Service Genie Z135

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

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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

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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

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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-5 Perform Engine Maintenance -Deutz TD2011L04i and Perkins 804D-33T Models ...................................... 3 - 58

E-6 Perform Engine Maintenance - Deutz TD2011L04i Models ......................... 3 - 59


E-8 Perform Engine Maintenance - Perkins 1104C-44 Models .......................... 3 - 60


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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

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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

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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

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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

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xv

Z-135/70 Part No. 106783

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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


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


2 - 4 Z-135/70 Part No. 106783


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





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)


Part No. 106783 Z-135/70 2 - 5



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


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


2 - 6 Z-135/70 Part No. 106783


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


Part No. 106783 Z-135/70 2 - 7


REV G

Lubrication system


Oil capacity 12.8 quarts(including filter) 12.1 liters


-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


Oil temperature switch


Oil temperature switch point 275°F135°C

Oil pressure switch



Deutz TD2011L04i Engine




HorsepowerNet intermittent @ 2400 rpm 74 / 55 kW

Induction system turbocharged











SPECIFICATIONS

2 - 8 Z-135/70 Part No. 106783


REV GSPECIFICATIONS



Injection pump make Motorpal

Injection pump pressure, maximum 15,000 psi1034 bar


Fuel requirement


Starter motor








Fan belt deflection 3/8 to 1/2 inch9 to 12 mm

Part No. 106783 Z-135/70 2 - 9


REV G

Cummins B4.5L Engine

Displacement 275 cu in4.5 liters



Horsepower 80 @ 2200 rpm60 kW @ 2200 rpm




Compression ratio 18:1





Lubrication system

Oil pressure, hot 50 psi(at 2000 rpm) 3.45 bar

Oil capacity 9.5 quarts(including filter) 9 liters


Below 68°F / 20°C 5W-30

-10° to 68°F / -23° to 20°C 10W-30

Above 15°F / -9°C 15W-40



Injection pump make Delphi

Injection pump pressure 3480 to 3680 psi240 to 254 bar


Fuel requirement






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


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


REV G

Cummins B3.3T Engine




Horsepower 80 @ 2200 rpm60 kW @ 2200 rpm




Compression ratio 17:1





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


Below 68°F / 20°C 5W-30

-10° to 68°F / -23° to 20°C 10W-30

Above 14°F / -10°C 15W-40



Injection pump make Zexel

Injection pressure 12,000 psi827 bar

Fuel requirement






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


Part No. 106783 Z-135/70 2 - 11



Perkins 1104C-44 Engine



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










Lubrication system


Oil capacity 7.3 quarts(including filter) 6.9 liters


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


Oil pressure sending unit




Injection pump make Bosch


Fuel requirement







2 - 12 Z-135/70 Part No. 106783


REV GSPECIFICATIONS

Starter motor



Engine coolant

Capacity 14 quarts13.2 liters




Alternator output 85A @ 13.8V DC

Fan belt deflection 3/8 in10 mm


Part No. 106783 Z-135/70 2 - 13



Perkins 804D-33T Engine




Horsepower

Gross intermittent @ 2500 rpm 83 / 62 kW

Induction system turbocharged










Lubrication system


Oil capacity 10.6 quarts(including filter) 10 liters


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


Oil pressure sending unit




Injection pump make Bosch


Fuel requirement







2 - 14 Z-135/70 Part No. 106783


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





Fan belt deflection 3/8 to 1/2 in9 to 12 mm


Part No. 106783 Z-135/70 2 - 15


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)


-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)


-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


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




Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


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


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



Part No. 106783 Z-135/70 3 - 5


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


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


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:


Perform every 3,000 hours:

E-5 Engine maintenance -Deutz models


E-6 Engine maintenance -Deutz TD2011L04imodels




E-8 Engine maintenance -Perkins 1104C-44models



Model

Serial number

Date

Hour meter

Machine owner


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


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


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


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



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






CHECKLIST A PROCEDURES

3 - 10 Z-135/70 Part No. 106783



A-6Perform Engine Maintenance -Perkins Models



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





A-7Check the Hydraulic ReturnFilter Condition Indicator


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


REV G

A-8Inspect the Fuel Filter/ WaterSeparator - Perkins Models


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.


a

3 - 12 Z-135/70 Part No. 106783



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


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.



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


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


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


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.


