2008 Section 3 • Scheduled Maintenance Procedures
Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B
Genie UKThe Maltings, Wharf Road
Grantham, LincolnshireNG31- 6BH England
(44) 1476-584333
Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation
Pre-Delivery Preparation Y N R
Pre-operation inspection completed
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.
Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.
If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.
LegendY = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.
A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removedfrom service.
Repairs to the machine may only be made by a qualifiedservice technician, according to the manufacturer'sspecifications.
Scheduled maintenance inspections shall be performed byqualified service technicians, according to themanufacturer's specifications and the requirements listedin the responsibilities manual.
3 - 4 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
This page intentionally left blank.
Part No. 106783 Z-135/70 3 - 5
April 2008 Section 3 • Scheduled Maintenance Procedures
Checklist B - Rev D Y N R
B-1 Batteries
B-2 Electrical wiring
B-3 Key switches
B-4 Exhaust system
B-5 Engine oil cooler andcooling fins -Deutz models
B-6 Tires and wheels
B-7 Brake configuration
B-8 Drive hub oil level
B-9 Ground control override
B-10 Platform self leveling
B-11 Engine idle select
B-12 Drive brakes
B-13 Drive speed - stowed
B-14 Drive speed - raisedor extended
B-15 Alarm and beacon
B-16 Hydraulic oil analysis
B-17 Replace fuel filter/separator -Perkins models
B-18 Engine RPM
B-19 Safety envelopelimit switches
B-20 Primary boomangle sensor
B-21 Fuel and hydraulictank cap venting
B-22 Engine maintenance -Cummins models
Checklist A - Rev G Y N R
A-1 Manuals and decals
A-2 Pre-operationinspection
A-3 Function tests
A-4 Engine maintenance -Deutz models
A-5 Engine maintenance -Cummins models
A-6 Engine maintenance -Perkins models
A-7 Hydraulic return filtercondition indicator
A-8 Inspect filter/separator -Perkins models
A-9 Drain fuel filter/separator - Deutz andCummins models
Perform after 40 hours:
A-10 30 Day Service
Perform every 100 hours:
A-11 Grease rotationbearing
Perform after 150 hours:
A-12 Drive hub oil
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions· Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) forthe type of inspection to be performed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Semi-annual or 500 hourInspection: A+B+C
Annual or 1000 hoursInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· Use the step-by-step procedures inthis section to learn how to performthese inspections.
· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Maintenance Inspection Report
Comments
3 - 6 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
Checklist C - Rev D Y N R
C-1 Engine maintenance -Deutz models
C-2 Engine maintenance -Cummins models
C-3 Engine maintenance -Perkins models
C-4 Grease platformoverload (if equipped)
C-5 Test the platformoverload (if equipped)
Checklist D - Rev D Y N R
D-1 Boom wear pads
D-2 Free-wheelconfiguration
D-3 Drive hub oil
D-4 Rotation gear backlash
D-5 Replace hydraulic filters
D-6 Engine maintenance -Deutz models
D-7 Engine maintenance -Cummins models
D-8 Engine maintenance -Perkins models
D-9 Turntable rotation bolts
D-10 Turntable bearingwear
MAINTENANCE INSPECTION REPORT
Comments
Checklist E - Rev D Y N R
E-1 Replace hydraulic oil
E-2 Engine maintenance -Cummins models
E-3 Engine maintenance -Perkins 804D-33Tmodels
Perform every 2 years:
E-4 Engine maintenance -Perkins 804D-33Tmodels
Perform every 3,000 hours:
E-5 Engine maintenance -Deutz models
Perform every 5,000 hours:
E-6 Engine maintenance -Deutz TD2011L04imodels
Perform every 6,000 hours:
E-7 Engine maintenance -Perkins 804D-33Tmodels
Perform every 8,000 hours:
E-8 Engine maintenance -Perkins 1104C-44models
Perform every 12,000 hours:
E-9 Engine maintenance -Perkins 804D-33Tmodels
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions· Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) forthe type of inspection to be performed.
Daily or 8 hourInspection: A
Quarterly or 250 hourInspection: A+B
Semi-annual or 500 hourInspection: A+B+C
Annual or 1000 hoursInspection: A+B+C+D
2 Year or 2000 hourInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· Use the step-by-step procedures inthis section to learn how to performthese inspections.
· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Part No. 106783 Z-135/70 3 - 7
April 2008 Section 3 • Scheduled Maintenance Procedures
REV G
A-1Inspect the Manuals and DecalsNote: Genie specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Maintaining the operator’s and safety manuals ingood condition is essential to safe machineoperation. Manuals are included with each machineand should be stored in the container provided inthe platform. An illegible or missing manual will notprovide safety and operational informationnecessary for a safe operating condition.
In addition, maintaining all of the safety andinstructional decals in good condition is mandatoryfor safe machine operation. Decals alert operatorsand personnel to the many possible hazardsassociated with using this machine. They alsoprovide users with operation and maintenanceinformation. An illegible decal will fail to alertpersonnel of a procedure or hazard and could resultin unsafe operating conditions.
1 Check to make sure that the operator's andsafety manuals are present and complete in thestorage container on the platform.
2 Examine the pages of each manual to be surethat they are legible and in good condition.
Result: The operator's manual is appropriate forthe machine and all manuals are legible and ingood condition.
Result: The operator's manual is not appropriatefor the machine or all manuals are not in goodcondition or are illegible. Remove the machinefrom service until the manual is replaced.
Checklist A Procedures
3 Open the operator's manual to the decalsinspection section. Carefully and thoroughlyinspect all decals on the machine for legibilityand damage.
Result: The machine is equipped with allrequired decals, and all decals are legible and ingood condition.
Result: The machine is not equipped with allrequired decals, or one or more decals areillegible or in poor condition. Remove themachine from service until the decals arereplaced.
4 Always return the manuals to the storagecontainer after use.
Note: Contact your authorized Genie distributor orGenie Industries if replacement manuals or decalsare needed.
3 - 8 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV GCHECKLIST A PROCEDURES
A-2Perform Pre-operationInspectionCompleting a pre-operation inspection is essentialto safe machine operation. The pre-operationinspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparently wrongwith a machine before the operator performs thefunction tests. The pre-operation inspection alsoserves to determine if routine maintenanceprocedures are required.
Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.
A-3Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.
Complete information to perform this procedure isavailable in the appropriate operator's manual. Referto the Operator's Manual on your machine.
Part No. 106783 Z-135/70 3 - 9
April 2008 Section 3 • Scheduled Maintenance Procedures
REV G
A-4Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theDeutz TD2011 Operation Manual(Deutz part number 0312 3547).
Deutz BF4L2011 Operation ManualGenie part number 84794
Deutz TD2011 Operation ManualGenie part number 139320
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
A-5Perform Engine Maintenance -Cummins Models
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01) OR theCummins B3.3 Operation and Maintenance Manual(Cummins part number 3666417-00).
Cummins B4.5 Operation andMaintenance ManualGenie part number 107527
Cummins B3.3 Operation andMaintenance ManualGenie part number 139324
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST A PROCEDURES
3 - 10 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV GCHECKLIST A PROCEDURES
A-6Perform Engine Maintenance -Perkins Models
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477) OR thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 1100 Series User's HandbookGenie part number 107526
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
A-7Check the Hydraulic ReturnFilter Condition Indicator
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Maintaining the hydraulic filters in good condition isessential to good system performance and safemachine operation. The filter condition indicator willshow when the hydraulic flow is bypassing aclogged filter. If the filter is not frequently checkedand replaced, impurities will remain in the hydraulicsystem and cause component damage.
Note: There are four hydraulic filters on themachine: one tank return filter, one mediumpressure filter, one high pressure filter and onedrive motor case drain filter. Only the tank returnfilter has a condition indicator.
1 Start the engine from the ground controls.
2 Press and release the engine idle select buttonto change the engine rpm to high idle.
Part No. 106783 Z-135/70 3 - 11
April 2008 Section 3 • Scheduled Maintenance Procedures
REV G
A-8Inspect the Fuel Filter/ WaterSeparator - Perkins Models
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Open the engine side turntable cover and locatethe fuel filter/water separator.
2 Inspect the filter bowl for water buildup.
Result: If water is present in the filter bowlcontinue with steps 3 through 7.
3 Open the ground control side turntable cover andinspect the filter condition indicator gauge.
a filter condition indicator gauge
Result: The needle on the gauge should beoperating in the green area.
Result: If the needle is in the red area, thisindicates that the hydraulic filter is beingbypassed and the filter needs to be replaced.See D-5, Replace the Hydraulic Filter Elements.
CHECKLIST A PROCEDURES
a
3 - 12 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV GCHECKLIST A PROCEDURES
3 Loosen the vent plug located on the fuel filter/water separator head.
a vent plugb drain plugc filter bowld separator head
4 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.
5 Tighten the vent plug.
Note: If the fuel filter/water separator is completelydrained, you must prime the fuel filter/waterseparator before starting the engine. See B-17,Replace The Fuel Filter/Water Separator Element -Perkins Models, for instructions on how to primethe fuel filter/water separator.
6 Clean up any fuel that may have spilled.
7 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
A-9Drain the Fuel Filter/ WaterSeparator - Deutz and CumminsModels
Note: Engine specifications require that thisprocedure be performed daily or every 8 hours,whichever comes first.
Proper maintenance of the fuel filter/water separatoris essential for good engine performance. Failure toperform this procedure can lead to poor engineperformance and component damage.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Open the engine side turntable cover and locatethe fuel filter/water separator.
2 Loosen the drain plug at the bottom of the filter.Allow the water to drain into a suitable containeruntil fuel starts to come out. Immediately tightenthe drain plug. Do not completely drain the filter.
3 Clean up any fuel that may have spilled.
4 Start the engine from the ground controls andcheck the fuel filter/water separator and ventplug for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
c
b
d
a
Part No. 106783 Z-135/70 3 - 13
April 2008 Section 3 • Scheduled Maintenance Procedures
REV G
A-10Perform 30 Day Service
The 30 day maintenance procedure is a one timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage, whichevercomes first. After this interval, refer to themaintenance checklists for continued scheduledmaintenance.
1 Perform the following maintenance procedures:
• A-11 Grease the Turntable RotationBearing and Rotate Gear
• B-6 Inspect the Tires, Wheels andLug Nut Torque
• B-8 Check the Drive Hub Oil Level andFastener Torque
• C-2 Perform Engine Maintenance -Cummins Models
• C-3 Perform Engine Maintenance -Perkins Models
• D-5 Replace the Hydraulic FilterElements
• D-6 Perform Engine Maintenance -Deutz Models
• D-9 Check the Turntable RotationBearing Bolts
CHECKLIST A PROCEDURES
A-11Grease the Turntable RotationBearing and Rotate Gear
Note: Genie specifications require that thisprocedure be performed every 100 hours ofoperation. Perform this procedure more often ifdusty conditions exist.
Frequent application of lubrication to the turntablebearing and rotate gear is essential to goodmachine performance and service life. Continueduse of an improperly greased bearing and gear willresult in component damage.
1 Locate the grease fitting below the groundcontrol box.
2 Pump grease into the turntable rotation bearing.Rotate the turntable in increments of 4 to 5inches / 10 to 13 cm at a time and repeat thisstep until the entire bearing has been greased.
3 Apply grease to each tooth of the drive gear,located under the turntable.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
3 - 14 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV G
A-12Replace the Drive Hub Oil
Note: Drive hub specifications require that this one-time procedure be performed after the first 150hours of usage. After this interval, refer to themaintenance checklist for continued scheduledmaintenance.
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may result in component damage.See D-3, Replace the Drive Hub Oil.
CHECKLIST A PROCEDURES
Part No. 106783 Z-135/70 3 - 15
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-1Inspect the Batteries
Note: Genie requires that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions. There are 3 batteries on the machine.One is used for starting the engine and poweringthe control system. The other two batteries are 6VDC deep cycle batteries which are wired in series toprovide power for the auxiliary power units. Thebatteries are charged by the alternator through abattery separator.
Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
Note: Perform this test after fully charging thebatteries.
Note: For a more accurate determination of thebattery condition, fully charge the batteries andallow the batteries to rest 24 hours beforeperforming this procedure to allow the battery cellsto equalize.
1 Put on protective clothing and eye wear.
2 Remove the cover from the auxiliary power unitbatteries located at the ground controls side ofthe machine.
Note: Perform the remaining steps on the auxiliarypower unit batteries and the engine starting battery.
3 Be sure that the battery cable connections arefree of corrosion.
Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosion onthe battery terminals and cables.
4 Be sure that the battery retainers and cableconnections are tight.
5 Be sure that the battery separator wireconnections are tight.
6 Fully charge the battery(s) and allow thebattery(s) to rest at least 6 hours.
7 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.
8 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:
• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. The batteryis fully charged. Proceed to step 12.
Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 9.
Checklist B Procedures
3 - 16 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
9 Perform an equalizing charge OR fully chargethe battery(s) and allow the battery(s) to rest atleast 6 hours.
10 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.
11 Check the ambient air temperature and adjustthe specific gravity reading for each cell asfollows:
• Add 0.004 to the reading of each cell forevery 10° / 5.5° C above 80° F / 26.7° C.
• Subtract 0.004 from the reading of each cell forevery 10° / 5.5° C below 80° F / 26.7° C.
Result: All battery cells display a specific gravityof 1.277 or greater. The battery is fully charged.Proceed to step 12.
Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.177. Replace the battery.
12 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch / 3 mmbelow the bottom of the battery fill tube. Do notoverfill.
13 Install the vent caps and neutralize anyelectrolyte that may have spilled.
14 Install the cover for the auxiliary power unitbatteries.
B-2Inspect the Electrical Wiring
Note: Genie requires that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.
Electrocution/burn hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.
1 Open the engine side turntable cover.
2 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.
a engine pivot plate anchor holeb engine pivot plate retaining fastener
CHECKLIST B PROCEDURES
Part No. 106783 Z-135/70 3 - 17
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
3 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
4 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
5 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Engine wiring harness
• Battery area wiring
6 Open the ground controls side turntable cover.
7 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Inside of the ground control box
• Hydraulic manifold wiring
• Battery area wiring
• Hydraulic oil cooler wiring
8 Inspect for a liberal coating of dielectric greasein the following locations:
• All wire harness connectors toground control box
• Wire harness connectors to SCON module
9 Open the hydraulic manifold box covers at bothsides of the drive chassis.
10 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Hydraulic manifold wiring
CHECKLIST B PROCEDURES
11 Inspect for a liberal coating of dielectric greasein the following location:
• Wire harness connectors to DCON module
12 Start the engine from the ground controls andraise the secondary boom above the turntablecovers.
Component damage hazard. Besure the hydraulic supply hoses tothe function and drive pumps arenot kinked before starting theengine.
13 Inspect the turntable area for burnt, chafed andpinched cables.
14 Lower the secondary boom to the stowedposition and turn the engine off.
15 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:
• Cable track on the boom
• Cables on the boom, jib boom and jib boompivot area
• Jib boom/platform rotate manifold
• Platform control box
• Inside of the platform control box
16 Inspect for a liberal coating of dielectric greasein the following location:
• All wire harness connectors toplatform control box
17 Remove the engine pivot plate retainingfastener from the engine pivot plate anchor holeat the pivot end of the engine pivot plate.
18 Swing the engine pivot plate in towards themachine.
19 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
3 - 18 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-3Test the Key SwitchesNote: Genie requires that this procedure beperformed every 250 hours or quarterly, whichevercomes first.
Proper key switch action and response is essentialto safe machine operation. Failure of either keyswitch to function properly could cause ahazardous operating situation.
There are two key switches on the machine - theMain key switch and the Service Bypass/Recoverykey switch.
The Main key switch controls machine operationfrom the ground or platform controls.
When the Service Bypass/Recovery key switch isturned to the service bypass position, the primaryboom can be raised while the axles are retracted.This feature of the machine is especially helpful forstorage purposes or when loading the machine fortransport.
Note: When the boom is raised with the axlesretracted, the boom cannot be rotated past eithercircle-end wheel.
When the Service Bypass/Recovery key switch isturned and held to the recovery position, theauxiliary power units will turn on and fully retract theboom and then lower the boom. This feature of themachine is especially helpful if the operator in theplatform cannot lower the boom, if the platformcontrols become inoperative or for returning themachine to a safe position when the safetyswitches have been tripped.
Note: Perform this procedure with the axlesretracted and the boom in the stowed position.
1 Open the ground controls side turntable sidecover.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 At the ground controls, turn the servicebypass/recovery key switch to the run position.
4 Turn the main key switch to ground control, startthe engine and then turn the key switch toplatform control.
5 Check any machine function from the groundcontrols.
Result: The machine functions should notoperate.
6 Turn the main key switch to ground control.
CHECKLIST B PROCEDURES
STOP
00000
Run
ServiceBypass
Recovery
Part No. 106783 Z-135/70 3 - 19
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
7 Check any machine function from the platformcontrols.
Result: The machine functions should notoperate.
8 Turn the main key switch to the off position.
Result: The engine should stop and nofunctions should operate.
9 Turn the main key switch to ground control andstart the engine.
10 Attempt to raise the primary boom.
Result: The boom should not raise.
Note: The primary boom will not raise until theaxles are fully extended.
11 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.
Note: The main key switch should remain in theground control position.
12 Turn the service bypass/recovery key switch tothe service bypass position.
13 Raise the boom.
Result: The boom should raise.
14 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.
15 Turn the main key switch to the off position.
16 Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.
17 Turn and hold the service bypass/recovery keyswitch to the recovery position.
Result: The boom should return to the stowedposition.
18 Turn the service bypass/recovery key switch tothe run position.
19 Remove the key from the servicebypass/recovery key switch and insert the keyinto the main key switch.
20 Turn the main key switch to the off position.
21 Close the turntable side cover.
CHECKLIST B PROCEDURES
3 - 20 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-4Check the Exhaust System
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining the exhaust system is essential togood engine performance and service life.Operating the engine with a damaged or leakingexhaust system can cause component damageand unsafe operating conditions.
Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.
Bodily injury hazard. Beware ofhot engine components. Contactwith hot engine components maycause severe burns.
1 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.
a engine pivot plate anchor holeb engine pivot plate retaining fastener
2 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
3 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
4 Be sure that all nuts and bolts are tight.
5 Inspect all welds for cracks.
6 Inspect for exhaust leaks (i.e., carbon buildup)around seams and joints.
7 Remove the engine pivot plate retainingfastener from the engine pivot plate anchor holeat the pivot end of the engine pivot plate.
8 Swing the engine pivot plate in towards themachine.
9 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
CHECKLIST B PROCEDURES
Part No. 106783 Z-135/70 3 - 21
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-5Check the Engine Oil Cooler andCooling Fins - Deutz Models
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining the oil cooler in good condition isessential for good engine performance. Operatinga machine with a damaged oil cooler may result inengine damage. Also, restricting air flow throughthe oil cooler will affect the performance of thecooling system.
Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.
Burn hazard. Beware of hotengine components. Contact withhot engine components may resultin severe burns.
1 Open the engine side turntable cover.
Oil cooler:
2 Remove the retaining fasteners from the engineside cover. Remove the cover.
3 Inspect the oil cooler for leaks and physicaldamage.
4 Clean the oil cooler of debris and foreignmaterial.
Cooling and blower fins:
5 Inspect the fan blower fins for physical damage.
6 Clean the fan blower fins of debris and foreignmaterial.
7 Using a flashlight, inspect the head coolingpassages and fins for physical damage orforeign material.
8 If needed, clean the cylinder head coolingpassages and fins of debris and foreignmaterial.
9 Install the engine side cover and tighten theretaining fasteners.
CHECKLIST B PROCEDURES
3 - 22 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-6Inspect the Tires, Wheels andLug Nut Torque
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining the tires and wheels, including properwheel fastener torque, is essential to safeoperation and good performance. Tire and/orwheel failure could result in a machine tip-over.Component damage may also result if problemsare not discovered and repaired in a timely fashion.
Note: The tires on this machine are foam filled anddo not need air added to them.
1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracked welds.
3 Check each lug nut for proper torque. Refer toSection 2, Specifications.
B-7Confirm the ProperBrake Configuration
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper brake configuration is essential to safeoperation and good machine performance.Hydrostatic brakes and hydraulically-released,spring-applied individual wheel brakes can appearto operate normally when they are actually not fullyoperational.
1 Check each drive hub disconnect cap to besure it is in the engaged position.
CHECKLIST B PROCEDURES
disengaged position
engaged position
Part No. 106783 Z-135/70 3 - 23
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
2 Be sure the free-wheel valve on the drive pumpis closed (clockwise).
Note: The free-wheel valve is located on the drivepump.
a drive pumpb screwdriverc lift pumpd free-wheel valve
Note: The free-wheel valve should always remainclosed.
B-8Check the Drive Hub Oil Leveland Fastener Torque
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Failure to maintain proper drive hub oil levels maycause the machine to perform poorly andcontinued use may cause component damage.
Drive hubs:
1 Drive the machine to rotate the hub until theplugs are located one at the side and the otherat the other side.
a drive hub plugs
2 Remove both plugs and check the oil level.
Result: The oil level should be even with thebottom of the plug holes.
3 If necessary, add oil until the oil level is evenwith the bottom of the plug holes. Refer toSection 2, Specifications.
4 Install the plugs in the drive hub.
5 Check the torque of the drive hub mountingfasteners. Refer to Section 2, Specifications.
6 Repeat this procedure for each drive hub.
CHECKLIST B PROCEDURES
a
d
c
b
a
3 - 24 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
Turntable rotate drive hubs:
1 Remove the fixed turntable cover at the groundcontrols side of the machine.
2 Remove the plug located on the side of the huband check the oil level.
Result: The oil level should be even with thebottom of the plug hole.
a drive hub plugs
3 If necessary, add oil until the oil level is evenwith the bottom of the plug hole. Refer toSection 2, Specifications.
4 Apply pipe thread sealant to the plug, andinstall the plug in the drive hub.
5 Repeat steps 2 through 4 for the other turntablerotate drive hub.
B-9Test the Ground ControlOverrideNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allowground personnel to operate the machine from theground controls whether or not the EmergencyStop button on the platform controls is in the on oroff position. This function is particularly useful if theoperator at the platform controls cannot return theboom to the stowed position.
1 Push in the platform red Emergency Stopbutton to the off position.
2 Start the engine from the ground controls.
3 At the ground controls, operate each boomfunction through a partial cycle.
Result: All boom functions should operate.
CHECKLIST B PROCEDURES
a
Part No. 106783 Z-135/70 3 - 25
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-10Test the Platform Self-leveling
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Automatic platform self-leveling throughoutthe full cycle of primary boom raising and loweringis essential for safe machine operation. Theplatform is maintained level by the communicationbetween the platform level sensor and the turntablelevel sensor. If the platform becomes out of level,the computer at the ground controls will open theappropriate solenoid valve(s) at the platformmanifold to maintain a level platform.A platform self-leveling failure creates an unsafeworking condition for platform and groundpersonnel.
1 Start the engine from the ground controls.
2 Press and hold a function enable/speed selectbutton and fully retract the primary boom.
3 Push one of the LCDscreen buttons shown untilplatform angle isdisplayed.
4 Press and hold a function enable/speed selectbutton and adjust the platform to zero degreesusing the platform level up/down buttons.
5 Push and hold a function enable/speed selectbutton and fully raise the primary boom whileobserving the platform angle shown on the LCDdisplay.
Result: The platform should remain level atall times to within ±2 degrees.
Note: If the platform becomes out of level, the tiltalarm will sound and the Platform Not LevelIndicator will flash at the ground controls. Theplatform level up/down buttons will only work in thedirection that will level the platform. Level theplatform until the indicator light turns off.
6 Push and hold a function enable/speed selectbutton and fully lower the primary boom.
Result: The platform should remain level atall times to within ±2 degrees.
Note: If the platform becomes out of level, the tiltalarm will sound and the Platform Not LevelIndicator will flash at the ground controls. Theplatform level up/down buttons will only work in thedirection that will level the platform. Level theplatform until the indicator light turns off.
Note: If the platform does not level properly, seeRepair Procedure 2-3, How to Calibrate the PlatformLevel Sensor.
CHECKLIST B PROCEDURES
3 - 26 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-11Test the Engine Idle SelectOperationNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
A properly operating engine idle select functionis essential to good engine performance and safemachine operation. There are three settings.
Low idle (turtle symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously, though at reduced speed. Thissetting maintains a consistent low idle.
High idle (rabbit symbol) allows the operatorto control multiple boom and/or drive functionssimultaneously. This setting maintains aconsistent high idle.
Foot switch activated high idle (rabbit and footswitch symbols) should be used for normalmachine operation. This selection activates highidle only when the foot switch is pressed down.
1 Turn the key switch to ground controls.
2 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
3 Start the engine from the ground controls.
4 Push and release the rpm select button untilhigh rpm is selected (rabbit symbol).
Result: The engine should change to high idle.
5 Push and release the rpm select button until lowrpm is selected (turtle symbol).
Result: The engine should return to low idle.
6 Turn the key switch to platform controls.
7 At the platform controls, press the engine idleselect button until high idle (rabbit symbol) isselected.
Result: The engine should change to high idle.
a foot switch activated high idleindicator light
b low idle indicator lightc high idle indicator lightd engine rpm select button
8 Press the engine idle select button until low idle(turtle symbol) is selected.
Result: The engine should change to low idle.
9 Press the engine idle select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.
Result: The engine should not change tohigh idle.
10 Press down the foot switch.
Result: The engine should change to high idle.
CHECKLIST B PROCEDURES
b
d
a c
Part No. 106783 Z-135/70 3 - 27
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-12Test the Drive Brakes
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.
Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-7, Confirm the ProperBrake Configuration.
Note: Select a test area that is firm, level and freeof obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected, then lower the boom intothe stowed position.
4 Choose a point on the machine (i.e., contactpatch of a tire) as a visual reference for usewhen crossing the test line.
5 Bring the machine to top drive speed beforereaching the test line. Release the drivecontroller when your reference point on themachine crosses the test line.
6 Measure the distance between the test line andyour machine reference point. Refer toSection 2, Specifications.
B-13Test the Drive Speed -Stowed Position
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Note: Select a test area that is firm, level and freeof obstructions.
Note: Perform this procedure with the boom in thestowed position.
1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.
4 Choose a point on the machine; i.e., contactpatch of a tire as a visual reference for usewhen crossing the start and finish lines.
5 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
6 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
3 - 28 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-14Test the Drive Speed -Raised or Extended Position
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper drive function movement is essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Note: Select a test area that is firm, level and freeof obstructions.
1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Press the engine rpm select button until the footswitch activated high idle (rabbit and foot switchsymbol) is selected.
4 Press down the foot switch and raise the boomgreater than 5 degrees.
5 Choose a point on the machine; i.e., contactpatch of a tire as a visual reference for usewhen crossing the start and finish lines.
6 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
7 Continue at full speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
8 Lower the boom to the stowed position.
9 Extend the primary boom 12 inches / 0.3 m.
10 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
11 Bring the machine to top drive speed beforereaching the start line. Begin timing when yourreference point on the machine crosses thestart line.
12 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.
CHECKLIST B PROCEDURES
Part No. 106783 Z-135/70 3 - 29
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-15Test the Alarm and OptionalFlashing BeaconNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
An alarm and optional flashing beacon are installedto alert operators and ground personnel ofmachine proximity and motion. There are fouralarm option modes that can be activated based onuser preference or requirement. Refer to DisplayModule in the Repair Section for information.
1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
Result: The alarm should sound twice. Theflashing beacon (if equipped) should be on andflashing.
B-16Perform Hydraulic Oil Analysis
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed moreoften.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.See E-1, Test or Replace the Hydraulic Oil.
CHECKLIST B PROCEDURES
3 - 30 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-17Replace the Inline Fuel Filter/Water Separator Element -Perkins Models
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Replacing the inline fuel filter/water separatorelement is essential for good engine performanceand service life. A dirty or clogged filter may causethe engine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Open the engine side turntable cover and locatethe fuel filter/water separator next to themedium pressure filter.
2 Tag, disconnect and plug the fuel line from thefuel tank at the inline fuel filter/water separatorhead.
3 Loosen the vent plug located on the inline fuelfilter/water separator head.
4 Place a suitable container under the filter bowl.
5 Loosen the drain plug located at the bottom ofthe bowl. Completely drain the fuel from thebowl.
a vent plugb filter elementc filter bowld drain pluge fuel filter/water separator head
6 Remove the filter element from the filter head.
7 Remove the filter bowl from the old filterelement and install the bowl onto the new filterelement. Tighten the drain plug.
8 Fill the element and bowl with clean diesel fuel.
9 Apply a thin layer of oil onto the element gasket.
CHECKLIST B PROCEDURES
d
c
b
ae
Part No. 106783 Z-135/70 3 - 31
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
10 Install the filter/bowl assembly onto the filterhead and tighten it securely by hand.
Note: The filter/bowl assembly must be full of fuelwhen it is installed onto the filter head or the fuelsystem will have to be bled.
11 Tighten the vent plug.
12 Clean up any diesel fuel that may have spilledduring the procedure.
13 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filter.
14 Install the fuel tank line onto the fuel filter/waterseparator head. Tighten the hose clamp.
B-18Check and Adjust theEngine RPM
Note: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Maintaining the engine rpm at the proper setting forboth low and high idle is essential to good engineperformance and service life. The machine will notoperate properly if the rpm is incorrect andcontinued use may cause component damage.
Deutz models:
1 Start the engine from the ground controls.
2 Push one of the LCDscreen buttons shown untilengine rpm is displayed.
Result: Low idle should be 1500 rpm.
Skip to step 5 if the low idle rpm is correct.
CHECKLIST B PROCEDURES
3 - 32 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
3 Loosen the locknut on the low idle adjustmentscrew.
a low idle adjustment screw
4 Adjust the low idle adjustment screw until lowidle is 1500 rpm. Tighten the locknut.
5 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.
Result: High idle should be 2350 rpm.
If the high idle is correct, disregard adjustmentstep 6.
6 Loosen the yoke lock nut. Turn the high idleadjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Note: Be sure the solenoid fully retracts whenactivating high idle.
CHECKLIST B PROCEDURES
Cummins and Perkins models:
1 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.
a engine pivot plate anchor holeb engine pivot plate retaining fastener
2 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
3 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
4 Start the engine from the ground controls.
Component damage hazard. Besure the hydraulic supply hoses tothe function and drive pumps arenot kinked before starting theengine.
5 Push one of the LCDscreen buttons shown untilengine rpm is displayed.
Result: Low idle should be 1300 rpm.
Skip to step 7 if the low idle rpm is correct.
a
Part No. 106783 Z-135/70 3 - 33
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST B PROCEDURES
6 Loosen the low idle lock nut. Turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the low idle lock nut and confirm therpm.
Perkins modelsa low idle adjustment screwb solenoid bootc yoke lock nut
Cummins modelsa low idle adjustment screwb solenoid cablec rpm solenoid
7 Push and hold the function enable/high speedbutton. Note the engine rpm on the display.
Result: High idle should be 2350 rpm.
If the high idle is correct, disregard adjustmentstep 8.
8 Perkins models: Loosen the yoke lock nut.Turn the high idle adjustment nut and solenoidboot counterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.Cummins models: Turn the high idle solenoidboot counterclockwise to increase the rpm orclockwise to decrease the rpm. Recheck therpm.
Note: Be sure the solenoid fully retracts whenactivating high idle.
9 Remove the engine pivot plate retaining fastenerfrom the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
10 Swing the engine pivot plate in towards themachine.
11 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
b
a
c
a b c
3 - 34 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-19Test the Safety Envelope LimitSwitchesNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Testing the machine envelope safety limit switchesis critical to safe machine operation. If the boom isallowed to operate when a safety switch is notfunctioning correctly, the machine stability could becompromised and may tip over.
Note: Perform this procedure with the axlesextended and the boom in the stowed position.
Note: This procedure may require two people.
Secondary Boom #1 Retracted Safety LimitSwitch, LSS1RS
1 Working at the platform end of the turntable,support and secure the lower turntable riserend cover to a suitable lifting device.
2 Remove the lower cover retaining fasteners andremove the lower cover from turntable.
Crushing hazard. The turntableriser lower cover could becomeunbalanced and fall whenremoved from the turntable if notproperly supported and secured tothe lifting device.
3 Support and secure the upper turntable riser endcover to a suitable lifting device.
4 Remove the upper cover retaining fasteners andremove the upper cover from turntable.
Crushing hazard. The turntableriser lower cover could becomeunbalanced and fall whenremoved from the turntable if notproperly supported and secured tothe lifting device.
5 Locate the secondary boom #1 retracted safetylimit switch (LSS1RS) inside the secondaryboom tube.
Note: The secondary boom #1 retracted safety limitswitch (LSS1RS) is attatched to the number 2boom tube and can easily be identified by the blueand red tie wraps attached to the limit switch cable.
6 Start the engine from the ground controls.
7 Fully raise the secondary boom. Do not extendthe boom. Turn the machine off.
8 Locate and disconnect the deutsch connector toLSS1RS.
9 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should not havecontinuity.
Result: The limit switch does have continuity.The limit switch is faulty and needs to bereplaced.
10 Remove the multimeter leads and connect thedeutsch connector to LSS1RS.
CHECKLIST B PROCEDURES
Part No. 106783 Z-135/70 3 - 35
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
11 Start the engine from the ground controls.
12 Extend the secondary boom while visuallyinspecting the roller arm of the limit switch.Continue to extend the boom until the limitswitch arm is released by the limit switch rampbracket. Turn the machine off.
Result: The roller arm of the limit switchremains centered with the limit switch rampbracket through the entire length of travel.
Result: The roller arm of the limit switch doesnot remain centered with the limit switch rampbracket through the entire length of travel.Adjust or replace the limit switch ramp bracketto ensure the limit switch roller arm remainscentered with the limit switch ramp bracketthrough the entire length of travel.
Note: The limit switch ramp bracket is attached tothe number 4 boom tube.
13 Locate and disconnect the deutsch connector toLSS1RS.
14 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should have continuity.
Result: The limit switch does not havecontinuity. The limit switch is faulty and needsto be replaced.
15 Remove the multimeter leads and connect thedeutsch connector to LSS1RS.
16 Install the secondary boom end covers.
CHECKLIST B PROCEDURES
Turntable Rotate Safety Limit Switch, LST1S
17 Locate the turntable rotate safety limit switch(LST1S) at the center of the turntable.
Note: The turntable rotate safety limit switch(LST1S) is located between the two operationalturntable rotate limit switches. It can easily beidentified by the orange and red tie wraps attachedto the limit switch cable.
18 Locate and disconnect the deutsch connector toLST1S.
19 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should have continuity.
Result: The limit switch does not havecontinuity. The limit switch is faulty and needsto be replaced.
20 Remove the multimeter leads and connect thedeutsch connector to LST1S.
21 Start the engine and rotate the turntable morethan 15°. Turn the engine off
22 Locate and disconnect the deutsch connector toLST1S.
23 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should not havecontinuity.
Result: The limit switch does have continuity.The limit switch is faulty and needs to bereplaced OR the mounting position of the limitswitch needs to be adjusted until it activateswhen the turntable is rotated more than 15°.
24 Remove the multimeter leads and connect thedeutsch connector to LST1S.
3 - 36 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST B PROCEDURES
Axle Extended Safety Limit Switches, LSFA1ESand LSRA1ES
25 Start the engine from the ground controls andlower the boom to the stowed postion.
26 Turn the key switch to platform controls.
27 From the platform controls, drive the machine ineither direction and fully retract the axles.Turn the machine off.
28 Choose an axle extend safety limit switch totest.
29 Locate and disconnect the deutsch connector tothe axle extend limit switch.
30 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should not havecontinuity.
Result: The limit switch does have continuity.The limit switch is faulty and needs to bereplaced.
31 Remove the multimeter leads and connect thedeutsch connector to the limit switch.
32 Repeat steps 29 through 31 for the other axleextend safety limit switch.
33 Start the engine from the platform controls andfully extend the axles. Turn the machine off.
34 Choose an axle extend safety limit switch totest.
35 Locate and disconnect the deutsch connector tothe axle extend limit switch.
36 Connect the leads from a multimeter withcontinuity checking capability to pins 1 and 2 atthe deutsch connector of the limit switch cable.
Result: The limit switch should have continuity.
Result: The limit switch does not havecontinuity. The limit switch is faulty and needsto be replaced.
37 Remove the multimeter leads and connect thedeutsch connector to the limit switch.
38 Repeat steps 35 through 37 for the other axleextend safety limit switch.
Part No. 106783 Z-135/70 3 - 37
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST B PROCEDURES
B-20Test the Primary Boom AngleSensorNote: Genie specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
A properly functioning primary boom angle sensoris essential to safe machine operation. The ECM atthe ground controls (TCON) monitors the positionand angle of the primary boom using the signalfrom the primary boom angle sensor. The primaryboom angle sensor signal is used to control theramping of the primary boom, limiting the speed ofthe primary boom to 2.3 feet / 0.7 meters persecond.
Note: Perform this procedure with the axles fullyextended, the boom fully stowed and the machineon a firm, level surface within ±2 degrees.
1 Turn the key switch to ground control and pullout the red Emergency Stop buttons out to theon position at both the ground and platformcontrols.
2 Start the engine from the ground controls.
3 Push one of the LCDscreen buttons shownuntil PRIMARY BOOM ANGLE
TO GRAVITY DEGREES isdisplayed.
4 Raise the primary boom while watching thedisplay screen.
5 Continue to raise the primary boom until it stopsat 58°.
Tip-over hazard. If the boom doesnot stop at 58°, release thefunction enable button immediatelyand lower the primary boom.Contact Genie Industries ServiceDepartment. Failure to lower theboom could cause the machine totip over resulting in death orserious injury.
3 - 38 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
B-21Inspect the Fuel and HydraulicTank Cap Venting Systems
Note: Genie requires that this procedure beperformed every 250 hours or quarterly, whichevercomes first. Perform this procedure more often ifdusty conditions exist.
Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Note: Perform this procedure with the engine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.Proceed to step 4.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.
Note: When checking for positive tank cap venting,air should pass freely through the cap.
3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulictank.
6 Check for proper venting.
Result: Air passes through the fuel tank cap.Proceed to step 8.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 7.
Note: When checking for positive tank cap venting,air should pass freely through the cap.
7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat this procedurebeginning with step 6.
8 Install the breather cap onto the hydraulic tank.
CHECKLIST B PROCEDURES
Part No. 106783 Z-135/70 3 - 39
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
B-22Perform Engine Maintenance -Cummins Models
Note: Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedures canlead to poor engine performance and componentdamage.
Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01) OR theCummins B3.3 Operation and Maintenance Manual(Cummins part number 3666417-00).
Cummins B4.5 Operation andMaintenance ManualGenie part number 107527
Cummins B3.3 Operation andMaintenance ManualGenie part number 139324
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST B PROCEDURES
3 - 40 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
C-1Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theDeutz TD2011 Operation Manual(Deutz part number 0312 3547).
Deutz BF4L2011 Operation ManualGenie part number 84794
Deutz TD2011 Operation ManualGenie part number 139320
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Checklist C Procedures
C-2Perform Engine Maintenance -Cummins Models
Note: Engine specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01) OR theCummins B3.3 Operation and Maintenance Manual(Cummins part number 3666417-00).
Cummins B4.5 Operation andMaintenance ManualGenie part number 107527
Cummins B3.3 Operation andMaintenance ManualGenie part number 139324
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 106783 Z-135/70 3 - 41
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
C-3Perform Engine Maintenance -Perkins Models
Note: Engine specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477) OR thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 1100 Series User's HandbookGenie part number 107526
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
C-4Grease the Platform OverloadMechanism (if equipped)
Note: Genie specifications requirethat this procedure be performed every 500 hours or6 months, whichever comes first. Perform thisprocedure more often if dusty conditions exist.
Application of lubrication to the platform overloadmechanism is essential to safe machine operation.Continued use of an improperly greased platformoverload mechanism could result in the system notsensing an overloaded platform condition and willresult in component damage.
1 Locate the grease fittings on each pivot pin ofthe platform overload assembly.
2 Thoroughly pump grease into each greasefitting.
Grease Specification
Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent
CHECKLIST C PROCEDURES
3 - 42 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST C PROCEDURES
C-5Test the Platform OverloadSystem (if equipped)
Note: Genie specifications require that thisprocedure be performed every 500 hours or sixmonths.
Genie specifications require that this procedure beperformed every 500 hours or six months,whichever comes first.
Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stablitycould be compromised resulting in the machinetipping over.
The platform overload system is designed to detectan overloaded platform and prevent machineoperation anytime the machine is turned on. Whenactivated, the system halts all normal boomoperation, giving visual and audible warning to theoperator.
Models equipped with the platform overload optionare provided with additional machine components:an adjustable spring-loaded platform supportsubassembly, a limit switch, an electronic modulewhich receives the overload signal and interruptspower, and an audio/visual warning indication toalert the operator of the overload.
The platform support subassembly utilizes twoload support arms that are opposed in a fullparallelogram link. This isolates platform loads intoa shear or vertical state, which translates into acompressive load. A spring in the parallelogramlink supports this purely compressive loadregardless of where the load is placed in theplatform.
As weight is added to the platform, the spring willcompress until, when the platform is overloaded,the lower arm contacts a limit switch and therebyactivating the overload signal. When adjustedcorrectly, the platform overload system willdeactivate normal boom operation at platformcapacity.
Note: Perform this procedure with the machine on afirm, level surface.
1 Turn the key switch to platform control. Start theengine from the platform controls.
2 Level the platform.
3 Determine the maximum platform capacity.Refer to the machine serial plate.
4 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity in one of thelocations shown.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.
5 Carefully move the test weight to eachremaining location.
Result: The platform overload indicator lightshould be off at both the ground and platformcontrols.
Part No. 106783 Z-135/70 3 - 43
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
6 Add an additional 12 lbs / 5.4 kg test weight tothe original test weight to overload the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls andPLATFORM OVERLOAD should be displayed on theLCD screen at the ground controls.
Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. Refer to repair procedure 2-4,How to Calibrate the Platform Overload System(if equipped).
Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.
7 Carefully move the test weights to eachremaining location in the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls andPLATFORM OVERLOAD should be displayed on theLCD screen at the ground controls.
Result: If the alarm does not sound and theplatform overload indicator light does not comeon with the test weights in any of the platformlocations, the platform overload system needsto be calibrated. Refer to repair procedure 2-4,How to Calibrate the Platform Overload System(if equipped).
Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.
8 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
9 Turn the key switch to ground control.
10 Test all machine functions from the groundcontrols.
Before serial number 471:
Result: All ground control functions should notoperate.
After serial number 470:
Result: All ground control functions shouldoperate using the auxiliary pump.
11 Lift the test weights off the platform floor using asuitable lifting device.
Result: The platform overload indicator light andalarm should turn off at both the ground andplatform controls.
Note: There may be an approximate 2 second delaybefore the overload indicator light and alarm turnoff.
12 Test all machine functions from the groundcontrols.
Result: All ground control functions shouldoperate normally.
13 Turn the key switch to platform control.
14 Test all machine functions from the platformcontrols.
Result: All platform control functions shouldoperate.
Note: If the platform overload system is notoperating properly, refer to repair procedure 2-4,How to Calibrate the Platform Overload System (ifequipped).
CHECKLIST C PROCEDURES
3 - 44 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
D-1Check the Boom Wear Pads
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Maintaining the boom wear pads in good conditionis essential to safe machine operation. Wear padsare placed on boom tube surfaces to provide a lowfriction, replaceable wear pad between movingparts. Improperly shimmed wear pads or continueduse of extremely worn wear pads may result incomponent damage and unsafe operatingconditions.
1 Measure each wear pad. Replace the wear padonce it reaches the minimum allowablethickness. If the wear pad is still withinspecification, shim as necessary to obtainminimum clearance with zero binding.
Note: The minimum shim clearance for thesecondary boom wear pads is 0.070 inch / 1.8 mmand the maximum allowable shim clearance is 0.25inch / 6.4 mm.
Note: The minimum shim clearance for the jib boomand primary boom wear pads is 0.070 inch / 1.8mm and the maximum allowable shim clearance is0.188 inch / 4.8 mm.
Primary boom wearpad specifications Minimum
Top, bottom and side wear pads 5/8 inch(platform end of boom) 15.9 mm
Top and bottom wear pads 1/2 inch(pivot end of boom) 12.7 mm
Side wear pads 3/8 inch(pivot end of boom) 9.5 mm
Checklist D Procedures
Secondary boom wearpad specifications Minimum
Top wear pads 3/8 inch(extension end of boom) 9.5 mm
Side wear pads 1/2 inch(extension end of boom) 12.7 mm
Bottom wear pads 7/8 inch(extension end of boom) 22 mm
Top and bottom wear pads 5/8 inch(pivot end of boom) 15.9 mm
Side wear pads 1/2 inch(pivot end of boom) 12.7 mm
Jib boom wearpad specifications Minimum
Bottom and side wear pads 5/8 inch(platform end of boom) 15.9 mm
Top wear pads 1/2 inch(platform end of boom) 12.7 mm
Top and side wear pads 3/8 inch(pivot end of boom) 9.5 mm
Bottom wear pads 5/8 inch(pivot end of boom) 15.9 mm
2 Extend and retract the boom through the entirerange of motion to check for tight spots thatmay cause binding or scraping of the boom.
Note: Always maintain squareness between theouter and inner boom tubes.
Part No. 106783 Z-135/70 3 - 45
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
D-2Check the Free-wheelConfiguration
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheel withoutoperator knowledge may cause death or seriousinjury and property damage.
Collision hazard. Select a worksite that is firm and level.
Component damage hazard. If themachine must be towed, do notexceed 2 mph / 3.2 km/h.
1 Chock both of the wheels at the circle-end of themachine to prevent the machine from rolling.
2 Place a lifting jack of ample capacity(35,000 lbs / 16000 kg) under each of the steeryokes at the square-end of the machine.
3 Lift the wheels off the ground and place blocksunder the drive chassis for support.
4 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hub atthe square-end of the machine.
5 Manually rotate each wheel at the square-end ofthe machine.
Result: Each wheel at the square-end of themachine should rotate with minimum effort.
6 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks. Lower themachine.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.
7 Chock both of the wheels at the square-end ofthe machine to prevent the machine fromrolling.
8 Place a lifting jack of ample capacity(35,000 lbs / 16000 kg) under each of the steeryokes at the circle-end of the machine.
9 Lift the wheels off the ground and place blocksunder the drive chassis for support.
10 Disengage the drive hubs by turning over thedrive hub disconnect caps on each wheel hubat the circle-end of the machine.
11 Manually rotate each wheel at the circle-end ofthe machine.
Result: Each wheel at the circle-end of themachine should rotate with minimum effort.
disengaged position
engaged position
CHECKLIST D PROCEDURES
disengaged position
engaged position
3 - 46 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
12 Re-engage the drive hubs by turning overthe drive hub disconnect caps. Rotate eachwheel to check for engagement. Lift themachine and remove the blocks. Lower themachine.
Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injuryand property damage.
All models:
13 Be sure the free-wheel valve on the drive pumpis closed (clockwise).
Note: The free-wheel valve is located on the drivepump, and should always remain closed.
a drive pumpb screwdriverc lift pumpd free-wheel valve
D-3Replace the Drive Hub Oil
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Replacing the drive hub oil is essential for goodmachine performance and service life. Failure toreplace the drive hub oil at yearly intervals maycause the machine to perform poorly andcontinued use may cause component damage.
Drive Hubs:
1 Select the drive hub to be serviced. Drive themachine until one of the two plugs is at thelowest point.
2 Remove both plugs and drain the oil into asuitable container.
3 Drive the machine to rotate the hub until theplugs are located one at the side and the otherat the other side.
a drive hub plugs
4 Fill the hub with oil from either plug hole until theoil level is even with the bottom of both plugholes. Install the plugs. Refer to Section 2,Specifications.
5 Repeat steps 1 through 4 for all the other drivehubs.
CHECKLIST D PROCEDURES
a
d
c
b
a
Part No. 106783 Z-135/70 3 - 47
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST D PROCEDURES
Turntable Rotate Drive Hub:
1 Secure the turntable from rotating with theturntable rotation lock pin.
2 Tag, disconnect and plug the hydraulic hoses tothe drive hub drive motor and brake for eachdrive hub assembly.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
3 Attach a suitable lifting device to the lifting eyeof one turntable rotate drive hub assembly.
4 Remove the drive hub mounting bolts from onedrive hub assembly. Carefully remove theturntable rotate drive hub assembly from themachine. Do not remove both turntable rotatedrive hub assemblies at the same time.
Crushing hazard. The turntablerotate drive hub assembly couldbecome unbalanced and fall whenremoved from the machine if notproperly supported by the liftingdevice.
a drive hub mounting boltsb drive hub plugs
ba
3 - 48 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST D PROCEDURES
5 Remove the plug from the side of the drive hub.Drain the oil from the hub into a suitablecontainer.
6 Install the drive hub assembly onto themachine. Lubricate and torque the drive hubmounting bolts to specification. Refer to Section2, Specifications.
7 Fill the drive hub with oil from the side hole untilthe oil level is even with the bottom of the hole.Apply pipe thread sealant to the plug. Install theplug. Refer to Section 2, Specifications.
8 Repeat steps 3 through 7 for the other turntablerotate drive hub assembly.
9 Adjust turntable rotation gear backlash. SeeD-4, Adjust the Turntable Rotation GearBacklash.
D-4Adjust the Turntable RotatationGear BacklashNote: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Properly adjusted turntable rotation gear backlashis essential for good machine performance andservice life. Improperly adjusted turntable rotationgear backlash will cause the machine to performpoorly and continued use will cause componentdamage. The turntable rotation drive hubs aremounted on an adjustable plate on the swingchassis behind the fixed side cover at the groundcontrols side of the machine.
Note: Perform this procedure with the machine fullystowed and the counterweight at the square end ofthe machine.
Note: Select a test area that is firm, level and freeof obstructions.
1 Secure the turntable from rotating with theturntable rotation lock pin.
2 Remove the fixed turntable cover at the groundcontrols side of the machine.
3 Loosen the backlash pivot plate mounting bolts.
4 Push the backlash pivot plate towards theturntable as far as possible (this will push therotation pinion gears into the turntable bearingring gear).
Part No. 106783 Z-135/70 3 - 49
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
5 Loosen the lock nut on the adjustment bolt.
6 Turn the adjustment bolt clockwise until itcontacts the backlash pivot plate.
a backlash pivot plateb adjustment bolt with lock nutc backlash pivot plate mounting bolts
7 Turn the adjustment bolt 1/4 turncounterclockwise. Tighten the lock nut on theadjustment bolt.
8 Pull the backlash pivot plate away from theturntable until it contacts the adjustment bolt.Then lubricate the mounting fasteners on thebacklash pivot plate and torque to specification.Refer to Section 2, Specifications.
9 Rotate the turntable through an entire rotation.Check for tight spots that could cause binding.Readjust if necessary.
D-5Replace the Hydraulic FilterElements
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first. Perform this procedure more often ifdusty conditions exist.
