Service Manual - Genie And Service Manuals...Part No 128907. Z-34/22 Bi-Energy January 2008 Danger...

Service Manual Part No. 128907

Rev A

January 2008

Bi-Energy Power(before serial number 4800)

Z-34/22 Bi-Energy Part No. 128907

January 2008

ii

Important

Read, understand and obey the safety rules andoperating instructions in the appropriateGenie Z-34/22 BE Operator’s Manual beforeattempting any maintenance or repair procedure.

This manual provides detailed scheduledmaintenance information for the machine owner anduser. It also provides repair procedures for qualifiedservice professionals.

Basic mechanical, hydraulic and electricalskills are 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 dealerservice center.

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 are subjectto 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 other manuals.

Contact Us:

http://www.genieindustries.come-mail: [email protected]

Copyright © 1997 by Genie Industries

128907 Rev A January 2008Second Edition, First 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. 128907 Z-34/22 Bi-Energy

January 2008

iii

Serial Number Legend

Z3422 07 - 12345

Model

Model year

Sequence

number

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-34/22

Serial number: Z342207-12345

Electrical schematic number: ESXXXX

Machine unladen weight:

Rated work load (including occupants): XX kg

Maximum allowable inclination of the chassis:

0 deg

Gradeability: N/A

Maximum allowable side force : XX N

Maximum number of platfrm occupants: XX

Model year: Manufacture date: 02/01/072007

Maximum wind speed : XX m/s

Maximum platform height : XX m

Maximum platform reach : XX m

Serial number

stamped on chassis

Serial label

(located under cover)

INTRODUCTION


January 2008

iv

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January 2008

DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Genie Z-34/22Bi-Energy Operator’s Manual will result in death orserious injury.

Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare 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.

Safety Rules

v

Section 1 • Safety Rules


January 2008

SAFETY RULES

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.

Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.

Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.

Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.

Yellow without safety alertsymbol—used to indicate thepresense of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.

Green—used to indicate operationor maintenance information.

Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.

vi

Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or

placing loads. Always wear approved steel-toedshoes.

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 that your workshop or work area isproperly ventilated and well lit.

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 .

Section 1 • Safety Rules


January 2008

Table of Contents

vii

Introduction

Important Information ................................................................................................... ii

Serial Number Legend ................................................................................................. iii

Section 1 Safety Rules

General Safety Rules .................................................................................................. v

Section 2 Rev Specifications

A Machine Specifications .......................................................................................... 2 - 1

Performance Specifications ................................................................................... 2 - 1

Hydraulic Oil Specifications ................................................................................... 2 - 3

Hydraulic Component Specifications ...................................................................... 2 - 4

Manifold Component Specifications ....................................................................... 2 - 5

Machine Torque Specifications .............................................................................. 2 - 5

Kubota Z482-E Engine Specifications .................................................................... 2 - 6

Generator ............................................................................................................... 2 - 7

Generator Torque Specifications ............................................................................ 2 - 7

Hydraulic Hose and Fitting Specifications .............................................................. 2 - 8

SAE and Metric Fasteners Torque Chart ................................................................ 2 - 9

Section 3 Rev Scheduled Maintenance Inspections

A Introduction ............................................................................................................ 3 - 1

Pre-Delivery Preparation ........................................................................................ 3 - 3

Maintenance Inspection Report .............................................................................. 3 - 5

A 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 ....................................................................... 3 - 9

A-5 Check the Generator Belts and Pulleys ........................................................ 3 - 9

A-6 Perform 30 Day Service ............................................................................. 3 - 11


January 2008

TABLE OF CONTENTS

viii

Section 3 Rev Scheduled Maintenance Procedures, continued

A A-7 Perform Engine Maintenance ..................................................................... 3 - 11

A-8 Perform Engine Maintenance ..................................................................... 3 - 12


A-10 Grease the Turntable Rotation Bearing and Worm Gear ............................. 3 - 13

A-11 Replace the Drive Hub Oil .......................................................................... 3 - 14


A Checklist B Procedures

B-1 Check the Exhaust System ....................................................................... 3 - 15

B-2 Inspect the Batteries .................................................................................. 3 - 15

B-3 Inspect the Electrical Wiring ....................................................................... 3 - 17

B-4 Inspect the Tires, Wheels and Lug Nut Torque ........................................... 3 - 17

B-5 Confirm the Proper Brake Configuration...................................................... 3 - 18

B-6 Check the Oil Level in the Drive Hubs ........................................................ 3 - 18

B-7 Check the Glow Plugs ................................................................................ 3 - 19

B-8 Check and Adjust the Engine RPM ............................................................ 3 - 19

B-9 Test the Ground Control Override ............................................................... 3 - 20

B-10 Test the Platform Self-leveling ................................................................... 3 - 21

B-11 Test the Engine Idle Select ........................................................................ 3 - 21

B-12 Test the Drive Brakes ................................................................................ 3 - 22

B-13 Test the Drive Speed - Stowed Position ..................................................... 3 - 23

B-14 Test the Drive Speed - Raised or Extended Position .................................. 3 - 23

B-15 Test the Alarm Package - Optional Equipment ........................................... 3 - 24

B-16 Test the Turntable Rotation Stop ................................................................ 3 - 25

B-17 Check the Electrical Contactors ................................................................. 3 - 25

B-18 Inspect the Fuel and Hydraulic Cap Venting Systems ................................ 3 - 26

B-19 Perform Hydraulic Oil Analysis ................................................................... 3 - 27

B-20 Perform Engine Maintenance ..................................................................... 3 - 27


January 2008

TABLE OF CONTENTS

ix

Section 3 Rev Scheduled Maintenance Procedures, continued

A Checklist C Procedures

C-1 Grease the Platform Overload Mechanisim (if equipped) ............................ 3 - 28

C-2 Test the Platform Overload System (if equipped) ....................................... 3 - 28

C-3 Clean the Fuel Tank ................................................................................... 3 - 31

C-4 Perform Engine Maintenance ..................................................................... 3 - 32

C-5 Perform Engine Maintenance ..................................................................... 3 - 32

A Checklist D Procedures

D-1 Check the Primary Boom Wear Pads ......................................................... 3 - 33

D-2 Check the Turntable Rotation Bearing Bolts ............................................... 3 - 33

D-3 Inspect for Turntable Bearing Wear ............................................................ 3 - 34

D-4 Check the Free-wheel Configuration ........................................................... 3 - 36

D-5 Replace the Drive Hub Oil .......................................................................... 3 - 37

D-6 Replace the Hydraulic Tank Return Filter ................................................... 3 - 37

A Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ............................................................... 3 - 38

E-2 Perform Engine Maintenance ..................................................................... 3 - 39

E-3 Grease the Steer Axle Wheel Bearings ...................................................... 3 - 40

E-4 Perform Engine Maintenance ..................................................................... 3 - 41

Section 4 Rev Repair Procedures

Introduction ............................................................................................................ 4 - 1

A Platform Controls

1-1 Controllers .................................................................................................... 4 - 2

1-2 Diodes .......................................................................................................... 4 - 4

1-3 Foot Switch .................................................................................................. 4 - 4

1-4 Toggle Switches ........................................................................................... 4 - 5


January 2008

TABLE OF CONTENTS

x

Section 4 Rev Repair Procedures, continued

A Platform Components

2-1 Platform ....................................................................................................... 4 - 6

2-2 Platform Leveling Slave Cylinder .................................................................. 4 - 6

2-3 Platform Rotator ........................................................................................... 4 - 7

2-4 Platform Overload System ........................................................................... 4 - 9

A Jib Boom Components

3-1 Jib Boom.................................................................................................... 4 - 11

3-2 Jib Boom Lift Cylinder ................................................................................ 4 - 12

A Primary Boom Components

4-1 Plastic Cable Track .................................................................................... 4 - 13

4-2 Primary Boom ............................................................................................ 4 - 13

4-3 Primary Boom Lift Cylinder ......................................................................... 4 - 16

4-4 Extension Cylinder ..................................................................................... 4 - 18

4-5 Platform Leveling Master Cylinder .............................................................. 4 - 19

A Secondary Boom Components

5-1 Secondary Boom........................................................................................ 4 - 21

5-2 Secondary Boom Lift Cylinder .................................................................... 4 - 24

A Kubota Z-482-E Engine

6-1 Timing Adjustment ..................................................................................... 4 - 25

6-2 Glow Plugs ................................................................................................. 4 - 25

6-3 Engine RPM ............................................................................................... 4 - 25

6-4 Engine Drive Pulley .................................................................................... 4 - 25

6-5 Water Temperature and Oil Pressure Switches .......................................... 4 - 27

A Generator

7-1 Generator ................................................................................................... 4 - 28

7-2 Generator Belts .......................................................................................... 4 - 30

7-3 Generator Voltage Regulator ...................................................................... 4 - 30


January 2008

TABLE OF CONTENTS

xi

Section 4 Rev Repair Procedures, continued

A Ground Controls

8-1 Control Relays ............................................................................................ 4 - 33

8-2 Toggle Switches, See 1-4, Toggle Switches ............................................... 4 - 34

8-3 Wago® Components ................................................................................... 4 - 34

A Hydraulic Pumps

9-1 Auxiliary Pump ........................................................................................... 4 - 35

9-2 Function Pump ........................................................................................... 4 - 36

A Function Manifolds

10-1 Function Manifold Components (before serial number 1112) ....................... 4 - 38

10-2 Function Manifold Components (after serial number 1111) ......................... 4 - 40

10-3 Valve Adjustments - Function Manifold ...................................................... 4 - 42

10-4 Jib Boom / Platform Rotate Manifold Components (before s/n 2006) .......... 4 - 46

10-5 Jib Boom / Platform Rotate Manifold Components (after s/n 2005) ............. 4 - 47

10-6 Steer/Brake Manifold Components (before serial number 1112) .................. 4 - 48

A Fuel and Hydraulic Tanks

11-1 Fuel Tank ................................................................................................... 4 - 49

11-2 Hydraulic Tank ........................................................................................... 4 - 50

A Turntable Rotation Components

12-1 Rotation Hydraulic Motor ............................................................................ 4 - 51

A Steer Axle Components

13-1 Yoke and Hub ............................................................................................ 4 - 52

13-2 Steer Cylinder ............................................................................................ 4 - 53

13-3 Tie Rod ...................................................................................................... 4 - 54

A Non-steer Axle Components

14-1 Drive Motor ................................................................................................ 4 - 55

14-2 Drive Hub ................................................................................................... 4 - 55

A Motor Controller

15-1 Motor Controller .......................................................................................... 4 - 57


January 2008

TABLE OF CONTENTS

xii

Section 5 Rev Troubleshooting Flow Charts

A Introduction ............................................................................................................ 5 - 1

Fault Code Chart .................................................................................................... 5 - 3

1 Engine Will Not Crank Over .......................................................................... 5 - 6

2 Engine Cranks Over But Will Not Start ......................................................... 5 - 9

3 Engine Glow Plugs Inoperative ................................................................... 5 - 12

4 Engine High Idle Inoperative ....................................................................... 5 - 14

5 Engine Low Idle Inoperative ....................................................................... 5 - 16

6 All Lift and Steer Functions Inoperative, Drive Function Operational(before serial number 1112) ........................................................................ 5 - 17

7 All Lift and Steer Functions Inoperative, Drive Function Operational(after serial number 1111) ........................................................................... 5 - 18

8 Ground Controls Inoperative, Platform Controls Operate Normally .............. 5 - 19

9 Platform Controls Inoperative, Ground Controls Operate Normally .............. 5 - 20

10 Primary Boom Up Function Inoperative ...................................................... 5 - 23

11 Primary Boom Down Function Inoperative .................................................. 5 - 26

12 Secondary Boom Up Function Inoperative .................................................. 5 - 29

13 Secondary Boom Down Function Inoperative ............................................. 5 - 32

14 Primary Boom Extend Function Inoperative ............................................... 5 - 35

15 Primary Boom Retract Function Inoperative ............................................... 5 - 38

16 Turntable Rotate Left Function Inoperative ................................................. 5 - 41

17 Turntable Rotate Right Function Inoperative ............................................... 5 - 44

18 All Platform Leveling Functions Inoperative ................................................ 5 - 47

19 Platform Level Up Function Inoperative ...................................................... 5 - 48

20 Platform Level Down Function Inoperative .................................................. 5 - 51

21 Platform Rotate Left Function Inoperative .................................................. 5 - 54

22 Platform Rotate Right Function Inoperative ................................................ 5 - 57


January 2008

Section 5 Rev Troubleshooting Flow Charts, continued

A 23 Jib Boom Up Function Inoperative .............................................................. 5 - 60

24 Jib Boom Down Function Inoperative ......................................................... 5 - 63

25 Steer Left Function Inoperative (before serial number 1112) ....................... 5 - 66

26 Steer Right Function Inoperative (before serial number 1112) ..................... 5 - 68

27 Steer Left Function Inoperative (after serial number 1111) .......................... 5 - 70

28 Steer Right Function Inoperative (after serial number 1111) ........................ 5 - 72

29 All Drive Functions Inoperative, All Other Functions Operate Normally ...... 5 - 74

29A Motor Controller Fault Code 21: Throttle Fault ............................................ 5 - 76

29B Motor Controller Fault Code 32: Main Contactor Welded ............................. 5 - 77

29C Motor Controller Fault Code 34: Mising Main Contactor orMain Contactor Did Not Close .................................................................... 5 - 78

30 Brake Release Function Inoperative ........................................................... 5 - 80

31 Traction Function Inoperative ..................................................................... 5 - 82

32 Machine Will Not Drive At Full Speed ......................................................... 5 - 83

33 Machine Drives At Full Speed With Platform Raised or Extended .............. 5 - 85

34 Drive Enable System Inoperative ............................................................... 5 - 86

35 Auxiliary Functions Inoperative .................................................................. 5 - 88

Section 6 Rev Schematics

A Introduction ............................................................................................................ 6 - 1

A Electrical Components ........................................................................................... 6 - 2

A Electrical Symbols Legend .................................................................................... 6 - 4

A Abbreviation Legend .............................................................................................. 6 - 5

A Hydraulic Symbols Legend .................................................................................... 6 - 6

A Electrical Schematic (before serial number 1468) .................................................. 6 - 7

A Electrical Schematic (from serial number 1468 to 3214) ......................................... 6 - 9

A Electrical Schematic (from serial number 3215 to 3577) ....................................... 6 - 11

A Electrical Schematic (from serial number 3578 to 4799) ....................................... 6 - 13

TABLE OF CONTENTS

xiii


January 2008

xiv

TABLE OF CONTENTS

Section 6 Rev Schematics, continued.................................................................................................

A Ground Control Box (before serial number 1468) .................................................. 6 - 15

A Ground Control Box (from serial number 1468 to 3214) ........................................ 6 - 16



A Platform Control Box (before serial number 1468) ................................................ 6 - 19

A Platform Control Box (from serial number 1468 to 1786) ...................................... 6 - 20




A Power Cable Wiring Diagram (before serial number 1486) .................................... 6 - 24

A Power Cable Wiring Diagram (from serial number 1486 to 4799) .......................... 6 - 25

A Drive Contactor Panel Wiring Diagram (before serial number 1787) ...................... 6 - 26

A Drive Contactor Panel Wiring Diagram (from serial number 1787 to 2060) ............ 6 - 27

A Drive Contactor Panel Wiring Diagram (from serial number 2061 to 4799) ............ 6 - 28

A Manifold and Limit Switch Wiring Diagram (before serial number 1112) ................ 6 - 29

A Manifold and Limit Switch Wiring Diagram (from serial number 1112 to 4799) ...... 6 - 30

A Engine Wiring Diagram ......................................................................................... 6 - 31

A Load Sense Option Wiring Diagram (before serial number 2098) .......................... 6 - 32

A Load Sense Option Wiring Diagram (from serial number 2098 to 3577) ................ 6 - 33

A LVI/BCI Option Wiring Diagram ............................................................................ 6 - 34

A Hydraulic Schematic (before serial number 1112) ................................................ 6 - 35

A Hydraulic Schematic (from serial number 1112 to 2005) ....................................... 6 - 36



Part No. 128907 Z-34/22 Bi-Energy 2 - 1

Section 2 • SpecificationsJanuary 2008

REV A Specifications

Machine Specifications

Tires and wheels Industrial

Tire size 9-14.5 LT

Tire ply rating Tread 6Sidewall 6

Overall tire diameter 28 in71.1 cm

Wheel diameter 14.5 in36.8 cm

Wheel width 7 in17.8 cm

Wheel lugsFront 8 @ 5/8-18Rear 9 @ 5/8-18

Tire pressure 100 psi6.89 bar

Lug nut torque 125 ft-lbs169.5 Nm

Fluid capacities

Fuel tank capacity 12 gallons(before serial number 1947) 45.4 liters

Fuel tank capacity 9.3 gallons(after serial numbar 1946) 35.2 liters

Hydraulic tank capacity 4 gallons15.1 liters

Hydraulic system capacity 6 gallons(including tank) 22.7 liters

Drive hubs 17 ounces0.5 liters

Drive hub oil type: EP 80-90W gear oilAPI service classification GL5

For operational specifications, refer to theOperator's Manual.

Continuous improvement of our products is aGenie policy. Product specifications are subjectto change without notice.

Performance Specifications

Drive speeds (maximum)

Boom stowed 3.7 mph5.9 km/h

40 ft/7.5 sec12.2 m/7.5 sec

Boom raised or extended 0.6 mph1 km/h

40 ft/45.5 sec12.2 m/45.5 sec

Braking distance, maximum

High range on paved surface 3 to 4 ft0.9 to 1.2 m

Gradeability (stowed) See Operator's Manual

2 - 2 Z-34/22 Bi-Energy Part No. 128907

Section 2 • Specifications January 2008

REV A

Boom function speeds, maximumfrom platform controls (with 500 lbs in platform)Before serial number 1734

Jib boom up 30 to 40 seconds

Jib boom down 15 to 25 seconds

Primary boom up 25 to 35 seconds

Primary boom down 15 to 25 seconds

Primary boom extend 25 to 35 seconds

Primary boom retract 15 to 25 seconds

Secondary boom up 15 to 25 seconds

Secondary boom down 10 to 15 seconds

Turntable rotate, 355° 50 to 70 seconds

Platform rotate, 160° 5 to 10 seconds

Platform level up 10 to 20 seconds

Platform level down 10 to 20 seconds

Boom function speeds, maximumfrom platform controls (with 500 lbs in platform)After serial number 1733

Jib boom up 23 to 29 seconds

Jib boom down 20 to 26 seconds

Primary boom up 15 to 21 seconds

Primary boom down 12 to 18 seconds

Primary boom extend 12 to 18 seconds

Primary boom retract 12 to 18 seconds

Secondary boom up 15 to 21 seconds

Secondary boom down 12 to 18 seconds

Turntable rotate, 355° 57 to 63 seconds

Platform rotate, 160° 5 to 10 seconds(before serial number 1892)

Platform rotate, 180° 6 to 11 seconds(after serial number 1891)

Platform level up 10 to 20 seconds

Platform level down 10 to 20 seconds

SPECIFICATIONS



REV A SPECIFICATIONS


Hydraulic Oil 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 MV46Statoil 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.

Use Chevron Aviation A hydraulicfluid when ambient temperaturesare consistently below0°F / -18°C.

Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.

Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.



REV A

Hydraulic ComponentSpecifications

Function pump

Type: Fixed displacement gear pump

Displacement 0.183 cu inper revolution 3 cc

Hydraulic tank 10 micron withreturn line filter with 25 psi / 1.7 bar bypass

Hydraulic tank 25 micronsuction line filter.with 5 psi / .34 bar bypass

Function manifold

Function relief 3200 psivalve pressure 220.6 bar

Primary boom down relief 1400 psiFunction relief 96.5 bar

Secondary boom down relief 1600 psivalve pressure 110.3 bar

Primary boom extend relief 1800 psivalve pressure 124 bar

Turntable rotate relief 1100 psivalve pressures 75.8 bar

Auxiliary pump

Type Fixed displacement gear pump

Displacement 0.75 gpm2.8 L / min


SPECIFICATIONS



REV A

Manifold ComponentSpecifications

Plug torque

SAE No. 2 36 in-lbs / 4 Nm

SAE No. 4 10 ft-lbs / 13 Nm





Valve Coil Resistance

Note: The following coil resistance specifications are atan ambient temperature of 68°F / 20°C. As valve coilresistance is sensitive to changes in air temperature,the coil resistance will typically increase or decrease by4% for each 18°F / 10°C that your air temperatureincreases or decreases from 68°F / 20°C.

Valve coil specifications

3 position 4 way solenoid valve 20V DC 22 - 25Ω(schematic items A, I, J, K, M, N, P, Q, R,S, T, U, W, X, BA, BB, BC, BD, CA and CB)

Proportional solenoid valve 24V DC 4 - 5.2Ω(schematic item H)

Machine Torque Specifications

Platform rotator

3/4 -10 center bolt, GR 8 (dry) 380 ft-lbs515 Nm

3/4 -10 center bolt, GR 8 (lubricated) 280 ft-lbs379 Nm

3/8 -16 bolts, GR 8 (dry) 44 ft-lbs60 Nm

3/8 -16 bolts, GR 8 (lubricated) 33 ft-lbs45 Nm

Turntable rotate assembly

Rotate bearing mounting bolts, lubricated 180 ft-lbs244 Nm

Rotate bearing motor 93 ft-lbsmounting bolts, lubricated 126 Nm

Drive motor and hubs

Drive hub mounting bolts, lubricated 180 ft-lbs244 Nm

Drive motor mounting bolts, lubricated3/8 -16, GR 5 23 ft-lbs

31 Nm7/16 -14, GR 5 37 ft-lbs

50 Nm


SPECIFICATIONS



REV A

Kubota Z482-E Engine

Displacement 29.23 cu in0.48 liters

Number of cylinders 2

Bore and stroke 2.64 x 2.68 inches67 x 68 mm

HorsepowerGross intermitent 12.5 @ 3600 rpm

Firing order 1 - 2

Compression ratio 23:1

Compression pressure 412 to 469 psi28.4 to 32.3 bar

Low idle 2000 rpm

High idle 3000 rpm

Governor centrifugal mechanical

Valve clearance, cold 0.0057 to 0.0072 in0.145 to 0.183 mm

Engine coolant

Capacity 2.9 quarts2.8 liters

Lubrication system

Oil pressure 36 to 64 psi2.48 to 4.41 bar

Oil capacity 2.6 quarts(including filter) 2.5 liters

Oil viscosity 10W-30requirements

Engine oil should have properties of API classificationCC/SE, CD/SE, CC/SF or CD/SF grades.

Injection system

Injection pump make Bocsh MD

Injection timing 21° BTDC

Injection pump pressure 1991 psi137 bar

Fuel requirement diesel number 2-D

AlternatorOutput 12V, 150 watts

Starter motor

Brush length, new 0.5188 in13 mm

Brush length, minimum 0.3346 in8.5 mm

Battery

Type 12V, Group 70

Quantity 1

Cold cranking ampere 450A

Reserve capacity @ 25A rate 125 minutes

Fan belt deflection 1/4 to 3/8 inch7 to 9 mm

SPECIFICATIONS




REV A

Generator

Generator outputwith engine @ 3000 rpm 54V DC, 100A

Generator pulley to engine 1/16 inchpulley offset, maximum 1.6 mm

Belt deflection, maximum 1/4 inch6.4 mm

SPECIFICATIONS


Generator Torque Specifications

Generator pulley retaining nut torque 80-90 ft-lbs108-122 Nm

Engine pulley retaining bolts 108 in-lbs12.2 Nm

#10 screw 25 in-lbs2.8 Nm

#10 nut 25 in-lbs2.8 Nm

#4 nut 8-10 in-lbs0.9-1.1 Nm

Voltage regulator 25 in-lbsmounting fasteners 2.8 Nm



REV ASPECIFICATIONS

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 / 15 Nm

-6 23 ft-lbs / 31 Nm

-8 40 ft-lbs / 54 Nm

-10 69 ft-lbs / 94 Nm

-12 93 ft-lbs / 126 Nm

-16 139 ft-lbs / 188 Nm

-20 172 ft-lbs / 233 Nm

-24 208 ft-lbs / 282 Nm

SAE O-ring Boss Port(tube fitting - installed into Steel)


-4 16 ft-lbs / 22 Nm

-6 35 ft-lbs / 47 Nm

-8 60 ft-lbs / 81 Nm

-10 105 ft-lbs / 142 Nm

-12 140 ft-lbs / 190 Nm

-16 210 ft-lbs / 285 Nm

-20 260 ft-lbs / 353 Nm

-24 315 ft-lbs / 427 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.

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 / 81 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 140 ft-lbs / 190 Nm

-24 180 ft-lbs / 244 Nm



REV A

SIZE THREAD

in-lbs N m in- lbs N m in- lbs N m in- lbs N m in- lbs N m

20 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

f t - lbs N m ft- lbs N m ft- lbs N m ft- lbs N m ft- lbs N m

18 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

5/16

3/8

7/16

1/2

1 1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

LUBED

1/4

LUBED DRY LUBED DRY

LUBEDDRYLUBED

SAE FASTENER TORQUE CHART

Grade 5

DRYLUBED

• This chart is to be used as a guide only unless noted elsewhere in this manual •A574 High Strength Black Oxide Bolts

Grade 8

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 m

5 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 m

8 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 42.610 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 4.6

DRYLUBED

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 8.8

DRY

10.9 12.98.84.6

SPECIFICATIONS

January 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, semi-annually,annually and every two years as specified onthe Maintenance Inspection Report.

Failure to properly complete eachinspection when required 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.

Keep records on all inspections for three years.

Unless otherwise specified, perform eachprocedure with the machine in the followingconfiguration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom between thenon-steer wheels

· Key switch in the off position with thekey removed

· Wheels chocked

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 alert personnel to potentialpersonal injury hazards. Obey allsafety messages that follow thissymbol to avoid possible injury ordeath.

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 presense of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.

Used to indicate operation ormaintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

January 2008Section 3 • Scheduled Maintenance Procedures


Maintenance Symbols Legend

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 will berequired to 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 year. 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

Annually 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. Store completed formsfor three years.

SCHEDULED MAINTENANCE PROCEDURES



Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800

Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries.Rev B

Genie UKThe Maltings, Wharf Road

Grantham, LincolnshireNG31- 6BH England

(44) 1476-584333

Pre-DeliverPre-DeliverPre-DeliverPre-DeliverPre-Delivery Preparationy Preparationy Preparationy Preparationy Preparation

Pre-Delivery Preparation Y N R

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing thePre-operation Inspection, the Maintenance items and theFunction Tests.

Use this form to record the results. Place a check in theappropriate box after each part is completed. Follow theinstructions in the operator’s manual.

If any inspection receives an N, remove the machine fromservice, repair and re-inspect it. After repair, place a checkin the R box.

LegendY = yes, completedN = no, unable to completeR = repaired

Comments

Fundamentals

It is the responsibility of the dealer to perform thePre-delivery Preparation.

The Pre-delivery Preparation is performed prior to eachdelivery. The inspection is designed to discover if anythingis apparently wrong with a machine before it is put intoservice.

A damaged or modified machine must never be used. Ifdamage or any variation from factory delivered condition isdiscovered, the machine must be tagged and removed fromservice.

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 listed inthe responsibilities manual.



Maintenance Inspection Report

Checklist A - Rev A Y N R

A-1 Manuals and decals

A-2 Pre-operationinspection

A-3 Function tests

A-4 Engine maintenance

A-5 Generator belts

Perform after 40 hours:

A-6 30 Day Service



Perform every 50 hours:




A-10 Grease rotationbearing


A-11 Drive hub oil



Instructions· Make copies of this page 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-annually 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”,tag and remove the machine fromservice, repair and re-inspect it.After repair, place a check in the “R”box.

LegendY = yes, acceptableN = no, remove from serviceR = repaired

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Checklist B - Rev A Y N R

B-1 Exhaust system

B-2 Batteries

B-3 Electrical wiring

B-4 Tires, wheels and lugnut torque

B-5 Brake configuration

B-6 Drive hub oil level

B-7 Glow plugs

B-8 Engine RPM

B-9 Ground controloverride

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 package(if equipped)

B-16 Turntable rotation stop

B-17 Electrical contactors

B-18 Fuel and hydraulictank cap venting

B-19 Hydraulic oil analysis


B-20 Engine maintenance

Comments



REV A

Checklist C - Rev A Y N R

C-1 Grease platformoverload (if equipped)

C-2 Test platform overload(if equipped)

C-3 Clean the fuel tank

C-4 Engine maintenance


C-5 Engine maintenance

Checklist D - Rev A Y N R

D-1 Boom wear pads

D-2 Turntable rotation bolts

D-3 Turntable bearingwear

D-4 Free-wheelconfiguration

D-5 Drive hub oil

D-6 Replace hydraulic filter

Checklist E - Rev A Y N R

E-1 Replace hydraulic oil

E-2 Engine maintenance

E-3 Grease wheel bearings


E-4 Engine maintenance

Model

Serial number

Date

Hour meter

Machine owner


Inspector signature

Inspector title

Inspector company

Comments

Instructions· Make copies of this page 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-annually 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



REV A

A-1Inspect the Manuals and Decals

Genie specifications require thatthis procedure be performed dailyor every 8 hours, whichever comesfirst.

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.

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.

Contact your authorized Geniedistributor or Genie Industries ifreplacement manuals are needed.

Checklist A Procedures



REV A

A-2Perform Pre-operationInspection


Completing 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 Genie Z-34/22Bi-Energy Operator's Manual. Refer to theOperator's Manual on your machine.

A-3Perform Function Tests


Completing 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 Genie Z-34/22Bi-Energy Operator's Manual. Refer to theOperator's Manual on your machine.

CHECKLIST A PROCEDURES



REV A

A-4Perform Engine Maintenance

Engine specifications require thatthis procedure be performed every8 hours or daily, whichever comesfirst.

Required maintenance procedures and additionalengine information is available in theKubota Z482-E Operator's Manual(Kubota part number 16676-8916-7).

Kubota Z482-E Operator's ManualGenie part number 52958

A-5Check the Generator Belts andPulleys


Maintaining the generator belts and the pulleys isessential to good engine performance and servicelife. The generator will not operate properly withloose or defective belts and continued use maycause component damage.

Bodily injury hazard. Do notinspect while the engineis running. Remove the key tosecure from operation.

Bodily injury hazard. Beware of hotengine components. Contact withhot engine components may causesevere burns.

Charging the batteries with theengine does not fully charge thebatteries. Periodically, use the ACbattery charger to fully charge thebatteries.

1 Be sure that all fasteners and cables on thegenerator are tight.

2 Remove the engine flywheel cover mountingfasteners, then remove the cover.

3 Be sure that the pulley mounting fasteners aretight and that the pulleys show no signs ofdamage or unusual wear.




REV A

4 Check to be sure the engine pulley and thegenerator pulley are aligned within specificationusing a straightedge.

a engine pulleyb straightedgec maximum pulley offsetd generator pulley

If alignment does not meetspecification, refer to 6-4, How toInstall the Engine Drive Pulley toadjust the pulley alignment.

Pulley alignment, 1/16 inchmaximum offset 1.58 mm

5 Inspect the generator belts for:

· Cracking

· Glazing

· Separation

· Breaks

6 Replace both belts if any damage is found.

7 Check the generator belts for proper tension. Ifthe belt deflection is not within specification,see 7-2, How to Adjust the Generator Belts.

a engine pulleyb generator beltsc generator pulley

Belt deflection, 1/4 inchmaximum allowable 6.5 mm

8 Check the torque of the pulley retaining nut onthe generator. Refer to Section 2,Specifications.


c

b

a

d

c

a

b



REV A

A-6Perform 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. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.

1 Perform the following maintenance procedures:

· A-10 Grease the Turntable Rotation Bearingand Worm Drive Gear

· B-4 Inspect the Tires, Wheels and LugNut Torque

· D-2 Check the Turnable Rotation BearingBolts

· D-6 Replace the Hydraulic Tank ReturnFilter


Engine specifications require thatthis one time procedure beperformed after the first 50 hoursof operation.






REV ACHECKLIST A PROCEDURES


Engine specifications require thatthis procedure be performed every50 hours or weekly, whichevercomes first.




Engine specifications require thatthis procedure be performed every100 hours.





REV A CHECKLIST A PROCEDURES

A-10Grease the Turntable RotationBearing and Worm Drive Gear

Genie specifications require thatthis procedure be performed every100 hours.

Yearly application of lubrication to the turntablebearing and worm drive gear is essential to goodmachine performance and service life. Continueduse of an improperly greased gear will result incomponent damage.

1 Raise the secondary boom and place a safetychock on the secondary boom lift cylinder.Carefully lower the boom onto the lift cylindersafety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

The lift cylinder safety chock isavailable through Genie ServiceParts (part number 36555).

2 Locate the grease fitting on the inside of thebearing in the middle of the turntable.

3 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.

4 Remove the safety chock. Lower the boom tothe stowed position.

5 Locate the grease fitting on the worm drivehousing.

a grease fitting

6 Pump grease into the gear until you see itcoming out of the side of the gear housing.

7 Grease each tooth on the outside of theturntable rotation bearing.

Grease Specification

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

a



REV A

A-11Replace the Drive Hub Oil

Manufacturer drive hubspecifications require that this one-time procedure be performed afterthe first 150 hours.

Replacing the torque hub oil is essential for goodmachine performance and service life. Failure toreplace the torque hub oil at yearly intervals maycause the machine to perform poorly and continueduse may cause component damage.

1 Select the drive torque hub to be serviced. Drivethe machine until one of the two plugs is at thelowest point.

2 Remove both plugs and drain the oil into asuitable container.

Models with pipe plugs


3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side hole.Refer to Section 2, Specifications.

5 Models with pipe plugs: Apply pipe threadsealant to the plugs. Install the plugs into thedrive hub.

Models with O-ring plugs: Install the plugs intothe drive hub.

6 Repeat this procedure for each torque hub.

plugs

plugs

Models with O-ring plugs



REV A








REV A

B-1Check the Exhaust System

Genie requires that this procedurebe performed every 250 hours orquarterly, whichever comes first.

Maintaining the exhaust system is essential togood engine performance and service life. Runningthe engine with a damaged or leaking exhaustsystem can cause component damage and unsafeoperating conditions.

Bodily injury hazard. Do notinspect while the engine is running.Remove the key to secure fromoperation.

Bodily injury hazard. Beware of hotengine components. Contact withhot engine components may causesevere burns.

1 Pull up on the pull pin on the engine pivot platelocated under the pump. Swing the engine pivotplate away from the machine to access theexhaust system.

2 Be sure that all nuts and bolts are tight.

3 Inspect all welds for cracks.

4 Inspect for exhaust leaks; i.e., carbon builduparound seams and joints.

Checklist B Procedures

B-2Inspect the Batteries

Genie require that this procedurebe performed every 250 hours orquarterly, whichever comes first.

Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damage andhazardous conditions.

Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.

Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.

1 Disconnect each battery pack from the machine.

2 Release the battery pack latches and rotateeach battery pack out and away from thechassis.

3 Remove the cover from each battery box.

4 Be sure that the battery cable connections arefree of corrosion.

Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.



REV A CHECKLIST B PROCEDURES

5 Be sure that the battery retainers and cableconnections are tight.

6 Fully charge the batteries. Allow the batteries torest 24 hours before continuing this procedure toallow the battery cells to equalize.

7 Put on protective clothing and eye wear.

8 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

9 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 13.

Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceed tostep 10.

10 Perform an equalizing charge OR fully chargethe batteries and allow the batteries to rest atleast 6 hours.

11 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer. Note the results.

12 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 specificgravity of 1.277 or greater. The battery is fullycharged. Proceed to step 13.

Result: The difference in specific gravityreadings between cells is greater than 0.1 ORthe specific gravity of one or more cells is lessthan 1.217. Replace the battery.

13 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.

14 Install the vent caps and neutralize anyelectrolyte that may have spilled.



REV A

B-3Inspect the Electrical Wiring


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 hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

1 Inspect the following areas for burnt, chafed,corroded and loose wires:

· Engine compartment electrical panel

· Engine wiring harness

· Inside of the ground control box

· Turntable manifold wiring

2 Start the engine from the ground controls.

3 Raise the secondary boom until the mid-pivot is10 feet / 3 m off the ground.

4 Inspect the turntable center area for burnt,chafed and pinched cables.

5 Lower the boom to the stowed position and turnthe engine off.

6 Inspect the following areas for burnt, chafed,corroded, pinched and loose wires:

· Cable track on the primary, jib and secondary booms

· Jib boom to platform cable harness· Inside of the platform control box

B-4Inspect the Tires, Wheels andLug Nut Torque


Maintaining the tires and wheels, including properwheel fastener torque, is essential to safe operationand good performance. Tire and/or wheel failurecould result in a machine tip-over. Componentdamage may also result if problems are notdiscovered and repaired in a timely fashion.

Bodily injury hazard. An over-inflated tire can explode and couldresult in death or serious injury.

Tip-over hazard. Do not usetemporary flat tire repair products.

The tires on some machines arefoam-filled and do not need airadded 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 to Section 2, Specifications.

4 Check the pressure in each air-filled tire.Refer to Section 2, Specifications.

CHECKLIST B PROCEDURES



REV A

B-6Check the Oil Level in theDrive Hubs


Failure to maintain proper drive hub oil levels maycause the machine to perform poorly and continueduse may cause component damage.

1 Drive the machine to rotate the hub until theplugs are located one on top and the other at 90degrees.



B-5Confirm the ProperBrake Configuration


Proper brake configuration is essential to safeoperation and good machine performance.Hydraulically-released, spring-applied individualwheel brakes can appear to operate normally whenthey are actually not fully operational.

1 Check each torque hub disconnect cap to besure it is in the engaged position.


brake disengaged position

brake engaged position

plugs

plugs



REV ACHECKLIST B PROCEDURES

2 Remove the plug located at 90 degrees andcheck the oil level.

Result: The oil level should be even with thebottom of the plug hole.

3 If necessary, remove the top plug and add oiluntil the oil level is even with the bottom of theside plug hole.



5 Check the torque of the drive hub mountingbolts. Refer to Section 2, Specifications.

6 Repeat this procedure for each drive hub.

B-7Check the Glow Plugs


Maintaining the glow plugs in good condition isessential to good engine performance and servicelife. Improperly functioning glow plugs will causethe engine to perform poorly and may result incomponent damage.

Perform this procedure with theengine turned off.

1 Connect the leads from an ohmmeter betweenmachine ground and the wire connected to theglow plugs.

Result: The resistance should be approximately1Ω.

2 If the ohm reading is different than 1Ω, removethe wire and connector plate from the twoindividual glow plugs. Then, one glow plug at atime, check the resistance between the glowplug and machine ground.

Result: The resistance should be approximately0.6Ω for each individual glow plug.

3 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition.

4 Connect the red (+) lead from a volt meterto one of the glow plugs. Connect the black (-)lead to ground.

5 Hold the glow plug switch in the on position.

Result: The volt meter should read 12 volts.

6 Repeat steps 4 and 5 for the other glow plug.



REV A

B-8Check and Adjust the EngineRPM


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.

1 Connect an rpm gauge to the engine, and thenstart the engine from the ground controls.

Result: Low idle should be 2000 rpm.

Skip to step 3 if the low idle rpm is correct.

2 Loosen the lock nut, then turn the low idleadjustment screw clockwise to increase the rpmor counterclockwise to decrease the rpm.Tighten the lock nut and recheck the rpm.


a low idle adjustment screw(not shown)

b high idle adjustment nutc rpm solenoidd fuel shut off solenoid

3 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.

Result: High idle should be 3000 rpm.

If high idle rpm is correct, disregard adjustmentstep 4.

4 Loosen the lock nut on the solenoid, then turnthe solenoid boot counterclockwise to increasethe rpm or clockwise to decrease the rpm.Tighten the lock nut and recheck the rpm.

a

b

c

d




B-9Test the Ground ControlOverride


A properly functioning ground control override isessential to safe machine operation. The groundcontrol override function is intended to allow groundpersonnel to operate the machine from the groundcontrols whether or not the red Emergency Stopbutton on the platform controls is in the on or offposition. 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 Stop buttonto the off position.


3 Operate each boom function through apartial cycle at the ground controls.

Result: All boom functions should operate.

B-10Test the Platform Self-leveling


Automatic platform self-leveling throughoutthe full cycle of boom raising and lowering isessential for safe machine operation. Theplatform is maintained at level by the platformleveling slave cylinder which is controlled by themaster cylinder located at the base of the primaryboom. A platform self-leveling failure creates anunsafe working condition.


2 Lower the boom to the stowed position.

3 Adjust the platform to a level position using theplatform leveling switch.

4 Raise and lower the primary boom througha full cycle.

Result: The platform should remain level at alltimes to within ±5 degrees.



REV A CHECKLIST B PROCEDURES

B-11Test the Engine Idle Select


A properly operating engine idle select switchis essential to good engine performance and safemachine operation. There are three settings.

Low idle (turtle symbol): Low idle and slow batterycharging.

High idle (rabbit symbol): High idle and quickestbattery charging.

Foot switch activated high idle (rabbit and footswitch symbols): Activates high idle only when thefoot switch is pressed down.

1 Pull out the red Emergency Stop button to theon position at both the ground and platformcontrols.

2 Start the engine from the ground controls. Thenmove the engine idle control switch to high idle(rabbit symbol) and hold in the on position.

Result: The engine should change to high idle.

3 Release the engine idle control switch.

Result: The engine should return to low idle.

4 Turn the key switch to platform controls.

5 At the platform controls, move the engine idlecontrol switch to high idle (rabbit symbol).


6 Move the engine idle control switch to low idle(turtle symbol).

Result: The engine should change to low idle.

7 Move the engine idle control switch to footswitch activated high idle (rabbit and foot switchsymbol).

Result: The engine should not change tohigh idle.

8 Press down the foot switch.




REV A

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 of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.

Select a test area that is firm, leveland free of obstructions.

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

2 Lower the boom into the stowed position.

3 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

4 Bring the machine to maximum drive speedbefore reaching the start line. Begin timing whenyour reference point on the machine crosses thestart line.

5 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.

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. Hydrostatic brakes and hydraulically-released individual wheel brakes can appear tooperate normally when not fully operational.

Collision hazard. Be sure that themachine is not in free-wheel orpartial free-wheel configuration.Refer to B-5 in this Section,Confirm the Proper BrakeConfiguration.


1 Mark a test line on the ground for reference.

2 Lower the boom into the stowed position.

3 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.

4 Bring the machine to maximum drive speedbefore reaching the test line. Release the drivejoystick when your reference point on themachine crosses the test line.

5 Measure the distance between the test line andyour machine reference point. Refer to section2, Specifications,

The brakes must be able to holdthe machine on any slope it is ableto climb.




REV A

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 of hesitation,jerking and unusual noise over the entireproportionally controlled speed range.


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

2 Raise the platform more than 5 feet/1.5 m.

3 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.

4 Bring the machine to maximum drive speedbefore reaching the start line. Begin timing whenyour reference point on the machine crosses thestart line.

5 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.

B-15Test the Alarm Package(if equipped)


The alarm package includes:

· Travel alarm

· Descent alarm

· Flashing beacon

Alarms and a beacon are installed to alert operatorsand ground personnel of machine proximity andmotion. The alarm package is installed on theground controls side turntable cover.