Part No. 106783 Z-135/70 3 - 15


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

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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

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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.


• 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.


• Hydraulic manifold wiring


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.


• 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.


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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.


STOP

00000

Run

ServiceBypass

Recovery

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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.


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.


21 Close the turntable side cover.


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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.






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.





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B-5Check the Engine Oil Cooler andCooling Fins - Deutz Models


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.


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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


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.


disengaged position

engaged position

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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


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.


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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.


3 At the ground controls, operate each boomfunction through a partial cycle.

Result: All boom functions should operate.


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B-10Test the Platform Self-leveling


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.


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.


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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.



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.


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.



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B-12Test the Drive Brakes


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


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: 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.


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.


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B-14Test the Drive Speed -Raised or Extended Position


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.


1 Create start and finish lines by marking two lineson the ground 40 feet / 12.2 m apart.


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.


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.


12 Continue at top speed and note the time whenthe machine reference point crosses the finishline. Refer to Section 2, Specifications.


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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


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.


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B-17Replace the Inline Fuel Filter/Water Separator Element -Perkins Models


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.



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.


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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


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:


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.


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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.


Cummins and Perkins models:







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.

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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.




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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.


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.


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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.


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.


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.




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.



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.

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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.



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.




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


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.


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.

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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.



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.


Part No. 106783 Z-135/70 3 - 39


REV D

B-22Perform Engine Maintenance -Cummins Models


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.









3 - 40 Z-135/70 Part No. 106783


REV D

C-1Perform Engine Maintenance -Deutz Models

Note: Engine specifications require that thisprocedure be performed every 500 hours or 6months, whichever comes first.









Checklist C Procedures

C-2Perform Engine Maintenance -Cummins Models










Part No. 106783 Z-135/70 3 - 41


REV D

C-3Perform Engine Maintenance -Perkins Models










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.


Chevron Ultra-duty grease, EP NLGI 2 (lithium based)or equivalent

CHECKLIST C PROCEDURES

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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


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: 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).


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.


Result: All ground control functions shouldoperate normally.

13 Turn the key switch to platform control.


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

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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


REV D

D-2Check the Free-wheelConfiguration


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

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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


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.


a

d

c

b

a

Part No. 106783 Z-135/70 3 - 47


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

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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.



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


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.


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.


b ca

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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.


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


REV D CHECKLIST D PROCEDURES

D-6Perform Engine Maintenance -Deutz Models

Note: Engine specifications require that thisprocedure be performed every 1000 hours.









D-7Perform Engine Maintenance -Cummins Models










3 - 52 Z-135/70 Part No. 106783


REV D

D-8Perform Engine Maintenance -Perkins Models











D-9Check the Turntable RotationBearing Bolts


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.




Part No. 106783 Z-135/70 3 - 53


REV D



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.




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)


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

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REV D

D-10Inspect for Turntable BearingWear


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.


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


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.


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.

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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.


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.


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


REV D CHECKLIST E PROCEDURES

E-2Perform Engine Maintenance -Cummins Models










E-3Perform Engine Maintenance -Perkins 804D-33T Models


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).






3 - 58 Z-135/70 Part No. 106783




Note: Engine specifications require that thisprocedure be performed every 2 years.








E-5Perform Engine Maintenance -Deutz TD2011L04i andPerkins 804D-33T Models



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).







Part No. 106783 Z-135/70 3 - 59


REV D CHECKLIST E PROCEDURES

E-6Perform Engine Maintenance -Deutz TD2011L04i Models



Required maintenance procedures and additionalengine information are available in theDeutz TD2011 Operation Manual(Deutz part number 0312 3547).







Note: Engine specifications require that thisprocedure be performed every 6000 hours or3 years, whichever comes first.








3 - 60 Z-135/70 Part No. 106783



E-8Perform Engine Maintenance -Perkins 1104C-44 Models



Required maintenance procedures and additionalengine information are available in thePerkins 1100 Series User's Handbook(Perkins part number TPD 1477).







Note: Engine specifications require that thisprocedure be performed every 12,000 hours or6 years, whichever comes first.








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.


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




With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.


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


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% 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)

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REV CDISPLAY MODULE

Screen or Menu


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



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


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REV CDISPLAY MODULE

Screen or Menu


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



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



Screen or Menu


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.