Replacement of the hydraulic filters is essential forgood machine performance and service life. A dirtyor clogged filter may cause the machine to performpoorly and continued use may cause componentdamage. Extremely dirty conditions may requirethat the filter be replaced more often.
Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.
Note: Perform this procedure with the engine off.
Hydraulic return filter:
1 Open the ground controls side turntable coverand locate the hydraulic return filter mounted onthe hydraulic tank.
2 Place a suitable container under the hydraulictank return filter.
3 Remove the filter with an oil filter wrench.
4 Apply a thin layer of fresh oil to the gasket ofthe new oil filter.
5 Install the new hydraulic return filter elementand tighten it securely by hand. Clean up anyoil that may have spilled during the installationprocedure.
6 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter.
CHECKLIST D PROCEDURES
b ca
3 - 50 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST D PROCEDURES
High pressure filter and drive motor casedrain filter:
Note: The high pressure filter is for all machinefunctions except the drive functions. The drivemotor case drain filter is used to filter oil returningto the hydraulic tank from the drive motors.
a drive motor case drain filterb high pressure filter
7 Locate the high pressure filter and the drivemotor case drain filter near the auxillary powerunits.
8 Place a suitable container under the filters.
9 Use a filter wrench to remove the drive motorcase drain filter element.
10 Install the new drive motor case drain filterelement onto the filter head and tighten itsecurely.
11 Remove the high pressure filter housing byusing a wrench on the nut provided on thebottom of the housing.
12 Remove the filter element from the housing.
13 Inspect the housing seal and replace it ifnecessary.
14 Install the new high pressure filter element intothe housing. Install the filter housing onto thefilter head and tighten it securely.
15 Clean up any oil that may have spilled duringthe installation procedure.
16 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housings.
Medium pressure filter:
Note: The medium pressure filter is for the chargepump.
17 Open the engine side turntable cover and locatethe medium pressure filter mounted to theengine tray near the hydraulic pumps.
18 Place a suitable container under the filter.
19 Remove the medium pressure filter housing byusing a wrench on the nut provided on thebottom of the housing.
20 Remove the filter element from the housing.
21 Inspect the housing seal and replace it ifnecessary.
22 Install the new medium pressure filter elementinto the housing. Install the filter housing ontothe filter head and tighten it securely.
23 Clean up any oil that may have spilled duringthe installation procedure.
24 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe oil filter housing.
25 Start the engine from the ground controls.
26 Inspect the all of the filter housings and relatedcomponents to be sure that there are no leaks.
a b
Part No. 106783 Z-135/70 3 - 51
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST D PROCEDURES
D-6Perform Engine Maintenance -Deutz Models
Note: Engine specifications require that thisprocedure be performed every 1000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theDeutz BF4L2011 Operation Manual(Deutz part number 0297 9929) OR theDeutz TD2011 Operation Manual(Deutz part number 0312 3547).
Deutz BF4L2011 Operation ManualGenie part number 84794
Deutz TD2011 Operation ManualGenie part number 139320
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
D-7Perform Engine Maintenance -Cummins Models
Note: Engine specifications require that thisprocedure be performed every 1000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01) OR theCummins B3.3 Operation and Maintenance Manual(Cummins part number 3666417-00).
Cummins B4.5 Operation andMaintenance ManualGenie part number 107527
Cummins B3.3 Operation andMaintenance ManualGenie part number 139324
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
3 - 52 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
D-8Perform Engine Maintenance -Perkins Models
Note: Engine specifications require that thisprocedure be performed every 1000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477) OR thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 1100 Series User's HandbookGenie part number 107526
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
CHECKLIST D PROCEDURES
D-9Check the Turntable RotationBearing Bolts
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Maintaining proper torque on the turntable bearingbolts is essential to safe machine operation.Improper bolt torque could result in an unsafeoperating condition and component damage.
1 Raise the secondary boom to the point where itbegins to extend. Turn the machine off.
2 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.
a engine pivot plate anchor holeb engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
Part No. 106783 Z-135/70 3 - 53
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D
4 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
5 Confirm that each turntable mounting bolt istorqued in sequence to specification. Refer toSection 2, Specifications.
Bolt torque sequence(from above turntable)
6 Lower the secondary boom to the stowedposition.
7 Remove the engine pivot plate retaining fastenerfrom the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
8 Swing the engine pivot plate in towards themachine.
9 Install the bolt that was just removed into theoriginal hole to secure the engine pivot plate.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
10 Confirm that each bearing mounting bolt underthe drive chassis is torqued in sequence tospecification. Refer to Section 2, Specifications.
Bolt torque sequence(from above turntable)
CHECKLIST D PROCEDURES
2
3
4
1
5
6
7
8
9
10
11
1213
1415
16
17
18
19
20
21
22
23
24
25
26
27
28
1
2
3
4
5
6
7
8
9
10
11
13
14
15
17
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
12
33
34
35
36
3 - 54 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV D
D-10Inspect for Turntable BearingWear
Note: Genie requires that this procedure beperformed every 1000 hours or annually, whichevercomes first.
Periodic inspection of turntable bearing wear isessential to safe machine operation, good machineperformance and service life. Continued use of aworn turntable bearing could create an unsafeoperating condition, resulting in death or seriousinjury and component damage.
Note: Perform this procedure with the machine on afirm, level surface and the boom in the stowedposition.
1 Grease the turntable bearing. See A-10, Greasethe Turntable Bearing and Rotate Gear.
2 Torque the turntable bearing bolts tospecification. See D-9, Check the TurntableRotation Bearing Bolts.
3 Start the machine from the ground controls andraise the boom to full height. Do not extend theboom.
4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or inline with, the boom and no morethan 1 inch / 2.5 cm from the bearing.
Note: To obtain an accurate measurement, placethe dial indicator no more than 1 inch /2.5 cm from the turntable rotation bearing.
CHECKLIST D PROCEDURES
a turntableb dial indicatorc drive chassisd turntable rotation bearing
5 At the dial indicator, adjust it to "zero" theindicator.
6 Fully extend the boom and lower to a horizontalposition.
7 Note the reading on the dial indicator.
Result: The measurement is less than0.063 inch / 1.6 mm. The bearing is good.
Result: The measurement is more than0.063 inch / 1.6 mm. The bearing is worn andneeds to be replaced.
8 Fully retract the boom and raise the boom to fullheight. Visually inspect the the dial indicator tobe sure the needle returns to the "zero"position.
9 Remove the dial indicator and rotate theturntable 90°.
10 Repeat steps 4 through 9 until the rotationbearing has been checked in at least fourequally spaced areas 90° apart.
11 Lower the boom to the stowed position and turnthe machine off.
12 Remove the dial indicator from the machine.
a
b
c
d
Part No. 106783 Z-135/70 3 - 55
April 2008 Section 3 • Scheduled Maintenance Procedures
REV DChecklist E Procedures
E-1Test or Replace the Hydraulic Oil
Note: Genie specifications require that thisprocedure be performed every 2000 hours or everytwo years, whichever comes first. Perform thisprocedure more often if dusty conditions exist.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction straineror hydraulic filters may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require oil changes to be performed morefrequently.
Note: Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levels ofcontamination to verify that changing the oil isnecessary. If the hydraulic oil is not replaced atthe two year inspection, test the oil quarterly.Replace the oil when it fails the test.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hose and FittingTorque Specifications.
Note: Perform this procedure with the boom in thestowed position.
1 Close the two hydraulic tank shut-off valves atthe hydraulic tank.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
2 Remove the drain plug from the hydraulic tankand completely drain the tank into a containerof suitable capacity. Refer to Section 2,Specifications.
3 Tag, disconnect and plug the two suction hosesfrom the hydraulic tank.
4 Tag, disconnect and plug the two supply hosesfor the auxiliary power units. Cap the fittings onthe hydraulic tank.
5 Tag, disconnect and plug the hydraulic hosefrom the drive motor case drain filter at thehydraulic tank. Cap the fitting on the hydraulictank.
6 Disconnect and plug the hydraulic hose at thereturn filter. Cap the fitting on the return filterhousing.
7 Remove the turntable cover using a suitablelifting device.
Crushing hazard. The turntablecover may become unbalancedand fall if not properly supportedand secured to a suitable liftingdevice.
3 - 56 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST E PROCEDURES
8 Remove the ground control box mountingfasteners. Move the ground control box out ofthe way.
9 Remove the cover from the auxiliary power unitbatteries.
10 Tag and disconnect the cables from theauxiliary power unit batteries.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
11 Tag and disconnect the cables from the enginestarting battery located on the engine side ofthe machine.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
12 Attach an overhead crane or similar liftingdevice to the battery box for the auxiliary powerunit batteries.
13 Remove the battery box retaining fasteners andcarefully remove the battery box from themachine.
Crushing hazard. The battery boxcould become unbalanced and fallwhen removed from the machine ifnot properly supported.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
14 Remove the hydraulic tank retaining fasteners.
15 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an appropriatelifting device.
16 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulictank could become unbalancedand fall when removed from themachine if not properly supported.
17 Remove the suction strainers from the tank andclean them using a mild solvent.
18 Rinse out the inside of the tank using a mildsolvent.
19 Install the suction strainers using pipe threadsealant on the threads.
20 Install the drain plug using pipe thread sealanton the threads.
21 Install the hydraulic tank onto the machine.
22 Install the ground control box and mountingfasteners.
23 Install the two suction hoses, return filter hose,drive motor case drain filter hose and thesupply hoses for the auxiliary power units.
24 Install the turntable cover.
25 Fill the tank with hydraulic oil until the level iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.
26 Open the two hydraulic tank shut-off valves atthe hydraulic tank.
27 Clean up any oil that may have spilled.
28 Start the engine and check for leaks.
Part No. 106783 Z-135/70 3 - 57
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST E PROCEDURES
E-2Perform Engine Maintenance -Cummins Models
Note: Engine specifications require that thisprocedure be performed every 2000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life.Failure to perform the maintenance procedurescan lead to poor engine performance andcomponent damage.
Required maintenance procedures and additionalengine information are available in theCummins B4.5 Operation and Maintenance Manual(Cummins part number 4021389-01) OR theCummins B3.3 Operation and Maintenance Manual(Cummins part number 3666417-00).
Cummins B4.5 Operation andMaintenance ManualGenie part number 107527
Cummins B3.3 Operation andMaintenance ManualGenie part number 139324
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
E-3Perform Engine Maintenance -Perkins 804D-33T Models
Note: Engine specifications require that thisprocedure be performed every 2000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
3 - 58 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST E PROCEDURES
E-4Perform Engine Maintenance -Perkins 804D-33T Models
Note: Engine specifications require that thisprocedure be performed every 2 years.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
E-5Perform Engine Maintenance -Deutz TD2011L04i andPerkins 804D-33T Models
Note: Engine specifications require that thisprocedure be performed every 3000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz TD2011 Operation Manual(Deutz part number 0312 3547) OR thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Deutz TD2011 Operation ManualGenie part number 139320
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 106783 Z-135/70 3 - 59
April 2008 Section 3 • Scheduled Maintenance Procedures
REV D CHECKLIST E PROCEDURES
E-6Perform Engine Maintenance -Deutz TD2011L04i Models
Note: Engine specifications require that thisprocedure be performed every 5000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in theDeutz TD2011 Operation Manual(Deutz part number 0312 3547).
Deutz TD2011 Operation ManualGenie part number 139320
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
E-7Perform Engine Maintenance -Perkins 804D-33T Models
Note: Engine specifications require that thisprocedure be performed every 6000 hours or3 years, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
3 - 60 Z-135/70 Part No. 106783
April 2008Section 3 • Scheduled Maintenance Procedures
REV DCHECKLIST E PROCEDURES
E-8Perform Engine Maintenance -Perkins 1104C-44 Models
Note: Engine specifications require that thisprocedure be performed every 8000 hours.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477).
Perkins 1100 Series User's HandbookGenie part number 107526
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
E-9Perform Engine Maintenance -Perkins 804D-33T Models
Note: Engine specifications require that thisprocedure be performed every 12,000 hours or6 years, whichever comes first.
Proper engine maintenance, following the enginemanufacturer's maintenance schedule, is essentialto good engine performance and service life. Failureto perform the maintenance procedures can lead topoor engine performance and component damage.
Required maintenance procedures and additionalengine information are available in thePerkins 800 Series Operation and MaintenanceManual (Perkins part number SEBU7853-00).
Perkins 800 Series Operation andMaintenance ManualGenie part number 111332
To access the engine:
1 Remove the engine tray retaining fastenerlocated under the engine tray. Swing the enginetray out and away from the machine.
2 Install the fastener that was just removedthrough the engine tray and into the engine trayanchor hole in the turntable.
Crushing hazard. Failure to installthe fastener into the engine trayanchor hole to secure the enginetray from moving could result indeath or serious injury.
Part No. 106783 Z-135/70 4 - 1
April 2008 Section 4 • Repair Procedures
Repair Procedures
Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Repairs Start:Read, understand and obey the safety rules andoperating instructions in the appropriateOperator's Manual on your machine.
Be sure that all necessary tools and parts areavailable and ready for use.
Use only Genie approved replacement parts.
Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in the stowed position
· Turntable rotated with the boom betweenthe circle-end (yellow arrow) wheels
· Turntable secured with the turntablerotation lock pin
· Key switch in the off position with thekey removed
· Wheels chocked
· All external AC power supply disconnectedfrom the machine
About This SectionMost of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem.
Perform disassembly procedures to the point whererepairs can be completed. To re-assemble, performthe disassembly steps in reverse order.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
4 - 2 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CDisplay Module
This table lists the various screens and menu options of the operating software. Some display menus arefor informational purpose only, while others can be used to change the machine operating parameters.
The key switch must be in the off position before entering the programming mode.
Activation of the or buttons scrolls through the screens. To change parameter values or select a
setting, use the button (to increase or scroll forward) and the button (to decrease or scroll
backwards). Then press the button to save new value to memory. An audible beep will indicate a save
to memory. Use the and buttons to scroll to the EXIT menu. Use the button to change to YES
and use the button to exit.
Screen or Menu
Procedure Description Range or Selection
Operator Default
Hour meter (on power up) Engine speed Engine oil pressure PSI* (English) Engine oil pressure kPa* (metric) Engine temperature °F** (English)
Engine temperature °C** (metric) TT level sensor X° TT level sensor Y° Platform angle Primary boom angle to gravity
Battery volts
* automatically displayed while engine is running ** engine temperature will not be displayed until coolant temperature reaches a minimum of 100° F / 38° C
Machine Status
With key switch on, press the
and at the same time.
Hydraulic pressure PSI (English)
Hydraulic pressure kPa (metric)
Primary boom to secondary boom angle*
Primary boom length
Secondary boom angle
Secondary boom length
Jib bellcrank angle*
0-4500 psi
0-31000 kPa -60 deg to +75 deg
=0’, >0’
0-80 deg
=0 ft, >0 ft
-10 deg to +10 deg
* referenced to chassis tilt angle
Unit of Measure, Language and engine selection
With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button and press
.
Metric/English measurements Language selection Engine selection
Use +/- buttons to change English, German, French, Spanish, Portuguese, Italian, Dutch and Swedish. Deutz, Perkins, Cummins
Part No. 106783 Z-135/70 4 - 3
April 2008 Section 4 • Repair Procedures
REV C DISPLAY MODULE
S creen or M enu
P rocedure D escrip tion R ange or S election
D rive Functions
W ith the key sw itch O FF, press and ho ld the button and turn the key sw itch to the O N pos ition. R elease the button and press .
Forw ard extended drive speed %
Forw ard not s tow ed drive speed %
Forw ard low drive speed %
Forw ard h igh drive speed %
R everse not s tow ed drive speed %
R everse low drive speed %
R everse h igh drive speed %
D rive acce lera tion %
D rive dece lera tion %
Speed lim it on s teer ang le
120% (defau lt) 50% m in
120% (defau lt) 50% m in
120% (defau lt) 50% m in
120% m ax, 50% m in, 100% (defau lt)
120% m ax, 50% m in, 100% (defau lt)
120% m ax, 50% m in, 100% (defau lt)
120% m ax, 50% m in, 100% (defau lt)
150% m ax, 50% m in, 100% (defau lt)
150% m ax, 50% m in, 100% (defau lt) 100% m ax, 0% m in, 75% (defau lt)
B oom Function S peeds
W ith the key sw itch O FF, press and ho ld the button and turn the key sw itch to the O N pos ition. R elease the button and press .
P rim ary boom up speed s tow ed %
P rim ary boom up speed not s tow ed %
P rim ary boom dow n speed s tow ed %
Prim ary boom dow n speed not s tow ed %
P rim ary boom extend speed %
P rim ary boom re trac t speed %
Secondary boom up speed s tow ed %
Secondary boom up speed not s tow ed %
Secondary boom dow n speed s tow ed %
Secondary boom dow n speed not s tow ed %
Secondary boom extend speed %
Secondary boom re trac t speed %
TT ro ta te speed re trac ted %
TT ro ta te speed not re trac ted %
TT ro ta te speed extended %
J ib up speed re trac ted %
J ib up speed not re trac ted %
J ib dow n speed re trac ted %
J ib dow n speed not re trac ted %
120% m ax, 50% m in, 100% (defau lt)
4 - 4 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CDISPLAY MODULE
Screen or Menu
Procedure Description Range or Selection
Lift Function Ramp Settings
With the key switch OFF, press and hold the
button and turn the key switch to the ON position. Release the button and press .
Primary boom up/down ramp acceleration %
Primary boom up/down ramp deceleration %
Primary boom extend/retract ramp acceleration %
Primary boom extend/retract ramp deceleration %
Secondary boom ramp acceleration %
Secondary boom ramp deceleration %
TT rotate ramp acceleration %
TT rotate ramp deceleration %
Jib boom up/down ramp deceleration %
150% max, 50% min, 100% (default), 5% increment
Part No. 106783 Z-135/70 4 - 5
April 2008 Section 4 • Repair Procedures
REV C DISPLAY MODULE
Valve Calibration
With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button and press .
Reset drive valve defaults
Reset primary boom up/down valve defaults
Reset primary boom extend/retract valve defaults
Reset secondary boom valve defaults
Reset turntable rotate valve defaults
Allow primary boom up/down speed calibration
Allow primary boom extend/retract speed calibration
Allow secondary boom up/down speed calibration
Allow turntable rotate speed calibration
Reset drive joystick defaults
Reset primary boom up/down joystick defaults
Reset primary boom extend/retract joystick defaults
Reset secondary boom joystick defaults
Reset turntable rotate joystick defaults
Reset steer joystick defaults
Reset jib up/down joystick
Screen or Menu
Procedure Description Range or Selection
4 - 6 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CDISPLAY MODULE
Screen or Menu
Procedure Description Range or Selection
Sensor Calibration
W ith the key sw itch OFF, press and hold the
button and turn the key sw itch to the ON position. Release the button and press .
Set unit X-axis to gravity
Set unit Y-axis to gravity
Set platform level to gravity (YES/NO)
YES: Set platform level to gravity (YES/NO)
Platform level sensor m illivolts per degree
Reset axle angle sensors (YES/NO)
YES: Axle angle fully retracted (YES/NO)
YES: Axle angle fully extended (YES/NO)
Reset all steer sensors (YES/NO)
Reset blue end blue side steer sensor (FL) (YES/NO)
Reset yellow end blue side steer sensor (RL) (YES/NO)
Reset blue end yellow side steer sensor (FR) (YES/NO)
Reset yellow end yellow side steer sensor (RR) (YES/NO)
Calibrate secondary boom angle sensor (YES/NO) secondary boom angle to gravity -3.5 deg secondary boom angle to gravity 20 deg secondary boom angle to gravity 35 deg secondary boom angle to gravity 50 deg secondary boom angle to gravity 65 deg secondary boom angle to gravity 76 deg
Calibrate primary boom angle sensor (YES/NO) primary boom angle to gravity 0 deg primary boom angle to gravity -50 deg primary boom angle to gravity -20 deg primary boom angle to gravity 10 deg primary boom angle to gravity 40 deg primary boom angle to gravity 70 deg
Reset level angle sensor (YES/NO) jib level calibration deg to gravity 60 deg jib level calibration deg to gravity 34 deg jib level calibration deg to gravity 8 deg jib level calibration deg to gravity -18 deg jib level calibration deg to gravity -44 deg jib level calibration deg to gravity -70 deg
Use +/- buttons to adjust
Use +/- buttons to adjust
Use +/- buttons to adjust
Default Reset
W ith the key sw itch OFF, press and hold the
button and turn the key sw itch to the ON position. Release the button and press .
Reset drive functions
Reset boom functions
Reset lift function ramps
Reset all
Part No. 106783 Z-135/70 4 - 7
April 2008 Section 4 • Repair Procedures
REV C DISPLAY MODULE
Screen or Menu
Procedure Description Range or Selection
Options With the key switch OFF, press and hold the button and turn the key switch to the ON position. Release the button and press .
Boom function limit: NO LT / EXT LT
AC Generator: NONE/BELT/HYDAC
Alarm: No (NO AL),
motion (MO AL), travel (TR AL), descent (DE AL), travel and descent (TD AL)
Lift/drive OPT: No (NO CO), drive cutout while not stowed (DCONS), lifting or driving (LORDR) Proximity kill switch OR platform: (NONE, PROX, PLTFS)
Chassis switch: (YES/NO)
Flashing beacon: (NO/YES)
Drive lights: (NO/YES)
Disable steer mode change while driving: (NO/YES)
Rocker switch: (NO/YES)
Chassis tilt cutout: (NO/YES)
Foot switch lockout: 0 to 30 minutes
Platform level to gravity: (NO/YES)
Axle whl drv: (NO/YES)
NO LT: no limit EXT LT: secondary boom extend inhibited.
0- 30 minutes, 10.0 (default)
Holding + or – button will cause display to scroll through options or increment number settings automatically in 0.2 min inc./dec.
4 - 8 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
The platform controls contains two printedcircuit boards:
The LED circuit board is mounted to the undersideof the control box lid which contains the LEDs. TheLED circuit board sends the input from the operatorto the platform controls circuit board (PCON). Thecircuit board (PCON) sends the data to theturntable control box (TCON) for processing.
The platform controls ECM circuit board(ALC-1000) communicates with the turntablecontrols. The joystick controllers at the platformcontrols utilize Hall Effect technology (non-contact)and require no adjustment. The operatingparameters of the joysticks are stored in memory atthe turntable controls. If a joystick controller erroroccurs or if a joystick is replaced, it will need to becalibrated before that particular machine functionwill operate. See 1-3, How to Calibrate a Joystick.
Each joystick controller should operate smoothlyand provide proportional speed control over itsentire range of motion.
For further information or assistance, consult theGenie Industries Service Department.
a platform controls ALC-1000circuit board
b jib boom up/down, jib boom extend/retract and platform rotate left rightjoystick
c secondary boom up/extend anddown/retract joystick
d drive/steer joystick controllere LED circuit boardf primary boom up/down, primary
boom extend/retract andturntable rotate left/right joystick
Platform Controls
a
e
f d
b
c
Part No. 106783 Z-135/70 4 - 9
April 2008 Section 4 • Repair Procedures
REV C
7 Attach a grounded wrist strap to the groundscrew inside the platform control box.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
8 Tag and carefully disconnect the wireconnectors from the circuit board.
9 Tag and disconnect the ribbon cable from theLED circuit board.
10 Remove the ALC-1000 circuit board mountingfasteners.
11 Carefully remove the ALC-1000 circuit boardfrom the platform control box.
1-1ALC-1000 Circuit Board
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Note: When the ALC-1000 circuit board is replaced,the joystick controllers will need to be calibrated.See 1-3, How to Calibrate a Joystick.
How to Remove the ALC-1000Circuit Board1 Push in the red Emergency Stop button to the
off position at both the ground and platformcontrols.
2 Locate the cables that connect to the bottom ofthe control box. Number each cable and itslocation at the control box.
3 Disconnect the cables from the bottom of theplatform control box.
4 Remove the control cable plug retainingfasteners from the bottom of the platformcontrol box.
5 Remove the platform control box lid retainingfasteners. Open the control box lid.
6 Locate the ALC-1000 circuit board mounted tothe inside of the platform control box.
PLATFORM CONTROLS
4 - 10 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CPLATFORM CONTROLS
How to Remove the LEDCircuit Board1 Push in the red Emergency Stop button to the
off position at both the ground and platformcontrols.
2 Remove the platform control box lid retainingfasteners. Open the control box lid.
3 Locate the LED circuit board mounted to theinside of the platform control box lid.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
4 Tag and carefully disconnect the ribbon cablesfrom the membrane circuit board.
5 Remove the LED circuit board retainingfasteners.
6 Carefully remove the LED circuit board from theplatform control box lid. Do not lose the plasticspacers.
Note: When installing the LED circuit board, be surethe plastic spacers are installed between the circuitboard and the control box lid.
1-2Membrane Decal
How to Replace the MembraneDecalThe membrane decal is a special decal thatincorporates an electronic membrane on thebackside. The membrane contains touch sensitiveareas that, when pushed, activates the machinefunctions. The membrane buttons function similarto toggle switches, but do not have any movingparts.
1 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.
2 Remove the platform control box lid retainingfasteners. Open the control box lid.
3 Tag and carefully disconnect the two riboncables from the membrane circuit board.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
Part No. 106783 Z-135/70 4 - 11
April 2008 Section 4 • Repair Procedures
REV C PLATFORM CONTROLS
4 Close the control box lid.
5 Remove the platform controls decal from theplatform control box.
6 Carefully remove the membrane decal from theplatform control box while guiding the ribboncables out of the control box lid.
7 Remove any decal adhesive from the controlbox lid with a mild solvent.
Note: Do not allow any solvent to come in contactwith the membrane circuit board.
8 Install the new membrane decal while guidingthe ribbon cables through the control box lid.
Note: Be sure that all LED locations on themembrane decal align with the LEDs on themembrane circuit board.
9 Install a new platform controls decal over themembrane decal.
10 Open the control box lid and carefuly connectthe ribbon cables from the membrane decal tothe membrane circuit board.
1-3Joysticks
How to Calibrate a JoystickThe joystick controllers on this machine utilizedigital Hall Effect technology for proportionalcontrol. If a joystick controller is disconnected orreplaced, it must be calibrated before that particularmachine function will operate.
Note: The joystick must be calibrated before thethreshold, max-out or ramping can be set.
Note: After each joystick is calibrated, check thedisplay at the ground control box. There should beno calibration faults shown on the display. Ifcalibration faults exist, repeat steps 1 through 8 forthat joystick controlled function.
Note: Perform this procedure with the engine off.
Drive functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET DRIVE JOYSTICK DEFAULTS is
displayed. Press the button to select YES,
then press the button.
4 - 12 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CPLATFORM CONTROLS
5 Do not start the engine.
6 Locate the drive/steer joystick.
7 Move the drive/steer joystick full stroke in theforward direction and hold for 5 seconds, thenreturn to the center or neutral position.
8 Move the drive/steer joystick full stroke in thereverse direction and hold for 5 seconds, thenreturn to the center or neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
Steer functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET STEER JOYSTICK DEFAULTS is
displayed. Press the button to select YES,
then press the button.
5 Do not start the engine.
6 Locate the drive/steer joystick.
7 Move the drive/steer joystick or thumb rockerswitch (if equipped) full stroke in the leftdirection and hold for 5 seconds, then return tothe center or neutral position.
8 Move the drive/steer joystick or thumb rockerswitch (if equipped) full stroke in the rightdirection and hold for 5 seconds, then return tothe center or neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
Primary boom extend/retract functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM EXTEND/RETRACT
JOYSTICK DEFAULTS is displayed. Press the
button to select YES, then press the button.
5 Do not start the engine.
6 Locate the thumb rocker switch on top of theprimary boom/turntable rotate joystick.
7 Move the primary boom extend/retract thumbrocker switch full stroke in the extend directionand hold for 5 seconds, then return to the centeror neutral position.
8 Move the primary boom extend/retract thumbrocker switch full stroke in the retract directionand hold for 5 seconds, then return to the centeror neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
Part No. 106783 Z-135/70 4 - 13
April 2008 Section 4 • Repair Procedures
REV C
Secondary boom up/down andextend/retract functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET SECONDARY BOOM JOYSTICK DEFAULTS
is displayed. Press the button to select YES,
then press the button.
5 Do not start the engine.
6 Locate the secondary boom up/down andextend/retract joystick.
7 Move the secondary boom up/down and extend/retract joystick full stroke in the up/extenddirection and hold for 5 seconds, then return tothe center or neutral position.
8 Move the secondary boom up/down and extend/retract joystick full stroke in the down/retractdirection and hold for 5 seconds, then return tothe center or neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
Primary boom up/down functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET PRIMARY BOOM UP/DOWN JOYSTICK
DEFAULTS is displayed. Press the button to
select YES, then press the button.
5 Do not start the engine.
6 Locate the primary boom/turntable rotatejoystick.
7 Move the boom/turntable rotate joystick fullstroke in the up direction and hold for 5seconds, then return to the center or neutralposition.
8 Move the boom/turntable rotate joystick fullstroke in the down direction and hold for 5seconds, then return to the center or neutralposition.
Result: The alarm at the ground controls shouldsound for a successful calibration.
PLATFORM CONTROLS
4 - 14 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
Jib boom up/down functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET JIB BOOM UP/DOWN JOYSTICK
DEFAULTS is displayed. Press the button to
select YES, then press the button.
5 Do not start the engine.
6 Locate the jib boom joystick.
7 Move the jib boom joystick full stroke in the updirection and hold for 5 seconds, then return tothe center or neutral position.
8 Move the jib boom joystick full stroke in thedown direction and hold for 5 seconds, thenreturn to the center or neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
Turntable rotate functions:
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until RESET TURNTABLE ROTATE JOYSTICK
DEFAULTS is displayed. Press the button to
select YES, then press the button.
5 Do not start the engine.
6 Locate the primary boom/turntable rotatejoystick.
7 Move the boom/turntable joystick full stroke inthe left direction and hold for 5 seconds, thenreturn to the center or neutral position.
8 Move the boom/turntable joystick full stroke inthe right direction and hold for 5 seconds, thenreturn to the center or neutral position.
Result: The alarm at the ground controls shouldsound for a successful calibration.
PLATFORM CONTROLS
Part No. 106783 Z-135/70 4 - 15
April 2008 Section 4 • Repair Procedures
REV C PLATFORM CONTROLS
How to Reset a ProportionalValve Coil DefaultNote: This procedure only needs to be performed ifa proportional valve has been replaced.
Note: After the valve coil defaults have been set,each machine function threshold and defaultfunction speed must be set. See How to Set theFunction Thresholds and Default Function Speeds.
1 Turn the key switch to the off position.
2 Press and hold the enter button on theground control panel while turning the keyswitch to platform controls. Hold the enterbutton for approximately 5 seconds.
3 Press the minus button twice, then press the
enter button twice.
4 Use the scroll button to scroll through themenu until the function valve that needs to be
reset is displayed. Press the button to
select YES, then press the button to save thesetting.
5 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
6 Press the plus button or minus button to
select YES and then press the enter button .
How to Set the FunctionThresholds and DefaultFunctions SpeedsNote: Before the threshold and default functionspeeds can be set, the boom function proportionalvalve coil defaults must be set first.See How to Reset a Proportional Valve CoilDefault.
Note: If a boom function proportional valve coil hasnot been replaced and just want to reset thefunction speed to original factory settings, beginwith step 12.
1 Start the engine from the platform controls.
2 Press down the foot switch.
Note: Be sure the engine rpm is set to foot switchactivated high idle.
Function threshold:
3 Select a joystick controlled function that needsto have the threshold set.
4 Slowly move the joystick off center in eitherdirection just until the machine function starts tomove, then move the joystick very slowlytowards the neutral or center position just beforethe machine function stops.Do not let go of the joystick.
5 While holding the joystick in position, press the
engine start button at the platform controls
to set the joystick controller threshold.
6 Slowly move the joystick off center in theopposite direction just until the machine functionstarts to move, then move the joystick veryslowly towards the neutral or center position justbefore the machine function stops.Do not let go of the joystick.
4 - 16 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
7 While holding the joystick in position, press the
engine start button at the platform controls
to set the joystick controller threshold.
8 Repeat steps 3 through 7 for each joystickcontrolled machine function (primary boom up/down and turntable rotate left/right, primaryboom extend/retract, secondary up/down andextend/retract, drive forward/reverse).
9 Once the threshold has been set, press and hold
the engine start button until the engine
shuts off. Do not press the red Emergency Stopbutton.
Note: Approximately 3 seconds after the engineshuts off, the alarm at the ground controls willsound to indicate the threshold settings are beingsaved in memory.
10 At the ground controls, turn the key switch tothe off position, wait a moment and then turnthe key switch to platform controls.
11 Check the display at the ground controls to besure there are no calibration faults.
Note: There should be no calibration faults shownon the display. If calibration faults exist, repeatthis procedure.
PLATFORM CONTROLS
Function speeds:
Note: Be sure the machine is in the stowed positionand the boom is rotated between the circle endtires.
Note: Perform this procedure with the machineparked on a firm, level surface which is free ofobstructions.
12 Start the engine from the platform controls.
13 Select a boom function that needs the functionspeed set.
14 Primary boom up/down and extend/retractfunctions: Move the joystick full stroke in theup or extend direction. When the alarm sounds,move the joystick in the opposite direction fullstroke until the alarm sounds again. Return thejoystick to center.
Secondary boom up/extend and down/retractfunctions: Move the joystick full stroke in theup or extend direction. When the alarm sounds,move the joystick in the opposite direction fullstroke until the alarm sounds again. Return thejoystick to center.
Turntable rotate functions: Move the joystickfull stroke in either the left or right direction.When the alarm sounds, move the joystick inthe opposite direction full stroke until the alarmsounds again. Return the joystick to center.
Part No. 106783 Z-135/70 4 - 17
April 2008 Section 4 • Repair Procedures
REV C
15 Once the function speeds have been set, press
and hold the engine start button until the
engine shuts off. Do not press the redEmergency Stop button.
Note: Approximately 3 seconds after the engineshuts off, the alarm at the ground controls willsound to indicate the speed settings are beingsaved in memory.
16 At the ground controls, turn the key switch tothe off position, wait a moment and then turnthe key switch to platform controls.
17 Check the display at the ground controls to besure there are no calibration faults.
Note: There should be no calibration faults shownon the display. If calibration faults exist, repeatthis procedure.
PLATFORM CONTROLS
How to Adjust the FunctionSpeedsNote: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls. Hold the enterbutton for approximately 5 seconds.
3 Press the plus button twice, then press the
minus button twice.
4 Press the scroll button until the function tobe adjusted is displayed.
5 Press the plus button to increase the speed
or press the minus button to decrease thespeed.
6 Press the enter button to save the setting inmemory.
7 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
8 Press the plus button or minus button to
select YES and then press the enter button .
9 Continue to perform this procedure until themachine function speed meets specification.Refer to Section 2, Specifications for functionspeeds.
4 - 18 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
How to Adjust the FunctionRamp Rate SettingThe ramp rate setting of a joystick controls the timeat which it takes for the joystick to reach maximumoutput, when moved out of the neutral position. Theramp rate settings of a joystick can be changed tocompensate for hydraulic pump wear to maintainpeak performance from the machine.
Note: Perform this procedure with the boom in thestowed position.
1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.
2 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls. Hold the enterbutton for approximately 5 seconds.
3 Press the plus button twice, then press thescroll button twice.
4 Press the scroll button until the function tobe adjusted is displayed.
5 Press the plus button to increase the ramp
rate or press the minus button to decreasethe ramp rate.
6 Press the enter button to save the setting inmemory.
7 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
8 Press the plus button or minus button to
select YES and then press the enter button .
PLATFORM CONTROLS
Part No. 106783 Z-135/70 4 - 19
April 2008 Section 4 • Repair Procedures
REV DPlatform Components
2-1Platform Leveling Cylinder
The platform leveling cylinder keeps the platformlevel through the entire range of boom motion.The platform is maintained level to the turntable. Toaccomplish this, the ECM at the ground controlscompares the difference in readings between theplatform angle sensor and the turntable levelsensor, which then sends a signal to the platformcontrols to open or close the appropriate platformlevel proportional valve on the platform manifold tomaintain a level platform. The platform levelingcylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.
How to Remove the PlatformLeveling CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Extend the jib boom until the platform levelingcylinder barrel-end pivot pin is accessible.
2 Raise the jib boom slightly and place blocksunder the platform.
3 Lower the jib boom until the platform is restingon the blocks just enough to support theplatform.
Note: Do not rest the entire weight of the boom onthe blocks.
4 Place a block under the platform levelingcylinder for support.
5 Remove the external snap rings from the barrel-end pivot pin. Use a soft metal drift to removethe barrel-end pivot pin.
6 Support the rod end of the platform levelcylinder.
7 Remove the pin retaining fasteners fromthe platform leveling cylinder rod-end pivot pin.Use a soft metal drift to remove the barrel-endpivot pin.
8 Carefully pull the platform leveling cylinder out ofthe boom to access the hydraulic hoses.
9 Tag, disconnect and plug the hydraulic hosesfrom the platform leveling cylinder. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
10 Remove the platform leveling cylinder from themachine.
Crushing hazard. The platformleveling cylinder may fall if notproperly supported when removedfrom the machine.
4 - 20 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV DPLATFORM COMPONENTS
2-2Platform Rotator
The platform rotator is a hydraulically activatedhelical gear assembly used to rotate the platform160 degrees.
How to Remove thePlatform Rotator
Component damage hazard. Markthe platform mounting weldmentand the rotator flange beforeremoving the platform mountingweldment. The platform mountingweldment must be replaced in theexact same position on the rotatorflange as it was before removal. Ifa new rotator is installed or therotator is disassembled, properalignment can be achieved byrotating the rotator all the way tothe left and then installing theplatform mounting weldment all theway in the left position.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the platform.
2 Tag and disconnect the electrical connectorfrom the platform angle sensor.
3 Remove the platform angle sensor retainingfasteners. Remove the platform angle sensorfrom the platform rotator.
Component damage hazard. Theplatform angle sensor is a verysensitive instrument. It can bedamaged internally if is dropped orsustains any physical shock, evenif the damage is not visible.
4 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold. Cap thefittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
5 Tag, disconnect and plug the hydraulic hosesfrom the platform manifold. Cap the fittings onthe manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
6 Remove the power to platform electrical outletbox bracket mounting fasteners. Do notdisconnect the wiring.
7 Remove the hose and cable guide retainingfasteners and remove the guide from theplatform support.
Part No. 106783 Z-135/70 4 - 21
April 2008 Section 4 • Repair Procedures
REV D PLATFORM COMPONENTS
8 Remove the weld cable from the platform(if equipped).
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
9 Support the platform mounting weldment, but donot apply any lifting pressure.
10 Remove the eight mounting bolts from theplatform mounting weldment.
11 Remove the center bolt and slide the platformmounting weldment off of the platform rotator.
Crushing hazard. The platformmounting weldment could becomeunbalanced and fall if not properlysupported.
12 Support the platform rotator with a suitable liftingdevice. Do not apply any lifting pressure.
13 Place a block under the platform levelingcylinder rod for support.
14 Remove the pin retaining fasteners fromthe platform leveling cylinder rod-end pivot pin.Do not remove the pin.
15 Remove the pin retaining fasteners from the jibboom to platform rotator pivot pin. Do notremove the pin.
16 Use a soft metal drift to remove both pins andremove the platform rotator from the machine.
Crushing hazard. The platformrotator could fall when removedfrom the machine if not properlysupported.
2-3Platform Level Sensor
The platform level sensor is mounted to the side ofthe platform rotator. The platform level sensor ismonitored by the control system to maintain a levelplatform throught boom range of motion. If aplatform level sensor is replaced, it must becalibrated prior to machine operation.
How to Calibrate the PlatformLevel SensorNote: Perform this procedure with the machine on afirm, level surface and in the stowed position.
1 Secure a digital level to one of the side railingsof the platform.
2 Start the machine and level the platform togravity. Turn the machine off.
3 Open the ground control box.
Before serial number 321:
4 Locate the 2 pin connector in the lower left handarea of the ground control box.
5 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
4 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
5 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
4 - 22 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV DPLATFORM COMPONENTS
All models:
6 Press and hold the enter button on theground control panel while turning the keyswitch to ground controls. Hold the enterbutton for approximately 5 seconds.
7 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
8 Push one of the LCDscreen buttons shownuntil RESET PLATFORM LEVEL
SENSOR TO GRAVITY isdisplayed.
9 Press the plus button to select YES, thenpress the enter button.
10 Push one of the LCDscreen buttons shownuntil PLATFORM LEVEL SENSOR
MV PER DEGREE is displayed.
11 Confirm that the number shown on the display isthe same as that shown on the data sheetsupplied with the new platform level sensor.
Result: If the number shown on the display isthe same as that shown on the data sheetsupplied with the new platform level sensor,continue to step 13.
Result: If the number shown on the display isnot the same as that shown on the data sheetsupplied with the new platform level sensor,continue to step 12.
12 Press the plus button or minus button tocorrect the display to match the data sheet.Then press the enter button to save thesetting in memory.
13 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
14 Press the plus button or minus button to
select YES and then press the enter button .
Before serial number 321:
15 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 5.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
16 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
15 Remove the fastener that was temporarilyinstalled in step 5. Close the control box doorand install the door retaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
Part No. 106783 Z-135/70 4 - 23
April 2008 Section 4 • Repair Procedures
REV D
2-4Platform Overload System(if equipped)
Proper calibration of the platform overload systemis essential to safe machine operation. Continueduse of an improperly calibrated platform overloadsystem could result in the system failing to sensean overloaded platform. The stability of themachine is compromised and it could tip over.
How to Calibrate the PlatformOverload System (if equipped)Note: Perform this procedure with the machine on afirm, level surface.
1 Level the platform.
2 Determine the maximum platform capacity.Refer to the machine serial plate.
3 Using a suitable lifting device, place anappropriate test weight equal to that of themaximum platform capacity at the center of theplatform floor.
Determine the limit switch trigger point:
4 Gently move the platform up and down by hand,so it bounces approximately 1 to 2 inches /2.5 to 5 cm. Allow the platform to settle.
Result: The overload indicator light and thealarm is on. Slowly tighten the load springadjustment nut by turning it clockwise just untilthe overload indicator light and alarm turns off.
Note: The platform will need to be moved up anddown and allowed to settle in between adjustments.
Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.
Result: The overload indicator light andalarm is off. Slowly loosen the load springadjustment nut by turning it counterclockwisejust until the overload indicator light and alarmturn on.
Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.
Note: The platform will need to be moved up anddown and allowed to settle in between adjustments.
Confirm the setting:
5 Turn the key switch to platform control. Start theengine from the platform controls.
6 Lift the test weight off the platform floor using asuitable lifting device.
PLATFORM COMPONENTS
4 - 24 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV DPLATFORM COMPONENTS
7 Place the test weight back onto the center of theplatform floor using a suitable lifting device.
Result: The alarm should be off. The platformoverload indicator light should be off at theplatform controls and there should be no errormessage on the LCD display at the groundcontrols.
Note: There may be an approximate 2 second delaybefore the overload indicator light and alarm turnoff.
8 Add an additional 12 lb / 5.4 kg test weight tothe original test weight to overload the platform.
Result: The alarm should be sounding.The platform overload indicator light should beflashing at the platform controls andPLATFORM OVERLOAD should be displayed on theLCD screen at the ground controls.
Note: There may be an approximate 2 second delaybefore the overload indicator light turns on and thealarm sounds.
9 Test all machine functions from the platformcontrols.
Result: All platform control functions should notoperate.
10 Turn the key switch to ground control.
11 Test all machine functions from the groundcontrols.
Result: All ground control functions should notoperate.
Part No. 106783 Z-135/70 4 - 25
April 2008 Section 4 • Repair Procedures
This page intentionally left blank.
4 - 26 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
Jib boom components
a primary extension boomb jib boom manifoldc bellcrankd cable track tubee platform rotatorf platform leveling cylinderg jib boomh jib extension boomi hose and cable junction boxj jib boom lift cylinderk jib boom cable trackl jib boom leveling cylinder
Jib Boom Components
a b c d e
fhijl k g
Part No. 106783 Z-135/70 4 - 27
April 2008 Section 4 • Repair Procedures
REV E
3-1Jib Boom Cable Track
The jib boom cable track guides the cables andhoses running up the jib boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire jib boomcable track is only necessary when performingmajor repairs that involve removing the jib boom.
How to Remove the Jib BoomCable TrackNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation.Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the jib boom to a horizontal position.Turn the machine off.
2 Remove the cover from the hose and cablejunction box under the jib boom cable track.
3 Tag and disconnect the electrical connectorsinside the cable track junction box.
4 Tag, disconnect and plug the two hydraulichoses from the jib boom manifold that lead tothe platform manifold. Cap the fittings on themanifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
Note: The jib boom manifold is located at theplatform end of the primary extension boom.
5 Pull the hoses out of the plastic hose guidelocated on the primary extension boom near thejib boom manifold.
6 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
7 Remove the hose and cable clamp retainingfasteners from the jib boom cable track junctionbox. Remove the clamps.
8 Pull the jib boom lift cylinder hydraulic hoses outof the jib boom cable track junction box.
9 Remove the hose and cable clamp retainingfasteners at the platform end of the jib boomcable track tube. Remove the clamps.
10 Tag and disconnect the electrical connectorsfrom the platform manifold.
11 Tag and disconnect the electrical connectorsfrom the platform box.
12 Tag and disconnect the electrical connectorfrom the foot switch.
13 Tag and disconnect the electrical connectorfrom the platform angle sensor.
14 Tag, disconnect and plug the hydraulic hosesfrom the "P" and "T" ports on the platformmanifold.
JIB BOOM COMPONENTS
4 - 28 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EJIB BOOM COMPONENTS
15 Pull the two hydraulic hoses just removed andall of the cables through the hose and cableguide at the platform support.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
16 Remove the cotter pin from the upper cabletrack tube at the platform end of the jib boom.Do not discard the washer.
Note: Always replace the cotter pin with a new one.
17 Remove the fasteners from the cable track tubeguide at the platform end of the jib boom.Remove the cable track tube guide from the jibboom.
18 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.
Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.
19 Attach a lifting strap from an overhead crane tothe cable track.
20 Remove the mounting fasteners that attach thelower cable track to the jib boom.
21 Remove the cable track from the machine andplace it on a structure capable of supporting it.
Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
How to Repair the Cable TrackComponent damage hazard.The boom cable track can bedamaged if it is twisted.
Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 77896. The kit includes a 4-link section ofcable track.
1 Visually inspect the cable track and determinewhich 4-link section needs to be replaced.
2 Carefully remove the snap rings and pins fromeach end of the damaged section of cable track.
3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.
Component damage hazard. Hosesand cables can be damaged ifthey are kinked or pinched.
5 Remove the upper rollers from the replacementsection of cable track.
6 Lift up the hoses and cables and carefully insertthe new 4-link section of cable track.
Component damage hazard.Hoses and cables can be damagedif they are kinked or pinched.
7 Connect the ends of the replacement cable tracksection to the existing cable track using thepins and snap rings.
8 Install the rollers onto the new section of cabletrack.
9 Operate the jib boom extend/retract functionthrough a full cycle to ensure smooth operationof the new section of cable track.
Part No. 106783 Z-135/70 4 - 29
April 2008 Section 4 • Repair Procedures
REV E
3-2Jib Boom
How to Remove the Jib BoomBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the platform mounting weldmentand the platform rotator. See 2-2, How toRemove the Platform Rotator.
2 Tag, disconnect and plug the the two hydraulichoses from the jib boom manifold that lead tothe platform manifold. Cap the fittings on themanifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
JIB BOOM COMPONENTS
3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses from the jib boommanifold. Cap the fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Remove the cotter pin from the upper cabletrack tube at the platform end of the jib boom.
Note: Always replace the cotter pin with a new one.
5 Remove the cable track guide fasteners fromthe cable track guide at the platform end of thejib boom and remove the cable track guide fromthe jib boom.
6 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.
Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.
7 Attach a lifting strap from an overhead crane tothe cable track.
8 Remove the mounting fasteners that attach thelower cable track to the jib boom.
9 Remove the cable track from the machine andlay to the side.
Crushing hazard. The cable trackcould become unbalanced and fallif not properly attached to theoverhead crane.
Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.
4 - 30 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
10 Disconnect the electrical connector from the jibboom angle sensor located at the jib boom pivotpin on the engine side of the machine.
11 Remove the cover retaining fasteners from thejib boom angle sensor. Remove the cover.
12 Remove the jib boom angle sensor mountingbracket fasteners from the side of the primaryextension boom.
13 Carefully remove the bracket and sensorassembly. Note the location of the springs.Do not lose the springs.
Note: There is one spring inside the jib boom pivotpin and one inside the angle sensor.
Note: When the jib boom is installed, the jib boomangle sensor will need to be calibrated. See 3-6, JibBoom Bellcrank Angle Sensor for the calibrationprocedure.
14 Attach a lifting strap from an overhead crane tothe platform end of the jib boom.
15 Support the barrel end of the jib boom liftcylinder with another suitable lifting device.
16 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin.
17 Use a soft metal drift to remove the jib boom liftcylinder barrel-end pivot pin.
Crushing hazard. The jib boomcould fall when the jib boom liftcylinder barrel-end pivot pin isremoved if not properly supported.
Crushing hazard. The jib boom liftcylinder could fall when thebarrel-end pivot pin is removed ifnot properly supported.
JIB BOOM COMPONENTS
18 Secure the jib boom lift cylinder to the jib boomwith a strap or other suitable device.
19 Raise the jib boom to a horizontal position usingthe overhead crane.
20 Attach a second lifting strap from the overheadcrane to the pivot end of the jib boom.
21 Remove the pin retaining fastener from the jibboom pivot pin. Do not remove the pin.
22 Place a block under the jib boom level cylinderfor support. Protect the cylinder rod fromdamage.
23 Use a soft metal drift to tap the pin halfway outin one direction and lower one side of the jibboom bellcrank. Tap the pin in the otherdirection and lower the other side of the jibboom bellcrank.
24 Use a soft metal drift to remove the jib boompivot pin. Remove the jib boom from themachine and place it on a structure capable ofsupporting it.
Crushing hazard. The jib boomassembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.
Part No. 106783 Z-135/70 4 - 31
April 2008 Section 4 • Repair Procedures
REV E
3-3Jib Boom Lift Cylinder
How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Lowerthe jib boom until the platform is resting on theblocks just enough to support the platform.
Note: Do not rest the entire weight of the boom onthe blocks.
2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Support the rod end of the jib boom lift cylinderwith a suitable lifting device.
4 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin and let the cylinderhang down.
5 Attach a lifting strap from an overhead crane tothe barrel end of jib boom lift cylinder.
6 Remove the pin retaining fasteners from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.
7 Remove the jib boom lift cylinder from themachine.
Crushing hazard. The jib boom liftcylinder could become unbalancedand fall when removed from themachine if not properly supportedby the overhead crane.
JIB BOOM COMPONENTS
4 - 32 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
3-4Jib Boom Level Cylinder
How to Remove the Jib BoomLevel CylinderNote: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Extend the primary boom until the jib boom levelcylinder barrel-end pivot pin is accessible.