The alarms and beacon willoperate with the enginerunning or not running.

1 At the ground controls, pull out the redEmergency Stop button to the on position andturn the key switch to ground control.

Result: The flashing beacon should be on andflashing.

2 Move the primary boom toggle switch to thedown position, hold for a moment and thenrelease it. Move the secondary boom toggleswitch to the down position, hold for a momentand then release it.

Result: The descent alarm should sound wheneach toggle switch is held down.




REV A

B-16Test the Turntable Rotation Stop


The turntable is capable of rotating the boom 355degrees and is stopped midpoint between the steerwheels by the rotation stop. Detecting a rotationstop malfunction is essential to safe operation andgood machine performance. If the turntable rotatespast the rotation stop, component damage mayresult.

1 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Rotate the turntable to the left as far as it willgo.

Result: Movement should stop when the primaryboom reaches mid-point between the steer tires.

3 Rotate the turntable to the right full circle as faras it will go.

Result: Movement should stop when the primaryboom reaches mid-point between the steer tires.


3 Turn the key switch to platform control.

4 At the platform controls, pull out the redEmergency Stop button to the on position.

Result: The flashing beacon should be onand flashing.

5 Press down the foot switch. Move the primaryboom toggle switch to the down position, holdfor a moment and then release it. Move thesecondary boom toggle switch to the downposition, hold for a moment and then release it.

Result: The descent alarm should sound wheneach toggle switch is held down.

6 Press down the foot switch. Move the drivecontrol handle off center, hold for a moment andthen release it. Move the drive control handle offcenter in the opposite direction, hold for amoment and then release it.

Result: The travel alarm should sound when thedrive control handle is moved off center in eitherdirection.



REV A

B-17Check the Electrical Contactors


Maintaining the electrical contactors in goodcondition is essential to safe machine operation.Failure to locate a worn or damaged contactor couldresult in an unsafe working condition andcomponent damage.

1 Remove the non-steer drive chassis cover andlocate the electrical contactors mounted on thecomponent mounting panel.

2 Visually inspect the contact points of eachcontactor for the following items:

· Excessive burns

· Excessive arcs

· Excessive pitting

Electrocution hazard. Contactwith hot or live circuits could resultin death or serious injury. Removeall rings, watches and otherjewelry.

Replace the contactors if anydamage is found.


B-18Inspect the Fuel and HydraulicTank Cap Venting Systems

Genie requires that this procedurebe performed every 250 hours orquarterly, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Free-breathing fuel and hydraulic tank caps areessential for good machine performance andservice life. A dirty or clogged tank cap may causethe machine to perform poorly and continued usemay cause component damage. Extremely dirtyconditions may require that the caps be inspectedmore often.

Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have an approvedfire extinguisher within easy reach.

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.

When checking for positive tankcap venting, air should pass freelythrough 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.

When checking for positive tankcap venting, air should pass freelythrough 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.

B-19Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.

Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test. See E-1,Test or Replace the Hydraulic Oil.



REV A

B-20Perform Engine Maintenance







REV A

C-1Grease the Platform OverloadMechanism (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months,whichever comes first. Performthis procedure more often if dustyconditions 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 grease fittingusing a multi-purpose grease.

Grease Specification

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

C-2Test the Platform OverloadSystem (if equipped)

Genie specifications require thatthis procedure be performed every500 hours or six months,whichever comes first.

Testing the platform overload system regularly isessential to safe machine operation. Continued useof 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.

Checklist C Procedures



REV A

The platform support subassembly utilizes two loadsupport 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 parallelogram linksupports this purely compressive load regardless ofwhere the load is placed in the platform.

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.

Perform this procedure with themachine on a firm, level surface.

1 Turn the key switch to platform control. Start theengine and level the platform.

2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Failure to remove all weight, toolsand accessories from the platformwill result in an inaccurate test.

4 Using a suitable lifting device, place a testweight equal to that of the available capacityone of the locations shown.Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

5 Carefully move the test weight to eachremaining location. Refer to Illustration 1.

Result: The platform overload indicator lightsshould be off at both the ground and platformcontrols and the alarm should not sound.

Result: The platform overload indicator lights areon and the alarm is sounding. Calibrate theplatform overload system. Refer to RepairProcedure 2-4, How to Calibrate the PlatformOverload System (if equipped).

Illustration 1

6 Using a suitable lifting device, place anadditional 10 lbs / 4.5 kg of weight onto theplatform.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4,How to Calibrate the Platform Overload System(if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.

CHECKLIST C PROCEDURES



REV A

7 Carefully move the test weights to eachremaining location on the platform.Refer to Illustration 1.

Result: The alarm should sound.The platform overload indicator lights should beflashing at both the ground and platformcontrols.

Result: The alarm does not sound and theplatform overload indicator lights are notflashing. Calibrate the platform overloadsystem. Refer to Repair Procedure 2-4,How to Calibrate the Platform OverloadSystem (if equipped).

There may be a 2 second delaybefore the overload indicator lightsflash and the alarm sounds.

8 Test all machine functions from the platformcontrols.

Result: All platform control functions should notoperate.

9 Turn the key switch to ground control.

10 Test all machine functions from the groundcontrols.

Result: All ground control functions should notoperate.

11 Using auxiliary power, test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate.

12 Using a suitable lifting device, lift the additionaltest weight from the platform.

Result: The platform overload indicator lightsshould turn off at both the ground and platformcontrols and the alarm should not sound.

There may be an 2 second delaybefore the overload indicator lightsand alarm turn off.

13 Start the engine and test all machine functionsfrom the ground controls.

Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate.

If the platform overload system isnot operating properly, Refer toRepair Procedure 2-4, How toCalibrate the Platform OverloadSystem (if equipped).

16 Using a suitable lifting device, remove theremaining test weights from the platform.

CHECKLIST C POCEDURES



REV A

C-3Clean the Fuel Tank

Genie requires that this procedurebe performed every 500 hours orsix months, whichever comes first.

Removing sediment from the fuel tank is essentialto good engine performance and service life. A dirtyfuel tank may cause the fuel filter to clogprematurely resulting in poor engine performanceand possible component damage.

Explosion and fire hazard. Enginefuels are combustible. Clean thefuel tank in an open, well-ventilatedarea away from heater, sparks,flames and lighted tobacco.Always have an approved fireextinguisher within easy reach.

Immediately clean up any fuel thatmay have spilled during thisprocedure.

1 Models with fuel shutoff valve: Turn themanual fuel shutoff valve, located next to thetank, to the closed position.

2 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer toSection 2, Specifications, for tank capacity.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Be sure to only use a handoperated pump suitable for usewith gasoline and/or diesel fuel.

3 Tag, disconnect and plug the fuel supply andreturn hoses at the tank. Clean up any fuel thatmay have spilled.

4 Remove the tank retainer plate fasteners at thebulkhead. Remove the tank from the machine.

Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.

5 Rinse out the inside of the tank using a mildsolvent.

6 Install the tank onto the machine. Install thetank retainer plate fasteners at the bulkhead.

7 Install the fuel supply and return hoses to thetank. Tighten the clamps.

8 Models with fuel shutoff valve: Turn themanual fuel shutoff valve, located next to thetank, to the open position.

CHECKLIST C POCEDURES



REV A

C-4Perform Engine Maintenance




CHECKLIST C PROCEDURES

C-5Perform Engine Maintenance






REV A

D-1Check the Primary BoomWear Pads

Genie requires that this procedurebe performed every 1000 hours orannually, whichever comes first.

Maintaining the primary boom wear pads in goodcondition is essential to safe machine operation.Wear pads are placed on boom tube surfaces toprovide a low friction, replaceable wear padbetween moving parts. Improperly shimmed wearpads or continued use of worn out wear pads mayresult in component damage and unsafe operatingconditions.


2 Extend the primary boom 10 inches / 25 cm.

3 Measure each wear pad. Replace the wear pad ifit is less than 0.41 inches / 1 cm thick. If thewear pad is more than 0.41 inches / 1 cm thick,shim as necessary to obtain zero clearance andzero drag.

4 Extend and retract the primary boom through theentire range of motion to check for tight spotsthat could cause binding or scraping.

Always maintain squarenessbetween the primary boom outerand inner tubes.

D-2Check 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 and place a safetychock on the secondary boom lift cylinder.Carefully lower the boom onto the lift cylindersafety chock.

Crushing hazard. Keep handsaway from the cylinder and allmoving parts when lowering thesecondary boom.

The lift cylinder safety chock isavailable through Genie serviceparts. (Genie part number 36555).

2 Check to ensure that each turntable bearing boltis torqued in specified order to190 foot-pounds / 258 Nm.

Bolt torque sequence

Checklist D Procedures



REV ACHECKLIST D PROCEDURES

3 Remove the safety chock. Lower the boom tothe stowed position.

4 Access the turntable bearing bolts through theaccess hole on the side of the chassis.

5 Check to ensure that each bearing mounting boltunder the drive chassis is torqued in specifiedorder to 190 foot-pounds / 25 Nm.

Bolt torque sequence

D-3Inspect 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.

1 Grease the turntable bearing. See A-10, Greasethe Turntable Rotation Bearing and Worm DriveGear.

2 Torque the turntable bearing bolts tospecification. See D-2, Check the TurntableRotation Bearing Bolts.

3 Raise the primary and secondary booms to fullheight using the ground controls. Do not extendthe primary boom.



REV A CHECKLIST D PROCEDURES

4 Place a dial indicator between the drive chassisand the turntable at a point that is directlyunder, or in line with, the boom and no morethan 1 inch / 2.5 cm from the bearing.

To obtain an accuratemeasurement, place the dialindicator no more than 1 inch / 2.5cm from the turntable rotationbearing.

a turntableb dial indicatorc drive chassisd turntable rotation bearing

5 Adjust the dial indicator to "0".

6 Lower the secondary boom to the stowedposition and lower the primary boom to ahorizontal position. Fully extend the primaryboom.

7 Note the reading on the dial indicator.

Result: The measurement is less than0.055 inch / 1.4 mm. The bearing is good.

Result: The measurement is more than0.055 inch / 1.4 mm. The bearing is worn andneeds to be replaced.

8 Fully retract the primary boom. Raise theprimary and secondary booms to full height.Visually inspect the the dial indicator to be surethe needle returns to the "0" 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 primary and secondary booms to thestowed position and turn the machine off.

12 Remove the dial indicator from the machine.

a

b

c

d



REV A

D-4Check the Free-wheelConfiguration


Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily for towing.A machine configured to free-wheel without operatorknowledge may cause death or serious injury andproperty damage.

Collision hazard. Select a work sitethat is firm and level.

1 Chock the steer wheels to prevent the machinefrom rolling.

2 Center a lifting jack of ample capacity(15000 lbs / 7000 kg) under the drive chassisbetween the non-steering wheels.

3 Lift the wheels off the ground and then placejack stands under the drive chassis for support.

4 Disengage the dive hubs by turning over thedrive hub disconnect caps on eachnon-steering wheel hub.

5 Manually rotate each non-steering wheel.

Result: Each non-steering wheel should rotatewith minimum effort.

6 Engage the drive hubs by turning overthe hub disconnect caps. Carefully removethe jack stands, lower the machine andremove the jack.

Collision hazard. Failure tore-engage the drive hubs couldresult in death or serious injury andproperty damage.

CHECKLIST D PROCEDURES

brake disengaged position

brake engaged position



REV A

D-5Replace 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 and continueduse may cause component damage.

1 Select the drive drive hub to be serviced. Thendrive the machine until one of the two plugs isat the lowest point.

2 Remove both plugs and drain the oil.




3 Drive the machine until one plug is at the topand the other is at 90 degrees.

4 Fill the hub with oil from the top hole until the oillevel is even with the bottom of the side plughole. Refer to Section 2, Specifications.



6 Repeat this procedure for each drive hub.

plugs

plugs



REV A

D-6Replace the Hydraulic TankReturn Filter

Genie requires that this procedurebe performed every 1000 hours orannually, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.

Bodily injury hazard. Beware of hotoil. Contact with hot oil may causesevere burns.

The return hydraulic filter is locatedinside of the filter housing on top ofthe hydraulic tank.

1 Clean the area around the oil filter housing, thenremove the filter housing cover mountingfasteners.

2 Carefully remove the filter housing cover and thespring.

3 Remove the filter element from the filterhousing.

4 Remove the filter cup from the housing andclean it using a mild solvent.

Be sure that the O-ring is in placeon the outlet tube inside of thefilter cup.

5 Install the new filter element.

6 Install the spring and the filter housing cover,then install the filter housing mountingfasteners. Clean up any oil that may havespilled during the replacement procedure.




REV A

E-1Test or Replace the Hydraulic Oil

Genie requires that this procedurebe performed every 2000 hours ortwo years, whichever comes first.Perform this procedure more oftenif dusty conditions exist.

Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly and continueduse may cause component damage. Extremelydirty conditions may require oil changes to beperformed more often.

The machine uses Dexronequivalent hydraulic oil. Beforereplacing the hydraulic oil, the oilmay be tested by an oil distributorfor specific levels of contaminationto verify that changing the oil isnecessary. If the hydraulic oilis not replaced at the two yearinspection, test the oil quarterly.Replace the oil when it fails thetest.

Perform this procedure with theboom in the stowed position.

When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose end must be replacedand then torqued to specificationduring installation. Refer to Section2, Hydraulic Hose and FittingTorque Specifications.

Checklist E Procedures

1 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operated withthe hydraulic tank shutoff valve inthe closed position or componentdamage will occur. If the tankvalve is closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.

2 Place a suitable container under the hydraulictank. See capacity specifications.

3 Disconnect and plug the hydraulic hose from thehydraulic tank shutoff valve.

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.

4 Open the valve on the hydraulic tank and drainthe oil into a suitable container.


5 Tag, disconnect and plug the hydraulic hosesfrom the hydraulic tank filter. Cap the fittings onthe filter.





REV A

6 Remove the hydraulic tank mounting fasteners.

7 Remove the hydraulic tank from the machine.

8 Remove the tank lid retaining fasteners thenremove the lid from the tank.

9 Clean the suction strainer using a mild solvent.

10 Rinse out the inside of the tank with a mildsolvent.

11 Install the lid onto the hydraulic tank.

12 Install the hydraulic tank on the machine. Installthe hydraulic tank mounting fasteners andtorque to 8 ft-lbs / 10.8 Nm.

Component damage hazard. Thehydraulic tank may becomedamaged if the tank mountingfasteners are over tightened.

13 Install the hydraulic hoses.

14 Fill the tank with hydraulic oil until the fluid untilthe fluid is within the full and add marks on thehydraulic tank. Do not overfill. Refer to Section2, Specifications.

15 Clean up any oil that may have spilled. Properlydiscard of oil.

Component damage hazard. Besure to open the hydraulic tankshutoff valve after installing thehydraulic tank.

E-2Perform Engine Maintenance

Engine specifications requires thatthis procedure be performed every2000 hours or every two years,whichever comes first.



CHECKLIST E PROCEDURES



REV A CHECKLIST E PROCEDURES

E-3Grease the Steer AxleWheel Bearings

Genie requires that this procedurebe performed every 2000 hours orevery two years, whichever comesfirst.

Maintaining the steer axle wheel bearings isessential for safe machine operation and servicelife. Operating the machine with loose or wornwheel bearings may cause an unsafe operatingcondition and continued use may result incomponent damage. Extremely wet or dirtyconditions or regular steam cleaning and pressurewashing of the machine may require that thisprocedure be performed more often.

1 Loosen the wheel lug nuts. Do not remove them.

2 Block the non-steer wheels and center a liftingjack of ample capacity under the steer axle.

3 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

Crushing hazard. The machinemay fall if not properly supported.

4 Remove the lug nuts. Remove the tire and wheelassembly.

5 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: There should be no side to side or upand down movement.

Skip to step 10 if there is no movement.

6 Remove the dust cap from the hub. Remove thecotter pin from the castle nut.

7 Tighten the castle nut to 158 ft-lbs / 214 Nm toseat the bearings.

Rotate the hub by hand whiletorquing the castle nut to makesure the bearings seat properly.

8 Loosen the castle nut one full turn and thentorque to 35 ft-lbs / 47 Nm.

9 Check for wheel bearing wear by attempting tomove the wheel hub side to side, then up anddown.

Result: If there is no side to side or up anddown movement, continue with step 10 togrease the wheel bearings.

Result: If there is side to side or up and downmovement, continue to step 10 and replace thewheel bearings with new ones.

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

10 Remove the castle nut.

11 Pull the hub off of the spindle. The washer andouter bearing should fall loose from the hub.

12 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove the rearbearing.

13 Pack both bearings with clean, fresh grease.

14 Place the large inner bearing into the rear of thehub.



REV ACHECKLIST E PROCEDURES

15 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

Always replace the bearing greaseseal when removing the hub.

16 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

17 Fill the hub cavity with clean, fresh grease.

18 Place the outer bearing into the hub.

19 Install the washer and castle nut.




22 Install a new cotter pin. Bend the cotter pinto lock it in.

Always use a new cotter pin wheninstalling a castle nut.

23 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

E-4Perform Engine Maintenance

Engine specifications requires thatthis procedure be performed every3000 hours.




January 2008 Section 4 • Repair Procedures

Repair Procedures

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 pointwhere repairs can be completed. Then tore-assemble, perform the disassembly steps inreverse order.

Symbols Legend

Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.

Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.

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.

Used to indicate operation ormaintenance information.

Indicates that a specific result is expected afterperforming a series of steps.

Indicates that an incorrect result has occurredafter performing a series of steps.

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 rulesand operating instructions in the appropriateGenie Z-34/22 Bi-Energy Operator's Manual onyour machine.

Be sure that all necessary tools and parts areavailable and ready for use.

Read each procedure completely and adhere tothe instructions. Attempting shortcuts mayproduce hazardous conditions.

Use only Genie approved replacement parts.

Unless otherwise specified, perform each repairprocedure with the machine in the followingconfiguration:

· Machine parked on a firm, level surface

· Boom in the stowed position

· Turntable rotated with the boom betweenthe non-steer wheels

· Key switch in the off position with the keyremoved

· Wheels chocked

· All external AC power supply disconnectedfrom the machine


January 2008Section 4 • Repair Procedures

REV APlatform Controls

1-1Controllers

Platform ControlsThe drive joystick is connected to the drive motorcontroller located under the non-steer end drivechassis cover. The drive motor controller can alsorecognize machine drive malfunctions and displaycontroller fault codes by flashing a LED at theground controls. See the Troubleshooting sectionof this manual for a list of fault codes andadditional information. There are no adjustmentsneeded on the drive joystick controller. For furtherinformation or assistance, consult the GenieIndustries Service Department.

a boom function speed controllerb drive joystick

Boom Function SpeedController Adjustments

Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.

Do not adjust the boom functionspeed controller unless the staticbattery supply voltage is above24V DC.

1 Turn the key switch to platform controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

2 Open the platform control box lid and locate theboom function speed controller.

a blk/red wireb diodec white/red wired boom function speed controllere max-out adjustable trimpotf threshold adjustable trimpotg ramp rate trimpot

(after serial number 1923)

3 Locate the diode between the black/red wirefrom the boom function speed controller and thewhite/red wire. Disconnect the white/red wirefrom the diode on the black/red wire.

a

b

a

b

c

d

f

g

e



REV A PLATFORM CONTROLS

4 Connect the negative lead from a multi-meterset to measure amperage to the wire connectorof the white/red wire. Connect the positive leadof the multi-meter to the diode on the black/redwire.

5 Turn the boom function speed controller to theCREEP position.

6 Set the threshold: Press down the foot switchand move the primary boom toggle switch to theup position. Adjust the amperage to 0.28A. Turnthe threshold trimpot adjustment screwclockwise to increase the amperage orcounterclockwise to decrease the amperage.

7 Turn the boom function speed controller tothe 9 position.

8 Set the max out: Press down the foot switchand move the primary boom toggle switch to thedown position. Adjust the amperageto 0.65A. Turn the max out trimpot adjustmentscrew clockwise to increase the amperage orcounterclockwise to decrease the amperage.

9 Start a timer and simultaneously press down thefoot switch and move the primary boom toggleswitch in the down direction. Note how long ittakes to reach 0.65A.

10 Set the ramp rate: Turn the ramp rate trimpot toobtain a 2 second delay from 0 to 0.65A. Turnthe trimpot clockwise to increase the time orcounterclockwise to decrease the time.

11 Disconnect the leads from the multi-meter andconnect the white/red wire to the diode on theblack/red wire.

Boom function speedcontroller specifications

Threshold 0.28A(controller turned to CREEP)

Max out 0.65A(controller turned to 9)

Ramp rate 2 seconds



REV APLATFORM CONTROLS

1-2Diodes

How to Test a Diode1 Connect the leads from an ohmmeter to each

end of the diode.

2 Re-connect the leads from the ohmmeter to theopposite ends (from step 1) of the diode. Thediode should have resistance in one directionand not the other.

1-3Foot Switch

How to Test the Foot Switch1 Turn the key switch to the off position. Remove

the fasteners securing the foot switch to theplatform and remove the bottom cover from thefoot switch.

2 Do not press down the foot switch. Connect theleads from an ohmmeter or continuity tester toeach wire combination listed on the next pageand check for continuity.

Test Desired result

red to black continuity(zero Ω)

red to white no continuity(infinite Ω)

black to white no continuity

Do not use the color of theconnector as a guide for thesetests. Use the actual wire colorto identify which connector touse for testing.

3 Press down the foot switch. Connect the leadsfrom an ohmmeter or continuity tester to eachwire combination listed below and check forcontinuity.

Test Desired result

red to black no continuity(infinite Ω)

red to white no continuity

black to white continuity(zero Ω)



REV A

1-4Toggle Switches

Toggle switches used for single function switchingare single pole double throw (SPDT) switches. Dualfunction switching requires a double pole doublethrow (DPDT) switch.

How to Test a Toggle SwitchContinuity is the equivalent of 0 to3 ohms. A simple continuity testermay not accurately test the switch.

This procedure covers fundamental switch testingand does not specifically apply to all varieties oftoggle switches.

1 Turn the key switch to the off position. Tagand disconnect all wiring from the toggle switchto be tested.

2 Connect the leads of an ohmmeter to the switchterminals in the following combinations listedbelow to check for continuity.

Test Desired result

Left position

terminal 1 to 2, 3, 4, 5 & 6 no continuity(infinite Ω)

terminal 2 to 3 continuity(zero Ω)

terminal 2 to 4, 5 & 6 no continuity


terminal 4 to 5 & 6 no continuity

terminal 5 to 6 continuity

Center position There are no terminalcombinations that will

produce continuity(infinite Ω)

Right position


terminal 1 to 3, 4, 5 & 6 no continuity(infinite Ω)

terminal 2 to 3, 4, 5 & 6 no continuity


terminal 4 to 5 continuity

terminal 4 to 6 no continuity

terminal 5 to 6 no continuity

PLATFORM CONTROLS

Single poledouble throw(SPDT)

Double poledouble throw(DPDT)

Left Center Right

1 2 3

4 5 6

1 2 3

1 2 3

4 5 6

1 2 3

1 2 3

4 5 6

1 2 3

1

2

3 1

2

3 1

2

3



REV APlatform Components

2-1Platform

How to Remove the Platform1 Open the platform control box. Disconnect the

foot switch wiring from the terminal strip andremove cable from control box.

2 Remove the platform control box mountingfasteners, then lower the control box.

If your machine is equipped withan air line to platform option, theair line must be disconnected fromthe platform before removal.

3 Place blocks under the platform railing forsupport. Then carefully lower the platform ontothe blocks.

4 Remove the platform mounting fasteners andremove the platform.

Do not overtighten the platformmounting fasteners duringinstallation.

2-2Platform Leveling Slave Cylinder

The slave cylinder and the rotator pivot are thetwo primary supports for the platform. The slavecylinder keeps the platform level through theentire range of primary boom motion. It operates ina closed-circuit hydraulic loop with the mastercylinder. The slave cylinder is equipped withcounterbalance valves to prevent movement inthe event of a hydraulic line failure.

How to Remove the SlaveCylinder

Before cylinder removal isconsidered, bleed the slavecylinder to be sure there is noair in the closed loop.


1 Extend the boom until the slave cylinderbarrel-end pivot pin is accessible.

2 Raise the boom slightly and place blocks underthe platform. Then lower the boom until theplatform is resting on the blocks.

3 Remove the pin retainer fastener fromthe rod-end pivot pin.

4 Remove the external retaining ring from thebarrel-end pivot pin.



REV A PLATFORM COMPONENTS

5 Use a soft metal drift and drive the rod-end pivotpin out.

6 Use a soft metal drift and drive the barrel-endpivot pin out.

7 Carefully pull the cylinder out of the boom.

8 Tag and disconnect the hydraulic hoses fromthe slave cylinder and connect them togetherwith a connector. Cap the fittings on thecylinder.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.

How to Bleed the Slave Cylinder1 Raise the jib boom to a horizontal position.

2 Move the platform level switch up and downthrough two platform leveling cycles to removeany air that might be in the system.

2-3Platform Rotator

The platform rotator is a hydraulically-activatedhelical gear assembly used to rotate the platform160 degrees.

How to Remove thePlatform Rotator


1 Remove the platform. See 2-1,How to Remove the Platform.

2 Tag, disconnect and plug the hydraulic hosesfrom the platform rotator manifold.




REV APLATFORM COMPONENTS

3 Support the platform mounting weldment, but donot apply any lifting pressure.

4 Remove the six mounting bolts from theplatform mounting weldment, then remove thecenter bolt and slide the platform mountingweldment off of the platform rotator.

5 Support the platform rotator. Do not applyany lifting pressure.

6 Remove the pin retainers from the jib boom andleveling links to platform rotator pivot pins. Donot remove the pins.

7 Support the jib boom and leveling links.

8 Use a soft metal drift to drive both pins out, thenremove the platform rotator from the machine.

How to Bleed the PlatformRotator1 Connect a clear hose to the top bleed valve.

Place the other end of the hose in a containerto collect any discharge.

a clear hoseb top bleed valvec bottom bleed valved container

b

c

d

a

2 Open the top bleed valve, but do not remove it.


4 Hold the function enable switch to either sideand activate and hold the platform rotate switchto the right for approximately 5 seconds, thenrelease it. Repeat three times.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

5 Hold the platform rotate switch to the left forapproximately 5 seconds, then release it.

6 Fully rotate the platform to the left and continueholding the platform rotate switch until air stopscoming out of the bleed valve. Immediatelyrelease the platform rotate switch and close thebleed valve.

7 Rotate the platform to the right until it iscentered.

8 Connect the clear hose to the bottom bleedvalve and open the valve.

9 Hold the platform rotate switch to the right andcontinue holding the platform rotate switch untilair stops coming out of the bleed valve.

Crushing hazard. Keep handsclear of the platform pivotweldment during rotation.

10 Close the bleed valve and remove the hose.

11 Turn the key switch to the off position and cleanup any hydraulic oil that may have spilled.


13 Rotate the platform full left and right and inspectthe bleed valves for leaks.



REV A

2-4Platform Overload System

How to Calibrate the PlatformOverload System (if equipped)Calibration of the platform overload system isessential to safe machine operation. Continued useof 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.

Perform this procedure with themachine on a firm, level surface.


2 Determine the maximum platform capacity.Refer to the machine serial plate.

3 Remove all weight, tools and accessories fromthe platform.

Failure to remove all weight, toolsand accessories from the platformwill result in an incorrectcalibration.

4 Using a suitable lifting device, place a testweight equal to the maximum platform capacityat the center of the platform floor.

5 Move the platform up and down by hand, so itbounces approximately 1 to 2 inches / 2.5 to5 cm. Allow the platform to settle.

Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 6.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Slowly tighten the load springadjustment nut in a clockwise direction in 10°increments until the overload indicator lightturns off, and the alarm does not sound.Proceed to step 8.

The platform will need to be movedup and down and allowed to settlebetween each adjustment.

There may be a 2 second delaybefore the platform overloadindicator light and alarm responds.


Result: The overload indicator lights are off atthe platform and ground controls, and the alarmdoes not sound. Slowly loosen the load springadjustment nut in a counterclockwise directionin 10° increments until the overload indicatorlight flashes at both the platform and groundcontrols, and the alarm sounds.Proceed to step 7.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.

The platform will need to be movedup and down and allowed to settlebetween each adjustment.

There may be a 2 second delaybefore the platform overloadindicator lights and alarmresponds.

PLATFORM COMPONENTS



REV A


Result: The overload indicator lights are off andthe alarm does not sound. Proceed to step 8.

Result: The overload indicator lights are flashingat the platform and ground controls, and thealarm is sounding. Repeat this procedurebeginning with step 5.


8 Add an additional 10 lb / 4.5 kg test weight tothe platform.

Result: The overload indicator light is flashing atboth the ground and platform controls, and thealarm is sounding. Proceed to step 9.

Result: The overload indicator light is off at boththe ground and platform controls, and the alarmdoes not sound. Remove the additional 10 lb /4.5 kg test weight. Repeat this procedurebeginning with step 6.



Result: All platform control functions should notoperate.

10 Turn the key switch to ground control.


Result: All ground control functions should notoperate.

12 Using a suitable lifting device, lift the test weightoff the platform floor.

Result: The platform overload indicator lightshould be off at both the ground and platformcontrols and the alarm should not sound.

There may be a 2 second delaybefore the overload indicator lightsand alarm turn off.


Result: All ground control functions shouldoperate normally.



Result: All platform control functions shouldoperate normally.

PLATFORM COMPONENTS



REV AJib Boom Components

3-1Jib Boom

How to Remove the Jib BoomPerform this procedure with theboom in the stowed position.



2 Remove the platform mounting weldmentand the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thejib boom lift cylinder.


4 Remove the jib boom manifold cover.

5 Remove the mounting fasteners from the jibboom manifold.

6 Remove the cable cover from the side of thejib boom.

7 Attach a lifting strap from an overhead crane tothe jib boom.

8 Remove the pin retaining fastener from the jibboom pivot pin at the jib boom mountingweldment. Use a soft metal drift to remove thepin, then remove the jib boom from the jib boommounting weldment.

Crushing hazard. The jib boom willfall when the pin is removedif it is not properly supported.

9 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

10 Remove both of the jib boom leveling links fromthe primary boom.

11 Attach a lifting strap from an overhead crane tothe jib boom lift cylinder.

12 Use a soft metal drift to remove the jib boom liftcylinder rod-end pivot pin, then remove the jibboom lift cylinder from the primary boom.

Crushing hazard. The jib boomlift cylinder will fall when the pinis removed if it is not properlysupported.

13 Support and secure the jib boom mountingweldment to an appropriate lifting device.

14 Remove the pin retaining fasteners from theslave cylinder rod-end pivot pin. Do not removethe pin.

15 Remove the pin retaining fasteners from the jibboom mounting weldment at the extensionboom. Use a soft metal drift to remove the pin.

16 Use a soft metal drift to remove the slavecylinder rod-end pivot pin.

17 Remove the jib boom mounting weldment fromthe boom.

Crushing hazard. The jib boommounting weldment may becomeunbalanced and fall when the pinsare removed if it is not properlysupported and secured to thelifting device.



REV A

3-2Jib Boom Lift Cylinder

How to Remove the Jib BoomLift Cylinder



1 Raise the jib boom slightly and place blocksunder the platform mounting weldment. Thenlower the jib boom until the platform is restingon the blocks.

2 Tag, disconnect and plug the jib boom liftcylinder hydraulic hoses. Cap the fittings on thejib boom lift cylinder.


JIB BOOM COMPONENTS

3 Remove the pin retaining fasteners from the jibboom lift cylinder rod-end pivot pin. Do notremove the pin.

4 Use a soft metal drift to tap the rod-end pivot pinhalf way out. Then lower one of the levelinglinks to the ground. Tap the pin the otherdirection and lower the opposite leveling link.Do not remove the pin.

5 Attach a lifting strap from an overhead crane tothe jib boom lift cylinder.

6 Remove the pin retaining fastener from the jibboom lift cylinder barrel-end pivot pin. Use asoft metal drift to remove the barrel-end pin.

7 Use a soft metal drift to remove the jib boom liftcylinder rod-end pin. Remove the cylinder fromthe machine.

Crushing hazard. The jib boom liftcylinder may fall when the pins areremoved if it is not properlysupported by the overhead crane.



REV A

a

b

4-1Plastic 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 Repair the Plastic CableTrack

Component damage hazard. Theprimary boom cable track can bedamaged if it is twisted.

a link separation pointb lower clip

1 Use a slotted screwdriver to pry down on thelower clip.

2 Repeat step 1 for each link.

3 To remove a single link, open the lower clipand then use a screw driver to pry the link tothe side.

4-2Primary Boom

How to Shim the Primary BoomMeasure each wear pad. Replacethe pad if it is less than 0.41 inch /1 cm thick. If the pad is more than0.41 inch / 1 cm thick, perform thefollowing procedure.

1 Extend the boom until the wear pads areaccessible.

2 Loosen the wear pad mounting fasteners.

3 Install the new shims under the wear pad toobtain zero clearance and zero drag.

4 Tighten the mounting fasteners.

5 Extend and retract the boom through an entirecycle. Check for tight spots that could causescraping or binding.

Always maintain squarenessbetween the outer and inner boomtubes.

Primary Boom Components



REV A

How to Remove thePrimary Boom

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.




2 Remove the platform rotator. See 2-3, How toRemove the Platform Rotator.

3 Remove the jib boom. See 3-1,How to Remove the Jib Boom.

4 Locate the 4 cables from the primary boomcable track to the platform control box. Numbereach cable and its entry location at the platformcontrol box.

5 Open the platform control box.

6 Label and disconnect each wire of the 4 cablesin the platform control box.


7 Pull all of the cables out of the platform controlbox.

8 Tag, disconnect and plug the hydraulic hosesfrom the slave cylinder.


9 Tag, disconnect and plug the hydraulic hosesfrom the jib/rotate manifold.


10 Remove the upper cable track mountingfasteners from the platform end of the boom.

11 Remove the cable track mounting fasteners,then remove the cable track from theboom and lay it flat on the ground.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

12 Remove all of the hose and cable clamps fromthe underside of the primary boom.

13 Remove the turntable end cover.

14 Remove the extension boom drive limit switchfrom the side of the primary boom at the pivotend. Do not disconnect the wiring.

15 Pull all of the electrical cables and hydraulichoses out of the plastic cable track.

16 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Use a softmetal drift to remove the pin. Pull the cylinderback and secure it from moving.

PRIMARY BOOM COMPONENTS



REV A PRIMARY BOOM COMPONENTS

17 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on the cylinder.


18 Attach an overhead 5 ton / 5000 kg crane to thecenter point of the boom.

19 Attach a similar lifting device to the lift cylinder.

20 Place support blocks under the cylinder, acrossthe secondary boom.

21 Remove the pin retaining fastener from theboom lift cylinder rod-end pivot pin. Use a softmetal drift to remove the pin.

Crushing hazard. The boom liftcylinder will fall unless it isproperly supported.

22 Lower the rod end of the lift cylinder ontosupport blocks.

23 Remove the pin retaining fastener from theprimary boom pivot pin.

24 Remove the primary boom pivot pin with a softmetal drift, then carefully remove the boom fromthe machine.

Crushing hazard. The boom maybecome unbalanced and fall whenit is removed from the machine Ifthe overhead crane is not properlyattached.

How to Disassemblethe Primary Boom

Complete disassembly of theboom is only necessary if the outeror inner boom tubes must bereplaced. The extension cylindercan be removed withoutcompletely disassembling theboom. See 4-4, How to Removethe Extension Cylinder.

1 Remove the boom. See 4-2,How to Remove the Primary Boom.

2 Place blocks under the extension cylinder forsupport.

3 Remove the retaining fasteners from theextension cylinder barrel-end pivot pin. Use asoft metal drift to remove the pin.

4 Remove and label the location of the wear padsfrom the top side of the boom tube, at theplatform end of the boom.

Pay careful attention to thelocation and amount of shimsused with each wear pad.

5 Carefully rotate the base end of the extensioncylinder until the pin mounting bore is in avertical position.

6 Support the extension tube with an overheadcrane at the platform end of the boom.

Crushing hazard. The boom tubescould fall when they are removedfrom the boom if they are notproperly supported.

7 Support and slide the number 2 extension tubeout of the number 1 primary boom tube. Placethe number 2 boom tube on blocks for support.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.



REV APRIMARY BOOM COMPONENTS

8 Remove the retaining rings from the extensioncylinder rod-end pivot pin at the platform end ofthe number 2 extension tube. Use a soft metaldrift to remove the pin.

9 Support and slide the extension cylinder out ofthe base end of the number 2 boom tube. Placethe extension cylinder on blocks for support.

During removal, the overheadcrane strap will need to becarefully adjusted for properbalancing.

10 Remove and label the wear pads from theextension cylinder.

Pay careful attention to thelocation of each wear pad.

4-3Primary Boom Lift Cylinder

The lift cylinder raises and lowers the primaryboom. The lift cylinder is equipped withcounterbalance valves to prevent movement in theevent of a hydraulic line failure.

How to Remove the PrimaryBoom Lift Cylinder



1 Raise the primary boom enough to access theprimary boom lift cylinder rod-end pivot pin.

2 Attach an overhead crane to the primary boomfor support. Do not lift it.

3 Remove the pin retaining fastener from theground controls side upper compression armpivot pin.

4 Place a block of wood across the uppersecondary boom to support the cylinder whenthe rod-end pivot pin is removed.



REV A PRIMARY BOOM COMPONENTS

5 Place a rod through the compression arm pivotpin and twist to remove the pin. Lower thecompression arm down.

6 Support the primary boom lift cylinder with alifting device.

7 Remove the pin retaining fastener from theprimary boom lift cylinder rod-end pivot pin.Then use a soft metal drift to remove the pin.

8 Lower the rod end of the cylinder onto theblocks that were placed on the uppersecondary boom.

9 Tag, disconnect and plug the primary boom liftcylinder hydraulic hoses. Cap the fittings on thecylinder.


10 Support the primary boom lift cylinder withstraps or ropes to restrict it from swingingfreely.

11 Remove the pin retaining fastener from theprimary boom lift cylinder barrel-end pivot pinDo not remove the pivot pin.

12 Use the overhead crane to lift the primary boom1 inch / 2.5 cm. This will relieve pressure on thebarrel-end pivot pin.

13 Place a rod through the barrel-end pivot pin andtwist to remove the pin.

Crushing hazard. The primaryboom lift cylinder will swing down ifit is not properly supported whenthe barrel-end pivot pin isremoved.

14 Attach and secure the rod-end of the primaryboom lift cylinder to a overhead crane or similarlifting device. Carefully loosen the straps andallow the primary boom lift cylinder to slowlyswing down.

15 Carefully remove the cylinder from the machine.

Crushing hazard. The primaryboom lift cylinder may becomeunbalanced and fall if it is notproperly supported when the rod-end pivot pin is removed.



REV APRIMARY BOOM COMPONENTS

4-4Extension Cylinder

The extension cylinder extends and retracts theprimary boom extension tube. The extensioncylinder is equipped with counterbalance valves toprevent movement in the event of a hydraulic linefailure.

How to Remove theExtension Cylinder



1 Raise the primary boom to the horizontalposition. Then extend the boom 3 to4 feet / 0.9 to 1.2 m until the extension cylinderrod-end pivot pins are accessible.

2 Remove the external snap rings from theextension cylinder rod-end pivot pins. Then usea soft metal drift to remove the pins.

3 Remove the rear turntable cover.

4 Raise the secondary boom until the mastercylinder rod-end pivot pin is accessible.

5 Remove the drive limit switch from the pivot endof the primary boom. Do not disconnect thewiring.

6 Remove the retaining fastener from the mastercylinder rod-end pivot pin, then use a soft metaldrift to remove the pin.

7 Manually retract the master cylinder and push ittoward the platform end of the boom to obtainenough clearance for the extension cylinderremoval.

8 Tag, disconnect and plug the extension cylinderhydraulic hoses. Cap the fittings on thecylinder.


9 Remove the extension cylinder barrel-end pivotpin retaining fastener, then use a soft metal driftto remove the pin.

10 Carefully pull out and properly support theextension cylinder from the primary boom.

Crushing hazard. The cylindercould fall if it is not properlysupported when it is pulled out ofthe extension tube.

To make installation of theextension cylinder easier, be surethat the cylinder rod is extended3 to 4 feet / 0.9 to 1.2 m.



REV A

4-5Platform Leveling MasterCylinder

The master cylinder acts as a pump for the slavecylinder. It is part of the closed circuit hydraulicloop that keeps the platform level through theentire range of primary boom motion. The mastercylinder is located inside the upper mid-pivot at thepivot end of the primary boom.

How to Remove the PlatformLeveling Master Cylinder


Before cylinder removal isconsidered, bleed the cylinder tobe sure that there is no air in theclosed loop. See 2-2, How toBleed the Slave Cylinder.



2 Raise the secondary boom until the mastercylinder barrel-end pivot pin is above theturntable counterweights.

3 Raise the primary boom until the mastercylinder rod-end pivot pin is accessible.

4 Attach an overhead crane to the pivot end of theprimary boom. Do not lift it.

5 Secure the upper secondary boom to the pivotend of the primary boom with a strap (this willprevent the upper secondary boom from fallingwhen the master cylinder barrel-end pin isremoved from the cylinder).

6 Tag, disconnect and plug the master cylinderhydraulic hoses. Cap the fittings on thecylinder.


7 Tie a strap around the lug on the rod end of themaster cylinder, then secure the strap to theprimary boom (use this strap to lower thecylinder out of the upper pivot).

8 Remove the pin retaining fastener from themaster cylinder rod-end pivot pin. Then use asoft metal drift to remove the pin.

9 Remove the pin retaining fastener from themaster cylinder barrel-end pivot pin. Then use asoft metal drift to remove the pin from thecylinder. Do not remove the pin from the upperpivot. Push the pin to one side, only far enoughto remove the cylinder. The pin should remain inone side of the upper secondary boom andupper pivot.

Crushing hazard. The uppersecondary boom and the upperpivot will fall if the pivot pin iscompletely removed.

10 Use the strap around the rod-end lug to lowerthe cylinder out of the machine.

PRIMARY BOOM COMPONENTS



REV ASecondary Boom Components

a b

d

e

f

g

f

h

b

c

Secondary Booma upper pivotb upper compression armc mid-pivotd compression linke lower secondary boomf lower compression armg turntable pivoth upper secondary boom



REV A

8 Label and disconnect each wire of the fourcables in the platform control box.


9 Pull the cables out of the platform control box.

10 Pull all of the electrical cables out of the plasticcable track. Do not pull out the hydraulic hoses.

11 Remove the hose clamps from the bottom sideof the primary boom.

12 Tag, disconnect and plug the platform rotatorhydraulic hoses at the union, located on thebottom side of the primary boom.


13 Remove the hose clamp from the side of theprimary boom at the pivot end.

14 Remove the drive speed limit switchmounted on the side of the pivot end ofthe primary boom. Do not disconnect the wiring.

15 Attach a strap from an overhead crane to thepivot end of the primary boom.

16 Carefully lift the secondary and primary boomassembly until the master and primary liftcylinder hydraulic hoses are accessible.