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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

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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


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

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REV CPLATFORM CONTROLS

How to Remove the LEDCircuit Board1 Push in the red Emergency Stop button to the



3 Locate the LED circuit board mounted to theinside of the platform control box lid.



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.


3 Tag and carefully disconnect the two riboncables from the membrane circuit board.



Part No. 106783 Z-135/70 4 - 11


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.


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.

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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:




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,



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.


Primary boom extend/retract functions:




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.


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.


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REV C

Secondary boom up/down andextend/retract functions:




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,



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.


Primary boom up/down functions:




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.


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.


PLATFORM CONTROLS

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REV C

Jib boom up/down functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET JIB BOOM UP/DOWN JOYSTICK




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.


Turntable rotate functions:




enter button twice.

4 Use the scroll button to scroll through themenu until RESET TURNTABLE ROTATE JOYSTICK




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.


PLATFORM CONTROLS

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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.




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.


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.

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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.


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.

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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.


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.




9 Continue to perform this procedure until themachine function speed meets specification.Refer to Section 2, Specifications for functionspeeds.

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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.




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.




PLATFORM CONTROLS

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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.

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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.


5 Tag, disconnect and plug the hydraulic hosesfrom the platform manifold. Cap the fittings onthe manifold.


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.

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REV D PLATFORM COMPONENTS

8 Remove the weld cable from the platform(if equipped).


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.


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.


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.

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All models:


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.





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.


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


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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.


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: 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



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: All platform control functions should notoperate.

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

Part No. 106783 Z-135/70 4 - 25



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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


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.


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.


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

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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


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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.



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.


JIB BOOM COMPONENTS

3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses from the jib boommanifold. Cap the fittings on the manifold.


4 Remove the cotter pin from the upper cabletrack tube at the platform end of the jib boom.


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.



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.

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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


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3-3Jib Boom Lift Cylinder

How to Remove the Jib BoomLift CylinderNote: Perform this procedure with the boom in thestowed position.


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.


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


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3-4Jib Boom Level Cylinder

How to Remove the Jib BoomLevel CylinderNote: Perform this procedure with the boom in thestowed position.


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.


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.


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


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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.



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.


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.


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


REV EJIB BOOM COMPONENTS


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


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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


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







All models:


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.


sequence: .

JIB BOOM COMPONENTS

Part No. 106783 Z-135/70 4 - 37


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


REV E

18 Press and hold a function enable/speed selectbutton and the platform level down button untilthe digital level displays approximately34 ± 5 degrees.







or minus button to to adjust the display toto the exact value shown on the digital level andpress the enter button .



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.




Note: Be sure the number entered at the groundcontrols is a negative number.









60�

34�

8� 0�-18�

-44�

-70�

Calibration angles

Part No. 106783 Z-135/70 4 - 39


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.




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.




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.






33 Remove the fastener that was temporarilyinstalled in step 6.

34 Close the control box door and install the doorretaining fasteners.


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


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


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.


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.


10 Remove the retaining fasteners from the cabletrack guide at the platform end of the boom.Remove the cable track guide from themachine.



BOOM COMPONENTS

4 - 42 Z-135/70 Part No. 106783


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.


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.


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.


Part No. 106783 Z-135/70 4 - 43


REV F

How to Repair the Primary BoomCable Track


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.











9 Operate the primary boom extend/retractfunction through a full cycle to ensure smoothoperation of the new section of cable track.

BOOM COMPONENTS

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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.



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.


BOOM COMPONENTS

Part No. 106783 Z-135/70 4 - 45


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.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



How to Repair the SecondaryBoom Cable Track


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.






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.






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



4-3Primary Boom

How to Remove the PrimaryBoom


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 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.

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REV F

10 Tag, disconnect and plug the primary boomextension cylinder hydraulic hoses. Cap thefittings on the cylinder.


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


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




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.


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

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4-5Secondary Boom Lift Cylinder

How to Remove the SecondaryBoom Lift Cylinder



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.







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



7 Close the two hydraulic tank shut-off valves atthe hydraulic tank.


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.


18 Tag and disconnect the cables from the enginestarting/controls battery located on the engineside of the machine.


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.


4 - 52 Z-135/70 Part No. 106783



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



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




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.


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



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




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.



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.


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



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.



6 Remove the sensor retaining fasteners from thebracket. Remove the angle sensor.



a b c

de

4 - 56 Z-135/70 Part No. 106783





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.