2 Raise the jib boom above horizontal.
3 Attach an overhead crane to the jib boomassembly for support.
4 Place a block under the jib boom level cylinderfor support. Protect the cylinder rod fromdamage.
5 Remove the pin retaining fasteners from the jibboom level cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.
Crushing hazard. The jib boomcould fall if not properly supportedwhen the jib boom level cylinderrod-end pivot pin is removed.
6 Remove the external snap rings from the jibboom level cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.
JIB BOOM COMPONENTS
7 Tag, disconnect and plug the jib boom levelcylinder hydraulic hoses from the jib boommanifold. Cap the fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
8 Attach an overhead crane or other suitabledevice to the jib boom level cylinder for support.
9 Carefully remove the jib boom level cylinderfrom the machine.
Crushing hazard. The jib boomlevel cylinder could becomeunbalanced and fall when removedfrom the machine if not properlysupported.
Part No. 106783 Z-135/70 4 - 33
April 2008 Section 4 • Repair Procedures
REV E
3-5Jib Boom Extension Cylinder
How to Remove the Jib BoomExtension Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: Perform this procedure with the boom in thestowed position.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
1 Remove the jib boom lift cylinder. See 3-3, Howto Remove the Jib Boom Lift Cylinder.
2 Attach a lifting strap from an overhead crane tothe platform end of the jib boom for support.Raise the jib boom to a horizontal position usingthe overhead crane.
3 Extend the jib boom until the jib boom extensioncylinder rod-end pivot pin is accessible.
4 Tag, disconnect and plug the the two hydraulichoses from the jib boom manifold that lead tothe platform manifold. Cap the fittings on themanifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
5 Tag, disconnect and plug the jib boom liftcylinder and jib boom extension cylinderhydraulic hoses from the jib boom manifold. Capthe fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Remove the cover from the lower jib boom cabletrack.
7 Tag and disconnect the electrical connectorsinside the lower cable track.
8 Remove the hose and cable clamp retainingfasteners from lower cable track at the pivot endof the jib boom. Remove the clamps.
9 Pull the electrical cables out of the lower cabletrack that lead to the primary boom.
10 Attach a lifting strap from a second overheadcrane to the pivot end of the jib boom forsupport. Do not apply any lifting pressure.
JIB BOOM COMPONENTS
4 - 34 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EJIB BOOM COMPONENTS
11 Place a block under the jib boom level cylinderfor support. Protect the cylinder rod fromdamage.
12 Remove the pin retaining fastener from the jibboom pivot pin. Do not remove the pin.
13 Use a soft metal drift to tap the jib boom pivotpin halfway out in one direction and lower oneside of the jib boom bellcrank. Tap the pin in theother direction and lower the other side of the jibboom bellcrank.
14 Use a soft metal drift to remove the jib boompivot pin. Remove the jib boom and platformassembly from the machine and place it on astructure capable of supporting it.
Crushing hazard. The jib boom andplatform assembly could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.
15 Remove the pin retaining fasteners from the jibboom extension cylinder rod-end pivot pin. Usea soft metal drift to remove the pin.
16 Attach a lifting strap from an overhead crane tothe barrel end of the jib boom extensioncylinder.
17 Remove the pin retaining fasteners from the jibboom extension cylinder barrel-end pivot pin.Use a soft metal drift to remove the pin.
18 Carefully slide the jib boom extension cylinderout of the jib boom and place it on a structurecapable of supporting it.
Crushing hazard. The jib boomextension cylinder could becomeunbalanced and fall when removedfrom the jib boom if not properlysupported.
Note: During removal of the extension cylinder, theoverhead crane strap will need to be carefullyadjusted for proper balancing.
3-6Jib Boom Bellcrank AngleSensor
The jib boom bellcrank angle sensor is monitoredby the control system to keep the jib boombellcrank vertical and to help maintain a levelplatform through boom range of motion. If a jibboom bellcrank angle sensor is replaced, it must becalibrated prior to machine operation. The jib boombellcrank angle sensor is mounted to the bellcrankpivot pin on the engine side of the machine.
How to Replace the Jib BoomBellcrank Angle SensorNote: Perform this procedure on a firm, levelsurface with the boom in the stowed position.
1 Locate the jib boom bellcrank angle sensorwhere the jib boom bellcrank connects to theprimary boom.
2 Disconnect the electrical connector from thesensor. Remove any tie wraps securing thewiring.
3 Remove the retaining fasteners from the anglesensor guard. Remove the guard from themachine.
4 Remove the angle sensor cover retainingfastener. Remove the cover.
5 Remove the angle sensor mounting bracketretaining fasteners.
Part No. 106783 Z-135/70 4 - 35
April 2008 Section 4 • Repair Procedures
REV E
6 Remove the angle sensor and bracketassembly. Do not lose the two springs or thehex-shaped key.
7 Remove the sensor retaining fasteners from themounting bracket. Remove the angle sensor.
Note: Note the sensor orientation on the bracketduring removal so the new sensor will be installedin the same position.
8 Install the new angle sensor onto the mountingbracket.
9 Install one spring, removed in step 6, into thehex-shaped hole in the angle sensor. Install theother spring into the hex-shaped hole in thecenter of the boom pivot pin.
10 Insert the hex-shaped key into the angle sensor.
11 Align the side of the sensor with flat area of theboom pivot pin as shown below.
a flat areab angle sensorc hex-shaped hole
12 Insert the hex-shaped key into the bellcrankpivot pin allowing free clockwise rotation of theangle sensor mounting bracket.
Note: Be sure the hex-shaped key remainsengaged in the sensor.
13 Rotate the angle sensor mounting bracket, whileholding the key in the sensor, clockwise untilthe mounting bracket fits into the machinedpocket.
14 Install the angle sensor bracket retainingfasteners.
15 Install the angle sensor cover and install thecover retaining fasteners.
16 Connect the electrical connector to the newsensor.
17 Install the angle sensor guard over the anglesensor.
18 Calibrate the jib boom bellcrank angle sensor.See How to Calibrate the Jib Boom BellcrankAngle Sensor.
JIB BOOM COMPONENTS
a cb
4 - 36 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
How to Calibrate the Jib BoomBellcrank Angle SensorNote: If the secondary boom and/or primary boomangle sensors have been removed or replaced, theywill need to be calibrated before the jib boombellcrank angle sensor. See 4-9, Secondary BoomAngle Sensor and/or 4-8, Primary Boom AngleSensor for the calibration procedures.
Note: Perform this procedure with the machine on afirm, level surface and in the stowed position withthe axles extended.
Note: A digital level will be required to perform thisprocedure.
Note: A kit is available through the Genie IndustriesService Department (Genie part number 58351).This kit includes a digital level with a magneticbase and cable harnesses.
Digital levels with alternate zero function:
1 Prepare the digital level by placing it verticallyon a known surface that is perpendicular togravity. Zero out the level with the alternate zerofunction.
Note: When the level is calibrated correctly, itshould read 0° on a vertical surface.
Digital levels without alternate zero function:
Note: If your digital level does not have an alternatezero function, it will read 90° on a vertical surface.During calibration, the measured value will need tobe subtracted from 90 degrees to get the correctnumber to enter into the system.
2 Raise the jib boom to a slightly less thanhorizontal position.
3 Push in the ground controls red Emergency Stopbutton to the off position. Do not turn the keyswitch to the off position.
4 Open the ground control box
Before serial number 321:
5 Locate the 2 pin connector in the lower left handarea of the ground control box.
6 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
5 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
6 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
7 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
8 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
9 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
JIB BOOM COMPONENTS
Part No. 106783 Z-135/70 4 - 37
April 2008 Section 4 • Repair Procedures
REV E JIB BOOM COMPONENTS
10 Remove the key from the main key switch.
11 Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
12 Push one of the LCDscreen buttons shownuntil RESET JIB LEVEL ANGLE
SENSOR is displayed.
13 Press the plus button to select YES, then
press the enter button to accept.
14 At the JIB LEVEL CALIBRATION DEG 60.0DEG screen,start the engine.
Note: If the system exits out of calibration modewhen the engine is started, repeat step 9 andcontinue to step 15.
15 Press and hold a function enable/speed selectbutton and the platform level up button. Fullyextend the jib boom level cylinder.
Note: When in service/bypass mode, the platformlevel buttons are used to adjust the jib boom levelcylinder.
Note: With the jib boom level cylinder is fullyextended, the jib boom bellcrank angle should be atapproximately 60 ± 5 degrees.
16 Attach the digital level to the surface of the jibboom bellcrank as shown.
a jib boom angle sensorb jib boom bellcrankc place level on this surface
17 At the ground controls, press the plus button
or minus button to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
bc a
STOP
00000
Run
ServiceBypass
Recovery
4 - 38 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
18 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately34 ± 5 degrees.
19 At the ground controls, press the plus button
or minus button to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
20 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately8 ± 5 degrees.
21 At the ground controls, press the plus button
or minus button to to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
JIB BOOM COMPONENTS
22 Press and hold a function enable/speed selectbutton and raise the jib boom above horizontalto provide additional ground clearance for theremaining calibration points.
23 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately18 ± 5 degrees.
24 At the ground controls, press the plus button
or minus button to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
25 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately44 ± 5 degrees.
26 At the ground controls, press the plus button
or minus button to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
60�
34�
8� 0�-18�
-44�
-70�
Calibration angles
Part No. 106783 Z-135/70 4 - 39
April 2008 Section 4 • Repair Procedures
REV E JIB BOOM COMPONENTS
27 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately70 ± 5 degrees. The jib boom level cylindershould be fully retracted at this point.
28 At the ground controls, press the plus button
or minus button to adjust the display toto the exact value shown on the digital level andpress the enter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
Note: With the jib boom level cylinder fullyretracted, the jib boom bellcrank angle should be atapproximately 70 degrees.
29 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
30 Press the plus button to select YES, then
press the enter button to accept.
31 Press and hold the engine start button forapproximately 5 seconds to shut off the engineand to save the calibration settings.
Note: Do not turn the engine off with the key switchor red Emergency Stop button or all calibrationpoints or values will not be saved.
32 Wait approximately 20 seconds and turn themachine off by pressing the red EmergencyStop button in to the off position or by turningthe main key switch to the off position.
Before serial number 321:
33 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 6.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
34 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
33 Remove the fastener that was temporarilyinstalled in step 6.
34 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
All models:
35 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
4 - 40 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBoom Components
Boom components
a upper primary boom lift cylinder linkage armb primary boomc cable trackd primary extension boome jib boom manifoldf secondary boom lift cylinderg secondary boom cable track
(inside of secondary boom)h primary boom lift cylinderi number 1 secondary boom tubej number 2 secondary boom tubek number 3 secondary boom tubel lower primary boom lift cylinder linkage armm number 4 secondary boom tube
b
fhkm
edca
j il g
Part No. 106783 Z-135/70 4 - 41
April 2008 Section 4 • Repair Procedures
REV F
4-1Primary Boom Cable Track
The primary boom cable track guides the cablesand hoses running up the boom. It can be repairedlink by link without removing the cables and hosesthat run through it. Removing the entire primaryboom cable track is only necessary whenperforming major repairs that involve removing theprimary boom.
How to Remove the Cable TrackNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the machine on afirm, level surface and the boom in the stowedposition.
1 Remove the cover from the lower jib boom cabletrack.
2 Tag and disconnect the electrical connectorsinside the lower cable track.
3 Remove the hose and cable clamp retainingfasteners from lower cable track at the pivot endof the jib boom. Remove the clamps.
4 Pull the electrical cables out of the lower cabletrack that lead to the primary boom.
Component damage hazard.Cables can be damaged if they arekinked or pinched.
5 Tag and disconnect the electrical connectorsfrom the jib boom manifold located at theplatform end of the primary extension boom.
6 Tag, disconnect and plug the two hydraulichoses from the side of the jib boom manifoldthat lead to the primary boom cable track.Cap the fittings on the manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
7 Remove the retaining fasteners from the hoseand cable guide at the platform end of theprimary boom. Remove the hose and cableguide.
8 Tag and disconnect the electrical connectorfrom the limit switch on the side of the primaryboom. Do not remove the limit switch.
9 Remove the cotter pin from the upper cabletrack tube at the platform end of the primaryextension boom.
Note: Always replace the cotter pin with a new one.
10 Remove the retaining fasteners from the cabletrack guide at the platform end of the boom.Remove the cable track guide from themachine.
11 Place blocks between the upper and lower cabletracks and secure the upper and lower trackstogether.
Crushing hazard. If the upper andlower cable tracks are not properlysecured together, the cable trackcould become unbalanced and fallwhen removed from the machine.
BOOM COMPONENTS
4 - 42 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
12 Remove the hose and cable clamps from theprimary boom lift cylinder.
13 At the counterweight end of the secondaryboom, support and secure the secondary boomlower end cover to a suitable lifting device.
14 Remove the cover retaining fasteners andremove the cover from the end of the secondaryboom.
Crushing hazard. The secondaryboom lower end cover couldbecome unbalanced and fall whenremoved from the secondary boomif not properly supported andsecured to the lifting device.
15 Locate the two hydraulic hoses inside the end ofthe secondary boom that lead to the primaryboom cable track.
16 Tag, disconnect and plug the hydraulic hosesfrom the unions. Cap the fittings on the unions.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
17 Disconnect the electrical connectors for theelectrical cables that lead to the cable track atthe end of the secondary boom.
18 Pull all hydraulic hoses and electrical cablesthat lead to the cable track out of the secondaryboom riser.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
19 Attach a lifting strap to each end of the cabletrack from an overhead crane for support. Donot apply any lifting pressure.
20 Remove the mounting fasteners that attach thelower cable track to the primary boom liftcylinder.
21 Remove the mounting fasteners that attach thecable track to the primary boom.
22 Carefully remove the cable track from themachine and lay it on a structure capable ofsupporting it.
Crushing hazard. The primaryboom cable track could becomeunbalanced and fall when removedfrom the primary boom if notproperly supported by the overheadcrane.
Component damage hazard.The boom cable track can bedamaged if it is twisted.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
Part No. 106783 Z-135/70 4 - 43
April 2008 Section 4 • Repair Procedures
REV F
How to Repair the Primary BoomCable Track
Component damage hazard.The boom cable track can bedamaged if it is twisted.
Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no. 77896. The kit includes a 4-link section ofcable track.
1 Visually inspect the cable track and determinewhich 4-link section needs to be replaced.
2 Carefully remove the snap rings and pins fromeach end of the damaged section of cable track.
3 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.
4 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.
Component damage hazard. Hosesand cables can be damaged ifthey are kinked or pinched.
5 Remove the upper rollers from the replacementsection of cable track.
6 Lift up the hoses and cables and carefully insertthe new 4-link section of cable track.
Component damage hazard.Hoses and cables can be damagedif they are kinked or pinched.
7 Connect the ends of the replacement cable tracksection to the existing cable track using thepins and snap rings.
8 Install the rollers onto the new section of cabletrack.
9 Operate the primary boom extend/retractfunction through a full cycle to ensure smoothoperation of the new section of cable track.
BOOM COMPONENTS
4 - 44 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
4-2Secondary Boom Cable Track
The secondary boom cable track guides the cablesand hoses running up through the inside of thesecondary boom. It can be repaired link by linkwithout removing the cables and hoses that runthrough it. Removal of the secondary boom cabletrack is required to repair it.
How to Remove the SecondaryBoom Cable TrackNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Working at the counterweight end of thesecondary boom, support and secure thesecondary boom end cover to a suitable liftingdevice.
2 Remove the cover retaining fasteners andremove the cover from the secondary boom.
Crushing hazard. The secondaryboom end cover could becomeunbalanced and fall when removedfrom the secondary boom if notproperly supported and secured tothe lifting device.
3 Working at the platform end of the secondaryboom, support and secure the secondary boomend cover to a suitable lifting device.
4 Remove the cover retaining fasteners andremove the cover from the secondary boom.
Crushing hazard. The secondaryboom end cover could becomeunbalanced and fall when removedfrom the secondary boom if notproperly supported and secured tothe lifting device.
5 Working at the platform end of the secondaryboom, remove the hose and cable U-boltfasteners near the upper cable track tube.
6 Working at the platform end of the secondaryboom, remove the upper cable track tuberetaining fasteners. Remove the curved hoseguide.
7 Working at the platform end of the secondaryboom, remove the lower cable track retainingfasteners.
8 Working at the counterweight end of thesecondary boom, remove the lower cable trackretaining fasteners.
9 Tag, disconnect and plug the hydraulic hosesfrom the following ports of the function manifold:PE, PR, P2, T1, PU and PD. Cap the fittings onthe manifold.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
BOOM COMPONENTS
Part No. 106783 Z-135/70 4 - 45
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
10 Pull the hydraulic hoses just removed throughthe turntable bulkhead.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
11 Working at the counterweight end of thesecondary boom, tag, disconnect and plug thehydraulic hoses from the unions that lead to thecable track.
12 Working at the counterweight end of thesecondary boom, tag and disconnect theelectrical connectors to all of the cables thatlead to the secondary boom cable track.
13 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
14 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses at the unionslocated above the primary boom lift cylinder.Cap the fittings on the unions.
15 Pull the hydraulic hoses for the primary boom liftcylinder and extension cylinder out through thehole in the number 4 secondary boom tube.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
16 Working at the platform end of the secondaryboom, place blocks between the upper andlower cable tracks for support.
17 Working at the counterweight end of thesecondary boom, attach a lifting strap from anoverhead crane to the secondary boom cabletrack.
18 Carefully pull the secondary boom cable trackout of the counterweight end of the boom.
19 Remove the secondary boom cable track fromthe machine and place it on a structure capableof supporting it.
Crushing hazard. The secondaryboom cable track could becomeunbalanced and fall if not properlysupported when removed from themachine.
Component damage hazard.Cables and hoses can be damagedif they are kinked or pinched.
Component damage hazard.The secondary boom cable trackcan be damaged if it is twisted.
Note: The lifting strap from the overhead crane willneed to be adjusted during removal for properbalancing of the cable track.
4 - 46 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
How to Repair the SecondaryBoom Cable Track
Component damage hazard.The boom cable track can bedamaged if it is twisted.
Note: A cable track repair kit is available throughthe Genie Industries Service Parts Department,part no.107717. The kit includes a 4-link section ofcable track.
1 Remove the secondary boom cable track.See How to Remove the Secondary BoomCable Track.
2 Visually inspect the cable track and determinewhich 4-link section needs to be replaced.
3 Carefully remove the snap rings and pins fromeach end of the damaged section of cable track.
4 Remove the retaining fasteners from the upperblack rollers from the 4-link section of cabletrack to be replaced. Remove the rollers.
5 Lift up the hoses and cables and carefullyremove the damaged 4-link section of cabletrack.
Component damage hazard. Hosesand cables can be damaged ifthey are kinked or pinched.
Note: If the section of cable track being replacedhas clamps or wear pads, those items will need tobe transferred to the replacement section of cabletrack.
6 Remove the upper rollers from the replacementsection of cable track.
7 Lift up the hoses and cables and carefully insertthe new 4-link section of cable track.
Component damage hazard.Hoses and cables can be damagedif they are kinked or pinched.
8 Connect the ends of the replacement cable tracksection to the existing cable track using thepins and snap rings.
9 Install the rollers onto the new section of cabletrack.
10 Install the secondary boom cable track into thesecondary boom.
11 Operate the secondary boom up/extend anddown/retract functions through a full cycle toensure smooth operation of the new section ofcable track.
Part No. 106783 Z-135/70 4 - 47
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
4-3Primary Boom
How to Remove the PrimaryBoom
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position.
1 Remove the platform.
2 Remove the platform mounting weldmentand the platform rotator. See 2-2, How toRemove the Platform Rotator.
3 Remove the jib boom.See 3-2, How to Remove the Jib Boom.
Note: When the jib boom is installed, the jib boomangle sensor will need to be calibrated. See 3-6, JibBoom Bellcrank Angle Sensor for the calibrationprocedure.
4 Remove the primary boom cable track.See 4-1, How to Remove the Cable Track.
5 Remove the end cover from the pivot end of theprimary boom.
6 Remove the limit switch mounting fastenersfrom the limit switch on the ground controls sideof the primary boom. Do not disconnect thewiring. Remove the limit switch.
7 Disconnect the electrical connector from theprimary boom angle sensor.
Note: The primary boom angle sensor is locatedinside the primary boom at the pivot end.
8 Remove the primary boom angle sensor bracketmounting fasteners and remove the primaryboom angle sensor from the primary boom. Donot remove the angle sensor from the bracket.Note the location of the springs.Do not lose the springs.
Note: There is one spring inside the primary boompivot pin and one inside the angle sensor.
Note: When the primary boom is installed, theprimary boom angle sensor will need to becalibrated. See 4-8, Primary Boom Angle Sensorfor the calibration procedure.
9 Remove the hose and cable guide fasteners atthe primary boom pivot pin. Remove the hoseand cable guide.
4 - 48 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
10 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
11 Place blocks under both ends of the primaryboom lift cylinder for support.
12 Attach a lifting strap from an overhead crane tothe rod end of the primary boom lift cylinder.
13 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin.
14 Use a soft metal drift to remove the rod-endpivot pin. Rest the rod end of the primary boomlift cylinder on the blocks.
15 Support both upper primary boom lift cylinderlinkage arms with a suitable lifting device. Donot apply any lifting pressure.
16 Remove the pin retaining fasteners from theupper primary boom lift cylinder linkage armpivot pin where it connects to the primary boom.
17 Use a soft metal drift to tap the pin halfway outand lower one of the linkage arms down. Tapthe pin in the other direction and lower the otherlinkage arm down.
Crushing hazard. The upperprimary boom lift cylinder linkagearms could fall if not properlysupported when the pivot pins areremoved.
BOOM COMPONENTS
18 Attach a 5 ton / 5000 kg overhead crane to bothends of the primary boom. Do not apply anylifting pressure.
19 Remove the pin retaining fasteners from theprimary boom pivot pins.
20 Use a soft metal drift to remove the primaryboom pivot pins.
21 Carefully remove the primary boom from themachine and place it on a structure capable ofsupporting it.
Crushing hazard. The primaryboom could become unbalancedand fall when removed from themachine if not properly attached tothe overhead crane.
Part No. 106783 Z-135/70 4 - 49
April 2008 Section 4 • Repair Procedures
REV F
4-4Primary Boom Lift Cylinder
The primary boom lift cylinder raises and lowers theprimary boom. The primary boom lift cylinder isequipped with a counterbalance valve to preventmovement in the event of a hydraulic line failure.
How to Remove the PrimaryBoom Lift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position.
1 Remove the hose and cable clamps from theprimary boom lift cylinder.
2 Remove the cable track retaining fasteners atthe primary boom lift cylinder.
3 Place blocks under both ends of the primaryboom lift cylinder. Place another block under thecylinder linkage arms under the primary boomlift cylinder barrel-end pivot pin.
4 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
5 Attach a lifting strap from an overhead crane tothe rod end of the primary boom lift cylinder. Donot apply any lifting pressure.
6 Remove the pin retaining fasteners from theprimary boom lift cylinder rod-end pivot pin. Usea soft metal drift to remove the pin and rest thecylinder on the block.
7 Attach a lifting strap from a second overheadcrane to the barrel end of the primary boom liftcylinder. Do not apply any lifting pressure.
8 Remove the primary boom lift cylinderbarrel-end pivot pin retaining fasteners.
9 Use a soft metal drift to remove the barrel-endpivot pin. Carefully remove the primary boom liftcylinder from the machine.
Crushing hazard. The lift cylindercould become unbalanced and fallwhen removed from the machine ifnot properly supported by theoverhead crane.
Crushing hazard. The primaryboom lift cylinder linkage armsmay fall if not properly supportedwhen the barrel-end pivot pin isremoved.
BOOM COMPONENTS
4 - 50 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
4-5Secondary Boom Lift Cylinder
How to Remove the SecondaryBoom Lift Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the boom in thestowed position and the axles extended.
1 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Thehoses can be accessed from under theturntable.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Remove the engine pivot plate retainingfastener. Swing the engine pivot plate out awayfrom the machine.
a engine pivot plate anchor holeb engine pivot plate retaining fastener
3 Locate the engine pivot plate anchor hole at thepivot end of the engine pivot plate.
4 Install the bolt that was just removed into theanchor hole to secure the engine pivot platefrom moving.
Crushing hazard. Failure to installthe bolt into the engine pivot plateto secure it from moving couldresult in death or serious injury.
5 Remove the retaining fasteners from the fixedturntable cover at the ground controls side ofthe machine. Remove the fixed turntable coverfrom the machine.
6 Tag, disconnect and plug the fuel hoses fromthe fuel tank. Clean up any fuel that may havespilled.
BOOM COMPONENTS
Part No. 106783 Z-135/70 4 - 51
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
7 Close the two hydraulic tank shut-off valves atthe hydraulic tank.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
8 Remove the drain plug from the hydraulic tankand completely drain the tank into a container ofsuitable capacity. Refer to Section 2,Specifications.
9 Tag, disconnect and plug the two suction hosesfrom the hydraulic tank.
10 Tag, disconnect and plug the two supply hosesfor the auxiliary power units. Cap the fittings onthe hydraulic tank.
11 Tag, disconnect and plug the hydraulic hosefrom the drive motor case drain filter at thehydraulic tank. Cap the fitting on the hydraulictank.
12 Tag, disconnect and plug the hydraulic hose atthe return filter. Cap the fitting on the return filterhousing.
13 Remove the turntable cover using a suitablelifting device.
Crushing hazard. The turntablecover may become unbalancedand fall if not properly supportedand secured to a suitable liftingdevice.
14 Remove the ground control box mountingfasteners. Move the ground control box out ofthe way.
15 Remove the hydraulic tank retaining fasteners.
16 Remove the cover from the auxiliary power unitbatteries.
17 Tag and disconnect the cables from the auxiliarypower unit batteries.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
18 Tag and disconnect the cables from the enginestarting/controls battery located on the engineside of the machine.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
19 Attach an overhead crane or similar liftingdevice to the battery box for the auxiliary powerunit batteries.
20 Remove the battery box retaining fasteners andcarefully remove the battery box from themachine.
Crushing hazard. The battery boxcould become unbalanced and fallwhen removed from the machine ifnot properly supported.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
4 - 52 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
21 Support the hydraulic tank with 2 lifting straps.Place one lifting strap at each end of the tankand attach the lifting straps to an appropriatelifting device.
22 Remove the hydraulic tank from the machine.
Crushing hazard. The hydraulictank could become unbalancedand fall when removed from themachine if not properly supported.
23 Place a block under the secondary boom liftcylinder for support.
24 Remove the secondary boom lift cylinderrod-end pivot pin retaining fasteners. Use a softmetal drift to remove the pin through the accessholes in the turntable bulkheads.
25 Attach an overhead crane with a minimumcapacity of 7 tons / 7000 kg to thecounterweight end of the secondary boom.
26 Raise the boom assembly with the overheadcrane approximately 20 feet / 6 m.
Crushing hazard. The boomassembly can fall if not properlysupported by the overhead crane.
27 Remove the secondary boom lift cylinderbarrel-end pivot pin retaining fasteners. Do notremove the pin.
28 Attach a lifting strap from a second overheadcrane to each end of the secondary boom liftcylinder.
Note: Protect the hoses and cables underneath thecylinder from damage.
29 Use a slide hammer to remove the barrel-endpivot pin.
Component damage hazard. Hosesand cables can become damagedif the barrel end of the secondaryboom lift cylinder is allowed to fallwhen the barrel-end pivot pin isremoved.
30 Carefully remove the secondary boom liftcylinder from the machine.
Crushing hazard. The secondaryboom lift cylinder could becomeunbalanced and fall when removedfrom the machine if not properlysupported by the overhead crane.
Component damage hazard. Hosesand cables can be damaged if thesecondary boom lift cylinder ispulled across them.
Part No. 106783 Z-135/70 4 - 53
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
4-6Primary Boom ExtensionCylinder
The primary boom extension cylinder extends andretracts the primary boom extension tube.Theprimary boom extension cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.
How to Remove the PrimaryBoom Extension Cylinder
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the axlesextended and the boom in the stowed position.
1 Extend the primary boom until the primary boomextension cylinder rod-end pivot pin isaccessible in the primary boom extension tube.
2 Remove the access cover from the pivot end ofthe primary boom.
3 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 At the platform end, remove the external snaprings from the extension cylinder rod-end pivotpin. Use a soft metal drift to remove the pin.
5 Remove the extension cylinder retainers fromthe saddle blocks.
6 Attach a lifting strap from an overhead crane tothe barrel end of the primary boom extensioncylinder.
7 Using the overhead crane, lift the extensioncylinder to clear the saddle blocks.
8 Support and slide the primary boom extensioncylinder out of the primary boom and place it ona structure capable of supporting it.
Crushing hazard. The extensioncylinder could fall when removedfrom the primary boom if notproperly supported.
Note: The lifting strap from the overhead crane willneed to be adjusted during removal for properbalancing of the extension cylinder.
Note: Note the length of the cylinder after removal.The cylinder must be at the same length forinstallation.
4 - 54 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
4-7Secondary Boom ExtensionCylinders
The secondary boom extension cylinders extendand retract the secondary boom. The secondaryboom extension system consists of 3 hydrauliccylinders and each are equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.
How to Remove the SecondaryBoom Extension Cylinders
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the axlesextended and the boom in the stowed position.
1 Raise the primary boom approximately10 feet / 3 m. Turn the machine off.
2 Working at the platform end of the secondaryboom, support and secure the secondary boomend cover to a suitable lifting device.
3 Remove the cover retaining fasteners andremove the cover from the secondary boom.
Crushing hazard. The secondaryboom end cover could becomeunbalanced and fall when removedfrom the secondary boom if notproperly supported and secured tothe lifting device.
4 Remove the retaining fasteners from bothsecondary boom extend limit switches andremove the limit switches. Do not disconnectthe wiring.
Note: Label the location of each limit switch as theyare not the same and their mounting locationscannot be exchanged.
5 Tag, disconnect and plug all hydraulic hoses forthe 3 secondary boom extension cylinders.Cap the fittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Remove the upper extension cylinder retainersfrom the saddle blocks.
7 Attach a lifting strap from an overhead crane tothe rod end of the upper extension cylinder.
8 Using the overhead crane, lift the extensioncylinder to clear the saddle blocks.
Part No. 106783 Z-135/70 4 - 55
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
9 Support and slide the upper extension cylinderout of the secondary boom and place it on astructure capable of supporting it.
Crushing hazard. The extensioncylinder could fall when removedfrom the secondary boom if notproperly supported.
Note: The lifting strap from the overhead crane willneed to be adjusted during removal for properbalancing of the extension cylinder.
10 Repeat steps 6 through 9 for the remainingsecondary boom extension cylinders.
Note: The secondary boom extension cylindersmust be installed in the same order they wereremoved.
Note: When installing the middle and uppersecondary boom extension cylinders, be sure thegrooved wear pads are correctly aligned with thechannels on the top of the cylinders.
a upper extension cylinder (#1)b middle extension cylinder (#2)c bottom extension cylinder (#3)d cylinder grooved wear padse channels
4-8Primary Boom Angle Sensor
The primary boom angle sensor is used to limit theangle of the primary boom relative to the angle ofthe secondary boom and gravity.
How to Replace the PrimaryBoom Angle SensorNote: Perform this procedure on a firm, levelsurface with the boom in the stowed position.
1 Remove the retaining fasteners from the boomend cover at the pivot end of the primary boom.Remove the cover from the machine.
2 Locate the primary boom angle sensor inside theprimary boom at the boom pivot pin.
3 Disconnect the electrical connector from thesensor.
4 Remove the angle sensor mounting bracketretaining fasteners.
5 Remove the angle sensor and bracketassembly. Do not lose the two springs or thehex-shaped key.
6 Remove the sensor retaining fasteners from thebracket. Remove the angle sensor.
Note: Note the sensor orientation on the bracketduring removal so the new sensor will be installedin the same position.
7 Install the new angle sensor onto the mountingbracket.
a b c
de
4 - 56 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
8 Install one spring, removed in step 5, into thehex-shaped hole in the angle sensor. Install theother spring into the hex-shaped hole in thecenter of the boom pivot pin.
9 Insert the hex-shaped key into the angle sensor.
10 Align the side of the sensor with flat area of theboom pivot pin shown as shown below whileholding the bracket away from key insertion.
a flat areab angle sensorc hex-shaped hole
11 While holding the hex-shaped key in position,rotate the angle sensor mounting bracketclockwise until it aligns with the machinedpocket. Do not allow the key to rotate whileholding it.
12 Insert the hex-shaped key into the boom pivotpin and the bracket into the machined pocket.
Note: Be sure the hex-shaped key remainsengaged in the sensor.
13 Install the angle sensor bracket retainingfasteners.
14 Connect the electrical connector to the newsensor.
15 Install the primary boom end cover.
16 Calibrate the primary boom angle sensor. SeeHow to Calibrate the Primary Boom AngleSensor.
a cb
Part No. 106783 Z-135/70 4 - 57
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
How to Calibrate the PrimaryBoom Angle SensorNote: If the secondary boom angle sensor has beenremoved or replaced, it will need to be calibratedfirst. See 4-9, Secondary Boom Angle Sensor forthe calibration procedure.
Note: Perform this procedure with the machine on afirm, level surface with the axles extended and inthe stowed position.
Note: A digital level will be required to perform thisprocedure.
Note: A kit is available through the Genie IndustriesService Department (Genie part number 58351).This kit includes a digital level with a magneticbase and cable harnesses.
1 Push in the ground controls red Emergency Stopbutton to the off position.
2 Turn the key switch to ground controls.
3 Open the ground control box.
Before serial number 321:
4 Locate the 2 pin connector in the lower left handarea of the ground control box.
5 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
4 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
5 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
6 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
7 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
8 Remove the key from the main key switch.Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
STOP
00000
Run
ServiceBypass
Recovery
4 - 58 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV FBOOM COMPONENTS
9 Start the engine from the ground controls.
Note: If the system exits out of calibration modewhen the engine is started, repeat step 7 andcontinue to step 10.
10 Push one of the LCDscreen buttons shownuntil RESET PRIMARY BOOM
ANGLE SENSOR is displayed.
11 Press the plus button to select YES, then
press the enter button to accept.
12 Place the digital level on top of the primaryboom and note the angle displayed on the digitallevel.
13 At the PRIMARY BOOM ANGLE TO GRAVITY 0.0 DEG
screen, press the plus button or minus
button to adjust the display to the exactvalue shown on the digital level, then press theenter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
14 Fully raise the secondary boom. Stop before thesecondary boom begins to extend.
15 Press and hold a function enable/speed selectbutton and the primary boom down button andlower the primary boom down as far as it will go.
16 Measure the angle of the primary boom with thedigital level.
Note: The angle of the primary boom must bebetween -45 and -55 degrees. If the primary boomangle is not within this range, adjust the primaryboom until the digital level displays approximately-50 ± 5 degrees.
17 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
18 Press and hold a function enable/speed selectbutton and the primary boom up button until thedigital level displays approximately-20 ± 5 degrees.
Part No. 106783 Z-135/70 4 - 59
April 2008 Section 4 • Repair Procedures
REV F
19 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
20 Press and hold a function enable/speed selectbutton and the primary boom up button until thedigital level displays approximately10 ± 5 degrees.
21 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
22 Press and hold a function enable/speed selectbutton and the primary boom up button until thedigital level displays approximately40 ± 5 degrees.
23 At the ground controls, press the plus button
or minus button to to adjust the display tothe exact value shown on the digital level andpress the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
24 Press and hold a function enable/speed selectbutton and the primary boom up button until theprimary boom is fully raised. The angle will beapproximately 70 ± 5 degrees.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
25 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
26 Press the plus button to select YES, then
press the enter button to accept.
27 Press and hold the engine start button forapproximately 5 seconds to shut off the engineand to save the calibration settings.
Note: Do not turn the engine off with the key switchor red Emergency Stop button or all calibrationpoints or values will not be saved.
28 Wait approximately 20 seconds and turn themachine off by pressing the red EmergencyStop button in to the off position or by turningthe main key switch to the off position.
BOOM COMPONENTS
4 - 60 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
Before serial number 321:
29 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 5.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
30 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
29 Remove the fastener that was temporarilyinstalled in step 5.
30 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
BOOM COMPONENTS
All models:
31 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
32 Start the engine and lower the boom to thestowed position. Be sure there are no calibrationfaults shown on the display.
STOP
00000
Run
ServiceBypass
Recovery
Part No. 106783 Z-135/70 4 - 61
April 2008 Section 4 • Repair Procedures
REV F BOOM COMPONENTS
4-9Secondary Boom Angle Sensor
The secondary boom angle sensor is used to limitthe angle of the primary boom relative to the angleof the secondary boom and gravity.
How to Replace the SecondaryBoom Angle SensorNote: Perform this procedure on a firm, levelsurface with the boom in the stowed position.
1 Locate the secondary boom angle sensor on theturntable riser bulkhead at the ground controlsside of the machine.
2 Disconnect the electrical connector from thesensor. Remove any tie wraps securing thewiring.
3 Remove the angle sensor cover retainingfastener. Remove the cover.
4 Remove the angle sensor mounting bracketretaining fasteners.
5 Remove the angle sensor and bracketassembly. Do not lose the two springs or thehex-shaped key.
6 Remove the sensor retaining fasteners from thebracket. Remove the angle sensor.
Note: Note the sensor orientation on the bracketduring removal so the new sensor will be installedin the same position.
7 Install the new angle sensor onto the mountingbracket.
8 Install one spring, removed in step 5, into thehex-shaped hole in the angle sensor. Install theother spring into the hex-shaped hole in thecenter of the boom pivot pin.
9 Insert the hex-shaped key into the angle sensor.
10 Align the side of the sensor with flat area of theboom pivot pin as shown below. Hold thebracket out to clear the side of the turntableside plate.
a flat areab angle sensorc hex-shaped hole
11 While holding the hex-shaped key in position,rotate the angle sensor mounting bracketclockwise until it aligns with the machinedpocket. Do not allow the key to rotate whileholding it.
Note: Be sure the hex-shaped key remainsengaged in the sensor only.
a cb
4 - 62 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
12 Insert the hex-shaped key into the boom pivotpin and the bracket into the machined pocket.
13 Install the angle sensor bracket retainingfasters.
14 Install the angle sensor cover and install thecover retaining fastener.
15 Connect the electrical connector to the newsensor.
16 Calibrate the secondary boom angle sensor. SeeHow to Calibrate the Secondary Boom AngleSensor.
How to Calibrate the SecondaryBoom Angle SensorNote: If the primary boom angle sensor and/or jibboom angle sensor has been removed or replaced,the secondary boom angle sensor will need to becalibrated first.
Note: Perform this procedure with the machine on afirm, level surface with the axles extended and inthe stowed position.
Note: A digital level will be required to perform thisprocedure.
Note: A kit is available through the Genie IndustriesService Department (Genie part number 58351).This kit includes a digital level with a magneticbase and cable harnesses.
1 Push in the ground controls red Emergency Stopbutton to the off position.
2 Turn the key switch to ground controls.
3 Open the ground control box.
Before serial number 321:
4 Locate the 2 pin connector in the lower left handarea of the ground control box.
5 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
4 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
5 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
6 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
7 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
BOOM COMPONENTS
Part No. 106783 Z-135/70 4 - 63
April 2008 Section 4 • Repair Procedures
REV F
8 Remove the key from the main key switch.Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
9 Push one of the LCDscreen buttons shownuntil RESET SECONDARY BOOM
ANGLE SENSOR is displayed.
10 Press the plus button to select YES, then
press the enter button to accept.
11 Place the digital level on top of the secondaryboom.
12 At the SECONDARY BOOM ANGLE TO GRAVITY -3.5DEG
screen, press the plus button or minus
button to adjust the display to the exactvalue shown on the digital level and press theenter button .
Note: Be sure the number entered at the groundcontrols is a negative number.
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
13 Start the engine from the ground controls.
Note: If the system exits out of calibration modewhen the engine is started, repeat step 7 andcontinue to step 14.
14 Press and hold a function enable/speed selectbutton and the secondary boom up button untilthe digital level displays approximately20 ± 5 degrees.
15 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
BOOM COMPONENTS
STOP
00000
Run
ServiceBypass
Recovery
4 - 64 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
16 Press and hold a function enable/speed selectbutton and the secondary boom up button untilthe digital level displays approximately35 ± 5 degrees.
17 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
18 Press and hold a function enable/speed selectbutton and the secondary boom up button untilthe digital level displays approximately50 ± 5 degrees.
19 At the ground controls, press the plus button
or minus button to to adjust the display tothe exact value shown on the digital level andpress the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
20 Press and hold a function enable/speed selectbutton and the secondary boom up button untilthe digital level displays approximately65 ± 5 degrees.
BOOM COMPONENTS
21 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
22 Press and hold a function enable/speed selectbutton and the secondary boom up button. Fullyraise the secondary boom. Stop before thesecondary boom begins to extend. The anglewill be approximately 76 ± 5 degrees.
23 At the ground controls, press the plus button
or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
24 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
25 Press the plus button to select YES, then
press the enter button to accept.
Part No. 106783 Z-135/70 4 - 65
April 2008 Section 4 • Repair Procedures
REV F
26 Press and hold the engine start button forapproximately 5 seconds to shut off the engineand to save the calibration settings.
Note: Do not turn the engine off with the key switchor red Emergency Stop button or all calibrationpoints or values will not be saved.
27 Wait approximately 20 seconds and turn themachine off by pressing the red EmergencyStop button in to the off position or by turningthe main key switch to the off position.
Before serial number 321:
28 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 5.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
29 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
28 Remove the fastener that was temporarilyinstalled in step 5.
29 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
BOOM COMPONENTS
All models:
30 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
31 Start the engine and lower the boom to thestowed position. Be sure there are no calibrationfaults shown on the display.
STOP
00000
Run
ServiceBypass
Recovery
4 - 66 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
5-1RPM Adjustment
Refer to Maintenance Procedure B-18, Check andAdjust the Engine RPM.
5-2Flex Plate
The flex plate acts as a coupler between the engineand the pump. It is bolted to the engine flywheeland has a splined center to drive the pump.
Two different styles of flex plates have been usedin the production of your machine model.Type "A" flex plates utilize a flex plate installedonto the flywheel of the engine and a separatecoupler installed onto the pump splined shaft.
Type "B" flex plates combines the pump coupler,as part of the flex plate, which is installed onto theengine flywheel.
Engines
How to Remove the Flex Plate1 Disconnect the wiring plug at the electronic
displacement controller (EDC), located onthe drive pump.
2 Support the drive pump with an appropriatelifting device. Then remove all of the pumpmounting plate to engine bell housing bolts.
3 Carefully pull the pump away from the engineand secure it from moving.
4 Remove the flex plate mounting fasteners,then remove the flex plate from the engineflywheel.
Type "A"(flexplate with
separate coupler)
Type "B"(flexplate with
coupler combined)
Part No. 106783 Z-135/70 4 - 67
April 2008 Section 4 • Repair Procedures
REV C
How to Install a Type "A"Flex Plate1 Install the flex plate onto the engine flywheel
with the raised spline towards the pump.
2 Ford models: Torque the flex plate mountingbolts in sequence to 14 ft-lbs / 19 Nm.Then torque the flex plate mounting bolts insequence to 20 ft-lbs / 27 Nm.
Deutz models: Torque the flex plate mountingbolts in sequence to 28 ft-lbs / 38 Nm.Then torque the flex plate mounting bolts insequence to 40 ft-lbs / 54 Nm.
Perkins models: Torque the flex plate mountingbolts in sequence to 49 ft-lbs / 66 Nm.Then torque the flex plate mounting bolts insequence to 70 ft-lbs / 95 Nm.
Ford and Deutz models
Perkins models
3 Install the pump coupler onto the pump shaftwith the set screw toward the pump. Leave theappropriate gap between coupler and pump endplate for your engine.
a pumpb pump shaftc pump couplerd flex plate with raised splinee engine flywheelf 0.188 inch / 4.8 mm gap -
Deutz models0.25 inch / 6.4 mm gap -Cummins and Perkins models
4 Cummins and Perkins models: Apply Loctite®
removable thread sealant to the pump couplerset screw. Torque the set screw to22 ft-lbs / 30 Nm.
Deutz models: Apply Loctite® removable threadsealant to the pump coupler set screw. Torquethe set screw to 61 ft-lbs / 83 Nm.
Component damage hazard. Donot force the drive pump duringinstallation or the flex plate teethmay become damaged.
a b c d e
f
1
2
3
4 5
6
1
2 3
ENGINES
4 - 68 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV C
How to Install a Type "B"Flex Plate1 Deutz and Perkins models: Install the flex
plate onto the engine flywheel with the rubbervibration isolators towards the pump.
Cummins models: Install the flex plate ontothe engine flywheel with the rubber vibrationisolators towards the engine flywheel.
2 Apply Loctite® removable thread sealant to theflex plate fasteners and loosely install thefasteners.
3 Deutz and Perkins models: Torque the flexplate mounting bolts in sequence to28 ft-lbs / 38 Nm. Then torque the flex platemounting bolts in sequence to 40 ft-lbs / 54 Nm.
Cummins models: Torque the flex platemounting bolts in sequence to14 ft-lbs / 19 Nm. Then torque the flex platemounting bolts in sequence to 20 ft-lbs / 27 Nm.
4 Apply a high viscosity coupling grease(Genie part number 128025) to the splines of thepump shaft and flex plate.
Grease Specification
Shell Alvania® Grease CG, NLGI 0/1 or equivalent.
Deutz and Perkins models
Cummins models
1
2
34
5
6
1
2
3
4 5
6
ENGINES
Part No. 106783 Z-135/70 4 - 69
April 2008 Section 4 • Repair Procedures
REV DGround Controls
STOP
00000
Run
ServiceBypass
Recovery
6-1Service Bypass/RecoveryKey Switch
The ground control box contains two key switches.The main key switch towards the top of the controlbox is for selection of ground or platform controls.The key switch at the bottom of the control box isthe Service Bypass/Recovery key switch. ServiceBypass and Recovery modes are only intended forcertain circumstances and are not part of normalmachine operation. If either the Service Bypass orthe Recovery function is required, this indicatesthere may be faults with the machine. Contacttrained personnel immediately.
Service Bypass is used for a platform out-of-envelope condition and certain service situations.
Recovery is only to be used as a last attempt tolower the platform when the operator in the platformis unable to do so, system failure or in emergencysituations.
Service Bypass /Recovery Key Switch
How to Use the Service BypassMode
Tip-over hazard. Operating themachine outside of the operatingenvelope while in Service Bypassmode will result in death or seriousinjury if proper operatingprocedures and safety precautionsare not followed. Do not use thismode if you are not trained andfamiliar with the operating envelopeof the machine.
Note: Before using the Service Bypass mode,make sure you understand the fault code or issueaffecting the operation of the machine to be surethe use of service bypass is required.
The Service Bypass mode will allow the platform tobe manually leveled when an out-of-envelopecondition exists. In the event that the platformangle is greater than 10° from level, the boom angleand platform level functions are disabled. Use ofthe Service Bypass mode will allow the platform tobe manually adjusted to within the normal operatingenvelope, ±4.5°. Only auxiliary power can be usedto correct an out of level platform fault.
1 Turn the engine off.
2 Turn the main key switch to ground controls.Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.
Note: The main key switch must remain in theground control position.
4 - 70 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV DGROUND CONTROLS
3 Turn the service bypass/recovery key switch tothe service bypass position.
4 Using auxiliary power, operate the platform leveltoggle switch to level the platform.
Note: Only the auxiliary power unit can be used tocorrect an out of level platform fault.
5 Turn the service bypass/recovery key switch tothe run position.
6 Remove the key from the service bypass/recovery key switch and insert the key into themain key switch.
Note: If the Service Bypass function has beenused, there may be faults with the machine. Checkthe LCD screen on the ground control box formachine faults, then contact trained servicepersonnel.
How to Use the Recovery ModeRecovery is only to be used as a last attempt tolower the platform when the operator in the platformis unable to do so, system failure or in emergencysituations.
Bodily injury hazard. When usingrecovery mode, the platform maynot fully lower to the ground whenthe recovery mode is completed.Failure to use only suitableequipment and/or practices toallow the operator to safely exit theplatform could result in death orserious injury.
Bodily injury hazard. Platformleveling is not active when usingrecovery mode. The platform couldreach high out-of-level conditionswhen using this mode. Theoperator will need to securethemself to the platform to preventfalling injury.
The Recovery mode allows the platform to belowered in the event the operator in the platform isunable to lower the platform using the platformcontrols, system failure or emergency situations.The recovery sequence will automatically retractthe primary boom and then lower the primary boomusing the auxiliary power unit to allow the operatorat the platform controls to exit the platform.
1 Turn the main key switch to the off position.Remove the key from the main key switch andinsert the key into the service bypass/recoverykey switch.
2 Turn and hold the service bypass/recovery keyswitch to the recovery position. The switchmust be held in the recovery position.
Result: The auxiliary power unit will turn on andthe boom will begin the following recoverysequence.
· The primary boom will retract
· The primary boom will lower
Note: The key switch must be held in the recoveryposition until the recovery sequence is complete oruntil the operator in the platform can safely exit theplatform.
Note: If any boom safety limit switches are faulty,the boom will only retract and not lower and theoperator will need to be recovered from that point.
Note: If the Recovery function has been used, thismay indicate there may be faults with the machine.Tag and remove the machine from service until thefault has been corrected by trained personnel.
Part No. 106783 Z-135/70 4 - 71
April 2008 Section 4 • Repair Procedures
REV D GROUND CONTROLS
The ground control box (TCON) is thecommunication and operations center for themachine. The ground control box contains two keyswitches. The key switch towards the top of thecontrol box is for selection of ground or platformcontrols. The key switch at the bottom of thecontrol box is the Service Bypass key switch. It isused when calibrating certain machine parametersand also to correct an out-of-level platform. If themachine trips an envelope safety switch, anoperator at the ground controls can turn and holdthe Service Bypass key switch in the recoverposition, which will automatically retract the boomand lower the platform close to the ground.
The ground control box contains a replaceablemembrane decal with touch sensitive buttons forvarious machine functions. The ground control boxalso contains two printed circuit boards:
The LCD (Liquid Crystal Display) circuit board ismounted to the inside of the control box lid whichcontrols the LCD display screen.
The ECM circuit board is the main circuit board forthe machine. All operating parameters andconfiguration of options for the machine are storedin the ECM memory.
Note: When the ECM circuit board is replaced, thejoysticks will need to be calibrated. See 1-3, How toCalibrate a Joystick.
Note: When the ECM circuit board is replaced, allthe boom, platform and axle angle sensors willneed to be calibrated and in a specific order.Contact the Genie Industries Service Department.
6-2Circuit Boards
How to Remove the LCD DisplayScreen Circuit Board1 Push in the red Emergency Stop button to the
off position at both the ground and platformcontrols.
2 Remove the ground control box lid fasteners.Open the control box lid.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
3 Carefully disconnect the LCD circuit boardribbon cable from the ECM circuit board.
4 Remove the LCD display circuit board retainingfasteners.
5 Carefully remove the LCD display circuit boardfrom the ground control box lid.
4 - 72 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV DGROUND CONTROLS
6-3Membrane Decal
The membrane decal is a special decal thatconsists of a decal with an electronic membrane onthe backside. The membrane contains touchsensitive areas that, when pushed, activates themachine functions. The membrane buttons activatemachine functions similar to toggle switches, butdo not have any moving parts.