17 Remove the cable covers from the top of theupper secondary boom.

SECONDARY BOOM COMPONENTS

5-1Secondary Boom

How to Disassemble theSecondary Boom

Bodily injury hazard. Theprocedures in this section requirespecific repair skills, liftingequipment and a suitableworkshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.

Follow the disassembly steps to the point requiredto complete the repair. Then re-assemble thesecondary boom by following the disassemblysteps in reverse order.


1 Lower the boom to the stowed position.

2 Place a lifting device under the front of theplatform.


4 Remove the cable cover from the side of the jibboom.

5 Remove the wire loom from the cables at theplatform control box.

6 Locate the four cables from the primary boomcable track to the platform control box. Numbereach cable and its entry location at the platformcontrol box.

7 Open the platform control box.



REV A

18 Tag, disconnect and plug the primary boom liftcylinder and master cylinder hydraulic hoses.


19 Lower the booms to the stowed position.

20 Pull all the cables and hoses through the uppermid-pivot.

Component damage hazard.Cables and hoses can bedamaged if they are kinked orpinched.

21 Position the strap from the overhead craneapproximately two feet from the platform end ofthe primary boom. Measure from the end of theprimary boom tube.

22 Remove the pin retaining fasteners from theupper pivot to upper compression arm pivotpins. Use a soft metal drift to remove the pins.

23 Swing the compression arms down and out ofthe way. Secure them from moving.

24 Remove the pin retainers from the upperpivot to upper secondary boom pivot pin. Use asoft metal drift to remove the pin.

25 Carefully remove the entire primary boomassembly from the machine (primary boomassembly, jib boom assembly, platform, mastercylinder, primary lift cylinder and upper pivot).

Crushing hazard. If the overheadcrane is not properly attached, theprimary boom assembly couldbecome unbalanced and fall whenit is removed from the machine. Donot remove the assembly frommachine until it is properlybalanced.

26 Place the entire assembly onto a structurecapable of supporting it.

27 Remove the pin retaining fasteners from theupper compression arm pivot pins. Do notremove the pins.

28 Position the lifting strap from an overhead craneat the center of the control box side uppercompression arm, then remove it from themachine. Repeat this step for the engine sideupper compression arm.

Crushing hazard. If the overheadcrane is not properly attached, theupper compression arm couldbecome unbalanced and fall whenit is removed from the machine.

29 Remove the pin retaining fastener from the rodend of the secondary boom lift cylinder. Use asoft metal drift to remove the pin. Secure thecylinder from moving.

30 Remove the pin retaining fastener from the lowerpivot pin on the compression link. Use a softmetal drift to remove the pin.

31 Attach the strap from an overhead crane to theupper secondary boom.

32 Remove the pin retaining fastener from theupper secondary boom to mid-pivot pivot pin.Use a soft metal drift to remove the pin.

33 Remove the upper secondary boom withcompression link from the machine.

Crushing hazard. If the overheadcrane is not properly attached, theupper secondary boom withcompression link may becomeunbalanced and fall when it isremoved from the machine.

SECONDARY BOOM COMPONENTS



REV A SECONDARY BOOM COMPONENTS

34 Remove the drive speed limit switchmounted on the inside of the mid-pivot. Do notdisconnect the wiring.

35 Remove the cable covers from the top of thelower secondary boom. Pull all the cables andhoses to the back of the turntable.

36 Remove the retaining fasteners from thesecondary boom lift cylinder barrel-end pivotpins.

37 Attach the strap from the crane to the lug on therod end of the secondary boom lift cylinder.

38 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


39 Use a slide hammer to remove the barrel-endpins (access the pins from the access holes inthe bulkheads, one on each side). Then removethe cylinder from the machine.

Crushing hazard. If the overheadcrane is not properly attached, thesecondary boom lift cylinder maybecome unbalanced and fall whenit is removed from the machine.

40 Attach the strap from the crane to the mid-pivot.

41 Remove the pin retainers from the mid-pivot tolower compression arm pivot pins. Use a slidehammer and remove the pin.

42 Remove the pin retainers from the mid-pivot tolower secondary boom pivot pins. Use a softmetal drift to remove the pin.

43 Remove the mid-pivot from the machine.

Crushing hazard. If the overheadcrane is not properly attached, themid-pivot could becomeunbalanced and fall when it isremoved from the machine.

44 Attach the strap from the crane to the controlbox side lower compression arm.

45 Remove the pin retainer from the lowercompression arm to turntable pivot pin. Use aslide hammer and remove the pin. Remove thearm from the machine. Repeat for the engineside lower compression arm.

Crushing hazard. If the overheadcrane is not properly attached, thelower compression arms couldbecome unbalanced and fall whenit is removed from the machine.

46 Attach the strap from the crane to the lowersecondary boom.

47 Remove the pin retainer from the lowersecondary boom to turntable pivot pin. Use asoft metal drift to remove the pin.

48 Remove the lower secondary boom from themachine.

Crushing hazard. If the overheadcrane is not properly attached, thelower secondary boom couldbecome unbalanced and fall whenit is removed from the machine.



REV ASECONDARY BOOM COMPONENTS

5-2Secondary Boom Lift Cylinder

The secondary boom lift cylinder raises andlowers the secondary boom. The secondaryboom lift cylinder is equipped with counterbalancevalves to prevent movement in the event of ahydraulic line failure.

How to Remove the SecondaryBoom Lift Cylinder



1 Rotate the turntable to the side until the boom iscentered between the steer and non-steer tires.

2 Raise the primary boom to full height. Do notextend it.

3 Attach the strap from an overhead crane to thelug on the rod end of the secondary boom liftcylinder.

4 From the bottom side of the cylinder, removethe retaining fasteners from the secondaryboom lift cylinder barrel-end pivot pins.

5 Use a slide hammer to remove the barrel-endpins (access the pins from the access holes inthe bulkheads, one on each side).

6 Remove the pin retaining fastener from thesecondary boom lift cylinder rod-end pivot pin.Then use a soft metal drift to remove the pin.

7 Carefully lower the cylinder down through thesecondary boom, enough to access thehydraulic hoses. Do not pinch the hoses.

Component damage hazard.Hoses can be damaged if theyare kinked or pinched.

8 Tag, disconnect and plug the hydraulic hosesfrom the secondary boom lift cylinder. Cap thefittings on the cylinder.


9 Remove the cylinder through the top of thesecondary boom.



REV AKubota Z482-E Engine

6-1Timing Adjustment

Complete information to perform this procedure isavailable in the Kubota Z482-E Workshop Manual(Kubota code number: 97897-01165). Genie partnumber 52956.

6-2Glow Plugs

How to Check the Glow PlugsSee the scheduled maintenance procedure B-7,Check The Glow Plugs.

6-3Engine RPM

RPM AdjustmentSee the scheduled maintenance procedure B-8,Check and Adjust the Engine RPM.

6-4Engine Drive Pulley

How to Remove the EngineDrive Pulley1 Remove the three bolts that attach the engine

drive pulley to the shaft bushing.

2 Install the same three bolts that were removedin step 1 into the threaded holes of the enginedrive pulley.

3 Carefully tighten each bolt evenly until theengine drive pulley slides off the shaft.

Component damage hazard. Theengine drive pulley and/or shaftcan be damaged if the bolts arenot tightened evenly.

4 Loosen the set screw on the pulley bushing,then slide the pulley bushing off of the engineshaft.

a gapb shaftc set screwd engine drive pulleye engine drive pulley boltf shaft bushingg woodruff key

a c a

e efg

b

dd f



REV AKUBOTA Z482-E ENGINE

How to Install the Engine DrivePulley

The generator pulley must alreadybe installed before performing thisprocedure. See 7-1, How to Installthe Generator Pulley.

1 Align the woodruff key on the engine shaft withthe slot in the pulley bushing and slide thepulley bushing onto the engine shaft. Do nottighten the set screw.

2 Loosen the set screw and align the flywheel sideof the pulley bushing on the engine shaft withthe outer face of the generator pulley using astraightedge.

a pulley shaftb pulley bushingc engine flywheeld straightedgee generator pulleyf generator

3 Tighten the set screw on the pulley bushinghand tight.

a c a

e efg

b

dd f

a b

de

c

f

4 Slide the engine pulley onto the pulley bushing.

5 Install the pulley mounting bolts and tightenthem evenly to 108 in-lbs / 12.2 Nm.

Component damage hazard. Donot overtighten the pulleymounting bolts. There must be agap visible between the enginedrive pulley and the pulleybushing.

a gapb shaftc set screwd engine drive pulleye pulley mounting boltf pulley bushingg woodruff key

6 Check the alignment between the engine drivepulley and the generator pulley using astraightedge.

If the pulley alignment is not withinspecification, remove the enginepulley and repeat steps 2through 6. See 6-4, How toRemove the Engine Drive Pulley.

Pulley alignment, 1/16 inchmaximum offset 1.58 mm



REV A

a

b

KUBOTA Z482-E ENGINE

6-5Water Temperature and OilPressure Switches

The water temperature switch is a normally openswitch that closes at approximately 225° F/ 107° C. When the switch closes, the engine willshut off to prevent damage and will not start untilthe temperature drops below the switch point. Anover-temperature indicator light at the groundcontrols should turn on when the switch closes.

Component damage hazard.Do not crank the engine withthe over-temperature light on.

The oil pressure switch is a normally closed switchthat opens at approximately 7 psi / 0.5 bar. If the oilpressure drops below the switch point, the switchcloses and shuts off the engine to prevent damage.A low oil pressure indicator light at the groundcontrols should turn on when the switch opens.

Component damage hazard.Do not crank the engine with thelow oil pressure light on.

a water temperature switchb oil pressure switch

How to Replace the WaterTemperature and Oil PressureSwitches

Perform this procedure with theengine off.

1 Pull up on the pull pin on the engine pivot traylocated next to the generator. Swing the enginepivot tray out from the machine to access bothswitches.

2 Disconnect the wiring from the desired switch.

3 Remove the switch from the engine block, andthen install the new switch using pipe threadsealant. Do not over tighten.

Bodily injury hazard. Contact withhot engine fluids or componentsmay cause severe burns.

Specifications

Water temperature switch

Torque 8-18 ft-lbs 11-24 Nm

Hex size 13/16 inch21 mm

Temperature switch point 225°F ±2%107°C ±2%

Oil pressure switch

Torque 8-18 ft-lbs 11-24 Nm

Hex size 1 1/16 inch27 mm

Oil pressure switch point 7.1 psi 0.5 bar



REV AGenerator

a c a

e efg

b

dd f

7-1Generator

How to Remove the GeneratorPulley(before serial number 1112)

1 Loosen the tension adjustment bolt on thegenerator.

2 Push the generator towards the machine andremove the belts from the generator pulley.

3 Remove the three bolts that attach the generatorpulley to the shaft bushing.

4 Install the same three bolts that were removedin step 1 into the threaded holes of thegenerator pulley.

5 Carefully tighten each bolt evenly until thegenerator pulley slides off the shaft.

Component damage hazard. Thegenerator pulley and/or shaft canbe damaged if the bolts are nottightened evenly.

6 Loosen the set screw on the pulley bushing,then slide the pulley bushing off of the generatorshaft.

a gapb shaftc set screwd generator pulleye pulley mounting boltf pulley bushingg woodruff key

How to Remove the GeneratorPulley(after serial number 1111)1 Loosen the tension adjustment bolt on the

generator.

2 Push the generator towards the machine andremove the belts from the generator pulley.

3 Remove the generator pulley retaining nut fromthe generator shaft.

4 Slide the pulley off of the generator shaft.



REV A

a c a

e efg

b

dd f

GENERATOR

How to Install the GeneratorPulley(before serial number 1112)

The pulley on the generator mustbe installed before installing theengine drive pulley.

1 Align the woodruff key on the generator shaftwith the slot in the pulley bushing and slide thepulley bushing all the way onto the generatorshaft.

2 Tighten the set screw on the pulley bushinghand tight.

4 Slide the generator pulley onto the pulleybushing.

5 Install the pulley mounting bolts and tightenthem evenly to 60 in-lbs / 6.8 Nm.

Component damage hazard. Donot overtighten the pulley mountingbolts. There must be a gap visiblebetween the generator pulley andthe pulley bushing.

6 Adjust the tension of the generator belts.See 7-2, How to Adjust the Generator Belts.

a gapb shaftc set screwd generator pulleye pulley mounting boltf pulley bushingg woodruff key

How to Install the GeneratorPulley(after serial number 1111)

The pulley on the generator mustbe installed before installing theengine drive pulley.

1 Align the woodruff key on the generator shaftwith the slot in the pulley and slide the pulley allthe way onto the generator shaft.

2 Install the flat washer and pulley retaining nutonto the generator shaft, then tighten the nut to80-90 ft-lbs / 108-122 Nm.

3 Adjust the tension of the generator belts.See 7-2, How to Adjust the Generator Belts.



REV AGENERATOR

c

a

b

7-2Generator Belts

How to Adjust the GeneratorBelts1 Disconnect the battery packs.

2 Loosen the tension adjustment bolt on thegenerator.

3 Pull the generator away from the machine andtighten the adjustment bolt.

4 Check the generator belts for proper tension. Ifthe belt deflection is not within specification,perform steps 1 and 2 and re-check the belttension.

a engine pulleyb generator beltsc generator pulley

Belt deflection, 1/4 inchmaximum allowable 6.5 mm

7-3Generator Voltage Regulator

How to Adjust the GeneratorVoltage RegulatorThe voltage regulator regulates the output voltageof the generator. A properly adjusted voltageregulator is essential to good generatorperformance and service life. A defective orimproperly adjusted voltage regulator could result incomponent damage.

Be sure the batteries are fullycharged before performing thisprocedure.

1 Connect the positive lead of a voltmeter to thePOS terminal on the generator and the negativelead of the voltmeter to the neg terminal on thegenerator.


2 Start the engine from the ground controls andmove the rpm select toggle switch to themaintained high idle position. Check the voltageon the generator.

Result: The voltage should be 54V DC.

3 If the voltage reading is not 54V DC, insert asmall flat blade screwdriver into thepotentiometer located inside of the generator.Use the access hole on the back of thegenerator labeled VOLT ADJ.

Component damage hazard. Besure that the screwdriver isproperly inserted into thepotentiometer or the generator and/or voltage regulator may becomedamaged.



REV A GENERATOR

b

g

h

c

f

d

e

a

4 Carefully adjust the potentiometer to obtain a54V DC voltage reading. Turn the potentiometerclockwise to increase the voltage orcounterclockwise to decrease the voltage. Donot rotate the potentiometer past the internalstops.

Component damage hazard. Thevoltage regulator inside thegenerator will become damaged ifthe potentiometer is rotated pastthe internal stops.

How to Replace the VoltageRegulator1 Disconnect the battery packs from the machine.

2 Tag and disconnect the positive and negativebattery cables from the generator.

3 Remove the generator mounting fasteners thenremove the generator from the machine.

4 Remove the three nuts that hold the plasticcover onto the generator. Carefully remove thecover.

5 Locate the three white wires that lead from thevoltage regulator to the negative rectifierassembly.

a white wires (#10 nuts)b negative rectifier assemblyc black wire (#10 screw)d black wire (#4 nut)e voltage regulator

mounting fastener (#8 screw)f voltage regulatorg red wire (#10 screw)h positive rectifier assembly



REV AGENERATOR

6 Remove the nuts on those three wires from thenegative rectifier assembly, then remove thewires.

Do not remove the spacers fromthe underneath the wires on thenegative rectifier assembly.

7 Locate the red wire that leads from the voltageregulator to the positive rectifier assembly.

8 Remove the screw that attaches the red wire tothe positive recitfier assembly.

9 Remove the nut that attaches the black wire tothe voltage regulator.

10 Remove the voltage regulator mounting screws.

11 Remove the voltage regulator while carefullyguiding the red and black wires from behind thenegative rectifier assembly.

12 Install the new voltage regulator (Genie partnumber 54446) by following the previous stepsin reverse order.

13 Apply Loctite® removable thread sealant ontothe voltage regulator mounting fasteners andtorque to 25 in-lbs / 2.8 Nm.

14 Torque all fasteners to the followingspecifications:

Fastener torque specifications

#10 screw 25 in-lbs2.8 Nm

#10 nut 25 in-lbs2.8 Nm

#4 nut 8-10 in-lbs0.9-1.1 Nm

Voltage regulator mounting fasteners 25 in-lbs2.8 Nm

15 Install the plastic cover onto the generator theninstall the generator onto the machine.

16 Adjust the generator belts. See 7-2, How toAdjust the Generator Belts.

17 Adjust the voltage regulator. See 7-3, How toAdjust the Voltage Regulator.

Component damage hazard. Thevoltage regulator and/or generatormay become damaged if thevoltage regulator is not properlyadjusted after replacement.

When the voltage regulator isreplaced, the voltage regulatormust be adjusted. See 7-3, How toAdjust the Voltage Regulator.



REV AGround Controls

Relay Schematic

Terminal Numbers

8-1Control Relays

Relays used for dual function switching are doublepole double throw (DPDT) relays.

How to Test a Single PoleDouble Throw Relay

Electrocution hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

This procedure covers fundamental relay testingand does not specifically apply to all varietiesof relays.

1 Turn the key switch to the off position andremove the key.

2 Label and then disconnect all the wiring from therelay to be tested.

3 Connect the leads from an ohmmeter to eachterminal combination and check for continuity.Terminals 85 and 86 represent the coil andshould not be tested in any other combination.

Test Desired result

terminal 85 to 86 85 to 95Ω

terminal 87 to 87a & 30 no continuity(infinite Ω)

terminal 87a to 30 continuity(zero Ω)

4 Connect 24V DC to terminal 85 and a groundwire to terminal 86, then test the followingterminal combinations.

Test Desired result

terminal 87a to 87 & 30 no continuity(infinite Ω)




REV AGROUND CONTROLS

8-2Toggle Switches

See Repair Procedure 1-4, Toggle Switches.

8-3Wago® Components

How to Remove a Wago®

ComponentElectrocution hazard.Contact with electrically chargedcircuits could result in death orserious injury. Remove all rings,watches and other jewelry.

A small screwdriver is providedand should be used when removinga Wago® component. Thisscrewdriver is located in theoperator’s manual storage box inthe platform.

1 Label the wiring from the component to beremoved.

2 Use the provided screwdriver to push in andrelease the wire from the component.

3 Locate the removal tab on the bottom or top sideof the component.

4 Use the provided screwdriver to gently pry up onthe tab of the component and remove it.



REV AHydraulic Pumps

9-1Auxiliary Pump

How to Test the Auxiliary Pump1 Disconnect and plug the high pressure hydraulic

hose from the auxiliary pump.



2 Connect a 0 to 5000 psi / 0 to 345 bar, pressuregauge to the high pressure port on the pump.

3 Turn the key switch to ground control and pullthe red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Activate any function using auxiliary power.

Result: If the pressure gauge reads 2800 psi /193 bar, immediately stop. The pump is good.

Result: If pressure fails to reach 2800 psi/ 193 bar, the pump is bad and will need to beserviced or replaced.

5 Remove the pressure gauge and reconnect thehydraulic hose.

How to Remove the AuxiliaryPump1 Tag, disconnect and plug the hydraulic hoses

from the pump.


2 Remove the pump mounting bolts. Carefullyremove the pump.



REV AHYDRAULIC PUMPS

9-2Function Pump

How to Test the Function PumpThis procedure will require twopeople.

1 Disconnect and plug the high pressure hydraulichose from the function pump.



2 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the high pressure port on the pump.

3 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.

4 Hold the function enable switch to either sideand activate any boom function from the groundcontrols.

Result: If the pressure gauge reads 3000 psi /207 bar, immediately stop. The pump is good.

Result: If pressure fails to reach 3000 psi /207 bar, the pump is bad and will need to beserviced or replaced.

Component damage hazard.Hydraulic pressure in excess of3200 psi / 221 bar, will causesevere component damage.

5 Remove the pressure gauge and reconnect thehydraulic hose.

How to Remove the FunctionPump1 Tag, disconnect and plug the hydraulic hoses

from the pump.


2 Remove the pump mounting bolts. Carefullyremove the pump.



REV AManifolds

10-1Function Manifold Components (before serial number 1112)

The function manifold is mounted to the turntable under the ground controls.

Index SchematicNo. Description Item Function Torque

1 3 position 4 way spool valve ............. A ........... Platform level up/down .....................10-12 ft-lbs / 14-16 Nm

2 Counterbalance valve ....................... B ........... Platform level down ..........................35-40 ft-lbs / 47-54 Nm

3 Counterbalance valve ....................... C ........... Platform level up ...............................35-40 ft-lbs / 47-54 Nm

4 Relief valve, 1100 psi / 75.8 bar ....... D ........... Turntable rotate left/right ..................25-30 ft-lbs / 34-41 Nm

5 Relief valve, 1600 psi / 110 bar ........ E ........... Secondary boom down ....................25-30 ft-lbs / 34-41 Nm

6 Relief valve, 1400 psi / 96.5 bar ....... F ........... Primary boom down .........................25-30 ft-lbs / 34-41 Nm

7 Relief valve, 1800 psi / 124 bar ........ G ........... Primary boom extend .......................25-30 ft-lbs / 34-41 Nm

8 Proportional solenoid valve .............. H ........... System flow regulating circuit ...........10-12 ft-lbs / 14-16 Nm

9 3 position 4 way spool valve ............. I ............ Primary boom extend/retract ............10-12 ft-lbs / 14-16 Nm

10 Differential sensing valve .................. J ............ Differential sensing circuit ................10-12 ft-lbs / 14-16 Nm

11 Relief valve, 3200 psi / 220.6 bar .... K ........... System relief .....................................25-30 ft-lbs / 34-41 Nm

12 Diagnostic fitting ................................ L ........... Testing

13 3 position 4 way spool valve ............. M .......... Primary boom up/down ....................10-12 ft-lbs / 14-16 Nm

14 3 position 4 way spool valve ............. N ........... Secondary boom up/down ...............10-12 ft-lbs / 14-16 Nm

15 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ O ........... Turntable rotate circuit ......................10-12 ft-lbs / 14-16 Nm

16 Flow regulator valve,0.8 gpm / 3 L/min ............................... P ........... Jib boom/platform rotate circuit ........10-12 ft-lbs / 14-16 Nm

17 3 position 4 way spool valve ............. Q ........... Turntable rotate left/right ..................10-12 ft-lbs / 14-16 Nm



REV A MANIFOLDS

A B C D E F H

I

J

K

L

M

N

OPQ

G

14151617

53 6 7 8

13

9

11

10

12

21 4



REV A

10-2Function Manifold Components (after serial number 1111)

The function manifold is mounted to the turntable under the ground controls.


1 3 position 4 way spool valve ............. A ........... Platform level up/down .....................10-12 ft-lbs / 14-16 Nm

2 Counterbalance valve ....................... B ........... Platform level down ..........................35-40 ft-lbs / 47-54 Nm

3 Counterbalance valve ....................... C ........... Platform level up ...............................35-40 ft-lbs / 47-54 Nm

4 Relief valve, 1100 psi / 75.8 bar ....... D ........... Turntable rotate left/right ..................25-30 ft-lbs / 34-41 Nm

5 Relief valve, 1600 psi / 110 bar ........ E ........... Secondary boom down ....................25-30 ft-lbs / 34-41 Nm

6 Relief valve, 1400 psi / 96.5 bar ....... F ........... Primary boom down .........................25-30 ft-lbs / 34-41 Nm

7 Relief valve, 1800 psi / 124 bar ........ G ........... Primary boom extend .......................25-30 ft-lbs / 34-41 Nm(removed after serial number 3215)

8 Proportional solenoid valve .............. H ........... System flow regulating circuit ...........10-12 ft-lbs / 14-16 Nm

9 Check valve ....................................... I ............ Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

10 Solenoid valve, 3 position 4 way ...... J ............ Steer left/right ....................................10-12 ft-lbs / 14-16 Nm

11 3 position 4 way spool valve ............. K ........... Primary boom extend/retract ............10-12 ft-lbs / 14-16 Nm

12 Pressure switch ................................. L ........... Brake circuit

13 Solenoid valve, N.C. poppet ............. M .......... Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

14 Orifice, 0.045 in / 1.02 mm ................ N ........... Steer circuit

15 Orifice, 0.045 in / 1.02 mm ................ O ........... Brake circuit

16 Solenoid valve, N.O. poppet ............. P ........... Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

17 Differential sensing valve .................. Q ........... Differential sensing circuit ................10-12 ft-lbs / 14-16 Nm

18 Relief valve, 3200 psi / 220.6 bar .... R ........... System relief .....................................25-30 ft-lbs / 34-41 Nm

19 Diagnostic fitting ................................ S ........... Testing

20 3 position 4 way spool valve ............. T ........... Secondary boom up/down ...............10-12 ft-lbs / 14-16 Nm

21 3 position 4 way spool valve ............. U ........... Primary boom up/down ....................10-12 ft-lbs / 14-16 Nm

22 Flow regulator valve,1.5 gpm / 5.7 L/min ............................ V ........... Turntable rotate circuit ......................10-12 ft-lbs / 14-16 Nm

23 Flow regulator valve,0.8 gpm / 3 L/min ............................... W .......... Jib boom/platform rotate circuit ........10-12 ft-lbs / 14-16 Nm

24 3 position 4 way spool valve ............. X ........... Turntable rotate left/right ..................10-12 ft-lbs / 14-16 Nm

MANIFOLDS



REV A MANIFOLDS

A B C D E F H I J

K

L

M

N

O

P

R

Q

S

T

UVWX

G

Old style, no

longer available

after serial

number 1821

21222324

5 6 7 8 109

20

16

19

18

13

14

15

17

11

1 43

12

2



REV A

10-3Valve Adjustments -Function Manifold

How to Adjust the System ReliefValve

Perform this procedure with theprimary boom fully retracted.

1 Connect a 0 to 5000 psi / 0 to 345 bar pressuregauge to the test port on the function manifold.

2 Hold the function enable toggle switch to eitherside and hold the primary boom extend/retracttoggle switch in the retract direction with theprimary boom fully retracted, and observe thepressure reading on the pressure gauge. Referto Section 2, Specifications.

3 Turn the machine off. Hold the relief valve andremove the cap (item 11, function manifold -models before serial number 1112 OR item 18,function manifold - models after serial number1111).

4 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Then install the reliefvalve cap.

Tip-over hazard. Do not adjustthe relief valves higher thanspecified.

5 Repeat steps 2 through 4 and recheck the valvepressure.

MANIFOLDS

How to Adjust the Primary BoomDown Relief Valve



2 Hold the function enable toggle switch to eitherside and hold down the primary boom downtoggle switch with the primary boom fullylowered, and observe the pressure reading onthe pressure gauge. Refer to Section 2,Specifications.

3 Turn the machine off. Hold the relief valve andremove the cap (item 6, function manifold).






REV A MANIFOLDS

How to Adjust the SecondaryBoom Down Relief Valve



2 Hold the function enable toggle switch to eitherside and hold down the secondary boom downtoggle switch with the secondary boom fullylowered, and observe the pressure reading onthe pressure gauge. Refer to Section 2,Specifications.





How to Adjust the Primary BoomExtend Relief Valve(before serial number 3216)



2 Raise the primary boom to a horizontal position.

3 Hold the function enable toggle switch to eitherside and hold the primary boom extend toggleswitch with the primary boom fully extended,and observe the pressure reading on thepressure gauge. Refer to Section 2,Specifications.







REV A

How to Adjust the TurntableRotate Relief Valve



2 Hold the function enable toggle switch to eitherside and hold the turntable rotate right toggleswitch with the turntable rotated to the right(until it is against the rotation stop), andobserve the pressure reading on the pressuregauge. Refer to Section 2, Specifications.





MANIFOLDS

How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil. Zero resistance indicates the coilhas failed.

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 Connect the positive lead from the ohmmeter tothe valve coil terminal, then connect thenegative lead from the ohmmeter to the internalring of the valve coil.

Result: The resistance should be withinspecification, plus or minus 30%.

Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.



REV A MANIFOLDS

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 specifications

3 position 4 way solenoid valve 20V DC 22 - 25Ω(schematic items A, I, J, K, M, N, P, Q, R, S,T, U, W, X, BA, BB, BC, BD, CA and CB)

Proportional solenoid valve 24V DC 4 - 5.2Ω(schematic item H)



REV AMANIFOLDS

10-4Jib Boom / Platform Rotate Manifold Components(before serial number 2006)

The jib boom/platform rotate manifold is mounted to the jib boom.


1 Solenoid valve, 2 position 3 way ...... BA ......... Jib boom down ................................. 25-30 ft-lbs / 34-41 Nm

2 Solenoid valve, 2 position 3 way ...... BC ........ Jib boom up ...................................... 25-30 ft-lbs / 34-41 Nm

3 Orifice plug, 0.025 inch / 0.64 mm .... BE ......... Platform rotate circuit

4 Solenoid valve, 2 position 3 way ...... BD ........ Platform rotate left ............................. 25-30 ft-lbs / 34-41 Nm

5 Solenoid valve, 2 position 3 way ...... BB ......... Platform rotate right .......................... 25-30 ft-lbs / 34-41 Nm

BA BC

BB BD

1 2

5 4

BE

3



REV A

10-5Jib Boom / Platform Rotate Manifold Components(after serial number 2005)

The jib boom/platform rotate manifold is mounted to the jib boom.


1 Solenoid valve, 2 position 3 way ...... CA ........ Jib boom circuit ................................. 25-30 ft-lbs / 34-41 Nm

2 Solenoid valve, 2 position 3 way ...... CB ........ Platform rotate circuit ........................ 25-30 ft-lbs / 34-41 Nm

3 Flow regulator, 0.3 gpm / 1.2 L/min ... CC ........ Platform rotate circuit ........................ 25-30 ft-lbs / 34-41 Nm

MANIFOLDS

CC

3

CA1

CB2



REV A

10-6Steer/Brake Manifold Components (before serial number 1112)

The steer/brake manifold is mounted under the steer-end drive chassis cover.


1 Solenoid valve, N.O. poppet ............. R ........... Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

2 Solenoid valve, 3 position 4 way ...... S ........... Steer left/right ....................................10-12 ft-lbs / 14-16 Nm

3 Pressure switch ................................. T ........... Brake circuit

4 Flow regulator valve,0.6 gpm / 2.3 L/min ............................ U ........... Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

5 Check valve ....................................... V ........... Brake circuit ......................................25-30 ft-lbs / 34-41 Nm

6 Solenoid valve, N.C. poppet ............. W .......... Brake circuit ......................................25-30 ft-lbs 34-41 Nm

7 Orifice, 0.045 in / 1.02 mm ................ X ........... Brake circuit

8 Orifice, 0.040 in / 1.02 mm ................ Y ........... Brake circuit

MANIFOLDS

R1

S

2

T3

U4

V5

X8

Y

7

W6



REV AFuel and Hydraulic Tanks

11-1Fuel Tank

How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.

Immediately clean up any fuel thatmay have spilled during thisprocedure.

1 Models with fuel shutoff valve: Turn themanual fuel shutoff valve, located next to thetank, to the closed position.

2 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer toSection 2, Specifications, for tank capacity.

Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.

Be sure to only use a handoperated pump suitable for usewith diesel fuel.

3 Tag, disconnect and plug the fuel supply andreturn hoses at the tank. Clean up any fuel thatmay have spilled.

4 Metal tank: Remove the fasteners from the tankmounting straps underneath of the tankmounting tray.

Plastic tank: Remove the fuel tank retainingfastener located underneath the tank mountingtray at the bottom of the fuel tank .

Metal fuel tank:

Clean the fuel tank and inspectfor rust and corrosion beforeinstalling.

Plastic fuel tank:

Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.Be sure the fuel tank is properlysupported.

Component damage hazard. Donot overtighten the fuel tankmounting fasteners.

Clean the fuel tank and inspect forcracks and other damage beforeinstalling.

Torque specification

1/4 -20 fasteners 4 ft-lbs 5.4 Nm3/8 -16 fasteners 15 ft-lbs 20.3 Nm



REV A

11-2Hydraulic Tank

The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply suction lines and has an externalreturn line filter.

How to Remove theHydraulic Tank

Component 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 Close the hydraulic shutoff valve located at thehydraulic tank.

Component damage hazard. Themachine must not be operatedwith the hydraulic tank shutoffvalve in the closed position orcomponent damage will occur. Ifthe tank valve is closed, removethe key from the key switch andtag the machine to informpersonnel of the condition.

2 Place a suitable container under the hydraulictank.

FUEL AND HYDRAULIC TANKS

3 Tag and disconnect and plug the hydraulic hosefrom the hydraulic tank shutoff valve.


4 Open the valve on the hydraulic tank and drainthe oil into a suitable container.

Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.

5 Tag, disconnect and plug the hydraulic hosesfrom the hydraulic tank filter. Cap the fittings onthe filter.


Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.

6 Remove the hydraulic tank mounting fasteners.

7 Remove the hydraulic tank from the machine.



REV A

12-1Rotation Hydraulic Motor

The rotation hydraulic motor is the only serviceablecomponent of the turntable rotation assembly. Theworm gear may not be removed from the housing.In order to remove the housing, the turntable hasto be removed.

How to Remove the TurntableRotation Motor


1 Tag, disconnect and plug the hydraulic hosesfrom the turntable rotation motor. Cap thefittings on the motor.


2 Remove the turntable rotation motor mountingbolts, then remove the motor.

Turntable Rotation Components



REV ASteer Axle Components

13-1Yoke and Hub

How to Remove the Yokeand Hub1 Remove the cotter pin and the clevis pin from

both the steering cylinder and the tie rod.

a axleb pin retaining fastenerc king pind yokee hubf clevis pin and cotter ping steering cylinderh tie rod

2 Loosen the wheel lug nuts. Do notremove them.

3 Block the non-steering wheels, and thencenter a lifting jack under the steering axle.

4 Raise the machine 6 inches / 15 cm and placeblocks under the drive chassis for support.

5 Remove the lug nuts, then the tire andwheel assembly.

6 Remove the pin retaining fasteners from theupper and lower yoke pivot pins.

7 Support the yoke/hub assembly with a liftingdevice.

8 Place a rod through the yoke pivot pins andtwist to remove the pins.

Crushing hazard. The yoke/hubassembly may becomeunbalanced and fall when the yokepivot pins are removed if it is notproperly supported and secured tothe lifting device.

Always use a new cotter pin wheninstalling a clevis pin.

How to Remove theHub and Bearings1 Loosen the wheel lug nuts. Do not remove

them.

2 Block the non-steering wheels and place alifting jack under the steering axle.

3 Raise the machine and place blocks underthe drive chassis for support.

4 Remove the lug nuts. Then remove the tireand wheel assembly.

5 Remove the dust cap, cotter pin andslotted nut.

6 Pull the hub off the spindle. The washer andouter bearing should fall loose from the hub.

7 Place the hub on a flat surface and gently prythe bearing seal out of the hub. Remove therear bearing.

a

b

d

c

e

g

h

f

f



REV A

How to Install theHub and Bearings

When replacing a wheel bearing,both the inner and outer bearings,including the pressed-in races,must be replaced.

1 Be sure that both bearings are packedwith grease.

2 Place the large inner bearing into the rearof the hub.

3 Install a new bearing grease seal into the hub bypressing it evenly into the hub until it is flush.

Always replace the bearing greaseseal when removing the hub.

4 Slide the hub onto the yoke spindle.

Component damage hazard. Donot apply excessive force ordamage to the lip of the seal mayoccur.

5 Fill the hub cavity with clean, fresh grease.

6 Place the outer bearing into the hub.

7 Install the washer and castle nut.




10 Install a new cotter pin. Bend the cotter pinto lock it in.

Always use a new cotter pin wheninstalling a castle nut.

11 Install the dust cap, then the tire and wheelassembly. Torque the wheel lug nuts tospecification. Refer to Section 2, Specifications.

STEER AXLE COMPONENTS

13-2Steer Cylinder

How to Remove aSteer Cylinder


1 Tag, disconnect and plug the hydraulic hosesfrom the steering cylinder. Cap the fittings.


2 Remove the cotter pin. Then removethe clevis pin from each end of the steeringcylinder.

3 Remove the steering cylinder.




REV ASTEER AXLE COMPONENTS

13-3Tie Rod

How to Remove the Tie Rod1 Remove the cotter pin, then remove the clevis

pin from each end of the tie rod.

2 Remove the tie rod.




REV A

14-2Drive Hub

How to Remove a Drive HubThe drive motor must be removedin order to access the drive hubmounting bolts.


1 Remove the drive motor. See 14-1,How to Remove a Drive Motor.

2 Disconnect and plug the hydraulic hose from thebrake. Remove the hydraulic fitting and thebleed valve.

Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.

14-1Drive Motor

How to Remove a Drive Motor1 Disconnect the battery packs.

2 Tag and disconnect the power cables and relaywiring from the drive motor.

Electrocution hazard. Contact withelectrically charged circuits mayresult in death or serious injury.Remove all rings, watches andother jewelry.

3 Remove the drive motor mounting fasteners.

4 Guide the drive motor shaft out of the brake andthen remove the drive motor.

Non-steer Axle Components



REV ANON-STEER AXLE COMPONENTS

3 Chock the steer wheels.

4 Loosen the wheel lug nuts. Do notremove them.

5 Center a lifting jack under the non-steer axle.Raise the machine and place blocks under thechassis for support.

6 Remove the wheel lug nuts, then the tire andwheel assembly.

7 Place a second lifting jack under the drivehub for support. Secure the drive hub to thelifting jack.

8 Remove the bolts that attach the drive hubto the chassis, then remove the drive hub.

Crushing hazard. The drivehub may become unbalanced andfall when the mounting fastenersare removed if it is not properlysupported and secured to the liftingjack.



REV AMotor Controller

15-1Motor Controller

The drive motor controller is located under the non-steer end drive chassis cover. The drive motorcontroller can recognize machine drivemalfunctions and display controller fault codes byflashing a LED at the ground controls and on themotor controller. See the Troubleshooting section ofthis manual for a list of fault codes and additionalinformation. There are no adjustments needed onthe drive joystick controller. For further informationor assistance, consult the Genie Industries ServiceDepartment.

How to Test the Motor ControllerUse the following procedure to testthe motor controller. If the motorcontroller is found to be faulty,note which test failed and whichfault code (if any) was present atthe time of failure.

1 Turn the key switch to the off position anddisconnect the battery packs from the machine.

2 Tag and disconnect all power cables from themotor controller.


3 Press the release tab on the motor controllerharness connector and remove the motorcontroller harness connector from the motorcontroller.

4 Connect the leads from an ohmmeter to testeach motor controller terminal combinationlisted below and check for resistance.

Result: All desired results must be 500 kilohmsor more. If any test has a result less than500 kilohms, replace the motor controller.

Test Desired result(in kilohms)

F1 to F2 (500k Ωor more)

F1 to B- (500k Ωor more)

F1 to M- (500k Ωor more)

F1 to B+ (500k Ωor more)

F2 to B- (500k Ωor more)

F2 to M- (500k Ωor more)

F2 to B+ (500k Ωor more)

B- to M- (500k Ωor more)

M- to B+ (500k Ωor more)

Pin 17 to B- (500k Ωor more)

Pin 20 to B- (500k Ωor more)


January 2008 Section 5 • Troubleshooting Flow Charts

Before Troubleshooting:

Read, understand and obey the safety rules andoperating instructions printed in theGenie Z-34/22 Bi-Energy Operator’s Manual.

Be sure that all necessary tools and testequipment are available and ready for use.

Read each appropiate flow chart thoroughly.Attempting shortcuts may produce hazardousconditions.

Be aware of the following hazards and followgenerally accepted safe workshop practices.

Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.

Electrocution hazard. Contactwith electrically charged circuitswill result in death or serious injury.Remove all rings, watches andother jewelry.


Perform all troubleshooting on afirm level surface.

Two persons will be required tosafely perform sometroubleshooting procedures.

Troubleshooting Flow Charts

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 flat level surface

· Boom in stowed position

· Turntable rotated with the boom between the non-steering wheels

· Key switch in the off position with the key removed

· Wheels chocked


January 2008Section 5 • Troubleshooting Flow Charts

General Repair Process

TROUBLESHOOTING FLOW CHARTS

About This SectionWhen a malfunction is discovered, the flow chartsin this section will help a service professionalpinpoint the cause of the problem. To use thissection, basic hand tools and certain pieces of testequipment are required—voltmeter, ohmmeter,pressure gauges.

The location of terminals mentioned in this sectioncan be found on the appropriate electrical orhydraulic schematics provided in Section 6,Schematics.

Since various degrees of a particular functionloss may occur, selecting the appropriate flowchart may be troublesome. When a function will notoperate with the same speed or power as amachine in good working condition, refer to theflow chart which most closely describes theproblem.

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test



REV AFault Code Chart

Fault codes are two digits. The Fault Indicator Light will blink the first digit of a two digit code then willpause for 1 second and then blink the second digit. There will be a 2 second pause between codes. Forexample: the Fault Indicator Light blinks 4 consecutive times then pauses for 1 second and then blinks 1time. That would indicate Fault Code 41.

Continued on next page

Fault CodeProgrammer

Diagnostic DisplayCondition Possible Causes Solution

Fault Indicator Light is OFF or is ON but not

blinking

COMMUNICATION ERROR

Machine will not drive. Controller fault indicator light may or may not be on at the platform controls.

The key switch or Emergency Stop button(s) was cycled on and off faster than 5 seconds OR controller sensed an internal error during start up.

Turn the ground control Emergency Stop button to the OFF position and wait for 5 seconds. Pull out the ground control Emergency Stop button out to the ON position. If problem persists, replace the motor controller.

01 Normal operation.

12 HW FAILSAFE 1-2-3

Machine will not drive. Controller fault indicator light on at the platform controls.

The motor controller failed self test.

Replace the motor controller.

13 M- SHORTED


The motor controller has a internal short between M- and B- terminals.

Test the motor controller, see the Repair Section.

FIELD OPEN


Motor wiring is loose OR motor is defective OR motor controller has an internal short.

Check for loose or open connections at the drive motors and motor controller OR replace the defective drive motor OR test the motor controller, see the Repair Section.

ARM SENSOR


Defective motor controller.


FLD SENSOR


Defective motor controller.




REV AFAULT CODE CHART

Fault CodeCode Scanner

DisplayCondition Possible Causes Solution

Continued on next page

21 THROTTLE FAULT 1


Open in wht/red wire #32 at pin 14 or red/wht wire #29 at pin 16 on the motor controller going from drive joystick to pins 14 and 16 at the motor controller OR pin 14 is internally shorted to power or ground OR the potentiometer on the drive joystick defective.

See Chart 29A

THROTTLE FAULT 2


Pin 14 (wht/red #32) is shorted to power or ground OR the potentiometer on the drive joystick is defective.

See Chart 29A

31 CONT DRVR OC


Main contactor (PR1) coil defective OR brake release relay CR5 defective.

Replace main contactor PR1 or brake release relay CR5 OR replace the motor controller.

32 MAIN CONT WELDED


Main contactor (PR1) contacts stuck closed OR grn wire at pin 17 on motor controller shorted to ground OR open in motor armature wiring OR motor controller has a internal short to ground.

See Chart 29B

33 PRECHARGE FAULT


External short between B+ terminal on motor controller and ground OR motor controller is defective.