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.


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



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.



1 Push in the ground controls red Emergency Stopbutton to the off position.









All models:



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.


STOP

00000

Run

ServiceBypass

Recovery

4 - 58 Z-135/70 Part No. 106783





10 Push one of the LCDscreen buttons shownuntil RESET PRIMARY BOOM

ANGLE SENSOR is displayed.



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 .



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.


or minus button to adjust the display to theexact value shown on the digital level and pressthe enter button .




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


REV F






20 Press and hold a function enable/speed selectbutton and the primary boom up button until thedigital level displays approximately10 ± 5 degrees.





22 Press and hold a function enable/speed selectbutton and the primary boom up button until thedigital level displays approximately40 ± 5 degrees.


or minus button to to adjust the display tothe exact value shown on the digital level andpress the enter button .



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.









BOOM COMPONENTS

4 - 60 Z-135/70 Part No. 106783


REV F









BOOM COMPONENTS

All models:



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



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.



6 Remove the sensor retaining fasteners from thebracket. Remove 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.


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


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.


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.












All models:



sequence: .

BOOM COMPONENTS

Part No. 106783 Z-135/70 4 - 63


REV F



9 Push one of the LCDscreen buttons shownuntil RESET SECONDARY BOOM

ANGLE SENSOR is displayed.



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 .






14 Press and hold a function enable/speed selectbutton and the secondary boom up button untilthe digital level displays approximately20 ± 5 degrees.





BOOM COMPONENTS

STOP

00000

Run

ServiceBypass

Recovery

4 - 64 Z-135/70 Part No. 106783


REV F








or minus button to to adjust the display tothe exact value shown on the digital level andpress the enter button .




BOOM COMPONENTS





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.








Part No. 106783 Z-135/70 4 - 65


REV F












BOOM COMPONENTS

All models:



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


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


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

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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.


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


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.

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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


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


2 Remove the ground control box lid fasteners.Open the control box lid.



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.

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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.



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


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.


2 Tag, disconnect and plug the function pumphydraulic hoses. Cap the fittings on the pump.


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.

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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.

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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.


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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.


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.


3 Tag, disconnect and plug the hydraulic hosesfrom the drive and function pumps. Cap thefittings on the pumps.


4 Support the pumps with a suitable lifting deviceand remove the two drive pump mountingfasteners.

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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.

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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

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8-2Function Manifold - View 2 (before serial number 440)


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

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8-3Function Manifold - View 1 (after serial number 439)


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

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8-4Function Manifold - View 2 (after serial number 439)


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

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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.


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.


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.




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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.



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.

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8-6Platform Manifold

The platform manifold is mounted to the platform mounting weldment.


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

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8-7Jib Boom Manifold

The jib boom manifold is mounted inside the primary extension boom at the platform end.


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

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8-8Function Enable Valve

The function enable valve is mounted behind the medium pressure filter.


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

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8-9Turntable Rotation Manifold

The turntable rotation manifolds are mounted to the turntable rotation drive hub motors.


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

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8-10Steer and Axle Manifold

The steer and axle manifold is mounted inside the manifold box at the yellow triangle side of the machine.


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


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.

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Steer and Axle Manifold, continued


14 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BK ......... Left rear steer cylinder


15 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BM ........ Right rear steer cylinder


16 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ BG ........ Left front steer cylinder


17 Flow regulator valve,2.1 gpm / 8 L/min ............................... BF ......... Left front steer cylinder


18 Flow regulator valve,2.1 gpm / 8 L/min ............................... BH ........ Right front steer cylinder


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

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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.


5 Adjust the internal hex socket clockwise toincrease the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.


6 Repeat steps 3 through 5 to confirm relief valvepressure.


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8-12Traction Manifold - View 1

The traction manifold is mounted inside the manifold box at the blue triangle side of the machine.


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


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


REV E

8-13Traction Manifold - View 2

The traction manifold is mounted inside the manifold box at the blue triangle side of the machine.


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


REV E

AK

AU

AV

AL

AQ

AS

4

6

5

1

2

3

MANIFOLDS

4 - 104 Z-135/70 Part No. 106783


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.


5 Press and hold the function enable/high rpmselect button (rabbit symbol) position. Note thereading on the pressure gauge.


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).