How to Replace the MembraneDecal1 Turn the key switch at the ground controls to the
off position.
2 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.
3 Remove the ground control box lid fasteners.Open the control box lid.
4 Tag and disconnect the two ribbon cables fromthe membrane decal at the ECM circuit board.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
5 Remove the membrane decal from the controlbox lid while guiding the ribbon cables out of thecontrol box lid.
6 Remove any decal adhesive from the controlbox lid with a mild solvent.
Note: Do not allow any solvent to come in contactwith the LCD display screen.
7 Install the new membrane decal while guidingthe ribbon cables through the control box lid.
8 Connect the ribbon cables to the ECM circuitboard.
9 Close the control box lid and install the retainingfasteners.
Part No. 106783 Z-135/70 4 - 73
April 2008 Section 4 • Repair Procedures
REV CHydraulic Pumps
7-1Function Pump
The function pump is a pressure compensated,variable displacement piston pump. Any internalservice to the pump should be performed at anauthorized Sauer-Danfoss service center. Contactthe Genie Industries Service Department to locateyour local authorized service center.
How to Remove theFunction PumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Locate the two hydraulic tank valves at thehydraulic tank. Close the valves.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
2 Tag, disconnect and plug the function pumphydraulic hoses. Cap the fittings on the pump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
3 Support the pump with a suitable lifting device.
4 Remove the two pump mounting fasteners.Carefully remove the pump.
Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.
open closed
4 - 74 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CHYDRAULIC PUMPS
How to Prime the FunctionPumpNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Remove the case drain hydraulic hose from thetop of the function pump.
Note: The case drain hose is the smaller of the twohoses on top of the function pump and closest tothe drive pump.
2 Locate and open the hydraulic tank shut-offvalve at the hydraulic tank that supplieshydraulic oil to the function pump. Do not openthe valve for the drive pump.
3 When hydraulic fluid begins to come out of thecase drain port of the function pump, install thefunction pump case drain hose.
4 Clean up any oil that may have spilled.
5 Start the engine from the ground controls andcheck for hydraulic leaks.
How to Adjust the FunctionPump Standby Pressure1 Connect a 0 to 5000 psi / 0 to 350 bar pressure
gauge to the TEST port on the function manifold.
2 Start the engine from the ground controls andallow the engine to run at low idle.
3 Observe the pressure reading on the pressuregauge.
Result: The gauge should show250 psi / 17 bar.
Result: If the gauge does not show250 psi / 17 bar, proceed with step 4 to adjustthe function pump standby pressure.
4 Loosen the set screw for the standby pressureadjustment screw.
a standby pressure set screwb standby pressure adjustment screw
5 Adjust the function pump standby pressure.Turn the adjustment screw clockwise toincrease the pressure or counterclockwise todecrease the pressure. Tighten the set screw.
6 Turn the engine off and remove the pressuregauge.
a
b
Part No. 106783 Z-135/70 4 - 75
April 2008 Section 4 • Repair Procedures
REV C
How to Adjust the FunctionPump Pressure CompensatorNote: Two people will be required to perform thisprocedure.
1 Confirm the system relief pressure is set tospecification. See 8-3, Valve Adjustments -Function Manifold.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST port on the function manifold.
3 Start the engine from the ground controls andchange the rpm to high idle.
4 Push and hold the high speed function enablebutton (rabbit symbol). Do not activate anyboom functions.
5 Observe the pressure reading on the pressuregauge.
Result: The gauge should show2900 psi / 200 bar.
Result: If the gauge does not show2900 psi / 200 bar, proceed with step 6 to adjustthe function pump pressure compensator.
HYDRAULIC PUMPS
6 Loosen the set screw for the pressurecompensator adjustment screw.
a pressure compensator set screwb pressure compensator
adjustment screw
7 Adjust the pressure compensator pressure. Turnthe adjustment screw clockwise to increase thepressure or counterclockwise to decrease thepressure. Tighten the set screw.
Component damage hazard. Donot adjust the pressurecompensator higher than specified.
8 Turn the engine off and remove the pressuregauge.
b
a
4 - 76 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV CHYDRAULIC PUMPS
7-2Drive Pump
The drive pump is a bi-directional variabledisplacement piston pump. The pump output iscontrolled by the electronic displacement controller(EDC), located on the pump. The only adjustmentthat can be made to the pump is the neutral or nulladjustment. Any internal service to the pumpshould be performed at an authorized Sauer-Danfoss service center. Contact the GenieIndustries Service Department to locate your localauthorized service center.
How to Remove the Drive PumpComponent damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
Note: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
1 Disconnect the electrical connection at theelectronic displacement controller (EDC) locatedon the drive pump.
2 Locate the two hydraulic tank valves at thehydraulic tank. Close the valves.
Component damage hazard. Theengine must not be started with thehydraulic tank shut-off valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.
open closed
Part No. 106783 Z-135/70 4 - 77
April 2008 Section 4 • Repair Procedures
REV C HYDRAULIC PUMPS
5 Carefully pull the drive pump out until the pumpcoupler separates from the flex plate.
6 Remove the drive pump from the machine.
Component damage hazard. Thepumps may become unbalancedand fall if not properly supported.
Component damage hazard. Besure to open the two hydraulic tankvalves and prime the pump afterinstalling the pump.
How to Prime the Drive PumpComponent damage hazard. Besure to open the two hydraulic tankvalves before performing thisprocedure.
1 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to either the "A" or "B" test port on thedrive pump.
2 Perkins and Cummins models: Disconnectthe engine wiring harness from the fuel shutoffsolenoid at the injector pump.
Deutz models: Hold the manual fuel shutoffvalve clockwise to the closed position.
3 Have another person crank the engine with thestarter motor for 15 seconds, wait 15 seconds,then crank the engine an additional 15 secondsor until the pressure reaches approximately250 psi / 17 bar.
4 Perkins and Cummins models: Connect theengine wiring harness to the fuel solenoid.
Deutz models: Release the manual fuelshutoff valve.
5 Start the engine from the ground controls andcheck for hydraulic leaks.
4 - 78 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EManifolds
8-1Function Manifold - View 1 (before serial number 440)
The function manifold is located next to the ground control box.
Index SchematicNo. Description Item Function Torque
1 Check valve ....................................... W .......... Prevents the draining ofhydraulic oil from thejib manifold and platformmanifold ............................................ 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm
3 Solenoid valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm
4 Solenoid valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 50-55 ft-lbs / 68-75 Nm
5 Solenoid valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 50-55 ft-lbs / 68-75 Nm
6 Plug, 16 SAE .................................................... Port plug ................................... 130-140 ft-lbs / 176-190 Nm
7 Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm
9 Solenoid valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm
10 Solenoid valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm
11 Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm
12 Solenoid valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm
Part No. 106783 Z-135/70 4 - 79
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
1
7
8
9
4
5
3
2
10
11
12
C
B
F
K
I
L H
D
G
J
W
6
4 - 80 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-2Function Manifold - View 2 (before serial number 440)
Index SchematicNo. Description Item Function Torque
1 Check valve ....................................... DB ........ Prevents hydraulic pressurefrom flowing back into auxiliarypump #1
2 Check valve ....................................... DC ........ Prevents hydraulic pressurefrom flowing back into auxiliarypump #2
3 Differential sensing valve,150 psi / 6.9 bar ................................. M .......... Turntable rotate circuit,
regulates pressure drop acrossturntable rotate proportional valve ... 30-35 ft-lbs / 41-47 Nm
4 Differential sensing valve,150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit,
regulates pressure drop acrossprimary boom up/downproportional valve ............................. 30-35 ft-lbs / 41-47 Nm
5 Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm
6 Differential sensing valve,150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit,
regulates pressure drop acrossprimary boom extend/retractproportional valve ............................. 30-35 ft-lbs / 41-47 Nm
7 Differential sensing valve,150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit,
regulates pressure drop acrosssecondary boom extend/retractproportional valve ............................. 50-55 ft-lbs / 68-75 Nm
8 Differential sensing valve,150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit,
regulates pressure drop acrosssecondary boom up/downproportional valve ............................. 50-55 ft-lbs / 68-75 Nm
9 Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm
10 Check valve ....................................... DD ........ Prevents hydraulic pressurefrom flowing back into thefunction pump ........................... 130-140 ft-lbs / 176-190 Nm
11 Proportional solenoid valve .............. V ........... Secondary boom extend/retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm
12 Proportional solenoid valve .............. R ........... Primary boom extend/retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm
13 Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm
14 Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm
Part No. 106783 Z-135/70 4 - 81
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
21
14
6
5
13
12
10
11
9
3 4
7
8
N
P
R
V
DD
T
DB DC M O
E
Q
U
S
4 - 82 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-3Function Manifold - View 1 (after serial number 439)
Index SchematicNo. Description Item Function Torque
1 Solenoid Valve, 2 position 3 way ...... D ........... Primary boom down ......................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid Valve, 2 position 3 way ...... C ........... Primary boom up .............................. 30-35 ft-lbs / 41-47 Nm
3 Solenoid Valve, 2 position 3 way ...... G ........... Primary boom retract ........................ 30-35 ft-lbs / 41-47 Nm
4 Solenoid Valve, 2 position 3 way ...... F ........... Primary boom extend ....................... 30-35 ft-lbs / 41-47 Nm
5 Solenoid Valve, 2 position 3 way ...... K ........... Secondary boom retract ................... 30-35 ft-lbs / 41-47 Nm
6 Solenoid Valve, 2 position 3 way ...... J ............ Secondary boom extend .................. 30-35 ft-lbs / 41-47 Nm
7 Solenoid Valve, 2 position 3 way ...... I ............ Secondary boom down .................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid Valve, 2 position 3 way ...... H ........... Secondary boom up ......................... 30-35 ft-lbs / 41-47 Nm
9 Check valve ....................................... DF ......... Tank return circuit ..................... 130-140 ft-lbs / 176-190 Nm
10 Solenoid valve, 3 position 4 way ...... B ........... Turntable rotate left/right .................. 30-35 ft-lbs / 41-47 Nm
11 Relief valve, 3100 psi / 214 bar ........ L ........... System relief ..................................... 30-35 ft-lbs / 41-47 Nm
12 Differential sensing valve,150 psi / 10.3 bar .............................. S ........... Secondary boom up/down circuit,
regulates pressure drop acrosssecondary boom up/downproportional valve ............................. 50-55 ft-lbs / 68-75 Nm
13 Differential sensing valve,150 psi / 10.3 bar .............................. U ........... Secondary boom extend/retract circuit,
regulates pressure drop acrosssecondary boom extend/retractproportional valve ............................. 50-55 ft-lbs / 68-75 Nm
14 Differential sensing valve,150 psi / 10.3 bar .............................. Q ........... Primary boom extend/retract circuit,
regulates pressure drop acrossprimary boom extend/retractproportional valve ............................. 30-35 ft-lbs / 41-47 Nm
MANIFOLDS
Part No. 106783 Z-135/70 4 - 83
April 2008 Section 4 • Repair Procedures
REV E
C
G
F
K
J
I
H
DF
B
L
Q
U
S
D
2
7
3
14
1
4
5
10
11
6
12
13
8
9
MANIFOLDS
4 - 84 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-4Function Manifold - View 2 (after serial number 439)
Index SchematicNo. Description Item Function Torque
1 Check valve ....................................... DB ........ Prevents hydraulic pressurefrom flowing back into auxiliarypump #1
2 Check valve ....................................... W .......... Prevents the draining ofhydraulic oil from thejib manifold and platformmanifold ............................................ 30-35 ft-lbs / 41-47 Nm
3 Differential sensing valve,150 psi / 10.3 bar .............................. O ........... Primary boom up/down circuit,
regulates pressure drop acrossprimary boom up/downproportional valve ............................. 30-35 ft-lbs / 41-47 Nm
4 Relief valve, 2600 psi / 179 bar ........ E ........... Primary boom extend ....................... 20-25 ft-lbs / 27-34 Nm
5 Proportional solenoid valve .............. P ........... Primary boom up/down circuit .......... 50-55 ft-lbs / 68-75 Nm
6 Proportional solenoid valve .............. R ........... Primary boom extend/retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm
7 Proportional solenoid valve .............. V ........... Secondary boom extend/retract circuit ..................................... 50-55 ft-lbs / 68-75 Nm
8 Proportional solenoid valve .............. T ........... Secondary boom up/down circuit ..... 50-55 ft-lbs / 68-75 Nm9 Proportional solenoid valve .............. N ........... Turntable rotate left/right circuit ........ 50-55 ft-lbs / 68-75 Nm
10 Differential sensing valve,150 psi / 10.3 bar .............................. M .......... Turntable rotate circuit,
regulates pressure drop acrossturntable rotate proportional valve ... 30-35 ft-lbs / 41-47 Nm
11 Check valve ....................................... DD ........ Prevents hydraulic pressurefrom flowing back into thefunction pump ........................... 130-140 ft-lbs / 176-190 Nm
12 Check valve ....................................... DC ........ Prevents hydraulic pressurefrom flowing back into auxiliarypump #2
MANIFOLDS
Part No. 106783 Z-135/70 4 - 85
April 2008 Section 4 • Repair Procedures
REV E
12
1
7
3
11
2
8
9
5
4
3
10
O
E
P
R
V
T
N
DC
DD
M
DB W
MANIFOLDS
4 - 86 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-5Valve Adjustments -Function Manifold
How to Adjust the SystemRelief Valve(before serial number 440)Note: Perform this procedure with the boom in thestowed position.
Note: Auxiliary power will be used to perform thisprocedure. Do not start the engine.
1 Locate the system relief valve on the functionmanifold (item L). Hold the relief valve andremove the cap.
2 Turn the internal hex socket counterclockwiseseveral turns. Do not allow the relief valve tocome apart. Install the relief valve cap.
3 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST port on the function manifold.
4 Simultaneously push and hold the auxiliarypower button and the primary boom retractbutton with the primary boom fully retracted.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.
5 Use a wrench to hold the relief valve andremove the cap (item L).
6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure. Install the relief valvecap.
Component damage hazard. Donot adjust the relief valve higherthan specified.
7 Repeat step 4 to confirm relief valve pressure.
8 Remove the pressure gauge.
MANIFOLDS
How to Adjust the SystemRelief Valve(after serial number 439)Note: Perform this procedure with the boom in thestowed position.
Note: Auxiliary power will be used to perform thisprocedure. Do not start the engine.
1 Locate the system relief valve on the functionmanifold (item L). Hold the relief valve stem witha hex wrench and loosen the lock nut.
2 Turn the valve stem counterclockwise severalturns. Do not allow the relief valve to comeapart. Tighten the lock nut.
3 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST port on the function manifold.
4 Simultaneously push and hold the auxiliarypower button and the primary boom retractbutton with the primary boom fully retracted.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.
5 Hold the relief valve stem with a hex wrench andloosen the lock nut.
6 Adjust the valve stem. Turn it clockwise toincrease the pressure. Tighten the lock nut.
Component damage hazard. Donot adjust the relief valve higherthan specified.
7 Repeat step 4 to confirm relief valve pressure.
8 Remove the pressure gauge.
Part No. 106783 Z-135/70 4 - 87
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
How to Adjust the Primary BoomExtend Relief ValveNote: Perform this procedure with the axlesextended.
1 Remove the primary boom end cover from thepivot end of the boom.
2 Locate the primary boom extend limit switch onthe side of the primary boom.
3 Follow the wiring from the switch to the pivotend of the primary boom. Locate and disconnectthe wire connector for the primary boom extendlimit switch.
Note: The correct wire connector will be a 2 pinconnector with a yellow marker on the cable.
4 Start the engine and fully extend the primaryboom. Turn the engine off.
5 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the PETST port on the function manifold.
6 Start the engine from the ground controls andpress and release the rpm select button until theengine changes to high idle.
7 Simultaneously push and hold the functionenable/high speed button and the primary boomextend button with the primary boom fullyextended. Observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.
8 Turn the engine off. Use a wrench to hold therelief valve and remove the cap (item E).
9 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Component damage hazard. Donot adjust the relief valve higherthan specified.
10 Repeat step 7 to confirm relief valve pressure.
11 At the pivot end of the primary boom, connectthe primary boom extend limit switch connector,that was disconnected in step 3.
12 Install the primary boom end cover and removethe pressure gauge.
13 Start the engine and fully retract the primaryboom. Turn the engine off.
4 - 88 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-6Platform Manifold
The platform manifold is mounted to the platform mounting weldment.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 3 position 4 way ......... AH ......... Platform rotate left/right ................. 20-25 ft-lbs / 27-34 Nm
2 Proportional solenoid valve,3 position 4 way ....................................AI .......... Platform level up/down ................. 20-25 ft-lbs / 27-34 Nm
3 Flow control valve,0.2 gpm / 0.76 L/min ............................. AG ......... Platform rotate left/right circuit ...... 20-25 ft-lbs / 27-34 Nm
Part No. 106783 Z-135/70 4 - 89
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
2
3
1
AH AI
AG
4 - 90 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-7Jib Boom Manifold
The jib boom manifold is mounted inside the primary extension boom at the platform end.
Index SchematicNo. Description Item Function Torque
1 Pressure compensator valve,150 psi / 10.3 bar .................................. X ........... Jib boom up/down circuit,
regulates pressure drop acrossjib boom up/downproportional valve ......................... 30-35 ft-lbs / 41-47 Nm
2 Solenoid valve, 2 position 3 way ......... AE .......... Jib boom retract ............................ 20-25 ft-lbs / 27-34 Nm
3 Solenoid valve, 2 position 3 way ......... AD ......... Jib boom extend ........................... 20-25 ft-lbs / 27-34 Nm
4 Flow regulator valve,2 gpm / 7.6 L/min .................................. AC ......... Jib boom extend/retract circuit ...... 20-25 ft-lbs / 27-34 Nm
5 Orifice, 0.040 inch / 1 mm ..................... AB .......... Jib boom extend/retract circuit
6 Check valve, 25 psi / 1.7 bar ................ AA .......... Holds oil in jib boom manifold ...... 20-25 ft-lbs / 27-34 Nm
7 Shuttle valve .......................................... Z ........... Jib boom up/down circuit .............. 10-12 ft-lbs / 14-16 Nm
8 Proportional solenoid valve,3 position 4 way .................................... Y ........... Jib boom up/down ........................ 20-25 ft-lbs / 27-34 Nm
9 Proportional solenoid valve,3 position 4 way ................................... AF .......... Jib boom bellcrank
level up/down ................................ 20-25 ft-lbs / 27-34 Nm
Part No. 106783 Z-135/70 4 - 91
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
2
5
9
8
3
7
6
1 4
X AE AD AC
AB
AA
Z
Y
AF
4 - 92 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-8Function Enable Valve
The function enable valve is mounted behind the medium pressure filter.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 2 way .....A ............ Enables lift pump to providehydraulic pressure for all boomand steer/axle functions .................. 20-25 ft-lbs / 27-34 Nm
1
A
Part No. 106783 Z-135/70 4 - 93
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
8-9Turntable Rotation Manifold
The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.
Index SchematicNo. Description Item Function Torque
1 Counterbalance valve .................... CA ........... Turntable rotate right ....................... 25-30 ft-lbs / 34-41 Nm
2 Counterbalance valve .................... CB ........... Turntable rotate left .......................... 25-30 ft-lbs / 34-41 Nm
3 Shuttle valve, 2 position 3 way ...... CC ........... Turntable rotation brake release ....... 8-10 ft-lbs / 11-14 Nm
4 Orifice plug, 0.030 inch / 0.76 mm . CD ........... Turntable rotation brake release
1 2
4
3
CA CB
CC
CD
4 - 94 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-10Steer and Axle Manifold
The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.
Index SchematicNo. Description Item Function Torque
1 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BI .......... Right front steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
2 Check valve ....................................... BC ........ Prevents right front steer cylinderfrom moving when not steering ........ 20-25 ft-lbs / 27-34 Nm
3 Check valve ....................................... BB ......... Prevents left front steer cylinderfrom moving when not steering ........ 20-25 ft-lbs / 27-34 Nm
4 Flow regulator valve,2.1 gpm / 8 L/min ............................... BL ......... Right rear steer cylinder
extend circuit .................................... 20-25 ft-lbs / 27-34 Nm
5 Solenoid valve, 3 position 4 way ...... BQ ........ Steer left/right,right rear steer cylinder ..................... 20-25 ft-lbs / 27-34 Nm
6 Check valve ....................................... BE ......... Prevents right rear steer cylinderfrom moving when not steering ........ 20-25 ft-lbs / 27-34 Nm
7 Check valve ....................................... BD ........ Prevents left rear steer cylinderfrom moving when not steering ........ 20-25 ft-lbs / 27-34 Nm
8 Solenoid valve, 3 position 4 way ...... BP ......... Steer left/right,left rear steer cylinder ....................... 20-25 ft-lbs / 27-34 Nm
9 Flow regulator valve,2.1 gpm / 8 L/min ............................... BJ ......... Left rear steer cylinder
extend circuit .................................... 20-25 ft-lbs / 27-34 Nm
10 Flow regulator valve,7 gpm / 26.5 L/min ............................. BS ......... Axle extend/retract circuit ................. 20-25 ft-lbs / 27-34 Nm
11 Solenoid valve, 2 position 3 way ...... BU ........ Axle retract ........................................ 30-35 ft-lbs / 41-47 Nm
12 Solenoid valve, 2 position 3 way ...... BT ......... Axle extend ....................................... 30-35 ft-lbs / 41-47 Nm
13 Pressure reducing valve,2400 psi / 165 bar ............................. BR ........ Axle extend/retract circuit ................. 30-35 ft-lbs / 41-47 Nm
This list continues. Please turn the page.
Part No. 106783 Z-135/70 4 - 95
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
6
14
13
1 3
20
19
18
17
16
6
2 2
7
5
8
101112
15
7
3
9
4
BO
BN
BH
BF
BG
BM
BE
BK
BD
BR
BI BC BB BC BB
BL
BQ
BE
BD
BP
BJBSBUBT
4 - 96 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
Steer and Axle Manifold, continued
Index SchematicNo. Description Item Function Torque
14 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BK ......... Left rear steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
15 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BM ........ Right rear steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
16 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BG ........ Left front steer cylinder
retract circuit ..................................... 20-25 ft-lbs / 27-34 Nm
17 Flow regulator valve,2.1 gpm / 8 L/min ............................... BF ......... Left front steer cylinder
extend circuit .................................... 20-25 ft-lbs / 27-34 Nm
18 Flow regulator valve,2.1 gpm / 8 L/min ............................... BH ........ Right front steer cylinder
extend circuit .................................... 20-25 ft-lbs / 27-34 Nm
19 Solenoid valve, 3 position 4 way ...... BN ........ Steer left/right,left front steer cylinder ...................... 20-25 ft-lbs / 27-34 Nm
20 Solenoid valve, 3 position 4 way ...... BO ........ Steer left/right,right front steer cylinder .................... 20-25 ft-lbs / 27-34 Nm
Part No. 106783 Z-135/70 4 - 97
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
6
14
13
1 3
20
19
18
17
16
6
2 2
7
5
8
101112
15
7
3
9
4
BO
BN
BH
BF
BG
BM
BE
BK
BD
BR
BI BC BB BC BB
BL
BQ
BE
BD
BP
BJBSBUBT
4 - 98 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-11Valve Adjustments -Steer and Axle Manifold
How to Adjust the AxleRelief ValveNote: Perform this procedure with the boom in thestowed position and the axles fully extended.
Note: This procedure will require 2 people.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the TEST port on the steer and axlemanifold.
2 Locate the axle relief valve on the steer and axlemanifold (item BR). Hold the relief valve with awrench and remove the cap.
3 Start the engine from the platform controls andpress down the footswitch. Press and hold theaxle extend button at the plaform controls.Observe the pressure reading on the pressuregauge. Refer to Section 2, Specifications.
4 Turn the engine off.
5 Adjust the internal hex socket clockwise toincrease the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Component damage hazard. Donot adjust the relief valve higherthan specified.
6 Repeat steps 3 through 5 to confirm relief valvepressure.
7 Remove the pressure gauge.
MANIFOLDS
Part No. 106783 Z-135/70 4 - 99
April 2008 Section 4 • Repair Procedures
REV E
This page intentionally left blank.
MANIFOLDS
4 - 100 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-12Traction Manifold - View 1
The traction manifold is mounted inside the manifold box at the blue triangle side of the machine.
Index SchematicNo. Description Item Function Torque
1 Check valve, 5 psi / 0.3 bar ............... BA ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
2 Check valve, 5 psi / 0.3 bar ............... AZ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
3 Check valve, 5 psi / 0.3 bar ............... AJ ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
4 Check valve, 5 psi / 0.3 bar ............... AT ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
5 Check valve, 5 psi / 0.3 bar ............... AW ........ Brake circuit ...................................... 20-25 ft-lbs / 27-34 Nm
6 Shuttle valve, 3 position 3 way ......... AO ........ Charge pressure circuit thatdirects hot oil out of low pressureside of drive pump ............................ 50-55 ft-lbs / 68-75 Nm
7 Relief valve, 250 psi / 17.2 bar ......... AN ........ Charge pressure circuit .................... 30-35 ft-lbs / 41-47 Nm
8 Solenoid valve, 2 position 3 way ...... AY ......... Brake release ................................... 20-25 ft-lbs / 27-34 Nm
9 Solenoid valve, 2 position 3 way ...... AX ......... 2-speed drive motor shift .................. 20-25 ft-lbs / 27-34 Nm
10 Flow divider/combiner valve ............. AR ........ Controls flow to square enddrive motors in forwardand reverse ................................. 90-100 ft-lbs / 122-136 Nm
11 Flow divider/combiner valve ............. AM ........ Controls flow to circle enddrive motors in forwardand reverse ................................. 90-100 ft-lbs / 122-136 Nm
12 Flow divider/combiner valve ............. AP ......... Controls flow to flow divider/combiner valves AR and AM in forward and reverse .............. 90-100 ft-lbs / 122-136 Nm
MANIFOLDS
Part No. 106783 Z-135/70 4 - 101
April 2008 Section 4 • Repair Procedures
REV E MANIFOLDS
BA AZ
AJ
AT
AW
AOAN
AY
AX
AR
AM
AP
67
1 2
11
12
9
8
5
3
4
10
4 - 102 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-13Traction Manifold - View 2
The traction manifold is mounted inside the manifold box at the blue triangle side of the machine.
Index SchematicNo. Description Item Function Torque
1 Orifice, 0.063 in / 1.6 mm(before serial number 180except for serial number 102) ........... AL ......... Equalizes pressure on both sides
of flow divider/combiner AM
— Orifice, 0.039 in / 1 mm(serial number 102 andafter serial number 179 ..................... AL ......... Equalizes pressure on both sides
of flow divider/combiner AM
2 Orifice, 0.052 in / 1.3 mm .................. AQ ........ Equalizes pressure on both sidesof flow divider/combiner AP
3 Orifice, 0.063 in / 1.6 mm .................. AS ......... Equalizes pressure on both sidesof flow divider/combiner AR
4 Orifice, 0.030 in / 0.76 mm ................ AV ......... Brake release and 2-speedmotor shift circuit
5 Check valve, 5 psi / 0.3 bar ............... AU ........ Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
6 Check valve, 5 psi / 0.3 bar ............... AK ......... Drive motor anti-cavitation ............... 20-25 ft-lbs / 27-34 Nm
MANIFOLDS
Part No. 106783 Z-135/70 4 - 103
April 2008 Section 4 • Repair Procedures
REV E
AK
AU
AV
AL
AQ
AS
4
6
5
1
2
3
MANIFOLDS
4 - 104 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV EMANIFOLDS
8-14Valve Adjustments,Traction Manifold
How to Adjust the Hot OilRelief ValveNote: The hydraulic oil temperature must be100°F to 150°F / 38°C to 65.5°C before performingthis procedure.
1 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to either the "A" or "B" test port on thedrive pump.
2 Locate the hot oil relief valve on the tractionmanifold (item AN). Hold the relief valve andremove the cap.
3 Turn the internal hex socket clockwise fully untilit stops. Install the cap.
4 Start the engine from the ground controls.
5 Press and hold the function enable/high rpmselect button (rabbit symbol) position. Note thereading on the pressure gauge.
5 Turn the engine off.
6 Remove the pressure gauge from the drivepump. Connect the gauge to the test portlocated on the traction manifold.
7 Hold the hot oil relief valve and remove the cap(item AN).
8 Start the engine from the ground controls.
9 Press and hold the function enable/high rpmselect button (rabbit symbol) position.
10 Adjust the internal hex socket until the pressurereading on the gauge is 40 psi / 2.8 bar lessthan the pressure reading on the pump. Turn itclockwise to increase the pressure orcounterclockwise to decrease the pressure.Install the relief valve cap.
11 Turn the engine off and remove the pressuregauge.
Part No. 106783 Z-135/70 4 - 105
April 2008 Section 4 • Repair Procedures
REV E
CY
CX
CU
CV
CW
1
3
4
5
2
8-15Drive Oil Diverter Manifold Components (welder option)
The oil diverter manifold is mounted to the hydraulic generator located in the engine compartment.
Index SchematicNo. Description Item Function Torque
1 Directional valve ............................ BV ........... Diverter valve ............................... 80-90 ft-lbs / 108-122 Nm
2 Orifice disc,0.030 inch / 0.080 cm ..................... BW........... Delays shift to drive
3 Solenoid valve ............................... BX ........... Pilot valve to diverter ....................... 35-40 ft-lbs / 47-54 Nm
4 Relief valve, 270 psi / 18.6 bar .......BZ ........... Charge pressure circuit ................... 35-40 ft-lbs / 47-54 Nm
5 Check valve .................................... BY ........... Prevents oil to generator ................. 35-40 ft-lbs / 47-54 Nm
MANIFOLDS
4 - 106 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
8-16Valve Coils
How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.
Since coil resistance is sensitive to temperature,resistance values outside specification can produceerratic operation. When coil resistance decreasesbelow specification, amperage increases. Asresistance rises above specification, voltageincreases.
While valves may operate when coil resistance isoutside specification, maintaining coils withinspecification will help ensure proper valve functionover a wide range of operating temperatures.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Tag and disconnect the wiring from the coil to betested.
2 Test the coil resistance.
Result: The resistance should be withinspecification, plus or minus 30%.
Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.Valve Coil Resistance Specification
Valve Coil ResistanceSpecificationNote: The following coil resistance specificationsare at an ambient temperature of 68°F / 20°C. Asvalve coil resistance is sensitive to changes in airtemperature, the coil resistance will typicallyincrease or decrease by 4% for each 18°F / 10°Cthat your air temperature increases or decreasesfrom 68°F / 20°C.
Valve coil resistance specifications
Proportional solenoid valve 3.5 to 5.5Ω(schematic items N, P, R, T, V)
3 position 4 way solenoid valve 4 to 6Ω(schematic item B)
3 position 4 way solenoid valve 7 to 9Ω(schematic items BN, BO, BP and BQ)
3 position 4 way solenoid valve 8 to 10Ω(schematic item AH)
3 position 4 way proportional 8 to 10Ωsolenoid valve(schematic items Y and AI)
2 position 3 way solenoid valve 5.5 to 7.5Ω(schematic items F and AD)
2 position 3 way solenoid valve 8 to 10Ω(schematic items AE and AF)
2 position 3 way solenoid valve 3.5 to 5.5Ω(schematic items H and J)
2 position 3 way solenoid valve 7.5 to 9.5Ω(schematic items C, D, G, I, K, AX, AY, BU and BT)
2 position 2 way solenoid valve 3.5 to 5.5Ω(schematic item A)
MANIFOLDS
Part No. 106783 Z-135/70 4 - 107
April 2008 Section 4 • Repair Procedures
REV E
How to Test a Coil DiodeProperly functioning coil diodes protect theelectrical circuit by suppressing voltage spikes.Voltage spikes naturally occur within a functioncircuit following the interruption of electrical currentto a coil. Faulty diodes can fail to protect theelectrical system, resulting in a tripped circuitbreaker or component damage.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
1 Test the coil for resistance. See, How to Test aCoil.
2 Connect a 10Ω resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.
Resistor, 10ΩΩΩΩΩGenie part number 27287
Note: The battery should read 9V DC or more whenmeasured across the terminals.
a multimeterb 9V DC batteryc 10Ω resistord coil
Note: Dotted lines in illustration indicate areversed connection as specified instep 6
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 terminalon the coil.
5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note and record the current reading.
6 At the battery or coil terminals, reverse theconnections. Note and record the currentreading.
Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.
MANIFOLDS
9VBATTERY
10
RESISTOR
�
MULTIMETER
COIL
+
-
+
-
d
b
b
a
c
c
4 - 108 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
6 Repeat steps 3 through 5 for the other turntablerotation assembly.
Tip-over hazard. If the turntablerotation lock pin is not properlyinstalled, machine stability iscompromised and the machinecould tip over when the drive hubis removed from the machine,which could result in death orserious injury.
Crushing hazard. The drive hubcould become unbalanced and fallif not properly supported by theoverhead crane or lifting devicewhen removed from the machine.
Note: When installing a turntable rotation assembly,the rotation gear backlash must be adjusted. SeeMaintenance Procedure D-4, Adjust the TurntableRotation Gear Backlash.
Turntable Rotation Components
9-1Turntable Rotation Assembly
How to Remove a TurntableRotation AssemblyNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section 2, Hydraulic Hose andFitting Torque Specifications.
Note: Perform this procedure with the primary boombetween the circle-end tires and with the machineon a firm, level surface.
1 Secure the turntable from rotating with theturntable rotation lock pin.
2 Remove the ground controls side fixed turntablecover.
3 Tag, disconnect the hydraulic hoses from theturntable rotation motor. Cap the fittings on themotor.
4 Attach a lifting strap from an overhead crane orother suitable lifting device to the lifting eye onthe turntable rotation assembly.
5 Remove the drive hub mounting bolts andremove the turntable rotation assembly from themachine.
Part No. 106783 Z-135/70 4 - 109
April 2008 Section 4 • Repair Procedures
REV E
9-2Turntable Level Sensor
How to Calibrate the TurntableLevel SensorNote: If the Safety Controller (SCON) has beenreplaced, the entire machine needs to be calibratedin a specific order. Consult the Genie IndustriesService Department.
Note: Perform this procedure with the machine on afirm, level surface and in the stowed position.
Note: A digital level will be required to perform thisprocedure.
Note: A kit is available through the Genie IndustriesService Department (Genie part number 58351).This kit includes a digital level with a magneticbase and cable harnesses.
1 Push in the ground controls red Emergency Stopbutton to the off position.
2 Open the ground control box.
Before serial number 321:
3 Locate the 2 pin connector in the lower left handarea of the ground control box.
4 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
3 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
4 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
5 Turn the key switch to ground controls.
6 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
7 Enter sensor calibration mode by pressing thebuttons at the ground controls in the followingsequence: .
8 Remove the key from the main key switch.Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
TURNTABLE ROTATION COMPONENTS
STOP
00000
Run
ServiceBypass
Recovery
4 - 110 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV E
9 Push one of the LCDscreen buttons shownuntil SET UNIT X AXIS LEVEL TO
GRAVITY is displayed.
10 Place the digital level along the X axis of theturntable.
11 Press the plus button or minus button toadjust the display to the exact value shown onthe digital level and press the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,
press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
12 Push one of the LCDscreen buttons shownuntil SET UNIT Y AXIS LEVEL TO
GRAVITY is displayed.
TURNTABLE ROTATION COMPONENTS
13 Place the digital level along the Y axis of theturntable.
14 Press the plus button or minus button toadjust the display to the exact value shown onthe digital level and press the enter button .
Note: If the measured angle already matches theangle shown on the display at the ground controls,press the plus button or minus button tochange the angle and then change back to themeasured value. The system must detect a changein displayed value to record the calibrated value.
15 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
16 Press the plus button to select YES, then
press the enter button to accept.
17 Wait approximately 20 seconds and turn themachine off by pressing the red EmergencyStop button in to the off position or by turningthe main key switch to the off position.
+Y axis -Y axis
Platform
+X axis
-X axis
Part No. 106783 Z-135/70 4 - 111
April 2008 Section 4 • Repair Procedures
REV E
Before serial number 321:
18 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 4.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
19 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
18 Remove the fastener that was temporarilyinstalled in step 4.
19 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
TURNTABLE ROTATION COMPONENTS
All models:
20 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
21 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
22 Start the engine. Be sure there are no calibrationfaults shown on the display.
4 - 112 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
10-1Steer Sensors
The steer sensors measure steer angle andcommunicates that information to the groundcontrols ECM. The steer sensor on the groundcontrols side of the machine at the square-end actsas the lead sensor when in front wheel steer mode.In rear wheel steer mode, the steer sensor on theground controls side of the machine at the circle-end acts as the lead sensor. The other threesensors follow the position, or steer angle, of thelead sensor. There is a steer sensor mounted to thetop of each steer yoke upper pivot pin.
How to Replace a Steer SensorNote: Perform this procedure with the axles fullyretracted and the boom in the stowed position.
1 Align the remaining wheels on the machine sothey are visually parallel to the chassis as closeas possible.
2 Disconnect the steer sensor assembly cablefrom the main harness to be replaced.
3 Remove the steer sensor cover retainingfasteners. Remove the steer sensor assembly.
Note: Inspect the sensor activator pin to make sureit is not broken or twisted.
Note: If the sensor activator pin needs to bereplaced, install the new activator pin perIllustration 1
Axle Components
Illustration 1(square end, yellow side andcircle end, blue side shown)
Part No. 106783 Z-135/70 4 - 113
April 2008 Section 4 • Repair Procedures
REV F
Left front (square-end, blue side) and right rear(circle-end, yellow side) angle sensors:
Illustration 2a starting positionb installed positionc sensor coverd rotation arrow
4 Position the new steer sensor assembly overthe sensor activator pin with the sensor cableangled towards the tire. Refer to Illustration 2.
5 Align the sensor with the pin and install thesensor on to the pin.
Note: Be sure the sensor activator pin is engagedinto the sensor.
6 Rotate the sensor housing in a clockwisedirection until the sensor cable is pointing awayfrom the machine. Refer to Illustration 2.
7 Install the steer sensor cover retainingfasteners. Do not tighten the cover retainingfasteners.
8 Connect the steer sensor assembly cable to themain harness.
9 Calibrate the steer sensor. See How to Calibratea Replacement Steer Sensor.
Note: Be sure the yoke pivot pin retaining plate isfully engaged into the pivot pin and that thefasteners are securely tightened.
AXLE COMPONENTS
d
c
b
a
4 - 114 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
c
b
a
d
Right front (square-end, yellow side) and leftrear (circle-end, blue side) angle sensors:
Illustration 3a installed positionb starting positionc sensor coverd rotation arrow
10 Position the new steer sensor assembly overthe sensor activator pin with the sensor cableangled away from the tire. Refer toIllustration 3.
11 Align the sensor with the pin and install thesensor on to the pin.
Note: Be sure the sensor activator pin is engagedinto the sensor.
12 Rotate the sensor housing in a clockwisedirection until the sensor cable is pointing awayfrom the machine. Refer to Illustration 2.
13 Install the steer sensor cover retainingfasteners. Do not tighten the cover retainingfasteners.
14 Connect the steer sensor assembly cable to themain harness.
15 Calibrate the steer sensor. See How to Calibratea Replacement Steer Sensor.
Note: Be sure the yoke pivot pin retaining plate isfully engaged into the pivot pin and that thefasteners are securely tightened.
AXLE COMPONENTS
Part No. 106783 Z-135/70 4 - 115
April 2008 Section 4 • Repair Procedures
REV F
How to Calibrate a ReplacementSteer SensorNote: If a steer angle sensor has been removed orreplaced, the steer angle sensors will need to becalibrated first.
Note: Perform this procedure with the axlesretracted and the tires straightened.
Note: This procedure will require two people.
Note: Be sure the yoke pivot pin retaining plate isfully engaged into the pivot pin and that thefasteners are securely tightened.
1 Start the engine from the platform controls.
2 Select the proper steer mode. If a front (square-end) steer angle sensor has been replaced,select rear steer mode. If a rear (circle-end)steer angle sensor has been replaced, selectfront steer mode.
3 Have another person press down the footswitch.
4 At the new steer angle sensor, loosen the steerangle sensor cover retaining fasteners. Do notremove the fasteners or the sensor cover.
5 Rotate the sensor cover clockwise orcounterclockwise until the tire is straight inrelation with the other tires. Tighten the sensorcover fasteners.
Note: If available, WebGPI can also be used forthis procedure.
6 Push in the red Emergency Stop button to theoff position.
How to Calibrate AllSteer SensorsNote: This procedure will only need to be performedif the ground controls circuit board (TCON) hasbeen replaced.
Note: Perform this procedure with the axlesretracted and the tires straightened.
Before serial number 321:
1 Locate the 2 pin connector in the lower left handarea of the ground control box.
2 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
1 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
2 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
3 Turn the key switch to ground controls and pullout the ground controls red Emergency Stopbutton to the on position.
4 Loosen the steer angle sensor cover retainingfasteners. Do not remove the fasteners or thesensor cover.
AXLE COMPONENTS
4 - 116 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
5 Using a voltmeter set to DC voltage, probe theback of the electrical connector at pins Band C.
6 Left front (square-end, blue side) and rightrear (circle-end, yellow side) angle sensors:Rotate the sensor cover clockwise orcounterclockwise until the voltage reading isbetween 1.4 to 1.6V DC. Tighten the sensorcover fasteners.
Right front (square-end, yellow side) and leftrear (circle-end, blue side) angle sensors:Rotate the sensor cover clockwise orcounterclockwise until the voltage reading isbetween 3.4 to 3.6V DC. Tighten the sensorcover fasteners.
Note: If available, WebGPI can also be used forthis procedure.
7 Push in the red Emergency Stop button to theoff position.
8 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
AXLE COMPONENTS
9 Remove the key from the main key switch.Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
10 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
11 Push one of the LCDscreen buttons shownuntil RESET ALL STEER
SENSORS is displayed.
12 Press the plus button to select YES, then
press the enter button to accept.
STOP
00000
Run
ServiceBypass
Recovery
Part No. 106783 Z-135/70 4 - 117
April 2008 Section 4 • Repair Procedures
REV F AXLE COMPONENTS
13 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
14 Press the plus button to select YES, then
press the enter button to accept.
15 Turn the machine off by pushing in the redEmergency Stop button to the off position.
Before serial number 321:
16 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 2.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
17 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
16 Remove the fastener that was temporarilyinstalled in step 2.
17 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
All models:
18 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the RUN position before attempting to operate themachine.
10-2Steer Cylinders
How to Remove a Steer CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
Note: Perform this procedure with the axlesextended.
1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Support the steer cylinder with a suitable liftingdevice. Protect the cylinder rod from damage.
3 Remove the pin retaining fasteners from bothsteer cylinder pivot pins.
4 Use a soft metal drift to remove the pins.
5 Remove the steering cylinder from the machine.
Crushing hazard. The steercylinder may become unbalancedand fall if not properly supported bythe lifting device when removedfrom the machine.
4 - 118 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
10-3Axle Extension Cylinders
How to Remove an AxleExtension CylinderNote: When removing a hose assembly or fitting,the O-ring on the fitting and/or hose end must bereplaced and then torqued to specification duringinstallation. Refer to Section Two, Hydraulic Hoseand Fitting Torque Specifications.
Note: Perform this procedure with the machine on afirm, level surface and the axles extended.
Note: This procedure will require the use of aportable hydraulic power unit.
1 Tag, disconnect and plug the hydraulic hosesfrom the axle extension cylinder. Cap thefittings on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Remove the axle extension limit switch coverfasteners. Remove the cover.
3 Remove the limit switch mounting fasteners andremove the limit switch. Do not disconnect thewiring.
4 Connect the hydraulic hoses from a portablehydraulic power unit to the axle extensioncylinder.
Note: Connect the pressure hose from the powerunit to the "R" port of the cylinder and the returnhose from the power unit to the "E" port on thecylinder.
5 Support the axle extension cylinder with asuitable lifting device. Protect the cylinder rodfrom damage.
6 Remove the pin retaining fasteners from bothaxle extension cylinder pivot pins.
7 Use a soft metal drift to remove the pins.
8 Using the portable hydraulic power unit, retractthe axle extension cylinder until the ends of thecylinder clears the axles.
9 Remove the axle extension cylinder from themachine.
Crushing hazard. The axleextension cylinder may becomeunbalanced and fall if not properlysupported by the lifting device.
AXLE COMPONENTS
Part No. 106783 Z-135/70 4 - 119
April 2008 Section 4 • Repair Procedures
REV F AXLE COMPONENTS
10-4Axle Angle Sensors
The axle angle sensors measure the axle angle andcommunicates that information to the groundcontrols ECM. There are two axle angle sensors.They are located on opposite axle pivot pins ateach end of the chassis.
How to Install an AxleAngle SensorNote: Perform this procedure with the machine inthe stowed position and the axles fully retracted.
1 Locate the axle angle sensor to be replaced.
2 Tag and disconnect the angle sensor electricalconnector from the chassis harness.
3 Remove the angle sensor cover retainingfasteners. Remove the angle sensor assembly.
Note: Inspect the sensor activator pin to make sureit is not broken or twisted.
Note: If the sensor activator pin needs to bereplaced, install the new activator pin parallel withthe drive chassis side plate. Refer to Illustration 1.
Illustration 1a drive chassis side plateb activator pin
a
b
4 - 120 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
b
a
c
d
e
Illustration 2a starting positionb installed positionc sensor coverd rotation arrowe drive chassis side plate
4 Align the sensor with the pin and install thesensor on to the pin.
Note: Be sure the sensor activator pin is engagedinto the sensor.
5 Rotate the sensor housing in a clockwisedirection until the sensor cable is parallel withthe drive chassis side plate. Refer toIllustration 2.
6 Install the axle sensor cover retaing fasteners.Do not tighten the cover retaining fasteners.
7 Connect the axle sensor assembly cable to themain harness.
8 Calibrate the axle angle sensor. See How toCalibrate the Axle Angle Sensors.
AXLE COMPONENTS
3 Position the new axle angle sensor assemblyover the sensor activator pin as shown. Refer toIllustration 2.
Part No. 106783 Z-135/70 4 - 121
April 2008 Section 4 • Repair Procedures
REV F
How to Calibrate the AxleAngle SensorsNote: If an axle angle sensor has been removed orreplaced, the axle angle sensors will need to becalibrated first.
Note: Perform this procedure with the machine inthe stowed position and the axles fully retracted.
Note: This procedure will require two people.
1 Turn the key switch to ground controls and pullout the ground controls red Emergency Stopbutton to the on position.
2 Loosen an axle angle sensor cover retainingfasteners. Do not remove the fasteners or thesensor cover.
3 Using a voltmeter set to DC voltage, probe theback of the electrical connector at pins 2 and 3.
Note: If available, WebGPI can also be used forthis procedure.
4 Rotate the sensor cover clockwise orcounterclockwise until the voltage reading isbetween 4.2 to 4.4V DC. Tighten the sensorcover fasteners.
5 Repeat steps 2 through 4 for each remainingaxle angle sensor.
6 Turn the machine off by pressing the groundcontrols red Emergency Stop button to the offposition. Do not turn the key switch to the offposition.
Before serial number 321:
7 Locate the 2 pin connector in the lower left handarea of the ground control box.
8 Remove the connector plug and insert a jumperwire between the two pins of the connector.
After serial number 320:
7 Locate the calibration toggle switch at the top ofthe ground control box. Activate calibrationmode by moving the toggle switch in the leftdirection.
8 Temporarily install a control box door retainingfastener between the door and the box toprevent the control box door from moving thetoggle switch while calibrating the machine.
All models:
9 Press and hold the enter button on theground control panel while pulling out the groundcontrols red Emergency Stop button to the onposition. Hold the enter button for approximately5 seconds and then release it.
10 Enter sensor calibration mode by pressing thebuttons at the ground controls in the following
sequence: .
AXLE COMPONENTS
4 - 122 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
REV F
11 Remove the key from the main key switch.Insert the key into the service/bypass keyswitch and turn it to the service/bypassposition.
Note: The angle sensor calibration values will notbe saved correctly unless the key switch is in theservice/bypass position.
12 Push one of the LCDscreen buttons shownuntil RESET AXLE ANGLE
SENSORS is displayed.
13 Press the plus button to select YES, then
press the enter button to accept.
14 At the AXLE ANGLES FULLY RETRACTED screen, press
the plus button to select YES, then press the
enter button to accept.
AXLE COMPONENTS
STOP
00000
Run
ServiceBypass
Recovery
15 When the AXLE ANGLES FULLY EXTENDED screen isdisplayed, start the engine and fully extend theaxles.
Note: If the system exits out of calibration modewhen the engine is started, repeat step 9.
16 Press the plus button to select YES, then
press the enter button to accept.
17 Push one of the LCDscreen buttons shownuntil EXIT is displayed.
18 Press the plus button to select YES, then
press the enter button to accept.
19 Press and hold the engine start button forapproximately 5 seconds to shut off the engineand to save the calibration settings.
Note: Do not turn the engine off with the key switchor red Emergency Stop button or all calibrationpoints or values will not be saved.
20 Wait approximately 20 seconds and turn themachine off by pressing the red EmergencyStop button in to the off position or by turningthe main key switch to the off position.
Part No. 106783 Z-135/70 4 - 123
April 2008 Section 4 • Repair Procedures
REV F AXLE COMPONENTS
Before serial number 321:
21 Remove the wire jumper from the 2 pinconnector in the lower left hand area of theground control box that was installed in step 8.Install the connector plug.
Tip-over hazard. Failure to removethe jumper wire will result in anunsafe configuration which willcompromise machine stability.Operating the machine in thisconfiguration will result in themachine tipping over causingdeath or serious injury. The jumperwire must be removed beforeoperating the machine.
22 Close the ground control box and install the doorretaining fasteners.
After serial number 320:
21 Remove the fastener that was temporarilyinstalled in step 8.
22 Close the control box door and install the doorretaining fasteners.
Note: When the control box door is closed, thecalibration toggle switch is automatically activatedto exit out of calibration mode.
All models:
23 Use the key to turn the service/bypass keyswitch to the run postion.
Note: Be sure that the service/bypass key switch isin the run position before attempting to operate themachine.
4 - 124 Z-135/70 Part No. 106783
April 2008Section 4 • Repair Procedures
This page intentionally left blank.
Part No. 106783 Z-135/70 5 - 1
April 2008 Section 5 • Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-135/70 Operator's Manual on yourmachine.
Be sure that all necessary tools and testequipment are available and ready for use.
Read each appropiate fault code thoroughly.Attempting shortcuts may produce hazardousconditions.
Be aware of the following hazards and followgenerally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Perform all troubleshooting on afirm, level surface.
Two persons will be required tosafely perform sometroubleshooting procedures.