Repair short between B+ terminal on motor controller and ground OR replace motor controller. Note: Short can be on any part of circuit connected to the B+ terminal on the motor controller.



REV A FAULT CODE CHART

Fault CodeCode Scanner

DisplayCondition Possible Causes Solution

34 MISSING CONTACTOR


Motor controller does not detect the main contactor PR1 or brake release relay CR5.

See Chart 29C

MAIN CONT DNC


Main contactor PR1 or brake release relay CR5 did not close OR open in org/red wire to PR1 and/or CR5 OR main contactor and/or brake release relay is defective.

See Chart 29C

41 LOW BATTERY VOLTAGE


Battery supply voltage to motor controller less than 32V.

Completely charge batteries OR check battery cable condition OR check for corrosion or loose connections at battery terminals and motor controller.

42 OVERVOLTAGE


Battery supply voltage to motor controller more than 55V OR machine is being operated with the battery charger plugged in OR 48V alternator voltage regulator improperly adjusted or is defective while the machine is being operated with the engine running.

Be sure the battery charger is disconnected OR check for loose battery cables or poor connections OR adjust 48V alternator voltage regulator OR replace the regulator.

43 THERMAL CUTBACK


Machine being operated outside of temperature range of -13°F to 185°F (-25°C to 85°C) OR machine being driven under excessive load OR motor controller is not being cooled sufficently.

Operate machine within specified temperature limits OR check for debris around motor controller preventing proper cooling of the controller OR check for mechanical restrictions causing excessive load on the machine.



REV A

Engine Will NotCrank OverBe sure key switch is inthe appropriate position.

Be sure that bothEmergency Stopbuttons are pulled out tothe ON position.

Be sure that the batterypack Anderson plugsare properly connectedto the battery packs.

Be sure the circuitbreaker and fuses arenot tripped or blown.

Chart 1

Check battery voltage.Check battery conditionOR check alternatorOR check battery cablesOR replace the battery.

less than24V

24V

0VRepair open in red wirecircuit from CB1 toEmergency Stop buttonP1 to keyswitch toTS52.

24V

Hold the start toggleswitch to either side andcheck the voltage ateither side terminal onstart toggle switch TS52.

0V Replace start toggleswitch TS52 .

24V

Hold the start toggleswitch TS52 to eitherside and check voltageat terminal TB33.

0V Repair open in blk wirecircuit from start toggleswitch TS52 to TB33.

24V

Hold the start toggleswitch TS52 to eitherside and check voltageat terminal #3 onignition/start module.

0VRepair open in blk wirecircuit from TB33 toterminal #3 on ignition/start module.

Continued on the nextpage.

24V

Check voltage atterminal #6 on theignition/start module.

0V Repair open in redpower supply wire circuitfrom CB1 to EmergencyStop button P1 tokeyswitch to terminal #6to on the ignition/startmodule.24V

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, check thevoltage at the centerterminal on the starttoggle switch TS52.



REV A CHART 1

Continued from theprevious page.

Hold the start toggleswitch TS52 to eitherside and check voltageat terminal #9 on theignition/start module.

0V Replace the ignition/start module.

24V

continuity

nocontinuity

24V

Hold the start toggleswitch TS52 to eitherside and check voltageat terminal #1 onignition/start module.

0V Check continuity frombrown ground wire atterminal #5 on ignition/start module to ground.

nocontinuity

Repair open in brownground wire fromignition/start module toground.

continuity

Replace the ignition/start module.

Disconnect the grn/blkwire from terminal #9 onthe ignition/start module.Check for continuityfrom the grn/blk wire atterminal #9 on theignition start module toTB21.

Repair open in grn/blkwire from terminal #9 onthe ignition/start modulethrough Anderson plug 2to wht wire then toterminal #86 on CR13 toTB21.

Hold the start toggleswitch TS52 to eitherside and check voltageat terminal #86 onCR12.

0V

24V

Repair open in wht wirefrom TB21 to terminal#86 on CR12.

Check voltage atterminal #30 on CR12.

0V Repair open in red wirecircuit from enginebattery to CB3 toterminal #30 on CR12.

12V




REV ACHART 1

Hold the start toggleswitch TS52 to eitherside and check voltageat the black wire on thestarter solenoid.

0V

Repair open in blk wirecircuit from CR11 to thestarter solenoid ORreplace CR11.

12V

Repair or replace starteror starter solenoid.


Replace CR12 relay.

Check continuity frombrown ground wire atterminal #85 on CR12 toground.

Check voltage at startercable.

Repair open in batterycable to starter.

0V

12V

continuity

nocontinuity

Repair open in brownground wire fromterminal #85 on CR12 toground.

0V

12V


0V

12V

Repair open in wht wirecircuit from terminal #87on CR12 to the enginerun solenoid to terminal#30 on CR11.


0V

24V

Repair open in blk wirefrom terminal #1 on theignition/start module toterminal #86 on CR11.

Check continuity frombrown ground wire atterminal #85 on CR11 toground.

continuity

nocontinuity

Repair open in brownground wire fromterminal #85 on CR11 toground.




REV A

Engine CranksOver But WillNot StartBe sure to check thefuel level.

Be sure to check engineoil level and enginecoolant level and fill asneeded.

Be sure the fuel shut-offvalve is in the ON

position.

Be sure the engine glowplugs operate normally.See the MaintenanceSection.

Be sure that the batterypack Anderson plugsare properly connectedto the battery packs.


Chart 2

Hold the start toggleswitch TS52 to eitherside and check batteryvoltage while engine iscranking.

lessthan10V

Check battery conditionOR check alternator ORcheck for short circuitsOR check battery cablesOR replace the battery.

more than 10V

Check if engine coolanttemperature switch posthas continuity to ground.

continuity Check if the radiatorand/or engine blockfeels excessively hot.

yes Check engine oil levelOR check radiator finsfor clogging OR checkengine fan belts OR seeKubota service manualfor troubleshooting anoverheating engine.no

Remove wht wire fromthe engine coolanttemperature switch.Check continuity toground on the watertemperature switch.

continuity Replace engine coolanttemperature switch.

no continuity

Remove the wht wirefrom terminal #10 on theignition/start module andcheck for continuity toground.

continuityRepair short in wht wirecircuit from terminal #10on the ignition/startmodule to the enginecoolant temperatureswitch.

no continuity


no continuity

Hold the start toggleswitch to either side andcheck voltage at the whtwire on the engine runsolenoid.

12V

0V


Replace the engine runsolenoid.

Check for continuity toground on the brownground wire at theengine run solenoid.

continuity

no continuity

Repair open in brownground wire from theengine run solenoid toground.



REV ACHART 2


Hold the start toggleswitch TS52 to eitherside and check thevoltage at the wht wireon terminal #87 ofCR12.

12VRepair open in wht wirefrom terminal #87 ofCR12 to the engine runsolenoid OR replace theengine run solenoid.

0V

Check the voltage at thered wire on terminal #30of CR12.

0V Repair open in red wirecircuit from the batteryto CB3 to terminal #30on CR12.

12V

Hold the start toggleswitch TS52 to eitherside and check thevoltage at terminal #86of CR12.

0V

24V

Check for continuity toground on the brownwire at terminal #85 onCR12.

nocontinuity Repair open in brown

ground wire circuit toCR12.

continuity

Hold the start toggleswitch TS52 to eitherside and check thevoltage at terminal #9 onthe ignition/start module.

24V


0V

Check the voltage atterminal #7 on theignition/start module.

24V

0V Repair open in wht wirecircuit from thekeyswitch to TB23 toterminal #7 on theignition/start module.


Repair open in grn/blkwire from terminal #9 onthe ignition/start modulethrough Anderson plug 2to wht wire then toterminal #86 on CR13 toTB21 then to terminal#86 on CR12.



REV A CHART 2

Crank engine and checkthe voltage at terminal#2 on the ignition/startmodule.

0V Crank engine and checkvoltage at org/blk wireon alternator.

0V Repair or replacealternator OR contactGenie Industries ServiceDepartment.

6 to 7V

Repair open in org/blkwire circuit fromalternator to terminal #2on ignition/start module.

6 to 7V

While cranking enginefor 15 seconds, checkcontinuity to ground onterminal #10 on ignition/start module. Iscontinuity maintained?

yes

Disconnect wht wirefrom oil pressure switchand check continuity toground on signal post ofthe switch whilecranking the engine. Iscontinuity maintained?

yes

Check oil level ORreplace oil pressureswitch OR refer toKubota service manualfor troubleshooting lowoil pressure.

no

Repair short to groundin wht wire from oilpressure switch toterminal #10 on theignition/start module.

no

Replace the ignition/start module OR refer tothe Kubota ServiceManual fortroubleshooting the fuelsystem OR consultGenie Industries ServiceDepartment.




REV A

Engine GlowPlugsInoperativeBe sure the enginestarting battery is fullycharged.


Chart 3

With the keyswitchturned to the groundcontrols position andboth Emergency Stopbuttons pulled out to theON position, hold theglow plug toggle switchTS56 to either side andcheck the voltage on theblk/wht wire on the glowplugs.

12V Refer to Kubota ServiceManual on troubleshooting the glow plugs.

0V

Hold the glow plugtoggle switch to eitherside and check thevoltage at terminal #87on CR15 with blk/whtwire attached.

12VRepair open in blk/whtwire from terminal #87on CR15 to the glowplugs.

24V

Repair open in red wirecircuit from CB3 toterminal #30 on CR15.

0V

Check the voltage atterminal #30 on CR15.

0V

Replace CR15.

no continuity

Check continuity fromterminal #85 on CR15 toground.

12V

continuity

Repair open in brownground wire at terminal#85 on CR15 to ground.0V


Hold the glow plugtoggle switch TS56 toeither side and checkthe voltage at terminal#86 on CR15.

0V

Hold the glow plugtoggle switch to eitherside and check thevoltage at TB34.

24V Repair open in blk/whtwire from TB34 toterminal #86 on CR15.



REV A CHART 3


Please begintroubleshooting from thebeginning of the chartOR consult GenieIndustries ServiceDepartment.

Hold the glow plugtoggle switch TS56 toeither side and checkthe voltage at the blk/wht wire on the glowplug toggle switch.

0V

24V

Check the voltage at thecenter terminal of theglow plug toggle switchTS56.

0VRepair open in powersupply circuit fromkeyswitch to glow plugtoggle switch TS56.

24V

Replace TS56.



REV AChart 4

Engine HighIdle InoperativeBe sure all otherfunctions operatenormally.

Be sure mechanicallinkage is not binding ordefective.

Be sure 2-speedsolenoid groundingwires are free ofcorrosion and have fullcontinuity to ground.

Start the engine fromthe ground controls andmove the RPM selecttoggle switch TS54 tothe high idle position(rabbit symbol) andcheck if RPM solenoidpulls in.

solenoidpulls in

Check the high idleadjustment (seeMaintenance section) orsee Kubota workshopmanual to troubleshootfuel injection system.

solenoid doesnot pull in

Hold the RPM toggleswitch to either side andcheck the voltage on theblk/red wire at theswitch.

0V Check voltage on redwire at center terminal ofRPM select toggleswitch TS54.

0VRepair open in powersupply circuit fromkeyswitch to centerterminal of RPM toggleswitch TS54.

24V

Replace RPM toggleswitch TS54.24V

Hold the RPM toggleswitch to either side andcheck the voltage atTB35.

0VReplace diode ORrepair open in blk/redwire circuit from toggleswitch to TB35.


24V

24V

Hold the RPM toggleswitch TS54 to eitherside and check thevoltage at terminal #30on CR13.

0V Repair open in blk/redwire from TB35 toterminal #30 on CR13.


24V

0V Check the voltage atterminal #86 on CR13.

0V

24V

Repair open in wht wirefrom Anderson plug 2 toterminal #86 on CR13.

Replace CR13.



REV A CHART 4



0V Repair open in wirecircuit from terminal #87on CR12 to terminal #30on CR14.

Move the RPM toggleswitch TS54 to eitherside and check thevoltage on the blk/redwire at the RPMsolenoid.

0V Repair open in blk/redwire from terminal #87on CR14 to the RPMsolenoid.

12V

12V

Check continuity frombrown wire at the RPMsolenoid to ground.


ground wire from theRPM solenoid toground.

continuity

Check if RPM solenoidmoves in and out freely.

solenoidbinds Check linkage or

replace solenoid.

moves freely

Replace RPM solenoid.Note: resistance acrosssolenoid terminalsshould be approximately0.3 ohms.


0V Repair open in wire fromterminal #87 on CR13 toterminal #86 on CR14.

Check continuity frombrown wire at terminal#85 on CR14 to ground.


ground wire fromterminal #85 on CR14 toground.

continuity

24V



REV A

Engine Low IdleInoperativeBe sure that themechanical linkage from2-speed solenoid to fuelinjection system is notbinding or defective.

Chart 5

At the platform controls,start the engine andmove the RPM selecttoggle switch TS4 to themaintained low idleposition (turtle symbol).Check the voltage onthe blk/red wire on theRPM select toggleswitch TS4.

24V

Isolate the platform andground control RPMtoggle switches (TS4and TS54), test eachtoggle switch individuallyand replace defectivetoggle switch. SeeRepair Section 1-4, Howto Test a Toggle Switch.

0V

Check the voltage onthe blk/red wire at theRPM solenoid.

Replace CR13 relay.

0V

Manually move theRPM solenoid in and outand check to see if itmoves freely or binds.

solenoidbinds Check linkage or

replace RPM solenoid.

moves freely

Check adjustment oflinkage and fuel injectionsystem low idle. SeeMaintenance section.

ok

See Kubota workshopmanual to troubleshootfuel injection system ORconsult Genie IndustriesService Department.

24V Check the voltage atterminal #86 on CR14.

0V

24V

Replace CR14 relay.



REV AChart 6

All Lift andSteer FunctionsInoperative,Drive FunctionOperational(models beforeserial number1112)Be sure the hydraulicsuction line shut-offvalve for the lift steerpump is in the openposition.

Be sure all groundingwires for the functionmanifold valves are freeof corrosion and havefull continuity to ground.

Install a 0 to 5000 PSI(345 bar) pressuregauge to the test port(item L) on the functionmanifold. Move thefunction enable toggleswitch to either side andhold the boom retracttoggle switch in theRETRACT direction andcheck the hydraulicpressure.

3000psi ormore

Troubleshoot eachfunction individually orconsult Genie IndustriesService Department.

less than 3000 psi

Adjust the functionmanifold relief valve(item K) all the way in(clockwise) countingthe number of turns.Move the functionenable toggle switch toeither side and hold theboom retract toggleswitch in the RETRACTdirection and recheckthe hydraulic pressure.

3200psi ormore

Hold the boom retracttoggle switch in theRETRACT position andreadjust the reliefpressure to 3200 psi.

less than 3200 psi

Check the functionpump. See Repairsection.

ok

bad

Replace the pump.

Turn the keyswitch toplatform controls andcheck steer functions.

steering operates Repair or replacedifferential sensing valve(item J) OR manifoldhas internal defect.Consult Genie IndustriesService Department.

steering inoperative

Repair or replace theproportional valve(item H) OR repair orreplace the relief valve(item K) OR manifoldhas an internal defect.Consult Genie IndustriesService Department.



REV AChart 7

All Lift andSteer FunctionsInoperative,Drive FunctionOperational(models afterserial number1111)Be sure the hydraulicsuction line shut-offvalve for the lift/steerpump is in the OPEN

position.

Be sure all ground wiresfor the function manifoldvalve coils are free ofcorrosion and have fullcontinuity to ground.

Install a 0 to 5000 PSI(345 bar) pressuregauge to the test port(item S) on the functionmanifold. Move thefunction enable toggleswitch to either side andhold the boom retracttoggle switch in theRETRACT direction andcheck the hydraulicpressure.

3000psi ormore

Troubleshoot eachfunction individually orconsult Genie IndustriesService Department.

less than 3000 psi

Adjust the functionmanifold relief valve(item R) all the way in(clockwise) countingthe number of turns.Move the functionenable toggle switch toeither side and hold theboom retract toggleswitch in the RETRACTdirection and recheckthe hydraulic pressure.

3200psi ormore

Hold the boom retracttoggle switch in theRETRACT position andreadjust the reliefpressure to 3200 psi.

less than 3200 psi

Check the functionpump. See Repairsection.

ok

bad

Replace the pump.

Turn the keyswitch toplatform controls andcheck steer functions.

steering operates Repair or replacedifferential sensing valve(item Q) OR manifoldhas internal defect.Consult Genie IndustriesService Department.

steering inoperative

Repair or replace theproportional valve(item H) OR repair orreplace the relief valve(item R) OR manifoldhas an internal defect.Consult Genie IndustriesService Department.



REV A

GroundControlsInoperative,PlatformControlsOperateNormallyBe sure all otherfunctions operatenormally, includingplatform controls.

Be sure that both theground and platformEmergency Stopbuttons are pulled out tothe ON position.

Chart 8

Check voltage at the redwire on the input side ofthe ground controlscontact of the keyswitch(the red wire checkedshould originate at theEmergency Stopbutton).

0VRepair open in red wirecircuit from EmergencyStop button to the keyswitch.

24V

Turn the keyswitch toground control andcheck the voltage on theoutput side of groundcontrols contact of thekeyswitch.

0VCheck to see if the keyswitch internal cam isactivating the groundcontrols contact.

yes Replace keyswitchcontact for groundcontrols.

no

Replace the keyswitch.24V

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the extend/retracttoggle switch (TS63) inthe EXTEND position.Check the voltage atTB6.

0V

24V

With key switch turnedto ground controls andboth Emergency Stopbuttons pulled out to theON position, move thefunction enable toggleswitch to either side andhold the jib boom toggle(TS58) switch in the UPposition. Check thevoltage at TB19.

0V

Check the diodeconnected to the grn/whtwire on the jib boomtoggle switch (TS58) onground panel. SeeRepair Section.

Repair open in grn/whtwire circuit from TB19 toeach ground controlfunction toggle switchesOR consult GenieIndustries ServiceDepartment.

good

Replace diode.bad

24v

Consult Genie IndustriesService Department.

Check the voltage onthe red wire at thecenter terminal of eachground control functiontoggle switch.

0VRepair open in red wirecircuit supplying 24V toeach ground controlfunction toggle switch.

24V

Repair open in wht/redwire circuit from TB6 toeach ground controlfunction toggle switchOR replace defectivetoggle switch(s) ORreplace the diode onTS63.



REV A

PlatformControlsInoperative,GroundControlsOperateNormallyBe sure all cables are ingood condition with nokinks or abrasions.

Be sure the jumper is inplace between terminalsA and B on the joystick.

Chart 9

Check voltage at TB22. 0V Repair open in black#22 wire circuit from keyswitch to TB22.

24V

Check the voltage at theinput side of the platformEmergency Stop buttoncontact.

0VRepair open inblk-2 wire circuit fromTB22 to platformEmergency Stop buttonOR open in brownground wire circuit toplatform from TB52.

24V

Check the voltage at thered wire on the inputside of the platformcontrols contact of thekeyswitch (the red wirechecked shouldoriginate from theEmergency Stopbutton).

0VRepair open in red wirecircuit from emergencystop button to the keyswitch.

24V

Turn the keyswitch toplatform controls andcheck the voltage on theoutput side of theplatform controls contacton the keyswitch.

0VCheck to see if the keyswitch internal cam isactivating the platformcontrols contact.

yes Replace the keyswitchcontact for platformcontrols.

no

Replace the keyswitch.24V


Check the voltage at theoutput side of platformEmergency Stop buttoncontact.

0V Replace the platformEmergency Stop buttoncontact.

24V

Check to see if theEmergency Stop buttonis activating the contact.

yes

no

Replace the platformEmergency Stop button.



REV A CHART 9

Activate the footswitchand check the voltage atterminal "A" on the drivecontroller (DP1).

24V

0V Repair open in wht wirecircuit from footswitch tothe center terminal ofTS1 to terminal "A" onthe drive controller.


Activate the footswitchand any boom functiontoggle switch and checkthe voltage at the redwire on the boomfunction speed controller(BP1).

0V

Repair open in powersupply circuit to boomfunction speed controllerBP1 from eachindividual boom functiontoggle switch ORconsult Genie IndustriesService Department.

24V

With the boom functionspeed controller set to 9,activate the footswitchand any boom functiontoggle switch and checkthe voltage at the blk/redwire on the boomfunction speed controller(BP1).

lessthan20V

20V or more

Readjust boom functionspeed controller (seeRepair section) ORreplace boom functionspeed controller ORconsult Genie IndustriesService Department.

Test the footswitch. SeeRepair Section.

good

bad

Replace the footswitch.

Activate the footswitchand check the voltage atthe center terminal ofeach function toggleswitch.

0V

24V

Repair open in red wirecircuit from terminal "B"on the drive controller toeach function toggleswitch.

Activate the footswitchand check the voltage atthe terminal "B" on thedrive controller.

24V

0V

Replace the drivejoystick DP1 or consultGenie Industries ServiceDepartment.




REV ACHART 9


Activate the footswitchand any boom functiontoggle switch and checkthe voltage at TB6.

0V

20V or more

Replace the diode onthe blk/red wire on boomfunction speed controllerOR repair open in wht/red wire circuit fromboom function speedcontroller to TB6.

Repair open in brnground wire circuit to theproportional valve(item H) ORtroubleshoot lift anddrive functionsindividually OR consultGenie Industries ServiceDepartment.

Activate the footswitchand any boom functiontoggle switch and checkthe voltage at the wht/red wire on theproportional valve(item H).

0V

20V or more

Repair open in wht/redwire from TB6 to theproportional valve(item H).



REV A

Primary BoomUp FunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 10

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the primary boomtoggle switch TS61 inthe UP direction. Checkthe voltage on the wht/red #6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe primary boom toggleswitch TS61 in the UPdirection and check thevoltage at TB6.

24V

Repair open in wht/red#6 wire circuit from TB6to boom functionproportional valve coil(item H) OR repair openin brn ground wire circuitto boom functionproportional valve coil(item H).

0V

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theprimary boom functiontoggle switch TS11 onplatform control panel inUP direction. Check thevoltage at TB6.

0V

24V

Troubleshoot primaryboom function toggleswitch TS61 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS61 to TB6.


Troubleshoot primaryboom function toggleswitches (TS61 andTS11) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS61 to TB6 and fromTS11 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS61 and TS11 hasbeen restored andprimary boom upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 10

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold primary boomtoggle switch TS61 inthe UP direction. Checkthe voltage on the red#1 wire on the primaryboom up directionalvalve coilBefore serial number1112: (item M)After serial number1111: (item U).

0V

24V

Move the functionenable toggle switch toeither side and hold theprimary boom toggleswitch TS61 in the UPdirection. Check thevoltage at TB1.

24V

Repair open in red #1wire circuit from TB1 toprimary boom updirectional valve coilBefore serial number1112: (item M)After serial number1111: (item U) ORrepair open in brnground wire circuit tomanifold.0V

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theprimary boom toggleswitch TS11 in the UPdirection. Check thevoltage at TB1.

0V

24V

Troubleshoot theprimary boom toggleswitch TS61 on groundcontrol panel ORreplace diode on TS61OR repair open in red#1 wire circuit fromTS61 to TB1 OR replaceTS61.


Troubleshoot primaryboom function toggleswitches (TS61 andTS11) on ground andplatform control panelsOR replace diodes onTS61 and TS11 ORrepair open in red #1wire circuit from TS61and TS11 to TB1 ORreplace TS61 or TS11.

If voltage to TB1 fromTS61 and TS11 hasbeen restored andprimary boom upfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 10

Disconnect the wire tothe primary boom updirectional valve coilBefore serial number1112: (item M)After serial number1111: (item U). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace primary boomup directional valve coilBefore serial number1112: (item M)After serial number1111: (item U).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theprimary boom functiontoggle switch TS61 inthe UP direction andcheck the pressure.

3200PSI

less than 3200 PSI

Repair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping theprimary boom upfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange the primaryand secondary boomdirectional valvesBefore serial number1112: (item M and N)After serial number1111: (item U and T).Activate primary boomup function.

function inoperative

functionoperates Replace defective

directional valve.



REV A

Primary BoomDown FunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 11

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the primary boomtoggle switch TS61 inthe DOWN direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe primary boom toggleswitch TS61 in theDOWN direction andcheck the voltage atTB6.

24V


0V

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theprimary boom functiontoggle switch TS11 onplatform control panel inDOWN direction. Checkthe voltage at TB6.

0V

24V

Troubleshoot primaryboom function toggleswitch TS61 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS61 to TB6.


Troubleshoot primaryboom function toggleswitches (TS61 andTS11) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS61 to TB6 and fromTS11 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS61 and TS11 hasbeen restored andprimary boom upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 11

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold primary boomtoggle switch TS61 inthe DOWN direction.Check the voltage onthe red/blk #2 wire onthe primary boom downdirectional valve coilBefore serial number1112: (item M)After serial number1111: (item U).

0V

24V

Move the functionenable toggle switch toeither side and hold theprimary boom toggleswitch TS61 in theDOWN direction. Checkthe voltage at TB2.

24V

Repair open in red/blk#2 wire circuit from TB2to primary boom downdirectional valve coilBefore serial number1112: (item M)After serial number1111: (item U) ORrepair open in brnground wire circuit tomanifold.0V

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theprimary boom toggleswitch TS11 in theDOWN direction. Checkthe voltage at TB2.

0V

24V

Troubleshoot theprimary boom toggleswitch TS61 on groundcontrol panel ORreplace diode on TS61OR repair open inred/blk #2 wire circuitfrom TS61 to TB2 ORreplace TS61.


Troubleshoot primaryboom function toggleswitches (TS61 andTS11) on ground andplatform control panelsOR replace diodes onTS61 and TS11 ORrepair open in red/blk #2wire circuit from TS61and TS11 to TB2 ORreplace TS61 or TS11.

If voltage to TB2 fromTS61 and TS11 hasbeen restored andprimary boom downfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 11

Disconnect the wire tothe primary boom downdirectional valve coilBefore serial number1112: (item M)After serial number1111: (item U). Test theresistance of the valvecoil. See Repair Section.


0 or infinite ohms

23 to 25ohms

Replace primary boomdown directional valvecoilBefore serial number1112: (item M)After serial number1111: (item U).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theprimary boom functiontoggle switch TS61 inthe DOWN direction andcheck the pressure.

1400 PSI(before s/n 3216)

less than 1400 PSI(before s/n 3216)

less than 1600 PSI(after s/n 3215)

Adjust the primary boomdown relief valve (itemF, see Repair Section)OR repair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping theprimary boom downfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange primary andsecondary boomdirectional valvesBefore serial number1112: (item M and N)After serial number1111: (item U and T).Activate primary boomdown function.


function operates Replace defectivedirectional valve.

1600 PSI(after s/n 3215)



REV A

SecondaryBoom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 12

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the secondaryboom toggle switchTS60 in the UP direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe secondary boomtoggle switch TS60 inthe UP direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and thesecondary boomfunction toggle switchTS10 on platform controlpanel in UP direction.Check the voltage atTB6.

0V

24V

Troubleshoot secondaryboom function toggleswitch TS60 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS60 to TB6.


Troubleshoot secondaryboom function toggleswitches (TS60 andTS10) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS61 to TB6 and fromTS11 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS60 and TS10 hasbeen restored andsecondary boom upfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 12

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold secondary boomtoggle switch TS60 inthe UP direction. Checkthe voltage on the blu#10 wire on thesecondary boom updirectional valve coilBefore serial number1112: (item N)After serial number1111: (item T).

0V

24V

Move the functionenable toggle switch toeither side and hold thesecondary boom toggleswitch TS60 in the UPdirection. Check thevoltage at TB10.

24V

Repair open in blu #10wire circuit from TB10 tosecondary boom updirectional valve coilBefore serial number1112: (item N)After serial number1111: (item T) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold thesecondary boom toggleswitch TS10 in the UPdirection. Check thevoltage at TB10.

0V

24V

Troubleshoot thesecondary boom toggleswitch TS60 on groundcontrol panel ORreplace diode on TS60OR repair open in blu#10 wire circuit fromTS60 to TB10 ORreplace TS60.


Troubleshoot secondaryboom function toggleswitches (TS60 andTS10) on ground andplatform control panelsOR replace diodes onTS60 and TS10 ORrepair open in blu #10wire circuit from TS60and TS10 to TB10 ORreplace TS60 or TS10.

If voltage to TB10 fromTS60 and TS10 hasbeen restored andsecondary boom upfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 12

Disconnect the wire tothe secondary boom updirectional valve coilBefore serial number1112: (item N)After serial number1111: (item T). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace secondaryboom up directionalvalve coilBefore serial number1112: (item N)After serial number1111: (item T).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold thesecondary boomfunction toggle switchTS60 in the UP directionand check the pressure.

3200PSI

less than 3200 PSI

Check for mechanicalrestrictions keeping thesecondary boom upfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange thesecondary and primaryboom directional valvesBefore serial number1112: (item N and M)After serial number1111: (item T and U).Activate secondaryboom up function.



directional valve.

Repair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.



REV A

SecondaryBoom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 13

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the secondaryboom toggle switchTS60 in the DOWNdirection. Check thevoltage on the wht/red#6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe secondary boomtoggle switch TS60 inthe DOWN direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and thesecondary boomfunction toggle switchTS10 on platform controlpanel in DOWN direction.Check the voltage atTB6.

0V

24V

Troubleshoot secondaryboom function toggleswitch TS60 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS60 to TB6.


Troubleshoot secondaryboom function toggleswitches (TS60 andTS10) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS61 to TB6 and fromTS11 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS60 and TS10 hasbeen restored andsecondary boom downfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 13

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold secondary boomtoggle switch TS60 inthe DOWN direction.Check the voltage onthe blu/blk #11 wire onthe secondary boomdown directional valvecoilBefore serial number1112: (item N)After serial number1111: (item T).

0V

24V

Move the functionenable toggle switch toeither side and hold thesecondary boom toggleswitch TS60 in theDOWN direction. Checkthe voltage at TB11.

24V

Repair open in blu/blk#11 wire circuit fromTB11 to secondaryboom down directionalvalve coilBefore serial number1112: (item N)After serial number1111: (item T) OR repairopen in brn ground wirecircuit to manifold.0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold thesecondary boom toggleswitch TS10 in theDOWN direction. Checkthe voltage at TB11.

0V

24V

Troubleshoot thesecondary boom toggleswitch TS60 on groundcontrol panel ORreplace diode on TS60OR repair open in blu/blk #11 wire circuit fromTS60 to TB11 ORreplace TS60.


Troubleshoot secondaryboom function toggleswitches (TS60 andTS10) on ground andplatform control panelsOR replace diodes onTS60 and TS10 ORrepair open in blu/blk#11 wire circuit fromTS60 and TS10 to TB11OR replace TS60 orTS10.

If voltage to TB11 fromTS60 and TS10 hasbeen restored andsecondary boom downfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 13

Disconnect the wire tothe secondary boomdown directional valvecoilBefore serial number1112: (item N)After serial number1111: (item T). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace secondaryboom down directionalvalve coilBefore serial number1112: (item N)After serial number1111: (item T).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold thesecondary boomfunction toggle switchTS60 in the DOWNdirection and check thepressure.

1600PSI

less than 1600 PSI

Adjust the secondaryboom down relief valve(item E, see RepairSection) OR repaircylinder or cylindercounterbalance valveOR function manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Check for mechanicalrestrictions keeping thesecondary boom downfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange thesecondary and primaryboom directional valvesBefore serial number1112: (item N and M)After serial number1111: (item T and U).Activate secondaryboom down function.



directional valve.



REV A

Primary BoomExtendFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 14

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the primary boomextend/retract toggleswitch TS63 in theEXTEND direction. Checkthe voltage on the wht/red #6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe primary boomextend/retract toggleswitch TS63 in theEXTEND direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theprimary boom extend/retract function toggleswitch TS13 on platformcontrol panel in EXTENDdirection. Check thevoltage at TB6.

0V

24V

Troubleshoot primaryboom extend/retractfunction toggle switchTS13 on the groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS13 toTB6.


Troubleshoot primaryboom extend/retractfunction toggle switches(TS63 and TS13) onground and platformcontrol panels OR repairopen in wht/red #6 wirecircuit from TS63 to TB6and from TS13 to redwire on boom functionspeed controller.

If voltage to TB6 fromTS63 and TS13 hasbeen restored andprimary boom extendfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 14

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold primary boomextend/retract toggleswitch TS63 in theEXTEND direction. Checkthe voltage on the blk #7wire on the primaryboom extend directionalvalve coilBefore serial number1112: (item I)After serial number1111: (item K).

0V

24V

Move the functionenable toggle switch toeither side and hold theprimary boom extend/retract toggle switchTS63 in the EXTENDdirection. Check thevoltage at TB7.

24V

Repair open in blk #7wire circuit from TB7 toprimary boom extenddirectional valve coilBefore serial number1112: (item I)After serial number1111: (item K) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theprimary boom extend/retract toggle switchTS13 in the EXTENDdirection. Check thevoltage at TB7.

0V

24V

Troubleshoot theprimary boom extend/retract toggle switchTS63 on ground controlpanel OR replace diodeon TS63 OR repair openin blk #7 wire circuitfrom TS63 to TB7 ORreplace TS63.


Troubleshoot primaryboom extend/retractfunction toggle switches(TS63 and TS13) onground and platformcontrol panels ORreplace diodes on TS63and TS13 OR repairopen in blk #7 wirecircuit from TS63 andTS13 to TB7 OR replaceTS63 or TS13.

If voltage to TB7 fromTS63 and TS13 hasbeen restored and theprimary boom extendfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 14

Disconnect the wire tothe primary boomextend directional valvecoilBefore serial number1112: (item I)After serial number1111: (item K). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace primary boomextend directional valvecoilBefore serial number1112: (item I)After serial number1111: (item K).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theprimary boom extend/retract function toggleswitch TS63 in theEXTEND direction andcheck the pressure.

1800 PSI(before s/n 3216)

less than 1800 PSI(before s/n 3216)

less than 3200 PSI(after s/n 3215)

Adjust primary boomextend relief valve (itemG, before serial number3216) OR repair cylinderor cylindercounterbalance valveOR function manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Check for mechanicalrestrictions keeping theprimary boom extendfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange the primaryboom extend/retract andprimary boom up/downdirectional valvesBefore serial number1112: (item I and M)After serial number1111: (item K and U).Activate primary boomextend function.



directional valve.

3200 PSI(after s/n 3215)



REV A

Primary BoomRetractFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 15

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the primary boomextend/retract toggleswitch TS63 in theRETRACT direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe primary boomextend/retract toggleswitch TS63 in theRETRACT direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theprimary boom extend/retract function toggleswitch TS13 on platformcontrol panel in RETRACTdirection. Check thevoltage at TB6.

0V

24V

Troubleshoot primaryboom extend/retractfunction toggle switchTS13 on the groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS13 toTB6.


Troubleshoot primaryboom extend/retractfunction toggle switches(TS63 and TS13) onground and platformcontrol panels OR repairopen in wht/red #6 wirecircuit from TS63 to TB6and from TS13 to redwire on boom functionspeed controller.

If voltage to TB6 fromTS63 and TS13 hasbeen restored andprimary boom retractfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 15

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold primary boomextend/retract toggleswitch TS63 in theRETRACT direction.Check the voltage onthe blk/wht #8 wire onthe primary boom retractdirectional valve coilBefore serial number1112: (item I)After serial number1111: (item K).

0V

24V

Move the functionenable toggle switch toeither side and hold theprimary boom extend/retract toggle switchTS63 in the RETRACTdirection. Check thevoltage at TB8.

24V

Repair open in blk/wht#8 wire circuit from TB8to primary boom retractdirectional valve coilBefore serial number1112: (item I)After serial number1111: (item K) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theprimary boom extend/retract toggle switchTS13 in the RETRACTdirection. Check thevoltage at TB8.

0V

24V

Troubleshoot theprimary boom extend/retract toggle switchTS63 on ground controlpanel OR replace diodeon TS63 OR repair openin blk/wht #8 wire circuitfrom TS63 to TB8 ORreplace TS63.


Troubleshoot primaryboom extend/retractfunction toggle switches(TS63 and TS13) onground and platformcontrol panels ORreplace diodes on TS63and TS13 OR repairopen in blk/wht #8 wirecircuit from TS63 andTS13 to TB8 OR replaceTS63 or TS13.

If voltage to TB8 fromTS63 and TS13 hasbeen restored and theprimary boom retractfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 15

Disconnect the wire tothe primary boom retractdirectional valve coilBefore serial number1112: (item I)After serial number1111: (item K). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace primary boomretract directional valvecoilBefore serial number1112: (item I)After serial number1111: (item K).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theprimary boom extend/retract function toggleswitch TS63 in theRETRACT direction andcheck the pressure.

3200PSI

less than 3200 PSI

Adjust the system reliefvalve (see RepairSection)Before serial number1112: (item K)After serial number1111: (item R) ORrepair cylinder orcylinder counterbalancevalve OR functionmanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Check for mechanicalrestrictions keeping theprimary boom retractfunction from operatingOR repair cylinder orcylinder counterbalancevalve OR consult GenieIndustries ServiceDepartment.

Exchange the primaryboom extend/retract andprimary boom up/downdirectional valvesBefore serial number1112: (item I and M)After serial number1111: (item K and U).Activate primary boomretract function.



directional valve.



REV A

TurntableRotate LeftFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 16

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the turntable rotatetoggle switch TS62 inthe LEFT direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe turntable rotatetoggle switch TS62 inthe LEFT direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theturntable rotate functiontoggle switch TS12 onplatform control panel inLEFT direction. Checkthe voltage at TB6.

0V

24V

Troubleshoot turntablerotate function toggleswitch TS12 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS12 to TB6.


Troubleshoot turntablerotate function toggleswitches (TS62 andTS12) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS62 to TB6 and fromTS12 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS62 and TS12 hasbeen restored andturntable rotate leftfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 16

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the turntable rotatetoggle switch TS62 inthe LEFT direction.Check the voltage onthe wht #4 wire on theturntable rotatedirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X).

0V

24V

Move the functionenable toggle switch toeither side and hold theturntable rotate toggleswitch TS62 in the LEFTdirection. Check thevoltage at TB4.

24V

Repair open in wht #4wire circuit from TB4 toturntable rotate leftdirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theturntable rotate toggleswitch TS12 in the LEFTdirection. Check thevoltage at TB4.

0V

24V

Troubleshoot theturntable rotate toggleswitch TS62 on groundcontrol panel ORreplace diode on TS62OR repair open in wht#4 wire circuit fromTS62 to TB4 OR replaceTS62.


Troubleshoot turntablerotate function toggleswitches (TS62 andTS12) on ground andplatform control panelsOR replace diodes onTS62 and TS12 ORrepair open in wht #4wire circuit from TS62and TS12 to TB4 ORreplace TS62 or TS12.

If voltage to TB4 fromTS62 and TS12 hasbeen restored and theturntable rotate leftfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 16

Disconnect the wire tothe turntable rotate leftdirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace turntable rotateleft directional valve coilBefore serial number1112: (item Q)After serial number1111: (item X).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theturntable rotate functiontoggle switch TS62 inthe LEFT direction andcheck the pressure.

morethan1100PSI

less than 1100 PSI

Adjust the turntablerotate relief valve(item D, see RepairSection) OR replace theturntable rotate reliefvalve OR repair orreplace turntablerotation motor ORfunction manifold couldhave an internal defect.Consult Genie IndustriesService Department.

Check for mechanicalrestrictions keeping theturntable rotate leftfunction from operatingOR replace flowregulator valveBefore serial number1112: (item O)After serial number1111: (item V)OR repair or replace theturntable rotation motorOR consult GenieIndustries ServiceDepartment.

Exchange the turntablerotate and steerdirectional valvesBefore serial number1112: (item Q and S)After serial number1111: (item X and J).Activate turntable rotateleft function.



directional valve.



REV A

TurntableRotate RightFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 17

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the turntable rotatetoggle switch TS62 inthe RIGHT direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe turntable rotatetoggle switch TS62 inthe RIGHT direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theturntable rotate functiontoggle switch TS12 onplatform control panel inRIGHT direction. Checkthe voltage at TB6.

0V

24V

Troubleshoot turntablerotate function toggleswitch TS12 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS12 to TB6.


Troubleshoot turntablerotate function toggleswitches (TS62 andTS12) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS62 to TB6 and fromTS12 to red wire onboom function speedcontroller.

If voltage to TB6 fromTS62 and TS12 hasbeen restored andturntable rotate rightfunction is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 17

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the turntable rotatetoggle switch TS62 inthe RIGHT direction.Check the voltage onthe wht/blk #5 wire onthe turntable rotatedirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X).

0V

24V

Move the functionenable toggle switch toeither side and hold theturntable rotate toggleswitch TS62 in the RIGHTdirection. Check thevoltage at TB5.

24V

Repair open in wht/blk#5 wire circuit from TB5to turntable rotate rightdirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theturntable rotate toggleswitch TS12 in the RIGHTdirection. Check thevoltage at TB5.

0V

24V

Troubleshoot theturntable rotate toggleswitch TS62 on groundcontrol panel ORreplace diode on TS62OR repair open in wht/blk #5 wire circuit fromTS62 to TB4 OR replaceTS62.


Troubleshoot turntablerotate function toggleswitches (TS62 andTS12) on ground andplatform control panelsOR replace diodes onTS62 and TS12 ORrepair open in wht/blk #5wire circuit from TS62and TS12 to TB5 ORreplace TS62 or TS12.

If voltage to TB5 fromTS62 and TS12 hasbeen restored and theturntable rotate rightfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 17

Disconnect the wire tothe turntable rotate rightdirectional valve coilBefore serial number1112: (item Q)After serial number1111: (item X). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace turntable rotateright directional valvecoilBefore serial number1112: (item Q)After serial number1111: (item X).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theturntable rotate functiontoggle switch TS62 inthe RIGHT direction andcheck the pressure.

morethan1100PSI

less than 1100 PSI

Adjust the turntablerotate relief valve(item D, see RepairSection) OR replace theturntable rotate reliefvalve OR repair orreplace turntablerotation motor ORfunction manifold couldhave an internal defect.Consult Genie IndustriesService Department.

Check for mechanicalrestrictions keeping theturntable rotate rightfunction from operatingOR replace flowregulator valveBefore serial number1112: (item O)After serial number1111: (item V)OR repair or replace theturntable rotation motorOR consult GenieIndustries ServiceDepartment.

Exchange the turntablerotate and steerdirectional valvesBefore serial number1112: (item Q and S)After serial number1111: (item X and J).Activate turntable rotateright function.



directional valve.



REV AChart 18

All PlatformLevelingFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure both automaticand manual platformleveling do not operate.

If automatic levelingoperates but manualleveling does not,troubleshoot platformleveling up functioninoperative.