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.


Part No. 106783 Z-135/70 4 - 105


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.


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


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.


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


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.


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


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.


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


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.











All models:



7 Enter sensor calibration mode by pressing thebuttons at the ground controls in the followingsequence: .



TURNTABLE ROTATION COMPONENTS

STOP

00000

Run

ServiceBypass

Recovery

4 - 110 Z-135/70 Part No. 106783


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 .



12 Push one of the LCDscreen buttons shownuntil SET UNIT Y AXIS LEVEL TO

GRAVITY is displayed.


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.





+Y axis -Y axis

Platform

+X axis

-X axis

Part No. 106783 Z-135/70 4 - 111


REV E










All models:





22 Start the engine. Be sure there are no calibrationfaults shown on the display.

4 - 112 Z-135/70 Part No. 106783


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


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


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.



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.


AXLE COMPONENTS

Part No. 106783 Z-135/70 4 - 115


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.



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.







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


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.


7 Push in the red Emergency Stop button to theoff position.


AXLE COMPONENTS




sequence: .

11 Push one of the LCDscreen buttons shownuntil RESET ALL STEER

SENSORS is displayed.



STOP

00000

Run

ServiceBypass

Recovery

Part No. 106783 Z-135/70 4 - 117


REV F AXLE COMPONENTS




15 Turn the machine off by pushing in the redEmergency Stop button to the off position.









All models:


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.


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


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.


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



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


REV F

b

a

c

d

e

Illustration 2a starting positionb installed positionc sensor coverd rotation arrowe drive chassis side plate



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


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.


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.







All models:



sequence: .

AXLE COMPONENTS

4 - 122 Z-135/70 Part No. 106783


REV F



12 Push one of the LCDscreen buttons shownuntil RESET AXLE ANGLE

SENSORS is displayed.



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.









Part No. 106783 Z-135/70 4 - 123











All models:



4 - 124 Z-135/70 Part No. 106783



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.



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.



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 0,



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


pressed)

Primary boom Ext/Ret disabled, display message on LCD.


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


Part No. 106783 Z-135/70 5 - 3


REV B CONTROL SYSTEM FAULT CODES


Not calibrated

Normal function except threshold for one or the other direction is zero. Display message on LCD.

Perform calibration procedure.


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


Check for shorts to ground in the wiring. Replace coil if necessary.

Not calibrated




No action required.

Value Too High


Check for opens in the wiring or a bad ground. Replace coil if necessary.

Value Too Low


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


5 - 4 Z-135/70 Part No. 106783


REV BCONTROL SYSTEM FAULT CODES


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


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.


No action required.


Value too high


Value too low


Value at 0,


Out of Tolerance

Recalibrate sensor.

Not calibratedPrimary Up only active from TCON activate alarm



No action required.

OPERATIONAL PRIMARY BOOM ANGLE SENSOR

Primary Up, Secondary Up/Dwn and Extend disabled, Alarm sounds

SAFETY PRIMARY BOOM ANGLE SENSOR


Part No. 106783 Z-135/70 5 - 5






Value at 0,



Sec Boom Up/Ext/Dwn/Ret

switches on TCON


pressed)

Sec Boom Up/Ext/Dwn/Ret disabled, display message on LCD.


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




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



Secondary Boom Joystick


SEC BOOM UP/DOWN/EXT/RET FLOW VALVE


5 - 6 Z-135/70 Part No. 106783





Value too high


Value too low


Value at 0,


Out of Tolerance

Recalibrate sensor.

Not calibratedSecondary Up only active from TCON activate alarm



No action required.

OPERATIONAL SECONDARY BOOM ANGLE

SENSOR


Part No. 106783 Z-135/70 5 - 7





Value too high


Value too low


Value at 0,


Out of Tolerance

Recalibrate sensor.

Not calibratedSecondary Up only active from TCON activate alarm



No action required.

SAFETY SECONDARY BOOM ANGLE

SENSOR


5 - 8 Z-135/70 Part No. 106783




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


pressed)

Axle Extend/Retract disabled, display message on LCD.


AXLE VALVE fault check



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




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


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


Recycle Power

fault check

fault check

fault check

5 - 10 Z-135/70 Part No. 106783




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


Recycle Power

SAFETY SWITCH P18


Recycle Power

SAFETY SWITCH P22


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


Recycle Power and check wiring on circuit S140ENL (orange/black) between SCON and TCON. Check SCON chart for possible fault conditions.