Fault Codes
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Boom in the stowed position
· Turntable rotated with the boom between the circle-end wheels (yellow arrow)
· Turntable secured with the turntable rotation lock pin
· Key switch in the off position with the key removed
· Welder disconnected from the machine (if equipped with the weld cable to platform option)
· Wheels chocked
· All external AC power supply disconnectedfrom the machine
5 - 2 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BControl System Fault Codes
Error Source Error Type Effects Corrective Action
Value at 5.0 VLimited Speed and Direction frozen at zero and neutral, Alarm sounds
Value too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Value at 5.0 VLimited Speed and Direction frozen at zero and neutral, Alarm sounds
Value too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Primary Boom Up/Down switches
on TCON
Fault Check, (both buttons
pressed)
Primary boom up/dwn disabled, display message on LCD.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
Primary Boom Ext/Ret switches
on TCON
Fault Check, (both buttons
pressed)
Primary boom Ext/Ret disabled, display message on LCD.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
Primary Boom Length
Fault check (unknown
length)
Default to low speed drive, display message on LCD.
Check primary boom retracted and extended switches for proper contact with the boom. Readjust or shim switch as necessary.
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
Primary Up/Down Joystick
Primary Extend/Retract
Joystick
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
Part No. 106783 Z-135/70 5 - 3
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure.
Just calibratedInitiate one second beep of audible warning device.
No action required.
Value Too High
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too Low
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for shorts to ground in the wiring. Replace coil if necessary.
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure.
Just calibratedInitiate one second beep of audible warning device.
No action required.
Value Too High
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too Low
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for shorts to ground in the wiring. Replace coil if necessary.
PRI BOOM EXT VALVE
PRI BOOM RET VALVE
PRI BOOM UP VALVE
PRI BOOM DOWN VALVE
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
Primary Boom Up/Down Flow
Valve
Primary Boom Ext/Ret Flow Valve
fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
5 - 4 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor.
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Out of Tolerance
Recalibrate sensor.
Not calibratedPrimary Up only active from TCON activate alarm
Perform calibration procedure per service manual or Z135 training CD.
Just calibratedInitiate one second beep of audible warning device.
No action required.
Value at 5.0 VCheck for an open ground circuit going to the sensor.
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Out of Tolerance
Recalibrate sensor.
Not calibratedPrimary Up only active from TCON activate alarm
Perform calibration procedure per service manual or Z135 training CD.
Just calibratedInitiate one second beep of audible warning device.
No action required.
OPERATIONAL PRIMARY BOOM ANGLE SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
SAFETY PRIMARY BOOM ANGLE SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
Part No. 106783 Z-135/70 5 - 5
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VLimited Speed and Direction frozen at zero and neutral, Alarm sounds
Value too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Sec Boom Up/Ext/Dwn/Ret
switches on TCON
Fault Check, (both buttons
pressed)
Sec Boom Up/Ext/Dwn/Ret disabled, display message on LCD.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
SEC BOOM UP/DOWN SPEED
Not calibratedDisplay message on LCD and allow operation at default speed.
See service manual on how to perform this procedure.
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure.
Just calibratedInitiate one second beep of audible warning device.
No action required.
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
SEC BOOM EXT VALVE
SEC BOOM RET VALVE
SEC BOOM UP VALVE
SEC BOOM DOWN VALVESEC EXT SEQ
VALVESEC DWN SEQ
VALVE
fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
Secondary Boom Joystick
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
SEC BOOM UP/DOWN/EXT/RET FLOW VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
5 - 6 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor.
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Out of Tolerance
Recalibrate sensor.
Not calibratedSecondary Up only active from TCON activate alarm
Perform calibration procedure per service manual or Z135 training CD.
Just calibratedInitiate one second beep of audible warning device.
No action required.
OPERATIONAL SECONDARY BOOM ANGLE
SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
Part No. 106783 Z-135/70 5 - 7
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor.
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Out of Tolerance
Recalibrate sensor.
Not calibratedSecondary Up only active from TCON activate alarm
Perform calibration procedure per service manual or Z135 training CD.
Just calibratedInitiate one second beep of audible warning device.
No action required.
SAFETY SECONDARY BOOM ANGLE
SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
5 - 8 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Engine Speedrange check (underspeed)
Engine is running below 50 RPM check fuel system.
Oil Pressurerange check
(low oil pressure)
Oil pressure is low check sender and oil level.
Water/Oil Temprange check
(high temperature)
Display message on LCD.Engine is overheating check sender, water or oil level, or radiator/heat exchanger.
Oil Pressure Sensor
Oil Temp Sender
AXLE EXT/RET BUTTONS
Fault Check, (both buttons
pressed)
Axle Extend/Retract disabled, display message on LCD.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
AXLE VALVE fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary.
DCON CAN BUS fault checkDisplay message on LCD. Disable propel
Check CAN Bus wiring from TCON to DCON through rotator. Repair or replace wiring or DCON.
CAN BUS fault check Display message on LCD.Check CAN Bus wiring from TCON to SCON/PCON. Repair or replace wiring or SCON/PCON.
Check wiring to senders for opens or shorts. Repair or replace senders.
Display message on LCD.
fault check Display message on LCD.
Part No. 106783 Z-135/70 5 - 9
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
SAFETY SWITCH P3
Display message on LCD. P3 SAFETY SWITCH FAULT
Internal Fault Not on Z135
SAFETY SWITCH P6R1
Display message on LCD. P6R1 SAFETY SWITCH FAULT
Check wiring for circuit P53LS (White/Black wire) for damage resulting in shorts or opens. Repair wiring or replace TCON
SAFETY SWITCH P6R2
Display message on LCD. P6R2 SAFETY SWITCH FAULT
Check wiring for circuit P54ENG (black/white wire) for damage resulting in shorts or opens. Repair wiring or replace TCON
SAFETY SWITCH P7
Display message on LCD. P7 SAFETY SWITCH FAULT
Check wiring for circuit S56PRV (red wire) for damage resulting in shorts or opens. Repair wiring or replace TCON
SAFETY SWITCH P7R
Display message on LCD. P7R SAFETY SWITCH FAULT
Function enable button was held down during startup. Recycle power with the function enable button released
SAFETY SWITCH DCON P7R
Display message on LCD. DCON P7R SAFETY SWITCH FAULT
Check wiring for circuit S56PRV (red wire) for damage resulting in shorts or opens. Repair wiring or replace DCON
SAFETY SWITCH P9A
Display message on LCD. P9A SAFETY SWITCH FAULT
Check wiring for circuit P53LS (White/Black wire) for damage resulting in shorts or opens. Repair wiring or replace TCON
SAFETY SWITCH P9B
Display message on LCD. P9B SAFETY SWITCH FAULT
Boom has violated the safety limits resulting in the engine being shutoff as a safety feature. Use aux to get the boom back into operational limits. Check P54ENG and P58LS between SCON and TCON for damage. Check SCON chart for possible fault conditions.
SAFETY SWITCH P10
Display message on LCD. P10 SAFETY SWITCH FAULT
Recycle Power
fault check
fault check
fault check
5 - 10 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
SAFETY SWITCH P11
fault checkDisplay message on LCD. P11 SAFETY SWITCH FAULT
Recycle Power and check wiring on circuit S140ENL (orange/black) between SCON and TCON. Check SCON chart for possible fault conditions.
SAFETY SWITCH P14
fault checkDisplay message on LCD. P14 SAFETY SWITCH FAULT
Recycle Power
SAFETY SWITCH P18
fault checkDisplay message on LCD. P18 SAFETY SWITCH FAULT
Recycle Power
SAFETY SWITCH P22
fault checkDisplay message on LCD. P22 SAFETY SWITCH FAULT
Re-level platform check for wiring damage on circuit P56PRV (red/white)
SAFETY SWITCH P22R
fault checkDisplay message on LCD. P22R SAFETY SWITCH FAULT
Re-level platform, Repair or Replace PCON
SAFETY SWITCH P30
fault checkDisplay message on LCD. P30 SAFETY SWITCH FAULT
Recycle Power and check wiring on circuit S140ENL (orange/black) between SCON and TCON. Check SCON chart for possible fault conditions.
SAFETY SWITCH P38
fault checkDisplay message on LCD. P38 SAFETY SWITCH FAULT
Recycle Power and check wiring on circuit S137PLL (red/wht) between SCON and TCON. Check SCON chart for possible fault conditions.
SAFETY SWITCH P39
fault checkDisplay message on LCD. P39 SAFETY SWITCH FAULT
Recycle Power and check wiring on circuit S139TRF (white/red) between SCON and TCON. Check SCON chart for possible fault conditions.
PLATFORM OVERLOAD
fault check (if active)
Display message on LCD.Check for an overload in the platform. Check the overload switch mounted on the platform support.
FOOTSWITCH TIMEOUT
Display message on LCD display
Check footswitch wiring for damage or remove blocking item on the footswitch.
Part No. 106783 Z-135/70 5 - 11
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective ActionValue at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
TURNTABLE ROTATE
BUTTONS
Fault Check, (both buttons
pressed)
TT rotate disabled, display message on LCD.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
TURNTABLE ROTATE SPEED
Not calibratedDisplay message on LCD and allow operation at default speed.
Calibrate turntable rotate speed in accordance with the service manual
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
TURNTABLE ROTATE CW
VALVETURNTABLE
ROTATE CCW VALVE
MULTI-FUNCTION VALVE
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
TURNTABLE ROTATE FLOW
VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
TURNTABLE ROTATE
JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
5 - 12 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective ActionValue at 5.0 V Check that the SCON is grounded.Value too highValue too low
Value at 0,Out of
Tolerance
Just calibratedInitiate one second beep of audible warning device.
No action required
Value at 5.0 V Check that the SCON is grounded.Value too highValue too low
Value at 0,Out of
Tolerance
Just calibratedInitiate one second beep of audible warning device.
No action required
Value at 5.0 V Check that the SCON is grounded.Value too high Replace SCONValue too low
Value at 0,Out of
Tolerance
Just calibratedInitiate one second beep of audible warning device.
No action required
Value at 5.0 V Check that the SCON is grounded.Value too highValue too low
Value at 0,Out of
Tolerance
Just calibratedInitiate one second beep of audible warning device.
No action required
Value at 5.0 V Check that the SCON is grounded.Value too highValue too low
Value at 0,
Just calibratedInitiate one second beep of audible warning device.
No action required
SAFETY TURNTABLE
LEVEL SENSOR Y-DIRECTION
Primary & Secondary Up and Extend disabled, Alarm sounds
Replace SCON
PLATFORM LEVEL SENSOR Y-
DIRECTION
Primary & Secondary Up and Extend disabled, Alarm sounds
Replace SCON
SAFETY TURNTABLE
LEVEL SENSOR X-DIRECTION
Flash unit out of level icon and LED and activate Alarm
Replace SCON
OPERATIONAL TURNTABLE
LEVEL SENSOR Y-DIRECTION
Primary & Secondary Up and Extend disabled, Alarm sounds
OPERATIONAL TURNTABLE
LEVEL SENSOR X-DIRECTION
Flash unit out of level icon and LED and activate Alarm
Replace SCON
Part No. 106783 Z-135/70 5 - 13
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective ActionPLAT ROT CW
VALVEPLAT ROT CCW
VALVEJIB UP VALVEJIB DN VALVEJIB LEVEL UP
VALVEJIB LEVEL DN
VALVE
JIB EXTEND VALVE
JIB RETRACT VALVE
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
JIB LEVEL UP/DWN FLOW
VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
fault check fault checkCheck for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
JIB UP/DWN FLOW VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
5 - 14 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
JIB UP/DWN SWITCHES
JIB EXT/RET SWITCHESPLAT ROT SWITCHES
Value at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Check ribbon and connector from membrane switch. If necessary replace membrane switch.
JIB UP/DWN JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
PLATFORM LEVEL DWN
FLOW VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Fault Check, (both closed)
Affected functions disabled, display message on LCD.
PLATFORM LEVEL UP FLOW
VALVE
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Part No. 106783 Z-135/70 5 - 15
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective ActionValue at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Value at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Not calibratedDisplay message at TCON activate alarm
Recalibrate sensor
Just calibratedInitiate one second beep of audible warning device.
Perform calibration procedure per service manual or Z135 training CD
FRONT AXLE ANGLE SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
JIB EXT/RET JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
PLATFORM ROTATE
JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick.
5 - 16 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Not calibratedDisplay message at TCON activate alarm
Recalibrate sensor
Just calibratedInitiate one second beep of audible warning device.
Perform calibration procedure per service manual or Z135 training CD
Value at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Not calibrated
Normal function except threshold for one or the other direction is zero. Display message on LCD.
Perform calibration procedure
Just calibratedInitiate one second beep of audible warning device.
No action required
Value Too HighCheck for opens in the wiring or a bad ground. Replace coil if necessary.
Value Too LowCheck for shorts to ground in the wiring. Replace coil if necessary.
PROPEL JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds Check for damaged wiring to the
joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick
PROPEL VALVES FWD
PROPEL VALVES REV
PROPEL EDC FWD
PROPEL EDC REV
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
REAR AXLE ANGLE SENSOR
Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds
Part No. 106783 Z-135/70 5 - 17
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective ActionMOTOR SPEED
VALVE
BRAKE VALVE
AUX PROPEL VALVE
Value at 5.0 VValue too highValue too low
Value at 0,
Not calibratedJoystick Speed and Direction frozen at zero and neutral
Just calibratedInitiate one second beep of audible warning device.
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
LF STR ANG SNSR
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
fault check fault checkCheck for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
STEERING JOYSTICK
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Check for damaged wiring to the joystick. Check the connectors to ensure the connector terminals have not backed out. Substitute a known good joystick. If necessary replace and recalibrate joystick
5 - 18 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV BCONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
LR STR ANG SNSR
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
RF STR ANG SNSR
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
Part No. 106783 Z-135/70 5 - 19
April 2008 Section 5 • Fault Codes
REV B CONTROL SYSTEM FAULT CODES
Error Source Error Type Effects Corrective Action
Value at 5.0 VCheck for an open ground circuit going to the sensor
Value too high
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value too low
Sensor is out of range check sensor and actuating pin for proper installation. Repair or replace sensor and recalibrate.
Value at 0,
Check for 5.0 VDC at the sensor. Check for damaged wiring going to the sensor. Check that the %.0 VDC LED is lit on the TCON board. Repair or replace as necessary.
LF STEER VALVE
RF STEER VALVE
LR STEER VALVE
RR STEER VALVE
fault check
Limited Speed and Direction frozen at zero and neutral, Alarm sounds.
Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary
RR STR ANG SNSR
Limited Speed and Direction frozen at zero and neutral, Alarm sounds
5 - 20 Z-135/70 Part No. 106783
April 2008Section 5 • Fault Codes
REV ASCON Fault Matrix
X = circuit power is turned off
P_3
8 –
Pro
pel
P_3
9 -
T
urnt
able
Rot
ate
P_1
0 –
Prim
ary
boom
ext
end
P_1
1 –
Prim
ary/
Sec
onda
ry
Up
P_3
0 –
Sec
onda
ry
Ext
end/
Dow
n
P_9
B –
Ig
nitio
n/F
uel
Turntable tilt Y axis (+5 degrees, sec boom not stowed) X X X X
Primary Boom Angle (crosscheck) X X X X X
Secondary Boom Angle (crosscheck) X X X X
Secondary Boom safety (not retracted & not raised) X X X
Axle Safety not stowed (not faulted primary & secondary stowed) X X X X
Axles crosscheck Angle sensor vs. safety switch X X X X
Axle (not fully extended) and Turntable Rotate (stowed and in drive disable zone) X X
Axle safety stowed (not faulted) X
Turntable Tilt Angle (crosscheck SCON internal sensors 3 in a delta configuration) X X X X X
Primary Boom Safety (max angle) X X X X X
Boom Not Stowed (not faulted) Loss of CAN X X X X X X
LSS1RS Disconnected (SCON pin #2) X X
Platform Overload (SCON pin #1) X
Secondary Boom Length (crosscheck LSS1RS and LSS1RO) X X X
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 1
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions printed in theGenie Z-135/70 Operator's Manual on yourmachine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Hydraulic Schematics
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
REV C
April 2008Section 6 • Schematics
6 - 2 Z-135/70 Part No. 106783
Circuit numbering1 Circuit numbers consist of three parts: the
circuit prefix, circuit number and circuit suffix.The circuit prefix indicates the type of circuit.The circuit number describes the function of thecircuit. The circuit suffix provides anabbreviation for the number or may be used tofurther define the function of this portion of thecircuit. It also may be used to indicate the finalend of the circuit, i.e., LS or limit sw.
2 The circuit number may be used more thanonce in a circuit.
For Example:
C 74 PL – This is the circuit for the lockoutvalve #1. C stands for control, 74 is the number ofthe circuit for the primary #1 lock out valve.PL stands for Primary Lockout.
S 62 BST – This is the circuit that communicatesto the onboard computers of the machine that theboom is fully stowed. S stands for safety, 62 is thenumber of the circuit for boom stowed and BSTstands for Boom Stowed.
P 48 LP – P stands for power. 48 is the circuitnumber for work lamps and LP stands for Lamp.
R 48 LP – R stands for relay. In this case it is thewire that feeds the relay coil for the work lamp. Allother numbers remain the same.
V61AXR – V stands for valve power. Number 61stands for axle retracted circuit; AXR stands forAxle retracted.
R46HN – R stands for Relay output, supplyingpower to the horn (HN). Number 46 is the circuitnumber for the horn.
Circuit prefixC.... Control
D.... Data
E .... Engine
G ... Gauges
N.... Neutral
P .... Power
R.... Relay Output
S .... Safety
V .... Valve
Circuit suffixDefinition suffixAC Generator GENAlternator Field AFAngle ANGAuxiliary Boom Valve ABVAuxiliary Forward Valve AFVAuxiliary Hydraulic Pump AHAuxiliary Platform Valve APVAuxiliary Reverse Valve ARVAuxiliary Steer/Drive Valve ASVAxle Extend Valve AXEAxle Oscillate AXOAxle Retract Valve AXRAxle Front Position FAPAxle Rear Position RAPBattery BATBoom Extended BEXBoom Stowed BSTBrake BRKBypass Valves BVCalibrate CALCAN Signal CANCAN Shield SHDCATS Module CATChain Break CNKData High DTHData Low DTLDrive Chassis Controller DCN
Wire Circuit Legend
REV C
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 3
Drive Enable DEDrive Enable Left DELDrive Enable Right DERElectrical Displacement Control EDCEnvelope Light ENVEngine Speed Select ESPEngine Status Lamp ESLEnvelope Lockout ENLExtend/Retract Lockout ERLFilter Restricted FLRFilter Switch FLTFlashing Beacon FBFloat Switch FSFoot switch Signal FTSForward FWDFuel Pump FPFuel Select (gas/LP) FLFuel Solenoid FSLFunction Enable FEGround Control TCNGround GNDHorn HRNHigh RPM HSHydraulic Generator HGIgnition IGNJib Bellcrank Down JBDJib Bellcrank Up JBUJib Sensor JBSJib Up/Down Control JUDJib Down JDJib Up/Down Flow Control JFCJib Select Valve JSVJib Up JUJib Extend/Retract Control JERJib Extend JBEJib Retract JBRJib Rotate Left (CCW) JRLJib Rotate Right (CW) JRRJoystick 5V DC Power JPWLamps LPSLeft Front LFLeft Front Steer Sensor LFSLeft Rear LRLeft Rear Steer Sensor LRSLimit Switch LSLift Speed Reduction LSRLoad Sensor LDSLockout LO
Low RPM LSLow fuel LOFMotor Shift (Speed) MSMulti Function Valve MFVPlatform Control PCNPrimary Ext/Ret Lockout PELPlatform Level Down PLDPlatform Level Flow Control PLFPlatform Level Up PLUPlatform Rotate Flow Control PRFPlatform Rotate Control PRCPlatform Rotate Left (CCW) PRLPlatform Rotate Right (CW) PRRPlatform Tilt Alarm PTAPlatform Tilt Sensor PTSPower PWRPower to Length Sensor PSLPressure Comp Enable PCEPressure Sender PSRPressure Switches PSPrimary Boom Angle Sensor PBSPrimary Boom Down PBDPrimary Boom Extend/Retract Lockout Valve PBLPrimary Boom Extend PBEPrimary Boom Extend/Retract Flow Control PERPrimary Boom Retract PBRPrimary Boom Up PBUPrimary Boom Up/Down Flow Control PUDPrimary Boom Extend/Retract Signal PLSPrimary Boom Up/Down Signal PESPrimary Lockout PLPropel Signal JPLProgram Setup Enable PSEPropel Lockout PLLProportional Valve PRVProximity Sensor PXSReceptacle RECRecovery RCVRetract Lockout RLReturn RETReverse REVRight Front RFRight Front Steer Sensor RFSRight Rear RRRight Rear Steer Sensor RRSRPM RPM
WIRE CIRCUIT LEGEND
REV C
April 2008Section 6 • Schematics
6 - 4 Z-135/70 Part No. 106783
Sec Boom Angle Sensor SBSSec Boom Elevated SBLSec Boom Down SBDSec Boom Extend SBESec Boom Extend/Retract Flow Control SERSec Boom Retract SBRSec Boom Up SBUSec Boom Up/Down Flow Control SUDSecondary Boom SBSecondary Boom Lockout Valve (extend) SLESecondary Boom Lockout Valve (riser down) SLDSensor SENSpare SPSpeed Sensor SSStart Aid (Glow Plug or choke) SAStarter STRSteer Control Signal STCSteering Valve (CW) SCWSteering Valve (CCW) SCCTemp Sender TSRTemp Switches TSTether TETTilt Alarm X axis TAXTilt Alarm Y axis TAYGround Control Panel TCNTurntable Rotate Flow Control TRFTurntable Rotate Right (CW) TRRTurntable Tilt Alarm TTATurntable Tilt Sensor TTSTest Switch TSW
WIRE CIRCUIT LEGEND
REV C
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 5
Wire Coloring1 All cylinder extension colors are solid and all
retract functions are striped black. When usingblack wire, the stripe shall be white.
2 All rotations that are LEFT or CW are solid,RIGHT or CCW are striped and black. When thewire is black, the stripe is white.
3 All proportional valve wiring is striped.
Wire Color LegendBL BlueBL/BK Blue/BlackBL/RD Blue/RedBL/WH Blue/WhiteBK BlackBK/RD Black/RedBK/WH Black/WhiteBK/YL Black/YellowBR BrownGR GreenGR/BK Green/BlackGR/WH Green/WhiteRD RedRD/BK Red/BlackRD/WH Red/WhiteOR OrangeOR/BK Orange/BlackOR/RD Orange/RedWH WhiteWH/BK White/BlackWH/RD White/Red
Color, Circuit #, and Primary functionRD 1 Primary boom up driver
RD/BK 2 Primary boom down driver
RD/WH 3 Primary boom up/down flow controlproportional valve driver
WH 4 Turntable rotate left valve driver
WH/BK 5 Turntable rotate right valve driver
WH/RD 6 Turntable rotate flow controlproportional valve driver
BK 7 Primary boom extend
BK/WH 8 Primary boom retract
BK/RD 9 Primary boom Extend/Retractproportional valve driver
BL 10 Secondary boom up valve driver
BL/BK 11 Secondary boom down valve driver
BL/WH 12 Secondary boom up/downflow control proportional valve driver
BL/RD 13 Drive enable
OR 14 Platform level up valve
OR/BK 15 Platform level down valve
OR/RD 16 Platform up/down flow controlproportional valve driver
GR 17 Platform rotate left valve driver
GR/BK 18 Platform rotate right valve driver
GR/WH 19 Jib select valve driver circuit
RD 20 12V DC battery supply
WH 21 12V DC ignition supply
BK 22 Key switch power to platform
WH 23 Power to platform
RD 24 Power to warning senders
WH/BK 25 Power to oil pressure sender
WH/RD 26 Power to temp sender
RD 27 Auxiliary Power
RD/BK 28 Platform level alarm
RD/WH 29 Drive Motor shift (speed)
WH 30 Forward/EDC-A
WH/BK 31 Reverse/EDC-B
WIRE CIRCUIT LEGEND
Power CircuitsP10 .... Primary boom extend valve
P11 .... Primary boom up valve
P30 .... Secondary boom down and extend valves
P38 .... Propel (drive) valves
P39 .... Turntable rotate flow control valve
REV C
April 2008Section 6 • Schematics
6 - 6 Z-135/70 Part No. 106783
WH/RD 32 Brake
BK 33 Start
BK/WH 34 Start Aid (glow plug or choke)
BK/RD 35 High Engine speed select
BL 36 Steer clockwise
BL/BK 37 Steer counterclockwise
BL/WH 38 Gasoline
BL/RD 39 LPG
OR 40 Limit switch signal stowed
OR/BK 41 RPM signal
OR/RD 42 Boom retracted signal
GR 43 Jib Up
GR/BK 44 Jib Down
GR/WH 45 AC Generator
WH 46 Horn
WH/BK 47 Output Power Enable
WH/RD 48 Work Lamp
WH/BK 49 Motion Lamp
BL 50 Auxiliary Boom
BL/WH 51 Auxiliary Steer
BL/RD 52 Auxiliary Platform
WH/BK 53 Boom envelope safety valve cutoff
BK/WH 54 Power to safety interlock switches(engine)
GR/BK 55 Axle oscillation
RD 56 Foot switch/TCON estop power
RD/WH 57 Boom down safety interlock
RD/BK 58 Safety interlock to engine
GR/WH 59 Chain break circuit
GR/WH 60 Axle extend
GR 61 Axle retract
OR 62 Boom stowed (safety)
OR/RD 63 Power to boom envelopesafety switch
WIRE CIRCUIT LEGEND
OR/BK 64 Power for operational switches
BL/WH 65 Low fuel indication
BL 66 Drive Enable
BL 67 Secondary boom not stowed
RD 68 Primary Boom lowered(operational)
BL 69 Primary boom #1 extended
BL/WH 70 Primary boom #2 retracted
BL/BK 71 Primary boom #2 extended
BL/WH 72 Secondary boom extended
BL/RD 73 Secondary boom retracted
RD 74 Primary #1 Lockout
RD/WH 75 Primary #2 Lockout
BL 76 Primary boom #3 extended
WH 77 Lower Angle #1 operational
WH/BK 78 Upper Angle #2 operational
BK 79 Power from TCON ESTOP
N/A 80 Can 2.0/J1939 Shield
GR 81 Can 2.0/J1939 Low
YL 82 Can 2.0/J1939 High
GR/WH 83 Tilt signal X axis
GR/BK 84 Tilt signal Y axis
GR 85 Tilt sensor power
OR 86 Hydraulic Filter restricted
RD 87 Platform Level Safety Power
RD/BK 88 Platform Level Safety Output
BR 89 Platform Level Safety Ground
RD/BK 90 Proximity Kill
RD/WH 91 Gate Interlock
WH/BK 92 Motor Speed (LO/HI)
WH/RD 93 Motor Bypass
WH 94 Load Sensor
OR 95 Tether ESTOP return
RD 96 Tether Power
REV C
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 7
BK 97 Tether ESTOP Power
WH 98 J1708 + (high)
BK 99 J1708- (low)
WH/RD 100 Outrigger lowered
WH/BK 101 Outrigger raised
OR 102 Pothole protector up
OR/RD 103 Pothole protector down
BK/WH 104 Proprietary Data buss -(I.e. ITT or AP)
BK/RD 105 Proprietary Data buss +(I.e. ITT or AP)
GR 106 Spare
RD 107 Alternator Field
BL/WH 108 Engine Status
GR/WH 109 Sensor Power
BK 110 Sensor Return
OR 111 Steer Signal
RD 112 Steer Signal to Solenoid Valve
OR/RD 113 Multi-function Valve
BK/RD 114 Load Moment Overweight
RD/BK 115 Load Moment Underweight
OR 116 Hydraulic Oil Cooler
RD 117 Flashing Beacon
OR 118 Lift Speed Reduction
BL 119 Hydraulic Pressure Sensor Output
OR 120 Oil Cooler Fan
GR 121 Axle Oscillate Left
GR/BK 122 Axle Oscillate Right
RD/BK 123 Primary Boom AngleSignal Operational
RD/WH 124 Secondary Boom AngleSignal Operational
WH/RD 125 Secondary Boom Lockout(Extend Enable)
WH/BK 126 Secondary Boom Lockout(Riser Down Enable)
GR 127 ECU Test Switch
OR/RD 128 Low Engine Speed
RD/BK 129 Descent Alarm
WH/RD 130 Travel Alarm
BL 131 Motion Alarm
GR 132 Platform Load Input
GR/WH 133 Platform Load Alarm
GR/BK 134 Key Switch power
BL/WH 135 Fuel Pump
RD 136 Power to Safety Module
RD/WH 137 Drive Power (P_38)
RD/BK 138 Primary Boom Up/SecondaryBoom Down-Extend (P_11/30)
WH/RD 139 Turntable Rotate Flow ControlSafety (P_39)
OR/RD 140 Boom Envelope Safety
RD 141 Primary Boom AngleSignal Safety
OR 142 Secondary Boom AngleSignal Safety
BL/RD 143 Drive Enable Left
BL/WH 144 Drive Enable Right
RD/WH 145 Calibrate
BL 146 Jib Bellcrank Up Flow Control
BL/BK 147 Jib Bellcrank Down Flow Control
BL/WH 148 Jib Bellcrank Sensor
GR/WH 149 Jib Up/Down Flow Control
GR/BK 150 Hydraulic Generator Bypass
GR 151 Hydraulic EDC Output
BK 152 Injector Retard
BK 153 Jib Extend
BK/WH 154 Jib Retract
OR/RD 155 Pressure Comp. Enable
GN/WH 156 Jib Up/Down
BK/RD 157 Jib Extend/Retract
BL/RD 158 Steer Signal Rocker
BL/WH 159 Steer Joystick Signal
WH/RD 160 Propel Joystick Signal
WH/BK 161 Secondary Boom Joystick Signal
OR 162 Joystick 5V DC power
BL/WH 163 Primary Extend/Retract Signal
RD/WH 164 Primary Up/Down Signal
WH/RD 165 TT Rotate Signal
WIRE CIRCUIT LEGEND
REV C
April 2008Section 6 • Schematics
6 - 8 Z-135/70 Part No. 106783
OR 166 Boom Length Signal Safety
OR/BK 167 Boom Length Signal Operational
BL/RD 168 Primary Boom HydraulicValve Lockout
GN 169 Envelope Active LED
WH/RD 170 Load Sense Relay Source
WH/BK 171 Load Sense Relay Sink
BL 172 UP/DN Flow Control Ground
BK 173 Ext/Ret Flow Control Ground
WH 174 Key Switch Power, Ground Position
WH/BK 175 Load Sensor Signal Operational
GN/WH 176 Secondary Extend/Retract FC
BL/RD 177 Extend/Retract Lockout
BK 178 Control Module Status Light
GN 179 Drive Power Relay
BK 180 Lift Power Relay
OR 181 48 Volt Alternator field (or Battery)
RD 182 24 Volt Battery
BL 183 Envelope or Load Sense Recovery
WH 184 Program setup Enable
WH 185 Encode A
BL 186 Encode B
BL 187 Bootstrap or Program Enable
GR 188 Safety cross check
BK 189 Data Receive
BK/WH 190 Data Transmit
WH/RD 191 Multi-Function Pressure Relief
WH/BK 192 Jib Rotate Left
WH/RD 193 Jib Rotate Right
WH/RD 194 Speed Select Input
OR/RD 195 Electric Brake Source
YL 196 2.5V Sensor Power
WH 197 Hour Meter
RD 198 +12V Sensor Power
WH/RD 199 Thermal Switch
BR N/A Ground or Return
WIRE CIRCUIT LEGEND
REV B
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 9
Limit Switches and Angle Sensors
Types of Limit SwitchesThere are two types of limit switches, found invarious locations throughout the machine:mechanical-type operational/safety switches androtation or angle sensors. As in aircraft, whichfeatures redundant safety systems, eachmechanical operational switch is backed up with aseparate, independently functioning safety switch.
The mechanical-type operational or safetyswitches are used to sense a positive displacementor movement of the limit switch actuator, or arm, asthe machine moves through its range of operationalfunctions. The rotation or angle sensors utilizeHall Effect technology and must be calibrated whenreplaced. Included in this group are envelope limitswitches which sense the extended length andangle of the booms and rotational position of theturntable.
For example, when the secondary boom is fullyraised and the operational sensor is activated, ittells the ECM at the ground controls to startextending the secondary boom.
Another example is the drive enable limit switch,which disables the drive function anytime the boomis rotated past the rear tires, indicated by the 'circle'end of the drive chassis.In some cases, the engine will be stopped if safetyparameters are exceeded.
Limit Switch and SensorNumberingLSP1RO Primary boom length retractedLSP1EO Primary boom length fully extendedLSS1RO Secondary boom fully retractedLSS1RS Secondary boom fully retracted,
safetyLSJ1RO Jib boom length fully retractedLST1O Drive enable, left directionLST2O Drive enable, right directionLST1S Drive enable safety, retracted axlesLSFA1ES Front axle fully retractedLSRA1ES Rear axle fully retractedRSP1AO Primary boom angle sensorRSP1AS Primary boom angle sensor, safetyRSJ1AO Jib boom angle sensorRSS1AO Secondary boom angle sensorRSS1AS Secondary boom angle sensor,
safetyRSFA1O Front axle postioning sensorRSRA1O Rear axle positioning sensorRSLF1SO Left front wheel positioning sensorRSRF1SO Right front wheel positioning sensorRSLR1SO Left rear wheel positioning sensorRSRR1SO Right rear wheel positioning sensor
RSLF1SO
RSRF1SO
RSFA1SO
LSFA1ES
LSS1RS
SECONDARYBOOM GROUND
CONTROLBOX
DRIVE CHASSISCONTROLLER
(DCON)
LST10
LST20 LST1S
SAFETYCONTROLLER
(SCON)
4 32 1
RSRA1SO
LSRA1ES
RSS1AS
RSLR1SO
RSRR1SO
LSP1RO
RSP1AORSP1AS
LSS1RO
RSS1AO
PRIMARY BOOM
LSP1EO
2
1
RSJ1AO
1
2
JIB
LSJ1ROPLATFORMCONTROL
BOX
PLATFORMANGLE
SENSOR
O OperationalS Safety
D DownA AngleL Load momentE ExtendR Retract
Numbering Legend
LS AX 1 R O
LS Limit switch
AX AxleB BoomT Turntable
Circuit number
REV B
April 2008Section 6 • Schematics
6 - 10 Z-135/70 Part No. 106783
LIMIT SWITCHES AND ANGLE SENSORS
Platform Angle Sensor: Measures the angle of theplatform. The range of measurement is +/- 20 degrees.The safety cutout is set at +/- 10 degrees from gravityand will disable the primary and secondary boom up/down functions and the platform level up/downfunctions.
Jib Bell Crank Angle Sensor: Measures the angle ofthe jib bell crank. The range of measurement is+ 60 / -70 degrees.
Safety Controller (SCON): Redundant dual axis tiltsensors measuring the X and Y tilt angles of theturntable. Also provides safety switch logic for functioncut-off. Alarm sounds at ±4.5 degrees.
LSFA1ES: Limit switch, Front Axle #1 Extended Safety.Prevents boom functions with the axles retracted.Switch closes when axles are fully extended.
LSRA1ES: Limit switch, Rear Axle #1 Extended Safety.Prevents boom functions with the axles retracted.Switch closes when axles are fully extended.
LST1O: Limit switch, Turntable #1 Operational.Activates the drive enable zone when the turntable isrotated in the left direction.
LST2O: Limit switch, Turntable #2 Operational.Activates the drive enable zone when the turntable isrotated in the right direction.
LST1S: Limit switch, Turntable #1 Safety. Prevents theturntable from rotating out past either rear tire whenaxles are retracted.
LSS1RO: Limit switch, Secondary Boom #1 RetractedOperational. NOHC when secondary boom is fullyretracted. Used to reduce turntable rotate speed whensecondary boom is extended and to disable secondaryboom down unitl fully retracted.
LSS1RS: Limit switch, Secondary Boom #1 RetractSafety Switch. Backup switch for LSS1RO. Used to cutcircuits P9B, P_11 and P_30.
LSJ1RO: Limit Switch, Jib Boom #1 RetractOperational. Switch is held closed when the jib boomfully retracted. Used to limit turntable rotate speed anddrive speed when jib boom is extended.
LSP1EO: Limit Switch, Primary Boom #1 ExtendOperational. Switch closes when the primary boom isfully extended. NOHC when fully extended.
LSP1RO: Limit Switch, Primary Boom #1 RetractOperational. Switch closes when the primary boom isextended. NCHO when fully retracted
RSP1AO: Rotary Sensor, Primary #1 AngleOperational. Provides operational primary boom anglepositioning relative to secondary boom angle.
RSP1AS: Rotary Sensor, Primary #1 Angle Safety.Provides safety primary boom angle positioningrelative to secondary boom angle.
RSJ1AO: Rotary Sensor, Jib #1 Angle Operational.Used to level jib bell crank relative to the primary,secondary and turntable angles.
RSS1AO: Rotary Sensor, Secondary #1 AngleOperational. Used to measure the angle of thesecondary boom. Lowers drive speed when elevated,sequences secondary boom up/extend anddown/retract.
RSS1AS: Rotary Sensor, Secondary #1 Angle Safety.Backup safety angle sensor for RSS1AO. Cuts power tocircuits P9B, P_11 and P_30 if the secondary boomdrifts down while still extended.
RSFA1O: Rotary Sensor, Front Axle #1 Operational.Provides front axle positioning information for adjustingsteering neutral setting during axle extension.
RSRA1O: Rotary Sensor, Rear Axle #1 Operational.Provides front axle positioning information for adjustingsteering neutral setting during axle extension.
RSLF1SO: Rotary Sensor, Left Front #1 SteerOperational. Provides wheel position informationduring steering. Master wheel in all steer modes exceptrear steer.
RSRF1SO: Rotary Sensor, Right Front #1 SteerOperational. Provides wheel position informationduring steering.
RSLR1SO: Rotary Sensor, Left Rear #1 SteerOperational. Provides wheel position informationduring steering. Master wheel for rear steer mode.
RSRR1SO: Rotary Sensor, Right Rear #1 SteerOperational. Provides wheel position informationduring steering.
REV B
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 11
Drive Chassis and Platform Controller Pin Legend
PIN NUMBERING FOR23 PIN
CONNECTORS
16 23
1 8
DCONDRIVE CHASSISCONTROLLER
J311 = GND-DCON - BR
2 = P21DCON - WH
3 = P53LS - WH/BK
4 = (UNUSED)
6 = C61AXRT - GR
5 = S56PRV - RD
7 = (UNUSED)
8 = (UNUSED)
9 = (UNUSED)
10 = (UNUSED)
12 = (UNUSED)
14 = (UNUSED)
16 = (UNUSED)
15 = (UNUSED)
13 = (UNUSED)
11 = (UNUSED)
17 = D81CAN(-) - GR
18 = D82CAN(+) - YL
19 = (UNUSED)
20 = C60FAP - GR/WH
21 = C60RAP - GR/WH
22 = (UNUSED)
23 = P61LSA - GR
DRIVE CHASSISCONTROLLER
J32
DCON
1 = VLVRET1 - BR
2 = V61AXRT - GR
3 = V60AXEX - GR/WH
4 = V29MS - RD/WH
6 = (UNUSED)
5 = (UNUSED)
7 = (UNUSED)
8 = V36RRS - BL
9 = V37RRS - BL/BK
10 = C111RRS - OR
12 = C111RFS - OR
14 = VLVRET2 - BR
16 = V36LRS - BL
15 = V32BRK - WH/RD
13 = C111LFS - OR
11 = C111LRS - OR
17 = V37LRS - BL/BK
18 = V36RFS - BL
19 = P110RT - BK
20 = P109ANG - GR/WH
21 = V37RFS - BL/BK
22 = V36LFS - BL
23 = V37LFS - BL/BK
J32WHITE23 PIN
CONNECTOR
J31BLACK23 PINCONNECTOR
PCONPLATFORM
CONTROLLER
J211 = GNDPCON - BR
2 = P52PCON - WH
3 = (UNUSED)
4 = S56PRV - RD
6 = (UNUSED)
5 = (UNUSED)
7 = P56PRV - RD/WH
8 = (UNUSED)
9 = (UNUSED)
10 = (UNUSED)
12 = (UNUSED)
14 = (UNUSED)
16 = C46HN - WH
15 = C47OUT - WH/BK
13 = (UNUSED)
11 = (UNUSED)
17 = D81CAN(-) - GR
18 = D82CAN(+) - YL
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = P23PCON - BK
J21BLACK23 PIN
CONNECTOR
J22WHITE35 PINCONNECTOR
PCONPLATFORM
CONTROLLER
J221 = VLVRET1 - BR
2 = V153JBE - BK
3 = V18PRR - GR/BK
4 = V17PRL - GR
6 = V44JD - GR/BK
5 = V43JU - GR
7 = V14PLU - OR
8 = V15PLD - OR/BK
9 = V154JBR - BK/WH
10 = R90PXS - RD/BK
12 = P110LDS - GR
14 = P109LDS - BK
16 = C64LS -OR/BK
15 = C88PTS - RD/BK
13 = C94LDS - WH
11 = C90PXS - RD/BK
17 = C56FTS - RD
18 = C154JBR - BK/WH
19 = P85RET - BR
20 = C84TAY - GR/BK
21 = P85PTS - GR
22 = P87RET - BR
23 = P87PTS - RD
24 = (UNUSED)
26 = (UNUSED)
28 = V146JBU - BL
27 = (UNUSED)
25 = (UNUSED)
29 = V147JBD - BL/BK
30 = P109JBS - GR/WH
31 = P110JBS - BK
32 = C148JBS - BL/WH
33 = (UNUSED)
34 = VLVRET2 - BR
35 = (UNUSED)
REV B
April 2008Section 6 • Schematics
6 - 12 Z-135/70 Part No. 106783
Safety Controller Pin Legend
PIN NUMBERING FOR12 PIN
CONNECTORS
7 12
6 1
SCONSAFETY
CONTROLLER
J1221 = P21DCON - WH
2 = C142SBS - OR
3 = C141PBS - RD
4 = C60AXEX - GR/WH
6 = S13DE - BL/RD
5 = S12SB - BL/WH
7 = P53LS - WH/BK
8 = S140ENL - OR/RD
9 = P54ENG - BK/WH
10 = P58LS - RD/BK
12 = C61AXRT - GR
11 = S56PRV - RD
SAFETYCONTROLLER
J121
SCON
1 = S132LDS - BL/WH
2 = S73SLE - BL/RD
3 = (UNUSED)
4 = C145CAL - RD/WH
6 = D82CAN (+) - YL
5 = (UNUSED)
7 = D81CAN (-) - GR
8 = S59CNBK - GR/WH
9 = S56PRV - RD
10 = S137PLL - RD/WH
12 = GNDSCON - BR
11 = S139TRF - WH/RD
J121GRAY
12 PINCONNECTOR
J122BLACK12 PINCONNECTOR
REV B
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 13
16
19
23
14
8
16
19
23
14
8
24
29
35
16
12
24
29
35
16
12
J14WHITE35 PIN
CONNECTOR
PIN NUMBERING FOR23 PIN
CONNECTORS
PIN NUMBERING FOR35 PIN
CONNECTORS
PIN NUMBERING FOR4 PIN
CONNECTOR
J12BLACK35 PIN
CONNECTOR
J13WHITE23 PIN
CONNECTOR
J11BLACK23 PIN
CONNECTOR
J154 PIN
CONNECTOR
TCONTURNTABLE
CONTROLLER
J151 = B1BAT - RD
2 = GND - BR
3 = GND - BR
4 = (UNUSED)
TCONTURNTABLE
CONTROLLER
J111 = GNDPCON - BR
2 = P52PCON - WH
3 = C46HN - WH
4 = C47OUT - WH/BK
6 = S56PRV - RD
5 = P23PCON - BK
7 = P56PRV - RD/WH
8 = (UNUSED)
9 = C117FB - RD
10 = (UNUSED)
12 = (UNUSED)
14 = (UNUSED)
16 = (UNUSED)
15 = (UNUSED)
13 = (UNUSED)
11 = C145CAL - RD/WH
17 = D81CAN(-) - GR
18 = D82CAN(+) - YL
19 = (UNUSED)
20 = (UNUSED)
21 = (UNUSED)
22 = (UNUSED)
23 = (UNUSED)
TCONTURNTABLE
CONTROLLER
J121 = GNDSCON - BR
2 = P21DCON - WH
3 = P53LS - WH/BK
4 = P54ENG - BK/WH
6 = P53LS - WH/BK
5 = S56PRV - RD
7 = P58LS - RD/BK
8 = S59CNBK - GR/WH
9 = S140ENL - OR/RD
10 = C61AXRT - GR
12 = (UNUSED)
14 = C65LOFL - BL/WH
16 = C73SBR - BL/RD
15 = C144DER - BL/WH
13 = C64LS - OR/BK
11 = (UNUSED)
17 = C67SBD - BL
18 = C64LS - OR/BK
19 = C70PBR - BL/WH
20 = C71PBE - BL/BK
21 = (UNUSED)
22 = (UNUSED)
26 = P109PSR - GR/WH
31 = (UNUSED)
32 = C123PBS - RD/BK
33 = C124SBS - OR/BK
34 = S140ENL - OR/RD
23 = (UNUSED)
24 = (UNUSED)
25 = SNSR GND - BR
27 = (UNUSED)
28 = C143DEL - BL/RD
29 = (UNUSED)
30 = (UNUSED)
35 = GND16 - BR
TCONTURNTABLE
CONTROLLER
J141 = VLVRET4 - BR
2 = V03PUD - RD/WH
3 = V09PER - BK/RD
4 = V06TRF - WH/RD
6 = V176SER - GR/WH
5 = V12SUD - BL/WH
7 = VO1PBU - RD
8 = V02PBD - RD/BK
9 = V07PBE - BK
10 = V08PBR - BK/WH
12 = V11SBD - BL/BK
14 = VLVRET5 - BR
16 = (UNUSED)
15 = (UNUSED)
13 = C49LP - WH/BK
11 = (UNUSED)
17 = VLVRET5 - BR
18 = VLVRET5 - BR
19 = V10SBU - BL
20 = V73SBR - GR/BK
21 = V72SBE - GR
22 = (UNUSED)
26 = V05TRR - WH/BK
31 = (UNUSED)
32 = C27AUX - RD
33 = (UNUSED)
34 = V155PSE - OR/RD
23 = (UNUSED)
24 = (UNUSED)
25 = V04TRL - WH
27 = VLVRET7 - BR
28 = (UNUSED)
29 = (UNUSED)
30 = VLVRET6 - BR
35 = V150HG - GR/BK
TCONTURNTABLE
CONTROLLER
J131 = (UNUSED)
2 = C35RPM - BK/RD
3 = C21IGN - WH
4 = C34SA - BK/WH
6 = (UNUSED)
5 = (UNUSED)
7 = C46HRN - WH
8 = (UNUSED)
9 = C33STR - BK
10 = C30EDC - WH
12 = C25PSR - WH/BK
14 = (UNUSED)
16 = (UNUSED)
15 = (UNUSED)
13 = C26TSR - WH/RD
11 = C31EDC - WH/BK
17 = S137PLL - RD/WH
18 = C41RPM - OR/BK
19 = S139TRF - WH/RD
20 = (UNUSED)
21 = (UNUSED)
22 = C45GEN - GR/WH
23 = (UNUSED)
24 29 35
1 6 12
16 19 23
1 4 8
32
41
3 2
4 1
STOP
00000
Turntable Controller Pin Legend
REV B
April 2008Section 6 • Schematics
6 - 14 Z-135/70 Part No. 106783
Engine Relay and Fuse Panel Legend
LABEL
F7
CB10
CR1
CR5
CR28
START RELAY
HORN RELAY
ENGINE RUN/ALT RELAY
FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CIRCUIT BREAKER, 20A, RPM SOLENOID
DESCRIPTION
CR17 HYDRAULIC OIL COOLER FAN RELAY
CR41 FLASHING BEACON RELAY
F22
F23
FUSE, 60A, GLOW PLUG
FUSE, 30A, ENG/STR/ALT
Cummins B3.3T
Cummins B4.5L
Perkins 804D-33TLABEL
F7
CB10
CR1
CR5
CR28
START RELAY
HORN RELAY
ENGINE / FUEL RELAY
FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CIRCUIT BREAKER, 20A, RPM SOLENOID
DESCRIPTION
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
CR41 FLASHING BEACON RELAY
F22
F23
FUSE, 60A, GLOW PLUG
FUSE, 30A, ENG/STR/ALT
Deutz TD2011L04iLABEL
F7
CB10
CR1
CR5
CR28
START RELAY
HORN RELAY
ENGINE / FUEL RELAY
FUSE, 20A, HYDRAULIC OIL COOLER FAN / HORN
CIRCUIT BREAKER, 20A, RPM SOLENOID
DESCRIPTION
CR15 GLOW PLUG RELAY
CR17 HYDRAULIC OIL COOLER FAN RELAY
CR41 FLASHING BEACON RELAY
F22
F23
FUSE, 60A, GLOW PLUG
FUSE, 30A, ENG/STR/ALT
R21PIGN
02PGND
1 2
5 6
3 4
7 8
F23
F7
CB10
F22
B1PBAT
B3PBAT
CR28
CR41
CR17
CR5 CR1 CR15
R21PIGN
02PGND
1 2
5 6
3 4
7 8
F23
F7
CB10
F22
B1PBAT
B3PBAT
CR28
CR41
CR17
CR5 CR1 CR15
R21PIGN
02PGND
1 2
5 6
3 4
7 8
F23
F7
CB10
F22
B1PBAT
B3PBAT
CR28
CR41
CR17
CR5 CR1
Deutz BF4L 2011
Perkins 1104C-44
REV A
Section 6 • SchematicsApril 2008
Part No. 106783 Z-135/70 6 - 15
Electrical Symbols Legend
Connectionno terminal
FB
Flashing beacon
Diode
Circuits crossingno connection
Quick disconnectterminal
BLK
WHT
Battery
+
-
Circuit breakerwith amperage
15A
CB1
Horn or alarm
H1
Emergency Stopbutton normally
closed
P1
Power relay
PR1
HM
Hour meter
N.O.OTS2
Oil temperatureswitch
normally open
N.O.CTS1
Coolant temperatureswitch
normally open
Oil pressure switchnormally closed
N.C.OPS1 BLK
FS1
Foot switch
PumpAux
Auxiliary pump
FAN
Hydraulic oilcooling fan
G1
Gauge
Tilt sensor
LED
L3
Limit switch
N.C.H.ON.O.H.C
LS3
Fusewith amperage
25A
F1
Starting aid:glow plug orflame ignitor
Control relay contactnormally open
CR4N.O.
Battery separator
MA
INA
UX
Coil
Fuel or RPMsolenoid
PU
LL
IN
HO
LD
CA B
Main key switch
A-A
B-A
A-B
B-B
2
2
4
4
1
1
3
3
OFF KS1MAIN
KEYSWITCHPCON
TCON
Service bypass/recovery
key switch
SERVICE BYPASS
RUN
A-A
A-B
B-B
C-B
C-A
B-A
2
2
2
4
4
4
1
1
1
3
3
3
RECOVERY
KS2
SERVICE BYPASS/
RECOVERY
KEY SWITCH
Sending unit
Current limitingdevice
Relay
85
87a
87
86 30
5 4
2 1
ALTERNATOR
D1ALTERNATOR
REGULATOR
BAT+
IND.