Remove both hydraulichoses from the functionmanifold (ports L1 & L2).Plug the hoses and capthe manifold fittings.Move the functionenable switch to eitherside and hold theprimary boom toggleswitch TS61 in the UPdirection and check tosee if platform selflevels.

no

Plumb a 0 to 5000 psi(0 to 345 bar) pressuregauge into mastercylinder rod-endhydraulic hose (hoseconnected to port L2)using a tee fitting. Movethe function enableswitch to either side andhold the primary boomtoggle switch TS61 inthe up direction andcheck the pressure.

less than 2000 PSI

Install a 0 to 5000 psi(0 to 345 bar) pressuregauge into the barrel-end hydraulic hose(hose connected toport L1) from the mastercylinder and raise theprimary boom one inchat a time. Continuallymonitor the pressuregauge while raising theprimary boom. Do notallow the pressure toexceed 2500 PSI.

2000 PSI or more

Repair or replace theslave cylinder.

Replace thecounterbalance valveson function manifold(items C & B).

yes

2000PSI

Check for mechanicalrestrictions keeping theplatform level functionfrom operating ORreplace the slavecylinder counterbalancevalves.

less than2000 PSI Repair or replace the

master cylinder.



REV AChart 19

Platform LevelUp FunctionInoperativeBe sure all otherfunctions operatenormally.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the platform leveltoggle switch TS59 inthe UP direction. Checkthe voltage on the wht/red #6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe platform level toggleswitch TS59 in the UPdirection and check thevoltage at TB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theplatform level functiontoggle switch TS9 on theplatform control panel inthe UP direction. Checkthe voltage at TB6.

0V

24V

Troubleshoot platformlevel function toggleswitch TS59 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS59 to TB6.


Troubleshoot platformlevel function toggleswitches (TS59 andTS9) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS59 to TB6 and fromTS9 to red wire on boomfunction speedcontroller.

If voltage to TB6 fromTS59 and TS9 has beenrestored and platformlevel up function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 19

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold platform leveltoggle switch TS59 inthe UP direction. Checkthe voltage on the org#14 wire on the platformlevel up directional valvecoil (item A).

0V

24V

Move the functionenable toggle switch toeither side and hold theplatform level toggleswitch TS59 in the UPdirection. Check thevoltage at TB14.

24V

Repair open in org #14wire circuit from TB14 toplatform level updirectional valve coil(item A) OR repair openin brn ground wire circuitto manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theplatform level toggleswitch TS9 in the UPdirection. Check thevoltage at TB14.

0V

24V

Troubleshoot theplatform level toggleswitch TS59 on groundcontrol panel ORreplace diode on TS59OR repair open in org#14 wire circuit fromTS59 to TB14 ORreplace TS59.


Troubleshoot platformlevel function toggleswitches (TS59 andTS9) on ground andplatform control panelsOR replace diodes onTS59 and TS9 ORrepair open in org #14wire circuit from TS59and TS9 to TB14 ORreplace TS59 or TS9.

If voltage to TB14 fromTS59 and TS9 has beenrestored and platformlevel up function is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 19

Disconnect the wire tothe platform level updirectional valve coil(item A). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace platform levelup directional valve coil(item A).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theplatform level functiontoggle switch TS59 inthe UP direction andcheck the pressure.

3200PSI

less than 3200 PSI

Test the master cylinder(refer to Chart #18) ORrepair or replace theslave cylindercounterbalance valvesOR function manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Exchange the platformlevel and secondaryboom directional valvesBefore serial number1112: (item A and N)After serial number1111: (item A and T).Activate platform levelup function.



directional valve.

Exchange the platformlevel counterbalancevalves (items B and C).Activate platform levelup function.

functionoperates


Replace defectivecounterbalance valve.

Check for mechanicalrestrictions keeping theplatform level upfunction from operatingOR replace flowregulator valveBefore serial number1112: (item P)After serial number1111: (item W)OR repair or replace theslave cylinder or slavecylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.



REV A

Platform LevelDown FunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 20

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the platform leveltoggle switch TS59 inthe DOWN direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe platform level toggleswitch TS59 in theDOWN direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theplatform level functiontoggle switch TS9 on theplatform control panel inthe DOWN direction.Check the voltage atTB6.

0V

24V

Troubleshoot platformlevel function toggleswitch TS59 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS59 to TB6.


Troubleshoot platformlevel function toggleswitches (TS59 andTS9) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS59 to TB6 and fromTS9 to red wire on boomfunction speedcontroller.

If voltage to TB6 fromTS59 and TS9 has beenrestored and platformlevel down function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 20

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold platform leveltoggle switch TS59 inthe DOWN direction.Check the voltage onthe org/blk #15 wire onthe platform level downdirectional valve coil(item A).

0V

24V

Move the functionenable toggle switch toeither side and hold theplatform level toggleswitch TS59 in theDOWN direction. Checkthe voltage at TB15.

24V

Repair open in org/blk#15 wire circuit fromTB15 to platform leveldown directional valvecoil (item A) OR repairopen in brn ground wirecircuit to manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theplatform level toggleswitch TS9 in the DOWNdirection. Check thevoltage at TB15.

0V

24V

Troubleshoot theplatform level toggleswitch TS59 on groundcontrol panel ORreplace diode on TS59OR repair open in org/blk #15 wire circuit fromTS59 to TB15 ORreplace TS59.


Troubleshoot platformlevel function toggleswitches (TS59 andTS9) on ground andplatform control panelsOR replace diodes onTS59 and TS9 ORrepair open in org/blk#15 wire circuit fromTS59 and TS9 to TB15OR replace TS59 orTS9.

If voltage to TB15 fromTS59 and TS9 has beenrestored and platformlevel down function isstill inoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 20

Disconnect the wire tothe platform level downdirectional valve coil(item A). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace platform leveldown directional valvecoil (item A).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theplatform level functiontoggle switch TS59 inthe DOWN direction andcheck the pressure.

3200PSI

less than 3200 PSI

Test the master cylinder(refer to Chart #18) ORrepair or replace theslave cylindercounterbalance valvesOR function manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Exchange the platformlevel and secondaryboom directional valvesBefore serial number1112: (item A and N)After serial number1111: (item A and T).Activate platform leveldown function.



directional valve.

Exchange the platformlevel counterbalancevalves (items B and C).Activate platform leveldown function.

functionoperates


Replace defectivecounterbalance valve.

Check for mechanicalrestrictions keeping theplatform level downfunction from operatingOR replace flowregulator valveBefore serial number1112: (item P)After serial number1111: (item W)OR repair or replace theslave cylinder or slavecylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.



REV A

Platform RotateLeft FunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 21

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the platform rotatetoggle switch TS57 inthe LEFT direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe platform rotatetoggle switch TS57 inthe LEFT direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theplatform rotate functiontoggle switch TS7 on theplatform control panel inthe LEFT direction.Check the voltage atTB6.

0V

24V

Troubleshoot platformrotate function toggleswitch TS57 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS57 to TB6.


Troubleshoot platformrotate function toggleswitches (TS57 andTS7) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS57 to TB6 and fromTS7 to red wire on boomfunction speedcontroller.

If voltage to TB6 fromTS57 and TS7 has beenrestored and platformrotate left function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 21

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold platform rotatetoggle switch TS57 inthe LEFT direction.Check the voltage onthe org wire on theplatform rotate leftdirectional valve coil(item DD).

0V

24V

Move the functionenable toggle switch toeither side and hold theplatform rotate toggleswitch TS57 in the LEFTdirection. Check thevoltage at TB17.

24V

Repair open in grn wirecircuit from TB17 to orgwire on TS7 to platformrotate left directionalvalve coil (item DD) ORrepair open in brnground wire circuit to jibboom/platform rotatemanifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theplatform rotate toggleswitch TS7 in the LEFTdirection. Check thevoltage on the org wireat the platform rotate leftdirectional valve coil(item DD).

0V

24V

Troubleshoot theplatform rotate toggleswitch TS57 on groundcontrol panel ORreplace diode on TS57OR repair open in grnwire circuit from TS57 toTB17 then to TS7 ORreplace TS57.


Troubleshoot platformrotate function toggleswitches (TS57 andTS7) on ground andplatform control panelsOR replace diodes onTS57 and TS7 ORrepair open in org wirecircuit from TS7 toplatform rotate left coilor grn wire circuit fromTS57 to TB17 then toTS7 OR replace TS57or TS7.

If voltage to the platformrotate left directionalvalve (item DD) hasbeen restored and theplatform rotate leftfunction is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 21

Disconnect the org wireto the platform rotate leftdirectional valve coil(item DD). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace platform rotateleft directional valve coil(item DD).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theplatform rotate functiontoggle switch TS59 inthe LEFT direction andcheck the pressure.

3200PSI

less than 3200 PSI

Repair or replace theplatform rotator OR theplatform rotate/jib boommanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Exchange the platformrotate left and rightdirectional valves(items DD and BB).Activate platform rotateleft function.



directional valve.

Check for mechanicalrestrictions keeping theplatform rotate leftfunction from operatingOR replace flowregulator valveBefore serial number1112: (item P)After serial number1111: (item W)OR the 0.025" orifice(item CC) may beplugged OR repair orreplace the platformrotator OR consultGenie Industries ServiceDepartment.



REV A

Platform RotateRightInoperativeBe sure all otherfunctions operatenormally.

Chart 22

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the platform rotatetoggle switch TS57 inthe RIGHT direction.Check the voltage onthe wht/red #6 wire atthe boom functionproportional valve coil(item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe platform rotatetoggle switch TS57 inthe RIGHT direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and theplatform rotate functiontoggle switch TS7 on theplatform control panel inthe RIGHT direction.Check the voltage atTB6.

0V

24V

Troubleshoot platformrotate function toggleswitch TS57 on theground control panel ORrepair open in wht/red#6 wire circuit fromTS57 to TB6.


Troubleshoot platformrotate function toggleswitches (TS57 andTS7) on ground andplatform control panelsOR repair open in wht/red #6 wire circuit fromTS57 to TB6 and fromTS7 to red wire on boomfunction speedcontroller.

If voltage to TB6 fromTS57 and TS7 has beenrestored and platformrotate right function isstill inoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 22

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold platform rotatetoggle switch TS57 inthe RIGHT direction.Check the voltage onthe blu wire on theplatform rotate rightdirectional valve coil(item BB).

0V

24V

Move the functionenable toggle switch toeither side and hold theplatform rotate toggleswitch TS57 in the RIGHTdirection. Check thevoltage at TB18.

24V

Repair open in grn/blkwire circuit from TB18 toblu wire on TS7 toplatform rotate rightdirectional valve coil(item BB) OR repairopen in brn ground wirecircuit to jib boom/platform rotate manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold theplatform rotate toggleswitch TS7 in the RIGHTdirection. Check thevoltage on the blu wireat the platform rotateright directional valvecoil (item BB).

0V

24V

Troubleshoot theplatform rotate toggleswitch TS57 on groundcontrol panel ORreplace diode on TS57OR repair open in grn/blk wire circuit fromTS57 to TB18 then toTS7 OR replace TS57.


Troubleshoot platformrotate function toggleswitches (TS57 andTS7) on ground andplatform control panelsOR replace diodes onTS57 and TS7 ORrepair open in blu wirecircuit from TS7 toplatform rotate right coilor grn/blk wire circuitfrom TS57 to TB18 thento TS7 OR replace TS57or TS7.

If voltage to the platformrotate left directionalvalve (item BB) hasbeen restored and theplatform rotate rightfunction is stillinoperative, check tomake sure the hydraulicfittings on the platformrotator are not insertedtoo far into the rotatorOR begintroubleshooting from thebeginning of the chart.




REV A CHART 22

Disconnect the blu wireto the platform rotaterotate directional valvecoil (item BB). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace platform rotateright directional valvecoil (item BB).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold theplatform rotate functiontoggle switch TS59 inthe RIGHT direction andcheck the pressure.

3200PSI

less than 3200 PSI

Repair or replace theplatform rotator OR theplatform rotate/jib boommanifold could have aninternal defect. ConsultGenie Industries ServiceDepartment.

Exchange the platformrotate right and leftdirectional valves(items BB and DD).Activate platform rotateright function.



directional valve.

Check for mechanicalrestrictions keeping theplatform rotate rightfunction from operatingOR replace flowregulator valveBefore serial number1112: (item P)After serial number1111: (item W)OR the 0.025" orifice(item CC) may beplugged OR repair orreplace the platformrotator OR consultGenie Industries ServiceDepartment.



REV A

Jib Boom UpFunctionInoperativeBe sure all otherfunctions operatenormally.

Chart 23

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the jib boom toggleswitch TS58 in the UPdirection. Check thevoltage on the wht/red#6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe jib boom toggleswitch TS58 in the UPdirection and check thevoltage at TB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and the jibboom function toggleswitch TS8 on theplatform control panel inthe UP direction. Checkthe voltage at TB6.

0V

24V

Troubleshoot jib boomfunction toggle switchTS58 on the groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS58 toTB6.


Troubleshoot jib boomfunction toggle switches(TS58 and TS8) onground and platformcontrol panels OR repairopen in wht/red #6 wirecircuit from TS58 to TB6and from TS8 to redwire on boom functionspeed controller.

If voltage to TB6 fromTS58 and TS8 has beenrestored and jib boomup function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV A CHART 23

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the jib boom toggleswitch TS58 in the UPdirection. Check thevoltage on the blk wireon the jib boom updirectional valve coil(item AA).

0V

24V

Move the functionenable toggle switch toeither side and hold thejib boom toggle switchTS58 in the UP direction.Check the voltage atTB43.

24V

Repair open in grn wirecircuit from TB43 to blkwire on TS8 to jib boomup directional valve coil(item AA) OR repairopen in brn ground wirecircuit to jib boom/platform rotate manifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold the jibboom toggle switch TS8in the UP direction.Check the voltage onthe blk wire at the jibboom up directionalvalve coil (item AA).

0V

24V

Troubleshoot the jibboom toggle switchTS58 on ground controlpanel OR replace diodeon TS8 OR repair openin grn wire circuit fromTS58 to TB43 then toTS8 OR replace TS58.


Troubleshoot jib boomfunction toggle switches(TS58 and TS8) onground and platformcontrol panels ORreplace diodes on TS58and TS8 OR repair openin blk wire circuit fromTS8 to jib boom up coilor grn wire circuit fromTS58 to TB43 then toTS8 OR replace TS58or TS8.

If voltage to the jib boomup directional valve(item AA) has beenrestored and the jibboom up function is stillinoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV ACHART 23

Disconnect the blk wireto the jib boom updirectional valve coil(item AA). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace the jib boom updirectional valve coil(item AA).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold the jibboom function toggleswitch TS58 in the UPdirection and check thepressure.

3200PSI

less than 3200 PSI

Repair or replace the jibboom lift cylinder ORreplace the jib boom liftcylinder counterbalancevalves OR platformrotate/jib boom manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Exchange the jib boomup and down directionalvalves (items AA andEE). Activate the jibboom up function.



directional valve.

Check for mechanicalrestrictions keeping thejib boom up functionfrom operating ORreplace flow regulatorvalveBefore serial number1112: (item P)After serial number1111: (item W)OR repair or replace thejib boom lift cylinder ORreplace the jib boomcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.



REV AChart 24

Jib Boom DownFunctionInoperativeBe sure all otherfunctions operatenormally.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the jib boom toggleswitch TS58 in theDOWN direction. Checkthe voltage on the wht/red #6 wire at the boomfunction proportionalvalve coil (item H).

0V

24V

Move the functionenable toggle switch toeither side and activatethe jib boom toggleswitch TS58 in theDOWN direction andcheck the voltage atTB6.

24V


0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch and the jibboom function toggleswitch TS8 on theplatform control panel inthe DOWN direction.Check the voltage atTB6.

0V

24V

Troubleshoot jib boomfunction toggle switchTS58 on the groundcontrol panel OR repairopen in wht/red #6 wirecircuit from TS58 toTB6.


Troubleshoot jib boomfunction toggle switches(TS58 and TS8) onground and platformcontrol panels OR repairopen in wht/red #6 wirecircuit from TS58 to TB6and from TS8 to redwire on boom functionspeed controller.

If voltage to TB6 fromTS58 and TS8 has beenrestored and jib boomdown function is stillinoperative, pleasecontinue troubleshootingfrom beginning of chartOR consult GenieIndustries ServiceDepartment.



REV ACHART 24

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, move thefunction enable toggleswitch to either side andhold the jib boom toggleswitch TS58 in theDOWN direction. Checkthe voltage on the whtwire on the jib boomdown directional valvecoil (item EE).

0V

24V

Move the functionenable toggle switch toeither side and hold thejib boom toggle switchTS58 in the DOWNdirection. Check thevoltage at TB44.

24V

Repair open in grn/blkwire circuit from TB44 towht wire on TS8 to jibboom down directionalvalve coil (item EE) ORrepair open in brnground wire circuit to jibboom/platform rotatemanifold.

0V

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition and the boomfunction speed controllerturned to 9, activate thefootswitch. Hold the jibboom toggle switch TS8in the DOWN direction.Check the voltage onthe wht wire at the jibboom down directionalvalve coil (item EE).

0V

24V

Troubleshoot the jibboom toggle switchTS58 on ground controlpanel OR replace diodeon TS8 OR repair openin grn/blk wire circuitfrom TS58 to TB44 thento TS8 OR replaceTS58.


Troubleshoot jib boomfunction toggle switches(TS58 and TS8) onground and platformcontrol panels ORreplace diodes on TS58and TS8 OR repair openin wht wire circuit fromTS8 to jib boom downcoil or grn/blk wirecircuit from TS58 toTB44 then to TS8 ORreplace TS58 or TS8.

If voltage to the jib boomdown directional valve(item EE) has beenrestored and the jibboom down function isstill inoperative, begintroubleshooting frombeginning of chart ORconsult Genie IndustriesService Department.




REV A CHART 24

Disconnect the wht wireto the jib boom downdirectional valve coil(item EE). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace the jib boomdown directional valvecoil (item EE).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Hold the function enabletoggle switch to eitherside and hold the jibboom function toggleswitch TS58 in theDOWN direction andcheck the pressure.

3200PSI

less than 3200 PSI

Repair or replace the jibboom lift cylinder ORreplace the jib boom liftcylinder counterbalancevalves OR platformrotate/jib boom manifoldcould have an internaldefect. Consult GenieIndustries ServiceDepartment.

Exchange the jib boomdown and up directionalvalves (items EE andAA). Activate the jibboom down function.



directional valve.

Check for mechanicalrestrictions keeping thejib boom down functionfrom operating ORreplace flow regulatorvalveBefore serial number1112: (item P)After serial number1111: (item W)OR repair or replace thejib boom lift cylinder ORreplace the jib boomcylinder counterbalancevalves OR consultGenie Industries ServiceDepartment.



REV A

Steer LeftFunctionInoperative -Models beforeserial number1112Be sure all otherfunctions operatenormally.

Chart 25

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atTB36.

0V

20V or more

Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atterminal "L" on the drivecontroller that has theblu wire attached.

20V ormore Repair open in blu #36

wire circuit from drivecontroller DP1 to TB36.

0V

Repair or replace thesteer microswitch on thethe drive controller ORconsult Genie IndustriesService Department.


Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atTB19.

0V

20V or more

Repair open in grn/wht#19 wire circuit withdiode from TB36 toTB19 OR replace thediode.

Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage onthe blu #36 wire at thesteer left directionalvalve coil (item S) on thesteer/brake manifold.

0V

Repair open in blu #36wire circuit from TB36 tothe steer left directionalvalve coil (item S) ORrepair open in brnground wire circuit to thesteer/brake manifold.

20V or more



REV A CHART 25

Disconnect the blu #36wire to the steer leftdirectional valve coil(item S). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace steer leftdirectional valve coil(item S).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Press down the footswitch and hold thesteer left microswitch inthe LEFT direction andcheck the pressure.

3200PSI

Check for mechanicalrestrictions keeping thesteer left function fromoperating OR replaceflow regulator valve(item U) OR repair orreplace the steercylinder OR consultGenie Industries ServiceDepartment.

Exchange the steer andturntable rotatedirectional valves(items S and Q).Activate the steer leftfunction.



directional valve.

Repair or replace thesteer cylinder ORfunction manifold mayhave an internal defect.Consult Genie IndustriesService Department.

less than 3200 psi



REV A

Steer RightFunctionInoperative -Models beforeserial number1112Be sure all otherfunctions operatenormally.

Chart 26

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atTB37.

0V

20V or more

Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atterminal "R" on the drivecontroller that has theblu wire attached.

20V ormore

Repair open in blu/blk#37 wire circuit fromdrive controller DP1 toTB37.

0V



Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atTB19.

0V

20V or more


Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage onthe blu/blk #37 wire atthe steer right directionalvalve coil (item S) on thesteer/brake manifold.

0V

Repair open in blu/blk#37 wire circuit fromTB37 to the steer rightdirectional valve coil(item S) OR repair openin brn ground wire circuitto the steer/brakemanifold.

20V or more



REV A CHART 26

Disconnect the blu/blk#37 wire to the steerright directional valvecoil (item S). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace steer rightdirectional valve coil(item S).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Press down the footswitch and hold thesteer left microswitch inthe RIGHT direction andcheck the pressure.

3200PSI

Check for mechanicalrestrictions keeping thesteer right function fromoperating OR replaceflow regulator valve(item U) OR repair orreplace the steercylinder OR consultGenie Industries ServiceDepartment.

Exchange the steer andturntable rotatedirectional valves(items S and Q).Activate the steer rightfunction.



directional valve.


less than 3200 psi



REV A

Steer LeftFunctionInoperative -Models afterserial number1111Be sure all otherfunctions operatenormally.

Chart 27

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atTB36.

0V

20V or more

Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atterminal "L" on the drivecontroller that has theblu wire attached.

20V ormore Repair open in blu #36

wire circuit from drivecontroller DP1 to TB36.

0V



Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage atTB19.

0V

20V or more


Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the LEFT direction.Check the voltage onthe blu #36 wire at thesteer left directionalvalve coil (item J).

0V

Repair open in blu #36wire circuit from TB36 tothe steer left directionalvalve coil (item J) ORrepair open in brnground wire circuit to thefunction manifold.

20V or more



REV A CHART 27

Disconnect the blu #36wire to the steer leftdirectional valve coil(item J). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace steer leftdirectional valve coil(item J).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Press down the footswitch and hold thesteer left microswitch inthe LEFT direction andcheck the pressure.

3200PSI

Check for mechanicalrestrictions keeping thesteer left function fromoperating OR the 0.060"orifice may be plugged(item O) OR repair orreplace the steercylinder OR consultGenie Industries ServiceDepartment.

Exchange the steer andturntable rotatedirectional valves(items J and X). Activatethe steer left function.



directional valve.


less than 3200 psi



REV A

Steer RightFunctionInoperative -Models afterserial number1111Be sure all otherfunctions operatenormally.

Chart 28

With the key switchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atTB37.

0V

20V or more

Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atterminal "R" on the drivecontroller that has theblu wire attached.

20V ormore

Repair open in blu/blk#37 wire circuit fromdrive controller DP1 toTB37.

0V



Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage atTB19.

0V

20V or more


Press down the footswitch and hold thesteer rocker switch onthe drive controller DP1in the RIGHT direction.Check the voltage onthe blu/blk #37 wire atthe steer right directionalvalve coil (item J).

0V

Repair open in blu/blk#37 wire circuit fromTB37 to the steer rightdirectional valve coil(item J) OR repair openin brn ground wire circuitto the function manifold.

20V or more



REV A CHART 28

Disconnect the blu/blk#37 wire to the steerright directional valvecoil (item J). Test theresistance of the valvecoil. See Repair Section.


0 orinfiniteohms

23 to 25ohms

Replace steer rightdirectional valve coil(item J).

Install a 0 to 5000 PSI(345 bar) pressuregauge at the quickdisconnect coupling onthe function manifold.Press down the footswitch and hold thesteer left microswitch inthe RIGHT direction andcheck the pressure.

3200PSI

Check for mechanicalrestrictions keeping thesteer right function fromoperating OR the 0.060"orifice may be plugged(item O) OR repair orreplace the steercylinder OR consultGenie Industries ServiceDepartment.

Exchange the steer andturntable rotatedirectional valves(items J and X). Activatethe steer right function.



directional valve.


less than 3200 psi



REV AChart 29

All DriveFunctionsInoperative, AllOtherFunctionsOperateNormallyTroubleshooting drivefunction faults may alsobe accomplished byusing the hand heldpendant motor controllerprogrammer (Genie partnumber 56303).

Be sure to check themotor controller statusindicator light on theground control box or onthe motor controller. Ifthe motor controllerstatus indicator light isflashing a fault code,refer to the fault codechart at the beginning ofthis section.

Be sure the circuitbreakers and fuses arenot tripped or blown.

Be sure the batteriesare properly connected.

Be sure the batteriesare fully charged.

Be sure the machine isnot in the free wheelconfiguration.

Be sure the machine isin the stowed positionwith the boom rotated inbetween the non-steerend tires.


Go to Chart 30, BrakeRelease FunctionInoperative.

Block the steer wheelsand raise the machineso the drive tires are offthe ground. With the keyswitch turned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and movethe joystick in eitherdirection. Havesomeone try and rotatethe drive tires by hand.Note: this will require 2people.

tiresdon'tmove

tires move

See Chart 29A, MotorController Fault Code21: Throttle Fault.

Press down the footswitch and move thejoystick controller ineither direction andcheck the voltage atterminal #5 on thejoystick controller.

20V ormore

Press down the footswitch and move thejoystick in the forwarddirection. Check thevoltage on terminal #4on the joystick.

0V

20V or more

Replace the joystick.

Press down the footswitch and move thejoystick in the forwarddirection. Check thevoltage at pin 10 on themotor controller harnessconnector.

0V

Repair open or short toground in the wht wirefrom terminal #4 on thejoystick to TB30 to pin10 on the motorcontroller harnessconnector.

Press down the footswitch and move thejoystick in the reversedirection. Check thevoltage on terminal #5on the joystick.

20V or more

Press down the footswitch and move thejoystick in the reversedirection. Check thevoltage at pin 11 on themotor controller harnessconnector.

0V

Repair open or short toground in the wht/blkwire from terminal #5 onthe joystick to TB31 topin 11 on the motorcontroller harnessconnector.

20V or more

20V or more

0V Replace the joystick.0V



REV A CHART 29


Press down the footswitch and move thejoystick in eitherdirection. Check thevoltage at terminal #6on CR6.

20V ormore

0V

Repair open in org/blkwire circuit from terminal#6 on CR6 to the driveenable toggle switchTS15 to terminal #5 onthe joystick controller.

Press down the footswitch and check thevoltage at the org/redwire on terminal #7 atCR6.

20V ormore

0V

Repair open in brnground wire fromterminal #8 on CR6 toground OR replaceCR6.

Press down the footswitch and check thevoltage at TB12.

Repair open in blu/whtwire circuit with diodefrom TB12 to TS4 ORreplace the diode.

0V

20V or more

Repair open in red wirefrom terminal #13 onLS3 to TB16 thenthrough the org/red wireto terminal #7 on CR6.

Check the voltage at theblk wire on terminal #14on LS3.

0V Repair open in blk wirefrom TB12 to terminal#14 on LS3.

20V or more

Check the voltage at theblk wire on terminal #13on LS3.

0V Check adjustment ofLS3 so that it activateswhen the turntable isrotated in between thenon-steer wheels ORreplace LS3.20V or more


20V or more

0VRepair open in red/blkwire from terminal "C"on joystick controller toTS15 to terminal #4 onCR6.



REV AChart 29A

MotorController FaultCode 21:Throttle FaultTroubleshooting drivefunction faults may alsobe accomplished byusing the hand heldpendant motor controllerprogrammer (Genie partnumber 56303).






Be sure the machine isin the stowed positionwith the turntablerotated so the boom isin between the non-steer end tires.

Turn the key switch tothe OFF position anddisconnect motorcontroller harnessconnector from themotor controller.Connect the leads froman ohmmeter to pins 14and 16 on the connector(pins 14 and 16 are thewht/red and red/whtwires). Check theresistance.

lessthan4000ohms

Repair open or short inwires from thepotentiometer toterminals1 and 2 on thejoystick OR replace thejoystick.

greaterthan7500ohms

Repair open or short toground in the red/wht orwht/red wires from pins14 and 16 to terminals 1and 2 on the joystick ORreplace the joystick.4000 to

7500 ohms

Block the steer wheelsand raise the machineso drive tires are off ofthe ground.With the leads from anohmmeter connected topins 14 and 16 on theconnector, move thejoystick slowly full strokein both the forward andreverse directions whilewatching the ohm meter.Does the resistanceevenly ramp down to 10ohms or less in bothdirections?Note: This will require 2people.

no Replace the joystick.

yes

Begin troubleshootingfrom the beginning ofthe chart OR consultGenie Industries ServiceDepartment.



REV AChart 29B

MotorController FaultCode 32:Main ContactorWeldedTroubleshooting drivefunction faults may alsobe accomplished byusing the hand heldpendant motor controllerprogrammer (Genie partnumber 56303).







1 ohm orless

more than1 ohm

Repair open in motorarmature cables fromthe M- and B+ terminalson the motor controllerto each drive motor.

Test the resistancebetween the "M-" and"B+" terminals on themotor controller.Note: An ohmmetercapable of reading 1ohm or less is neededfor this test.

Test the resistancebetween the A1 and A2terminals on each drivemotor. Is the resistance1 ohm or less on eachdrive motor?

no

yes

Replace defective drivemotor that has aresistance of more than1 ohm.

Remove the motorcontroller harnessconnector from themotor controller. Checkcontinuity from the grnwire that was justremoved from PR1 tothe B- terminal on themotor controller.

morethan 500kilohms

less than500kilohms

Repair short to groundin grn wire from pin 17on the motor controllerharness connector toPR1.

Please begintroubleshooting frombeginning of chart.

Disconnect the batterypacks from the machine.Visually inspect thecontacts on PR1. Arethey stuck closed?

yes

no

Replace drive contactor(PR1) contacts ORreplace the drivecontactor PR1.

Check continuity frompin 17 (grn wire) on themotor controller to theB- terminal on the motorcontroller.

less than500kilohms Replace the motor

controller.

Remove the grn wirefrom PR1. Checkcontinuity from the grnwire that was justremoved from PR1 tothe B- terminal on themotor controller.

less than500kilohms

morethan 500kilohms

morethan 500kilohms

Please begintroubleshooting frombeginning of chart.



REV AChart 29C

MotorController FaultCode 34:Missing MainContactor ORMain ContactorDid Not CloseTroubleshooting drivefunction faults may alsobe accomplished byusing the hand heldpendant motor controllerprogrammer (Genie partnumber 56303).








Block the steer wheelsand raise the machineso drive tires are off ofthe ground. Press downthe foot switch andcheck the voltage at pin1 on the motor controllerharness connector.

48V

0V Repair open in org/redwire circuit with diodefrom TB42 to pin 1 onthe motor controllerharness connector.


48V

0V

Check the voltage atTB3.

0V

24V

Repair open in red/whtwire circuit from TB3 toplatform EmergencyStop button P2.

0V

24V

Repair open in brnground wire fromterminal #85 on CR2 toground OR repair openin wire from terminal #87on CR2 to terminal #6on CR1 OR repair openin org/red #CR2 fromthe 10A fuse F4 toterminal #30 on CR2 ORreplace CR2.


0V Repair open in red/whtwire from TB3 toterminal #86 on CR2.


48V


0V Repair open in brnground wire fromterminal #8 on CR1 toground OR repair openin red/wht wire from TB3to terminal #7 on CR1OR replace CR1.

Repair open in org/redwire from terminal #4 onCR1 to TB42.

48V



REV A CHART 29C


Check the voltage onthe battery cable on theinput side of PR1.

48V

0V Repair open in powercable from battery packsto 500A fuse F1 ORreplace the 500A fuseF1.


20V or more

0V Repair open in blu/whtwire from TB12 to TS4to terminal "A" on thejoystick controller.

Repair open in grn wirefrom PR1 to pin 17 ORreplace PR1 OR test themotor controller. SeeRepair Section.

Press down the footswitch and check thevoltage at pin 2 on themotor controller harnessconnector.

20V or more

0VRepair open in blu/whtwire from TB12 to pin 2on the motor controllerharness connector.

Replace PR1.Turn the key switch tothe OFF position and waitfor 5 seconds, then turnthe key switch toplatform controls. Do notpress down the footswitch. Check thevoltage at the green wireon PR1.

48V

0V

yes

no Replace the motorcontroller.

Check the voltagebetween the B+ and B-terminals on the motorcontroller. Note thevoltage. Press down thefoot switch and checkthe voltage between pin1 on the motor controllerharness connector andthe B- terminal. Is thevoltage within 1V of thefirst reading?

Check the voltage onthe org/red wire at PR1.

0V

48V

Repair open in org/redwire circuit from TB42 toPR1.



REV AChart 30

BrakeReleaseFunctionInoperativeBe sure all otherfunctions operatenormally.

Troubleshootingbrake release faultsmay also beaccomplished byusing the hand heldpendant motorcontrollerprogrammer (Geniepart number 56303).

Be sure to check themotor controllerstatus indicator lighton the ground controlbox or on the motorcontroller. If themotor controllerstatus indicator lightis flashing a faultcode, refer to thefault code chart atthe beginning of thissection.

Be sure the circuitbreakers and fusesare not tripped orblown.

Be sure the machineis in the stowedposition with theturntable rotated sothe boom is inbetween the non-steer end tires.

no

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and checkthe status indicator lighton the motor controllerto see if there is a fault.Is there a fault?

yesRefer to the fault codechart at the beginning ofthis section to determinethe cause of the fault.


24V

0VBlock the steer wheelsand raise the machineso drive tires are off ofthe ground. With the keyswitch turned toplatform controls andboth Emergency Stopbuttons pulled out to theON position, press downthe foot switch andmove the joystick ineither direction andcheck the voltage atTB41.

See Chart 34, DriveEnable SystemInoperative.


0V

24V

Repair open in org/blk#41 wire from TB41 toterminal #87 on CR5.


0V

24V

48V

0V

Repair open in org/redwire circuit from TB42 toterminal #85 on CR5 ORrepair open in red/blkwire from pin 20 toterminal #86 on CR5 ORreplace CR5.

Do not press down thefoot switch. Check thevoltage at the red/blkwire on pin 20 of themotor controller harnessconnector.

Replace CR5.

Press down the footswitch and check thevoltage at the red/blkwire on pin 20 of themotor controller harnessconnector.

0V

24V

Replace the motorcontroller.



REV A CHART 30


Press down the footswitch and move thejoystick in eitherdirection. Check thevoltage on the red/whtwires on the brakerelease valve coilsBefore serial number1112: items W and RAfter serial number1111: items M and P.

0V

24V

Repair open in red/whtwires from TB48 to thebrake release valvecoilsBefore serial number1112: items W and RAfter serial number1111: items M and P.

Disconnect the wiresfrom each of the valvecoils and check theresistance of the valvecoils. See RepairSection.

Check continuity of brnground wires from thebrake release valvecoils to ground.

continuity

nocontinuity

Repair open in brnground wire circuit fromthe brake release valvecoils to ground.

0 orinfiniteohms

22 to 25ohms

Replace defective valvecoil.

Consult Genie IndustriesService Department.

Press down the footswitch and move thejoystick in eitherdirection. Check thevoltage at TB48.

0V Repair open in red/wht#48 wire from terminal#30 on CR5 to TB48.

24V

Press down the footswitch and move thejoystick in eitherdirection. Check thevoltage at TB19.

0VRepair open in red/wht#48 wire from TB48through red/wht wirecircuit to pressureswitch, then grn/wht #19wire with diode to TB19OR replace pressureswitch OR replace thediode.24V



REV AChart 31

Any type of tractionproblem, consult GenieIndustries ServiceDepartment.

TractionFunctionInoperativeBe sure all otherfunctions operatenormally.



REV AChart 32

Machine WillNot Drive AtFull SpeedBe sure all otherfunctions operatenormally.

Be sure the boom is inthe stowed postion withthe primary boom fullyretracted.

Be sure that the primaryboom extension limitswtich (LS1) is beingactivated when theprimary boom isretracted.

Be sure that the primaryboom secondary boomlimit swtiches (LS2 andLS4) are not beingactivated when theprimary and secondarybooms are in thestowed position.

no

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, check thestatus indicator light onthe motor controller tosee if there is a fault. Isthere a fault?




0V

24V

Repair open in blk wirefrom the platformEmergency Stop buttonto TB22.

Check the voltage at thewht wire on the inputside of LS1.

0V Repair open in wht wirefrom TB22 to the inputside of LS1.

24V


0V Check to make sure LS1is being activated whenthe primary boom isretracted OR repairopen in blk wire from theoutput side of LS1 toTB49 OR replace LS1contacts OR replaceLS1.

24V

Check the voltage at theblk wire on the inputside of LS2.

0V

24V

Repair open in blk wirefrom TB49 to the inputside of LS2.


24V

0V Check to make sure LS2is not being activatedwhen the primary boomis in the stowed positionOR repair open in whtwire from the output sideof LS2 to TB50 ORreplace LS2 contactsOR replace LS2.



REV ACHART 32


24V

0V

Check to make sure LS4is not being activatedwhen the secondaryboom is in the stowedposition OR repair openin blk wire from theoutput side of LS4 toTB40 OR replace LS4contacts OR replaceLS4.

Repair open in wht wirefrom TB50 to the inputside of LS4.

Check the voltage at thewht wire on the inputside of LS4.


0V

24V

Check the voltage at pin3 on the motor controllerharness connector.

24V

0V Repair open in org #40wire from TB40 to pin 3on the motor controllerharness connector.

Test the motor controller(see Repair Section) ORconsult Genie IndustriesService Department.



REV AChart 33

MachineDrives AtFull SpeedWithPlatformRaised OrExtendedRemove machinefrom serviceimmediately.

Be sure wiring tolimit switches isintact and shows nosigns of damage orcorrosion.

Be sure the primaryboom drive limitswitch is beingactivated by thecam on the boomwhen the primaryboom is raised.

Be sure thesecondary boomdrive limit switch isbeing activated bythe secondaryboom compressionarm when thesecondary boom israised.

no

With the keyswitchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, check thestatus indicator light onthe motor controller tosee if there is a fault. Isthere a fault?


With the boom in thestowed position, checkthe voltage at pin 3 onthe motor controllerharness connector.

0V

24V

Refer to Chart 32.

Check for properactivation of primaryboom drive limit switchLS2 OR replace LS2contact OR replace LS2.

Raise the primary boomapproximately 10 feet(3 m) and check thevoltage at pin 3 on themotor controller harnessconnector.

24V

0V

Lower the primary boomto the stowed positionand raise the secondaryboom approximately 10feet (3 m). Check thevoltage at pin 3 on themotor controller harnessconnector.

Check for properactivation of secondaryboom drive limit switchLS4 OR replace LS4contact OR replace LS4.

24V

0V

Lower the secondaryboom to the stowedposition and extend theprimary boomapproximately 12 inches(30 cm). Check thevoltage at pin 3 on themotor controller harnessconnector.

24V

0V

Check for properactivation of primaryboom extend drive limitswitch LS1 OR replaceLS1 contact OR replaceLS1.

Replace the motorcontroller OR consultGenie Industries ServiceDepartment.



REV AChart 34

Drive EnableSystemInoperativeBe sure the machine isin the stowed positionwith the turntablerotated so the boom isin between the non-steer wheels.

Be sure all otherfunctions operatenormally.

24V

With the keyswitchturned to platformcontrols and bothEmergency Stop buttonspulled out to the ONposition, press down thefoot switch and checkthe voltage at TB12.

0VRepair open in blu/whtwire circuit from TB12 tothe red wire on thecenter terminal of TS4.

Press down the footswitch and check thevoltage at terminal #14on the drive enable limitswitch LS3.

0V

24V

Repair open in the blkwire from TB12 toterminal #14 on thedrive enable limit switchLS3.

Check for properactivation of driveenable limit switch LS3when the boom isrotated past either non-steer wheel OR replaceLS3 contact OR replaceLS3.

Rotate the boom pasteither non-steer wheeland check the voltageon the red wire atterminal #13 of the driveenable limit switch LS3.

24V

0V

Press down the footswitch and move thejoystick in eitherdirection. Check thevoltage at the red/blkwire on TS15.

Press down the footswitch and check thevoltage at terminal #6 onCR6.

24V Replace CR6.

0V

24V

0VRepair open in red/blkwire from terminal C onthe joystick to the centerterminal of TS15.




REV A CHART 34

Replace the driveenable toggle switchTS15 OR repair open inthe org/blk wire fromTS15 to terminal #5 onthe joystick.

Press down the footswitch and move thejoystick in eitherdirection. Hold the driveenable toggle switchTS15 to either side andcheck the voltage atterminal #5 on thejoystick.

0V

24V

Begin troubleshootingfrom the beginning ofthe chart OR consultGenie Industries ServiceDepartment.




REV AChart 35

AuxiliaryFunctionsInoperativeBe sure all otherfunctions operatenormally.

Be sure keyswitch is inthe appropriate positionand both of theEmergency StopButtons are pulled outto the ON position.

With the key switchturned to groundcontrols and bothEmergency Stop buttonspulled out to the ONposition, lift the redauxiliary pump switchcover and hold auxiliarytoggle switch TS51 andlisten for the sound ofauxiliary pump motoroperating.

motoroperates

Install a 0 to 5000 psi(0 to 345 bar) pressuregauge into the pressureport of the auxiliarypump and hold theauxiliary power toggleswitch and note thepressure.

3200 psi

Repair or replace pumpOR consult GenieIndustries ServiceDepartment.

less than3200 psi

Immediately stop. Thepump is good.Reconnect the pressureline and check thebattery condition. Thereis possibly not enoughbattery capacity tooperate both theauxiliary pump andfunction valves.

motor doesnot operate

With the keyswitchturned to ground controland both EmergencyStop buttons pulled outto the ON position,activate the auxiliarypump toggle switchTS51 and check thevoltage on the red cableon the auxiliary powerunit.

goodCheck for a positiveconnection betweenelectric motor and thepump by removing thepump from the motor,but leave all the hosesconnected. Visuallycheck couplingconnection.

bad

Replace the auxiliarypower unit.

0V

24V


Check continuity fromnegative terminal onauxiliary power unit toground.

continuity

nocontinuity Replace negative cable

from auxiliary pump toground.

Replace the auxiliarypump motor.



REV A CHART 35


Activate the auxiliarypump toggle switchTS51 and check thevoltage at TB27.

0V

24V

Repair open in red wirecircuit with diode fromTS51 to TB27 ORreplace TS51.

Activate the auxiliarypump toggle switchTS51 and check thevoltage at terminal #86on CR3.

0V Repair open in red #27wire from TS51 toterminal #86 on CR3.

24V

Check continuity of brnground wire fromterminal #85 on CR3 toground.

Check the voltage at thecenter terminal on TS51.

0V Repair open in redpower supply wire circuitfrom TS51 throughboom function toggleswitches to key switchKS1.24V

continuity

nocontinuity

Repair open in brnground wire circuit fromterminal #85 on CR3 toground.

Activate the auxiliarypump toggle switchTS51 and any functiontoggle switch. Check thevoltage at terminal #87on CR3.

0V

24V

Replace CR3.

Activate the auxiliarypump toggle switchTS51 and any functiontoggle switch. Check thevoltage at the red wireon PR3.

24V Check continuity of brnground wire on PR3 toground.

continuity

nocontinuity Repair open in brn

ground wire from PR3 toground.