SAFETY SWITCH P38


Recycle Power and check wiring on circuit S137PLL (red/wht) between SCON and TCON. Check SCON chart for possible fault conditions.

SAFETY SWITCH P39


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



Error Source Error Type Effects Corrective ActionValue at 5.0 VValue too highValue too low

Value at 0,



TURNTABLE ROTATE

BUTTONS


pressed)

TT rotate disabled, display message on LCD.


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


Perform calibration procedure


No action required



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


fault check


TURNTABLE ROTATE

JOYSTICK

Limited Speed and Direction frozen at zero and neutral, Alarm sounds


5 - 12 Z-135/70 Part No. 106783



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


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


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


No action required


Value at 0,Out of

Tolerance


No action required


Value at 0,


No action required

SAFETY TURNTABLE

LEVEL SENSOR Y-DIRECTION

Primary & Secondary Up and Extend disabled, Alarm sounds

Replace SCON

PLATFORM LEVEL SENSOR Y-

DIRECTION


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


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



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




No action required



Not calibrated




No action required



JIB LEVEL UP/DWN FLOW

VALVE


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


5 - 14 Z-135/70 Part No. 106783




Not calibrated




No action required



Not calibrated




No action required



JIB UP/DWN SWITCHES

JIB EXT/RET SWITCHESPLAT ROT SWITCHES

Value at 5.0 VValue too highValue too low

Value at 0,




JIB UP/DWN JOYSTICK



PLATFORM LEVEL DWN

FLOW VALVE


Fault Check, (both closed)

Affected functions disabled, display message on LCD.

PLATFORM LEVEL UP FLOW

VALVE


Part No. 106783 Z-135/70 5 - 15



Error Source Error Type Effects Corrective ActionValue at 5.0 VValue too highValue too low

Value at 0,




Value at 0,


Value at 5.0 VCheck for an open ground circuit going to the sensor

Value high


Value too low


Value at 0,


Not calibratedDisplay message at TCON activate alarm

Recalibrate sensor


Perform calibration procedure per service manual or Z135 training CD

FRONT AXLE ANGLE SENSOR


JIB EXT/RET JOYSTICK



PLATFORM ROTATE

JOYSTICK



5 - 16 Z-135/70 Part No. 106783





Value too high


Value too low


Value at 0,


Not calibratedDisplay message at TCON activate alarm

Recalibrate sensor


Perform calibration procedure per service manual or Z135 training CD


Value at 0,



Not calibrated




No action required



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


REAR AXLE ANGLE SENSOR


Part No. 106783 Z-135/70 5 - 17



Error Source Error Type Effects Corrective ActionMOTOR SPEED

VALVE

BRAKE VALVE

AUX PROPEL VALVE


Value at 0,




Value too high


Value too low


Value at 0,


LF STR ANG SNSR


fault check fault checkCheck for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary

STEERING 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

5 - 18 Z-135/70 Part No. 106783





Value too high


Value too low


Value at 0,



Value too high


Value too low


Value at 0,


LR STR ANG SNSR


RF STR ANG SNSR


Part No. 106783 Z-135/70 5 - 19





Value too high


Value too low


Value at 0,


LF STEER VALVE

RF STEER VALVE

LR STEER VALVE

RR STEER VALVE

fault check


Check for defective or damaged wiring. Check for an open or shorted valve coil. Repair or replace as necessary

RR STR ANG SNSR


5 - 20 Z-135/70 Part No. 106783


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.



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


Hydraulic Schematics


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


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


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


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


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


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


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


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


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


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


6 - 12 Z-135/70 Part No. 106783

Safety Controller Pin Legend


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


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


CONNECTORS


CONNECTORS


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


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



DESCRIPTION

CR15 GLOW PLUG RELAY



F22

F23



Deutz TD2011L04iLABEL

F7

CB10

CR1

CR5

CR28

START RELAY

HORN RELAY

ENGINE / FUEL RELAY



DESCRIPTION

CR15 GLOW PLUG RELAY



F22

F23



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


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


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


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


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


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

+

-

-

+


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


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







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






TO HORN BUTTON

PWR TO TCON ESTOP


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


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


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


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


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


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

+

-

-

+


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)