STA.
BAT-
EXCT
Starter motor
STARTER
Power relay
Steer sensor
BL
BK
RD
BA C
Chassis ground
Toggle switch
T-circuitsconnect
REV A
April 2008Section 6 • Schematics
6 - 16 Z-135/70 Part No. 106783
Hydraulic Symbols Legend
Pumpfixed displacement
Motorbi-directional
Shut off valve
Check valve
2 position, 3 way, shuttle valve
Double actingcylinder
Flow regulator valve
Solenoid operatedproportional valve
Hydraulic oil cooler
Brake
Pilot operated 3 position,3 way, shuttle valve
Filter withbypass valverelief setting
25 psi
Motor2-speed,
bi-directional
Pumpbi-directional,
variable displacement
Relief valvewith pressure setting
200 psi
Orifice with size
.035"
Solenoid operated 3 position,4 way, directional valve
Directional valvepilot operated
2 position, 2 way
Flow divider/combiner valvewith pressure balancing orifice
and flow percentages
50% 50%
Counterbalance valvewith pressure and pilot ratio
(206.8 bar)3000 psi
3:1
Solenoid operated 2 position,3 way, directional valve
2 position, 2 waysolenoid valve
E
Pump prime mover(engine or motor)
Pressure reducing valve
Pilot operatedcheck valve
Differentialsensing valve
Pumpvariable displacement
Motor
Pump stroke piston
Section 6 • Schematics April 2008
6 - 17
Electrical Schematic Layout
6 - 18
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 18 Z-135/70 Part No. 106783
Electrical Schematic Layout
DETAIL A PPERKINS 1104C ENGINE
TO SHEET 5J13 WHITE 23 PIN
ENGINE HARN
B1ENG-RD
ENGINE
BLOCK
ENGINE
BLOCK
-
+ BAT
GND-BR
AU
XH
YD
EN
GS
TA
RT
PC
ON
TR
OL
S
PB
AT
TE
RY
STA
RT
ER A
UX
HY
DP
UM
P
STA
RT
ER
RE
LA
Y
B1B2
PUMP
AUX.
R33STR-BK
PR1
C33STR-BK
F23
60A
20A
F20
F22
20A
F7
20A
B1ENG-RD
F7 OIL COOLERPF20 HI/LO COOLERPF22 GLOW PLUGPF23 ENG/ST/ALT
B1ENG-RD
C35RPM-BK/RD
CR1PSTARTERPRELAY30
86
8587
P35RPM-BK/RD
10A
1
2
J146 ENGINE HARN
ENGINEPHARNESS
F7
12-3 CABLE
S139TRF-WH/RD
S137PLL-RD/WH
WORKPLAMP
WORK LPPON/OFFPTOGGLEPSWITCH
MAIN
AUX
S139TRF-WH/RD
S137PLL-RD/WH
GND-BR
B2BAT-RD
GND-BR
SYS_BAT_PWR
SYS
BAT
GND
P1-01
J15 BLACK 4 PIN
POWER HARN
P1-02
P1-04
P1-03
BATECU
GND
CR17POILPCOOLERPRELAY
CR5PHORNPRELAY
30
J120
C27AUX-RD
FAN
ALTERNATOR
REGULATOR
BAT.
+
IND.
STA.
BAT.
-
EXCT.
GL
OW
PL
UG
SE
RV
ICE
PH
OR
N
ALT
ER
NA
TO
R
HO
RN
PR
EL
AY
HI/L
OS
PE
ED
PS
OL
EN
OID
GL
OW
PL
UG
PR
EL
AY
DU
AL
PC
OIL
PE
DC
H1
TO
J4
-32
PW
HIT
E3
5P
IN
BAT
GND-BR
AUX.
PUMP
PULL
IN
HOLD
DCA B
HY
DR
AU
LIC
PO
ILC
OO
LE
RF
AN
TE
MP
PS
W
CO
OL
ER
PR
EL
AY
WATER
TEMP
SENDER
OIL
PRESSURE
BAT
GND-BR
BAT
GND-BR
30
87a
R34SA-BK/WH
C31EDC-WH/BK
C30EDC-WH
VLVRET2-BR
R46HRN-WH
C41RPM-OR/BK
BATGND(A)
PR1
GND04-BR
GND04-BR
VLVRET-BR
1 2 3
BK
RD
WH
85
C107AF-RD
AUX+
GND- C
S-500
8787a
RD-HOLD
CR15PGLOWPPLUGPRELAY
WH-PULL
IN
J57
8587
86
C116HYD-OR
R116HYD-OR
OTS1PN.O.
8630
87a8785
C26TSR-WT/RD
C25PSR-WT/BK
B3BAT/14-RD
P34SA/10-BK/WHP34SA/10-BK/WH
86
BAT+
B
A
TIME DELAY
MOM N.O.
TROMBETTA
WH-PULL IN
RD-HOLD
B3BAT/14-RD
C34SA-BK/WH
B3BAT/14-RD
B3BAT/14-RD
C21IGN-WH
R21IGN-WH
R21IGN-WH
CR28PENG FUELPRELAY
C25PSR-WH/BK
C26TSR-WH/RD
C21IGN-WH
SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATOR
C41RPM-OR/BK
C31EDC-WH/BK
C25PSR-WH/BK
C26TSR-WH/RD
C35RPM-BK/RD
C34SA-BK/WH
S137PLL-RD/WH
C45GEN-GR/WH
C30EDC-WH
C33STR-BK
C46HRN-WH
C21IGN-WH
S139TRF-WH/RD
P_39
POWER
TO
TTROT
FC
P_38
PWR
TO
PROPEL
VALVE
RTN#3
CHOKE/GLOW
PLUG
RELAY
VALVE
RTN#1
SERVICE
HRN
STARTER
RELAY
AC
GENERATOR
TT_TILT_Y_AXIS
TT_TILT_X_AXIS
TT_TILT_SNSR_PWR
VALVE
RTN#2
ALTERNATOR
RPM
OIL_PRESSURE
TT_TILT_SNSR_GND
OIL/WATER_TEMP
P1-14
P1-01
P1-04
P1-05
P1-02
P1-03
P1-11
P1-12
P1-09
P1-10
P1-07
P1-06
P1-08
P1-13
FWD
PWM
THROTTLE
IGN/FUEL
LP
EDC
REV
EDC
FWD
REV
PWM
P1-23
P1-21
P1-19
P1-18
P1-16
P1-15
P1-22
P1-20
P1-17
LOWER LS PHARNESS
BAT
GND-BR
BAT
GND-BR
BAT
GND-BR
HOLD
CO
LD
STA
RT
AD
VA
NC
E
FU
EL
LIF
TP
UM
P
CR
2R
EL
AY
FU
EL
SH
UT
DO
WN
J56
FUEL
PUMP
SW28 = ENGINE CYLINDER HEAD TEMPERATURE
87a
85
87
86
30
R21IGN-WH
R21IGN-WH
GND-BR
4
BATGND(A)
R21IGN-WH
2
1
TO AUX HYD BATTERYPNEG TERM (B2)
B1ENG-RD B1ENG-RD
C45GEN-GR/WH
B2BAT-RD
J32-ENG HARN
B1ENG-RD
B1BAT-RD
B1BAT-RD
INTEGRA
B2BAT-RD
SEPARATEP4 GA WIRE
SEPARATEP4 GA WIRE
TWO 6 VOLTPBATTERIES
-
+
+
-
B1BAT-RD
B1BAT-RD
B1BAT-RD
POWERPHARN
ENGINEPHARNESS
DETAIL A CUMMINS ENGINE
GL
OW
PL
UG
PR
EL
AY
GR
IDH
EA
TE
R
R34SA/4-RD
VLVRET-BR
PR15PGRIDPHEATERPRELAY
WORK LPPON/OFFPTOGGLEPSWITCH
TO
J4
-32
PW
HIT
E3
5P
IN
DU
AL
PC
OIL
PE
DC
STA
RT
&P
EL
EC
TR
ON
ICS
BA
T
STA
RT
ER
RE
LA
Y
ALT
ER
NA
TO
R
AU
XH
YD
PU
MP
STA
RT
ER
HI/L
OS
PE
ED
PS
OL
EN
OID
HO
RN
PR
EL
AY
SE
RV
ICE
PH
OR
N
WATER
TEMP
SENDER
CO
OL
ER
PR
EL
AY
HY
DR
AU
LIC
PO
ILC
OO
LE
RF
AN
TE
MP
PS
W
FU
EL
SH
UT
DO
WN
CR
2R
EL
AY
OIL
PRESSURE
B3BAT/14-RDB3BAT/14-RD
P35RPM-BK/RD B1ENG-RD
WH-PULL
IN
C41RPM-OR/BK
R46HRN-WH
VLVRET2-BR
-
+
B2 B1
ALTERNATOR
REGULATOR
BAT.
+
IND.
STA.
BAT.
-
EXCT.
C27AUX-RD
BAT
GND-BR
AUX.
PUMP PUMP
AUX.
BAT
GND-BR
H1
BA
HOLD
PULL
IN
R33STR-BK
PR1
PR1
GND04-BR
GND04-BR
C30EDC-WH
WH
RD
BK
4
J57
321
S-500
A
CGND-
AUX+
C107AF-RD
RD-HOLD
BATGND(A)
CR5PHORNPRELAY
86
87a 8785
30
TIME DELAY
C35RPM-BK/RD
87a 8785
8630
CR1PSTARTERPRELAY
MOM N.O.
B
BAT+
TROMBETTA
P34SA/4-RD
RD-HOLD
B3BAT/14-RD
BATGND(A)
WH-PULL IN
P34SA/4-RD
2
20A
F7
SPARE
B1BAT-RD
B1BAT-RD
B2BAT-RD
B1BAT-RD
J146 ENGINE HARN
F7 OIL COOLERPF20 HI/LO COOLERPFXX NOT USEDPF23 ENG/ST/ALTB1ENG-RD
20A
F20
20A
F23
F7
10A
B1ENG-RD B1ENG-RD B1ENG-RD
12-3 CABLELOWER LS PHARNESSENGINEPHARNESS
1
MAIN
AUX
S137PLL-RD/WH
S139TRF-WH/RD
C33STR-BK
WORKPLAMP
C34SA-BK/WH
R116HYD-OR
C116HYD-OR
C31EDC-WH/BK
FAN
BAT
GND-BR
BAT
GND-BR
C D
J120
BAT
GND-BR
HOLD
OTS1PN.O.
J56
85 87 87a
3086
CR17POILPCOOLERPRELAY
C25PSR-WT/BK
C26TSR-WT/RD
C21IGN-WH
B3BAT/14-RD
R21IGN-WH
R21IGN-WH
R21IGN-WH
30
86
87
85
87a
CR28PENG FUELPRELAY
C21IGN-WH
B1ENG-RD
C26TSR-WH/RD
C25PSR-WH/BK
TO AUX HYD BATTERYPPOS TERM (B2)
TO AUX HYD BATTERYPNEG TERM (B2)
OIL/WATER_TEMP
TT_TILT_SNSR_GND
OIL_PRESSURE
ALTERNATOR
RPM
TT_TILT_SNSR_PWR
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC
GENERATOR
STARTER
RELAY
CHOKE/GLOW
PLUG
RELAY
P_38
PWR
TO
PROPEL
P_39
POWER
TO
TTROT
FC
S139TRF-WH/RD
C21IGN-WH
C46HRN-WH
C33STR-BK
C30EDC-WH
C45GEN-GR/WH
S137PLL-RD/WH
C34SA-BK/WH
C35RPM-BK/RD
C26TSR-WH/RD
C25PSR-WH/BK
C31EDC-WH/BK
C41RPM-OR/BK
S137PLL-RD/WH
S139TRF-WH/RD
J15 BLACK 4 PIN
POWER HARN
GND-BR
B2BAT-RD
GND-BR
REV
PWM
P1-06
IGN/FUEL
THROTTLE
FWD
PWM
VALVE
RTN#1
BATECU
GND
SYS
BAT
GND
SYS_BAT_PWR
P1-03
P1-04
P1-02
P1-01
P1-03
P1-02
P1-05
P1-04
P1-01
ENGINE HARN
J13 WHITE 23 PIN
EDC
FWD
EDC
REV
VALVE
RTN#2
SERVICE
HRN
VALVE
RTN#3
P1-15
P1-16
LP
P1-13
P1-08
P1-07
P1-10
P1-09
P1-12
P1-11
P1-14
P1-17
P1-20
P1-22
P1-18
P1-19
P1-21
P1-23
C45GEN-GR/WH
J32-ENG HARN
GND-BR
B2BAT-RD
SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATORPWELDMASTER
TO SHEET 5
275
A
F22
+
-
-
+
TWO 6 VOLTPBATTERIES
B2BAT-RD
B1BAT-RD
B1BAT-RD
SEPARATEP4 GA WIRE
INTEGRAPCABLE
POWERPHARN
POWERPHARN
AU
XH
YD
PB
AT
TE
RY
EN
GIN
EP
BL
OC
K
SEPARATEP4 GA WIRE
SEPARATEP4 GA WIRE
INTEGRAPCABLE
ENG HARN
AU
XH
YD
PU
MP
TO FLASHING BEACON
S56PRV-RD
GNDDCON-BR
P21DCON-WH
R117FB-RD
P56PRV-RD/WH
S56PRV-RD
C47OUT-WH/BK
C46HN-WH
P52PCON-WH
GNDPCON-BR
P23PCON-BK
D81CAN-
-GR
D82CAN+
-YL
P11-03
P11-02
P11-01
P11-04
P11-05
P11-08
P11-06
P11-07
HORN
RELAY
COIL
PCON
POWER
PCON
GND
TCON O
UT
PWR
ENBL
PWR-PCON
ESTOP
SPARE
P_22
P_7
P11-14
P11-09
P11-10
P11-11
P11-13
P11-12
P11-16
P11-15
P11-17
P11-19
P11-18
CAL
FREQ
1
FLASHING
BEACON
RLY
CAN
SHIELD
(1939-11)
NOT
USED
TET
ESTOP
PWR
CAL
FREQ
2
CAN
LOW
NOT
USED
CAN
HIGH
TET
ESTOP
RET
P11-20
P11-21
P11-22
P11-23
TETHER
FUNC
ENBL
DIAG/TETHER
GND
DIAG/TETHER
PWR
TO MICRO
BM
U/D
FC
O
PRIBM
RET
ST
I
AUX
HYD
O
MLT
FNC
VLV
O
BM
RET
O
BM
E/R
FC
O
BM
DWN
O
INS
ER
VO
RR
EC
OV
ER
YP
RO
VID
ES
PW
RT
OM
INIM
AL
HA
RD
WA
RE
P15
PL
DSERV.OR
OPER.REC.
OPTIONAL SWINGPGATE WIRING
FOOTSWITCH
ECU
PLAT
LEVEL
DN
(J81)
PLAT
LEVEL
UP
(J80)
PLAT
ROT
CW
(J76)
PLAT
ROT
CCW
(J77)
JIB
DWN
(J79)
JIB
UP(J78)
FOOTSW (FS1)
SWING GATE
INTERLOCK
LIMIT
SWITCH
PWR
P1-16
P1-15
P1-14
P1-13
P1-12
P1-10
P1-11
P1-09
P1-08
P1-07
P1-06
P1-05
P1-04
P1-03
P1-02
P1-01
V18PRR-GR/BK
VLVRET2-BR
V17PRL-GR
R90PXS-RD/BK
V15PLD-OR/BK
V44JD-GR/BK
V14PLU-OR
V43JU-GR
C88PTS-RD/BK
C90PXS-RD/BK
PLAT
ROT
CW
VLV
RTN
PLAT
ROT
CCW
JIB
UP
JIB
DWN
PLAT
LEVEL
UP
PLAT
LEVEL
DOWN
PROX
KILL
GND
SAFE
PL
TILT
OUT
PROX
KILL
CMD
P1-23
P1-21
P1-22
P1-19
P1-18
P1-17
P1-20
C84TAY-GR/BK
P85PTS-GR
P85RET-BR
P87PTS-RD
P87RET-BR
C23PTS-WH
C56PTS-RD
PL
TILT
SNSR
FOOT
SW
RTN
PL
TILT
SNSR
PWR
PL
TILT
SNSR
GND
SAFE
PL
TILT
PWR
SAFE
PL
TILT
GND
U20
J8
21 3 64 5 7 8
109 11
13
12
14
17
15
16
18
19
20
GND12-BR
ALARM+
RD/BK
ALARM
PCON
J128
PLAT
LVL
UP-OR
PLAT
LVL
DN-OR/BK
GND6-BR
JSGND4-BR
J127
1
C164PLS-RD/WH
C165TRS-WH/RD
P162JPW-OR
42 3 5 6
LEVEL
PLATFORM
C156JUD-GR/WH
P162JPW-OR
JSGND3-BR
JSGND2-BR
P162JPW-OR
J28
JSGND1-BR
C159STC-BL/WH
C160JPL-WH/RD
P162JPW-OR
C158STC-BL/RD
C161SB-WH/BK
J25
P21-03
P21-01
P21-02
P52PCON-WH
GNDPCON-BR
PCON
GND
PCON
PWR
P21-04
P21-05
P21-06
P21-07
P21-08
P21-09
P21-11
P21-10
P21-12
P21-13
P21-14
P21-15
P21-20
P21-16
P21-17
P21-18
P21-19
P21-22
P21-21
P21-23
S56PRV-RD
P56PRV-RD/WH
C47OUT-WT/BK
D81CAN-GR
D82CAN+
-YL
C46HN-WH
P23PCON-BK
P_7
P_22
OUT
PWR
ENBL
HRN
RLY
CNTRL
CAN
H
CAN
L
PWR-PCON
ESTOP
P1
MEMBRANE/LED INTERFACE CARD
J24A 10PIN
P1
P1
1 2
1 2 3
J23 10PIN
5
P1
P1
P1
3 4
P1
P1
6 7
P6
P7R
3
954 6 7 8
10
J24B 10PIN
P1
P1
8 9
10
P2
P2
P2
1 2
P2
P2
P2
4 5
P2
P2
6 7 8
P2
P2
109
PCON MEMBRANE PANEL (MS1)
HORN
ESTOP
RET-BK
ESTOP
PWR-RD
START
ASSIST
AC
GENERATOR
AUXILIARY
DRIVE
ENABLE
START
PCON
E-STOP (P2)
AXLE
RETRACT
SPARE
1
ENGINE
SPEED
DRIVE
SPEED
AXLE
EXTEND
FRONT
STEER
REAR
STEER
CRAB
STEER
COORD
STEER
SPARE
2
FUEL
TYPE
D81CAN- -GR
D82CAN+ -YL
P56PRV-RD/WH
GNDPCON-BR
P23PCON-BK
P52PCON-WH
S56PRV-RD
C46HN-WH
Y57-LR
STEER
RIGHT
(J93)
S11-RR
STEER
RIGHT
SNSR
Y2-BRAKE
RELEASE
(J106)
Y27-TWO
SPEED
MOTOR
STROKE
(J87)
BL
RD
BA
S14-LF
STEER
RIGHT
S13-RF
STEER
RIGHT
S12-LR
STEER
RIGHT
Y55-RR
STEER
RIGHT
(J91)
Y56-RR
STEER
LEFT
(J92)
C
BK
Y60-RF
STEER
LEFT
(J96)
Y61-LF
STEER
RIGHT
(J97)
Y62-LF
STEER
LEFT
(J98)
Y59-RF
STEER
RIGHT
(J95)
Y58-LR
STEER
LEFT
(J94)
V37LFS-BL/BK
V36LFS-BL
V37RFS-BL/BK
P109ANG-GR/WH
V32BRK-WH/RD
V36RFS-BL
V37LRS-BL/BK
V36LRS-BL
P110RT-BK
C111LFS-OR
C111RFS-OR
C111LRS-OR
C111RRS-OR
V37RRS-BL/BK
V36RRS-BL
VLVRET2-BRN
VLVRET1-BR
V29MS-RD/WH
SPARE
SPARE
MOTOR
SPEED
VALVE
RTN1
P32-03
P32-06
P32-05
P32-04
P32-02
P32-01
P32-07
LR
STEER
LEFT
P32-17
LR
STEER
RIGHT
VALVE
RTN2
LF
STEER
SNSR
BRAKE
RR
STEER
RIGHT
RR
STEER
LEFT
RR
STEER
SNSR
LR
STEER
SNSR
RF
STEER
SNSR
P32-10
P32-16
P32-15
P32-14
P32-12
P32-13
P32-11
P32-09
P32-08
LF
STEER
RIGHT
RF
STEER
LEFT
STEER
SNSR
PWR
(5.0
VDC)
STEER
SNSR
GND
LF
STEER
LEFT
P32-21
P32-23
P32-22
P32-19
P32-20
P32-18
RF
STEER
RIGHT
N EN7
D82CAN+
-YL
D81CAN-
-GR
C61AXRT-GR
S56PRV-RD
P53LS-WH/BK
P21DCON-WH
GND-DCON-BR
DCON
ECU
GND
AXLE
NOT
RET
RTN
DIGIN
AXLE
RET
GND
NOT
USED
P12
P_7R
P_6R1
DCON
ECU
PWR
P1-01
P1-02
P1-04
P1-05
P1-06
P1-07
P1-08
P1-09
P1-03
RS232
GND
P1-19
CAN
+
CAN
-
AXLE
NOT
EXT
SIG
BOOT
RS232
TXD
RS232
RXD
CAN
SHIELD
P1-11
P1-13
P1-12
P1-14
P1-15
P1-16
P1-17
P1-18
P1-10
AXLE
NOT
EXT
PWR
P1-20
P1-22
P1-23
P1-21
SPARE
J32 23 PIN WHITEPDRIVE CHASSISPHARNESS J31 23 PIN BLACKPDRIVE CHASSISPHARNESS
C154JBR-BK/WH
PLATFORM PTILT SENSORPASSEMBLY
LSP1PROXPPROXIMITYPKILL SWITCHP(NOHC)POPTIONAL
PIN CKT #P P2 RS232_RXDP3 RS232_TXDP5 RS232_GND
U30
+ -
5
+ -
+ -
21 3 4 6
PIN CKT #P P2 RS232_RXDP3 RS232_TXDP5 RS232_GND
ON CIRCUIT BOARDPDB9 CONNECTOR
J107 J108 J109 J110
J82
J119
J84
21
JIB
NOT
RETRACTED
1 2
P6 P6
P7R
P774HC08
SLP_MODE
1
2
3
5
46
P22
C45GEN-GR/WH
SJ3-WH
SJ2-WH/BK
S56PRV-RD
S56PRV-RD
SJ2-WH
P56PRV-RD
SJ3-WH
SJ3-WH
PRIANG
INPUT
SNSR
PWR
DCON
ECU
PWR
DCON
ECU
GND
OPER
SW
PWR
PRESSURE
GA
SNSR
GND
P12-04
P_6R2
P54ENG-BK/WH
P53LS-WH/BK
P21DCON-WH
GNDDCON-BR
P12-01
P12-02
P12-03
P_6R1
S56PRV-RD
C64LS-OR/BK
P_11
P12-06
P12-05
P12-07
P12-08
P_9A
P_7R
P_9B
P_10
P12-11
P12-09
P12-10
P12-12
P12-13
P_14
P_12
P_18
P1SEQ
P12-23
C64LS-OR/BK
C65LOF-BL/WH
C67SBD-BL
C71PBE-BL/BK
C70PBR-BL/WH
LSB2RO.
P12-18
P12-16
P12-14
P12-15
P12-17
LSS1RO
FST1S-LOW
FUEL
LST10DR
ENBL
R
LSP1AO
P12-20
P12-19
P12-21
P12-22
LSP1RO
LSP1EO
LSS2AO
LSS2EO
C143DEL-BL/RD
P109PSR-GR/WH
SNSR
GND-BR
P56PRV-RD
LST20DR
ENBL
L
P12-25
P12-24
P12-26
P12-27
P2
SEQ
P12-30
P12-29
P12-28
P12-32
P12-31
LSB14AO
LSB13AO
PCON POWER
U30
U31
U32
P_6R1
P_11
P_9A
P_22
P_7R
P_10
P_22
TO
MICRO
TO
PLD
TO
MICRO
TO
PLD TO
MICRO
TO
PLD
TO
MICRO
TO
MICRO
TO
PLD
TO HORN BUTTON
PWR TO TCON ESTOP
OUT PWR ENABLE
PRI BOOM LENGTH 100' STATUS
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
PRI BOOM RETRACTED STATUS
LOCKOUT VALVE #1 SIG
PRI BOOM LENGTH 3' STATUS
TO
PM
ICR
O
BATECU
GND
SYS
BAT
GND
SYS_BAT_PWR
SEC
ANG
INPUT
P12-35
P12-34
P12-33
VLV
RET
P_30
CB
20A
P_7R
P_10
U32
P_7
OIL/WATER_TEMP
TT_TILT_SNSR_GND
OIL_PRESSURE
ALTERNATOR
RPM
VALVE
RTN#2
TT_TILT_SNSR_PWR
TT_TILT_X_AXIS
TT_TILT_Y_AXIS
AC
GENERATOR
STARTER
RELAY
SERVICE
HRN
VALVE
RTN#1
CHOKE/GLOW
PLUG
RELAY
IGN/FUEL
THROTTLE
REV
PWM
FWD
PWM
EDC
FWD
EDC
REV
OUT PWR ENABLE
P_6R2
P_9B
TO MICRO
U95
P
TT
ROT
CW/CCW
F.C.(J69)
PRIBM
EXT/RET
F.C.(J61)
PRIBM
UP/DWN
F.C.(J58)
P P
SEC
EXT
VLV
(J65)
SEC
RET
VLV
(J66)
SEC
DWN
VLV
(J68)
SEC
UP
VLV
(J67)
SEC.BM
ER
F.C.(J64)
PRIRET
VLV
(J63)
PRIUP
VLV
(J59)
PRIEXT
VLV
(J62)
PRIDWN
VLV
(J60)
P
V06TRF-WH/RD
VLVRET4-BR
V03PUD-RD/WH
V09PER-BK/RD
V07PBE-BK
V02PBD-RD/BK
V01PBU-RD
VLVRET5-BR
V08PBR-BK/WH
C49LP
-WH/BK
V11SBD-BL/BK
V72SBE-BL/WH
V73SBR-BL/RD
V10SBU-BL
TT
ROT
CCW
VLV
(J71)
TT
ROT
CW
VLV
(J70)
C04TRL-WH
C05TRR
WH/BK
VLVRTN7-BR
VLVRTN6-BR
C27AUX-RD
PLTFRM
UP
TO
MICRO
P11
P6R1
P10
TO
MICRO
TO
MICRO
V06TRF-WH/RD
VLVRET4-BR
V03PUD-RD/WH
V09PER-BK/RD
VALVE_RTN4
PRIBM
E/R
FC
VLV
PRIBM
U/D
FC
VLV
TT
ROT
FC
VLV
P14-02
P14-01
P14-03
P14-04
VLVRET5-BR
V07PBE-BK
V09SER-BK/RD
V02PBD-RD/BK
V01PBU-RD
V11SBD-BL/BK
V08PBR-BK/WH
C49LP
-WH/BK
V10SBU-BL
V73SBR-BL/RD
V72SBE-BL/WH
VLVRET5-BR
VLVRET5-BR
VALVE_RTN5
P14-14
SEC_DWN_VLV
DRIVE
LIGHT
RELAY
PRI_DOWN_VLV
PRI_UP_VLV
PRI_EXTEND_VLV
PRI_RET_VALVE
P14-09
P14-07
P14-05
P14-06
P14-08
P14-10
P14-11
P14-13
P14-12
SEC_EXT_VLV
SEC_RET_VLV
SEC_UP_VLV
MULTI_FUNCT_VLV
HYD_FILTER1DI
HYD_FILTER2
DI
BOOM
REVERSE
LOAD
DI
BOOM
OVERLOAD
DI
P14-19
P14-16
P14-15
P14-17
P14-18
P14-21
P14-20
P14-22
P14-23
TO
PLD
TO
MICRO
TO
PLD
TO
MICRO
TO
PLD
TO
MICRO
TO
MICRO
TO
PLD
TO
MICRO
TO
PLD
BOOM DWN RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
J10
P_30
P_22R
P7R
SCRL
F/ENT
15
P10 14
13
START
STRT
ASST
SCROLL
R
10
11
12 9 8
+BUTTON
-BUTTON
ENG
SPEED
GAS/LP
TO
MICRO
37 6 5 4
BOOM
UP
AUXILIARY
SEC.UP
2
1
J11
P_30
14
P11
15 13
12
BOOM
EXT
BOOM
RET
BOOM
DOWN
SEC.DOWN
RABBIT
11
10 9 8 7
TURTLE
BOOM
CCW
PLTFRM
CCW
JIB
UP
TO
MICRO
PRESS
COMP
ENABLE
VLV
VLVRET7-BR
V04TRL-WH
V05TRR-WH/BK
VLVRET6-BR
C27AUX-RD
SPARE
P14-33
VALVE_RTN6
AUX_RELAY
VALVE_RTN7
ROTATE_CW_VLV
ROTATE_CCW_VLV
P14-28
P14-26
P14-25
P14-24
P14-27
P14-30
P14-29
P14-31
P14-32
P14-35
P14-34
TO
MICRO
TO
MICRO
TO
MICRO
TO
MICRO
TO
PLD
46 5 3 2
JIB
DOWN
PLTFRM
DOWN
PLTFRM
CW
BOOM
CW
1
TCON MEMBRANE PANEL
PCON POWER
P_9A
P_6R1
P_11
P_10
P_7R
P_22
P_7
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
TO HORN BUTTON
PWR TO TCON ESTOP
BOOM UP/DWN FC RECOVERY SIGNAL
P_30
74HC08
74HC08
74HC08
74HC08
U22
U21
GND
1412
13
8
10
9
6
5
4
3
1
2
P_1
P_7
P_7
P_7R
P7R
P22R
4
5
~SLP MODE (~SM)
AUX HYD (AH)(~SM)+(AH)
OUT PWR ENABLE (OE)
(OE)
((~SM)+(AH))(OE)
(SM
)+(A
H)
P_22
P_7
P_6R1
P_6R2
TCON MODE TCON MODE(TM)
FUNC ENABLE (FE)(TM)(FE)
V72SBE-BL/WH
V73SBR-BL/RD
V10SBU-BL
PCON POWER
P6R1
P11
P7R
TCON MODE
P_7
P7R
TCON MODE
P_7
PCON POWER
P6R1
P11
TO HORN BUTTON
OUT PWR ENABLE
PWR TO TCON ESTOP
PCON POWER
P6R1
P11
P9A
P7R
P10
BOOM STOWED
P_7
SEC
BM
E/R
FC
VLV
P21DCON-WH
S56PRV-RD
GNDDCON-BR
P_22
TCON MODE
P_7
ESTOP
PWR-RD/BK
ALARM+
RD/BK
GND12-BR
ESTOP
RET-BK
PLAT
LVL
DN-OR/BK
PLAT
LVL
UP-OR
GND6-BR
1 5432 9
10
14
12
131176 8
16
15
JSGND1-BR
P162JPW-OR
JSGND4-BR
P162JPW-OR
C165TRS-WH/RD
C164PLS-RD/WH
C163PES-BL/WH
C161SB-WH/BK
C158STC-BL/RD
C159STC-BL/WH
C160JPL-WH/RD
P162JPW-OR
JSGND3-BR
P162JPW-OR
JSGND2-BR
74HC08
Vbb BTS621
IN2
IN1OUT 1
ST OUT 2
Vbb
OUT
IS
IN
BTS650
Vbb
OUT
IN
IS
BTS650
Vbb
OUT
IN
IS
BTS650
Vbb
OUT
IN
IS
BTS650
GND
VbbBTS621
IN1
IN2
ST OUT 2
OUT 1
ST OUT 2
GND
Vbb
IN2
IN1
BTS621
OUT 1
P117FB-RD
GND-BR
7
14
74HC08 12V5V
GND
P15 P15
ECU POWER
(P15)+(ECU POWER) (P15)+(ECU POWER)
TO
HO
RN
BU
TT
ON
(P15)+(ECU POWER)
(P15)+(ECU
POWER)
S140ENL-OR/RD
C73SBR-BL/RD
P58LS
RD/BK
NO
BR
BK
RD
WH
21
NC
22
1314
2 1
LOAD
SNSR
PWR
LOAD
SNSR
GND
LOAD
SNSR
IN
J150B-3
J149B-1
J149B-2
J150B-1
J148B-1
J147B-1
J151B-B
J151B-A13
NO
14
WH
RD
BK
BR
4 3 2 1
NC
22 21
P_6R2
P22R
P_22R
P53LS-WH/BK
C56FTS-RD
C56FTS-RD
10
74HC08
BTS621
OUT 2
OUT 1
Vbb
IN1
IN2
ST
GND
89
BOOM
STOWED
P23PCON-BK
P56PRV-RD
S56PRV-RD/BK
SRV
REC-WH
P53LS-BK/WH
C47OUT
GR/BK
C47OUT
WH/BK
VIC
EO
RR
EC
OV
ER
YM
OD
E
OUTPUT
PWR
ENABLE
SERV.OR
OPER.REC.
PWR
TO
TCON
ESTOP-BL/BK
TCON
ESTOP-BL/WH
ON CIRCUIT BOARDPDB9 CONNECTOR
BL
15
ALARM
PWR
ALARM
GND
16 PRILO#1O
ECU
POWER
P7R
P6R1
P22
P7-GN/WH
P11
OPER.REC.
TCON
MODE
PCON
MODE
GR/WH
OR
RD/WH
OR/BK
5 468 7910
12
13
14
11 J17
123 BM
3'I
BM
100'I
TCON
ESTOP
P23PCON-BK
G-P
MODE
GR/BK
GROUND
TCON
MODE
P_7
PLAT-GR/WH
ALM
PWR-BL
ALM-GND-BR
2
S1PBU-OR
C47OUT
WH/BK
P_15-OR/BK
C47OUT
WH/BK
BL/BK
1
V
4
2
4
3 12
GROUNDW
1
WH/BK
12
B
PLAT
PLAT
OFF
GROUND
3
Z
12
A
PLAT
OFF
BL/WH
4
2
RECOVERY
SERV BYPASS
RUN
GROUNDX
3
Y
12
D
E
PLAT
OFF
OFF
GROUNDU
1
C
12
PLAT
OFF
OVERLOAD PLIMIT SWPLSP1OLS
NO
NC
RD
BOOM STOWED
((~SM)+(AH))(BM STOWED)
((~SM)+(AH))(P_22)
(SM)+(AH)
WH
GR
P110LDS-GR
C94LDS-WH
P109LDS-BK
V60AXEX-GR/WH
V61AXRT
-GR
AXLE
EXTEND
AXLE
RETRACT
13
NO
14
WH
NC
21
RD
BR
1 2
BK
22
14
NO
13
22
1 2
WH
BK
BR
RD
21
NC
BLP18BL
YL
GR
5 5
6 6
P6R1
88 P11
88
YL
GR
J37-DRIVE CHASSIS HARN
J38-DRIVE CHASSIS HARN
RD
OR
BR
22
4 4
3 3
1 1
P17
RDDCON PWR
88 P9A
88 P12
88
OR
BR
P RING
88
WH
BK
22
P18
11
CC
DCON GND88
P7R88
BK
WH
88
J36-DRIVE CHASSIS HARN
YEL
B BGRN
A
P16
ACAN HIGH
CAN LOW
88
88
YEL
GRN
P RING
55
66
P21DCON-WH
22
44
33
J35-LIMIT SW HARN
11
GNDDCON-BR
S56PRV-RD
J34-LIMIT SW HARN
2 2
1 1
CC
D82CAN+ -YL
D81CAN- -GR
J33-BOOM HARN
BB
AA
LS
RA
1E
SP
RE
AR
AX
LE
SE
NS
OR
PJ1
38
LS
FA
1E
SP
FR
ON
T
AX
LE
SE
NS
OR
PJ1
37
P61LSA-GR
P53LS-WH/BK
P21DCON-WH
GNDDCON-BR
S56PRV-RD
D82CAN+ -YL
D81CAN- -GR
FS
T1
SP
LO
WF
UE
LF
S
LS
P1
E0
P3
'FR
OM
FU
LLY
PE
XT
EN
DE
DP
J4
5
LS
P1
R0
P3
'EX
TP
J4
4
LS
T2
0P
DR
VE
NA
BL
EL
EF
TP
J4
8
PE
RP
J4
9
RD
BR
WH
BK
14
22
NC
13
21
NO
C64LS-OR/BK
C73SBR-BL/RD
C64LS-OR/BK
C65LOFL-BL/WH
BR
BK
RD
WH
RD
BK
WH
BR
NC
21
NO
13
22
14
1314
NO
NO
232414
22
13
NO
21
NC
LS
T1
0P
DR
VE
NA
BL
ER
IGH
TP
J4
8
BR
WH
BK
RD
C64LS-OR/BK
C144DER-BL/WH
FRONT
AXLE
POSITION
SENSOR
REAR
AXLE
POSITION
SENSOR
AXLE
RETRACT
AXLE
EXTEND
P12
P_7R
P_6R1
S15
FRT
AXLE
POS
1 2
BL
RD
3
BK
S16
REAR
AXLE
POS
PRIMARY BOOM UP/DOWN,PEXT/RET AND TURNTABLEPROTATE JOYSTICK (JC7)
JIB EXT/RET, UP/DOWNPPLAT ROT JOYSTICK (JC6)
SEC BM UP/DWNPEXT/RET JOYSTICKP(JC5)
DRIVE & STEERINGPJOYSTICK (JC3)
NOT
USED
NOT
USED
NOT
USED
NOT
USED
CAN
SHIELD
NOT
USED
NOT
USED
NOT
USED
NOT
USED
JIB
EXTEND
SERV/CAL
MODE
NOT
USED LP
VALVE
RTN#3
J14 WHITE 35 PINPMANIFOLD HARNESSJ12 BLACK 35 PINPLIMIT SWITCH HARNJ11 BLACK 23 PINPBOOM HARN
SEC
BM
U/D
FC
VLV
UNUSED
NOT
USED
NOT
USED
NOT
USED
NOT
USED
NOT
USED
JIB
RETRACT
NOT
USED
NOT
USED
NOT
USED
BOOT
NOT
USED
UNUSED
UNUSED
PROPEL
POWER
INPUT
HYD
WELDER
PROPEL
BYPASS
J22 35 PIN WHITEPPCON MANIFOLDPHARNESS J21 23 PIN BLACKPBOOM HARNESSPHARNESS
OUT PWR ENABLE
((~SM)+(AH))(P_7)
TO
MICRO
D82CAN+ -YL
D81CAN- -GR
D81CAN- -GR
D82CAN+ -YL
P_7R
P_7R
TO
MICRO
P_10
P_10
C60AXEX-GR/WH
C61AXRT-GR
C61AXRT-GR
C61AXRT-GR C61AXRT-GR C61AXRT-GR
S56PRV-RD
P56PRV-RD/WH
C46HN-WH
S139TRF-WH/RD
S137PLL-RD/WH
S140ENL-OR/RD
P_9B
D81CAN- -GR
D82CAN+ -YL
D81CAN- -GR
D82CAN+ -YL
P52PCON-WH
GNDPCON-BR
P23PCON-BK
BK
RD
S18-PRIBM
ANGLE
SAFETY
31 2 S20-SEC
BM
ANGLE
SAFETY
C60AXEX-GR/WHT C60AXEX-GR/WH C60AXEX-GR/WHT
S17-PRIBM
ANGLE
OPER
S19-SEC
BM
ANGLE
OPER
C124SBS-OR/BK
C123PBS-RD/BK
C123PBS-RD/BK
C124SBS-OR/BK
C141PBS-RD
P109PSR-GR/WH
P109PSR-GR/WH
SNSR
GND-BR
SNSR
GND-BR
SNSR
GND-BR
YEL
14
NO
13
BK
BR
RD
WH
22 21
NC
LS
S1
RS
P3
'EX
TP
J4
6
RED
NO
13
NC
14
WH
2122
BK
BR
RD
LS
T1
SP
DR
VE
NP
J1
26
C144DER-BL/WH
C67SBD-BL
C64LS-OR/BK
C71PBE-BL/BK
C64LS-OR/BK
C64LS-OR/BK
C64LS-OR/BK
C64LS-OR/BK
C70PBR-BL/WH
C64LS-OR/BK
C64LS-OR/BK
C64LS-OR/BK
TCON MODE
P53LS-WH/BK P53LS-WH/BK
P21DCON-WH
GNDDCON-BR
S56PRV-RD
P53LS-WH/BK
S13DE-BL/RD
TO
PM
ICR
O
TO
PM
ICR
O
TO
PM
ICR
O
TO
PM
ICR
O
C143DEL-BL/RD
C64LS-OR/BK
C64LS-OR/BK
S12SB-BL/WH
C163PES-BL/WH
C16PRL-OR/RD
C157JER-BK/RD
TO
MICRO
C145CAL-RD/WH
SEE OPTIONS SHEETPFOR BELT DRIVEN PAC GENERATORPWELDMASTER
TO
PM
ICR
O
TO
PM
ICR
OC45GEN-GR/WH
JIB
BELLCRANK
UP
(J135)
JIB
BELLCRANK
DOWN
(J136)
P109JBS-GR/WH
4
P
3
V146JBU-BL
S21JIB
BELLCRANK
SENSOR
RD
BL
BK
YL
OR
BR
6 5 4
BL
YL
BR
OR
RD
BL
BK
46 5321
P109PSR-GR/WH
P109PSR-GR/WH
SNSR
GND-BR
C142SBS-OR
4
BK
BL
RD
4321
A B C
BK
BL
RD
RD BL
BK
A B C
RD BL
BK
A B C
P53LS-WH/BK
D81CAN- -GR
S56PRV-RD
GNDDCON-BR
D82CAN+ -YL
P21DCON-WH
P53LS-WH/BK
V153JBE-BK
V154JBR-BK/WH
JIB
RETRACT
(J141)
JIB
EXTEND
(J140)
C64LS-OR/BK
C64LS-OR/BK
1 2 3
C154JBR-BK/WH
PLAT
ROT
GND JIB
EXT/RET
JIB
UP/DWN
GND
GND PLAT
LVL
UP
PLAT
LVL
DN
GND
OUT
PWR
ENBL
BOOT!
GND
GND
JIB
UP
JIB
DN
GND PLAT
ROT
L
PLAT
ROT
R
ALARM
PWR-PCN
ES
C1
57
JE
R-B
K/R
D
C1
56
JU
D-G
R/W
H
C1
6P
RL
-OR
/RD
4 3 2 112 1234
12 1234
4 3 2 14 3 2 1
P53LS-WH/BK
P54ENG-BK/WH
S139TRF-WH/RD
S137PLL-RD/WH
S59CNBK-GR/WH
C60AXEX-GR/WH
D81CAN-
-GR
GND-BR
P21DCON-WH
C142SBS-OR
S56PRV-RD
S56PRV-RD
D82CAN+
-YL
C141PBS-RD
C61AXRT-GR
S13DE-BL/RD
S12SB-BL/WH
P58LS-RD/BK
S73SLE-BL/RD
S140ENL-OR/RD
C60AXEX-GR/WHT
C61AXRT-GR
C60AXEX-GR/WHT
C61AXRT-GR
D82CAN+ -YL
D81CAN- -GR
S59CNBK-GR/WH
C70PBR-BL
C64LS-WH
C64LS-WH/BK
C71PBE-BL/BK
SNSR
GND-GR
SNSR
GND-BK
P109PSR-RD/BK
S64LS-OR
C141PBS-RD
C123PBS-GR/BK
11 12 2 10 7 6 9 4 8 3
P1-29
P1-24
P1-25
P1-26
P1-27
P1-28
P1-32
P1-30
P1-31
P1-34
P1-33
P1-35
NOT
USED
NOT
USED
NOT
USED
NOT
USED
JIB
BELLCRANK
LEVEL
UP
JIB
BELLCRANK
LEVEL
DOWN
JIB
SENSOR
POWER
JIB
SENSOR
GROUND
JIB
SENSOR
SIGNAL
JIB
ELEVATED
VALVE
RETURN
NOT
USED
V147JBD-BL/BK
P110JBS-BK
C148JBS-BL/WH
9 11 12 10 1 2 3 4 5 6
OR GR
GR/BK
OR/BK
RD
RD/BK
WH
WH/BK
BK
VLVRET1-BK/WH
C60RAP-GR/WH
C60FAP-GR/WH
P_39
P9A
S137PLL-RD/WH
V155PSE-OR/RD
V150HG
GR/BK
V150HG
GR/BK
WELDER
GEN
BYPASS
VLV
(Y75)
V155PSE
OR/RD
TO AUX HYDPPUMP RELAYS
FUNCTION
ENABLE
VALVE
(Y74)
J146 ENGINE HARN
LOWER LS PHARNESSENGINEPHARNESS
C21IGN-WH
C46HRN-WH
C34SA-BK/WH
C33STR-BK
C30EDC-WH
C35RPM-BK/RD
C26TSR-WH/RD
C25PSR-WH/BK
C31EDC-WH/BK
C41RPM-OR/BK
GND-BR
B1BAT-RD
GND-BR
D5 D3
DUETZ BF4L2011 PENGINE SHOWNPSEE: DETAIL A PFOR PERKINS PDETAIL BPFOR FORD
VLVRET-BR
R34SA-BK/WH
WH
RD
BK
ALTERNATOR
REGULATOR
BAT.
+
IND.
STA.
BAT.
-
EXCT.
HY
DR
AU
LIC
PO
ILC
OO
LE
RF
AN
FAN
CO
OL
ER
PR
EL
AY
GL
OW
PL
UG
PR
EL
AY
GL
OW
PL
UG
ENGINE
BLOCK
SE
RV
ICE
PH
OR
N
STA
RT
ER
RE
LA
Y
AU
XH
YD
PU
MP
HI/L
OS
PE
ED
PS
OL
EN
OID
ALT
ER
NA
TO
R
AU
XH
YD
PB
AT
TE
RY
STA
RT
BA
TP
EL
EC
TR
ON
ICS
BA
TT
ER
Y
STA
RT
ER
B2 B1
BAT
GND-BR
-
+
BAT
GND-BR
BAT
GND-BRH1
BAT
GND-BR
TO
J4
-32
PW
HIT
E3
5P
IN
HO
RN
PR
EL
AY
DU
AL
PC
OIL
PE
DC
TE
MP
PS
W
C27AUX-RD
AUX.
PUMP
PR1
D1J120
BA C D
HOLD
PULL
IN
FU
EL
SO
LE
NO
IDBAT
GND-BR
OIL
PRESSURE
OIL
TEMP
SENDER
D8
C21IGN-WH
B3BAT/14-RD
C35RPM-BK/RD
TROMBETTA
R33STR-BK
87
CR1PSTARTERPRELAY
85
8630
C107AF-RD
86
WH-PULL
IN
S-500
07GND-BR
C41RPM-OR/BK
R46HRN
WH
VLVRET2-BR
D2
C30EDC-WH
C31EDC-WH/BK
R116HYD-OR
C116HYD-OR
J57
GND04-BR
GND04-BR
321 OTS1PN.O.
CR15PGLOWPPLUGPRELAY
RD-HOLD
87a8785
30
CGND-
AUX+
A
87a 8785
8630
CR5PHORNPRELAY
B
BAT+
MOM N.O.
TIME DELAYRD-HOLD
85 87 87a
3086
CR17POILPCOOLERPRELAY
R21IGN-WH
F7 OIL COOLERPF20 HI/LO COOLERPF22 GLOW PLUGPF23 ENG/ST/ALT
B1ENG-RD
P35RPM-BK/RD
20A
F7
20A
F22
F20
20A
60A
F23
C34SA-BK/WH
P34SA-BK/WH
WH-PULL IN
P34SA-BK/WH
B3BAT/14-RD
C21IGN-WH
B1BAT-RD
B1ENG-RD B1ENG-RD B1ENG-RD
C26TSR-WH/RD
C25PSR-WH/BK
B1ENG-RD
C25PSR-WT/BK
C26TSR-WT/RD
D7
B1ENG-RD
CR23PDRIVE LPSPRELAY
87a 8785
8630
P1-03
P1-04
P1-02
POWER HARN
J15 BLACK 4 PIN
P1-01
P1-23
P1-13
P1-14
P1-17
P1-20
P1-22
P1-08
P1-03
P1-02
P1-06
P1-05
P1-04
P1-07
P1-10
P1-09
P1-01
ENGINE HARN
J13 WHITE 23 PIN
P1-12
P1-15
P1-16
P1-11
P1-18
P1-19
P1-21
PUMP
PR1
AUX.
J32-ENG HARN
10A
F7
WORK LPPON/OFFPTOGGLEPSWITCH
WORKPLAMP
(BM STOWED)
(~SM)+(AH)
V12SUD-BL/WH
V09SER-BK/RD
V12SUD-BL/WH
P
SEC.BM
UD
F.C.(J64)
TO MICRO
C33STR-BK
ENGINE
BLOCK
TO
MICRO
654321 1 2 3 4 5 6 654321
GN
D3
-BR
GN
D4
-BR
GN
D2
-BR
GN
D1
-BR
J7
GN
D1
-BR
GN
D2
-BR
GN
D4
-BR
GN
D3
-BR
J121-GR 12 PINPSCON MODULE J122-BK 12 PINPSCON MODULE
N MODULE
P122-10
P122-11
P122-12
P122-09
P122-04
P122-01
P122-02
P122-03
P122-07
P122-05
P122-06
P122-08
P121-05
P121-06
P121-07
P121-03
P121-04
P121-08
P121-09
P121-11
P121-10
P121-12
P121-01
P121-02
P39
P38
TD
RS232
DIG
IN
CAN-
CAN+
RD
232
CALIBRATION
IN
P10
P7R
P6R1
ECU
PWR
RSS1AS
RSP1AS
AXLE
EXTENDED
P7R
DRV.ENA.