Replace 100A fuse F3OR replace PR3contacts OR replacePR3.0V

Repair open in red wirefrom terminal #87 onCR3 to PR3.

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-34/22 Bi-Energy Operator's Manual.

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.An illustration legend precedes each group ofdrawings.

Electrical Schematics


Hydraulic Schematics


General Repair Process

Malfunctiondiscovered

Identifysymptoms

Troubleshoot

Performrepair

Return toservice problem

solved

problemstill exists

Inspectand test


January 2008Section 6 • Schematics


Electrical Components


Item Description Genie Part Manufacturer Manufacturer QtyNumber Part Number

AP1, AP2 ....... Anderson connector ............ 19436 ............ Anderson ............................. 63325-G1 ....................... 2

BAT1 .............. Battery, 12V DC ................... 56050 ............ Allied Battery Co. ................. Group 70 ........................ 1

BAT2 .............. Battery, 6V DC, 315 AH ....... 44820 ............ Dyno Battery Co. ................. S4H - Dry ....................... 8

BCI ................. Battery charge indicator ..... 101423 ........... Curtis Instruments ............... PT2848B1A ................... 1

BP1 ................ Rotational Controller(before serial number 1924) 36557 ............ OEM Controls ...................... RS10T4331 ................... 1

BP1 ................ Rotational Controller(after serial numbeer 1923) 56886 ............ OEM Controls ...................... RS10T6585 ................... 1

CB1 ................ Circuit breaker .................... 375785 ........... ETA ...................................... 45-700-IG1-P10 ............. 1

CR1,6 and 10 Relay, DPDT, 24V DC ......... 42616 ............ Potter and Brumfield ............ K10P 11D15-24 ............. 3

CR2-5 andCR11-CR15 ... Relay, SPST, 24V DC.......... 56302 ............. Potter and Brumfield ............ VF4-15H11-CO5 ............ 9

Diode .............. Diode, 6 amp, 200 PIV......... 45782 ............. Motorola ............................... MOTMR752 ................. 36

DP1 ................ Joystick controller(before serial number 1787) 56274 ............ OEM Controls ...................... MS6M11498 .................. 1

DP1 ................ Joystick controller (after serial number 1786) ... 56773 ............ OEM Controls ...................... MS4M11750 .................. 1

FB ................... Flashing beacon .................. 20189 ............ ECCO Electronic Controls ... 6400X ............................ 1

F1 ................... Fuse, 500 amp ..................... 43179 ............ Buss ..................................... ANN-500 ........................ 1

F2 and F3 ....... Fuse, 100 amp ..................... 36355 ............ Buss ..................................... ANN-100 ........................ 2

FS1 ................ Footswitch ........................... 13482 ............ Linemaster Switch Corp. ..... SP-522-398 ................... 1

H1 .................. Alarm, Warble tone .............. 45383 ............ Floyd Bell Inc. ...................... MW-09-530-Q ................ 1

H2 .................. Horn, 24V DC, 108 dB ......... 81579 ............ WESCO ............................... HELLA-95348 ................ 1

H3 .................. Alarm, intermittent ............... 18963 ............ Floyd Bell Inc. ...................... XB-09-630-Q ................. 1

H4 .................. Alarm, chime tone ............... 45462 ............ Floyd Bell Inc. ...................... CH-09-525-Q ................. 1

This list continues on the next page.

REV A

Item Description Genie Part Manufacturer Manufacturer QtyNumber Part Number

HM ................. Hourmeter(before serial number 3218) 56100 ............ Curtis Instruments ............... 17305628 ...................... 1

HM ................. Hourmeter(after serial number 3217 .... 19506 ............ ENM Corp ............................ T4OA5808 ..................... 1

KS1 ................ Contact - Keyswitch, N.O. .... 45081 ............ Telemecanique ................... ZB2-BE101 .................... 2

LS1-LS4 ......... Contact - Limit switch .......... 19491 ............ Telemecanique ................... XESP2051 ..................... 1

Level sensor .. Level sensor, 4.5°(ANSI & CSA)(before serial number 3309) 44586 ............ Parker Hannifin ................... LS60-00733 ................... 1

Level sensor .. Level sensor, 4.5°(ANSI & CSA)(after serial number 3308) ... 94077 ............ Parker Hannifin ................... LS60-03027 ................... 1

MC1 ............... Motor controller, SEPEX, 48V, 500 amp ....................94474-01 .......... Curtis Instruments ............... 1244-5553 ..................... 1

P1, P2 ............ Contact, N.C. ....................... 29732 ............ Telemecanique ................... ZB2-BE102 .................... 4

P3 ................... Contact, N.O. ....................... 45081 ............ Telemecanique ................... ZB2-BE101 .................... 1

PR1 ................ Relay, 180 amp ................... 74267 ............ Curtis Instruments ............... SW180-695T ................. 1

PR2 ................ Relay, 180 amp ................... 74266 ............ Curtis Instruments ............... SW180-677L ................. 1

PR3 ................ Relay, 80 amp ..................... 74268 ............ Curtis Instruments ............... SW80-1160 .................... 1

TS1, TS51 ...... Toggle switch, DPST2 position momentary .......... 13480 ............. Microswitch Control Inc. ...... 2NT1-8 ........................... 2

TS54 .............. Toggle switch, DPST2 position maintained ........... 27378 ............. Microswitch Control Inc. ...... 2NT1-3 ........................... 1

TS7-13 andTS57-63 ......... Toggle switch, DPDT

3 position momentary .......... 16397 ............. Microswitch Control Inc. ...... 2NT1-7 ......................... 14

TS2,6,15,5255 and 56 ....... Toggle switch, SPDT

3 position momentary .......... 13037 ............. Microswitch Control Inc. ...... 1NT1-7 ........................... 6

TS4 ................ Toggle switch, DPDT3 position maintained ........... 13038 ............. Microswitch Control Inc. ...... 2NT1-1 ........................... 1

January 2008 Section 6 • Schematics

ELECTRICAL COMPONENTS


REV A



Electrical Symbols Legend

+

-

OR

G/B

LK

-1

15AMP.

TB20

TP29

GR

N/B

LK

TB17

BLK #21 TB21

Battery

12V 6V

Wire color

with cable

number

Circuit breaker

Connection

no terminal

Terminal

P1

Red Emergency

Stop button

normally closed

KS1

GRND

PLAT

Key switch

Pressure switch

Brake release

plug

PR4

Contactor

Solenoid or

relay coil

Horn or Alarm

Tilt sensor

LS2

NC

Limit switch

normally closed

held open

NO

LS1

Limit switch

normally open

held closed

P4

Horn button

normally open

T-circuits

connect

Light

Quick disconnect

terminal

Diode

REDBLK

FS1

Foot switch

CR4

Relay contact

normally open

TS3

EN

GIN

E

STA

RT

Toggle switch SPDT

Circuits crossing

no connection

TS6

RIG

HT

LE

FT

Toggle switch DPDT

Ground

supression

circuit

T-circuits connect

at terminal

Auxiliary Pump

Drive motor

Rotary OEM

flow control

AUX.

PUMP

Limit switch

NO

LS3

NC

A2

A1 S1

S2

WH

T

GRN

RED

BP1 BL

K/R

ED

PSI

Water temperature

switch, normally open

Oil pressure switch,

normally closed

WT

S1

N.O

.O

PS

1N

.C.

WHT

-

+

REV A

LABEL DESCRIPTION

A .................. Alarm

ALT.............. Alternator

AP ............... Anderson plug

BAT ............. Battery

BP ............... Proportional controller

CB ............... Circuit breaker

CR ............... Control relay

DP ............... Drive proportional controller

FB................Flashing beacon

FS................Foot switch

H.................. Horn

HM............... Hour meter

ISM .............. Ignition/start module

KS ............... Keyswitch

L .................. LED

LS ................ Limit switch

P .................. Power switch

PR ............... Power relay

PS ............... Pressure switch

R.................. Resistor

TB ............... Terminal base location

TP ............... Terminal platform location

TS ............... Toggle switch

VR ............... Voltage regulator


Abbreviation Legend


REV A



Hydraulic Symbols LegendREV A

E

Pressure gauge

Filter

Fixed displacement

pump

Bi-directional motor

Pump prime mover

engine or motor

Double acting

cylinder

Orifice with size

.035

Check valve

Relief valve

Priority

flow divider

Solenoid operated

dump valve

Differential

sensing valve

Solenoid operated

proportional valve

Pressure switch

Brake

Variable orifice or

shut off valve

Solenoid operated 2 pos.,

3 way, directional valve

Solenoid operated 3 pos.,

4 way, directional valve

Shuttle valve

Counterbalance valve

N.C.COM

N.O.


Electrical Schematic(before serial number 1468)



1

2

3

4

5

6

7

8

A B C D E F G H I J K L M N


TB34 TB33TB35

STA

RT

ER

RE

LA

Y

EN

GIN

EP

OW

ER

GL

OW

PL

UG

RE

LA

Y

GL

OW

PL

UG

S

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

R

TE

MP.

SW

ITC

H

RE

LA

Y(C

R1

3)

RP

MC

UT

OU

T

(CR

14

)

RP

MR

EL

AY

SO

LE

NO

ID

12

VV

OLTA

GE

RE

GU

LA

TO

R

RE

LA

Y

AL

ER

NA

TO

R

12

VE

NG

INE

BRN

FU

EL

ON

SO

LE

NO

ID

10 A

ORG/BLK

WHTCR13

CR14

RP

M

BR

N

BL

K/R

ED

GROUND

ENGINE

(GND)

(GND)

BLK

BLK/RED

BL

K/W

HT

BLK

WHT

(12V)

WHT

GRN/BLK

AP2

AUX.

RED

START RELAY1

TACH. INPUT2

START INPUT3

(NOT USED)4

GROUND5

BATTERY +6

KEY SWITCH PWR.7

(NOT USED)8

IGNITION ON9

ENGINE FAULT10

IGNITION START MODULE

WHT

86

85

30

87 85

86

30

87

86

85

WHT

-

+

STARTER

CB3

CR11

CR12

BL

K

ALT

BLU

BLU

YE

L

RE

D BL

K/W

HT

CR15+12V

RED

WH

TB

LK

BL

K

VR1

WHT/BLK #21

(12V)

RE

D

WH

TB

RN

(12V)

30

87

86

85

86

85

30

87

TB21

30

87

GLOW

PLUGS

EN

GIN

E

STA

RT

GL

OW

PL

UG

EN

GIN

E

STA

RT

FU

NC

TIO

N

EN

AB

LE

BL

K/W

HT

-1

WHT-FS

RP

M

RPM

LOW

RPMFOOTSWITCH

HIGH RPM

HIGH

RPM

RED

RED

TS56 TS54TS52 TS55

WHT/RED-1

RED/WHT-1

RED

BLU/WHT #12

ORG/RED-1

TS4TS6 TS2

HILO

BL

K-1

BL

K/R

ED

-1

WHT/BLK-1

WHT-1

CONTROLLER

FAULT LED

M- B+

CURTIS 1244

SEPEX MOTOR CONTROLLER

F1 F2

B-

9 14

2-W

IRE

PO

T.

WHT/RED #32

OF

F-L

IMIT

SP

EE

DIN

PU

T

PR1

10 A

CB1

P1

TB29RED/WHT #29

GROUND

PLATFORM

10 A

CB2

TB52HORN

RE

LA

Y

TB40 BLK-8

LS4

WH

T-8

WH

T-6

LS2

BL

K-7

LS1*

WH

T-7

TB22

P3

HORN

TB9

TILT

ALARM

FB

HM

2

BE

AC

ON

FL

AS

HIN

G

(OP

TIO

N)

HO

UR

ME

TE

R

HO

RN

ORG/RED #CR2

AP1

BLK #22

BL

K-6

TB50

TB49

BLK-2

BL

K#

22

BL

K/R

ED

-3

WH

T#

23

RE

D/B

LK

-1

BL

K/R

ED

#C

R4

TB28

RE

D/B

LK

#2

8

OR

G/R

ED

1

5

17

OR

G/R

ED

#4

2

OR

G/R

ED

GR

N

BL

K

TB23

TB42

CR2

CR1

48

VP

OW

ER

RE

LA

YC

R2

RE

LA

YC

R1

48

VP

OW

ER

CONTROLLER

FAULT INDICATOR

LIGHT

CO

IL(P

R1

)

BLU/RED-1

OR

G/R

ED

RE

D/W

HT

WH

T-2

RE

DCR4

SE

NS

OR

TIL

T

6 2 16

3

BL

U/W

HT

#1

2

CO

NTA

CT

OR

DR

IVE

TB39BLU/RED #39

+4

8V

INP

UT

DIO

DE

RE

TU

RN

ORG #40

PO

T.

LO

W

INT

ER

LO

CK

FA

ULT

LE

D

RED/WHT-1

KS1

BOX GROUND

BASE CONTROL

A1

F1

500A

RE

D/W

HT

#2

3

1

3

DR

IVE

CO

NTA

CT

OR

RE

D/B

LK

BR

AK

E/R

EL

20

CR5

WHT/BLK #31 TB31

WHT #30 TB30

RE

VE

RS

E11

FO

RW

AR

D1

0

TB32 WHT/RED-1

WHT-1

WHT/BLK-1

RED

RE

D/W

HT

TB3

WH

T

BL

K

BL

K/R

ED

BR

N

RED

+

BR

N

85

8630

87

7

8

6

4

85

86

BL

K

BL

KB

LK

+48V

-

+

-

+

+

-

+

-

GROUND

+24V

-

+

-

+

+

-

+

-

AP1

AP2

RED RED

BLKBLK

BL

K

AU

XIL

IAR

Y

LIF

TP

UM

P

PR

IMA

RY

LIF

TP

UM

P

48

V

ALT

ER

NA

TO

R

48

VB

AT

TE

RY

CH

AR

GE

R

PR3 PR2

100A

RE

D#

CB

1

100A

F3

F2

BL

K

BL

K

BL

K

RE

D

RE

D

RE

D

WH

T

BL

K

-

+

PUMPPUMP

30

87 85

86

AP2

MOTOR

MOTOR

F2

A2A2 F1F2

A1A1F1

* Shown with

boom extended

10A

F4

OR

G/R

ED

-1

RE

D/W

HT

-3

P2BLK-FS

RED-FS

WHT-FS

FS1

RED

ES34BE1B


Electrical Schematic(before serail number 1468)

1

2

3

4

5

6

7

8

N M L K J I H G F E D C B A


RIG

HT

LE

FT

TB4 TB5

SE

CO

ND

AR

YB

OO

M

DO

WN

DO

WN

DO

WN D

OW

N

UP

UP

UP

UP

PR

IMA

RY

BO

OM

PR

IMA

RY

BO

OM

RE

TR

AC

T

EX

TE

ND

PL

AT

FO

RM

LE

VE

L

TB11 TB10 TB44 TB43

BLK-JIB

WHT-JIB

ROTARY

OEM

FLOW

CONTROL

RED

BRN

BLK/RED

GR

N/W

HT

-3

TB19

GR

N/W

HT

#1

9

GR

N/W

HT

AU

XIL

IAR

Y

PU

MP

RE

DA

UX

ILIA

RY

PU

MP

RE

D-1

TB27

GRN/WHT #19

TB48

RE

D/W

HT

#4

8

TB41

Jumper (remove for CE version)

DRIVE

ENABLE

RED/BLK

BR

N

CR6

OR

G/R

ED

-3

RE

D-5

TB16

BR

N-5

LS3*

WH

T-5

BL

K-5

TB12

TB13

BL

U/W

HT

-3

BL

U/R

ED

-3

RED

WHT/BLK-1

RED/WHT-1

WHT-1

BLU/WHT #12

RED

RED

LE

FT

RIG

HT

TS12

TU

RN

TA

BL

ER

OTA

TE

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

RE

D/B

LK

-3

RE

D-3

BL

K/W

HT

-3

BL

K-3

OR

G/B

LK

-3

OR

G-3

GR

N/B

LK

-1

GR

N-1

TS59TS63

TS51

TS61TS60TS62

TU

RN

TA

BL

ER

OTA

TE

WH

T/B

LK

#5

WH

T#

4

TS1

TS15

WH

T/R

ED

-3

F

E

BCI

TB37

TB36

BL

U/B

LK

#3

7

BL

U#

36

BR

N-2

RE

D/W

HT

#4

8

A

B

C

R

L

OR

G/B

LK

-1

WHT-FS

ORG/RED-1

L

STEER

LIFT

RED/WHT

DP1

BL

U/B

LK

-1

BL

U-1

RE

D

BRAKE RELEASE

RECEPTACLE

J1

BRN-JIB

BP1

RED

PL

AT

FO

RM

LE

VE

L

TS9

DO

WN

DO

WN

DO

WN

UP

UPUP

SE

CO

ND

AR

YB

OO

M

RE

TR

AC

T

EX

TE

ND

TS13

PR

IMA

RY

BO

OM

PL

AT

FR

OM

RO

TA

TE

LE

FT

RIG

HT

TS7

PS

1

PR

IMA

RY

BO

OM

DO

WN

UP

TS11TS10

PLATFORM

CONTROL BOX

GROUND

RED

DRIVE

ENABLE

LED

DRIVE

ENABLE

RELAY

RE

D/W

HT

A2

13 22

CR5

5

4

3

2

1

WHT/RED-1

DRIVE

R

ORG/BLK

RED/WHT #48

OR

G/B

LK

#4

1

REV

FWD

2114

GROUND

FUNCTION MANIFOLD

BRN

(GND)

(GND)

TB52 TB52

*Shown with the boom

rotated past either

non-steer wheel

+

4 7

6 8

87

30

JIB

BO

OM

TS8

TU

RN

RO

TA

TO

R

RIG

HT

CO

IL

DE

SC

EN

T

AL

AR

M

(OP

T)

(A3

)

SE

CO

ND

AR

Y

BO

OM

DO

WN

CO

IL

SE

CO

ND

AR

Y

BO

OM

UP

CO

IL

PR

IMA

RY

BO

OM

DO

WN

CO

IL

PR

IMA

RY

BO

OM

UP

CO

IL

PR

IMA

RY

BO

OM

RE

TR

AC

TC

OIL

PR

IMA

RY

BO

OM

EX

TE

ND

CO

IL

PL

AT

FO

RM

LE

VE

LD

OW

N

CO

IL

PL

AT

FO

RM

LE

VE

LU

PC

OIL

LIF

TP

UM

P

CO

NTA

CT

OR

CO

ILP

R2

AU

XIL

IAR

Y

CO

NT

RO

LR

EL

AY

CO

IL

ST

EE

RR

IGH

T

CO

IL

ST

EE

RL

EF

T

CO

IL

BR

AK

ER

EL

EA

SE

N.O

.C

OIL

BR

AK

ER

EL

EA

SE

N.C

.C

OIL

PL

AT

FR

OM

LE

VE

LC

UT

OU

T

RE

LA

YC

OIL

AU

XIL

IAR

Y

LIF

TP

UM

P

CO

NTA

CT

OR

CO

ILP

R3

DR

IVE

EN

AB

LE

LIM

ITS

WIT

CH

BR

AK

ER

EL

EA

SE

PR

ES

SU

RE

SW

ITC

HP

S1

BR

AK

ER

EL

EA

SE

TR

AV

EL

AL

AR

M

A2

TU

RN

RO

TA

TO

R

LE

FT

CO

IL

PR

OP

OR

TIO

NA

L

FL

OW

CO

NT

RO

L

CO

IL

A3

+

+

TB6

RE

D

RE

D#

27

WH

T/R

ED

#6

RE

D/B

LK

#2

BL

U#

10

BL

U/B

LK

#11

BL

K#

7

BL

K/W

HT

#8

RE

D#

1

PL

AT

FO

RM

RO

TA

TE

LE

FT

RIG

HT

TB17 TB18

TS57

JIB

BO

OM

TS58

WHT/RED #6

GR

N/W

HT

CR3 86

85

87A

30

87

TB2 TB1 TB8 TB7

TB15TB14

PLATFORM LEVEL

CUTOUT

ONLY

CE VERSION

CR10

RE

D-6

ORG-6

7

8

14 13

LS2

5 6

1 2

OR

G#

14

OR

G/B

LK

#1

5

ORG-JIB

BLU-JIB

GR

N-3

GR

N/B

LK

-3

JIB

MANIFOLD

GROUND

Section 6 • SchematicsJanaury 2008



Electrical Schematic(from serial number 1468 to 3214)



1

2

3

4

5

6

7

8



BLK-2

HORN

AU

XIL

IAR

Y

LIF

TP

UM

P

BLK

- +

GROUND

BLK

AP1

BL

K

48

VB

AT

TE

RY

CH

AR

GE

R

PR

IMA

RY

LIF

TP

UM

P

BL

K

BL

K

48

V

ALT

ER

NA

TO

R

BL

K

ORG

ORG

CB2

10A TB52

BR

N

WH

T-8

OR

G/R

ED

#4

2

OR

G/R

ED

85

BL

U/W

HT

#1

2

OR

G/R

ED

F4

DIO

DE

RE

TU

RN

+

-

-

+

RE

D

AP2

RED

BLK

AP1

RED

BLK

+24V

+ -

100A

24V

F3

PR3

PR

1D

RIV

E

CO

NTA

CT

OR

WH

T

RE

D

RE

D

-

+

F2

PR2

F1

+ -

- +

- +

RE

D#

CB

1

+48V

RED RED

AP2

+ -

10A

F2

100A

48V

91

+4

8V

INP

UT

BL

K

PR1

F1

500A

BL

K-7

20

16

10

14

STATUS LED

A2

A1

A2

A1F1

F1

F2

CURTIS 1244

SEPEX CONTROLLER

M-

17

B-

5

B+ F2

30

BL

K

87 BL

K/R

ED

DR

IVE

CO

NT

RO

LL

ER

STA

TU

SL

ED

PR

1D

RIV

E

CO

NTA

CT

OR

CO

IL

LS1

13

14

WH

T-7

RE

D/B

LK

OF

F-L

IMIT

SP

EE

DIN

PU

T

211

INT

ER

LO

CK

RE

VE

RS

E

FO

RW

AR

D

3

PO

T.

LO

W

BR

AK

E/R

EL

2-W

IRE

PO

T.

CR5

86

BL

K

GR

N

BL

K-6

LS2

TB49

22

TB50

21

WH

T-6

ORG/RED #CR2

10 A

CB1

P1

WHT/BLK-1

OR

G#

40

WH

T/R

ED

#3

2

RE

D/W

HT

#2

9

WH

T#

30

WH

T/B

LK

#3

1

TB30

TB31

BLK-8TB40

LS4

22

21

TB29

TB32

WHT-1

RED/WHT-1

WHT/RED-1

BLK #22

GROUND

PLATFORM

KS1

RED

TB22

AUX.

BR

N

FL

AS

HIN

G

BE

AC

ON

(OP

TIO

N)

HO

UR

ME

TE

R

HO

RN

RE

LA

Y

TIL

T

SE

NS

OR

CR

2P

OW

ER

RE

LA

Y(4

8V

)

CR

1P

OW

ER

RE

LA

Y(4

8V

)

CR

16

FIE

LD

RE

LA

Y

EN

GIN

ER

UN

SO

LE

NO

ID

STA

RT

ER

RE

LA

Y

STARTER

EN

GIN

E

PO

WE

RR

EL

AY

VO

LTA

GE

RE

GU

LA

TO

R

BR

N

12

V

ALT

ER

NA

TO

R

CR

13

RP

M

CU

TO

UT

RE

LA

Y

GL

OW

PL

UG

RE

LA

Y

GL

OW

PL

UG

S

RP

M

SO

LE

NO

ID

CR

14

RP

MR

EL

AY

BRN

ENGINE

GROUND

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

R

TE

MP

ER

AT

UR

E

SW

ITC

H

(GND)

(GND)

TS56

GLOW

PLUGS

TB34

CR15

BL

K/W

HT

RE

D/W

HT

RE

D/B

LK

-1

(12V)

RE

D/B

LK

#2

8

RE

D/W

HT

#2

3

BL

K/R

ED

#C

R4

86CR4

85

BL

K

FB

3HM

2

1

RE

D

CR16

85

86

87

30

WH

T

WHT/BLK #21

WH

T#

23

TB9

BL

K/R

ED

-3

TB23

48

CR230

87

6CR17

TB28

85

86

CB3

WH

T87

-

85BL

K

(12V)

30

+

+12V

WHT

CR11 86

RE

D

WH

TY

EL

RE

D

VR1

(12V)

BL

K

30

87

ALT.

BLU

BLU

3086

TB21

CR12

85 87

WHT

10 A

OR

G/R

ED

RED (12GA)

BL

K/W

HT

-1

RE

D/W

HT

TB3

RED

+

WH

T-2

BLK-FS

P2

P3

HORN

FS1

RE

D/W

HT

-3

TILT

ALARMA1

RED-FS

WHT-FS

RED

TB42

OR

G/R

ED

-1

GLOW

PLUGS

TS6

TS55TS54TS52

START RELAY

TACH. INPUT

START INPUT


GROUND

BATTERY +

KEY SWITCH POWER

(NOT USED)

IGNITION ON

(NOT USED)

ENGINE FAULT

CR14

86

85

87

30

BL

K/R

ED

85

86

CR13

8587

30 86

BR

N

GRN/BLK

WHT

WHT

8

9

7

WHT

10

HI

BL

K/W

HT

BLK/RED

TB33

ENGINE

START

LOW

RPM

SELECT

BLK

ORG/BLK

BLK

RED

1

2

3

5

6

4

FUNCTION

ENABLE

TB35

BL

K/R

ED

-1

RED

WH

T

AP2

BL

K-1

RED

BLU/WHT #12

WHT/BLK-1

WHT-1

WHT/RED-1

RED/WHT-1

RPM

SELECT

ENGINE

START

TS2

LOHI

TS4

RED

FS-HI

RED

RED

WHT-FS

ORG/RED-1

SWITCH SHOWN WITH BOOM EXTENDED

SWITCH SHOWN WITH BOOM ROATED PAST EITHER NON STEER WHEEL

1. ALL LIMIT SWITCHES WITH BOOM IN STOWED POSITION EXCEPT AS NOTED

NOTES:

COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.

5. ALL SOLENOID AND RELAY COILS ARE 24VDC EXCEPT WHERE NOTED.

+

2

2

3

4

4

L3

H1

ES34BEH

OR

G/R

ED

(12V)



1

2

3

4

5

6

7

8



FUNCTION

MANIFOLD

GROUND

SE

CO

ND

AR

Y

BO

OM

DO

WN

(GND)

(GND)

BRN

TU

RN

TA

BL

E

RO

TA

TE

RIG

HT

DE

SC

EN

T

AL

AR

M

(OP

TIO

N)

TU

RN

TA

BL

E

RO

TA

TE

LE

FT

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

Y

BO

OM

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

EX

TC

OIL

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LC

UT

OU

T

(CE

OP

TIO

N)

PR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

CO

IL

PR

2L

IFT

PU

MP

CO

NTA

CT

OR

CO

IL

PR

OP

OR

TIO

NA

L

FL

OW

CO

NT

RO

L

CR

20

LIF

TP

UM

P

CO

NTA

CT

OR

RE

LA

Y

CR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

RE

LA

Y

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

A2

TR

AV

EL

AL

AR

M

BR

AK

ER

EL

EA

SE

N.O

.V

ALV

E

BR

AK

E

PR

ES

SU

RE

SW

ITC

H

BR

AK

ER

EL

EA

SE

N.C

.V

ALV

E

TB52

FWD

AUX.

PUMP

TB27

15 3

OR

G/R

ED

4

WH

T

PLATFORM

LEVEL

BL

U/B

LK

#11

WH

T/B

LK

#5

WH

T#

4

A3

+

RED DN

TS60

TB11

L

TS62

R

TURNTABLE

ROTATE

TB5

TB4

BL

K/W

HT

#8

RE

D/B

LK

#2

BL

U#

10

RE

D#

1

BL

K#

7

UP

TB1

DN

TS61

TB2

PRIMARY

BOOM

BOOM

UP

SECONDARY

BOOM

TB10

EXT

PRIMARY

BOOM

TB7

TB8

RET

TS63

WH

T-3

RED/WHT-1

WHT/RED-1

RED

BLU/WHT #12

WH

T/B

LK

-3

BL

U-3

BL

U/B

LK

-3

TURNTABLE

ROTATE

RL

TS12

RED

WHT-1

RED

WHT/BLK-1

DN

TS10

SECONDARY

BOOM

UP

CR196

4

BL

K/W

HT

-3

RE

D-3

RE

D/B

LK

-3

OR

G-3

BL

K-3

OR

G/B

LK

-3

RET

TS13

UP

PRIMARY

BOOM

5

3

CR19

TS11

DN UPDN

TS9

EXT

PRIMARY

BOOM

WHT/RED #6

14

CR10

21

OR

G#

14

OR

G/B

LK

#1

5

5 6

ORG-6

13

RE

D-6

LS2

7

8

TS57

TB17

UP

PLATFORM

LEVEL

DN

TS59

TB14TB15

DN

RED

L R

TB18

PLATFORM

ROTATE

TB44

TS58

RE

D#

27

CR20

87A

TB6

87

30

RE

D

87

30

RE

D

WH

T/R

ED

#6

86

85

CR3

86

85

GR

N/W

HT

TB19

JIB

BOOM

UP

TB43

GR

N/W

HT

WH

T/R

ED

-3

ONR

ED

GRN/WHT #19

BRN

CR19

ROTARY

OEM

FLOW

CONTROL

BRN-JIB

GR

N/B

LK

-3

BLU-JIB

ORG-JIB

JIB

MANIFOLD

GROUND

GR

N-3

BP1

GR

N-1

BLK-JIB

WHT-JIB GR

N/B

LK

-1

R

PLATFORM

ROTATE

L

TS7

DN UP

TS8

JIB

BOOM

7

8

BRN

RED

GRN

BLK/RED

RED

F

E

RE

D-1

TS51

BCI

+

4 3 2 1

O/R

OR

G

8 7 6 5

BLK

O/B

SET TO "N"SET TO "B"

L.V.I.

DISCHARGERESET

5

4

3

2TS1

AUX.

PUMP

ON

WHT-FS

ORG/RED-1

LVI/BCI OPTION

BCI

RED

DP1

WH

T6

BL

U/R

ED

-3

RE

D/W

HT

#4

8

PLATFORM

CONTROL BOX

GROUND

OR

G/R

ED

RE

D/W

HT

#4

8

BL

U/B

LK

#3

7

BL

U#

36

+

A2

RE

D/W

HT

TB36

TB37

CR5

87

30

RE

D/W

HT

PS

1

RED/WHT

TB48

DRIVE

ENABLE

LIMIT

SWITCH22

BR

N-5

13

TB16

RE

D-5

TB13

BR

N-2

OR

G/R

ED

-3

BL

K-5

2114 LS3

WH

T-5

BL

U-1

BL

U/B

LK

-1

RE

D

LIFT

L

DRIVE

7

8

9

10

REV

R

ORG/RED

STEERTS15

DRIVE

ENABLE

BL

U/W

HT

-3

TB12

L1

DRIVE

ENABLELED

JP1

(REMOVE FOR

CE VERSION)

BRAKE

RELEASE

JACK

J1

+

3

Section 6 - SchematicsJanuary 2008




1

2

3

4

5

6

7

8



ES34BEL

BLK-2

HO

RN

AU

XIL

IAR

Y

LIF

TP

UM

P

BLK

- +

GROUND

BLKAP1

BL

K

48

VB

AT

TE

RY

CH

AR

GE

R

PR

IMA

RY

LIF

TP

UM

P

BL

K

BL

K

48

V

ALT

ER

NA

TO

R

BL

K

ORG

ORG

CB2

10ATB52

BR

N

WH

T-8

OR

G/R

ED

#4

2

OR

G/R

ED

85

BL

U/W

HT

#1

2

OR

G/R

ED

F4

10A

DIO

DE

RE

TU

RN

+

-

-

+

RE

D

AP2

RED

BLK

AP1

RED

BLK

+24V

+ -

100A

24V

F3

PR3

PR

1D

RIV

E

CO

NTA

CT

OR

WH

T

RE

D

RE

D

-

+

F2

PR2

F1

+ -

- +

- +

RE

D#

CB

1

+48V

RED RED

AP2

+ -

F2

100A

91+

48

VIN

PU

T

BL

K

PR1

F1

500A

BL

K-7

20

16

10

14

STATUS LED

A2

A1

A2

A1F1

F1

F2

CURTIS 1244

SEPEX CONTROLLER

M-

17

B-

5

B+ F2

30

BL

K

87

BL

K/R

ED

L3

DR

IVE

CO

NT

RO

LL

ER

STA

TU

SL

ED

PR

1D

RIV

E

CO

NTA

CT

OR

CO

IL

LS1

13

14

WH

T-7

RE

D/B

LK

OF

F-L

IMIT

SP

EE

DIN

PU

T

211

INT

ER

LO

CK

RE

VE

RS

E

FO

RW

AR

D

3

PO

T.

LO

W

BR

AK

ER

EL

EA

SE

2-W

IRE

PO

T.

CR5

86

BL

K

GR

N

BL

K-6

LS2

TB49

22

TB50

21

WH

T-6

ORG/RED #CR2

10 A

CB1

P1

WHT/BLK-1

OR

G#

40

WH

T/R

ED

#3

2

RE

D/W

HT

#2

9

WH

T#

30

WH

T/B

LK

#3

1

TB30

TB31

BLK-8TB40

LS4

22

21

TB29

TB32

WHT-1

RED/WHT-1

WHT/RED-1

BLK #22

GROUND

PLATFORMKS1

RED

TB22

BR

N

FL

AS

HIN

G

BE

AC

ON

(OP

TIO

N)

HO

UR

ME

TE

R

HO

RN

RE

LA

Y

TIL

T

SE

NS

OR

CR

2P

OW

ER

RE

LA

Y

CR

1P

OW

ER

RE

LA

Y

CR

16

FIE

LD

RE

LA

Y

EN

GIN

ER

UN

SO

LE

NO

ID

STA

RT

ER

RE

LA

Y

STARTER

EN

GIN

E

PO

WE

R

RE

LA

Y

VO

LTA

GE

RE

GU

LA

TO

R

BR

N

12

V

ALT

ER

NA

TO

R

CR

13

RP

M

CU

TO

UT

RE

LA

Y

GL

OW

PL

UG

RE

LA

Y

GL

OW

PL

UG

S

RP

M

SO

LE

NO

ID

CR

14

RP

MR

EL

AY

BRN

ENGINE

GROUND

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

R

TE

MP

ER

AT

UR

E

SW

ITC

H

(GND)

(GND)

TS56

GLOW

PLUGS

TB34

CR15

BL

K/W

HT

RE

D/W

HT

RE

D/B

LK

-1R

ED

/BL

K#

28

RE

D/W

HT

#2

3

BL

K/R

ED

#C

R4

86CR4

85

BL

K

FB

HM

+

RE

D

CR16

85

86

87

30

WH

T

WH

T#

23

TB9

BL

K/R

ED

-3

TB23

48

CR230

87

6CR17

TB28

85

86

CB3

WH

T

87

-

85

BL

K

30

+

+12V

WHT

CR11 86

RE

D

WH

TY

EL

RE

D

VR1

BL

K

30

87

ALT.

BLU

BLU

3086

CR12

85 87

WHT

10 A

OR

G/R

ED

RED (12GA)

BL

K/W

HT

-1

RE

D/W

HT

TB3

RED

+

WH

T-2

BLK-FS

P2

P3

HORN

FS1

RE

D/W

HT

-3

TILT

ALARMA1

RED-FS

WHT-FS

RED

TB42

OR

G/R

ED

-1

GLOW

PLUGS

TS6

TS55TS54TS52

START RELAY

TACH. INPUT

START INPUT


GROUND

BATTERY +

KEY SWITCH POWER

(NOT USED)

IGNITION ON

(NOT USED)

ENGINE FAULT

CR14

86

85

87

30

BL

K/R

ED

85

86

CR13

8587

30 86

BR

N

GRN/BLK

WHT

WHT

8

9

7

WHT

10

HI

BL

K/W

HT BLK/RED

TB33

ENGINE

START

LO

RPM

SELECT

BLK

ORG/BLK

BLK

RED

1

2

3

5

6

4

FUNCTION

ENABLE

TB35

BL

K/R

ED

-1

RED

WH

T

AP2

AUX.

BL

K-1

RED

BLU/WHT #12

WHT/BLK-1

WHT-1

WHT/RED-1

RED/WHT-1

ENGINE

START

TS2

LOHI

RPM

SELECT

RED

FS-HI

RED

ORG/RED

WHT-FS

ORG/RED-1



NOTES:

REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.


+

BLK

ORG/RED #CR20

BLK

BRN BRN

BL

K#

22

A C

BH1

TS4

BRN

2

3

2

3

(12V)

(12V)

(12V)

(12V)

(12V)

(12V)

(12V)

(12V)

(12V)

5 SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL



1

2

3

4

5

6

7

8



FUNCTION

MANIFOLD

GROUND

SE

CO

ND

AR

Y

BO

OM

DO

WN

(GND)

(GND)

TU

RN

TA

BL

E

RO

TA

TE

RIG

HT

DE

SC

EN

T

AL

AR

M

(OP

TIO

N)

TU

RN

TA

BL

E

RO

TA

TE

LE

FT

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

Y

BO

OM

UP

PR

I.B

OO

M

RE

TR

AC

T

PR

I.B

OO

M

EX

TE

ND

EX

TC

OIL

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LC

UT

OU

T

(CE

OP

TIO

N)

PR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

CO

IL

PR

2L

IFT

PU

MP

CO

NTA

CT

OR

CO

IL

PR

OP

OR

TIO

NA

L

FL

OW

CO

NT

RO

L

CR

20

LIF

TP

UM

P

CO

NTA

CT

OR

RE

LA

Y

CR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

RE

LA

Y

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

A2

TR

AV

EL

AL

AR

M

BR

AK

ER

EL

EA

SE

N.O

.V

ALV

E

BR

AK

E

PR

ES

SU

RE

SW

ITC

H

BR

AK

ER

EL

EA

SE

N.C

.V

ALV

E

TB52

FWD

AUX

TB27

15 3

OR

G/R

ED

4

WH

T

PLATFORM

LEVEL

BL

U/B

LK

#11

WH

T/B

LK

#5

WH

T#

4

A3

+

RED DN

TS60

TB11

L

TS62

R

TURNTABLE

ROTATE

TB5

TB4

BL

K/W

HT

#8

RE

D/B

LK

#2

BL

U#

10

RE

D#

1

BL

K#

7

UP

TB1

DN

TS61

TB2

PRIMARY

BOOM

UP

SECONDARY

BOOM

TB10

EXT

PRIMARY

BOOM

TB7

TB8

RET

TS63

WH

T-3

RED/WHT-1

WHT/RED-1

RED

BLU/WHT #12

WH

T/B

LK

-3

BL

U-3

BL

U/B

LK

-3

TURNTABLE

ROTATE

RL

TS12

RED

WHT-1

ORG/RED

WHT/BLK-1

DN

TS10

SECONDARY

BOOM

UP

CR196

4

BL

K/W

HT

-3

RE

D-3

RE

D/B

LK

-3

OR

G-3

BL

K-3

OR

G/B

LK

-3

RET

TS13

UP

PRIMARY

BOOM

5

3

CR19

TS11

DN UPDN

TS9

EXT

PRIMARY

BOOM

WHT/RED #6

14

CR10

21

OR

G#

14

OR

G/B

LK

#1

5

5 6

ORG-6

13 RE

D-6

LS2

7

8

TS57

TB17

UP

PLATFORM

LEVEL

DN

TS59

TB14

TB15

DN

RED

L R

TB18

PLATFORM

ROTATE

TB44

TS58

RE

D#

27

CR20

87A

TB6

87

30

RE

D

87

30

OR

G/R

ED

(48

V)

WH

T/R

ED

#6

86

85CR3

86

85

GR

N/W

HT

TB19

JIB

BOOM

UP

TB43

GR

N/W

HT

-3G

RN

/WH

T

WH

T/R

ED

-3

ON

RE

D

GRN/WHT #19

BRN

CR19

ROTARY

OEM

FLOW

CONTROL

BRN-JIB

GR

N/B

LK

-3

BLU-JIB

ORG-JIB

JIB

MANIFOLD

GROUND

GR

N-3

BP1

GR

N-1

BLK-JIB

WHT-JIB

GR

N/B

LK

-1

R

PLATFORM

ROTATE

L

TS7

DN UP

TS8

JIB

BOOM

7

8

BRN

RED

GRN

BLK/RED

RED

F

E

RE

D-1

TS51

BCI

+

4 3 2 1

O/R

OR

G

8 7 6 5

BLK

O/B


L.V.I.

DISCHARGERESET

5

4

3

2

TS1

AUX

ON

WHT-FS

ORG/RED-1

LVI/BCI OPTION

BCI

RED

DP1

WH

T

6

BL

U/R

ED

-3

RE

D/W

HT

#4

8

PLATFORM

CONTROL BOX

GROUND

OR

G/R

ED

RE

D/W

HT

#4

8

BL

U/B

LK

#3

7

BL

U#

36

+

A2

RE

D/W

HT

TB36

TB37

CR5

87

30

RE

D/W

HT

PS

1

RED/WHT

TB48

DRIVE

ENABLE

LIMIT

SWITCH22

BR

N-5

13

TB16

RE

D-5

TB13

BR

N-2

OR

G/R

ED

-3

BL

K-5

2114 LS3

WH

T-5

BL

U-1

BL

U/B

LK

-1

RE

D

LIFT

L

DRIVE

7

8

9

10

REV

R

ORG/RED

STEER TS15 DRIVE

ENABLE

BL

U/W

HT

-3

TB12

L1

DRIVE

ENABLE

LED

JP1

(REMOVE FOR

CE VERSION)

BRAKE

RELEASE

JACK

J1

+

BLK (24V)

5

BRN

Section 5 • SchematicsJanuary 2008




1

2

3

4

5

6

7

8



ES34BES

BLK-2

HO

RN

AU

XIL

IAR

Y

LIF

TP

UM

P

LIF

TP

UM

P

BLK

+

GROUND

BLK

AP1

BL

K

48

VB

AT

TE

RY

CH

AR

GE

R

PR

IMA

RY

LIF

TP

UM

P

BL

K

BL

K

48

V

ALT

ER

NA

TO

R

BL

K

ORG

ORG

CB3

10ATB52

BR

N

WH

T-8

OR

G/R

ED

#4

2

OR

G/R

ED

85

BL

U/W

HT

#1

2

OR

G/R

ED

F4

10A

DIO

DE

RE

TU

RN

-

-

+

+

RE

D

AP2

RED

BLK

AP1

RED

BLK

+24V

- +

24V

F3

100A

PR3

PR

1D

RIV

E

CO

NTA

CT

OR

WH

T

RE

D

RE

D

-

+

F2

PR2

F1

- +

- +

- +

RE

D#

CB

1

+48V

RED RED

AP2

- +

F1

100A

91+

48

VIN

PU

T

BL

K

PR1

F1

500A

BL

K-7

20

16

10

14

STATUS LED

A2

A1

A2

A1F1

F1

F2

CURTIS 1244

SEPEX CONTROLLER

M-

17

B-

5

B+ F2

30

BL

K

87 BL

K/R

ED

L3

DR

IVE

CO

NT

RO

LL

ER

STA

US

LE

D

PR

1D

RIV

E

CO

NTA

CT

OR

CO

IL

LS1

13

14

WH

T-7

RE

D/B

LK

OF

F-L

IMIT

SP

EE

DIN

PU

T

211

INT

ER

LO

CK

RE

VE

RS

E

FO

RW

AR

D

3

PO

T.L

OW

BR

AK

E/R

EL

2-W

IRE

PO

T.