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


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


6 - 21

Electrical Schematic - View 1Drive Chassis Controller (DCON)

6 - 22


1

2

3

4

5

6

7

8


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


1

2

3

4

5

6

7

8


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


6 - 24

Electrical Schematic - View 2Platform Controls (PCON)

6 - 23


6 - 25

Electrical Schematic - View 3Ground Controls (TCON)

6 - 26


1

2

3

4

5

6

7

8


6 - 26 Z-135/70 Part No. 106783


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











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


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 27


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











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






TO HORN BUTTON

PWR TO TCON ESTOP


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


6 - 28


6 - 27


6 - 29


6 - 30


1

2

3

4

5

6

7

8


6 - 30 Z-135/70 Part No. 106783


Continued on View 6

Continuedon View 4


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







P_30

P_22R

P7R

PCON POWER

P_9A

P_6R1

P_11

P_10

P_7R

P_22

P_7






TO HORN BUTTON

PWR TO TCON ESTOP


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


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 31


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







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


TO

MIC

RO

REV C


6 - 32


6 - 31


6 - 33

Electrical Schematic - View 7

6 - 34


1

2

3

4

5

6

7

8


6 - 34 Z-135/70 Part No. 106783


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


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 35


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


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


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)


J147

J157-1

2

SLIP RING

+ -

3 2 1

P

J82

3 4

R90PXS-RD/BK

PLATFORM LEVEL RECOVERYSWITCH (ANSI/CSA ONLY)

REV D


6 - 36


6 - 35


6 - 37


6 - 38


1

2

3

4

5

6

7

8


6 - 38 Z-135/70 Part No. 106783



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


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 39

Electrical Schematic - View 10Limit Switches


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

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GN

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Continued on View 10A

REV D


6 - 40

Electrical Schematic - View 10Limit Switches

6 - 39


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 41

Electrical Schematic - View 10ALimit Switches

LSP1E03'FROM FULLYEXTENDEDJ45

LSP1R03' EXTENDEDOPERATIONALJ44

RD

BR

WH

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AFTER SERIALNUMBER 129WITH SOFTWAREVERSION S0675110

Continued onView 10

OR



RD

BR

WH

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14

22NC

13

21

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31 2


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BEFORE SERIALNUMBER 130WITH SOFTWAREVERSION S0675110

RD

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31 2


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AFTER SERIALNUMBER 129WITH SOFTWAREVERSION S0675100

BEFORE SERIALNUMBER 130WITH SOFTWAREVERSION S0675100

REV A


6 - 42

Electrical Schematic - View 10ALimit Switches

6 - 41


6 - 43

Electrical Schematic - View 11Deutz BF4L 2011 Engine

Deutz TD2011L04i Engine

6 - 44


1

2

3

4

5

6

7

8


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

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INTEGRAL WITHBATTERY CABLE

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F2020A

F2260A

F720A

REV D


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 45



Continued on View 6

P

TT

RO

TC

W/C

CW

F.C

.(J

69

)

PR

IB

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REV B


6 - 46


6 - 45


6 - 47

Electrical Schematic - View 13Perkins 1104C-44 EnginePerkins 804D-33T Engine

6 - 48


1

2

3

4

5

6

7

8


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 5


B1ENG-RD

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B1ENG-RD B1ENG-RD

C45GEN-GR/WH

B2BAT-RD

J32-ENG HARN

B1ENG-RD

B1

BA

T-R

D

B1

BA

T-R

D


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


1

2

3

4

5

6

7

8


Part No. 106783 Z-135/70 6 - 49

Electrical Schematic - View 14Cummins B4.5L Engine and Cummins B3.3T Engine


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


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


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


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


6 - 50

Electrical Schematic - View 14Cummins B4.5L EngineCummins B3.3T Engine

6 - 49


1

2

3

4

5

6

7

8


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


6 - 52

Generator Wiring

6 - 51


6 - 53

Hydraulic Schematic(before serial number 180, except for serial number 102)

6 - 54


1

2

3

4

5

6

7

8


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


1

2

3

4

5

6

7

8


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


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



JU


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


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


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


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


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


6 - 56

Hydraulic Schematic(serial number 102 and from serial number 180 to 534)

6 - 55


1

2

3

4

5

6

7

8


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


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



JU


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


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


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


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


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


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

Service Genie Z135

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