GND
P9B
P11+P30
P6R2
SEC.BOOM
RET
P12
22 21
NO
1314
NC
BK
BR
RD
WH
BA
BB
AA
AB
BA
BB
AA
AB
BA
BB
C61AXRT-GR
AC
BC
J152B
J152A
BA
BC ACJ151B-C
BA
BB
BC
J148A-1
J147A-1
J149A-1
J149A-2
J150A-2
J150A-3
J151A-B
J151A-A
J150A-1
J151A-C
J148C-1
J147C-1
VLVRET2-BL
7
VLVRET3-BL/BK
8
J149
J147
VLVRET1-BR
BK
V155PSE
OR/RD
MANIFOLD HARNESS
ENGINE HARNESS
MANIFOLD HARNESS
ENGINE HARNESS
J153
J153
J129-01
C145CAL-RD/WHC145CAL-RD/WH
S139TRF-WH/RD
2
1
B3BAT/14-RD
B3BAT/14-RD
B1ENG-RD
SERV/CAL
MODE
P_38
PWR
TO
PROPEL
S139TRF-WH/RD
P_39
POWER
TO
TTROT
FC
P_39
J20
J114
J154
R117FB-RD R117FB-RD
30
85
86
87a 87
CR45PWORK LPPRELAY
J156
J155
J156
J155
P20BAT-RD
GND-BR
GND-BR
P48LPS-WH/RD
C49LP - WH/BK
WORKPLAMP
P12
B1ENG-RD
B1ENG-RD
S137PLL-RD/WH
B1BAT-RD
B1BAT-RD
B2BAT-RD
MAIN
AUX
B1BAT-RD
B1BAT-RD
INTEGRA
ENG HARN
INTEGRA
POWER HARN
SEPARATEP4 GA WIRE
SUPPLIEDPBY DEUTZ
SEPARATEP4 GA WIRE
+
-
-
+
TWO 6 VOLTPBATTERIES
VLVRET
BR
B1BAT-RD
J2-GR/BK
DIG
IN
C64LS-OR/BK
C64LS-OR/BK
C145CAL-RD/WH
S73SLE-BL/RD
S132LDS-BL/WH
J150A-4
C47OUT-WH/BKJ150B-2
C47OUT-WH/BK
S132LDS-BL/WHJ150B-4
S132LDS-BL/WH S132LDS-BL/WH
S132LDS-BL/WH
S132LDS-BL/WH
POWER
FET
PLAT
TILT
SNSR
10DEG
10DEG
POWER
FET
J55
0-20DEG
YAXIS
SAFETY
CUTOUT
LSJ1RO
JIB NOT
RETRACTED
(RETRACTED POS)
S132LDS-BL/WH S132LDS-BL/WH
J147
30
858787a
86
CR28PENG FUELPRELAY
C21IGN-WH
J129-02
J157-1
SEE ES0385PFOR HYD GENERATOR/PWELDER OPTION
View 14View 13
View 1
View 7 View 8 View 9 View 10View 11
View 12
View 2 View 3 View 4 View 5 View 6
REV A
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 19
Electrical Connector and Circuit Legend
White 35 pin AMP connector on TCONJ14
12 pin Deutsch connector lower/upper limit switch harnessJ20
10 pin ribbon conn. mem driver board to membrane switch
Black 23 pin AMP connector on PCON
J24A
6 pin Deutsch connector on drive/steer joystickJ25
J24B
J21
Black 4 pin DTP connector on PCONJ15
White 23 pin AMP connector on TCON
Black 35 pin AMP connector on TCON
Black 23 pin AMP connector on TCON
DescriptionConn No.
J13
J12
J11
4 pin Deutsch connector on LSS1RS
4 pin Deutsch connector on sec boom retract (LSS1RO)
J46
J49
3 pin Deutsch connector on RPM solenoidJ57
2 pin Deutsch connector for primary boom up valve
2 pin Deutsch connector for pri boom up/down flow control
J59
J58
6 pin Deutsch connector on platform tilt sensorJ55
DescriptionConn No.
2 pin Deutsch connector forright rear steer right valve
J91
DescriptionConn No.
4 pin Weatherpack EDC connectionJ120
DescriptionConn No.
Ribbon connector from TCON to membrane #1J9
Ribbon connector from TCON to membrane #2J10
16 pin Molex mini fit circuit board to key switchJ17
White 35 pin AMP connector on PCONJ22
10 pin ribbon connector PCON to membrane driver boardJ23
10 pin ribbon conn. mem driver board to membrane switch
6 pin Deutsch connector on secondary boom up/extendand down/retract joystick
J28
16 pin Molex mini fit circuit board to joystick and switchesJ29
Black 23 pin AMP connector on DCONJ31
White 23 pin AMP connector on DCONJ32
2 pin Deutsch connector for primary boom down valveJ60
2 pin Deutsch connector for primary boom ext/retflow control valve
J61
2 pin Deutsch connector for primary boom extend valveJ62
2 pin Deutsch connector for primary boom retract valveJ63
2 pin Deutsch connector for secondary boom extend valveJ65
2 pin Deutsch connector for secondary boom retract valveJ662 pin Deutsch connector for secondary boom up valveJ67
2 pin Deutsch connector for secondary boom down valveJ68
2 pin Deutsch connector for turntable rotate flow controlJ69
2 pin Deutsch connector for turntable rotate CW valveJ70
2 pin Deutsch connector for turntable rotate CCW valveJ71
2 pin Deutsch connector for jib boom up valveJ78
2 pin Deutsch connector for jib boom down valveJ79
2 pin Deutsch connector for prox killJ82
2 pin Deutsch connector for platform footswitchJ84
2 pin Deutsch connector for two-speed motor stroke valveJ87
2 pin Deutsch connector forright rear steer left valve
J92
2 pin Deutsch connector forleft rear steer right valve
J93
2 pin Deutsch connector forleft rear steer left valve
J94
2 pin Deutsch connector forright front steer right valve
J95
2 pin Deutsch connector forright front steer left valve
J96
2 pin Deutsch connector forleft front steer right valve
J97
2 pin Deutsch connector forleft front steer left valve
J98
2 pin Deutsch connector foraxle extend valve
J99
2 pin Deutsch connector foraxle retract valve
J100
2 pin Deutsch connector forbrake release valve
J106
3 pin Deutsch connector forright rear steer sensor
J107
3 pin Deutsch connector forleft rear steer sensor
J108
3 pin Deutsch connector forright front steer sensor
J109
3 pin Deutsch connector forleft front steer sensor
J110
6 pin Deutsch connector forprimary boom angle sensor (PBAS)
J114
2 pin Deutsch connector forjib not retracted
J119
12 pin Deutsch gray SCON connectorJ121
12 pin Deutsch black SCON connectorJ122
2 pin Deutsch connector fordrive enable right limit switch (LST1O)
J124
2 pin Deutsch connector fordrive enable left limit switch (LST2O)
J125
4 pin Deutsch connector for driveenable safety limit switch (LST1S)
J126
6 pin Deutsch connector for primary boomup/down, ext/ret and turntable joystick
J127
6 pin Deutsch connector for jib boomup/down, ext/ret and platform rotate
J128
2 pin Deutsch connector for boomcomposite/lower limit switch harness
J129
2 pin Deutsch connector for jib boombellcrank up
J135
2 pin Deutsch connector for jib boombellcrank down
J136
2 pin Deutsch connector for front axlesafety switch
J137
2 pin Deutsch connector for rear axlesafety switch
J138
2 pin Deutsch connector for jib extendJ140
2 pin Deutsch connector for jib retractJ141
2 way Deutsch connector for lower limitswitch harness/engine harness
J146
1 way Deutsch connector for platformpower jib/primary
J147
1 way Deutsch connector for platformground jib/primary
J148
2 pin Deutsch connector, boom compositeJ149
4 pin Deutsch connector, boom compositeJ150
3 pin Deutsch connector, CAN connector,jib/primary
J151
3 pin SAE Deutsch teeJ152
2 pin Deutsch connector for engine andmanifold harness
J153
6 pin Deutsch connector for secondaryboom angle sensor
J154
2 pin Deutsch connector for PCONmanifold/boom composite harness
J157
4 pin Deutsch connector for frontaxle angle sensor
J160
4 pin Deutsch connector for rearaxle angle sensor
J161
3 pin Deutsch connector for jibbellcrank angle sensor
J162
2 pin Deutsch connector for secondaryboom up/down flow control
J163
2 pin Deutsch connector for secondaryboom extend/retract flow control
J164
12 pin Deutsch connector located at PCONJ165
6 pin Deutsch connector for jibbellcrank sensor
J166
1 way 0.25 inch slide terminal for beltgenerator excite
J168
20 pin Molex connector for circuit boardto joystick and switches #2
J169
2 pin Deutsch connectorJ175
REV B
April 2008 Section 6 • Schematics
6 - 20
Electrical Connector and Circuit Legend
6 - 19
Section 6 • Schematics April 2008
6 - 21
Electrical Schematic - View 1Drive Chassis Controller (DCON)
6 - 22
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 22 Z-135/70 Part No. 106783
Electrical Schematic - View 1Drive Chassis Controller (DCON)
Continued on View 2
Continued on View 7
V3
7L
FS
-BL
/BK
V3
6L
FS
-BL
V3
7R
FS
-BL
/BK
P1
09
AN
G-G
R/W
H
V3
2B
RK
-WH
/RD
V3
6R
FS
-BL
V3
7L
RS
-BL
/BK
V3
6L
RS
-BL
P11
0R
T-B
K
C111
LF
S-O
R
C111
RF
S-O
R
C111
LR
S-O
R
C111
RR
S-O
R
V3
7R
RS
-BL
/BK
V3
6R
RS
-BL
VLV
RE
T2
-BR
N
VLV
RE
T1
-BR
V2
9M
S-R
D/W
H
SP
AR
E
SP
AR
E
MO
TO
RS
PE
ED
VA
LV
ER
TN
1
P3
2-0
3
P3
2-0
6
P3
2-0
5
P3
2-0
4
P3
2-0
2
P3
2-0
1
P3
2-0
7
LR
ST
EE
RL
EF
TP
32
-17
LR
ST
EE
RR
IGH
T
VA
LV
ER
TN
2
LF
ST
EE
RS
NS
R
BR
AK
E
RR
ST
EE
RR
IGH
T
RR
ST
EE
RL
EF
T
RR
ST
EE
RS
NS
R
LR
ST
EE
RS
NS
R
RF
ST
EE
RS
NS
R
P3
2-1
0
P3
2-1
6
P3
2-1
5
P3
2-1
4
P3
2-1
2
P3
2-1
3
P3
2-1
1
P3
2-0
9
P3
2-0
8
LF
ST
EE
RR
IGH
T
RF
ST
EE
RL
EF
T
ST
EE
RS
NS
RP
WR
(5.0
VD
C)
ST
EE
RS
NS
RG
ND
LF
ST
EE
RL
EF
T
P3
2-2
1
P3
2-2
3
P3
2-2
2
P3
2-1
9
P3
2-2
0
P3
2-1
8R
FS
TE
ER
RIG
HT
DCON EN7
D8
2C
AN
+-Y
L
D8
1C
AN
--G
R
C6
1A
XR
T-G
R
S5
6P
RV
-RD
P5
3L
S-W
H/B
K
P2
1D
CN
-WH
GN
D-D
CO
N-B
RD
CO
NE
CU
GN
D
AX
LE
NO
TR
ET
RT
N
DIG
INA
XL
ER
ET
GN
DN
OT
US
ED
P1
2
P_
7R
P_
6R
1
DC
ON
EC
UP
WR
P1
-01
P1
-02
P1
-04
P1
-05
P1
-06
P1
-07
P1
-08
P1
-09
P1
-03
RS
23
2G
ND
P1
-19
CA
N+
CA
N-
AX
LE
NO
TE
XT
SIG
BO
OT
RS
23
2T
XD
RS
23
2R
XD
CA
NS
HIE
LD
P1
-11
P1
-13
P1
-12
P1
-14
P1
-15
P1
-16
P1
-17
P1
-18
P1
-10
AX
LE
NO
TE
XT
PW
R
P1
-20
P1
-22
P1
-23
P1
-21
SP
AR
E
J32 23 PIN WHITEDRIVE CHASSISHARNESS
J31 23 PIN BLACKDRIVE CHASSISHARNESS
V6
0A
XE
X-G
R/W
H
V6
1A
XR
T-
GR
P6
1L
SA
-GR
FR
ON
TA
XL
EP
OS
ITIO
NS
EN
SO
R
RE
AR
AX
LE
PO
SIT
ION
SE
NS
OR
AX
LE
RE
TR
AC
T
AX
LE
EX
TE
ND
P12
P_7R
P_6R1
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
C6
0R
AP
-GR
/WH
C6
0F
AP
-GR
/WH
REV B
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 23
Electrical Schematic - View 2Platform Controls (PCON)
Continued on View 3
Continued onView 1
Continued on View 8
ECU
LIM
ITS
WIT
CH
PW
RP
1-1
6
P1
-15
P1
-14
P1
-13
P1
-12
P1
-10
P1
-11
P1
-09
P1
-08
P1
-07
P1
-06
P1
-05
P1
-04
P1
-03
P1
-02
P1
-01
V1
8P
RR
-GR
/BK
VLV
RE
T2
-BR
V1
7P
RL
-GR
R9
0P
XS
-RD
/BK
V1
5P
LD
-OR
/BK
V4
4JD
-GR
/BK
V1
4P
LU
-OR
V4
3JU
-GR
C8
8P
TS
-RD
/BK
C9
0P
XS
-RD
/BK
PL
AT
RO
TC
W
VLV
RT
N
PL
AT
RO
TC
CW
JIB
UP
JIB
DW
N
PL
AT
LE
VE
LU
P
PL
AT
LE
VE
LD
OW
N
SA
FE
PL
TIL
TO
UT
PR
OX
KIL
LC
MD
P1
-23
P1
-21
P1
-22
P1
-19
P1
-18
P1
-17
P1
-20
C8
4TA
Y-G
R/B
K
P8
5P
TS
-GR
P8
5R
ET
-BR
P8
7P
TS
-RD
P8
7R
ET
-BR
PL
TIL
TS
NS
R
FO
OT
SW
RT
N
PL
TIL
TS
NS
R P
WR
PL
TIL
TS
NS
R G
ND
SA
FE
PL
TIL
TP
WR
SA
FE
PL
TIL
TG
ND
U20
J169
21 3 64 5 7 8
109 11
13
12
14
17
15
16
18
19
20
GN
D1
2-B
R
AL
AR
M+
RD
/BK
PCONALARM
J128
PL
AT
LV
LU
P-O
R
PL
AT
LV
LD
N-O
R/B
K
GN
D6
-BR
JS
GN
D4
-BR
J127
1
C1
64
PL
S-R
D/W
H
C1
65
TR
S-W
H/R
D
P1
62
JP
W-O
R
42 3 5 6
PLATFORMLEVEL
C1
56
JU
D-G
R/W
H
P1
62
JP
W-O
R
JS
GN
D3
-BR
JS
GN
D2
-BR
P1
62
JP
W-O
R
J28
JS
GN
D1
-BR
C1
59
ST
C-B
L/W
H
C1
60
JP
L-W
H/R
D
P1
62
JP
W-O
R
C1
58
ST
C-B
L/R
D
C1
61
SB
-WH
/BK
J25
P2
1-0
3
P2
1-0
1
P2
1-0
2P
52
PC
ON
-WH
GN
DP
CO
N-B
RP
CO
N G
ND
PC
ON
PW
R
P2
1-0
4
P2
1-0
5
P2
1-0
6
P2
1-0
7
P2
1-0
8
P2
1-0
9
P2
1-1
1
P2
1-1
0
P2
1-1
2
P2
1-1
3
P2
1-1
4
P2
1-1
5
P2
1-2
0
P2
1-1
6
P2
1-1
7
P2
1-1
8
P2
1-1
9
P2
1-2
2
P2
1-2
1
P2
1-2
3
S5
6P
RV
-RD
P5
6P
RV
-RD
/WH
C4
7O
UT
-WT
/BK
D8
1C
AN
-GR
D8
2C
AN
+ -Y
L
C4
6H
N-W
H
P2
3P
CO
N-B
K
P_
7
P_
22
OU
TP
WR
EN
BL
HR
N R
LY
CN
TR
L
CA
N H
CA
N L
PW
R-P
CO
N E
ST
OP
P1
MEMBRANE/LED INTERFACE CARD
J24A 10PIN
P1
P1
1 2
1 2 3
J23 10PIN
5
P1
P1
P1
3 4
P1
P1
6 7
P6
P7R
3
954 6 7 8
10
J24B 10PIN
P1
P1
8 9 10
P2
P2
P2
1 2
P2
P2
P2
4 5
P2
P2
6 7 8
P2
P2
109
PCON MEMBRANE PANEL (MS1)
HO
RN
ES
TO
PR
ET
-BK
ES
TO
PP
WR
-RD
STA
RT
AS
SIS
T
AC
GE
NE
RA
TO
R
AU
XIL
IAR
Y
DR
IVE
EN
AB
LE
STA
RT
PCON EMERGENCYSTOP BUTTON
(P2)
AX
LE
RE
TR
AC
T
SP
AR
E 1
EN
GIN
E S
PE
ED
DR
IVE
SP
EE
D
AX
LE
EX
TE
ND
FR
ON
TS
TE
ER
RE
AR
ST
EE
R
CR
AB
ST
EE
R
CO
OR
D S
TE
ER
SP
AR
E 2
FU
EL
TY
PE
C1
54
JB
R-B
K/W
H
PIN CKT #2 RS232_RXD3 RS232_TXD5 RS232_GND
ON CIRCUIT BOARDDB9 CONNECTOR
JIB
NO
TR
ET
RA
CT
ED
P6 P6
P7R
P774HC08
SLP_MODE1
2
3
5
46
P22U22
U21
GND
ES
TO
PP
WR
-RD
AL
AR
M+
RD
/BK
GN
D1
2-B
R
ES
TO
PR
ET
-BK
PL
AT
LV
LD
N-O
R/B
K
PL
AT
LV
LU
P-O
R
GN
D6
-BR
1 5432 9
10
14
12
131176 8
16
15
JS
GN
D1
-BR
P1
62
JP
W-O
R
JS
GN
D4
-BR
P1
62
JP
W-O
R
C1
65
TR
S-W
H/R
D
C1
64
PL
S-R
D/W
H
C1
63
PE
S-B
L/W
H
C1
61
SB
-WH
/BK
C1
58
ST
C-B
L/R
D
C1
59
ST
C-B
L/W
H
C1
60
JP
L-W
H/R
D
P1
62
JP
W-O
R
JS
GN
D3
-BR
P1
62
JP
W-O
R
JS
GN
D2
-BR
74HC08
Vbb BTS621
IN2
IN1OUT 1
ST OUT 2
Vbb
OUT
IS
IN
BTS650
LO
AD
SN
SR
PW
R
LO
AD
SN
SR
GN
D
LO
AD
SN
SR
IN
C5
6F
TS
-RD
P11
0L
DS
-GR
C9
4L
DS
-WH
P1
09
LD
S-B
K
PRIMARY BOOM UP/DOWN,EXTEND/RETRACT AND
TURNTABLE ROTATE JOYSTICK (JC7)
JIB BOOM EXTEND/RETRACT,UP/DOWN AND PLATFORM ROTATE
JOYSTICK (JC6)
SECONDARY BOOM UP/DOWN ANDEXTEND/RETRACT JOYSTICK (JC5)
DUAL AXIS DRIVE ANDSTEER JOYSTICK (JC3)
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
CA
N S
HIE
LD
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
JIB
EX
TE
ND
JIB
RE
TR
AC
T
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
BO
OT
NO
TU
SE
D
J22 35 PIN WHITEMANIFOLDPHARNESS
J21 23 PIN BLACKBOOM HARNESS
C1
63
PE
S-B
L/W
H
C1
6P
RL
-OR
/RD
C1
57
JE
R-B
K/R
D
P1
09
JB
S-G
R/W
H
V1
46
JB
U-B
L
V1
53
JB
E-B
K
V1
54
JB
R-B
K/W
H
C6
4L
S-O
R/B
K
PL
AT
RO
T
GN
D
JIB
EX
T/R
ET
JIB
UP
/DW
N
GN
D
GN
D
PL
AT
LV
LU
P
PL
AT
LV
LD
N
GN
D
OU
TP
WR
EN
BL
BO
OT
!
GN
D
GN
D
JIB
UP
JIB
DN
GN
D
PL
AT
RO
TL
PL
AT
RO
TR
AL
AR
M
PW
R-P
CN
ES
C1
57
JE
R-B
K/R
D
C1
56
JU
D-G
R/W
H
C1
6P
RL
-OR
/RD
P1
-29
P1
-24
P1
-25
P1
-26
P1
-27
P1
-28
P1
-32
P1
-30
P1
-31
P1
-34
P1
-33
P1
-35
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
NO
TU
SE
D
JIB
BE
LL
CR
AN
K L
EV
EL
UP
JIB
BE
LL
CR
AN
K L
EV
EL
DO
WN
JIB
SE
NS
OR
PO
WE
R
JIB
SE
NS
OR
GR
OU
ND
JIB
SE
NS
OR
SIG
NA
L
JIB
EL
EV
AT
ED
VA
LV
E R
ET
UR
N
NO
TU
SE
D
V1
47
JB
D-B
L/B
K
P11
0JB
S-B
K
C1
48
JB
S-B
L/W
H
654321 1 2 3 4 5 6 654321
GN
D3
-BR
GN
D4
-BR
GN
D2
-BR
GN
D1
-BR
J29
GN
D1
-BR
GN
D2
-BR
GN
D4
-BR
GN
D3
-BR
VLV
RE
T1
-BR
TO TERM #86CR45WORK LIGHTRELAY
JS
GN
D1
-BR
C1
59
ST
C-B
L/W
H
C1
60
JP
L-W
H/R
D
P1
62
JP
W-O
R
C1
58
ST
C-B
L/R
D
J25
DRIVE JOYSTICK WITHSTEER ROCKER SWITCH (JC3)
654321
GN
D1
-BR
REV D
April 2008 Section 6 • Schematics
6 - 24
Electrical Schematic - View 2Platform Controls (PCON)
6 - 23
Section 6 • Schematics April 2008
6 - 25
Electrical Schematic - View 3Ground Controls (TCON)
6 - 26
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 26 Z-135/70 Part No. 106783
Electrical Schematic - View 3Ground Controls (TCON)
Continued on View 4Continued on View 2
Continued on View 9
TCON
BM
U/D
FC
O
PR
IB
MR
ET
ST
I
AU
XH
YD
O
MLT
FN
CV
LV
O
BM
RE
TO
BM
E/R
FC
O
BM
DW
NO
P1
5
PLD
PIN CKT #2 RS232_RXD3 RS232_TXD5 RS232_GND
U30
P_22
TO HORN BUTTON
PWR TO TCON ESTOP
OUT PWR ENABLE
PRI BOOM LENGTH 100' STATUS
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
PRI BOOM RETRACTED STATUS
LOCKOUT VALVE #1 SIG
PRI BOOM LENGTH 3' STATUS
PCON POWER
P6R1
P11
P7R
TCON MODE
P_7
P7R
TCON MODE
P_7
PCON POWER
P6R1
P11
TO HORN BUTTON
OUT PWR ENABLE
PWR TO TCON ESTOP
P_22
P15 P15
ECU POWER
(P15)+(ECU POWER)
P2
3P
CO
N-B
K
P5
6P
RV
-RD
S5
6P
RV
-RD
/BK
SR
VR
EC
-WH
P5
3L
S-B
K/W
H
C4
7O
UT
WH
/BK
C4
7O
UT
WH
/BK
SE
RV
ICE
OR
RE
CO
VE
RY
MO
DE
OU
TP
UT
PW
RE
NA
BL
E
SE
RV
.O
RO
PE
R.
RE
C.
PW
RT
OT
CO
NE
ST
OP
-BL
/BK
TC
ON
ES
TO
P-B
L/W
H
ON CIRCUIT BOARDDB9 CONNECTOR
BL
15
AL
AR
MP
WR
AL
AR
MG
ND
16
PR
IL
O#
1O
EC
UP
OW
ER
P7
R
P6
R1
P2
2
P7
-GN
/WH
P11
OP
ER
.R
EC
.
TC
ON
MO
DE
PC
ON
MO
DE
GR
/WH
RD
/WH
OR
/BK
5 468 7910
12
13
14
11 J17
123
BM
3'I
BM
10
0'I
EMERGENCY STOPBUTTON
P2
3P
CO
N-B
K
G-P
MO
DE
GR
/BK
GROUND
TC
ON
MO
DE
P_
7P
LA
T-G
R/W
H
AL
MP
WR
-BL
AL
M-G
ND
-BR
2
C4
7O
UT
WH
/BK
P_
15
-OR
/BK
C4
7O
UT
WH
/BK
BL
/BK
1
V
4
2
4
3 12
GROUNDW
1
WH
/BK
12
B
PLAT
PLAT
OFF
GROUND
3
Z
12
A
PLAT
OFF
BL/WH
4
2
RECOVERY
SERVICE BYPASS
RUN
GROUNDX
3
Y
12
D
E
PLAT
OFF
OFF
GROUNDU
1
C
12
PLAT
OFF
R11
7F
B-R
D
P5
6P
RV
-RD
/WH
S5
6P
RV
-RD
C4
7O
UT
-WH
/BK
C4
6H
N-W
H
P5
2P
CO
N-W
H
GN
DP
CO
N-B
R
P2
3P
CO
N-B
K
D8
1C
AN
--G
R
D8
2C
AN
+-Y
L
P11
-03
P11
-02
P11
-01
P11
-04
P11
-05
P11
-08
P11
-06
P11
-07
HO
RN
RE
LA
YC
OIL
PC
ON
PO
WE
R
PC
ON
GN
D
OU
TP
WR
EN
BL
PW
R-P
CO
NE
ST
OP
SP
AR
E
P_
22
P_
7
P11
-14
P11
-09
P11
-10
P11
-11
P11
-13
P11
-12
P11
-16
P11
-15
P11
-17
P11
-19
P11
-18
CA
LF
RE
Q1
FL
AS
HIN
GB
EA
CO
NR
LY
CA
NS
HIE
LD
(19
39
-11
)
NO
TU
SE
D
TE
TE
ST
OP
PW
R
CA
LF
RE
Q2
CA
NL
OW
NO
TU
SE
D
CA
NH
IGH
TE
TE
ST
OP
RE
T
P11
-20
P11
-21
P11
-22
P11
-23
TE
TH
ER
FU
NC
EN
BL
DIA
G/T
ET
HE
RG
ND
DIA
G/T
ET
HE
RP
WR
SE
RV
/CA
LM
OD
E
NO
TU
SE
D
J11 BLACK 23 PINBOOM HARNESS
C1
45
CA
L-R
D/W
H
TO MICRO
SE
RV
/CA
LM
OD
E
PA
NE
L
NO
NC
NO
PANEL
X3
U
NC2
Z
NO
3
3
RECOVERY
4
Y
4
NC
2
4
W
1
V2
1
1
2
B 1 E
1
2
NCNC
A
C
NC
NC
D NC
KEY SWITCH
PA
NE
L
2
1NC
ESTOP
INSTALL WIREJUMPER TOCALIBRATESENSORS
REV C
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 27
Electrical Schematic - View 4Ground Controls (TCON)
Continued on View 3 Continued on View 5
Continued on View 10
PR
IA
NG
INP
UT
SN
SR
PW
R
DC
ON
EC
UP
WR
DC
ON
EC
UG
ND
OP
ER
SW
PW
R
PR
ES
SU
RE
GA
SN
SR
GN
D
P1
2-0
4P
_6
R2
P5
4E
NG
-BK
/WH
P5
3L
S-W
H/B
K
P2
1D
CO
N-W
H
GN
DD
CO
N-B
RP
12
-01
P1
2-0
2
P1
2-0
3P
_6
R1
S5
6P
RV
-RD
C6
4L
S-O
R/B
K
P_
11
P1
2-0
6
P1
2-0
5
P1
2-0
7
P1
2-0
8
P_
9A
P_
7R
P_
9B
P_
10
P1
2-1
1
P1
2-0
9
P1
2-1
0
P1
2-1
2
P1
2-1
3
P_
14
P_
12
P_
18
P1
SE
QP
12
-23
C6
4L
S-O
R/B
K
C6
5L
OF
-BL
/WH
C6
7S
BD
-BL
C7
1P
BE
-BL
/BK
C7
0P
BR
-BL
/WH
LS
B2
RO.
P1
2-1
8
P1
2-1
6
P1
2-1
4
P1
2-1
5
P1
2-1
7
LS
S1
RO
FS
T1
S-L
OW
FU
EL
LS
T1
0D
RE
NB
LR
LS
P1
AO
P1
2-2
0
P1
2-1
9
P1
2-2
1
P1
2-2
2
LS
P1
RO
LS
P1
EO
LS
S2
AO
LS
S2
EO
C1
43
DE
L-B
L/R
D
P1
09
PS
R-G
R/W
H
SN
SR
GN
D-B
R
LS
T2
0D
RE
NB
LL
P1
2-2
5
P1
2-2
4
P1
2-2
6
P1
2-2
7
P2
SE
Q
P1
2-3
0
P1
2-2
9
P1
2-2
8
P1
2-3
2
P1
2-3
1
LS
B1
4A
O
LS
B1
3A
O
PCON POWER
U30 U31 U32
P_6R1
P_11
P_9A
P_7R
P_10
P_22
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
MIC
RO
TO
PL
D
TO HORN BUTTON
PWR TO TCON ESTOP
OUT PWR ENABLE
PRI BOOM LENGTH 100' STATUS
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
PRI BOOM RETRACTED STATUS
LOCKOUT VALVE #1 SIG
PRI BOOM LENGTH 3' STATUS
SE
CA
NG
INP
UT
P1
2-3
5
P1
2-3
4
P1
2-3
3
VLV
RE
T
P_
30
OUT PWR ENABLE
P_6R2
P_9B
P_22
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
TO HORN BUTTON
PWR TO TCON ESTOP
BOOM UP/DWN FC RECOVERY SIGNAL
P_30
PCON POWER
P6R1
P11
P7R
TCON MODE
P_7
PCON POWER
P6R1
P11
P9A
P7R
P10
BOOM STOWED
P_7
P_22
TCON MODE
P_7
(P15)+(ECU POWER) (P15)+(ECU POWER)
S1
40
EN
L-O
R/R
D
C7
3S
BR
-BL
/RD
P5
8L
SR
D/B
K
P5
3L
S-W
H/B
K
BO
OM
ST
OW
ED
J12 BLACK 35 PINLIMIT SWITCH HARNESS
OUT PWR ENABLE
S1
40
EN
L-O
R/R
D
P_9B
C1
24
SB
S-O
R/B
K
C1
23
PB
S-R
D/B
K
C1
44
DE
R-B
L/W
H
TCON MODE
S5
9C
NB
K-G
R/W
H
C6
1A
XR
-GR
REV B
April 2008 Section 6 • Schematics
6 - 28
Electrical Schematic - View 4Ground Controls (TCON)
6 - 27
Section 6 • Schematics April 2008
6 - 29
Electrical Schematic - View 5Ground Controls (TCON)
6 - 30
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 30 Z-135/70 Part No. 106783
Electrical Schematic - View 5Ground Controls (TCON)
Continued on View 6
Continuedon View 4
Continued on View 11
TO
MIC
RO
BA
TE
CU
GN
D
SY
SB
AT
GN
D
SY
S_
BA
T_
PW
R
CB20A
P_7R
P_10
U32
P_7
OIL
/WA
TE
R_
TE
MP
TT
_T
ILT
_S
NS
R_
GN
D
OIL
_P
RE
SS
UR
E
ALT
ER
NA
TO
RR
PM
VA
LV
ER
TN
#2
TT
_T
ILT
_S
NS
R_
PW
R
TT
_T
ILT
_X
_A
XIS
TT
_T
ILT
_Y
_A
XIS
AC
GE
NE
RA
TO
R
STA
RT
ER
RE
LA
Y
SE
RV
ICE
HR
N
VA
LV
ER
TN
#1
CH
OK
E/G
LO
WP
LU
GR
EL
AY
IGN
/FU
EL
TH
RO
TT
LE
RE
VP
WM
FW
DP
WM
ED
CF
WD
ED
CR
EV
OUT PWR ENABLE
P_6R2
P_9B
TO MICRO
U95
P11
P6R1
P10
BOOM DWN RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
P_30
P_22R
P7R
PCON POWER
P_9A
P_6R1
P_11
P_10
P_7R
P_22
P_7
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM DWN RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
TO HORN BUTTON
PWR TO TCON ESTOP
BOOM UP/DWN FC RECOVERY SIGNAL
P_30
74HC08
74HC08
74HC08
74HC08
1412
13
8
10
9
6
5
4
3
1
2
P_
1P
_7
P_
7
P_
7R
P7R
P22R
4
5
~SLP MODE (~SM)
AUX HYD (AH)(~SM)+(AH)
OUT PWR ENABLE (OE)
(OE)
((~SM)+(AH))(OE)
(SM
)+(A
H)
P_22
P_7
P_
6R
1
P_6R2
TCON MODE TCON MODE(TM)
FUNC ENABLE (FE)(TM)(FE)
Vbb
OUT
IN
IS
BTS650
Vbb
OUT
IN
IS
BTS650
Vbb
OUTIN
IS
BTS650
GND
VbbBTS621
IN1
IN2
STOUT 2
OUT 1
ST OUT 2
GND
Vbb
IN2
IN1
BTS621
OUT 1
7
14
74HC08 12V5V
GND
(P15)+(ECU POWER)
TO
HO
RN
BU
TT
ON
(P15)+(ECU POWER)
(P1
5)+
(EC
UP
OW
ER
)
P_
6R
2
P22R
P_22R
10
74HC08
BTS621
OUT 2
OUT 1
Vbb
IN1
IN2
ST
GND
89
BOOM STOWED
((~SM)+(AH))(BM STOWED)
((~SM)+(AH))(P_22)
(SM)+(AH)
LP
VA
LV
ER
TN
#3
((~SM)+(AH))(P_7)
P_7R
P_
7R
P_10
P_
10
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
C4
5G
EN
-GR
/WH
P_39
P9A
S1
37
PL
L-R
D/W
H
C2
1IG
N-W
H
C4
6H
RN
-WH
C3
4S
A-B
K/W
H
C3
3S
TR
-BK
C3
0E
DC
-WH
C3
5R
PM
-BK
/RD
C2
6T
SR
-WH
/RD
C2
5P
SR
-WH
/BK
C3
1E
DC
-WH
/BK
C4
1R
PM
-OR
/BK
GN
D-B
R
B1
BA
T-R
D
GN
D-B
R
P1
-03
P1
-04
P1
-02
J15 BLACK 4 PINPOWER HARNESS
P1
-01
P1
-23
P1
-13
P1
-14
P1
-17
P1
-20
P1
-22
P1
-08
P1
-03
P1
-02
P1
-06
P1
-05
P1
-04
P1
-07
P1
-10
P1
-09
P1
-01
J13 WHITE 23 PINENGINE HARNESS
P1
-12
P1
-15
P1
-16
P1
-11
P1
-18
P1
-19
P1
-21
(BM STOWED)
(~SM)+(AH)
P_
38
PW
RT
OP
RO
PE
L
S1
39
TR
F-W
H/R
DP
_3
9P
OW
ER
TO
TT
RO
TF
C
P_39
REV A
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 31
Electrical Schematic - View 6Ground Controls (TCON)
Continued on View 5
PLT
FR
MU
P
TO
MIC
RO
P11
P6R1
P10
TO
MIC
RO
TO
MIC
RO
V0
6T
RF
-WH
/RD
VLV
RE
T4
-BR
V0
3P
UD
-RD
/WH
V0
9P
ER
-BK
/RD
VA
LV
E_
RT
N4
PR
IB
ME
/RF
CV
LV
PR
IB
MU
/DF
CV
LV
TT
RO
TF
CV
LV
P1
4-0
2
P1
4-0
1
P1
4-0
3
P1
4-0
4
VLV
RE
T5
-BR
V0
7P
BE
-BK
V1
76
SE
R-G
R/W
H
V0
2P
BD
-RD
/BK
V0
1P
BU
-RD
V11
SB
D-B
L/B
K
V0
8P
BR
-BK
/WH
C4
9L
P-
WH
/BK
VLV
RE
T5
-BR
VLV
RE
T5
-BR
VA
LV
E_
RT
N5
P1
4-1
4
SE
C_
DW
N_
VLV
DR
IVE
LIG
HT
RE
LA
Y
PR
I_D
OW
N_
VLV
PR
I_U
P_
VLV
PR
I_E
XT
EN
D_
VLV
PR
I_R
ET
_V
ALV
E
P1
4-0
9
P1
4-0
7
P1
4-0
5
P1
4-0
6
P1
4-0
8
P1
4-1
0
P1
4-1
1
P1
4-1
3
P1
4-1
2
SE
C_
EX
T_
VLV
SE
C_
RE
T_
VLV
SE
C_
UP
_V
LV
MU
LT
I_F
UN
CT
_V
LV
HY
D_
FIL
TE
R1
DI
HY
D_
FIL
TE
R2
DI
BO
OM
RE
VE
RS
EL
OA
DD
I
BO
OM
OV
ER
LO
AD
DI
P1
4-1
9
P1
4-1
6
P1
4-1
5
P1
4-1
7
P1
4-1
8
P1
4-2
1
P1
4-2
0
P1
4-2
2
P1
4-2
3
TO
PL
D
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
MIC
RO
TO
PL
D
TO
MIC
RO
TO
PL
D
BOOM DWN RECOVERY SIGNAL
AUXILIARY HYD RECOVERY SIGNAL
BOOM RET RECOVERY SIGNAL
MULTI FUNCTION VLV RECOVERY SIGNAL
BOOM EXT/RET FC RECOVERY SIGNAL
BOOM UP/DWN FC RECOVERY SIGNAL
J10
P_30
P_22R
P7R
SC
RL
F/E
NT
15
P10
14
13
STA
RT
ST
RT
AS
ST
SC
RO
LL
R
1011
12 9 8
+B
UT
TO
N
-B
UT
TO
N
EN
GS
PE
ED
GA
S/L
P
TO
MIC
RO
37 6 5 4
BO
OM
UP
AU
XIL
IAR
Y
SE
C.
UP
2 1
J9
P_30
14P9
15
13
12
BO
OM
EX
T
BO
OM
RE
T
BO
OM
DO
WN
SE
C.
DO
WN
RA
BB
IT
11
10 9 8 7
TU
RT
LE
BO
OM
CC
W
PLT
FR
MC
CW
JIB
UP
TO
MIC
RO
PR
ES
SC
OM
PE
NA
BL
EV
LV
VLV
RE
T7
-BR
V0
4T
RL
-WH
V0
5T
RR
-WH
/BK
VLV
RE
T6
-BR
C2
7A
UX
-RD
SP
AR
EP
14
-33
VA
LV
E_
RT
N6
AU
X_
RE
LA
Y
VA
LV
E_
RT
N7
RO
TA
TE
_C
W_
VLV
RO
TA
TE
_C
CW
_V
LV
P1
4-2
8
P1
4-2
6
P1
4-2
5
P1
4-2
4
P1
4-2
7
P1
4-3
0
P1
4-2
9
P1
4-3
1
P1
4-3
2
P1
4-3
5
P1
4-3
4
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
TO
PL
D
46 5 3 2
JIB
DO
WN
PLT
FR
MD
OW
N
PLT
FR
MC
W
BO
OM
CW
1
TCON MEMBRANE PANEL
V7
2S
BE
-GR
V7
3S
BR
-GR
/BK
V1
0S
BU
-BL
SE
CB
ME
/RF
CV
LV
J14 WHITE 35 PINMANIFOLD HARNESS
SE
CB
MU
/DF
CV
LV
UN
US
ED
UN
US
ED
UN
US
ED
PR
OP
EL
PO
WE
RIN
PU
T
HY
DW
EL
DE
RP
RO
PE
LB
YP
AS
S
TO
MIC
RO
TO
MIC
RO
TO
MIC
RO
P_39
P9A
V1
55
PS
E-O
R/R
D
V1
50
HG
GR
/BK
V1
2S
UD
-BL
/WH
TO
MIC
RO
Continued on View 12
TO
MIC
RO
REV C
April 2008 Section 6 • Schematics
6 - 32
Electrical Schematic - View 6Ground Controls (TCON)
6 - 31
Section 6 • Schematics April 2008
6 - 33
Electrical Schematic - View 7
6 - 34
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 34 Z-135/70 Part No. 106783
Electrical Schematic - View 7
Continued on View 8
Continued on View 1
Y5
7-L
RS
TE
ER
RIG
HT
(J9
3)
S11
-RR
ST
EE
RR
IGH
TS
NS
R
Y2
-BR
AK
ER
EL
EA
SE
(J1
06
)
Y2
7-T
WO
SP
EE
DM
OT
OR
ST
RO
KE
(J8
7)
BL
RD
BA
S1
4-L
FS
TE
ER
RIG
HT
S1
3-R
FS
TE
ER
RIG
HT
S1
2-L
RS
TE
ER
RIG
HT
Y5
5-R
RS
TE
ER
RIG
HT
(J9
1)
Y5
6-R
RS
TE
ER
LE
FT
(J9
2)
C
BK
Y6
0-R
FS
TE
ER
LE
FT
(J9
6)
Y6
1-L
FS
TE
ER
RIG
HT
(J9
7)
Y6
2-L
FS
TE
ER
LE
FT
(J9
8)
Y5
9-R
FS
TE
ER
RIG
HT
(J9
5)
Y5
8-L
RS
TE
ER
LE
FT
(J9
4)
V3
7L
FS
-BL
/BK
V3
6L
FS
-BL
V3
7R
FS
-BL
/BK
P1
09
AN
G-G
R/W
H
V3
2B
RK
-WH
/RD
V3
6R
FS
-BL
V3
7L
RS
-BL
/BK
V3
6L
RS
-BL
P11
0R
T-B
K
C111
LF
S-O
R
C111
RF
S-O
R
C111
LR
S-O
R
C111
RR
S-O
R
V3
7R
RS
-BL
/BK
V3
6R
RS
-BL
VLV
RE
T2
-BR
N
VLV
RE
T1
-BR
V2
9M
S-R
D/W
H
P3
2-0
3
P3
2-0
6
P3
2-0
5
P3
2-0
4
P3
2-0
2
P3
2-0
1
P3
2-0
7
P3
2-1
7
P3
2-1
0
P3
2-1
6
P3
2-1
5
P3
2-1
4
P3
2-1
2
P3
2-1
3
P3
2-1
1
P3
2-0
9
P3
2-0
8
P3
2-2
1
P3
2-2
3
P3
2-2
2
P3
2-1
9
P3
2-2
0
P3
2-1
8
D8
2C
AN
+-Y
L
D8
1C
AN
--G
R
C6
1A
XR
T-G
R
S5
6P
RV
-RD
P5
3L
S-W
H/B
K
P2
1D
CN
-WH
GN
D-D
CN
-BR
P1
-01
P1
-02
P1
-04
P1
-05
P1
-06
P1
-07
P1
-08
P1
-09
P1
-03
P1
-19
P1
-11
P1
-13
P1
-12
P1
-14
P1
-15
P1
-16
P1
-17
P1
-18
P1
-10
P1
-20
P1
-22
P1
-23
P1
-21
J32 23 PIN WHITEDRIVE CHASSIS HARNESS
J31 23 PIN BLACKDRIVE CHASSISHARNESS
J107 J108 J109 J110
V6
0A
XE
X-G
R/W
H
V6
1A
XR
T-
GR
AX
LE
EX
TE
ND
AX
LE
RE
TR
AC
T
13
NO
14
WH
NC
21
RD
BR
BK
22
14
NO
13
22
1
WH
BK
BR
RD
21
NC
LS
RA
1E
SR
EA
RA
XL
ES
AF
ET
YS
WIT
CH
J1
38
LS
FA
1E
SF
RO
NT
AX
LE
SA
FE
TY
SW
ITC
HJ1
37
P6
1L
SA
-GR
1 2
BL
RD
3
BK
RS
RA
10
RE
AR
AX
LE
SE
NS
OR
J1
61
C6
0A
XE
-GR
/WH
C61AXR-GR
C6
1A
XR
T-G
R
4
BK
BL
RD
4321
A B C
BK
BL
RD RD
BL
BK
A B C
RD
BL
BK
A B C
D81CAN- -GR
S56PRV-RD
GNDDCON-BR
D82CAN+ -YL
P21DCON-WH
P53LS-WH/BK
C6
0R
AP
-GR
/WH
C6
0F
AP
-GR
/WH
J2
-GR
/BK
2 2 1
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
P6
1L
SA
-GR
C6
0A
XE
-GR
/WH
J2
-GR
/BK
RS
FA
10
FR
ON
TA
XL
ES
EN
SO
RJ1
60
REV B
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 35
Electrical Schematic - View 8
Continued onView 9Continued on
View 7
Continued on View 2
S56PRV-RD
GNDDCON-BR
P21DCON-WH
OPTIONAL SWINGGATE WIRING
FOOTSWITCH
PL
AT
LE
VE
LD
N (J
81
)
PL
AT
LE
VE
LU
P(J
80
)
PL
AT
RO
TC
W (J
76
)
PL
AT
RO
TC
CW
(J7
7)
JIB
DW
N (J
79
)
JIB
UP
(J7
8)
FOOTSWITCH(FS1)
SWING GATEINTERLOCK
P1
-16
P1
-15
P1
-14
P1
-13
P1
-12
P1
-10
P1
-11
P1
-09
P1
-08
P1
-07
P1
-06
P1
-05
P1
-04
P1
-03
P1
-02
P1
-01
V1
8P
RR
-GR
/BK
VLV
RE
T2
-BR
V1
7P
RL
-GR
V1
5P
LD
-OR
/BK
V4
4JD
-GR
/BK
V1
4P
LU
-OR
V4
3JU
-GR
C8
8P
TS
-RD
/BK
C9
0P
XS
-RD
/BK
P1
-23
P1
-21
P1
-22
P1
-19
P1
-18
P1
-17
P1
-20
C8
4TA
Y-G
R/B
K
P8
5P
TS
-GR
P8
5R
ET
-BR
P8
7P
TS
-RD
P8
7R
ET
-BR
C2
3P
TS
-WH
C5
6P
TS
-RD
P2
1-0
3
P2
1-0
1
P2
1-0
2P
52
PC
N-W
H
GN
DP
CN
-BR
P2
1-0
4
P2
1-0
5
P2
1-0
6
P2
1-0
7
P2
1-0
8
P2
1-0
9
P2
1-1
1
P2
1-1
0
P2
1-1
2
P2
1-1
3
P2
1-1
4
P2
1-1
5
P2
1-2
0
P2
1-1
6
P2
1-1
7
P2
1-1
8
P2
1-1
9
P2
1-2
2
P2
1-2
1
P2
1-2
3
S5
6P
RV
-RD
P5
6P
RV
-RD
/WH
C4
7O
UT
-WT
/BK
D8
1C
AN
-GR
D8
2C
AN
+ -Y
L
C4
6H
N-W
H
P2
3P
CN
-BK
D81CAN- -GR
D82CAN+ -YL
P56PRV-RD/WH
GNDPCON-BR
P23PCON-BK
P52PCON-WH
S56PRV-RD
C46HN-WH
C1
54
JB
R-B
K/W
H
PLATFORM TILTSENSOR ASSEMBLY
LSP1PROXPROXIMITY KILLSWITCH (NOHC)OPTIONAL
+ -
5
+ -
21 3 4 6
J82
J119
J84
21
1 2
NO
BR
BK
RD
WH
21
NC
22
1314
1
J150B-3
J149B-1
J149B-2
J150B-1
J148B-1
J147B-1
J151B-B
J151B-A13
NO
14
WH
RD
BK
BR
4
NC
22 21
C5
6F
TS
-RD
C5
6F
TS
-RD
OVERLOAD LIMITSWITCH LSP1OLS
NO
NC
RD
WH
GR
P11
0L
DS
-GR
C9
4L
DS
-WH
P1
09
LD
S-B
K
BLP18BL
YL
GR
5 5
6 6P6R1
88 P11
88
YL
GR
J37-DRIVE CHASSIS HARNESS
J38-DRIVE CHASSIS HARNESS
RD
OR
BR
22
4 4
3 3
1 1
P17
RDDCON PWR
88 P9A
88 P12
88
OR
BR
88
WH
BK22
P18
11
CC
DCON GND88
P7R88
BK
WH
88
J36-DRIVE CHASSIS HARNESS
YEL
B BGRN
A
P16
ACAN HIGH
CAN LOW
88
88
YEL
GRN
SLIP RING
55
66
P21DCON-WH
22
44
33
J35-LIMIT SWITCH HARNESS
11
GNDDCON-BR
S56PRV-RD
J34-LIMIT SWITCH HARNESS
2 2
1 1
CC
D82CAN+ -YL
D81CAN- -GR
J33-BOOM HARNESS
BB
AA
P53LS-WH/BK
P21DCON-WH
GNDDCON-BR
S56PRV-RD
D82CAN+ -YL
D81CAN- -GR
PIN WHITEPCON MANIFOLD HARNESSJ22 35 J21 23 PIN BLACK
BOOM HARNESS
D82CAN+ -YL
D81CAN- -GR
D81CAN- -GR
D82CAN+ -YL
C61AXR-GR C61AXR-GR C61AXRT-GR
S56PRV-RD
P56PRV-RD/WH
C46HN-WH
P52PCON-WH
GNDPCON-BR
P23PCON-BK
C60AXE-GR/WHT C60AXE-GR/WH C60AXEX-GR/WHT
P53LS-WH/BK
JIB
BE
LL
CR
AN
K U
P(J
13
5)
JIB
BE
LL
CR
AN
K D
OW
N (J
13
6)
P1
09
JB
S-G
R/W
H
V1
46
JB
U-B
L
S2
1 J
IB B
EL
LC
RA
NK
SE
NS
OR
RD
BL
BK
P53LS-WH/BK
V1
53
JB
E-B
K
V1
54
JB
R-B
K/W
HJIB
RE
TR
AC
T(J
14
1)
JIB
EX
TE
ND
(J1
40
)
C6
4L
S-O
R/B
KC
64
LS
-OR
/BK
1 2 3
C1
54
JB
R-B
K/W
H
P1
-29
P1
-24
P1
-25
P1
-26
P1
-27
P1
-28
P1
-32
P1
-30
P1
-31
P1
-34
P1
-33
P1
-35
V1
47
JB
D-B
L/B
K
P11
0JB
S-B
K
C1
48
JB
S-B
L/W
H
9 11 12 10 1 2 3 4 5 6
OR GR
GR
/BK
OR
/BK
RD
RD
/BK
YL
BR
/BK
YL
/BK
VLV
RE
T1
-BR
WORK LIGHT ON/OFFTOGGLE SWITCH
WORKPLAMP
J151B-C
J1
48
A-1
J1
47
A-1
J1
49
A-1
J1
49
A-2
J1
50
A-2
J1
50
A-3
J1
51
A-B
J1
51
A-A
J1
50
A-1
J1
51
A-C
VLV
RE
T2
-BL
7
VLV
RE
T3
-BL
/BK
8
J165
J147
VLV
RE
T1
-BR
BK
30
85
86
87a 87
CR45WORK LIGHTRELAY
J156
J155
J1
56
J1
55
P20BAT-RD
GND-BR
GND-BR
P4
8L
PS
-WH
/RD
S132LDS-BL/WH
J1
50
A-4
C47OUT-WH/BKJ150B-2
C47OUT-WH/BK
S132LDS-BL/WHJ150B-4
S132LDS-BL/WH
PO
WE
R F
ET
PL
AT
TIL
TS
NS
R
10
DE
G1
0 D
EG
PO
WE
R F
ET
J55
0-2
0 D
EG
YA
XIS
SA
FE
TY
CU
TO
UT
LSJ1ROJIB NOTRETRACTED(RETRACTED POS)
S132LDS-BL/WH S132LDS-BL/WH
J147
J157-1
2
SLIP RING
+ -
3 2 1
P
J82
3 4
R90PXS-RD/BK
PLATFORM LEVEL RECOVERYSWITCH (ANSI/CSA ONLY)
REV D
April 2008 Section 6 • Schematics
6 - 36
Electrical Schematic - View 8
6 - 35
Section 6 • Schematics April 2008
6 - 37
Electrical Schematic - View 9
6 - 38
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 38 Z-135/70 Part No. 106783
Electrical Schematic - View 9
Continued on View 10Continued on View 8
Continued on View 3
TO FLASHING BEACON
S56PRV-RD
GNDDCON-BR
P21DCON-WH
R11
7F
B-R
D
P5
6P
RV
-RD
/WH
S5
6P
RV
-RD
C4
7O
UT
-WH
/BK
C4
6H
N-W
H
P5
2P
CO
N-W
H
GN
DP
CO
N-B
R
P2
3P
CO
N-B
K
D8
1C
AN
--G
R
D8
2C
AN
+-Y
L
P11
-03
P11
-02
P11
-01
P11
-04
P11
-05
P11
-08
P11
-06
P11
-07
TCON
P11
-14
P11
-09
P11
-10
P11
-11
P11
-13
P11
-12
P11
-16
P11
-15
P11
-17
P11
-19
P11
-18
P11
-20
P11
-21
P11
-22
P11
-23
P21DCON-WH
S56PRV-RD
GNDDCON-BR
P117FB-RD
GND-BR
J11 BLACK 23 PINBOOM HARNESS
D82CAN+ -YL
D81CAN- -GR
D81CAN- -GR
D82CAN+ -YL
C61AXR-GR
S56PRV-RD
P56PRV-RD/WH
C46HN-WH
D81CAN- -GR
D82CAN+ -YL
D81CAN- -GR
D82CAN+ -YL
P52PCON-WH
GNDPCON-BR
P23PCON-BK
C60AXE-GR/WHT
P53LS-WH/BK P53LS-WH/BK
C1
45
CA
L-R
D/W
H
C60AXE-GR/WHT
C61AXR-GR
D82CAN+ -YL
D81CAN- -GR
BA
BB
AA
AB
BA
BB
AA
AB
BA
BB
AC
BC
J152B
J152A
BA
BC AC
BA
BB
BC
J1
48
C-1
J1
47
C-1
J129-01
C145CAL-RD/WHC145CAL-RD/WH
R117FB-RD R117FB-RD
C47OUT-WH/BK
S132LDS-BL/WH S132LDS-BL/WH S132LDS-BL/WH
J129-02
TO HYDRAULICGENERATOR/WELDEROPTION
86 85
3087
87a
REV B
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 39
Electrical Schematic - View 10Limit Switches
Continued on View 11Continued on View 9
Continued on View 4
P1
2-0
4P
54
EN
G-B
K/W
H
P5
3L
S-W
H/B
K
P2
1D
CO
N-W
H
GN
DD
CO
N-B
RP
12
-01
P1
2-0
2
P1
2-0
3
S5
6P
RV
-RD
C6
4L
S-O
R/B
K
P1
2-0
6
P1
2-0
5
P1
2-0
7
P1
2-0
8
P1
2-1
1
P1
2-0
9
P1
2-1
0
P1
2-1
2
P1
2-1
3
P1
2-2
3
C6
4L
S-O
R/B
K
C6
5L
OF
-BL
/WH
C6
7S
BD
-BL
C7
1P
BE
-BL
/BK
C7
0P
BR
-BL
/WH
P1
2-1
8
P1
2-1
6
P1
2-1
4
P1
2-1
5
P1
2-1
7
P1
2-2
0
P1
2-1
9
P1
2-2
1
P1
2-2
2
C1
43
DE
L-B
L/R
D
P1
09
PS
R-G
R/W
H
SN
SR
GN
D-B
RP
12
-25
P1
2-2
4
P1
2-2
6
P1
2-2
7
P1
2-3
0
P1
2-2
9
P1
2-2
8
P1
2-3
2
P1
2-3
1
P1
2-3
5
P1
2-3
4
P1
2-3
3
S1
40
EN
L-O
R/R
D
C7
3S
BR
-BL
/RD
P5
8L
SR
D/B
K
P5
3L
S-W
H/B
K
FS
T1
SL
OW
FU
EL
FL
OA
TS
WIT
CH
LS
T2
0D
RIV
EE
NA
BL
EL
EF
TO
PE
RA
TIO
NA
LJ1
25
C6
4L
S-O
R/B
K
C7
3S
BR
-BL
/RD
C6
4L
S-O
R/B
K
C6
5L
OF
L-B
L/W
H
BR
BK
RD
WH
RD
BK
WH
BR
NC
21
NO
13
22
14
1314
NO
NO
232414
22
13
NO
21
NC
LS
T1
0D
RIV
EE
NA
BL
ER
IGH
TO
PE
RA
TIO
NA
LJ1
24
BR
WH
BK
RD
C6
4L
S-O
R/B
K
C1
44
DE
R-B
L/W
H
J12 BLACK 35 PINLIMIT SWITCH HARNESS
S1
40
EN
L-O
R/R
D
S2
0S
EC
ON
DA
RY
BO
OM
AN
GL
ES
AF
ET
Y
S1
9S
EC
ON
DA
RY
BO
OM
AN
GL
EO
PE
RA
TIO
NA
L
C1
24
SB
S-O
R/B
K
C1
23
PB
S-R
D/B
K
C1
23
PB
S-R
D/B
K
C1
24
SB
S-O
R/B
K
C1
41
PB
S-R
D
P1
09
PS
R-G
R/W
H
P1
09
PS
R-G
R/W
H
SN
SR
GN
D-B
R
SN
SR
GN
D-B
R
SN
SR
GN
D-B
R
ORN/RED
14
NO
13
BK
BR
RD
WH
22 21
NC
LS
S1
RS
3'E
XT
EN
DE
DS
AF
ET
YJ4
6
BLU/RED
NO
13
NC
14
WH
2122
BK
BR
RD
LS
T1
SD
RIV
EE
NA
BL
ES
AF
ET
YJ1
26
C1
44
DE
R-B
L/W
H
C6
7S
BD
-BL
C6
4L
S-O
R/B
K
C7
1P
BE
-BL
/BK
C6
4L
S-O
R/B
KC
64
LS
-OR
/BK
C6
4L
S-O
R/B
KC
64
LS
-OR
/BK
C7
0P
BR
-BL
/WH
C6
4L
S-O
R/B
K
C6
4L
S-O
R/B
KC
64
LS
-OR
/BK
S1
3D
E-B
L/R
D
C1
43
DE
L-B
L/R
D
C6
4L
S-O
R/B
K
C6
4L
S-O
R/B
K
S1
2S
B-B
L/W
H
YL
BR
OR
RD
BL
BK
46 5321
P1
09
PS
R-G
R/W
H
P1
09
PS
R-G
R/W
H
SN
SR
GN
D-B
R
C1
42
SB
S-O
R
4 3 2 112 12344 3 2 14 3 2 1
P5
3L
S-W
H/B
K
P5
4E
NG
-BK
/WH
S1
39
TR
F-W
H/R
D
S1
37
PL
L-R
D/W
H
S5
9C
NB
K-G
R/W
H
C6
0A
XE
-GR
/WH
D8
1C
AN
--G
R
GN
D-B
R
P2
1D
CO
N-W
H
C1
42
SB
S-O
R
S5
6P
RV
-RD
S5
6P
RV
-RD
D8
2C
AN
+-Y
L
C1
41
PB
S-R
D
C6
1A
XR
T-G
R
S1
3D
E-B
L/R
D
S1
2S
B-B
L/W
H
P5
8L
S-R
D/B
K
S7
3S
LE
-BL
/RD
S1
40
EN
L-O
R/R
D
S5
9C
NB
K-G
R/W
H
J146 ENGINEHARNESS
LOWER LIMITSWITCH HARNESS
ENGINEHARNESS
J121 GRAY 12 PINSCON MODULE
J122 BLACKSCON MODULE
12 PIN
SCON MODULEP
12
2-1
0
P1
22
-11
P1
22
-12
P1
22
-09
P1
22
-04
P1
22
-01
P1
22
-02
P1
22
-03
P1
22
-07
P1
22
-05
P1
22
-06
P1
22
-08
P1
21
-05
P1
21
-06
P1
21
-07
P1
21
-03
P1
21
-04
P1
21
-08
P1
21
-09
P1
21
-11
P1
21
-10
P1
21
-12
P1
21
-01
P1
21
-02
P3
9
P3
8
TD
RS
23
2
LO
AD
SE
NS
E
CA
N-
CA
N+
RD
23
2
CA
LIB
RA
TIO
NIN
P1
0
P7
R
P6
R1
EC
UP
WR
RS
S1
AS
RS
P1
AS
AX
LE
EX
TE
ND
ED
P7
R
DR
V.E
NA
.