CR5

86

BL

K

GR

N

BL

K-6

LS2

TB49

22

TB50

21

WH

T-6

ORG/RED #CR2

10A

CB2

P1

WHT/BLK-1

OR

G#

40

WH

T/R

ED

#3

2

RE

D/W

HT

#2

9

WH

T#

30

WH

T/B

LK

#3

1

TB30

TB31

BLK-8TB40

LS4

22

21

TB29

TB32

WHT-1

RED/WHT-1

WHT/RED-1

BLK #22

GROUND

PLATFORMKS1

RED

TB22

(12V)

BR

N

FL

AS

HIN

G

BE

AC

ON

(OP

TIO

N)

HO

UR

ME

TE

R

HO

RN

RE

LA

Y

TIL

T

SE

NS

OR

CR

2P

OW

ER

RE

LA

Y

CR

1P

OW

ER

RE

LA

Y

CR

16

FIE

LD

RE

LA

Y

EN

GIN

ER

UN

SO

LE

NO

ID

STA

RT

ER

RE

LA

Y

STARTER

EN

GIN

E

PO

WE

R

RE

LA

Y

12

VV

OLTA

GE

RE

GU

LA

TO

R

BR

N

12

V

ALT

ER

NA

TO

R

CR

13

RP

M

CU

TO

UT

RE

LA

Y

GL

OW

PL

UG

RE

ALY

CR

14

RP

MR

EL

AY

GL

OW

PL

UG

S

RP

M

SO

LE

NO

ID

BRN

GROUND

ENGINE

OIL

PR

ES

SU

RE

SW

ITC

H

WA

TE

RT

EM

P.

SW

ITC

H

(GND)

(GND)

TS56

GLOW

PLUGS

TB34

CR15

BL

K/W

HT

RE

D/W

HT

RE

D/B

LK

-1

(12V)

RE

D/B

LK

#2

8

RE

D/W

HT

#2

3

BL

K/R

ED

#C

R4

86CR4

85

BL

K

FB

HM

+

RE

D

CR16

85

86

87

30

WH

T

WH

T#

23

TB9

BL

K/R

ED

-3

TB23

48

CR230

87

6CR17

TB28 85

86

CB1

WH

T

87

-

85

BL

K(12V)

30

+

+12V

WHT

CR11 86

RE

D

WH

TY

EL

RE

D

VR1

(12V)

BL

K

30

87

ALT.

BLU

BLU

3086

CR12

85 87

WHT

15A

OR

G/R

ED

RED (12GA)

BL

K/W

HT

-1

RE

D/W

HT

TB3

RED

+GR

/WH

-1

BLK-FS

P2

P3

HORN

FS1

RE

D/W

HT

-3

TILT

ALARMA1

RED-FS

WHT-FS

RED

TB42

OR

G/R

ED

-1

GLOW

PLUGS

TS6

TS55TS54TS52

START RELAY

TACH. INPUT

START INPUT


GROUND

BATTERY +

KEY SWITCH POWER

(NOT USED)

IGNITION ON

(NOT USED)

ENGINE FAULT

CR14

86

85

87

30

BL

K/R

ED

85

86

CR13

8587

30 86

BR

N

GRN/BLK

WHT

WHT8

9

7

WHT

10

HIB

LK

/WH

T

BLK/RED

TB33

ENGINE

START

LO

RPM

SELECT

BLK

ORG/BLK

BLK

RED

1

2

3

5

6

4

FUNCTION

ENABLE

TB35

BL

K/R

ED

-1

RED

WH

T

AP2

AUX

BL

K-1

RED

BLU/WHT #12

WHT/BLK-1

WHT-1

WHT/RED-1

RED/WHT-1

RPM

SELECT

ENGINE

START

TS2

LOHI

TS4

FS-HI

ORG/RED

WHT-FS

ORG/RED-1



NOTES:

REDUNDANT COIL SUPPRESION DIODE FOR PR1 IS INSIDE CONTROLLER BETWEEN J1-9 AND J1-17.

DIODE ADDED AT SERIAL NUMBER Z3404-3819.


+

BLK (24V)

ORG/RED #CR20

BLK

BRN BRN

BL

K#

22

A C

B

21

GR

N/B

LK

1 3

4

U33

6 7

5

L45

A6

12 8

D39

L4

L48

LS18

BL/WH-1

TB134

WH

-2

BL/RD-1

CE & PLATFORM LOAD SENSE OPTION.

ADD D40 ONLY IF UNIT HAS L4 & L48.

ANSI/CSA

D40

- H1

WHT

2

3

2

3

5

6

7

6

5

5

5

5 7

SWITCH SHOWN WITH BOOM ROTATED PAST EITHER NON-STEER WHEEL8



1

2

3

4

5

6

7

8



FUNCTION

MANIFOLD

HARNESS

SE

CO

ND

AR

Y

BO

OM

DO

WN

(GND)

(GND)

BRN

TU

RN

TA

BL

E

RO

TA

TE

RIG

HT

DE

SC

EN

T

AL

AR

M

(OP

TIO

N)

TU

RN

TA

BL

E

RO

TA

TE

LE

FT

PR

IMA

RY

BO

OM

DO

WN

PR

IMA

RY

BO

OM

UP

SE

CO

ND

AR

Y

BO

OM

UP

PR

IMA

RY

BO

OM

RE

TR

AC

T

PR

IMA

RY

BO

OM

EX

TE

ND

PL

AT

FO

RM

LE

VE

LD

OW

N

PL

AT

FO

RM

LE

VE

LU

P

PL

AT

FO

RM

LE

VE

LC

UT

OU

T

(CE

VE

RS

ION

)

PR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

CO

IL

PR

2L

IFT

PU

MP

CO

NTA

CT

OR

CO

IL

PR

OP

OR

TIO

NA

L

FL

OW

CO

NT

RO

L

CR

20

LIF

TP

UM

P

CO

NTA

CT

OR

RE

LA

Y

ST

EE

RR

IGH

T

ST

EE

RL

EF

T

A2

TR

AV

EL

AL

AR

M

BR

AK

ER

EL

EA

SE

N.O

.V

ALV

E

BR

AK

E

PR

ES

SU

RE

SW

ITC

H

BR

AK

ER

EL

EA

SE

N.C

.V

A;V

E

TB52

FWD

AUX

TB27

15 3

OR

G/R

ED

4

WH

TPLATFORM

LEVEL

BL

U/B

LK

#11

WH

T/B

LK

#5

WH

T#

4

A3

+

RED DN

TS60

TB11

L

TS62

R

TURNTABLE

ROTATE

TB5

TB4

BL

K/W

HT

#8

RE

D/B

LK

#2

BL

U#

10

RE

D#

1

BL

K#

7

UP

TB1

DN

TS61

TB2

PRIMARY

BOOM

UP

SECONDARY

BOOM

TB10

EXT

PRIMARY

BOOM

TB7TB8

RET

TS63

WH

T-3

RED/WHT-1

WHT/RED-1

RED

BLU/WHT #12

WH

T/B

LK

-3

BL

U-3

BL

U/B

LK

-3

TURNTABLE

ROTATE

RL

TS12

WHT-1

ORG/RED

WHT/BLK-1

DN

TS10

SECONDARY

BOOM

UP

CR196

4

BL

K/W

HT

-3

RE

D-3

RE

D/B

LK

-3

OR

G-3

BL

K-3

OR

G/B

LK

-3

RET

TS13

UP

PRIMARY

BOOM

5

3

CR19

TS11

DN UPDN

TS9

EXT

PRIMARY

BOOM

WHT/RED #6

14

CR10

21

OR

G#

14

OR

G/B

LK

#1

5

5 6

ORG-6

13

RE

D-6

LS2

7

8

TS57

TB17

UP

PLATFORM

LEVEL

DN

TS59

TB14

TB15

DN

RED

L R

TB18

PLATFORM

ROTATE

TB44

TS58

RE

D#

27

CR20

87A

TB6

87

30

RE

D

87

30

OR

G/R

ED

(48

V)

WH

T/R

ED

#6

86

85

CR3

86

85

GR

N/W

HT

TB19

JIB

BOOM

UP

TB43

GR

N/W

HT

-3G

RN

/WH

T

WH

T/R

ED

-3

ONR

ED

GRN/WHT #19

BRN

CR19

ROTARY

OEM

FLOW

CONTROL

BRN-JIB

GR

N/B

LK

-3

BLU-JIB

ORG-JIB

MANIFOLD

GROUND

JIB

GR

N-3

BP1

GR

N-1

BLK-JIB

WHT-JIB

GR

N/B

LK

-1

R

PLATFORM

ROTATE

L

TS7

DN UP

TS8

JIB

BOOM

7

8

BRN

RED

GRN

BLK/RED

RED

F

E

RE

D-1

TS51

BCI

+

4 3 2 1

O/R

OR

G

8 7 6 5

BLK

O/B


L.V.I.

DISCHARGERESET

5

4

3

2

TS1

AUX.

PUMP

WHT-FS

ORG/RED-1

LVI/BCI OPTION

BCI

RED

DP1

WH

T

6

BL

U/R

ED

-3

PLATFORM

CONTROL BOX

GROUND

OR

G/R

ED

RE

D/W

HT

#4

8

BL

U/B

LK

#3

7

BL

U#

36

+

A2

RE

D/W

HT

TB36

TB37

CR5

87

30

RE

D/W

HT

PS

1

RED/WHT

TB48

DRIVE

ENABLE

LIMIT

SWITCH22

BR

N-5

13

TB16

RE

D-5

TB13

BR

N-2

OR

G/R

ED

-3

BL

K-5

2114 LS3

WH

T-5

BL

U-1

BL

U/B

LK

-1

LIFT

L

DRIVE

7

8

9

10

REV

R

ORG/RED

STEERTS15 DRIVE

ENABLE

BL

U/W

HT

-3

TB12

L1

DRIVE

ENABLE

LED

JP1

(REMOVE FOR

CE VERSION)

+

BLK (24V)

ON

8

CR

3

AU

XIL

IAR

YP

UM

P

CO

NTA

CT

OR

RE

LA

Y

Section 6 • SchematicsJanuary 2008



Ground Control Box Wiring Diagram(before serial number 1468)


Ground Control Box Wiring Diagram(before serial number 1468)

1

2

3

4

5

6

7

8



5

CABLE

CHASSIS HARNESS

ENGINE/MANIFOLD/

3

CABLE

2

CABLE

1

7

CABLE

CABLE

6

CABLE

CABLE

8

LS4

LS1

LS2

LS3

CABLE

9

(OPT.)

OPTION NUMBERS

3 - DESCENT ALARM

1 - PLATFORM LEVEL CUTOUT

2 - FLASHING BEACON

HM

NC

NC

NO NO

WHT-23A

BLK-22A

RED-27A

BLK/WHT-34A

GRN-17A

GRN/BLK-18A

BLK/WHT-8A

BLK-7A

RED-1A

RED/BLK-2A

BLU-10A

BLU/BLK-11A

WHT-4A

WHT/BLK-5A

RED-CH (16 GA)

GRN-43A

GRN/BLK-44A

ORG-14A

ORG/BLK-15A

BRN-52A

BLK/RED-35A

BLK-33A

P1KS1

TS51

TS63

TS61

TS60

TS62

TS57

TS59

TS58

CB1

TS52TS56

CB2

CB3

RED/WHT-48A

TS54

RED-EH (12 GA)

BRN-CH

1 2

3

RED-CR11 (12 GA)

BRN

RED

RED

RED

RED

J1

WHT/BLK-21A

GRN/WHT-19A

SWITCH PANEL

WHT/RED-6A

TS55

A2

L3

ORG/RED-42A

BLK-CH

RED/WHT

5

24V

OR

G/R

ED

RED/BLK-CH

ORG/BLK-41A

(TOP VIEW)

RED-ISM-6

BOOM EXTEND/RETRACT SWITCH

CIRCUIT BREAKER, ENGINE, 10A

CIRCUIT BREAKER, CONTROLS, 10A

PRIMARY BOOM UP/DOWN SWITCH

PLATFORM ROTATE SWITCH

TURNTABLE ROTATE SWITCH

BRAKE RELEASE JACK

CKT. BRKR., CONTROLS RETURN, 10A

PLATFORM LEVEL SWITCH

AUXILIARY SWITCH

KEY SWITCH

ENGINE RPM SWITCH

EMERGENCY STOP BUTTON

ENGINE START SWITCH

ENGINE GLOW PLUG SWITCH

SECONDARY BOOM UP/DOWN SWITCH

JIB UP/DOWN SWITCH

ENGINE HOURMETER

FUNCTION ENABLE SWITCH

KS1

TS51

TS52

TS54

TS57

TS55

P1

DESCRIPTIONLABEL

TS61

TS63

TS62

CB1

CB2

CB3

J1

TS59

TS56

TS60

TS58

HM

CHASSIS HARNESS

ENGINE HARNESS

MANIFOLD HARNESS

SWITCH PANEL

12/24V IGNITION START MODULE

CONTROLLER STATUS LED

BRK. REL./TRAVEL ALARM

DESCRIPTIONLABEL

L3

CH

EH

MH

SP

ISM

CONTROL RELAY - SECONDARY 48V POWER

CONTROL RELAY - PRIMARY 48V POWER

CONTROL RELAY - AUXILIARY PUMP

CONTROL RELAY - HORN

CONTROL RELAY - BRAKE RELEASE

CONTROL RELAY - PLATFORM LEVEL CUTOUT

CONTROL RELAY - ENGINE START

CONTROL RELAY - ENGINE RUN

CONTROL RELAY - RPM CUTOUT

CONTROL RELAY - HI RPM

CONTROL RELAY - GLOW PLUG

CR1

CR2

CR3

CR4

CR5

CR10

CR11

CR12

CR13

CR14

CR15

A2

ORG-14B

RED-6

3

4

ORG/BLK-MH

ORG-MH2

1

5

6

3

42

CR10

1

8

6

75

7

8BRN-52D

ORG/BLK-15B

RED-SP1RED-3 PRIMARY BOOM UPRED-MH

D C B A

ORG/RED-1

ORG/BLK-1

BLU/BLK-1

BLU-1

BLK/RED-1

BLK/WHT-1

BLK-1

WHT/BLK-1

WHT-1

RED/WHT-1

RED-1

WHT-2

BLK-2

RED/BLK-1

GRN/WHT-3

GRN/BLK-3

ORG/RED-3

ORG-3

ORG/BLK-3

GRN-3

BLU-3

BLU/BLK-3

BLU/WHT-3

BLK-3

BLK/WHT-3

BLK/RED-3

BLU/RED-3

WHT-3

WHT/BLK-3

RED/BLK-3

WHT/RED-3 WHT/RED-MH

WHT/BLK-MH

RED/BLK-MH

WHT-MH

BLK/WHT-MH

BLK/RED-CR4

BLK-MH

ORG-MH *

BLU/WHT-CH

WHT-5

BLK-CR4

WHT/BLK-CH

RED/WHT-CH

RED/BLK-MH

BLU/BLK-CH

BLU-CH

BLK-ISM-3

BLK-8

FOOTSWITCH

HORN

BOOM FUNCTION F.C.

BOOM EXTEND

SEC. BOOM DOWN

SEC. BOOM UP

LIFT PUMP

BOOM RETRACT

PLAT. LEVEL UP

PLAT. LEVEL DOWN

PLAT. ROTATE RIGHT

PLAT. ROTATE LEFT

DRIVE ENABLE LIGHT

PRIMARY BOOM DOWN

TURN. ROTATE RIGHT

TURN. ROTATE LEFT

BLU/BLK-SP11

6

2

5

4

3

10

7

9

8

WHT/RED-SP

WHT-SP

RED/BLK-SP

RED/WHT-CR2

WHT/BLK-SP

BLU-SP

BLK-SP

BLK/WHT-SP

16

15

14

12

13

19

19

18

17

ORG-SP

ORG/BLK-SP

BLK-5

GRN/WHT-CH

GRN-SP

GRN/BLK-SP

DRIVE ENABLE OUTPUT

OFF-LIMIT SPEED

STEER RIGHT

START

HIGH RPM

2-WIRE POT.

FORWARD

REVERSE

AUXILIARY PUMP

KEYSWITCH POWER

+24V TO PLATFORM

TILT ALARM

GLOW PLUG

STEER LEFT

23

22

29

30

31

27

28

RED-SP

BLK-SP

WHT-SP

BLK/RED-CR13

37

36

33

34

35

42

40

41

BLK-SP

BLK/RED-SP

GRN-1

JIB DOWN

JIB UP

44

43

GRN/BLK-1 GRN/BLK-SP

GRN-SP

WHT-8 50WHT-6

ORG-CH

**

BLK/WHT-SPBLK/WHT-CR15

BLU/BLK-MH

BLU-MH

48V RELAY COIL PWR.RED/WHT-CR1

DRIVE ENABLE RELAY

LIFT PUMPGRN/WHT-SP

GRN/WHT-CR3 TB36/TB37

RED-CR3

WHT-CH

BLU/BLK-19B

BLU-19B

ORG/BLK-SP

SWITCHED 48VORG/RED-CH ORG/RED-SP

RED/WHT-CH

BRN-5

BRN-2

BLK-6

48

49

52

52

RED/WHT-SP

BRN-GND. STUD

BRN-SP

BRN [OPT. 2/3] 52 BRN-CR1

BLK-7

BRN-MH

BRN [OPTION 1]

RED-5

ORG/BLK-MH *

LS1-LS2 JUNCTION

BRAKE RELEASE

GROUND

GROUND

GROUND

LS2-LS4 JUNCTION

RED/WHT-3

WHT/BLK-SP21WHT-CR13 HOURMETER ENABLE

WHT/RED-CH32WHT/RED-1 JOYSTICK POT. LOW

ORG/RED-CR1

WHT-7

[ OPTION 3]

OPTION 3][

OPTION 3][

BLU/RED-1 39 BLU/RED-CH CONTR. FAULT LED

RED/WHT-MH[OPTION 2]

BLK/RED-EH (14GA)

WHT-CH

BLK-ISM-1

RED-SP (12GA)

BLK-22B

BLK/RED-9D

BLK-EH (14 GA)

BLK/RED-MH (14 GA)

4

WHT-EH (14GA) 11 12 13

BLK/RED-35D

BLK/WHT-34D

BLK/WHT-EH (14 GA)

15

14

BRN-ISM-5

23

24V

24V 24V 24V 24V

24V 24V 24V

WHT (14GA)

GRN/WHT-CH

RED-27D

RED-CH

GRN/WHT-19C RED/WHT-3D

ORG/RED-CR1

ORG/RED-CH

BLK/RED

CONTROL BOX

GROUND STUD

WHT-21C

BRN-EH BRN-52A

23

WHT/BLK-ISM-7

KEYSWITCH POWER

BRN-CR14

RED-SP

GRN/BLK-CH

WHT-EH

BLK-33B

BLK-CR11

ORG/BLK-EH

MODULE

IGNITION/START

1 START RELAY

2 TACH. INPUT

(NOT USED)4

3 START INPUT

5 GROUND

KEYSWITCH PWR.7

9

10

8

ENGINE FAULT

(NOT USED)

IGN./FUEL ON

6 BATTERY +

WHT/BLK-23D

12/24 VOLT

4 6 82 4 6

2

1 3 5

1 3 5

8

7

7

CR1

RED/WHT-3A

BRN-52A

ORG/RED-CR2

ORG/RED-42D

PLATFORM LEVEL CUTOUT (CE VERSION ONLY)

ORG/BLK-SPORG/BLK-3

ORG-6

ORG-3

ORG/BLK-CR10

14

15

ORG-CR10 ORG-SP

PLAT. LEVEL DN.

PLAT. LEVEL. UP

[ SEE OPTIONAL WIRING]*

ES34BEA


Ground Control Box Wiring Diagram(from serial number 1468 to 3214)

1

2

3

4

5

6

7

8



WHT/RED-6A

HM

NC

NC

NO NO

CABLE

3

ENGINE/MANIFOLD/

CHASSIS HARNESS

CABLE

2

CABLE

1

CABLE

5

CABLE

6

CABLE

7

P1

KS1

KS1

TS51

TS52

TS57

TS54

P1

LABEL

TS61

TS63

TS62

CB1

CB2

HM

TS59

BOOM EXTEND/RETRACT TOGGLE SWITCH



PRIMARY BOOM UP/DOWN TOGGLE SWITCH

PLATFORM ROTATE TOGGLE SWITCH

TURNTABLE ROTATE TOGGLE SWITCH

HOUR METER

PLATFORM LEVEL TOGGLE SWITCH

DESCRIPTION

AUXILIARY TOGGLE SWITCH

KEY SWITCH

ENGINE RPM TOGGLE SWITCH


ENGINE START TOGGLE SWITCH

TS56 ENGINE GLOW PLUG TOGGLE SWITCH

TS60 SECONDARY BOOM UP/DOWN TOGGLE SWITCH

TS58 JIB UP/DOWN TOGGLE SWITCH

CABLE

8

ENGINE HARNESSEH

MANIFOLD HARNESSMH

CABLE

9(OPTION)

LS1

LS4

LS2

LS3

CONTROL RELAY

SP

CR_

CH CHASSIS HARNESS

SWITCH PANEL

TRAVEL ALARM (OPTION)A2

IGNITION/START MODULEISM

+

ORG/BLK-15A

BLK-7A

BLK/WHT-8A

RED-27A

RED-CR11 12GA

BLK-22A

ORG-14A

GRN-17A

GRN/BLK-18A

WHT/BLK-5A

RED/BLK-2A

BLU/BLK-11A

BLU-10A

WHT-4A

BLK/RED-35A

GRN-43A

BLK/WHT-34A

BLK-33A

GRN/BLK-44A

A2

TS51

TS59

TS57

TS62

TS63

TS61

TS60

TS58

TS56 TS52

TS55

CB2 CB1

TS54

CB3RED-EH 12GA

WHT-23B

WHT/BLK-21A

RED

RED-CH 16GA

5

BLK-CH

ORG/RED-42A

ORG/RED-16A

RED/BLK-CH

RED/WHT-48A

3

21

RED-ISM-6

BRN-CH

BRN-52A

RED

RED-1A

GRN/WHT-19A

ORG/RED-CR1

WHT-CR13

ORG/RED-42D

RED-CR3

TB36/TB37

BLK/WHT-CR15

WHT-EH (14GA)

BLK/RED-MH (14 GA)

BLK-EH (14 GA)

BLK/RED-CR13

RED/WHT-CR2

BLK-ISM-3

BLK/RED-CR4

ORG/BLK-EH

GRN/BLK-CH

BLK-ISM-1

WHT-CH

BLK-33B

WHT-23A

WHT-EH

RED-SP

BRN-CR14

BLK-CR11

D

OPTION 3][

OPTION 3][

RED-5

BLK-5

WHT-5

*

*

WHT-7

BLU/BLK-19D

BLU-19D

BLK-8

OPTION 3][

BLK-7

BRN-2

BRN-5

WHT-6

24V24V24V24V

GRN/WHT-19C

GRN/WHT-CH

BLK/RED-9D

BLK-22B

CONTROL BOX GROUND

ORG/RED-CH

RED/WHT-3D

BRN-EH

BRN-MH

BRN-52A

BRN-SP

BLK/WHT-34D

[ DENOTES TEST PORT]

[* SEE OPTIONAL WIRING]

ORG/RED-CR1

BLK/WHT-EH (14 GA)

BLK/RED-35D

BLK/RED-EH (14GA)

ENGINE FAULT10

12

RED-SP (12GA)

4

RED-CH

3

24V

11

2

RED-27D

WHT (14GA)

24V

BLK/RED

24V

13

WHT-21C

RED/BLK-MH

RED-MH

BATTERY +

IGN./FUEL ON

(NOT USED)

KEYSWITCH PWR.

GROUND

START INPUT

(NOT USED)

8

9

7

6

5

3

4

RED/WHT-3

TACH. INPUT

START RELAY

RED/BLK-3

C

2

1

RED-3 1

3

2

RED/WHT-CR1

RED/BLK-SP

RED-SP

12/24 VOLT

IGNITION/START

MODULE

B A

15

24V

BRN-ISM-5

14

48V RELAY COIL PWR.

PRIMARY BOOM DOWN

PRIMARY BOOM UP

GRN/WHT-CR3 GRN/WHT-MH19

ORG/BLK-MH *

BLU-MH

BLU/BLK-MH

ORG-MH *

BLK-MH

BLK/WHT-MH

WHT-MH

WHT/BLK-MH

WHT/RED-MH

BLU/WHT-3

WHT/RED-3

WHT/BLK-3

BLK/RED-3

BLK/WHT-3

BLU/BLK-3

WHT-3

BLK-3

BLU-3

4

5

7

6

8

9

10

11

BLU/RED-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

GRN/WHT-3

ORG-3

GRN-3

16

13

12

14

15

18

17

19

BLU/WHT-CH

BLK/WHT-SP

BLK-SP

BLU-SP

WHT/BLK-SP

WHT-SP

WHT/RED-SP

BLU/BLK-SP

ORG/RED-CR5

GRN/WHT-SP

GRN/BLK-SP

GRN-SP

ORG/BLK-SP

ORG-SP

WHT-SP

BLK-CR4

30WHT-1

[OPTION 2]

RED/BLK-1

RED/WHT-1

BLK-2

WHT-2

RED-1

23

22

21

23

28

27

29

WHT/RED-1

WHT/BLK-1

BLK/WHT-1

BLK/RED-1

BLU/BLK-1

BLK-1

BLU-1

34

32

31

33

35

36

40

37

WHT-CH

RED/WHT-MH

WHT/BLK-SP

WHT-ISM-7

BLK-SP

RED-SP

RED/BLK-MH

RED/WHT-CH

WHT/RED-CH

BLK/WHT-SP

ORG-CH

BLK/RED-SP

BLK-SP

BLU-MH

BLU/BLK-MH

WHT/BLK-CH

LIFT PUMP

TURNTABLE ROTATE RIGHT

TURNTABLE ROTATE LEFT

SECONDARY BOOM DOWN

BOOM FUNCTION FLOW CNTRL.

PRIMARY BOOM EXTEND

PRIMARY BOOM RETRACT

SECONDARY BOOM UP

HORN

DRIVE ENABLE LIGHT

PLATFORM ROTATE RIGHT

PLATFORM ROTATE LEFT

PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

DRIVE ENABLE

FOOTSWITCH

LIFT PUMP

FORWARD

KEYSWITCH POWER

HOURMETER ENABLE

+24V TO PLATFORM

KEYSWITCH POWER

TILT ALARM

2-WIRE POT.

JOYSTICK POT. LOW

OFF-LIMIT SPEED

GLOW PLUG

REVERSE

START

STEER LEFT

HIGH RPM

STEER RIGHT

RED/WHT-MH

ORG/RED-CH

BRN [OPTION 2/3]

BRN [OPTION 1]

GRN/BLK-1

ORG/RED-1

GRN-1

BLK-6

WHT-8

43

42

48

44

49

50

52

52

21

124

3

53

64

87

BRN-GND. STUD

BRN-CR1

RED/WHT-SP

ORG/RED-SP

GRN-SP

GRN/BLK-SP

ORG/RED-CR2

RED/WHT-3A

786

5

BRN-52A

CR1

LS2-LS4 JUNCTION

BRAKE RELEASE

LS1-LS2 JUNCTION

SWITCHED 48V

JIB DOWN

JIB UP

GROUND

GROUND


CR1 - SECONDARY 48V POWER

CR2 - PRIMARY 48V POWER

CR3 - AUXILIARY PUMP

CR4 - HORN

CR5 - BRAKE RELEASE

CR10 - PLATFORM LEVEL CUTOUT

(CE VERSION ONLY)

CR11 - ENGINE START

CR12 - ENGINE RUN

CR13 - PRM CUTOUT

CR14 - HIGH RPM

CR15 - GLOW PLUGS

CONTROL RELAY I.D.

ORG-3

ORG/BLK-3

ORG/BLK-MH

ORG-MH

ORG-6

SPARE WIRE LIST

GRN/WHT-1

ORG-1

BLU/WHT-1

BLU/RED-1

ORG/BLK-1

PLAT. LEVEL. UP

PLAT. LEVEL DN.ORG/BLK-CR1015

14

2

4

ORG-CR10

2 4 6

1 3 5

8

6

1 3

CR10

7

5

RED-6

ORG/BLK-SP

BRN-52D

ORG-14B

ORG-SP

87

ORG/BLK-15B


2 - FLASHING BEACON

3 - DESCENT ALARM

OPTION NUMBERS

OR

G/R

ED

RED/WHT

(TOP VIEW)

24V

L3

+

D

U

D

U

U

D

U

D

R E

RL

RL

CB3 CIRCUIT BREAKER, CONTROLS RTRN,10A

J1 BRAKE RELEASE JACK

CONTROLLER STATUS LEDL3

TS55 FUNCTION ENABLE TOGGLE SWITCH

AUXILIARY PUMP SELECT

RED

RED

BRN

WHT

J1

ES34BEH

Section 6 • SchematicsJanaury 2008


January 2008Section 6 - Schematics


1

2

3

4

5

6

7

8



WHT/RED-6A

HM

NC

NC

NO NO

ENGINE

HARNESS

MANIFOLD/

CHASSIS HARNESS

CABLE

3

CABLE

5

CABLE

1

CABLE

2

CABLE

9

P1

KS1

KS1

TS51

TS52

TS57

TS54

LABEL

TS61

TS63

TS62

CB1

CB2

HM

TS59







HOUR METER


DESCRIPTION


KEY SWITCH




TS56 ENGINE GLOW PLUG TOGLE SWITCH



CABLE

7

ENGINE HARNESSEH

MANIFOLD HARNESSMH

CABLE

8LS4

(OPTION)

LS1

LS3

CONTROL RELAY

SP

CR_

CH CHASSIS HARNESS

SWITCH PANEL



+

ORG/BLK-15A

BLK-7A

BLK/WHT-8A

RED-27A

RED-CR12 12GA

BLK-22A

ORG-14A

GRN-17A

GRN/BLK-18A

WHT/BLK-5A

RED/BLK-2A

BLU/BLK-11A

BLU-10A

WHT-4A

BLK/RED-35A

GRN-43A

BLK/WHT-34A

BLK-33A

GRN/BLK-44A

A2

TS51

TS59

TS57

TS62

TS63

TS61

TS60

TS58

TS56 TS52

TS55

CB1 CB3

TS54

CB2RED-EH 12GA

WHT-23A

WHT/BLK-21A

RED

RED-CH 16GA

5

BLK-CH

ORG/RED-42A

ORG/RED-16A

RED/BLK-CH

RED/WHT-48A

RED-ISM-6

BRN-CH

BRN-52A

RED

RED-1A

GRN/WHT-19A

ORG/RED-CR1

ORG/RED-42D

BLU-19D

BLU/BLK-19D

RED-CR3

TB36/TB37

BLK/WHT-CR15

WHT-EH (14GA)

BLK/RED-MH

BLK-EH (14 GA)

BLK/RED-CR13

RED/WHT-CR2

BLK-ISM-3

BLK/RED-CR4

ORG/BLK-EH

GRN/BLK-CH

BLK-ISM-1

WHT-CH

BLK-33B

WHT-23D

WHT-EH

RED-SP

BRN-CR14

BLK-CR11

D

OPTION 3][

OPTION 3][

RED-5

BLK-5

WHT-5

*

*

WHT-7

BLK-8

OPTION 3][

BLK-7

BRN-2

BRN-5

WHT-6

24V24V24V24V

GRN/WHT-19D

GRN/WHT-CH

BLK/RED-9D

BLK-22B

CONTROL BOX GROUND

ORG/RED-CH

RED/WHT-3D

BRN-EH

BRN-MH

BRN-52A

BRN-SP

BLK/WHT-34D


ORG/RED-CR1

BLK/WHT-EH (14 GA)

BLK/RED-35D

BLK/RED-EH (14GA)

ENGINE FAULT10

12

RED-SP (12GA)

4

RED-CH

3

24V

11

2

RED-27D

WHT (14GA)

24V

BLK/RED

24V

13

RED/BLK-MH

RED-MH

BATTERY +

IGN./FUEL ON

(NOT USED)

KEYSWITCH PWR.

GROUND

START INPUT

(NOT USED)

8

9

7

6

5

3

4

RED/WHT-3

TACH. INPUT

START RELAY

RED/BLK-3

C

2

1

RED-3 1

3

2

RED/WHT-CR1

RED/BLK-SP

RED-SP

12/24 VOLT

IGNITION/START

MODULE

B A

15

24V

BRN-ISM-5

14

48V RELAY COIL POWER

PRIMARY BOOM DOWN

PRIMARY BOOM UP

GRN/WHT-CR3

GRN/WHT-MH19

ORG/BLK-MH *

BLU-MH

BLU/BLK-MH

ORG-MH *

BLK-MH

BLK/WHT-MH

WHT-MH

WHT/BLK-MH

WHT/RED-MH

BLU/WHT-3

WHT/RED-3

WHT/BLK-3

BLK/RED-3

BLK/WHT-3

BLU/BLK-3

WHT-3

BLK-3

BLU-3

4

5

7

6

8

9

10

11

BLU/RED-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

GRN/WHT-3

ORG-3

GRN-3

16

13

12

14

15

18

17

19

BLU/WHT-CH

BLK/WHT-SP

BLK-SP

BLU-SP

WHT/BLK-SP

WHT-SP

WHT/RED-SP

BLU/BLK-SP

ORG/RED-CR5

GRN/WHT-SP

GRN/BLK-SP

GRN-SP

ORG/BLK-SP

ORG-SP

BLK-CR4

30WHT-1

[OPTION 2]

RED/BLK-1

RED/WHT-1

BLK-2

WHT-2

RED-1

23

22

23

28

27

29

WHT/RED-1

WHT/BLK-1

BLK/WHT-1

BLK/RED-1

BLU/BLK-1

BLK-1

BLU-1

34

32

31

33

35

36

40

37

WHT-CH

RED/WHT-MH

WHT-SP

BLK-SP

RED-SP

RED/BLK-MH

RED/WHT-CH

WHT/RED-CH

BLK/WHT-SP

ORG-CH

BLK/RED-SP

BLK-SP

BLU-MH

BLU/BLK-MH

WHT/BLK-CH

LIFT PUMP



SECONDARY BOOM DOWN

BOOM FUNCTION FLOW CNTRL.

PRIMARY BOOM EXTEND

PRIMARY BOOM RETRACT

SECONDARY BOOM UP

HORN

DRIVE ENABLE LIGHT



PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

DRIVE ENABLE

FOOTSWITCH

LIFT PUMP

FORWARD

KEYSWITCH POWER

+24V TO PLATFORM

KEYSWITCH POWER

TILT ALARM

2-WIRE POT.

JOYSTICK POT. LOW

OFF-LIMIT SPEED

GLOW PLUG

REVERSE

START

STEER LEFT

HIGH RPM

STEER RIGHT

RED/WHT-MH

ORG/RED-CH

BRN [OPTION 2/3]

BRN [OPTION 1]

GRN/BLK-1

ORG/RED-1

GRN-1

BLK-6

WHT-8

43

42

48

44

49

50

52

52

21

124

3

53

64

87

BRN-GND. STUD

BRN-CR1

RED/WHT-SP

ORG/RED-SP

GRN-SP

GRN/BLK-SP

ORG/RED-CR2

RED/WHT-3A

786

5

BRN-52A

CR1

LS2-LS4 JUNCTION

BRAKE RELEASE

LS1-LS2 JUNCTION

SWITCHED 48V

JIB DOWN

JIB UP

GROUND

GROUND




CR4 - HORN

CR5 - BRAKE RELEASE


(CE VERSION ONLY)

CR11 - ENGINE START

CR12 - ENGINE RUN

CR13 - RPM CUTOUT

CR14 - HIGH RPM

CR15 - GLOW PLUG

CONTROL RELAY I.D.

SPARE WIRE LIST

GRN/WHT-1

ORG-1

BLU/WHT-1

BLU/RED-1

ORG/BLK-1


2 - FLASHING BEACON

3 - DESCENT ALARM

OPTION NUMBERS

OR

G/R

ED

RED/WHT

(TOP VIEW)

24V

L3

+

D

U

D

U

U

D

U

D

R E

RL

RL

CB3 CIRCUIT BREAKER, CONTROLS RETURN,10A

J1 BRAKE RELEASE JACK




RED

RED

BRN

WHT

BRN

WHT-ISM-7

BRN-CH

LS2CABLE

6

J1

P1


ORG-3

ORG/BLK-3

ORG/BLK-MH

ORG-MH

ORG-6

PLAT. LEVEL. UP


14

2

4

ORG-CR10

2 4 6

1 3 5

8

6

1 3

CR10

7

5

RED-6

ORG/BLK-SP

BRN-52D

ORG-14B

ORG-SP

87

ORG/BLK-15B

ES34BEL

January 2008 Section 6 - Schematics


1

2

3

4

5

6

7

8



ES34BES

WHT/RED-6A

HM

NC

NC

ENGINE

HARNESS

MANIFOLD/

CHASIS HARNESS

CABLE

3

CABLE

5

CABLE

1

CABLE

2

CABLE

9

P1

KS1

KS1

TS51

TS52

TS57

TS54

P1

LABEL

TS61

TS63

TS62

CB1

CB2

HM

TS59







HOUR METER


DESCRIPTION


KEY SWITCH




TS56 ENGINE GLOW PLUG TOGGLE SWITCH



CABLE

7

ENGINE HARNESSEH

MANIFOLD HARNESSMH

CABLE

8LS4

(OPTION)

LS1

LS3

CONTROL RELAY

SP

CR_

CH CHASSIS HARNESS

SWITCH PANEL



+

ORG/BLK-15A

BLK-7A

BLK/WHT-8A

RED-CR12 12GA

BLK-22A

ORG-14A

GRN-17A

GRN/BLK-18A

WHT/BLK-5A

RED/BLK-2A

BLU/BLK-11A

BLU-10A

WHT-4A

BLK/RED-35A

GRN-43A

BLK/WHT-34A

BLK-33A

GRN/BLK-44A

A2

TS51

TS59

TS57

TS62

TS63

TS61

TS60

TS58

TS56 TS52

TS55

CB1 CB3

TS54

CB2RED-EH 12GA

WHT-23A

WHT/BLK-21A

RED

RED-CH 16GA

5

BLK-CH

ORG/RED-42A

ORG/RED-16A

RED/BLK-CH

RED/WHT-48A

RED-ISM-6

BRN-CH

BRN-52A

RED

RED-1A

GRN/WHT-19A

ORG/RED-CR1

ORG/RED-42D

RED-CR3

TB36/TB37

BLK/WHT-CR15

WHT-EH (14GA)

BLK/RED-MH

BLK-EH (14 GA)

BLK/RED-CR13

RED/WHT-CR2

BLK-ISM-3

BLK/RED-CR4

ORG/BLK-EH

GRN/BLK-CH

BLK-ISM-1

WHT-CH

BLK-33B

WHT-23D

WHT-EH

RED-SP

BRN-CR14

BLK-CR11

D

OPTION 3][

OPTION 3][

RED-5

BLK-5

WHT-5

*

*

WHT-7

BLU/BLK-19D

BLU-19D

BLK-8

OPTION 3][

BLK-7

BRN-2

BRN-5

WHT-6

24V24V24V24V

GRN/WHT-19D

GRN/WHT-CH

BLK/RED-9D

BLK-22B

CONTROL BOX GROUND

ORG/RED-CH

RED/WHT-3D

BRN-EH

BRN-MH

BRN-52A

BRN-SP

BLK/WHT-34D


ORG/RED-CR1

BLK/WHT-EH (14 GA)

BLK/RED-35D

BLK/RED-EH (14GA)

ENGINE FAULT10

12

RED-SP (12GA)

4

RED-CH

3

24V

11

2

RED-27D

WHT (14GA)

24V

BLK/RED

24V

13

RED/BLK-MH

RED-MH

BATTERY +

IGN./FUEL ON

(NOT USED)

KEYSWITCH PWR.

GROUND

START INPUT

(NOT USED)

8

9

7

6

5

3

4

RED/WHT-3

TACH. INPUT

START RELAY

RED/BLK-3

C

2

1

RED-3 1

3

2

RED/WHT-CR1

RED/BLK-SP

RED-SP

12/24 VOLT

IGNITION/START

MODULE

B A

15

24V

BRN-ISM-5

14

48V RELAY COIL POWER

PRIMARY BOOM DOWN

PRIMARY BOOM UP

GRN/WHT-CR3

GRN/WHT-MH19

ORG/BLK-MH *

BLU-MH

BLU/BLK-MH

ORG-MH *

BLK-MH

BLK/WHT-MH

WHT-MH

WHT/BLK-MH

WHT/RED-MH

BLU/WHT-3

WHT/RED-3

WHT/BLK-3

BLK/RED-3

BLK/WHT-3

BLU/BLK-3

WHT-3

BLK-3

BLU-3

4

5

7

6

8

9

10

11

BLU/RED-3

ORG/BLK-3

ORG/RED-3

GRN/BLK-3

GRN/WHT-3

ORG-3

GRN-3

16

13

12

14

15

18

17

19

BLU/WHT-CH

BLK/WHT-SP

BLK-SP

BLU-SP

WHT/BLK-SP

WHT-SP

WHT/RED-SP

BLU/BLK-SP

ORG/RED-CR5

GRN/WHT-SP

GRN/BLK-SP

GRN-SP

ORG/BLK-SP

ORG-SP

BLK-CR4

30WHT-1

RED/BLK-1

RED/WHT-1

BLK-C23-4

WHT-2

RED-1

22

23

28

27

29

WHT/RED-1

WHT/BLK-1

BLK/WHT-1

BLK/RED-1

BLU/BLK-1

BLK-1

BLU-1

34

32

31

33

35

36

40

37

WHT-CH

WHT-SP

BLK-SP

RED-SP

RED/BLK-MH

RED/WHT-CH

WHT/RED-CH

BLK/WHT-SP

ORG-CH

BLK/RED-SP

BLK-SP

BLU-MH

BLU/BLK-MH

WHT/BLK-CH

LIFT PUMP



SECONDARY BOOM DOWN

BOOM FUNCTION F.C.

BOOM EXTEND

BOOM RETRACT

SECONDARY BOOM UP

HORN

DRIVE ENABLE LIGHT



PLATFORM LEVEL DOWN

PLATFORM LEVEL UP

DRIVE ENABLE

FOOTSWITCH

LIFT PUMP

FORWARD

+24V TO PLATFORM

KEYSWITCH POWER

TILT ALARM

2-WIRE POT.