GN
D
P9
B
P11
+P
30
P6
R2
SE
C.B
OO
MR
ET
P1
2C
61
AX
R-G
R
C145CAL-RD/WH
2
1
J154
VLV
RE
TB
R
SE
C.S
W.C
ON
NE
CT
ION
C6
4L
S-O
R/B
KC
64
LS
-OR
/BK
C1
45
CA
L-R
D/W
H
S7
3S
LE
-BL
/RD
S1
32
LD
S-B
L/W
H
S132LDS-BL/WH
LS
S1
RO
SE
CO
ND
AR
YB
OO
MR
ET
RA
CT
OP
ER
AT
ION
AL
LE
FT
J4
9
ORN ORN/YEL BLU
Continued on View 10A
REV D
April 2008 Section 6 • Schematics
6 - 40
Electrical Schematic - View 10Limit Switches
6 - 39
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 41
Electrical Schematic - View 10ALimit Switches
LSP1E03'FROM FULLYEXTENDEDJ45
LSP1R03' EXTENDEDOPERATIONALJ44
RD
BR
WH
BK
14
22NC
13
21
NO
BK
RD
S18PRIMARY BOOMANGLE SAFETY
31 2
S17PRIMARY BOOOMANGLEOPERATIONAL
YL
OR
BR
6 5 4
BL
12 1234
RD
/BK
OR
/BK
BK
BL
/BK
11 12 2 10 7 6 9 4 8 3
22 21
NO1314
NC
BK
BR
RD
WH
J20
J114
YEL WHT
GR
/BK
BK
/WH
1
RD
WH
/BK
BL
GR
WH
5
AFTER SERIALNUMBER 129WITH SOFTWAREVERSION S0675110
Continued onView 10
OR
LSP1E03'FROM FULLYEXTENDEDJ45
LSP1R03' EXTENDEDOPERATIONALJ44
RD
BR
WH
BK
14
22NC
13
21
NO
BK
RD
S18PRIMARY BOOMANGLE SAFETY
31 2
S17PRIMARY BOOOMANGLEOPERATIONAL
YL
OR
BR
6 5 4
BL
12 1234
BK
BL
/BK
11 12 2 10 7 6 9 4 8 3
22 21
NO1314
NC
BK
BR
RD
WH
J20
J114
YEL WHT
GR
/BK
BK
/WH
1
RD
WH
/BK
BL
GR
WH
5
OR
RD
/BK
OR
/BK
LSP1E03'FROM FULLYEXTENDEDJ45
LSP1R03' EXTENDEDOPERATIONALJ44
RD
BR
WH
BK
14
22NC
13
21
NO
BK
RD
S18PRIMARY BOOMANGLE SAFETY
31 2
S17PRIMARY BOOOMANGLEOPERATIONAL
YL
OR
BR
6 5 4
BL
12 1234
BL
WH
WH
/BK
BL
/BK
11 12 2 10 7 6 9 4 8 3
22 21
NO1314
NC
BK
BR
RD
WH
J114
YEL WHT
BK
/WH
OR
/BK
1
OR
GR
RD
BK
GR
/BK
5
BEFORE SERIALNUMBER 130WITH SOFTWAREVERSION S0675110
RD
/BK
LSP1E03'FROM FULLYEXTENDEDJ45
LSP1R03' EXTENDEDOPERATIONALJ44
RD
BR
WH
BK
14
22NC
13
21
NO
BK
RD
S18PRIMARY BOOMANGLE SAFETY
31 2
S17PRIMARY BOOOMANGLEOPERATIONAL
YL
OR
BR
6 5 4
BL
12 1234
WH
/BK
BL
/BK
11 12 2 10 7 6 9 4 8 3
22 21
NO1314
NC
BK
BR
RD
WH
J114
YEL WHT
BK
/WH
OR
/BK
1
OR
GR
RD
BK
GR
/BK
5
RD
/BK
BL
WH
J20
J20
AFTER SERIALNUMBER 129WITH SOFTWAREVERSION S0675100
BEFORE SERIALNUMBER 130WITH SOFTWAREVERSION S0675100
REV A
April 2008 Section 6 • Schematics
6 - 42
Electrical Schematic - View 10ALimit Switches
6 - 41
Section 6 • Schematics April 2008
6 - 43
Electrical Schematic - View 11Deutz BF4L 2011 Engine
Deutz TD2011L04i Engine
6 - 44
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 44 Z-135/70 Part No. 106783
Electrical Schematic - View 11Deutz BF4L 2011 Engine and Deutz TD2011L04i Engine
Continued onView 12
Continued onView 10
Continued on View 5
C45GEN-GR/WH
S139TRF-WH/RD
S137PLL-RD/WH
TO BELT DRIVEN AC GENERATOR/WELDER
C4
5G
EN
-GR
/WH
S1
37
PL
L-R
D/W
H
J146 ENGINEHARNESS
LOWER LIMITSWITCH
HARNESS
J146ENGINEHARNESS
C2
1IG
N-W
H
C4
6H
RN
-WH
C3
4S
A-B
K/W
H
C3
3S
TR
-BK
C3
0E
DC
-WH
C3
5R
PM
-BK
/RD
C2
6T
SR
-WH
/RD
C2
5P
SR
-WH
/BK
C3
1E
DC
-WH
/BK
C4
1R
PM
-OR
/BK
GN
D-B
R
B1
BA
T-R
D
GN
D-B
R
D5 D3
VLV
RE
T-B
R
R3
4S
A-B
K/W
H
WH
RD
BK
ALTERNATOR
REGULATOR
BAT.+
IND.
STA.
BAT.
-
EXCT.
HY
DR
AU
LIC
OIL
CO
OL
ER
FA
N
FAN
HY
DR
AU
LIC
CO
OL
ER
RE
LA
Y
GL
OW
PL
UG
GL
OW
PL
UG
RE
LA
Y
HO
RN
STA
RT
ER
RE
LA
Y
AU
XIL
IAR
YH
YD
RA
UL
ICP
UM
PS
RP
MS
OL
EN
OID
ALT
ER
NA
TO
R
AU
XIL
IAR
YP
OW
ER
BA
TT
ER
IES
EN
GIN
ES
TA
RT
AN
DE
LE
CT
RO
NIC
SB
AT
TE
RY
STA
RT
ER
B2 B1
BA
TG
ND
-BR
-
+
BA
TG
ND
-BR
BA
TG
ND
-BRH1
BA
TG
ND
-BR
TO
J4
-32
PW
HIT
E3
5P
IN
HO
RN
PR
EL
AY
DU
AL
CO
ILE
DC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
C2
7A
UX
-RD
AUX.PUMP
PR
1
D1J120
BA C D
HO
LD
PU
LL
IN
FU
EL
SO
LE
NO
IDB
AT
GN
D-B
R
OIL
PR
ES
SU
RE
SE
ND
ER
OIL
TE
MP
ER
AT
UR
ES
EN
DE
R
C2
1IG
N-W
H
B3
BA
T/1
4-R
D
C3
5R
PM
-BK
/RD
TROMBETTA
R3
3S
TR
-BK
87
CR1STARTERRELAY
85
8630
C1
07
AF
-RD
86
WH
-PU
LL
IN
S-500
07
GN
D-B
R
C4
1R
PM
-OR
/BK
R4
6H
RN
WH
VLV
RE
T2
-BR
D2
C3
0E
DC
-WH
C3
1E
DC
-WH
/BK
R11
6H
YD
-OR
C11
6H
YD
-OR
J57
GN
D0
4-B
R
GN
D0
4-B
R
321
OTS1PN.O.
CR15GLOWPLUGRELAY
RD
-HO
LD
87a8785
30
CGND-
AUX+
A
87a 8785
8630 CR5
HORNRELAY
B
BAT+
MOM N.O.
TIME DELAYRD-HOLD
85 87 87a
3086
CR17OIL COOLER
RELAY
R21IGN-WH
F7 OIL COOLERF20 RPMF22 GLOW PLUGF23 ENG/ST/ALT
B1
EN
G-R
D
P3
5R
PM
-BK
/RD
C3
4S
A-B
K/W
H
P34SA-BK/WH
WH-PULL IN
P34SA-BK/WH
B3BAT/14-RD
C21IGN-WH
B1
BA
T-R
D
B1ENG-RD B1ENG-RD B1ENG-RD
C26TSR-WH/RD
C25PSR-WH/BK
B1ENG-RD
C2
5P
SR
-WT
/BK
C2
6T
SR
-WT
/RD
B1
EN
G-R
D
P1
-03
P1
-04
P1
-02
POWER HARNESS
J15 BLACK 4 PIN
P1
-01
P1
-23
P1
-13
P1
-14
P1
-17
P1
-20
P1
-22
P1
-08
P1
-03
P1
-02
P1
-06
P1
-05
P1
-04
P1
-07
P1
-10
P1
-09
P1
-01ENGINE HARNESS
J13 WHITE 23 PIN
P1
-12
P1
-15
P1
-16
P1
-11
P1
-18
P1
-19
P1
-21
PUMP
PR
1
AUX.
J168ENGINEHARNESS
F7
10
A
C33STR-BK
EN
GIN
EB
LO
CK
GR
OU
ND
S1
39
TR
F-W
H/R
D
2
1
B3BAT/14-RD
B3
BA
T/1
4-R
D
B1
EN
G-R
D
S1
39
TR
F-W
H/R
D
B1ENG-RD
B1
EN
G-R
D
S1
37
PL
L-R
D/W
H
B1
BA
T-R
DB
1B
AT
-RD
B2
BA
T-R
D
MA
INA
UX
B1
BA
T-R
D
B1
BA
T-R
D
INTEGRAL WITHBATTERY CABLE
ENGINEHARNESS
INTEGRAL WITHBATTERY CABLE
POWERHARNESS
SEPARATE4 GA WIRE
SUPPLIEDBY DEUTZ
SEPARATE4 GA WIRE
+
-
-
+
TWO 6V DCBATTERIES
B1BAT-RD
30
858787a
86CR28ENGINE
FUELRELAY
C2
1IG
N-W
H
F2320A
F2020A
F2260A
F720A
REV D
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 45
Electrical Schematic - View 12
Continued on View 11
Continued on View 6
P
TT
RO
TC
W/C
CW
F.C
.(J
69
)
PR
IB
ME
XT
/RE
TF.C
.(J
61
)
PR
IB
MU
P/D
WN
F.C
.(J
58
)
P P
SE
CE
XT
VLV
(J6
5)
SE
CR
ET
VLV
(J6
6)
SE
CD
WN
VLV
(J6
8)
SE
CU
PV
LV
(J6
7)
SE
C.
BM
ER
F.C
.(J
64
)
PR
IR
ET
VLV
(J6
3)
PR
IU
PV
LV
(J5
9)
PR
IE
XT
VLV
(J6
2)
PR
ID
WN
VLV
(J6
0)
P
V0
6T
RF
-WH
/RD
VLV
RE
T4
-BR
V0
3P
UD
-RD
/WH
V0
9P
ER
-BK
/RD
V0
7P
BE
-BK
V0
2P
BD
-RD
/BK
V0
1P
BU
-RD
VLV
RE
T5
-BR
V0
8P
BR
-BK
/WH
C4
9L
P-
WH
/BK
V11
SB
D-B
L/B
K
V7
2S
BE
-GR
V7
3S
BR
-GR
/BK
V1
0S
BU
-BL
TU
RN
TA
BL
ER
OTA
TE
CC
WV
ALV
E(J
71
)
TU
RN
TA
BL
ER
OTA
TE
CW
VA
LV
E(J
70
)
C0
4T
RL
-WH
C0
5T
RR
WH
/BK
VLV
RT
N7
-BR
VLV
RT
N6
-BR
C2
7A
UX
-RD
V0
6T
RF
-WH
/RD
VLV
RE
T4
-BR
V0
3P
UD
-RD
/WH
V0
9P
ER
-BK
/RD
P1
4-0
2
P1
4-0
1
P1
4-0
3
P1
4-0
4
VLV
RE
T5
-BR
V0
7P
BE
-BK
V0
9S
ER
-BK
/RD
V0
2P
BD
-RD
/BK
V0
1P
BU
-RD
V11
SB
D-B
L/B
K
V0
8P
BR
-BK
/WH
C4
9L
P-
WH
/BK
V1
0S
BU
-BL
V7
3S
BR
-GR
/BK
V7
2S
BE
-GR
VLV
RE
T5
-BR
VLV
RE
T5
-BR
P1
4-1
4
P1
4-0
9
P1
4-0
7
P1
4-0
5
P1
4-0
6
P1
4-0
8
P1
4-1
0
P1
4-1
1
P1
4-1
3
P1
4-1
2
P1
4-1
9
P1
4-1
6
P1
4-1
5
P1
4-1
7
P1
4-1
8
P1
4-2
1
P1
4-2
0
P1
4-2
2
P1
4-2
3
VLV
RE
T7
-BR
V0
4T
RL
-WH
V0
5T
RR
-WH
/BK
VLV
RE
T6
-BR
C2
7A
UX
-RD
P1
4-3
3
P1
4-2
8
P1
4-2
6
P1
4-2
5
P1
4-2
4
P1
4-2
7
P1
4-3
0
P1
4-2
9
P1
4-3
1
P1
4-3
2
P1
4-3
5
P1
4-3
4
V7
2S
BE
-GR
V7
3S
BR
-GR
/BK
V1
0S
BU
-BL
J14 WHITE 35 PINMANIFOLD HARNESS
V1
55
PS
E-O
R/R
D
V1
50
HG
GR
/BK
V1
50
HG
GR
/BK
WE
LD
ER
GE
NB
YP
AS
SV
ALV
E(Y
75
)
V1
55
PS
EO
R/R
D
TO AUXILIARYHYDRAULIC PUMP RELAYS
FU
NC
TIO
NE
NA
BL
EV
ALV
E(Y
74
)
CR23DRIVE LIGHTSRELAY
87a 8785
8630
V1
2S
UD
-BL
/WH
V1
76
SE
R-G
R/W
H
V1
2S
UD
-BL
/WH
P
SE
C.
BM
UD
F.C
.(J
64
)
V1
55
PS
EO
R/R
D
MANIFOLD HARNESS
ENGINE HARNESS
MANIFOLD HARNESS
ENGINE HARNESS
J153
J153
C49LP - WH/BK
DRIVE LIGHTS
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
REV B
April 2008 Section 6 • Schematics
6 - 46
Electrical Schematic - View 12
6 - 45
Section 6 • Schematics April 2008
6 - 47
Electrical Schematic - View 13Perkins 1104C-44 EnginePerkins 804D-33T Engine
6 - 48
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 48 Z-135/70 Part No. 106783
Electrical Schematic - View 13Perkins 1104C-44 Engine and Perkins 804D-33T Engine
Continued onView 10
Continued on View 12
Continued on View 5
J13 WHITE 23 PINENGINE HARNESS
B1ENG-RD
EN
GIN
EB
LO
CK
GR
OU
ND
-
+ BA
TG
ND
-BR
AU
XIL
IAR
YP
OW
ER
BA
TT
ER
IES
EN
GIN
ES
TA
RT
AN
DE
LE
CT
RO
NIC
SB
AT
TE
RY
STA
RT
ER
AU
XIL
IAR
YH
YD
RA
UL
ICP
UM
P
STA
RT
ER
RE
LA
Y
B1B2
PUMPAUX.
R3
3S
TR
-BK
PR
1
C3
3S
TR
-BK
F2320A
F2020A
F2260A
F720A
B1
EN
G-R
D
F7OIL COOLERF20 RPMF22 GLOW PLUGF23 ENG/ST/ALT
B1
EN
G-R
D
C3
5R
PM
-BK
/RD
CR1STARTERRELAY
3086
8587
P3
5R
PM
-BK
/RD
1
2
J146ENGINEHARNESS
F710A
12-3 CABLE
S1
39
TR
F-W
H/R
D
S1
37
PL
L-R
D/W
H
WORKLAMPS WORK
LAMPTOGGLESWITCH
MA
INA
UX
S139TRF-WH/RD
S137PLL-RD/WH
GN
D-B
R
B2
BA
T-R
D
GN
D-B
R
P1
-01
J15 BLACK 4 PINPOWER HARNESS
P1
-02
P1
-04
P1
-03
CR17OILCOOLERRELAY
CR5HORNRELAY
30
J120
C2
7A
UX
-RD
FAN
ALTERNATOR
REGULATOR
BAT.+
IND.
STA.
BAT.-
EXCT.
HO
RN
ALT
ER
NA
TO
R
HO
RN
RE
LA
Y
RP
MS
OL
EN
OID
GL
OW
PL
UG
GL
OW
PL
UG
RE
LA
Y
DU
AL
CO
ILE
DC
H1
TO
J4
-32
PW
HIT
E3
5P
IN
BA
TG
ND
-BR
AUX.PUMP
PU
LL
IN
HO
LD DCA B
HY
DR
AU
LIC
OIL
CO
OL
ER
FA
N
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
CO
OL
ER
RE
LA
Y
WA
TE
RT
EM
PS
EN
DE
R
OIL
PR
ES
SU
RE
SE
ND
ER
BA
TG
ND
-BR
BA
TG
ND
-BR
30
87a
R3
4S
A-B
K/W
H
C3
1E
DC
-WH
/BK
C3
0E
DC
-WH
VLV
RE
T2
-BR
R4
6H
RN
-WH
C4
1R
PM
-OR
/BK
BA
TG
ND
(A)
PR
1
GN
D0
4-B
R
GN
D0
4-B
R VLV
RE
T-B
R
1 2 3
BK
RD
WH
85
C1
07
AF
-RD
AUX+
GND-C
S-500
8787a
RD
-HO
LD
CR15GLOWPLUGRELAY
WH
-PU
LL
IN
J57
8587
86
C11
6H
YD
-OR
R11
6H
YD
-OR
OTS1N.O.
8630
87a8785
C2
6T
SR
-WT
/RD
C2
5P
SR
-WT
/BK
B3
BA
T/1
4-R
D
P34SA/10-BK/WHP34SA/10-BK/WH
86
BAT+
B
A
TIME DELAY
MOM N.O.
TROMBETTAWH-PULL IN
RD-HOLD
B3BAT/14-RD
C3
4S
A-B
K/W
H
B3BAT/14-RD
B3
BA
T/1
4-R
D
C2
1IG
N-W
H
R21IGN-WH
R2
1IG
N-W
H
CR28ENGINE FUELRELAY
C25PSR-WH/BK
C26TSR-WH/RD
C21IGN-WH
C4
1R
PM
-OR
/BK
C3
1E
DC
-WH
/BK
C2
5P
SR
-WH
/BK
C2
6T
SR
-WH
/RD
C3
5R
PM
-BK
/RD
C3
4S
A-B
K/W
H
S1
37
PL
L-R
D/W
H
C4
5G
EN
-GR
/WH
C3
0E
DC
-WH
C3
3S
TR
-BK
C4
6H
RN
-WH
C2
1IG
N-W
H
S1
39
TR
F-W
H/R
D
P1
-14
P1
-01
P1
-04
P1
-05
P1
-02
P1
-03
P1
-11
P1
-12
P1
-09
P1
-10
P1
-07
P1
-06
P1
-08
P1
-13
P1
-23
P1
-21
P1
-19
P1
-18
P1
-16
P1
-15
P1
-22
P1
-20
P1
-17
LOWER LIMITSWITCHHARNESS
BA
TG
ND
-BR
BA
TG
ND
-BR
BA
TG
ND
-BR
HO
LD
CO
LD
STA
RT
AD
VA
NC
E
FU
EL
LIF
TP
UM
P
CR
2R
EL
AY
FU
EL
SO
LE
NO
ID
J56
FUEL
PUMP
SW28ENGINE CYLINDERHEAD TEMPERATURE
87a85
87
86 30
R21IGN-WH
R2
1IG
N-W
H
GND-BR
4
BATGND(A)
R2
1IG
N-W
H
2
1
TO AUXILIARY HYDRAULIC POWER UNITBATTERYPNEG TERM (B2)
B1ENG-RD B1ENG-RD
C45GEN-GR/WH
B2BAT-RD
J32-ENG HARN
B1ENG-RD
B1
BA
T-R
D
B1
BA
T-R
D
INTEGRAL WITHBATTERY CABLE
B2
BA
T-R
D
SEPARATE4 GA WIRE
TWO 6V DCBATTERIES
-
+
+
-
B1
BA
T-R
D
B1
BA
T-R
DB
1B
AT
-RD
POWERHARNESS
ENGINE HARNESS
GL
OW
PL
UG
GL
OW
PL
UG
GL
OW
PL
UG
REV B
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 49
Electrical Schematic - View 14Cummins B4.5L Engine and Cummins B3.3T Engine
Continued on View 12
Continued onView 10
Continued on View 5
PR
E-H
EA
TE
RR
EL
AY
PR
E-H
EA
TE
RR
34
SA
/4-R
D
VLV
RE
T-B
R
CR15GRIDHEATERRELAY
WORK LAMPTOGGLESWITCH
TO
J4
-32
WH
ITE
35
PIN
DU
AL
CO
ILE
DC
EN
GIN
ES
TA
RT
ING
AN
DE
LE
CT
RO
NIC
SB
AT
TE
RY
STA
RT
ER
RE
LA
Y
ALT
ER
NA
TO
R
AU
XIL
IAR
YP
OW
ER
UN
ITS
STA
RT
ER
RP
MS
OL
EN
OID
HO
RN
RE
LA
Y
HO
RN
WA
TE
RT
EM
PE
RA
TU
RE
SE
ND
ER
OIL
CO
OL
ER
RE
LA
Y
HY
DR
AU
LIC
OIL
CO
OL
ER
FA
N
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
FU
EL
SO
LE
NO
ID
CR
2R
EL
AY
OIL
PR
ES
SU
RE
SE
ND
ER
B3BAT/14-RDB3BAT/14-RD
P3
5R
PM
-BK
/RD
B1
EN
G-R
D
WH
-PU
LL
IN
C4
1R
PM
-OR
/BK
R4
6H
RN
-WH
VLV
RE
T2
-BR
-
+
B2 B1
ALTERNATOR
REGULATOR
BAT.+
IND.
STA.
BAT.-
EXCT.
C2
7A
UX
-RD
BA
TG
ND
-BR AUX.
PUMP PUMPAUX.
BA
TG
ND
-BR
H1
BA
HO
LD
PU
LL
IN
R3
3S
TR
-BK
PR
1
PR
1
GN
D0
4-B
R
GN
D0
4-B
R
C3
0E
DC
-WH
WH
RD
BK
4
J57
321
S-500
A
CGND-
AUX+
C1
07
AF
-RD
RD
-HO
LD
BA
TG
ND
(A)
CR5HORNRELAY
86
87a 8785
30
C3
5R
PM
-BK
/RD
87a 8785
8630CR1
STARTERRELAY
B
BAT+
TIME DELAY
MOM N.O.
TROMBETTA
P34SA/4-RD
RD-HOLD
B3
BA
T/1
4-R
D
BATGND(A)
WH-PULL IN
P34SA/4-RD
2
B1
BA
T-R
D
B1
BA
T-R
D
B2
BA
T-R
D
B1
BA
T-R
D
J146ENGINEHARNESS
F7 OIL COOLERF20 RPMF23 ENG/ST/ALT
B1
EN
G-R
D
F7
10
A
B1ENG-RD B1ENG-RD B1ENG-RD
12-3 CABLE
LOWERLIMIT SWITCHHARNESS
1
MA
INA
UX
S1
37
PL
L-R
D/W
H
S1
39
TR
F-W
H/R
D
C3
3S
TR
-BK
WORK LAMPS
C3
4S
A-B
K/W
H
R11
6H
YD
-OR
C11
6H
YD
-OR
C3
1E
DC
-WH
/BK
FAN
BA
TG
ND
-BR
BA
TG
ND
-BR
C D
J120
BA
TG
ND
-BR
HO
LD
OTS1N.O.
J56
85 87 87a
3086CR17
OILCOOLERRELAY
C2
5P
SR
-WT
/BK
C2
6T
SR
-WT
/RD
C2
1IG
N-W
H
B3
BA
T/1
4-R
D
R21IGN-WH
R2
1IG
N-W
H
R21IGN-WH
3086
8785
87a
CR28ENGINEFUELRELAY
C21IGN-WH
B1ENG-RD
C26TSR-WH/RD
C25PSR-WH/BK
TO AUXILIARY POWER UNITBATTERY NEG TERMINAL (B2)
S1
39
TR
F-W
H/R
D
C2
1IG
N-W
H
C4
6H
RN
-WH
C3
3S
TR
-BK
C3
0E
DC
-WH
C4
5G
EN
-GR
/WH
S1
37
PL
L-R
D/W
H
C3
4S
A-B
K/W
H
C3
5R
PM
-BK
/RD
C2
6T
SR
-WH
/RD
C2
5P
SR
-WH
/BK
C3
1E
DC
-WH
/BK
C4
1R
PM
-OR
/BK
S137PLL-RD/WH
S139TRF-WH/RD
J15 BLACK 4 PINPOWER HARNESS
GN
D-B
R
B2
BA
T-R
D
GN
D-B
R
P1
-06
P1
-03
P1
-04
P1
-02
P1
-01
P1
-03
P1
-02
P1
-05
P1
-04
P1
-01
J13 WHITE 23 PINENGINE HARNESS
P1
-15
P1
-16
P1
-13
P1
-08
P1
-07
P1
-10
P1
-09
P1
-12
P1
-11
P1
-14
P1
-17
P1
-20
P1
-22
P1
-18
P1
-19
P1
-21
P1
-23
C45GEN-GR/WH
J32-ENGINE HARNESS
GND-BR
B2BAT-RD
TO BELT DRIVEN AC GENERATOR WELD MASTER
F2
22
75
A
+
-
-
+
TWO 6V DCBATTERIES
B2
BA
T-R
D
B1
BA
T-R
D
B1
BA
T-R
D
POWERHARNESS
AU
XIL
IAR
YP
OW
ER
BA
TT
ER
IES
EN
GIN
EB
LO
CK
GR
OU
ND
SEPARATE4 GA WIRE
INTEGRALWITHBATTERYCABLE
ENGINEHARNESS
TO AUXILIARY POWER UNITBATTERY POS TERMINAL (B2)
F2320A
F2020ASPARE
F720A
REV B
April 2008 Section 6 • Schematics
6 - 50
Electrical Schematic - View 14Cummins B4.5L EngineCummins B3.3T Engine
6 - 49
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 51
Generator Wiring
BRN
RD
WT
BK/WH
BK
BRN GND
WH
RD/12VDC
120V AC W/REGULATOR
BK/WH
WH
BK
BRN
RED
11
0V
AC
RE
GU
LA
TO
R
BLK-120VAC
15A
WHT-NEUTRAL
AUTO
120V AC
RESET CB
87a
87
585
4
3
286
1 3030A
CB
RD
WT
BRN
WHT-NEUTRAL
BLK-220VAC
5
87a
87
1
286
30 4
85
3
5
87a
87
1
286
30 4
85
3
BLK-120VAC
15A
AUTO
RESET CB
120V AC
30A
WHT-NEUTRAL
GR
120V AC W/O REGULATOR
CB
RD
BRN
WT
30A
BK
RED/12V
WH
BRN
BK/WH
12.5A
220V AC
RESET CB
AUTO
22
0V
AC
RE
GU
LA
TO
R
BK/WH
BK
BRN
WH
RED
220V AC W/REGULATOR
BRN
GR
REV B
April 2008 Section 6 • Schematics
6 - 52
Generator Wiring
6 - 51
Section 6 • Schematics April 2008
6 - 53
Hydraulic Schematic(before serial number 180, except for serial number 102)
6 - 54
April 2008Section 6 • Schematics
1
2
3
4
5
6
7
8
A B C D E F G H I J K L M N
6 - 54 Z-135/70 Part No. 106783
Hydraulic Schematic(before serial number 180, except for serial number 102)
M
CHARGE FILTER
PLATFORM LEVEL
PLATFORM ROTATE
TANK
0.30 GPM
FILTER
PRESSURE
HIGH
RATIO PRESS
1000 PSI
1500 PSI
2500 PSI
3:1
2500 PSI
PSI
102
E 9
ROTATE
PRIMARY EXT/RET
8.5/5.0GPM 13.3(REGEN)9.0/7.2 GPM
PRIMARY LIFT
6.5 GPM
SECONDARY LIFT
10.5/5.0 GPM
TRACTION MANIFOLD
LRAREARLEFT
LRB
RRB
50%
50%
REARRIGHT RRA
T
LFA
LEFTFRONT
LFB
A BTEST
50%50%
50%
50%
FRONT
RFB
RIGHTRFA
3:1
1:1
3:1
3:1
4.5:1
3000 PSI
3000 PSI
DEM1
B
M4
M5
L1 L2 S
Ø.030
TANK
PMP SRSESDSUPRPEPDPU
STR
LFBK
LF2SP
P2
AX2
AUXILIARY
PUMP 2
T2
RFBK
RF2SP
LRBK
LR2SP
RR2SP
RRBK
TURNTABLE
T2
A
3625
PSI
315
PSI
PSI
3625
1.5:1 3500 PSI
4.5:1 2000 PSI
PUMP
DRIVE PUMP
FUNCTION
0.9/0.7 GPM
2.0 GPM 3.8 (REGEN)JIB EXT/RET
3.3/1.2 GPMJIB UP/DWN
JU
BELLCRANK LEVEL3.6/1.6 GPM
T1
2.0
TRRTRL
Ø.030
RAE
STEERINGLEFT REAR
STEERINGLEFT FRONT
P LFE LFR RFR
RIGHT FRONT
RFE
STEERING
LRE
STEERINGRIGHT REAR
LRR RRE RRR FAE FAR
FRONT AXLE
EXTENSION
RAR
EXTENSION
REAR AXLE
PSI
2600
SECONDARY EXTENSION CYLINDERS
17.0/5.6GPM 22.6(REGEN)
A
B
A
B
A
B
B
A
2:1 4000 PSI
4.5:1 4000 PSI
3:1 1250 PSI
3:1 3300 PSI
GPM
3100PSI
FUNCTION
ENABLE
VALVE
JD
JE
JR
JLU
JLD
PRL
PRR
PLU
PLD
T
P2
P
0.2GPM
PUMP 1
AUXILIARY
M
AX1
T
B
S
XM2
PETST
25PSI
P1
M2
2 4 3 1 5
5342A2B 1
P
T
STEER/AXLE
FUNCTION MANIFOLD
JIB MANIFOLD
PLATFORM MANIFOLD
COUNTERBALANCE VALVES
1 2
TEST
OIL
COOLER
25PSI PSI
25
TEST
Ø.040L1
DRIVEPUMP
270 PSIGENERATOR21
A
B
PMP A
PMP B
G2
G1
ROTARYHYDRAULIC
COUPLER
4
3
MTR A
MTR B
TO APU SUCTION
WELDER MANIFOLDWELDER OPTION
CLR
1
OIL COOLER
MANIFOLD
Ø.030
250 PSI
2900 PSI
GPM1.5
GPM2.1
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM7.0
2400 PSI
250 PSI
Ø.063
Ø.031
Ø.052
Ø.063
A
LQ
B C
H
D
I
E
F
J
G
K
M
R
N
S
O
TP
U
W
X
Y
Z
AA
AB
AC AD
AF
AE
AG
BN
BM
BT
BS
BLBK
BR
BQ
BJBI
BC BDBB
BA
BHBGBF
BE
BO BP
BU
BV
BW
BY
BXAX AY
AT
AW
AV
AN
AO
AH
AIAL
AM
AKAJ
AR
AS
AQ
AP
V
AU
AZ
BZ
CA CB
CT
CG
CU
CM
CL
CE
CH
CX
CR
CV
CI
CJ
CF
CN
CP
CO
CS
CK
CQ
CZ DA
CW
CY
DA
CZ
CY
CX
CW
CV
CU
CT
CS
CR
CQCPCOCMCL
CN
CK
CJCICHCGCFCECACBCB CA
CD CD
CCCC
DB DC DD DE
DB DC
DD DE
DC
DB
DD
PSI
51
REV D
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 55
Hydraulic Schematic(serial number 102 and from serial number 180 to 534)
M
CHARGE FILTER
PLATFORM LEVEL
PLATFORM ROTATE
TANK
0.30 GPM
FILTER
PRESSURE
HIGH
RATIO PRESS
1000 PSI
1500 PSI
2500 PSI
3:1
2500 PSI
PSI
102
E 9
ROTATE
PRIMARY EXT/RET
8.5/5.0GPM 13.3(REGEN)9.0/7.2 GPM
PRIMARY LIFT
6.5 GPM
SECONDARY LIFT
10.5/5.0 GPM
TRACTION MANIFOLD
LRAREARLEFT
LRB
RRB
50%
50%
REARRIGHT RRA
T
LFA
LEFTFRONT
LFB
A BTEST
71%29%
50%
50%
FRONT
RFB
RIGHTRFA
3:1
1:1
3:1
3:1
4.5:1
3000 PSI
3000 PSI
DEM1
B
M4
M5
L1 L2 S
Ø.030
TANK
PMP SRSESDSUPRPEPDPU
STR
LFBK
LF2SP
P2
AX2
AUXILIARY
PUMP 2
T2
RFBK
RF2SP
LRBK
LR2SP
RR2SP
RRBK
TURNTABLE
T2
A
3625
PSI
315
PSI
PSI
3625
1.5:1 3500 PSI
4.5:1 2000 PSI
PUMP
DRIVE PUMP
FUNCTION
0.9/0.7 GPM
2.0 GPM 3.8 (REGEN)JIB EXT/RET
3.3/1.2 GPMJIB UP/DWN
JU
BELLCRANK LEVEL3.6/1.6 GPM
T1
2.0
TRRTRL
Ø.030
RAE
STEERINGLEFT REAR
STEERINGLEFT FRONT
P LFE LFR RFR
RIGHT FRONT
RFE
STEERING
LRE
STEERINGRIGHT REAR
LRR RRE RRR FAE FAR
FRONT AXLEEXTENSION
RAR
EXTENSIONREAR AXLE
PSI
2600
SECONDARY EXTENSION CYLINDERS
17.0/5.6GPM 22.6(REGEN)
A
B
A
B
A
B
B
A
2:1 4000 PSI
4.5:1 4000 PSI
3:1 1250 PSI
3:1 3300 PSI
GPM
3100PSI
FUNCTION
ENABLE
VALVE
JD
JE
JR
JLU
JLD
PRL
PRR
PLU
PLD
T
P2
P
0.2GPM
PUMP 1
AUXILIARY
M
AX1
T
B
S
XM2
PETST
25PSI
P1
M2
2 4 3 1 5
5342A2B 1
P
T
STEER/AXLE
FUNCTION MANIFOLD
JIB MANIFOLD
PLATFORM MANIFOLD
COUNTERBALANCE VALVES
1 2
TEST
OIL
COOLER
25PSI PSI
25
TEST
Ø.040L1
DRIVEPUMP
270 PSIGENERATOR21
A
B
PMP A
PMP B
G2
G1
ROTARYHYDRAULIC
COUPLER
4
3
MTR A
MTR B
TO APU SUCTION
WELDER MANIFOLDWELDER OPTION
CLR
1
OIL COOLER
MANIFOLD
Ø.030
250 PSI
2900 PSI
GPM1.5
GPM2.1
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM7.0
2400 PSI
250 PSI
Ø.039
Ø.031
Ø.052
Ø.063
A
LQ
B
H
D
I
F
J
G
K
M
R
N
S
TP
U
W
X
Y
Z
AA
AB
AC AD
AF
AE
AG
BN
BM
BT
BS
BLBK
BR
BQ
BJBI
BC BDBB
BA
BHBGBF
BE
BO BP
BU
BV
BW
BY
BXAX AY
AT
AW
AV
AN
AO
AH
AIAL
AM
AKAJ
AR
AS
AQ
AP
V
AU
AZ
BZ
CA CB
CT
CG
CU
CM
CL
CE
CH
CX
CR
CV
CI
CJ
CF
CN
CP
CO
CS
CK
CQ
CZ DA
CW
CY
DA
CZ
CY
CX
CW
CV
CU
CT
CS
CR
CQCPCOCMCL
CN
CK
CJCICHCGCFCECACBCB CA
CD CD
CCCC
DB DC DD DE
DB DC
DD DE
DC
DB
DD
PSI
51
O
EC
100PSI DF
AFTER SERIALNUMBER 439
HS0080F
REV B
April 2008 Section 6 • Schematics
6 - 56
Hydraulic Schematic(serial number 102 and from serial number 180 to 534)
6 - 55
Section 6 • SchematicsApril 2008
1
2
3
4
5
6
7
8
N M L K J I H G F E D C B A
Part No. 106783 Z-135/70 6 - 57
Hydraulic Schematic(from serial number 535)
M
CHARGE FILTER
PLATFORM LEVEL
PLATFORM ROTATE
TANK
0.30 GPM
FILTER
PRESSURE
HIGH
RATIO PRESS
1000 PSI3:1
2500 PSI
PSI
102
E 9
ROTATE
PRIMARY EXT/RET
8.5/5.0GPM 13.3(REGEN)9.0/7.2 GPM
PRIMARY LIFT
6.5 GPM
SECONDARY LIFT
10.5/5.0 GPM
TRACTION MANIFOLD
LRAREARLEFT
LRB
RRB
50%
50%
REARRIGHT RRA
T
LFA
LEFTFRONT
LFB
A BTEST
71%29%
50%
50%
FRONT
RFB
RIGHTRFA
3:1
4.5:1 3000 PSI
DEM1
B
M4
M5
L1 L2 S
Ø.030
TANK
PMP SRSESDSUPRPEPDPU
STR
LFBK
LF2SP
P2
AX2
AUXILIARY
PUMP 2
T2
RFBK
RF2SP
LRBK
LR2SP
RR2SP
RRBK
TURNTABLE
T2
A
3625
PSI
315
PSI
PSI
3625
1.5:1 3500 PSI
4.5:1 2000 PSI
PUMP
DRIVE PUMP
FUNCTION
0.9/0.7 GPM
2.0 GPM 3.8 (REGEN)JIB EXT/RET
3.3/1.2 GPMJIB UP/DWN
JU
BELLCRANK LEVEL3.6/1.6 GPM
T1
2.0
TRRTRL
Ø.030
RAE
STEERINGLEFT REAR
STEERINGLEFT FRONT
P LFE LFR RFR
RIGHT FRONT
RFE
STEERING
LRE
STEERINGRIGHT REAR
LRR RRE RRR FAE FAR
FRONT AXLEEXTENSION
RAR
EXTENSIONREAR AXLE
PSI
2600
SECONDARY EXTENSION CYLINDERS
17.0/5.6GPM 22.6(REGEN)
A
B
A
B
A
B
B
A
2:1 4000 PSI
4.5:1 4000 PSI
3:1 1250 PSI
3:1 3300 PSI
GPM
3100PSI
FUNCTION
ENABLE
VALVE
JD
JE
JR
JLU
JLD
PRL
PRR
PLU
PLD
T
P2
P
0.2GPM
PUMP 1
AUXILIARY
M
AX1
T
B
S
XM2
PETST
25PSI
P1
M2
2 4 3 1 5
5342A2B 1
P
T
STEER/AXLE
FUNCTION MANIFOLD
JIB MANIFOLD
PLATFORM MANIFOLD
COUNTERBALANCE VALVES
1 2
TEST
OIL
COOLER
25PSI PSI
25
TEST
Ø.040L1
DRIVEPUMP
270 PSIGENERATOR21
A
B
PMP A
PMP B
G2
G1
ROTARYHYDRAULIC
COUPLER
4
3
MTR A
MTR B
TO APU SUCTION
WELDER MANIFOLDWELDER OPTION
CLR
1
OIL COOLER
MANIFOLD
Ø.030
250 PSI
2900 PSI
GPM1.5
GPM2.1
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM2.1
GPM1.5
GPM7.0
2400 PSI
250 PSI
Ø.039
Ø.031
Ø.052
Ø.063
A
LQ
B
H
D
I
F
J
G
K
M
R
N
S
TP
U
W
X
Y
Z
AA
AB
AC AD
AF
AE
AG
BN
BM
BT
BS
BLBK
BR
BQ
BJBI
BC BDBB
BA
BHBGBF
BE
BO BP
BU
BV
BW
BY
BXAX AY
AT
AW
AV
AN
AO
AH
AIAL
AM
AKAJ
AR
AS
AQ
AP
V
AU
AZ
BZ
CA CB
CT
CG
CU
CM
CL
CE
CH
CX
CR
CV
CI
CJ
CF
CN
CP
CO
CS
CK
CQ
CZ DA
CW
CY
DA
CZ
CY
CX
CW
CV
CU
CT
CS
CR
CQCPCOCMCL
CN
CK
CJCICHCGCFCECACBCB CA
CD CD
CCCC
DB DC DD DE
DB DC
DD DE
DC
DB
DD
PSI
51
2500 PSI
3000 PSICU
2:1 3000 PSICU
1500 PSI
O
EC
100PSI DF
AFTER SERIALNUMBER 439
HS0080J
(before serial number 558)
3:1
3:1
1:1
(from serial number558 to 658)
(after serial number 657)
REV A
April 2008 Section 6 • Schematics
6 - 58
Hydraulic Schematic(from serial number 535)
6 - 57
Dis
trib
ute
d B
y:
Genie North America
Genie Australia Pty Ltd.
Genie China
Genie Malaysia
Genie Japan
Genie Korea
Genie Brasil
Genie Holland
Phone 425.881.1800
Toll Free USA and Canada
800.536.1800
Fax 425.883.3475
Phone +61 7 3375 1660
Fax +61 7 3375 1002
Phone +86 21 53852570
Fax +86 21 53852569
Phone +65 98 480 775
Fax +65 67 533 544
Phone +81 3 3453 6082
Fax +81 3 3453 6083
Phone +82 25 587 267
Fax +82 25 583 910
Phone +55 11 41 665 755
Fax +55 11 41 665 754
Phone +31 183 581 102
Fax +31 183 581 566
Genie Scandinavia
Genie France
Genie Iberica
Genie Germany
Genie U.K.
Genie Mexico City
Phone +46 31 575100
Fax +
Phone +33 (0)2 37 26 09 99
Fax +33 (0)2 37 26 09 98
Phone +34 93 579 5042
Fax +34 93 579 5059
Phone 0800 180 9017
Fax +49 422 149 1820
Phone +44 (0)1476 584333
Fax +44 (0)1476 584334
Phone +52 55 5666 5242
Fax +52 55 5666 3241
46 31 579020
Phone +49 422 149 1818
California Proposition 65
The exhaust from this product
contains chemicals known to
the State of California to
cause cancer, birth defects
or other reproductive harm.
Warning