JOYSTICK POT. LOW

OFF-LIMIT SPEED

GLOW PLUG

REVERSE

START

STEER LEFT

HIGH RPM

STEER RIGHT

RED/WHT-MH

ORG/RED-CH

BRN [OPTION 2/3]

BRN [OPTION 1]

GRN/BLK-1

ORG/RED-1

GRN-1

BLK-6

WHT-8

43

42

48

44

49

50

52

52

21

124

3

53

64

87

BRN-GND. STUD

BRN-CR1

RED/WHT-SP

ORG/RED-SP

GRN-SP

GRN/BLK-SP

ORG/RED-CR2

RED/WHT-3A

786

5

BRN-52A

CR1

LS2-LS4 JUNCTION

BRAKE RELEASE

LS1-LS2 JUNCTION

SWITCHED 48V

JIB DOWN

JIB UP

GROUND

GROUND





CR4 - HORN

CR5 - BRAKE RELEASE


(CE VERSION ONLY)

CR11 - ENGINE START

CR12 - ENGINE RUN

CR13 - RPM CUTOUT

CR14 - HIGH RPM

CR15 - GLOW PLUGS

CONTROL RELAY I.D.

ORG-3

ORG/BLK-3

ORG/BLK-MH

ORG-MH

ORG-6

SPARE WIRE LIST

ORG-1

ORG/BLK-1

PLAT. LEVEL. UP


14

2

4

ORG-CR10

2 4 6

1 3 5

8

6

1 3

CR10

7 5

RED-6

ORG/BLK-SP

BRN-52D

ORG-14B

ORG-SP

87

ORG/BLK-15B


2 - FLASHING BEACON

3 - DESCENT ALARM

OPTION NUMBERS

OR

G/R

ED

RED/WHT

(TOP VIEW)

24V

L3

+

D

U

D

U

U

D

U

D

R E

RL

RL

CB3 CIRCUIT BREAKER, CONTROLS RTRN,10A




RED

RED-C23-7

BRN

WHT

BRN

WHT-ISM-7

BRN-CH

LS2CABLE

6

C23

1

U33

BR

N/G

ND

BL

K-2

BL

K2

2C

BL

U/W

HT

-1

RE

DT

S5

2

GR

N/B

LK

H6

RE

DT

S5

1

RE

DA

6

3 4 5 6 7 8 12

RED-134A

RED-27A

RED-C23-6

GRN/BLK-H6

L45

+

PLATFORM OVERLOAD LEDL45

A6 PLATFORM OVERLOAD ALARM

A6

GR/BK C23-8

GR/BK L45

BL/RD-1

RD C23-1

RD 134B

KEYSWITCH POWER

KEYSWITCH POWER

RD-KS1134

134A

GRN/WHT-1

[OPTION 2]

RED/WHT-MH RD-A6


Platform Control Box Wiring Diagram(before serial number 1468)


Platform Control Box Wiring Diagram(before serial number 1468)

1

2

3

4

5

6

7

8



CABLE

#3

#2

CABLE

#1

JIB

F.S.

110

A1

NO

NC

NC

WH

T/R

ED

-3

GR

N/W

HT

-3

WH

T-2

BL

K-F

.S.

BL

K-2

BL

K/R

ED

-3

BL

U/B

LK

-1

WH

T-1

WH

T/B

LK

-1

RE

D-1

BL

K-3

OR

G/B

LK

-3

OR

G-3

RE

D/B

LK

-3

RE

D-3

GR

N/B

LK

-3

GR

N-3

BL

U/R

ED

-1

BL

K/W

HT

-3

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

GR

N/B

LK

-1

GR

N-1

OR

G/B

LK

-1

BL

K/R

ED

-1

BL

K/W

HT

-1

BL

K-1

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

21 43 5

P3

TS1 TS15

TS12

TS10

TS11TS13

TS7 TS9

TS8

DP1

TS4

TS6

TS2

P2

L1

RE

D-F

.S.

REMOVE JUMPER JP1 FOR CE VERSION.

WH

T/R

ED

-1

BL

U-1

L2

GRN

RED

BLK/RED

BL

U/W

HT

-3

BL

U/R

ED

-3

WH

T-F

.S.

BRN6 88

5

7

7

4

35 1

3

46 2

1

2

ORG/BLK

OR

G/R

ED

-1

RE

D/B

LK

-1

OR

G/R

ED

-3

TS15

DP1

BP1

TS1

TS2

TS5

TS6

P2

LABEL

TS10

TS12

TS11

TS13

TS9

TS7

TS8

TS4

TURNTABLE ROTATE SWITCH

PLATFORM LEVEL SWITCH

EXTEND/RETRACT SWITCH

SECONDARY BOOM UP/DOWN SWITCH

PRIMARY BOOM UP/DOWN SWITCH

JIB UP/DOWN SWITCH

DRIVE ENABLE SWITCH

PLATFORM ROTATE SWITCH

RPM SWITCH

START SWITCH

DESCRIPTION

BOOM FUNCTION SPEED CONTROLLER

DRIVE CONTROLLER

GLOW PLUG


AUXILIARY SWITCH

P3 HORN BUTTON

DRIVE ENABLE LIGHTL1

L2 CONTROLLER FAULT LIGHT

A1 TILT ALARM

CR6

BCI

DRIVE ENABLE RELAY

BATTERY CHARGE INDICATOR

RE

D/W

HT

-3

ORG/BLK

BR

N

BCI

RED/BLK

REMOVE THIS WIRE WHEN

LOAD SENSE OPTION IS REQUIRED.

RE

D

RED

RED

BP1

CR6

A B C R L

RE

D/W

HT

-1

RED/BLK

BRN-JIB

ES34BEC

RED

RED


Platform Control Box Wiring Diagram(from serial number 1468 to 1786)

1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.11

0

A1

NO

NC

NC

WH

T/R

ED

-3

GR

N/W

HT

-3

WH

T-2

BL

K-F

.S.

BL

K-2

BL

K/R

ED

-3

BL

U/B

LK

-1

WH

T-1

WH

T/B

LK

-1

RE

D-1

BL

K-3

OR

G/B

LK

-3

OR

G-3

RE

D/B

LK

-3

RE

D-3

GR

N/B

LK

-3

GR

N-3

BL

K/W

HT

-3

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

GR

N/B

LK

-1

GR

N-1

OR

G/B

LK

-1

GR

N/W

HT

-1

OR

G-1

BL

U/W

HT

-1

BL

U/R

ED

-1

BL

K/R

ED

-1

BL

K/W

HT

-1

BL

K-1

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

SP

AR

EW

IRE

S

21 43 5

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

TS

7

TS

9

TS

8

DP

1

TS

4

TS

6T

S2

P2

L1

TS

15

DP

1

BP

1

TS

1

TS

2

TS

6

P2

LA

BE

L

TS

10

TS

12

TS

11

TS

13

TS

9

TS

7

TS

8

TS

4

TU

RN

TA

BL

ER

OTA

TE

SW

ITC

H

PL

AT

FO

RM

LE

VE

LS

WIT

CH

EX

TE

ND

/RE

TR

AC

TS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P/D

OW

NS

WIT

CH

PR

IMA

RY

BO

OM

UP

/DO

WN

SW

ITC

H

JIB

UP

/DO

WN

SW

ITC

H

DR

IVE

EN

AB

LE

SW

ITC

H

PL

AT

FO

RM

RO

TA

TE

SW

ITC

H

RP

MS

WIT

CH

STA

RT

SW

ITC

H

DE

SC

RIP

TIO

N

BO

OM

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LL

ER

DR

IVE

CO

NT

RO

LL

ER

GL

OW

PL

UG

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

AU

XIL

IAR

YS

WIT

CH

P3

HO

RN

BU

TT

ON

DR

IVE

EN

AB

LE

LIG

HT

L1

RE

D-F

.S.

NOTES:


WH

T/R

ED

-1

BL

U-1

GR

N

RE

D

BL

K/R

ED

BL

U/W

HT

-3

BL

U/R

ED

-3

WH

T-F

.S.

BR

N

6

8

8

5

7

7

4

35 1

3

46 2

12

OR

G/B

LK

OR

G/R

ED

-1

RE

D/B

LK

-1

OR

G/R

ED

-3

A1

TIL

TA

LA

RM

CR

6

BC

I

DR

IVE

EN

AB

LE

RE

LA

Y

BA

TT

ER

YC

HA

RG

EIN

DIC

AT

OR

RE

D/W

HT

-3

OR

G/B

LK

BR

N

-

RED/BLK

REMOVE THIS WIRE WHEN LOAD SENSE OPTION IS REQUIRED.

RE

D

REDB

P1

CR

6

A B C R L

RE

D/W

HT

-1

RED/BLK

BR

N-J

IB

BR

N-2

RE

D

RE

D

RED

ES34BEC

+

BC

I

1

1

2

2



1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.11

0

A1

NO

NC

NC

WH

T/R

ED

-3

GR

N/W

HT

-3

WH

T-2

BL

K-F

S

BL

K-2

BL

K/R

ED

-3

BL

U-1

WH

T-1

WH

T/B

LK

-1

RE

D-1

BL

K-3

OR

G/B

LK

-3

OR

G-3

RE

D/B

LK

-3

RE

D-3

GR

N/B

LK

-3

GR

N-3

BL

K/W

HT

-3

WH

T/B

LK

-3

WH

T-3

BL

U/B

LK

-3

BL

U-3

GR

N/B

LK

-1

GR

N-1

OR

G/R

ED

-3

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

21 43 5

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

TS

7

TS

9

TS

8

DP

1

P2

L1

NOTES:


WH

T/R

ED

-1

BL

U/B

LK

-1

GR

N

RE

D

BL

K/R

ED

BL

U/W

HT

-3

BL

U/R

ED

-3

WH

T-F

S

BR

N-J

IB

OR

G/R

ED

-1

RE

D/B

LK

-1

OR

G/R

ED

BC

I


RE

D

BP

1

6 7 8 9 10

RE

D/W

HT

-1

WHT

BR

N-2

RE

D

WH

T

RED

BRN

BRN

WHT

UU

UU

DD

DD

LR

LR

E R

L R

SP

AR

EW

IRE

S

BL

U/W

HT

-1

BL

U/R

ED

-1

OR

G-1

OR

G/B

LK

-1

GR

N/W

HT

-1

JIB

UP

/DO

WN

SW

ITC

H

BA

TT

ER

YC

HA

RG

EIN

DIC

AT

OR

DR

IVE

EN

AB

LE

LIG

HT

EX

TE

ND

/RE

TR

AC

TS

WIT

CH

TU

RN

TA

BL

ER

OTA

TE

SW

ITC

H

TIL

TA

LA

RM

DR

IVE

EN

AB

LE

SW

ITC

H

PR

IMA

RY

BO

OM

UP

/DO

WN

SW

ITC

H

SE

CO

ND

AR

YB

OO

MU

P/D

OW

NS

WIT

CH

PL

AT

FO

RM

LE

VE

LS

WIT

CH

BC

I

L1

A1

TS

15

TS

13

TS

12

TS

10

TS

11

TS

8

TS

9

DR

IVE

CO

NT

RO

LL

ER

RP

MS

WIT

CH

PL

AT

FO

RM

RO

TA

TE

SW

ITC

H

GL

OW

PL

UG

BO

OM

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LL

ER

AU

XIL

IAR

YS

WIT

CH

STA

RT

SW

ITC

H

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

HO

RN

BU

TT

ON

DE

SC

RIP

TIO

N

DP

1

TS

4

TS

7

TS

6

TS

1

TS

2

BP

1

P2

P3

LA

BE

L

TS

6T

S2

WHT

RED

TS

4

BL

K/R

ED

-1

RE

D/W

HT

-3

RE

D-F

S

BL

K/W

HT

-1

BL

K-1

1

2

1

2ES34BEG



1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.

A1

NO

NC

NC

NO

NC

NC

WH

T-2

BL

K-F

S

BL

K-2

BL

K/R

ED

-3

RE

D-1

BL

K-3

BL

K/W

HT

-3

GR

N/W

HT

-1

OR

G-1

BL

U/W

HT

-1

BL

U/R

ED

-1

OR

G/B

LK

-1

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

SP

AR

EW

IRE

S

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

P2

L1

DP

1

BP

1

TS

1

P2

LA

BE

L

TS

10

TS

12

TS

11

TS

13

TS

9

TS

6

TS

8

TU

RN

TA

BL

ER

OTA

TE

SW

ITC

H

PL

AT

FO

RM

LE

VE

LS

WIT

CH

EX

TE

ND

/RE

TR

AC

TS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P/D

OW

NS

WIT

CH

PR

IMA

RY

BO

OM

UP

/DO

WN

SW

ITC

H

JIB

UP

/DO

WN

SW

ITC

H

GL

OW

PL

UG

SW

ITC

H

DE

SC

RIP

TIO

N

BO

OM

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LL

ER

DR

IVE

CO

NT

RO

LL

ER

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

AU

XIL

IAR

YS

WIT

CH

P3

HO

RN

BU

TT

ON

DR

IVE

EN

AB

LE

LIG

HT

L1

NOTES:


BL

U/R

ED

-3

BR

N-J

IB

A1

TIL

TA

LA

RM

OR

G/R

ED


RE

D

WHT

BR

N-2

RE

D

WHT

U

UU D

DD

LR

E R

RL

TS

7

D U

TS

9

TS

15

DR

IVE

EN

AB

LE

SW

ITC

H

OR

G/B

LK

-3

RE

D-3

RE

D/B

LK

-3

GR

N/B

LK

-1

GR

N-1

GR

N-3

GR

N/B

LK

-3

GR

N/W

HT

-3

BL

U-3

BL

U/B

LK

-3

WH

T-3

WH

T/B

LK

-3

OR

G/R

ED

-3

BL

U/W

HT

-3

RE

D/B

LK

-1

TS

4TS

6T

S2

RE

D-F

S

RE

D/W

HT

-3

BL

K/W

HT

-1

BL

K-1

OR

G-3

BR

N

TS

8

TS

4H

IGH

/LO

WR

PM

SW

ITC

H

STA

RT

EN

GIN

ES

WIT

CH

TS

2

WHT

RED

TS

7P

LA

TF

OR

MR

OTA

TE

SW

ITC

H

L R

RE

D/W

HT

-1

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

WH

T-F

S

BL

U-1

BL

U/B

LK

-1

DP

1

RED

102

1

3 4 765 8 9

BL

K/R

ED

RE

D

GR

N

BP

1

WH

T

BC

I

BA

TT

ER

YC

HA

RG

EIN

DIC

AT

OR

BC

I

WH

T/R

ED

-3

BL

K/R

ED

-1

OR

G/R

ED

-1

1

2

1

2

ES34BEL



1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.

A1

NO

NC

NC

WH

T-2

BL

K-F

S

BL

K-2

BL

K/R

ED

-3

RE

D-1

BL

K-3

BL

K/W

HT

-3

OR

G-1

OR

G/B

LK

-1

BL

K-J

IB

WH

T-J

IB

BL

UE

-JIB

OR

G-J

IB

SP

AR

EW

IRE

S

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

P2

L1

DP

1

BP

1

TS

1

P2

LA

BE

L

TS

10

TS

12

TS

11

TS

13

TS

9

TS

6

TS

8

TU

RN

TA

BL

ER

OTA

TE

SW

ITC

H

PL

AT

FO

RM

LE

VE

LS

WIT

CH

EX

TE

ND

/RE

TR

AC

TS

WIT

CH

SE

CO

ND

AR

YB

OO

MU

P/D

OW

NS

WIT

CH

PR

IMA

RY

BO

OM

UP

/DO

WN

SW

ITC

H

JIB

UP

/DO

WN

SW

ITC

H

GL

OW

PL

UG

SW

ITC

H

DE

SC

RIP

TIO

N

BO

OM

FU

NC

TIO

NS

PE

ED

CO

NT

RO

LL

ER

DR

IVE

CO

NT

RO

LL

ER

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

AU

XIL

IAR

YS

WIT

CH

P3

HO

RN

BU

TT

ON

DR

IVE

EN

AB

LE

LIG

HT

L1

NOTES:


BL

U/R

ED

-3

BR

N-J

IB

A1

TIL

TA

LA

RM

OR

G/R

ED

RE

D

WHT

BR

N-2

RE

D

WHT

U

UU D

DD

LR

E R

RL

TS

7

D UTS

9

TS

15

DR

IVE

EN

AB

LE

SW

ITC

H

OR

G/B

LK

-3

RE

D-3

RE

D/B

LK

-3

GR

N/B

LK

-1

GR

N-1

GR

N-3

GR

N/B

LK

-3

GR

N/W

HT

-3

BL

U-3

BL

U/B

LK

-3

WH

T-3

WH

T/B

LK

-3

OR

G/R

ED

-3

BL

U/W

HT

-3

RE

D/B

LK

-1

TS

4TS

6T

S2

RE

D-F

S

RE

D/W

HT

-3

BL

K/W

HT

-1

BL

K-1

OR

G-3

BR

N

TS

8

TS

4H

IGH

/LO

WR

PM

SW

ITC

H

STA

RT

EN

GIN

ES

WIT

CH

TS

2

WHT

RED

TS

7P

LA

TF

OR

MR

OTA

TE

SW

ITC

H

L R

RE

D/W

HT

-1

WH

T/R

ED

-1

WH

T/B

LK

-1

WH

T-1

WH

T-F

S

BL

U-1

BL

U/B

LK

-1

DP

1

RED

1021 3 4 765 8 9

BL

K/R

ED

RE

D

GR

N

BP

1

WH

T

BC

I

BA

TT

ER

YC

HA

RG

EIN

DIC

AT

OR

BC

I

WH

T/R

ED

-3

BL

K/R

ED

-1

OR

G/R

ED

-1

NC

L4

8

RE

D/B

LK

L4

F.S

.

BL

U/W

HT

-1

BL

U/R

ED

-1

GR

N/W

HT

-1

L4

8P

LA

TF

OR

ML

OA

DS

EN

SE

L4

TIL

TA

LA

RM

LE

D

1

1

ES34BES


Power Cable Wiring Diagram(before serial number 1486)


Power Cable Wiring Diagram(before serial number 1486)

1

2

3

4

5

6

7

8



ENGINE SIDE

BATTERY PACK

+

-

+

_

-

+

+

-

-

+

A1 D1

48V

ALTERNATOR

A2

F2

A2

F1

A1 A2

F2

F1

A1

48V

D1

+

- -

+ -

+

-

+

AP2 AP1

-

+

WHT (10 )Gauge

BLK (10 )Gauge

BATTERY

AC

CHARGER

+

-

-

+

+

-

-

BATTERY PACK

+

GROUND CONTROLS SIDE

24V

AUXILIARY

LIFT PUMP

BLK (4 )Gauge

PRIMARY

LIFT

BL

K(4

)G

au

ge

BL

K(4

)G

au

ge

BLK (2 )Gauge

BLK

(2 Gauge)

WH

T(1

0)

Ga

ug

e

BL

K(1

0)

Ga

ug

e

RED

(2 Gauge)

DRIVE MOTOR

RIGHT SIDE

DRIVE MOTOR

LEFT SIDE

RED (10 )Gauge

RED (10 )Gauge

RE

D

(10

)G

au

ge

BLK (2 )Gauge

100APRIMARY LIFT PUMP

CONTACTOR (PR2)

AUXILIARY

LIFT PUMP

CONTACTOR

(PR3)

BLK (2 )Gauge

CONTROLLER

MOTOR

100A

RED (4 )Gauge

BL

K(2

)G

au

ge

RE

D

(4)

Ga

ug

e

BL

K(2

)G

au

ge

RE

D

(2)

Ga

ug

e

RE

D(2

)G

au

ge

BL

K

(2)

Ga

ug

e

AMMETER

PUMP

RED (2 )Gauge

F2 500A

F1

F3

BLK (2 )Gauge

B+M-B-

F1 F2

RE

D(4

Ga

ug

e)

WHT (16 )Gauge

WHT (16 )Gauge

GRN/BLK (16 )GaugeGRN/BLK-ISM-9

WHT-CR12

CONTACTOR

DRIVE

(PR1)

ES34BEA


Power Cable Wiring Diagram(from serial number 1486 to 4799)

1

2

3

4

5

6

7

8



LEFT SIDE

BATTERY PACK

+

-

+

-

+

+

-

-

+

A1 D1

48V

ALTERNATOR

A2

F2 A2

F1

A1 A2

F2

F1A1

48V

D1

+

- -

+ -

+

-

+

AP2 AP1

-

+

WHT (10)

BLK (10)

AC

BATTERY

CHARGER

+

-

-

+

+

-

-

+

RIGHT SIDE

BATTERY PACK

24V

AUXILIARY

LIFT PUMP

BLK (4)

PRIMARY

LIFT PUMP

BL

K(4

)

BL

K(4

)

BLK (2)

BLK (2)

WH

T(1

0)

BL

K(1

0)

RED (2)

RIGHT SIDE

DRIVE MOTOR

LEFT SIDE

DRIVE MOTOR

RED (10)

RED (10) RED (10)

BLK (2)

PR2

PRIMARY

LIFT PUMP

CONTACTOR

PR3

AUXILIARY

LIFT PUMP

CONTACTOR

BLK (2)

RE

D(4

)

BL

K(2

)

RE

D(4

)

BL

K(2

)

RE

D(2

)

RE

D(2

)

BL

K(2

)

AMMETER

RED (2)

F2

100A

F1

500A

F3

100A

BLK (2)

B+M-B-

F1 F2

RE

D(4

)

WHT (16)

WHT (16)

GRN/BLK (16)GRN/BLK-ISM-9

WHT-CR12

PR1

DRIVE

CONTACTOR

CURTIS

MOTOR

CONTROLLER

BATTERY

CONTROLLER 3 DIODES

3

4

NOTES:

1. WIRE GAUGE NOTED IN PARENTHESES AFTER WIRE COLOR.

2. AUXILIARY CONTACTS OF BATTERY CONNECTOR AP2 USED FOR

ENGINE INTERLOCK. ALTERNATOR MUST BE CONNECTED TO

BATTERY WHEN OPERATED OR ALTERNATOR DAMAGE WILL OCCUR.

DO NOT ROUTE POWER CABLES ACROSS THE FRONT OF THE CURTIS

CONTROLLER. DOING SO CAN AFFECT INTERNAL CURRENT SENSORS,

CAUSING REDUCED MOTOR PERFORMANCE.

DIODE PCB ADDED AFTER SERIAL NUMBER 1834.

3

4

-

ES34BES


Power Cable Wiring Diagram(from serial number 1486 to 4799)


Drive Contactor Panel Wiring Diagram(before serial number 1787)


Drive Contactor Panel Wiring Diagram(before serial number 1787)

1

2

3

4

5

6

7

8



1 2 3 4 5 6 7 8 9 10 11 12

2413 14 15 16 17 18 19 20 21 22 23

WHT/RED #32

RED/WHT #29

RED/BLK #CR5

GRN/WHT #CR3

ORG/RED #CR2

ORG/RED #42

BLU/WHT #12

ORG #40

RED #CB1

RED #CR3

J1

BRN

GRN

ORG/RED

ORG/RED

BRN

48V

F4

10A

(FUSE)

24V

BLK #L3

BLU/RED #39

WHT #30

WHT/BLK #31

PR2

PRIMARY

LIFT PUMP

CONTACTOR

PR1

DRIVE

CONTACTOR

PR3

AUXILIARY

LIFT PUMP

CONTACTOR

CURTIS

SEPEX MOTOR

CONTROLLER

BRN #CB2

ES34BEC


Drive Contactor Panel Wiring Diagram(from serial number 1787 to 2060)

1

2

3

4

5

6

7

8



1 2 3 4 5 6 7 8 9 10 11 12

2413 14 15 16 17 18 19 20 21 22 23

WHT/RED #32

RED/WHT #29

RED/BLK #CR5

GRN/WHT #PR2

ORG/RED #CR2

ORG/RED #42

BLU/WHT #12

ORG #40

RED #CB1

RED #CR3

J1

BRN

GRN

ORG/RED

ORG/RED

BRN

48V

F4

10A

(FUSE)

24V

BLK #L3

WHT #30

WHT/BLK #31

PR2

PRIMARY

LIFT PUMP

CONTACTOR

PR1

DRIVE

CONTACTOR

PR3

AUXILIARY

LIFT PUMP

CONTACTOR

CURTIS

SEPEX MOTOR

CONTROLLER

BRN #CB2

CR20

PRIMARY

LIFT PUMP

CONTACTOR

RELAY

BRN

GRN/WHT #CR3

DETAIL ALIFT PUMP CONTACTOR

RELAY SOCKET WIRING

(WIRE INSERTION SIDE SHOWN)

BRNGRN/WHT #CR3

GRN/WHT #PR2

RE

D

RED

ES34BED



1

2

3

4

5

6

7

8



1

RED/WHT #29

GRN/WHT #PR2

ORG/RED #CR20

ORG/RED #42

BLU/WHT #12

ORG #40

RED #CB1

RED #CR3

J1

GRN

ORG/RED

ORG/RED

BRN

48V

F4

10A

(FUSE)

24V

BLK #L3

WHT #30

WHT/BLK #31

PR2

PRIMARY

LIFT PUMP

CONTACTOR

PR1

DRIVE

CONTACTOR

PR3

AUXILIARY

LIFT PUMP

CONTACTOR

CURTIS

SEPEX MOTOR

CONTROLLER

BRN #CB2

CR20

PRIMARY

LIFT PUMP

CONTACTOR

RELAY

GRN/WHT #CR3

BRNGRN/WHT #CR3

GRN/WHT #PR2

OR

G/R

ED

#C

R2

RED/BLK #CR5

WHT/RED #32

12 11 10 9 8 7 6 5 4 3 2

202324 22 21 14171819 1516 13

BRN

BLK

ORG/RED #CR2

OR

G/R

ED

#C

R2

0

DETAIL ACR20

PRIMARY LIFT PUMP

CONTACTOR RELAY

SOCKET WIRING


ES34BES


Manifold and Limit Switch Wiring Diagram(before serial number 1112)


Manifold and Limit Switch Wiring Diagram(before serial number 1112)

1

2

3

4

5

6

7

8



BL

K/W

HT

#8

MANIFOLD HARNESS (MH)

TO GROUND CONTROL BOX

RE

D/B

LK

#2

8

RE

D/W

HT

#3

TILT SENSOR

BR

N

BLK

WHT

RED

BL

K#

7

WH

T/R

ED

#6

BR

N

WHT-JIB

BLK-JIB

BLU-JIB

ORG-JIB

BRN-JIB

BL

K/R

ED

#R

5

BR

N

SERVICE HORN

JIB CABLE TO

PLATFORM BOXORG-6

N.O.

WHT-8 BLK-8N.C.

LS4

SECONDARY LIFT

LIMIT SWITCH

RED-5

WHT-5

N.O. BLK-5

BRN-5N.C.

RED-6

WHT-6

LS3

DRIVE ENABLE

LIMIT SWITCH

BLK-6N.C.

N.O.

LS2

PRIMARY LIFT

LIMIT SWITCH

WHT-7 BLK-7

N.C.

N.O.

LS1

EXTEND/RETRACT

LIMIT SWITCH

RE

D#

1

RE

D/B

LK

#2

BL

U/B

LK

#11

BL

U#

10

WH

T#

4

WH

T/B

LK

#5

OR

G/B

LK

#1

5

OR

G#

14

CABLE 8

CABLE 5

CABLE 6

CABLE 7

(SHOWN WITH BOOM EXTENDED)

NOTE:

ALL LIMIT SWITCHES SHOWN WITH BOOM

IN STOWED POSITION EXCEPT AS NOTED.

JIB MANIFOLD

(TOP VIEW)

BR

N

FUNCTION MANIFOLD

(SIDE VIEW)

(SHOWN WITH BOOM ROTATED

PAST EITHER NON-STEER WHEEL)

ES34BEA


Manifold and Limit Switch Wiring Diagram(from serial number 1112 to 4799)

1

2

3

4

5

6

7

8



BL

K/W

HT

#8

(RE

TR

AC

T)

BL

K#

7(E

XT

EN

D)

WH

T/R

ED

#6

BR

N

ORG-6

WHT-8 BLK-8

LS4

SECONDARY LIFT

LIMIT SWITCH

RED-5

WHT-5

BLK-5

BRN-5

RED-6

WHT-6

LS3

DRIVE ENABLE

LIMIT SWITCH

BLK-6

LS2

PRIMARY LIFT

LIMIT SWITCH

WHT-7 BLK-7

22

14

LS1

EXTEND/ RETRACT

LIMIT SWITCH

RE

D#

1(U

P)

RE

D/B

LK

#2

(DO

WN

)

BL

U/B

LK

#11

(DO

WN

)

BL

U#

10

(UP

)

WH

T#

4(L

EF

T)

WH

T/B

LK

#5

(RIG

HT

)

OR

G/B

LK

#1

5(D

OW

N)

OR

G#

14

(UP

)

CABLE 8

CABLE 5

CABLE 6

CABLE 7

(SHOWN WITH BOOM EXTENDED)

NOTE:

ALL LIMIT SWITCHES SHOWN WITH BOOM

STOWED EXCEPT AS NOTED.

BR

N

(SHOWN WITH BOOM ROTATED

PAST EITHER NON-STEER WHEEL)

PL

AT

FO

RM

LE

VE

L

TU

RN

TA

BL

ER

OTA

TE

SE

CO

ND

AR

YB

OO

M

PR

IMA

RY

BO

OM

BO

OM

EX

TE

ND

PR

OP.

FL

OW

CO

NT

RO

L

ST

EE

R

BR

N

BL

K/R

ED

#C

R4

SERVICE HORN

MANIFOLD HARNESS (MH) TO GROUND CONTROL BOX

PRESSURE SWITCH

BRAKE RELEASE N.C.

BL

U/B

LK

#3

7(R

IGH

T)

BL

U#

36

(LE

FT

)

RE

D/W

HT

#4

8

GR

N/W

HT

#1

9

BRAKE RELEASE N.O.

13

21

13 14

2221

13 14

2221

21 22

13 14

TILT SENSORWHT

RED

BLK

RE

D/W

HT

#2

3

RE

D/B

LK

#2

8

BR

N

JIB MANIFOLD

(TOP VIEW)

(AFTER SERIAL NUMBER 2005)

WHT-JIB

(JIB DOWN)

BLK-JIB

(JIB UP)

T

P

BLU-JIB

(PLAT. ROT. R)

ORG-JIB

(PLAT. ROT. L)

BRN-JIB

(GROUND)

JIB CABLE TO

PLATFORM

CONTROL BOX

A B C

WHT-JIB

(JIB DOWN)

BLK-JIB

(JIB UP)

BLU-JIB

(PLAT. ROT. R)

ORG-JIB

(PLAT. ROT. L)

BRN-JIB

(GROUND)

JIB CABLE TO

PLATFORM

CONTROL BOX

JIB MANIFOLD

(TOP VIEW)

(BEFORE SERIAL NUMBER 2006)

ES34BES


Manifold and Limit Switch Wiring Diagram(from serial number 1112 to 4799)


Engine Wiring Diagram

1

2

3

4

5

6

7

8



12V

STARTING BATTERY

+ -

STARTER

MOTOR

GLOW PLUGS

WATER

TEMP. SWITCH

OIL

PRESSURE

SWITCH

12V

ALTERNATOR

BLK

BL

U

BL

U

RE

D

BL

U

BR

N

BL

U

WH

T

WH

T-IS

M1

0

RE

D

BL

K-C

R11

BR

N

BL

K/W

HT

-CR

15

BL

K/R

ED

-CR

14

WH

T

BR

N

HIGH RPM

SOLENOID

ENGINE RUN

SOLENOID

RED

12V VOLTAGE

REGULATOR CONNECTOR


ENGINE HARNESS

INTAKE

SIDE

EXHAUST

SIDE

ENGINE

GROUND

BR

N

WH

T

STARTER

SOLENOID

FIELD FIELD

OR

G

OR

G

WH

T

BR

N

FIELD RELAY SOCKET


48V

ALTERNATOR

ES34BES

INTAKE

SIDE

EXHAUST

SIDE


Engine Wiring Diagram


Load Sense Option Wiring Diagram(before serial number 2098)


Load Sense Option Wiring Diagram(before serial number 2098)

1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.11

0

NO

NC

NC

NO

NC

NC

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

TS

7

TS

9

TS

8T

S4

TS

6T

S2

P2

L1

L4

LA

BE

LD

ES

CR

IPT

ION

OV

ER

LO

AD

LIG

HT

GR

N

RE

D

BL

K/R

ED

BC

I

BP

1

LO

AD

SE

NS

OR

LO

AD

SE

NS

EP

CB11

12

10

97

86

54 4

23

1

23

1

YEL

RED

WHT

BLK

RED/BLKFUSE

RE

D/B

LK

BRN

WHT

BL

K-

FS

CR

17

43

21

1

3

2

4

65

7

5

8

6

7 8

RE

D/B

LK

L4

P2

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

L R

DP

1 21 3 4 5 76 8 9 10

BRN

RE

D/W

HT

BRN

LO

AD

SE

NS

EO

PT

ION

RE

D/B

LK

LO

AD

SE

NS

EP

CB

WH

T

3A

BR

N

42

13

57

6

42

13

RE

D/B

LK

CR

17

98

11

10

12

P2

WH

T-F

S

OL

RED/WHT

FS

1

BL

K-F

S

L4

RE

D-F

S

CR

17

ES34BEG

CR

17

OV

ER

LO

AD

RE

LA

Y


Load Sense Option Wiring Diagram(from serial number 2098 to 3577)

1

2

3

4

5

6

7

8



ES34BEL

CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.

NO

NC

NC

P3

TS

1

TS

15

TS

12

TS

10

TS

11

TS

13

TS

8

TS

4

TS

6T

S2

P2

L1

LO

AD

CE

LL

L2

+

TS

7

TS

9

RED/BLK

LOAD SENSE

PCB

5NO

CN

C

97

68

-+

23

41

3

BLK

41

RED

WHT

2

GRN

WHT

BRN

RED/WHT

WH

T-F

S

L R

DP

1 21 3 4 5 76 8 9 10

GR

N

BL

K/R

ED

RE

D

BP

1

BRN

BRN

RE

D/W

HT

LO

AD

SE

NS

EP

CB

RE

D/B

LK

RED

BL

K-F

S

P2

FS

1

C

-8

+

NO

WH

T-F

S

NC

WH

T

LO

AD

SE

NS

EO

PT

ION

RE

D-F

S

OL

L2

LA

BE

LD

ES

CR

IPT

ION

OV

ER

LO

AD

LIG

HT

P2

EM

ER

GE

NC

YS

TO

PB

UT

TO

N

DP

1D

RIV

EJO

YS

TIC

K


Load Sense Option Wiring Diagram(from serial number 2098 to 3577)


LVI / BCI Option Wiring Diagram

1

2

3

4

5

6

7

8



CA

BL

E

#3

#2

CA

BL

E

#1

JIB

F.S

.

NO

NC

NC

P3

TS

15

TS

12

TS

10

TS

11

TS

13

TS

8

P2

CR19

LABEL DESCRIPTION

LIFT LOCKOUT RELAY

GR

N

RE

D

BL

K/R

ED

6

8

8

5

7

7

4

3

5

1

3

4

6

2

1 2

BC

I

BP

1

CR19

OR

G/R

ED

-1

BL

U-3

RE

D-3

L R

DP

1 21 3 4 5 76 8 9 10

35

4

OR

G

OR

G/B

LK

OR

G/R

ED

SET TO "N"

DISCHARGE

123

SET TO "B"

6

L.V.I.

45

RESET

78

OR

G/R

ED

OR

G

OR

G/B

LK

L1

TS

1

TS

9

TS

7

WH

T

BR

N

BL

K

BLU

RED

BRN

TS

6

TS

4

TS

2

ES34BEN

TS1 AUXILIARY TOGGLE SWITCH


TS11 PRIMARY BOOM UP/DOWN TOGGLE SWITCH

BCI BATTERY CHARGE INDICATOR

LVI LOW VOLTAGE INTERRUPT


LVI / BCI Option Wiring Diagram


Hydraulic Schematic(before serial number 1112)


Hydraulic Schematic(before serial number 1112)

1

2

3

4

5

6

7

8



JIB BOOM

CYLINDER

PLATFORM ROTATE

2500 PSI

(172.3 bar)

3:1

EXTENSION

CYLINDER

1800 PSI

(124 bar)

PRIMARY

CYLINDER

0.032”

(0.081 mm)

1600 PSI

(110.3 bar)

SECONDARY

CYLINDER

3000 PSI

(206.8 bar)

3:1

3000 PSI

(206.8 bar)

8:1

3000 PSI

(206.8 bar)

1.5:1

3000 PSI

(206.8 bar)

3:1

3000 PSI

(206.8 bar)

3:1

2500 PSI

(172.3 bar)

3:1

MASTER

PLATFORM LEVEL

SLAVE CYLINDER

MM

P1 G1ST

T2

0.025”

(0.635 mm)

1100 PSI

(75.8 bar)

TANK, 5 GALLON

(18.9 Liters)

100 MESH

3200 PSI

(220.6 bar)

10 MIC.

L1 L2 TR1 TR2 SC1 SC2 PC1 PC2 EXT RET

1.5

GPM

(5.6 L/min)

0.8

GPM

(3 L/min)

1400 PSI

(96.5 bar)

T

P

PRIMARY PUMP

2.1 GPM

(7.9 L/min)

J1 J2 PR1 PR2

0.035”

(0.088 MM)

AUX.

PUMP

0.5 GPM

(1.9 L/min.)

TURNTABLE

ROTATE

T1

P2

K

H

L

R

U

SV Y

T

W

X

EEAABB

CC

DD

I

J

P

A

O

Q

DE

N M

GF

BC

STEER/BRAKE

MANIFOLD

PUMP

STEER

CYLINDER

M

0.045”

(1.14 mm)

0.040”

(1 mm)

0.6 GPM

(2.27 L/min)

N.C.COM

N.O.

M

BRAKES

TANK

BRAKE

S2

S1

HSZ34DCA


Hydraulic Schematic(from serial number 1112 to 2005)

1

2

3

4

5

6

7

8



JIB BOOM

CYLINDERPLATFORM ROTATE

2500 PSI

(172.3 bar)

3:1

EXTENSION

CYLINDER

1800 PSI

(124 bar)

PRIMARY

CYLINDER

0.032”

(0.081 mm)

1600 PSI

(110.3 bar)

SECONDARY

CYLINDER

3000 PSI

(206.8 bar)

3:1

3000 PSI

(206.8 bar)

8:1

3000 PSI

(206.8 bar)

1.5:1

3000 PSI

(206.8 bar)

3:1

3000 PSI

(206.8 bar)

3:1

2500 PSI

(172.3 bar)

3:1

MASTER

M M

MM

BRAKESSTEER

CYLINDER

P1

G1

T2

0.025”

(0.635 mm)

1100 PSI

(75.8 bar)

TANK, 5 GALLON

(18.9 Liters)

100 MESH

3200 PSI

(220.6 bar)

10 MIC.

L1 L2 TR1 TR2 SC1 SC2 PC1 PC2 EXT RET

1.5 GPM

(5.6 L/min)

0.8

GPM

(3 L/min)

1400 PSI

(96.5 bar)

T

P

PRIMARY PUMP

2.1 GPM

(7.9 L/min)

J1 J2 PR1 PR2

0.035”

(0.088 MM)

0.045”

(1.5 mm)

S1 S2PS

COMN.C.

N.O.

0.045”

(1.1 mm)

AUX. PUMP

0.5 GPM

(1.9 L/min.)

TURNTABLE

ROTATE

BRAKE

T1

P2

PLATFORM LEVEL

SLAVE CYLINDER

Q

R

H

O

P

S

M

L

AA

BB

EE

DD

CC

I

J

W

A

V

X

DE

T U K

GF

BC

N

HSZ34BEB

December 2007Section 6 - Schematics




1

2

3

4

5

6

7

8



L2

3200 PSI

AUX.

PUMP

.5 GPM

100 MESH

10 MIC.

TANK (5 GAL.)

M

PRIMARY

PUMP

2.1 GPM

T1

M

COM

.045

.045

P1 G1 BRAKE

BRAKES

M M

S2

0.8

GPM

3000 PSI

3:1

N.O.

N.C.

PS S1

STEER

MASTER

CYLINDER

L1P2

3000 PSI

8:1

SLAVE

CYLINDER

.032

3000 PSI

1.5:1

1600 PSI

1.5

GPM

1100 PSI

TURNTABLE ROTATE

5.9 CU. IN.

/REV

TR1 TR2 SC1

1400 PSI

3000 PSI

3:1

SC2 PC1 PC2 EXT

.035

RET

T2

1800 PSI

2500 PSI

3:1

EXTENSION

CYLINDER

JIB

CYLINDER

SECONDARY

CYLINDER

3000 PSI3:1

P

J1

EXT

PRIMARY

CYLINDER

J2

0.3

GPM

PR1

T

PR2

3300 PSI

PLATFORM ROTATE

RET PR1

3:1

PR2

JIB MANIFOLD

ROTATE

MANIFOLD

PLATFORM LEVEL

CA

CCCB

GFED

BC

J

A

L

M

N

P

O

R

Q

H

I

S

W V

X T U K

AA

.035

1EXTERNAL ORIFICE REMOVED AND ADDED TO FUNCTION

MANIFOLD AFTER SERIAL NUMBER 2894.

1

HSZ34BEE



1

2

3

4

5

6

7

8



L2

3200 PSI

AUXILIARY

PUMP

RESERVOIR

M

PRIMARY

PUMP

T1

COM

.045

.045

P1 G1 BRAKE

BRAKES

M M

S2

0.8

GPM

N.O.

N.C.

PS S1

STEER

L1P2

SLAVE

CYLINDER

.032

1600 PSI

1.5

GPM

1100 PSI

TURNTABLE ROTATE

5.9 CU. IN.

/REV

TR1 TR2 SC1

1600 PSI

SC2 PC1 PC2

.035

T2

JIB BOOM

SECONDARY CYLINDER

P

J1

PRIMARY CYLINDER

J2

0.3 GPM

PR1

T

PR2

PLATFORM ROTATE

JIB MANIFOLD

EXT RET

EXTENSION CYLINDER

.090

PLATFORM LEVEL

MASTER

CYLINDER

0.5 2.1M

FUNCTION MANIFOLD

RATIO PRESS

2500 PSI

3000 PSI

3200 PSI

3:1

3300 PSI

3:1

3:1

3:1

4.5:1 3000 PSI

1.5:1 3000 PSI

COUNTERBALANCE VALVES

R

Q N

H

S O

M

P

I

J

Y

W

A

C B

V

X

D

T

E F

U K

1

1

ORIFICE ADDED AFTER 3327.

CA CB

CC

DC DD

ACAB

AD

AA

ZY

AE AF

AD

AB AC

AA

X Y

AE AF

DC DD

M N

2COUNTERBALANCE VALVE CHANGED FROM

3000 PSI TO 3200 PSI AFTER SERIAL NUMBER 3644.

2

L

HS0079A

Dis

trib

ute

d B

y:

California Proposition 65

WARNINGThe exhaust from this product contains chemicals

known to the State of California to cause cancer,

birth defects or other reproductive harm.

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

Service Manual - Genie And Service Manuals...Part No 128907. Z-34/22 Bi-Energy January 2008 Danger...

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Transcript of Service Manual - Genie And Service Manuals...Part No 128907. Z-34/22 Bi-Energy January 2008 Danger...